Heat Exchanger Coupling Assembly With Non-Rotating Mechanical Lock
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Solution Overview
Problem
Existing coupling devices for connecting heat exchangers to standardized connectors, such as VDA-Connectors, are time-consuming and costly due to the need for brazing and material bonding, which limits the use of non-bondable materials and increases manufacturing complexity.
Innovation Solution
A coupling device comprising a tubular piece and a hollow cylindrical adapter piece with a form-fitting unit that non-rotatably fixes the adapter to the tubular piece, eliminating the need for material bonding by using a combination of stop projections and recesses, locking grooves, and resilient locking elements, allowing for the use of materials like metal and plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to connect the pipe and adapter, then the connection strength is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent replaces the thermal-bonding brazing process with a mechanical connection system consisting of a form-fitting unit with locking elements. The locking elements engage with corresponding features on the pipe and adapter to provide a secure mechanical connection, eliminating the need for heat-based brazing while maintaining connection strength.
Solution Approach 2:
The coupling device is divided into separate components (pipe, adapter, form-fitting unit with locking elements) that can be manufactured independently and assembled through simple insertion. This segmentation allows each component to be optimized separately and assembled quickly without time-consuming bonding processes.
2Strength
If brazing is used to connect the pipe and adapter, then the connection strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the thermal-bonding brazing process with a mechanical connection system consisting of a form-fitting unit with locking elements. The locking elements engage with corresponding features on the pipe and adapter to provide a secure mechanical connection, eliminating the need for heat-based brazing while maintaining connection strength.
Solution Approach 2:
The invention changes the connection mechanism from thermal-bonding to mechanical-interlocking. The form-fitting unit with locking elements creates a secure connection through geometric interlocking rather than material bonding, fundamentally changing the connection parameter from chemical/thermal to mechanical.
3Reliability
If material bonding is used to fix the adapter to the tubular piece, then the connection reliability is improved, but the material selection is limited
Solution Approach 1:
The patent replaces material bonding with a mechanical locking system. The form-fitting unit with locking elements provides a reliable connection that works with any combination of materials that can be mechanically interlocked, including metal-to-metal, metal-to-plastic, or plastic-to-plastic connections.
Solution Approach 2:
The mechanical locking mechanism serves as a universal connection method that can accommodate different material combinations. The form-fitting unit design allows the same basic structure to connect various materials without requiring material-specific bonding processes, enhancing versatility.
4Ease of operation
If a form-fitting unit with locking elements is used, then the assembly simplicity is improved, but the device complexity increases
Solution Approach 1:
The patent combines the connection and anti-rotation functions into a single integrated form-fitting unit. The locking elements serve dual purposes: providing mechanical connection strength and preventing rotational movement, thereby simplifying the overall assembly process despite the added structural features.
Solution Approach 2:
The form-fitting unit incorporates asymmetric locking elements and corresponding features that naturally prevent rotation. The asymmetric geometry ensures that the components can only be assembled in the correct orientation, providing inherent anti-rotation functionality without requiring separate symmetric components.
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 solution simplifies the manufacturing process, reduces costs, and enables the use of non-bondable materials, while ensuring a secure and non-rotatable connection between the tubular and adapter pieces, facilitating efficient assembly and reducing material usage.
Implementation Method 1
The at least one locking element is radially resilient and engages radially in the locking groove
Implementation Method 2
The stop projection engages radially in the stop recess and, as a result, the adapter piece lies on the tubular piece axially in one direction
Data Source
Figure 1~3
AI summary
The invention relates to a coupling device (1) for connecting a heat exchanger to a standardized connector. The coupling device (1) comprises a tubular piece (2) and a hollow cylindrical adapter piece (3). The tubular piece (2) is inserted into the adapter piece (3) along a mounting axis (MA) to a predetermined distance and is axially fixed to the adapter piece. According to the invention, the coupling device (1) comprises a form-fitting unit (13) and the form-fitting unit (13) non-rotatably fixes the adapter piece (3) to the tubular piece (2).