Heat Exchanger Claw Provisional Fixing Method
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Solution Overview
Problem
The existing method of manufacturing heat exchangers for car air conditioners can result in cracks and breakage of claws during the joining process, leading to reduced joint strength between tank constituting members.
Innovation Solution
A manufacturing method that forms elongated holes in plate-shaped portions, creates bending notches on the claws, and bends the claws to form inclined pieces that project outward and fold-back portions, ensuring secure provisional fixing of tank constituting members without breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If claws are formed by punching the plate-shaped portion, then the two tank constituting members can be provisionally fixed together, but cracks may be formed in the claws and the claws may break, which decreases the joint strength
Solution Approach 1:
Bending notches are formed on the claw forming portion before the claws are actually formed through punching. This preliminary action creates stress relief zones that prevent crack propagation during the claw formation process, thereby maintaining claw integrity while enabling provisional fixing.
Solution Approach 2:
The claw forming portion is divided into multiple segments by forming bending notches at specific positions. These notches segment the continuous material into sections that can bend independently, preventing stress concentration and crack formation across the entire claw structure.
2Ease of operation
If elongated holes are formed in the plate-shaped portions, then the claws can be inserted and engaged for provisional fixing, but the punching process may cause cracks in the claws
Solution Approach 1:
Bending notches are formed on the claw forming portion before the punching process that creates the elongated holes and claws. This preliminary action prepares the material to accommodate the punching process without cracking, ensuring both proper claw engagement and manufacturing precision.
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 method prevents breakage of claws and ensures a firm provisional fixation of tank constituting members, enhancing the joint strength and reliability of the heat exchanger.
Implementation Method 1
the claws are bent such that distal end portions of the claws are engaged with an outer surface, with respect to the lamination direction, of a second plate-shaped portion
Implementation Method 2
the plate-shaped portions of the plurality of tank constituting members are brazed together in this state
Data Source
AI summary
A method of manufacturing a heat exchanger includes forming elongated holes in two connection walls among a plurality of connection walls to be laminated, and forming paired notches on a claw forming portion of the remaining connection wall facing the elongated holes. A longitudinally intermediate portion of the claw forming portion is pressed toward the other end to break the claw forming portion at the longitudinal center and bend the claw forming portion at the notches to thereby form two claws forming pieces and form bent portions at the distal ends of the claws forming pieces. The claws forming pieces are bent at the notches to form claws. Distal end portions of the claws are bent outward to form fold-back portions, which are engaged with the outer surface of the connection wall at the other end, whereby all the connection walls are provisionally fixed together.