Heat Exchanger Reinforcing Member Layout to Prevent Brazing Detachment
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Solution Overview
Problem
The existing reinforcing structure for heat exchangers, as described in JP5706665B, faces challenges in ensuring the secure attachment of reinforcing members during brazing, leading to potential detachment and misalignment issues, which hinders work efficiency and product yield due to the inability to visually confirm detachment and alignment after assembly.
Innovation Solution
A heat exchanger design featuring a reinforcing member with leg portions and a connection portion that includes a protruding portion, where the leg portions are inserted into openings such that the gap between the protruding portion and the inner surface of the tank is smaller than the insertion amount, preventing detachment and ensuring reliable attachment without requiring special visual confirmation, thereby improving work efficiency and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reinforcing member is inserted into the opening of the flat tube to prevent detachment, then the reliability of the connection is improved, but the device complexity increases and visual confirmation of detachment becomes impossible
Solution Approach 1:
The reinforcing member is nested within the opening of the flat tube, with its leg portions inserted into the opening and its connection portion positioned inside the flat tube. This nested configuration allows the reinforcing member to be contained within the existing structure, providing reinforcement without adding external complexity or requiring additional confirmation steps.
Solution Approach 2:
The reinforcing member is inserted into the opening before the brazing process, ensuring proper positioning and preventing detachment during subsequent manufacturing steps. This preliminary action secures the reinforcing member in place before thermal and mechanical stresses are applied during brazing and assembly.
2Reliability
If the reinforcing member is inserted deeply into the opening to prevent detachment, then the reliability is improved, but the manufacturing precision requirements increase due to misalignment risks
Solution Approach 1:
The reinforcing member features different structural characteristics at different locations: the leg portions have a first thickness for insertion into the opening, while the connection portion has a different thickness configuration. This local differentiation allows the leg portions to provide deep insertion for reliability while the connection portion maintains proper alignment and positioning within the flat tube.
Solution Approach 2:
The reinforcing member extends in multiple dimensions: the leg portions extend in the insertion direction into the opening, while the connection portion extends in a direction intersecting with the insertion direction inside the flat tube. This multi-dimensional configuration ensures both deep insertion for reliability and proper alignment through spatial distribution.
3Ease of manufacture
If the reinforcing member structure is simplified for ease of manufacture, then the ease of manufacture is improved, but the ability to prevent detachment during brazing is reduced
Solution Approach 1:
The reinforcing member is divided into distinct segments: leg portions for insertion into the opening and a connection portion for positioning inside the flat tube. This segmentation allows each part to be optimized for its specific function while maintaining overall structural simplicity that facilitates manufacturing processes.
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 design enhances work reliability and manufacturing efficiency by preventing the reinforcing member from detaching and allows for improved alignment, even in processes where visual confirmation is not possible, resulting in higher product yield and reduced manufacturing complexity.
Implementation Method 1
The flat tubes, the plate, the medium tank, and the reinforcing member are connected by a brazing material
Data Source
AI summary
A heat exchanger includes: flat tubes; a plate attached to the flat tubes; a medium tank configured to form a medium flow path by covering openings of flat tubes; and a reinforcing member to reinforce the openings. The reinforcing member includes a pair of leg portions and a connection portion that connects the leg portions. An insertion amount of the leg portions into the opening is larger than a sum of a gap between the connection portion and an inner surface and a length from the opening to a position corresponding to a brazed portion between the flat tube and the plate, or when a protruding portion protruding in a direction opposite an insertion direction is provided in the connection portion, larger than a sum of a gap between the protruding portion and the inner surface and a length from the opening to the position corresponding to the brazed portion.