Fluid Connector Assembly with Locking Structures
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Solution Overview
Problem
Existing fluid connectors require both components to be made of metal for secure brazing, limiting the use of non-metallic materials like plastic in heat exchangers.
Innovation Solution
A fluid connector assembly that uses a plastic connector body and a metal flat tube with male and female locking structures, including an adapter with a through passage and adhesive for secure connection and fluid-tight seal, allowing for quick and cost-efficient connection between different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing is used to join manifolds with flat tubes, then secure joining and fluid tight seals are achieved, but both components must be made of metal which limits material selection and increases manufacturing complexity
Solution Approach 1:
The patent replaces the thermal joining process (brazing) with a mechanical locking system consisting of locking tabs on the manifold that engage with corresponding locking features on the flat tube. This mechanical substitution allows joining of dissimilar materials (metal manifold with plastic or metal flat tube) while maintaining secure connection and fluid tight seals through the locking mechanism and sealing surfaces.
2Strength
If brazing process is used for connecting manifolds and flat tubes, then strong joints are achieved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The complex thermal brazing process is replaced with a simple mechanical insertion and locking process. The locking tabs are molded or formed directly onto the manifold, and the flat tube is inserted and locked into place mechanically, eliminating the need for brazing equipment, flux application, heating cycles, and post-brazing cleaning operations.
Solution Approach 2:
The joining method transitions from a high-temperature thermal process to a room-temperature mechanical process. This parameter change in joining temperature and process type significantly reduces manufacturing complexity and cost while maintaining joint strength through the mechanical locking design.
3Reliability
If traditional fluid connectors are used, then material compatibility is ensured, but connection time and manufacturing efficiency are reduced
Solution Approach 1:
The time-consuming brazing operation is replaced with a rapid mechanical locking operation. The locking tabs and corresponding features are designed for quick engagement, allowing the flat tube to be inserted and secured in seconds without heating, cooling, or post-processing steps, thereby dramatically increasing connection speed and manufacturing productivity.
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
Enables a quicker and more cost-effective connection between metal flat tubes and non-metallic connector bodies, overcoming the limitations of traditional brazing methods and allowing for the use of plastic manifolds in heat exchangers.
Implementation Method 1
an adapter with a through passage and wherein an end of the flat tube is received within the through passage and wherein the flat tube and the through passage are adhesively bonded with one another
Data Source
AI summary
The fluid connector assembly includes a connector body with an intermediate portion that extends between opposite end portions and has a first bore. The connector body has an elongated wall that projects outwardly from the intermediate portion and that surrounds a second bore which opens to the first bore. A flat tube, which is made of a second material that is different than the first material and has at least one fluid passage, is in fluid communication with the second bore of the connector body. The flat tube has generally flat side walls and is lockingly retained with the connector body by male and female locking structures that cooperate with one another.