Header-Tank Tabs with Notches for Reduced Crimping Force
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Solution Overview
Problem
Conventional header-tank assemblies for heat exchangers require high crimping forces to secure connections, which can damage tabs, crimping tools, and plastic tanks, leading to cracks and defects that may go unnoticed, reducing reliability and service life.
Innovation Solution
The header-tank assembly features tabs with notches along fold lines that reduce thickness by 10-35% to facilitate crimping with less force, making the process safer for both the tool and the tank, and allowing visual inspection for cracks or defects post-crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick sectioned tabs are used in the header, then the connection strength between header and tank is improved, but higher crimping force is required which may damage the tabs, crimping tool, or plastic tank
Solution Approach 1:
The patent applies local quality by providing notches at specific locations on the tabs (at the根部 and along the fold lines) to create localized weak points. This allows the tabs to have thick sections for overall strength while having localized thin sections that require less crimping force, resolving the contradiction between connection strength and crimping force requirement
Solution Approach 2:
The notches segment the tab structure into different thickness zones - thick sections for structural integrity and thin sections at the notches for easier crimping. This segmentation allows the tab to fulfill both requirements of being strong overall while requiring reduced crimping force at critical locations
2Reliability
If high crimping force is applied to secure the connection, then the connection reliability is improved, but cracks and defects may be formed in the tabs or tank that go un-noticed
Solution Approach 1:
The patent converts the potential harm of undetected cracks into a benefit by designing visible notches that serve as indicators. The notches create controlled weak points that, if cracking occurs, will visibly manifest at the notch locations rather than creating hidden defects, allowing operators to detect issues immediately
Solution Approach 2:
The notches create visual contrast or visible features on the tab structure. When crimping occurs, any cracking or deformation will be evident at the notched areas, providing visual feedback similar to color change indicators, enabling immediate detection of defects
3Strength
If thick sectioned tabs are crimped over the tank foot portion, then the mechanical strength of the connection is improved, but the plastic tank may be damaged due to high crimping forces
Solution Approach 1:
The notches create localized thin sections on the tabs that require significantly less crimping force to deform. This allows the connection to achieve adequate mechanical strength while the reduced force at the notched areas prevents damage to the plastic tank foot portion
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The header-tank assembly includes a tank, a header a sealing element. The tank includes foot portions configured on at least one pair of opposite sides thereof. The header includes tabs configured on at least one pair of opposite sides. The tabs are crimped along fold lines configured thereon to receive the respective foot portions of the tank and configure connection between the header and the tank. The sealing element is disposed between the foot portions of the tank and the header. A notch is configured on an outside wall of each tab, wherein the notch extends along the fold line to facilitate crimping of the tabs over the respective foot portions and is visible after crimping operation.