Heat Exchanger Tank Welding Layout for Unobstructed Laser Access
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Solution Overview
Problem
The use of laser welding in heat exchangers is hindered by space constraints and large connectors that obstruct the laser beam, leading to difficulties in defining welding trajectories, overheating, and thermal stresses, such as hot cracking.
Innovation Solution
The heat exchanger design includes strategically defined welding trajectories along the peripheries of smaller connectors, allowing unobstructed laser access and non-interfering paths for secure welding, using complementary tank portions with recesses and connectors to facilitate laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connectors are secured to tank portions before joining, then fluid communication is established early, but laser welding is prevented due to blockage of laser beam by large connectors
Solution Approach 1:
The patent applies preliminary action by pre-securing connectors to tank portions before joining, which establishes fluid communication early in the assembly process. This resolves the contradiction by performing the beneficial action (connector attachment) in advance, while the welding trajectory is subsequently planned to navigate around the pre-positioned connectors.
Solution Approach 2:
The patent resolves the laser beam blockage issue by transitioning to another dimension - designing three-dimensional welding trajectories that wrap around connectors rather than attempting straight-line welding. The trajectory moves in multiple spatial dimensions to access weld zones that would otherwise be blocked by connectors with larger radial dimensions.
2Area of stationary object
If connectors are closely disposed on tank, then space constraints are addressed, but welding trajectories cannot be defined due to connector interference
Solution Approach 1:
The patent addresses the complexity of defining welding trajectories by moving into the third dimension. Instead of confining welding paths to a two-dimensional surface, the trajectory is designed as a three-dimensional path that can wrap around connectors, access recessed areas, and navigate the complex spatial arrangement of closely disposed connectors on the tank surface.
Solution Approach 2:
The welding trajectory is segmented into multiple discrete segments or waypoints that can be individually planned and executed. This segmentation allows the welding system to break down the complex task of welding around closely disposed connectors into manageable steps, moving from one accessible zone to the next along the defined trajectory.
3Device complexity
If welding is performed in limited space with multiple components, then assembly is compact, but overheating and thermal stresses occur due to interfering welding trajectories
Solution Approach 1:
The patent applies preliminary action by pre-defining the welding trajectory and identifying potential thermal interference zones before welding begins. This allows for proactive planning of welding sequences and parameters that prevent overheating, rather than reacting to thermal issues during the welding process.
Solution Approach 2:
The welding process employs periodic action through pulsed welding sequences along the trajectory, allowing cooling intervals between welding passes. This periodic on-off cycling of the welding energy prevents continuous heat accumulation in limited spaces, reducing thermal stresses and overheating while maintaining compact component integration.
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 configuration ensures effective laser welding without obstruction, preventing overheating and thermal stresses, resulting in robust and defect-free joints.
Implementation Method 1
the first tank portion and the second tank portion are joined to each other by welding along a first welding trajectory and a second welding trajectory
Implementation Method 2
a battery cooler for cooling batteries used in an electric vehicle
Implementation Method 3
the tube is an extruded micro-channel tube formed with multiple channels for flow of coolant there through
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A heat exchanger (100) includes a tank (10) and a tube (20). The tank (10) formed by joining a first and a second tank portion (11a) and (11b) respectively. The tank (10) comprises first, second, third and fourth connectors (32a), (34b), (32b) and (34a) for ingress and egress of fluid with respect to a first enclosure (12a) and a second enclosure (12b). The first and third connectors (32a) and (32b) being comparatively larger than the respective fourth and second connectors (34a) and (34b) are disposed on opposite walls (10a) and (10b) of the tank (10). The first tank portion (11a) and the second tank portion (11b) are joined by welding along first and second welding trajectories along at least a portion of the periphery of fourth and second connectors (34a) and (34b) comparatively smaller than the first and third connectors (32a) and (32b).