Flat Tube Insertion Support for Heat Exchanger Fin Assembly

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Solution Overview

Problem

Existing manufacturing devices for heat exchangers face challenges in efficiently and accurately inserting flat heat transfer tubes into fin slits, often resulting in tube dropping and potential deformation due to excessive force application.

Innovation Solution

A manufacturing device featuring an insertion head that moves up and down to insert flat tubes into fin slits, supported by a heat transfer tube support that holds the tubes from below, reducing the risk of dropping and deformation by applying minimal force.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a heat transfer tube grip unit with a press member having an elastic body is used to grip the heat transfer tubes, then the tubes are less dropped, but the device complexity increases

Engineering Contradiction:

Improvetube dropping preventionVSAvoidgrip unit structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heat transfer tube grip unit is divided into multiple press members (first press member and second press member) that can independently grip the tube from different sides. This segmentation allows the elastic bodies to be distributed and work independently, providing reliable gripping force while keeping each individual press member structurally simple.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Elastic bodies are introduced as intermediary elements between the press members and the heat transfer tubes. These elastic bodies provide the necessary gripping force through their elasticity, preventing tube dropping while reducing the need for complex mechanical gripping structures. The elastic bodies act as mediators that convert mechanical pressure into reliable tube holding.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If excessive force is applied during tube insertion, then the tube is securely inserted, but tube deformation occurs

Engineering Contradiction:

Improveinsertion accuracyVSAvoidtube integrity

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

Elastic bodies are installed in the press members before the tube insertion process begins. These elastic bodies are pre-positioned to provide cushioning during the gripping and insertion operations. When the press members apply force to the tubes, the elastic bodies deform elastically, absorbing excess force and preventing tube deformation while still ensuring secure insertion.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The elastic bodies change their physical state (deformation) in response to applied force, dynamically adjusting the gripping pressure. As the tube is inserted, the elastic bodies compress and reduce their force output, automatically adapting to prevent over-compression and tube deformation while maintaining insertion accuracy throughout the process.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250010413A1Heat exchanger manufacturing device and manufacturing method

Publication Date: 2025.01.09

AI summary

A heat exchanger includes a flat tube and a fin that is formed in an elongated plate shape and that includes a fin slit formed by notching the fin in a direction orthogonal to a longitudinal direction of the fin. A manufacturing device for manufacturing the heat exchanger includes an insertion head configured to move up and down in order to insert the flat tube held by the insertion head into the fin slit from above the fin, and a support. The support is configured to support, from below, the flat tube held by the insertion head.