Cooler Header Wave-Profile Design for Thermal Shock Resistance
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Solution Overview
Problem
Coolers for motor vehicles experience joint damage due to thermal shocks caused by rapid temperature changes, leading to strain on the connections between tubes and headers as they expand differently.
Innovation Solution
A header profile with a cross-sectional shape featuring at least two wave troughs and three wave crests, where the slots for the tubes extend between the wave troughs, improves the distribution of tension and enhances resistance to thermal shocks, with specific radius values and flat portions optimizing the joint resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional header with straight cross-section is used, then the structure is simple and easy to manufacture, but the joints between tubes and header are damaged by thermal shocks
Solution Approach 1:
The header cross-section is designed with wave-like curved profiles including wave troughs and wave crests, replacing the conventional straight cross-section. This curvature distributes thermal stress more evenly across the header-tube joints, preventing damage from thermal shocks while maintaining manufacturing feasibility through standard extrusion processes.
2Reliability
If the header profile is modified to include wave troughs and crests, then thermal shock resistance improves by a factor of 2-3, but the manufacturing precision requirements increase
Solution Approach 1:
The wave profile parameters (radii R1-R5, flat portion widths W1-W4) are optimized within specific ranges to achieve the desired stress distribution. The design allows for parameter variations while maintaining functional effectiveness, balancing manufacturing precision requirements with thermal shock resistance performance.
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
The solution significantly improves thermal shock resistance by a factor of 2-3, ensuring a secure and durable connection between the header and tubes, even under varying temperature conditions.
Implementation Method 1
In the event of the strain described above, this results in a better distribution of the tension, so that resistance to thermal shocks is considerably improved
Implementation Method 2
there are considerable temperature differences between individual tubes, such that the tubes expand differently, which results in considerable strain on the joints between the tubes and the header
Data Source
AI summary
A profile for a header of a cooler which also includes numerous parallel tubes. The parallel tubes have a cross-sectional shape between slots for the tubes which further include at least two wave troughs Further, the header is also included having such a profile. A cooler may also be provided, wherein the cooler has such a header.