Integrated connector and heat exchanger including the same
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional connectors for heat exchangers, such as condensers, face challenges in precise dimension manufacturing and assembly failures due to inclination and dispersion issues, leading to poor brazing and potential leaks during the coupling of header tanks and gas-liquid separators.
Innovation Solution
An integrated connector design featuring a tubular shape with flange portions that are formed by compressing a tube to create a seamless connection, ensuring precise dimensions and improved structural rigidity, which enhances the coupling strength and prevents leaks by matching surface shapes for airtight contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a connector is assembled by inserting a pipe into a through hole of a connection block, then the connector can be manufactured using conventional processes, but the central axis of the pipe may be inclined with respect to the central axis of the through hole or dispersion may occur in the length of the pipe protruding to both sides, making it difficult to manufacture the connector with precise dimensions
Solution Approach 1:
The patent merges the pipe and connection block into a single integrated connector component. The connector includes a body with a through hole and pipe insertion portions that are formed as one integral structure, eliminating the need for separate assembly of pipe and connection block. This integration ensures precise dimensional control and eliminates axis inclination issues that occur in conventional assembled connectors.
2Reliability
If the pipe and connection block are assembled separately, then the manufacturing processes can be performed independently, but the area in which the outer surface of the header tank and connection block are in contact is reduced, resulting in poor brazing and potential leaks
Solution Approach 1:
The connector is designed as an integrated single component where the body and pipe insertion portions are formed together. This integration ensures consistent positioning and maximizes the contact area between the connector and header tank, improving brazing quality and preventing leaks that occur in assembled connectors with misaligned or reduced contact surfaces.
3Productivity
If the connector is manufactured by rolling a clad plate and assembling multiple components, then the manufacturing flexibility is maintained, but the process requires multiple steps including rolling, cleaning, assembling, and drying, increasing manufacturing complexity and time
Solution Approach 1:
The connector is manufactured as a single integrated component formed from a clad plate through rolling and forming processes. The body, through hole, and pipe insertion portions are all created in one continuous manufacturing process, eliminating the need for separate cleaning, assembly, and drying steps required in conventional multi-component connectors.
Data Source
AI summary
Provided are an integrated connector and a heat exchanger including the same, which may prevent assembly defects and leaks of a heat exchanger because the connector may be manufactured with precise dimensions, and is easy to manufacture, by integrally forming the connector that connects and firmly couples a header tank and a gas-liquid separator so that a heat exchanger medium communicates in the heat exchanger such as a condenser, in which the integrated connector is formed by molding a first pipe portion inserted into a hole of the header tank, a first flange portion in surface contact with an outer surface of the header tank, a second pipe portion inserted into a hole of the gas-liquid separator, and a second flange portion in surface contact with an outer surface of the gas-liquid separator so as to be connected to one another and have an interior communicating with one another.