Heat Exchanger Manifold Reinforcing Rib Design
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Solution Overview
Problem
Conventional heat exchanger manifolds, particularly in charge air coolers for internal combustion engines, face issues with rigidity and complexity due to thick, heavy, and costly metal casings, which are exacerbated by the high temperatures encountered with turbocharged engines or diesel fuel use, and require complex welding operations.
Innovation Solution
A heat exchanger manifold design featuring a connection flange with a reinforcing rib that rests on a raised edge of a box, providing enhanced rigidity, and a stamped flange with a brazing coating, which reduces the number of parts and simplifies assembly, using a combination of walls to support the flange and facilitate fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick metal casing is used for the manifold, then strength and rigidity are improved, but weight and cost increase
Solution Approach 1:
The manifold is divided into separate functional components: a circulation box, a connection flange, and integrated walls. This segmentation allows each part to be optimized independently, using thinner materials where sufficient strength is achieved through design rather than sheer thickness.
Solution Approach 2:
The connection flange incorporates a reinforcing rib that extends in a specific dimension, providing structural strength through geometric configuration rather than increasing overall material thickness. This dimensional approach to reinforcement reduces weight while maintaining strength.
2Strength
If a thick metal casing is used for the manifold, then strength and rigidity are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The connection flange is merged with the circulation box through integration of the reinforcing rib structure, eliminating the need for separate welding operations between distinct components. This merging simplifies manufacturing while maintaining structural integrity.
Solution Approach 2:
The reinforcing rib serves multiple functions: it strengthens the connection flange, provides a mounting surface for sealing gaskets, and integrates the flange with the circulation box. This multi-functionality reduces the number of separate components and manufacturing steps.
3Adaptability or versatility
If a separate flange is added to the manifold, then connection capability is improved, but device complexity increases
Solution Approach 1:
The connection flange is merged with the circulation box through the reinforcing rib structure, creating an integrated component rather than separate parts. This reduces assembly steps and overall device complexity while maintaining connection capability.
Solution Approach 2:
The reinforcing rib provides multiple functions: structural reinforcement, sealing surface provision, and connection integration. This multi-functionality allows a single structural element to fulfill multiple roles, reducing the need for additional 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
The design achieves satisfactory rigidity and reduced assembly complexity while minimizing material thickness and cost, allowing the manifold to withstand operational forces and simplify the assembly process.
Implementation Method 1
said flange is coated with a brazing coating, at least on one of its faces
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a heat exchanger manifold, in particular the charge air cooler of an internal combustion engine, comprising a bundle (20) for exchanging heat between a first fluid and a second fluid. The manifold (1) comprises a connection flange (4) for the passage of the first fluid and a casing for the circulation of the first fluid between the flange (4) and the heat exchange bundle (20), said casing comprising an assembly formed by a raised edge (7) of a so-called entry wall (8) of the casing, supporting the flange (4), and at least one other wall of the casing (5), said flange (4) comprising a reinforcing rib (10) resting on the assembly.