Heat Exchanger Connection Device Using Segmented Socket and Plate
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Solution Overview
Problem
Heat exchangers, particularly those used in motor vehicle air conditioning systems, have complex and expensive connection devices that require a large amount of material and numerous production steps, leading to high costs due to their design based on solid profiles.
Innovation Solution
The connection device is redesigned to comprise a connecting pipe socket and a connecting plate with a small wall thickness, produced using extrusion and stamping, respectively, reducing material usage and simplifying production with fewer steps, and incorporating a fluid opening and fastening mechanism for efficient fluid handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid profile produced by extrusion is used for the connecting device, then the connection device has sufficient strength and structural integrity, but a large amount of material is required leading to high costs
Solution Approach 1:
The connecting device is divided into two separate components: a connecting pipe socket made from extruded profile and a connecting plate made from sheet metal. This segmentation allows each component to be optimized for its specific function while reducing overall material usage compared to a solid profile design.
Solution Approach 2:
The connecting plate is made from thin sheet metal with wall thickness less than 2 cm (preferably 0.3-1 cm), replacing the need for thick solid profile material in the connecting device while maintaining sufficient structural integrity for its connection function.
2Strength
If a solid profile produced by extrusion is used for the connecting device, then the connection device is mechanically robust, but numerous production steps including machining and screw fastening are required
Solution Approach 1:
The connecting plate integrates multiple functions into a single component: it provides the connection opening for fluid passage, the mounting hole for fastening, and the bonding surface for joining to the pipe socket. This merging eliminates the need for separate machining and assembly steps required by the prior art.
Solution Approach 2:
The connecting plate serves multiple purposes simultaneously: structural support, fluid conduit interface, and mechanical fastening element, reducing the overall complexity of the connection device and simplifying manufacturing compared to the multi-component solid profile design.
3Quantity of substance
If the wall thickness of the connecting pipe socket and connecting plate is reduced, then material requirements and production costs decrease, but the structural strength may be compromised
Solution Approach 1:
The connection device uses a composite construction combining extruded profile material for the socket and sheet metal for the connecting plate. This composite approach allows optimized wall thicknesses for each material type, achieving sufficient strength with reduced overall material usage compared to a solid profile design.
Solution Approach 2:
The connecting plate provides a curved/bonding surface that distributes mechanical and thermal stresses more effectively than flat connections, allowing thinner wall thickness while maintaining structural integrity and bonding strength to the pipe socket.
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 significantly reduces material requirements and production costs while maintaining a fluid-tight connection, enhancing the efficiency and cost-effectiveness of heat exchanger production.
Implementation Method 1
The connecting pipe socket (9) is connected to the connecting plate (10) at the connecting opening (11)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The heat exchanger comprises multiple pipes (3) and a mainfold (4) with openings in which the pipes are arranged for a hydraulic connection between the pipes and the mainfold. An inlet (6) is provided for introduction of fluid, where an outlet (7) is provided for discharging the fluid. A connection device (8) is arranged at the inlet or the outlet, where the connection device comprises a connection pipe socket (9). An independent claim is also included for a method for producing a heat exchanger.