Heat Exchanger Header Box Crimping with Rolled Flange
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Solution Overview
Problem
The existing method for crimping manifolds in heat exchangers requires the use of two different punches, leading to inefficiencies and productivity losses due to the need for frequent punch changes based on the number and position of flanges, which complicates the assembly process.
Innovation Solution
A manifold design where a longitudinal portion of the collector or flange is rolled to facilitate simultaneous crimping using a single punch profile, allowing the collector and cover to be blocked without flanges, thereby eliminating the need for multiple punch profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two different punches are used to crimp the collector onto the flange and cover, then the crimping operation can accommodate different flange configurations, but the device complexity increases and productivity decreases due to frequent punch changes
Solution Approach 1:
A single punch profile is designed to perform multiple functions: it can crimp the collector onto the cover and simultaneously crimp flanges of different configurations. The punch is universally applicable to various flange positions and numbers by utilizing the rolled longitudinal portion of the collector as a standardized interface, eliminating the need for multiple specialized punches.
Solution Approach 2:
The longitudinal portion of the collector is pre-rolled before the crimping operation to create a standardized reduced-thickness section. This preliminary action prepares the collector in advance to accommodate flanges of different configurations, allowing the single punch to effectively crimp various flange arrangements without requiring punch changes.
2Manufacturing precision
If two different punches are used for crimping operations, then proper blocking of the collector and cover can be achieved, but the loss of time increases due to regular punch change operations
Solution Approach 1:
The single punch profile is universally designed to provide proper blocking for both the collector and cover while accommodating different flange configurations. The rolled longitudinal portion of the collector serves as a consistent reference feature that enables the single punch to achieve precise blocking without requiring multiple specialized punches.
Solution Approach 2:
The variability of flange configurations is extracted from the crimping process by pre-rolling the longitudinal portion of the collector. This separates the flange configuration variable from the punch selection variable, allowing a single punch to handle all flange variations while maintaining precise blocking of the collector and cover.
3Device complexity
If the longitudinal portion of the collector is rolled to reduce thickness, then the crimping operation can be simplified to use a single punch, but the manufacturing complexity increases during the rolling process
Solution Approach 1:
The physical parameter of the collector's longitudinal portion is changed by rolling it to reduce its thickness. This parameter change creates a standardized interface that simplifies the crimping device to a single punch profile, while the rolling process itself is a standard metal forming operation that can be integrated into the manufacturing flow.
Solution Approach 2:
The rolling of the longitudinal portion is performed as a preliminary action before the crimping operation. This advance preparation of the collector creates the necessary geometric feature that enables the use of a single punch profile, separating the complexity of the rolling process from the simplicity of the subsequent crimping operation.
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
This approach enables efficient crimping of the collector, flanges, and cover using a single punch profile, improving productivity by eliminating the need for punch changes and simplifying the assembly process.
Implementation Method 1
a longitudinal portion of the collector and/or of the flange is rolled such that the flange is blocked between the collector and the cover
Data Source
AI summary
A header box (3′) includes a header (10) and a cover (11) having a longitudinal extent dimension and at least one flange (8′) crimped in-between the header (10) and the cover (11). The header (10) has a ductility different from that of the flange (8′). At the flange (8′), a longitudinal portion (18) of the header (10) and/or of the flange (8′) is rolled in such a way that the flange (8′) is trapped between the header (10) and the cover (11). Additionally, a heat exchanger includes such a box.