Double Conical Brazing Sleeve for Thermal Exchanger Tightness
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Solution Overview
Problem
Conventional brazed connections in thermal exchangers for motor vehicles face issues with inconsistent brazing material distribution and temperature homogeneity, leading to potential shrinkage cavities and inadequate tightness due to cylindrical configurations and reliance on precise tolerances and applied forces.
Innovation Solution
A connecting device featuring a female sleeve with a double conical shape, comprising a first conical part with a 2° inclination and a second conical part with a 4° inclination, creating an optimized gap for improved brazing material distribution and temperature homogeneity, increasing the contact surface area and reducing the risk of shrinkage cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a cylindrical connection is used between the sleeve and pipe, then the structure is simple, but the brazing material distribution and temperature homogeneity become unstable
Solution Approach 1:
The patent applies asymmetry by transitioning from a cylindrical symmetric connection to an asymmetric conical connection. The sleeve and pipe are designed with conical surfaces having different inclination angles (first conical part with 2° inclination, second conical part with 4° inclination), which creates an asymmetric geometry that improves brazing material distribution and temperature homogeneity while maintaining structural simplicity.
2Reliability
If conical shapes with the same inclination are used, then tightness between male and female parts is improved, but a predetermined force must be applied to maintain contact during brazing
Solution Approach 1:
The patent applies local quality by differentiating the inclination angles of different conical parts. The first conical part has a 2° inclination optimized for tightness, while the second conical part has a 4° inclination optimized for gap control. This local differentiation allows each region to serve its specific function without requiring additional applied forces.
Solution Approach 2:
The patent changes the geometric parameter (inclination angle) from uniform to variable. By specifying different inclination angles (2° for the first conical part, 4° for the second conical part) for different regions of the connection, the design achieves both tightness and proper gap control without requiring external forces during brazing.
3Reliability
If the gap length is controlled to 2.1 mm for proper brazing conditions, then brazing reliability is improved, but the quality and distribution of brazing material become unstable due to tolerances and position variations
Solution Approach 1:
The patent applies preliminary action by pre-establishing the gap geometry through the conical configuration before brazing occurs. The specific inclination angles (2° and 4°) are designed to automatically create and maintain the optimal 2.1 mm gap length during the brazing process, compensating for tolerances and position variations without requiring real-time adjustment.
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 double cone configuration enhances the stability and quality of the brazed connection, ensuring reliable fluid communication and mechanical resistance while maintaining temperature homogeneity during the brazing process, addressing the limitations of cylindrical connections.
Implementation Method 1
during brazing, the brazing ring is melted and thus secures the connection
Data Source
AI summary
The invention relates to a connecting device having a female part and a complementary male part, wherein the female part is a sleeve able to receive at least partially the associated male part with a gap between the sleeve and the male part for receiving a brazing material. The sleeve at least partially has a conical shape. The conical shape has a first substantially conical part having a complementary shape to the male part, with a first inclination angle with respect to a longitudinal axis of the sleeve. The conical shape also has a second substantially conical part with a second inclination angle with respect to the axis, with the second inclination angle being larger than the first inclination angle.