HVAC Heat Exchanger Connector with Segmented Blocks
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Solution Overview
Problem
Conventional connectors for heat exchangers in HVAC systems are inflexible and costly to manufacture, making it difficult to adapt to different orientations and configurations, which complicates the repositioning of heat exchangers and conduits for optimal space utilization and packaging in vehicles.
Innovation Solution
A connector comprising two blocks with fluid channels that can be interconnected at various angles, featuring a protruded portion for secure orientation and locking mechanisms, allowing for adjustable angular positioning without the need for extensive machining, manufactured through extrusion for reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-piece metal connectors are used, then manufacturing strength is ensured, but adaptability to different orientations and configurations deteriorates
Solution Approach 1:
The connector is divided into multiple separate blocks (first block, second block, third block) that can be assembled together. Each block can be independently manufactured and then connected through fluid channels, allowing the connector to adapt to different orientations and configurations without requiring complex single-piece designs.
2Adaptability or versatility
If conventional connectors are repositioned for different configurations, then space utilization improves, but manufacturing complexity and cost deteriorate
Solution Approach 1:
By segmenting the connector into multiple standardized blocks with matching fluid channels, the system allows repositioning and reconfiguration without requiring custom complex manufacturing. The blocks can be assembled in different arrangements to accommodate various spatial requirements.
Solution Approach 2:
The connector blocks are designed with universal interfaces and fluid channel configurations that can serve multiple functions and positions. The same basic blocks can be used in different orientations and arrangements, making the connector system universally applicable to various HVAC configurations.
3Reliability
If conventional connectors are machined to provide connection interfaces, then connection reliability improves, but manufacturing time and cost deteriorate
Solution Approach 1:
The connection interfaces are integrated into the segmented block structure itself rather than being added through separate machining operations. The fluid channels and connection surfaces are formed as part of the block manufacturing process, eliminating the need for subsequent machining while maintaining reliable connections.
4Strength
If conventional connectors are manufactured by extrusion and milling, then structural strength is ensured, but manufacturing time and cost deteriorate
Solution Approach 1:
The connector is manufactured as multiple separate blocks that can be produced simultaneously through extrusion or other efficient processes. This segmentation allows parallel manufacturing of multiple components, significantly reducing total manufacturing time compared to producing a single complex piece through multiple sequential machining operations.
Data Source
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AI summary
A heat exchanger having a connector for introducing heat exchange fluid to or receive heat exchanger fluid from the heat exchanger is described. The connector includes a first block and a second block. The first block further includes a first fluid channel and a second fluid channel that is in a fluid communication with each other. The second block further includes a solid portion having a protruded portion protruded from the solid portion. The protruded portion further includes a secondary fluid channel. Further, at least a portion of the protruded portion protrudes into the second fluid channel of the first block to secure the second block with the first block in a desired orientation, and the secondary fluid channel of the second block is being in fluid communication with the second fluid channel of the first block.