Heat Exchanger Fin Bonding via Low-Temperature Adhesive
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Solution Overview
Problem
Conventional heat exchangers face issues with dew scattering and contamination due to the melting of coating materials during brazing, which compromises the hydrophilic and antifouling properties of the fin surfaces, especially in indoor units where dew discharge is critical.
Innovation Solution
A heat exchanger design featuring a flat tube with an anticorrosive layer and a corrugated fin bonded using a bonding agent on a roughened surface, subjected to a lower temperature heat treatment to prevent the coating material from melting, ensuring the hydrophilic and antifouling properties are maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to join the fin to the flat tube, then strong bonding is achieved, but the coating material on the fin melts and loses its hydrophilic and antifouling properties
Solution Approach 1:
The invention changes the temperature parameter from conventional brazing (600°C) to adhesive bonding (room temperature or low temperature), thereby preserving the coating material's hydrophilic and antifouling properties while achieving sufficient bonding strength between the fin and flat tube
Solution Approach 2:
The invention introduces an adhesive as an intermediary substance between the fin and flat tube, replacing direct metallurgical bonding with chemical adhesion, which allows bonding without exposing the coating material to high temperatures
2Reliability
If the coating material is applied to the fin surface, then dew discharge performance is improved, but the coating material melts during conventional brazing
Solution Approach 1:
The coating material is applied to the fin surface before the bonding process, and then low-temperature adhesive bonding is used to join the fin to the flat tube, ensuring the coating is already in place and not exposed to melting temperatures
Solution Approach 2:
The bonding temperature parameter is changed from high temperature (600°C brazing) to low temperature (adhesive bonding), enabling the coating material to maintain its functional properties during the bonding process
3Strength
If the anticorrosive layer surface is roughened, then adhesive bonding strength is improved, but the surface area increases
Solution Approach 1:
The anticorrosive layer surface is roughened to create micro-segments and irregularities that increase mechanical interlocking area for the adhesive, thereby improving bonding strength without significantly increasing the macroscopic surface area of the heat exchanger
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 solution effectively bonds the fin to the flat tube without melting the coating material, preventing dew scattering and contamination, thereby enhancing the heat exchanger's performance and reliability, particularly in indoor units by maintaining the hydrophilic and antifouling properties.
Implementation Method 1
The fin is bonded to the flat tube with a bonding agent on a first surface of the anticorrosive layer interposed therebetween
Implementation Method 2
Heat treatment is conducted while the flat tube and the fin are being pressed
Data Source
AI summary
There are provided a heat exchanger having a flat tube and a fin bonded together, without causing melting of a coating material covering the fin, and a method of manufacturing thereof. A heat exchanger includes: a flat tube having a flat cross-sectional shape and covered with an anticorrosive layer; and a fin bonded to the flat tube with a bonding agent on a first surface of the anticorrosive layer interposed therebetween, and covered with a coating material, the first surface of the anticorrosive layer having been roughened, and the bonding agent being fixed to the roughened first surface.