Heat Exchanger Fin Alignment via Preliminary Action

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Solution Overview

Problem

Conventional plate-fin type heat exchangers face challenges in mass production due to difficulties in inserting plates into grooves or holes, leading to friction, deformation, and non-uniform fin placement, which increases defect rates and reduces manufacturing efficiency.

Innovation Solution

A manufacturing method involving processing metal sheets into rows of heat exchange fins, transferring and integrating them using specialized apparatuses to achieve precise alignment and press-fitting into refrigerant tubes, with contact ribs and interval maintenance parts to maintain designated intervals and enhance heat exchange efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If plates are inserted into grooves or holes of stacked fins to manufacture plate-fin type heat exchangers, then heat exchange efficiency is improved through fin-plate contact, but friction between stacked fins and plates makes insertion difficult and causes fin deformation or non-uniform location

Engineering Contradiction:

Improvecontact between fins and platesVSAvoidinsertion of plates into grooves

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by forming protrusions on the plates before insertion, and corresponding grooves on the fins, so that the plates can be easily inserted into the stacked fins without excessive friction. This preliminary structural preparation resolves the insertion difficulty while maintaining the contact efficiency between fins and plates.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions and grooves act as intermediaries between the plates and fins, facilitating smooth insertion by reducing direct friction between large surface areas. The mechanical interlocking through these features ensures proper positioning and contact while making the insertion process feasible for mass production.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If plates are forcibly inserted into grooves or holes to improve contact, then heat exchange efficiency increases, but fins become deformed or non-uniformly located increasing defect rates

Engineering Contradiction:

Improvecontact between fins and platesVSAvoiduniform location of fins

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The protrusions and grooves are pre-formed on the plates and fins respectively, creating a guided insertion path that prevents misalignment and non-uniform fin location. This preliminary structural design ensures that plates insert smoothly without forcing, maintaining manufacturing precision while achieving reliable contact.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If conventional insertion methods are used to manufacture plate-fin heat exchangers, then production can proceed, but the process cannot be continuously mass-produced due to insertion difficulties and defect rates

Engineering Contradiction:

Improvemass production capabilityVSAvoidinsertion process

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

By pre-forming protrusions and grooves on plates and fins during the manufacturing process, the invention enables continuous mass production through automated insertion. The preliminary structural preparation eliminates manual adjustment and rework, allowing high-speed continuous production of plate-fin heat exchangers with consistent quality.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the conventional mechanical insertion method (which requires force and causes deformation) with a guided insertion system using protrusions and grooves. This substitution allows for automated, continuous insertion processes suitable for mass production while maintaining manufacturing precision and reducing defects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9551539B2Heat exchanger and manufacturing method thereof

Publication Date: 2017.01.24 SAMSUNG ELECTRONICS CO LTD

AI summary

A heat exchanger which may be continuously mass-produced by press-fitting heat exchange fins into refrigerant tubes and a manufacturing method thereof. The manufacturing method includes processing a metal sheet into a plurality of rows of heat exchange fins, transferring the plurality of rows of heat exchange fins through a transfer apparatus, dividing the plurality of rows of heat exchange fins into heat exchange fins in odd-numbered rows and heat exchange fins in even-numbered rows and integrating the heat exchange fins in odd-numbered rows and even-numbered rows through integration apparatuses, vertically standing and aligning the heat exchange fins in odd-numbered rows and even-numbered rows, separating the heat exchange fins in odd-numbered rows and even-numbered rows into a number of heat exchange fins, which may be simultaneously press-fitted into refrigerant tubes, through separation apparatuses, and press-fitting the separated heat exchange fins into the refrigerant tubes.