Heat Exchanger Box Cover Connection for Thermal Movement
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Solution Overview
Problem
Existing heat exchangers face challenges in connecting non-metallic box covers to metal parts effectively, particularly in achieving a reliable sealing effect and managing thermal movements, which complicates manufacturing and increases costs.
Innovation Solution
A heat exchanger design featuring a shaft slot flange connection between a non-metallic box cover and a metal base, allowing for a cost-effective and flexible attachment that accommodates thermal movements, with a bead on the base for enhanced sealing and reduced material thickness for weight savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic box cover is used instead of metal, then manufacturing complexity and cost are reduced, but sealing reliability and thermal movement management deteriorate
Solution Approach 1:
A metal bracket is introduced as an intermediary component between the plastic box cover and the heat exchanger housing. The bracket serves as a mediator that provides both mechanical support and sealing functionality, allowing the plastic cover to be easily manufactured while maintaining sealing reliability through the metal bracket's compression seal and threaded fastening mechanism.
2Ease of manufacture
If a plastic box cover is used instead of metal, then cost is reduced, but thermal movement accommodation deteriorates
Solution Approach 1:
The threaded fastening mechanism with compression seal creates a dynamic connection that can accommodate thermal expansions and contractions. The threads allow for controlled movement and adjustment, enabling the plastic box cover to expand and contract with temperature changes while maintaining a secure, sealed connection to the heat exchanger housing.
3Temperature
If deep-drawn sheet metal box cover with brazing is used, then high-temperature performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention uses a relatively inexpensive plastic box cover with a simple metal bracket instead of expensive deep-drawn sheet metal components requiring brazing. The plastic cover can withstand the operational temperatures while the bracket provides the necessary mechanical connection, eliminating the need for complex brazing operations and reducing manufacturing complexity and cost.
4Shape
If complex box shapes are manufactured using deep drawing, then design flexibility is improved, but manufacturing feasibility deteriorates
Solution Approach 1:
The box cover is segmented into two separate components: a plastic cover for complex shapes and a metal bracket for structural support and connection. This segmentation allows the plastic portion to be molded into complex shapes easily while the metal bracket provides the necessary mechanical strength and connection interface, making the overall manufacturing process more feasible.
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 design enables more complex shapes, improved sealing, and reduced manufacturing complexity while maintaining stability and cost-effectiveness, suitable for applications like charge air coolers in internal combustion engines.
Implementation Method 1
a connection of a box lid, particularly one made of non-metal, for example a plastic, fiber composite or ceramic, should be relatively secure and, secondly, sufficiently flexible with regard to relative thermal movements of the base, which is preferably made of metal
Implementation Method 2
a block for the separate and heat-exchanging guidance of the first and second fluids
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A heat exchanger (10, 20, 30, 40, 50), in particular a charge air heat exchanger or exhaust gas heat exchanger, for heat exchange between a first fluid, in particular charge air (3) or exhaust gas, and a second fluid, in particular a coolant, is specified, which has: a heat-exchanging guide for the first and second fluids separated from each other in the block (1), which block (1) has a number of flow channels (5) through which the first fluid flows and a housing (7, 37, 47, 57) accommodating the flow channels (5) through which the second fluid flows; at least one box cover (11, 11') which is flow-connected to the flow channels (5), a bottom (15, 15') which is fixed to the box cover (11, 11') and is provided with one or more through-openings (17) for flow channels (5).In order to achieve an advantageous connection of the box lid (11, 11') to the base (15, 15'), particularly in the case that the box lid (11, 11') and base (15, 15') are made of different materials, the invention provides that the box lid (11, 11') is fixed to the base (15, 15') by one or more connections as a screw connection (19) and/or slotted flange (26).