Heat Exchanger Bracket Deformable Protrusion Locking
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Solution Overview
Problem
Existing heat exchanger mounting brackets face issues such as irregular braze temperature distribution, limited compatibility with different configurations, damage to reinforcement members, and assembly complications, particularly in downflow cooling modules.
Innovation Solution
A heat exchanger assembly with a mounting bracket featuring a body portion and a protrusion that plastically deforms to interlock with a recessed part of the reinforcement member, ensuring a secure and stable attachment without additional fasteners, allowing for easy assembly and improved resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal brackets are brazed into fixed attachment during furnace brazing, then the bracket is securely fixed to the heat exchanger, but the braze temperature distribution becomes irregular and the bracket is limited to specific locations
Solution Approach 1:
The bracket is attached to the reinforcement member before the brazing operation, allowing the heat exchanger to be brazed without the bracket interfering with temperature distribution. The bracket is then secured after brazing completes, eliminating the conflict between secure attachment and uniform braze temperature.
2Manufacturing precision
If plastic brackets are snapped onto the heat exchanger post-braze, then the bracket avoids interfering with braze temperature, but the bracket design is limited to rectangle or square-shaped tanks and rigid snap features damage reinforcement members
Solution Approach 1:
The invention changes the attachment mechanism from rigid snap-fit to a deformable protrusion that can be plastically deformed. This allows the bracket to adapt to different reinforcement member configurations (including downflow modules with horizontal tanks) while avoiding damage to the reinforcement members, as the protrusion deforms to accommodate variations in geometry.
3Volume of moving object
If U-shaped brackets are clamped on the heat exchanger around reinforcement members, then the bracket design is more compact, but the bracket lacks robustness and may rotate or tilt around the reinforcement members
Solution Approach 1:
The protrusion is designed with a curved, collar-like shape that fits into a corresponding recessed part of the reinforcement member. This curved geometry provides rotational stability and prevents the bracket from tilting or rotating, while maintaining a compact overall bracket design. The curved interface distributes clamping forces more effectively than flat surfaces.
4Strength
If brackets use the surface of the core like a clamp load, then the bracket achieves sufficient robustness, but tube damage and center deformation occur
Solution Approach 1:
The invention extracts the clamping function from the core surface and relocates it to the reinforcement member. The protrusion attaches to the reinforcement member's recessed part, eliminating the need to clamp on the core's tube surfaces. This prevents tube damage and center deformation while maintaining bracket robustness through the reinforced attachment point.
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
The solution provides a secure, rapid, and stable mounting of the bracket to the heat exchanger, enhancing its resistance and preventing rotation or tilting, while being compatible with various configurations, including downflow modules.
Implementation Method 1
the protrusion having been plastically deformed from the external side into said opening in the body portion of the bracket, the protrusion having been plastically deformed from the external side into said opening in the body portion of the bracket, the protrusion having been plastically deformed from the external side into said opening in the body portion of the bracket
Data Source
Figure 1~2
Figure 3~5
Figure 6a~6c
AI summary
The present invention relates to a heat exchanger assembly (10) comprising a heat exchanger (12) having a core (20) with a plurality of heat exchanger tubes (26) for carrying a coolant fluid, the core (20) extending between two opposite manifolds (16, 18), a reinforcement member (30, 32) extending along each lateral side (24) of the core between the manifolds (16, 18); at least one mounting bracket (14, 114) fixed to the reinforcement member (30, 32), the mounting bracket comprising a body portion (14.1) and a mounting feature (70). The body portion (14.1) has an internal side (14.2) in contact with the reinforcement member (30, 32) and an opposite external side (14.3), and at least one opening (56) extending from the internal side to the external side. The reinforcement member (30, 32) comprises at least one recessed part (42) and a protrusion (40), arranged onto the recessed part, extending from the external side into said opening (56) in the body portion (14.1) of the bracket, the protrusion (40) having been plastically deformed from the external side to interlock with the opening (56) and lock the mounting bracket in place.