Modular Pipe Joint Block for Heat Exchangers

Solution Overview

Problem

Current pipe joint blocks for heat exchangers, typically made from a single piece of aluminum, are costly and require intricate machining, leading to high production time and expenses due to their one-piece design.

Innovation Solution

A modular pipe joint block design featuring separate support and pipe components with a press fit and flanges, allowing for reduced material usage and simplified manufacturing processes, such as die casting or extrusion, which eliminates the need for extensive machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a one-piece block design is used, then structural integrity is improved, but manufacturing cost and machining complexity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connection block is divided into multiple components: a support block and separate pipes. The support block contains through-holes that receive the pipes, which are then permanently installed using interference fits. This segmentation allows each component to be manufactured separately using simpler, less expensive processes while maintaining overall structural integrity through the interference fit connections.

Inventive Principle:

Principle #1Segmentation

2Strength

If a one-piece block design is used, then structural integrity is improved, but machining time increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmachining time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The connection block is divided into multiple components: a support block and separate pipes. The support block contains through-holes that receive the pipes, which are then permanently installed using interference fits. This segmentation allows each component to be manufactured separately using simpler, less expensive processes while maintaining overall structural integrity through the interference fit connections.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If separate pipes are used instead of a one-piece design, then manufacturing cost decreases, but connection reliability may worsen

Engineering Contradiction:

Improvemanufacturing costVSAvoidconnection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The pipes are prepared in advance with specific dimensional tolerances and surface finishes before installation. The support block is also pre-manufactured with precisely dimensioned through-holes. These preliminary actions ensure that when the pipes are installed, they achieve proper interference fits that guarantee connection reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The interference fit design creates a pressure distribution between the pipe outer surfaces and the through-hole inner surfaces. This pressure field ensures secure mechanical connection and sealing, maintaining connection reliability while allowing separate component manufacturing.

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Loss of substance

If separate pipes are used instead of a one-piece design, then material usage decreases, but device complexity increases

Engineering Contradiction:

Improvematerial usageVSAvoiddevice complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The connection block is divided into multiple components: a support block and separate pipes. The support block contains through-holes that receive the pipes, which are then permanently installed using interference fits. This segmentation allows each component to be manufactured separately using simpler, less expensive processes while maintaining overall structural integrity through the interference fit connections.

Inventive Principle:

Principle #1Segmentation

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 modular design reduces production costs and time by allowing for easier manufacturing and assembly, while ensuring secure fluid flow and connection to heat exchangers without the complexity of machining a single, solid piece.

Implementation Method 1

The elongate portions reside tightly within the through holes with a press or contact fit against an inside diameter of the through holes

Methodology Applied

Scientific EffectPress fit: Friction

Data Source

PatentUS7926854B2Pipe joint block for fluid transfer

Publication Date: 2011.04.19 DENSO INTERNATIONAL AMERICA INC

AI summary

A connection block employs a support block with two parallel through holes that pass through parallel first and second flat block surfaces. First and second insert pipes have elongate portions and flanges. The elongate portions press-fit into the connection block and the flanges, not at pipe ends, abut against the first flat surface of the connection block when the pipes are installed. Upon installation, the ends the elongate portions of the pipes are formed into a flange by flattening the end against the second connection block surface. The junctures of the elongate portions and the first flanges form a flange radius that contacts a radius of the support block when the pipes are installed into the block. The elongate portions residing within the first and second through holes make a full contact fit against the inside diameters of the through holes. The flanges are perpendicular to the elongate portions.