Heat Exchanger Adapter Crimping Endplate Corrosion
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Solution Overview
Problem
Existing heat exchanger assembly methods, such as clinching and punching, face challenges including increased component size, weight, and cost, as well as potential for external leakage and reduced resistance to corrosion, particularly when connecting an adapter block to an end plate in motor vehicle air conditioning and battery temperature management systems.
Innovation Solution
The method involves crimping a semi-cutout on the end plate into a recessed housing on the adapter block, utilizing the block as an anvil for crimping, which maintains the block's mass and avoids thinning the plate, ensuring a secure connection without exposing the connection zone to external corrosion and maintaining fluid flow integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If clinching operation is performed to connect adapter block to end plate, then secure connection is achieved, but component size, weight, and cost increase due to required free area for rivets and lateral protrusions
Solution Approach 1:
The connection interface is segmented into discrete crimping positions around the peripheral zone of the adapter block, allowing localized attachment points rather than requiring extensive free area. This segmentation enables secure connection while minimizing the overall size and weight of the adapter block.
Solution Approach 2:
The connection approach transitions from a two-dimensional planar attachment (requiring free area on the plate surface) to a three-dimensional circumferential attachment (crimping around the peripheral zone). This dimensional change allows secure connection without increasing the adapter block's footprint or weight.
2Strength
If clinching operation is performed to connect adapter block to end plate, then secure connection is achieved, but manufacturing cost increases due to additional passes on stamping tool
Solution Approach 1:
The crimping operation is merged with the existing peripheral zone structure of the adapter block, eliminating the need for separate stamping passes to create rivet housings and lateral protrusions. This integration reduces manufacturing steps and associated costs while maintaining connection strength.
3Strength
If clinching operation is performed to connect adapter block to end plate, then secure connection is achieved, but access requirements increase the size, weight, and cost of the adapter block
Solution Approach 1:
The crimping operation is nested within the existing peripheral zone structure of the adapter block, utilizing the block's own geometry rather than requiring external access space. This nesting approach maintains connection strength without increasing the adapter block's external dimensions.
4Strength
If clinching operation is performed to connect adapter block to end plate, then secure connection is achieved, but material thinning occurs reducing resistance to external corrosion
Solution Approach 1:
The crimping operation is localized to the peripheral zone of the adapter block, concentrating the deformation and connection strength where needed while preserving the material thickness and corrosion resistance of the main body. This localized approach maintains both connection strength and overall structural reliability.
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 solution provides a secure, corrosion-resistant, and cost-effective assembly method that maintains the structural integrity and fluid flow of the heat exchanger, overcoming the drawbacks of previous techniques by using the block's mass for crimping and avoiding material thinning, thus enhancing the assembly process.
Implementation Method 1
The semi-cutout is held by crimping in a housing provided, in particular machined or cold-formed, in the face of the block in contact with the plate
Data Source
Figure 1~3
Figure 4~6
AI summary
The present invention relates to a heat exchanger comprising a bundle for the exchange of heat between fluids, an endplate (10) of said bundle provided with orifices (11, 12) for the distribution of fluid through the bundle, and an adapter unit (20) with an external fluid circuit having one or more fluid-distribution ducts (21, 22) corresponding with one of said or with said distribution orifices of the endplate and being fixed by one face to the endplate, characterized in that the endplate (10) comprises at least one semi-cutout (110, 120) held by crimping in a housing (210, 220) formed in the face of the unit (20) in contact with the plate.