Heat Exchanger Thermal Joining with Induction-Heated Thermal Mass
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Solution Overview
Problem
Existing thermal joining methods for heat exchangers in motor vehicles are inefficient, requiring significant energy and time, and often result in reduced surface quality and limited dimensions due to the use of complex frame structures and large brazing furnaces.
Innovation Solution
A device for thermal joining featuring a first and second locating element with thermal insulation and a heat source, allowing for efficient heat transfer and minimal deformation, enabling the joining of heat exchanger elements without the need for complex fixtures or large furnaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional furnace brazing or CAB process is used to join heat exchanger elements, then the joining process is reliable, but the process time is long (20-30 minutes) and energy consumption is high
Solution Approach 1:
The invention divides the heating process into localized zones using multiple independent heating zones within the fixture, allowing different parts of the heat exchanger assembly to be heated at different rates and temperatures, thereby reducing overall process time while maintaining reliable joining
Solution Approach 2:
The fixture incorporates pre-positioned thermal masses and heating elements that are prepared in advance, allowing the heat exchanger elements to be quickly assembled and immediately heated to the required temperature without prolonged setup or heating time
2Productivity
If large heat exchanger elements are joined using conventional CAB furnace, then the elements can be connected, but the surface quality is reduced due to deformation from fixtures and thermal mass
Solution Approach 1:
The fixture design applies localized support and heating only where needed for each specific heat exchanger element, rather than using uniform large thermal masses that cause deformation. This allows large elements to be joined while maintaining their surface quality and geometric precision
Solution Approach 2:
The invention replaces conventional mechanical fixtures that physically constrain and deform elements with a system that uses controlled thermal fields and minimal contact points, thereby achieving the necessary holding and heating without the deformation caused by traditional mechanical clamping and support structures
3Reliability
If complex frame structures and large thermal masses are used in conventional brazing, then the joining process can be performed, but the device complexity and manufacturing costs increase
Solution Approach 1:
The invention extracts and eliminates the complex frame structures and large thermal masses from the conventional brazing fixture, retaining only the essential elements needed for holding and heating the heat exchanger components, thereby simplifying the overall device structure and reducing manufacturing costs
Solution Approach 2:
The simplified fixture design incorporates multi-functional elements that perform multiple tasks (holding, positioning, and heating) simultaneously, eliminating the need for separate complex frame structures and large thermal masses that were previously required for each function
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 enables fast and reliable thermal joining with minimal energy consumption, maintaining high surface quality and allowing for the joining of elements of various sizes without the limitations of conventional methods.
Implementation Method 1
the plate-shaped thermal mass (8) is indirectly heated by means of one or more induction coils (7) as an in-process temperature control. By means of the induction coils (7) of the heat source, a voltage is induced and eddy currents are generated in the plate-shaped thermal mass (8)
Implementation Method 2
a voltage is induced and eddy currents are generated in the plate-shaped thermal mass (8), which is designed to evenly distribute heat within the object (12) to be joined
Implementation Method 3
direct heating of the elements of the object to be joined by thermal contact with the adjacent first thermal mass via heat conduction
Data Source
AI summary
Device for thermal joining of a heat exchanger for a motor vehicle. The device has a first and a second locating elements and at least one heat source. The locating elements are designed with at least one thermal insulation and with mutually aligned contact surfaces for joining an object between them. At least one locating element is designed movably in relation to the other locating element. At least the first locating element has at least one thermal mass, which is heatable by means of the heat source. The second locating element has a support element with a contact surface for the object, while at least a first thermal mass of the first locating element has a contact surface for heating the object via heat conduction.Method for thermal joining with the device. The use of the method for manufacturing a heat exchanger of plate elements for a motor vehicle.