Integrated Gas Tank Filter for Exhaust Heat Exchanger Assembly
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Solution Overview
Problem
Current EGR heat exchangers face challenges with complex and time-consuming assembly processes due to the use of additional gaskets and hardware, which increases the exchanger's volume and assembly costs, making them difficult to integrate in compact engine compartments.
Innovation Solution
A compact, integrated particulate filter is designed within the gas tank, eliminating the need for separate metal collars or hardware, with the filter being securely attached via welding or brazing, allowing for a simpler and faster assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional gaskets and hardware are used to assemble the filter to the gas tank, then the sealing and fixing reliability is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The filter is integrated directly into the gas tank as a single component, eliminating the need for separate gaskets and hardware fasteners. This merging of components simplifies the assembly process while maintaining reliable sealing and fixing through the unified structure.
2Reliability
If additional gaskets and hardware are used to assemble the filter to the gas tank, then the sealing and fixing reliability is improved, but the assembly time increases
Solution Approach 1:
The filter and gas tank are designed as an integrated single-piece component, eliminating the need for multiple assembly steps involving gaskets and hardware. This reduces assembly time significantly while maintaining the reliability of the connection through the unified structure.
3Strength
If separate metal collars or intermediate fixing parts are used, then the structural strength is improved, but the exchanger volume increases
Solution Approach 1:
The filter is integrated directly into the gas tank structure, eliminating the need for separate metal collars or intermediate fixing parts. This integration maintains structural strength through the unified design while reducing the overall volume of the heat exchanger by removing redundant components.
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
This solution reduces assembly costs and volume, simplifies the design, and accelerates the welding process, resulting in a more economical and efficient heat exchanger with improved integration in limited engine spaces.
Implementation Method 1
the filter being securely attached via welding or brazing
Implementation Method 2
the filter being securely attached via welding or brazing
Implementation Method 3
The main function of EGR exchangers is the exchange of heat between the exhaust gases and the coolant, with the aim of cooling the gases
Implementation Method 4
the refrigerant circulating in the casing, outside tubes
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A heat exchanger (1) for gases, in particular for the exhaust gases of an engine, comprising a bundle of tubes (2) arranged inside a casing (3), intended for the circulation of the gases in order to exchange heat with a coolant, at least one gas tank (6) that can be fitted to one end of the casing (3) and connected to the gas recirculation line, and a particle filter (7) for filtering the exhaust gases, associated with said gas tank (6). Said filter (7) is incorporated into the gas tank (6) and forms a single inseparable part that can be fitted to the casing (3) of the exchanger (1). Preferably, the filter (7) is incorporated into the gas tank (6) by welding. A filter which is fully incorporated into the gas tank in a single part is obtained, which therefore facilitates the assembly thereof to the exchanger casing.