Corrugated Fin Thickness Layout for Brazing Erosion Control
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Solution Overview
Problem
Existing heat exchangers face challenges in efficiently transferring heat due to erosion of fins during the brazing process, which can lead to increased material and weight costs, and reduced heat transfer efficiency.
Innovation Solution
A corrugated fin formed by bending a metal plate into a specific shape with alternating peak and valley portions, where the thickness of the apexes is greater than the inclined portions, is designed to minimize erosion during brazing while maintaining efficient heat transfer by increasing contact area with refrigerant and air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fin thickness is increased to prevent erosion during brazing, then the reliability is improved, but the weight and material costs increase
Solution Approach 1:
The fin structure employs varying thickness across different regions: the apex portions (where brazing occurs) have increased thickness to resist erosion, while the inclined portions maintain thinner profiles to minimize weight. This local differentiation of thickness resolves the contradiction between erosion resistance and weight reduction.
Solution Approach 2:
The fin is segmented into distinct functional zones with different thickness characteristics - thicker apex regions for brazing durability and thinner inclined regions for weight efficiency. This segmentation allows each portion to be optimized for its specific function without compromising the other.
2Reliability
If the fin thickness is increased to prevent erosion during brazing, then the reliability is improved, but the material costs increase
Solution Approach 1:
Material is concentrated only where needed - at the apex portions subject to brazing erosion - rather than uniformly throughout the entire fin. This localized material distribution reduces overall material consumption and cost while maintaining reliability at critical locations.
Solution Approach 2:
The fin structure segments material allocation between high-need apex regions and low-need inclined regions, optimizing material usage efficiency and reducing total material cost while preserving erosion resistance where required.
3Weight of moving object
If the fin thickness is decreased to reduce weight and material costs, then the weight and material costs are reduced, but the fin erosion during brazing increases
Solution Approach 1:
The fin employs non-uniform thickness distribution where the apex portions have greater thickness to withstand brazing erosion, while inclined portions have reduced thickness for weight savings. This local quality variation protects against erosion only where the harmful factor is present.
4Loss of substance
If the fin thickness is decreased to reduce material costs, then the material costs are reduced, but the fin erosion during brazing increases
Solution Approach 1:
Material is strategically distributed with higher concentration at apex portions exposed to brazing erosion and lower concentration at inclined portions. This local quality differentiation minimizes material cost while providing erosion resistance where the harmful factor acts.
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 effectively suppresses fin erosion, reduces material and weight costs, and enhances heat transfer efficiency between refrigerant and air in heat exchangers.
Implementation Method 1
a heat exchanger including the fin, where the fin increases contact area with a fluid
Implementation Method 2
heat transfer efficiency between refrigerant and air in heat exchangers
Data Source
AI summary
A fin according to the present disclosure is a corrugated fin formed of a metal plate by bending into a corrugated shape, and the corrugated fin includes peak portions extending in a first direction, valley portions extending in the first direction, and inclined portions connecting the peak portions and the valley portions adjacent to each other. The peak portions and the valley portions are alternately arranged in a second direction perpendicular to the first direction, and a thickness of the metal plate at each apex of the peak portions and the valley portions is larger than a thickness of the inclined portions of the metal plate.