Heat Exchanger Collector Recess Platform Design
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Solution Overview
Problem
The crimp connection between the collector and the tube sheet in heat exchangers is a weak point due to increased pressure from charge air and integration into the air diffuser, leading to stress peaks and potential breakage.
Innovation Solution
The collector features recesses with platforms spaced apart from the edges, allowing for extensive deformation and a more secure crimp connection, reducing stress peaks by increasing the radii of curvature and enhancing the contact area between the tube sheet projections and the collector platforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tube sheet projections are pressed into the collector recesses to form a crimp connection, then the connection between collector and tube sheet is achieved, but stress peaks occur at the transition between opening edges leading to potential breakage
Solution Approach 1:
The patent applies curvature by forming the recesses with rounded transition edges instead of sharp corners. The recesses are designed with a curved profile that gradually transitions from the opening edge to the bottom, eliminating stress concentration points. This curved geometry distributes stress more evenly across the connection interface, preventing stress peaks that would otherwise occur at sharp transitions between opening edges.
Solution Approach 2:
The patent changes the geometric parameters of the recesses by introducing a platform structure with specific dimensional relationships. The platform has a first width at its upper end and a second width at its lower end, where the first width is larger than the second width. This parameter variation creates a gradual transition zone that reduces stress concentration while maintaining adequate connection strength.
2Reliability
If the opening edges are deformed extensively to improve connection, then the radii of curvature increase and stress peaks reduce, but the deformation requires additional space that may affect the heat exchanger design
Solution Approach 1:
The patent resolves the space requirement by utilizing the vertical dimension within the recess structure. The platform extends vertically from the opening edge downward, creating the necessary deformation space in the vertical direction rather than requiring additional horizontal space. This allows extensive deformation of opening edges to increase radii of curvature while maintaining the overall compact footprint of the heat exchanger.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces maximum stress by approximately 30% compared to prior art, improving the durability and security of the connection between the collector and the tube sheet.
Implementation Method 1
the opening edges which are adjacent to the opening edge that is directly adjacent to the projection are bent out of the plane of the opening
Implementation Method 2
the transition, or the corner, between the respective opening edge 24 and opening edge 26 represents a position at which stress peaks occur as a result of the extensive deformation
Data Source
AI summary
A collector of a heat exchanger for a vehicle, which collector has numerous recesses for projections on a tube sheet that are pressed into the recesses as part of a crimp connection, and wherein the recesses have at least one platform which is spaced apart from at least one edge of the recess in such a way that a free space is created. A heat exchanger for a vehicle, which heat exchanger has a tube sheet with projections that adjoin openings and are pressed into recesses of a collector, and wherein at least one opening edge, which is adjacent to an opening edge that is directly adjacent to the projection, is bent out of the plane of the opening.