Condenser Holder Strip with Adjustable Soldered Flange
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Solution Overview
Problem
Existing heat exchanger designs for motor vehicle air conditioning systems lack flexibility in adapting to different installation conditions within vehicles, as they rely on fixed soldered connections that do not easily accommodate varying installation requirements.
Innovation Solution
A flexible strip holder system is introduced, where a strip is indirectly attached to the header via a connection flange and intermediate bracket, both soldered to the manifold, allowing for adjustable attachment points and variable length configurations, enabling self-fixing without additional tools during the soldering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed holder design is used for the heat exchanger, then the manufacturing process is simple, but the adaptability to different installation conditions in vehicles is poor
Solution Approach 1:
The holder strip is designed with a variable length that can be adjusted during installation. The strip can be cut to different lengths depending on the specific installation requirements in different vehicles, transforming a static fixed-length design into a dynamic adjustable-length design, thereby improving adaptability without significantly increasing structural complexity
Solution Approach 2:
The holder system is divided into multiple components: the holder strip, connection flange, and intermediate bracket. This segmentation allows each component to be independently optimized and assembled in different configurations to suit various installation conditions, enhancing versatility while maintaining manageable complexity
2Ease of operation
If multiple separate components are used for holder and connection flange, then the positioning flexibility is improved, but the number of soldering connections and tools required increases
Solution Approach 1:
The connection flange and intermediate bracket are designed to be combined into a single integrated component. This merging eliminates the need for a separate soldering connection between the holder strip and the collecting tube, reducing the number of soldering operations from three to two, and eliminating the need for additional clamping devices during soldering, thereby improving ease of operation
3Stability of the object's composition
If the holder strip is directly soldered to the header pipe, then the connection is stable, but the positioning flexibility and adaptability to different installation points is reduced
Solution Approach 1:
The connection flange and intermediate bracket serve as intermediary components between the holder strip and the collecting tube. These intermediaries provide standardized soldering connection points while allowing the holder strip to be positioned at various locations along its length, thus maintaining attachment stability through reliable soldered connections while enabling positioning flexibility for different installation requirements
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 solution provides a stable and flexible attachment method for heat exchangers, allowing for easier installation and soldering without additional clamping devices, enhancing adaptability to various vehicle installation conditions.
Implementation Method 1
a connection flange and an intermediate bracket, both of which are soldered to the manifold
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The heat exchanger has a block (2) made from pipes and ribs and a collecting tube (3), which communicate with the pipes. A connection flange (4) and a holder are fixed at the collecting tube. The holder is formed as continuous guide rail (7) and is fixed at the connection flange and intermediate holder (8).