Heat Exchanger Flat Pipe Sealing Cushion Welding
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Solution Overview
Problem
The existing heat exchangers face challenges with weak connection strength between the flow collecting pipe and flat pipes, leading to difficulties in welding, especially near plug-in holes, resulting in potential false welding and compromised pressure resistance.
Innovation Solution
The introduction of first sealing cushion blocks between flat pipes and a flow collecting shell with a plug-in portion allows for an encircling flow collecting channel, enabling the flat pipes to be freely declined during welding, ensuring all welding points are properly connected, thus enhancing the connection strength and pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the flat pipe is rigidly constrained by the plug-in hole during welding, then the flat pipe maintains its position, but the composite layer melts and welding points near plug-in holes become difficult to weld, forming false welding
Solution Approach 1:
The plug-in hole is segmented into two parts: a first plug-in hole in the flow collecting pipe for positioning, and a second plug-in hole in the flat pipe that extends into the first plug-in hole. This segmentation allows the flat pipe to be positioned accurately while enabling the welding torch to access welding points near the plug-in holes without rigid constraint, eliminating false welding.
2Reliability
If the flat pipe is pre-tightened by a fixture, then the flat pipe is held in position, but the flat pipe close to the end portion cannot move in height direction, making welding difficult
Solution Approach 1:
The plug-in hole structure transitions from a two-dimensional surface connection to a three-dimensional insertion structure. The second plug-in hole of the flat pipe extends into the first plug-in hole of the flow collecting pipe, creating a depth dimension that allows welding access from multiple angles while maintaining positional stability through the insertion fit.
3Strength
If the flat pipe is welded while constrained, then the structure maintains rigidity, but false welding occurs near plug-in holes, compromising pressure resistance
Solution Approach 1:
The nested plug-in hole structure acts as an intermediary that facilitates proper welding. The second plug-in hole of the flat pipe serves as a mediator that allows the welding torch to reach and properly weld the composite layer near the plug-in holes, ensuring welding integrity while maintaining the structural strength through the insertion connection.
Data Source
AI summary
A heat exchanger, including: a plurality of flat pipes, wherein, the plurality of flat pipes are arranged at intervals; first sealing cushion blocks, arranged between two adjacent flat pipes, wherein the first sealing cushion blocks are located on end portions of the flat pipes, so as to seal gaps between two adjacent flat pipes by means of the first sealing cushion blocks; and a flow collecting shell, provided with a first opening portion, wherein at least part of the first sealing cushion blocks and the end portions of the flat pipes are all plugged into the first opening portion, so that the flow collecting shell, the flat pipes and the first sealing cushion blocks form a flow collecting channel in an encircling manner.