Vehicle Condenser Support Notches to Prevent Fin Melting
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Solution Overview
Problem
Conventional vehicle condenser supports with protruding portions are prone to melting the radiation fins during brazing, leading to increased failure rates and reduced efficiency, and the manufacturing process is inefficient due to the need for separate molds for different lengths and arbitrary adjustment limitations.
Innovation Solution
The vehicle condenser design features a notch portion or through-hole in the coupling parts of the supports that extend inward from the tip, preventing the radiation fins from melting during brazing and allowing for efficient heat transfer while maintaining the original state of the fins, regardless of the manufacturing method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the protruding portion is randomly formed on the support and connected to a coupling portion, then the support structure is simple, but the radiation fin melts during brazing and the failure rate increases
Solution Approach 1:
The notch portion is formed in advance on the support before brazing, creating a protective feature that prevents molten clad from reaching the radiation fin. This preliminary structural modification ensures that during the brazing process, the molten material flows into the notch portion instead of melting the radiation fin, thus preventing failures while maintaining structural simplicity
Solution Approach 2:
The notch portion acts as an intermediary element between the coupling portion and the radiation fin. It serves as a receptacle for the molten clad material, intercepting it before it can contact and damage the radiation fin. This intermediary structure resolves the contradiction by providing a controlled path for molten material that protects the critical radiation fin component
2Productivity
If the radiation fin is not perfectly melted during brazing, then the manufacturing process is faster, but the condenser efficiency is reduced and appearance is poor
Solution Approach 1:
The harmful effect of molten clad is extracted and isolated into the notch portion, separating it from the radiation fin. This allows the brazing process to proceed without needing to perfectly control the melting of the radiation fin, as the notch portion captures any excess molten material. The radiation fin can be partially melted or not melted at all, yet the process remains successful and efficient
Solution Approach 2:
The potential harm of molten clad damaging the radiation fin is converted into a benefit by directing it into the notch portion. The molten material that would otherwise be a defect becomes a feature that fills the notch portion, potentially strengthening the joint while protecting the radiation fin. This converts the harmful melting effect into a beneficial bonding mechanism
3Manufacturing precision
If the press mold is changed for different support lengths, then the manufacturing precision is improved, but the manufacturing time and cost increase
Solution Approach 1:
The support structure with the notch portion is designed to be universal, where the same basic mold can produce supports of different lengths by adjusting the positioning or stopping point of the forming process. The notch portion serves multiple functions: it protects the radiation fin, accommodates molten clad, and can be formed with the same tooling regardless of the final support length, reducing the need for separate specialized molds
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 design reduces the failure rate of the condenser, enhances its efficiency, and maintains the aesthetic appearance by preventing radiation fin melting and supporting efficient brazing processes across various manufacturing methods.
Implementation Method 1
a notch portion of each coupling part of a pair of supports installed at the outermost sides of radiation fins extends so as to have a certain length from the tip of a body part to the inside end of the notch portion, or a through-hole is formed so as to be spaced by a predetermined distance toward the inside of the body part from the tip thereof, thereby preventing the radiation fins from melting when the clad on a header of a header tank is melted during the brazing of the radiation fins and flows along an embossing part
Implementation Method 2
when the clad on a header of a header tank is melted during the brazing of the radiation fins
Data Source
AI summary
Disclosed herein is a vehicle condenser in which a notch portion of each coupling part of a pair of supports installed at the outermost sides of radiation fins extends so as to have a certain length from the tip of a body part to the inside end of the notch portion, or a through-hole is formed so as to be spaced by a predetermined distance toward the inside of the body part from the tip thereof, thereby preventing the radiation fins from melting when the clad on a header of a header tank is melted during the brazing of the radiation fins and flows along an embossing part, regardless of a method for manufacturing the supports. Consequently, it is possible to reduce the failure rate of the condenser and increase the efficiency of the condenser by maintaining the original state of the radiation fins.