Heat Exchanger Manifold Tab for Compact Crimping
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Solution Overview
Problem
The existing crimping method for fixing header tanks to heat-exchange cores in heat exchangers requires a minimum distance, limiting the reduction of heat exchanger dimensions, especially at the outlet header tank due to its proximity to other motor vehicle components.
Innovation Solution
A connecting part with a tab that extends into the internal volume of the header tank, allowing crimping within the tank's internal space, which reduces the heat exchanger's dimensions by eliminating the need for external crimping space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the tab is crimped onto the header tank on the outside of the heat exchanger, then the crimping operation can be performed with sufficient space, but the dimensions of the heat exchanger cannot be reduced
Solution Approach 1:
Instead of crimping the tab from the outside of the heat exchanger, the invention inverts the approach by extending the tab into the internal volume of the header tank and crimping it from the inside. This reversal of the crimping direction allows the heat exchanger dimensions to be reduced while still providing sufficient space for the crimping operation within the internal volume.
Solution Approach 2:
The invention moves the crimping operation from the external dimension to the internal dimension of the header tank. By extending the tab into the internal volume and performing the crimping operation within this internal space, the solution transforms the spatial requirement from an external constraint to an internal arrangement, enabling compact external dimensions.
2Volume of moving object
If the heat exchanger dimensions are reduced, then space efficiency is improved, but the crimping operation cannot be performed due to insufficient space
Solution Approach 1:
The invention nests the crimping operation within the internal volume of the header tank. By placing the tab and crimping tools inside the existing internal space of the header tank, the solution effectively nests the manufacturing operation within the product's own structure, eliminating the need for external crimping space.
3Adaptability or versatility
If the outlet header tank is positioned adjacent to the cylinder head, then the heat exchanger integrates well with the motor vehicle, but the minimum crimping distance cannot be achieved
Solution Approach 1:
The invention inverts the crimping approach to work from the inside of the header tank rather than from the outside. This allows the crimping operation to be performed in the internal volume where space is available, even when the external dimensions are constrained by proximity to the cylinder head.
Data Source
AI summary
A heat exchanger (1) comprising a heat-exchange core (2) in which a plurality of tubes (28) in which a second fluid circulates and a plurality of dissipation devices (30) between which a first fluid circulates are received, and at least one manifold (8) defining an internal volume (42) through which the first fluid passes and facing which is a foot (48) of said manifold (8), the heat exchanger (1) also comprising a connecting part (10) disposed between the heat-exchange core (2) and the manifold (8), the connecting part (10) comprising at least one tab (72) which extends in the internal volume (42) of the manifold (8) and so as to partially overlap the foot (48) of the manifold (8).