Heat Exchanger Overlap Joint for Sealant-Free Gas Sealing
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Solution Overview
Problem
Conventional heat exchanger assemblies in HVAC systems require sealants to prevent gas leakage, which is costly, time-consuming, and prone to leaks as the sealant ages, due to gaps formed during the crimping process.
Innovation Solution
A furnace heat exchanger assembly with a joint flange formed by overlapping capturing tabs and an inner joint flange, which creates a metal seal when crimped, eliminating the need for sealants and enhancing reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealants are used to prevent gas leakage at joints, then gas tightness is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent removes the sealant layer from the joint assembly process entirely. Instead of applying sealant between the inner and outer heat exchanger halves, the design uses a capturing tab mechanism that mechanically interlocks the halves to form a gas-tight joint without any sealant material.
Solution Approach 2:
The capturing tabs on the outer heat exchanger half automatically engage with and secure the inner heat exchanger half during assembly. The joint flange structure self-seals through its geometric design and crimping action, eliminating the need for external sealants or additional sealing components.
2Reliability
If sealants are used to prevent gas leakage, then gas tightness is improved, but the system becomes more complex and costly
Solution Approach 1:
The patent eliminates sealants and complex sealing mechanisms from the joint design. The gas tightness is achieved through a simple mechanical interlocking system using capturing tabs and a crimped joint flange, reducing both material complexity and assembly complexity.
Solution Approach 2:
The capturing tabs are strategically positioned on the outer heat exchanger half to provide localized mechanical engagement points. This localized feature creates a gas-tight seal at the critical joint interface without requiring complex structures throughout the entire heat exchanger assembly.
3Ease of manufacture
If conventional crimping process is used, then assembly is simplified, but gaps form that allow gas leakage
Solution Approach 1:
The capturing tabs are pre-formed on the outer heat exchanger half before assembly. These tabs are designed to automatically engage with the inner heat exchanger half and maintain continuous contact during the crimping process, ensuring gas tightness is preserved throughout the simplified assembly operation.
Solution Approach 2:
The joint flange structure allows for dynamic adjustment during crimping. The capturing tabs can deform slightly to accommodate manufacturing tolerances and maintain optimal contact pressure, ensuring a gas-tight seal is achieved even with variations in the crimping process.
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 provides a reliable, cost-effective, and leak-free crimp seal between the heat exchanger and exhaust port, improving manufacturing efficiency and safety without the use of sealants.
Implementation Method 1
The first and second heat exchanger halves are coupled together such that the first and second capturing tabs substantially overlap the inner joint flange half to form a joint flange... provides a reliable, cost-effective, and leak-free crimp seal between the heat exchanger and exhaust port
Data Source
AI summary
A furnace heat exchanger assembly includes first and second heat exchanger halves. The first heat exchanger half includes a first half of an exhaust channel and an inner joint flange half at an end thereof. The second heat exchanger half includes a second half of the exhaust channel and an outer joint flange half at an end thereof having first and second capturing tabs. The first and second heat exchanger halves are coupled together such that the first and second capturing tabs substantially overlap the inner joint flange half to form a joint flange.