Pipe Heat Exchanger Brazing Gap Control via Intermediary Bar
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Solution Overview
Problem
Existing pipe-type heat exchange devices face inefficiencies due to gaps between wave-shaped pipes during brazing, leading to inadequate soldering and reduced heat transfer efficiency, as well as pipe separation during the brazing process resulting in defective products.
Innovation Solution
The introduction of a bar or continuous sheet material between the pipes, which are subjected to brazing, ensures a consistent and reduced gap for strong thermal linking, enhancing heat transfer efficiency. The bar or sheet material is temporarily held with the pipes using a stay or partial welding before brazing, maintaining the gap and ensuring effective solder distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wave-shaped pipes are attached directly to each other, then the structure is simple, but gaps exceed specified limits resulting in inferior solder and reduced heat exchange efficiency
Solution Approach 1:
A bar is introduced as an intermediary component between the two wave-shaped pipes. The bar fills the gap between pipes that exceeds specified limits, providing a surface for solder to adhere to and ensuring proper thermal contact while maintaining the simple wave-shaped pipe structure
Solution Approach 2:
The bar is temporarily held between the pipes using a stay before brazing occurs. This preliminary positioning ensures that the bar is in place to bridge the gap before the soldering process, preventing pipe separation and ensuring proper alignment during manufacturing
2Reliability
If pipes are temporarily held together using a stay before brazing, then alignment is improved, but pipes separate during the process resulting in insufficient brazing
Solution Approach 1:
The bar serves as a stable intermediary that remains positioned between the pipes during the entire brazing process. Unlike the temporary stay that may fail, the bar provides continuous structural support and positioning, preventing pipe separation and ensuring consistent brazing quality
Solution Approach 2:
The bar is preliminarily positioned between the pipes using a stay before brazing, and this positioning is maintained throughout the process. The preliminary placement of the bar creates a stable framework that prevents pipe separation during heating and soldering operations
3Ease of manufacture
If gaps between pipes exceed specified limits, then manufacturing is easier, but solder does not persist resulting in reduced heat exchange efficiency
Solution Approach 1:
The bar acts as a mediator that enables solder adhesion even when the gap between pipes is large. The solder can properly adhere to the bar surface, which is positioned within the gap, ensuring persistent solder joints without requiring tight pipe tolerances or complex assembly procedures
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 results in a pipe-type heat exchange device with improved heat transfer efficiency and reduced defects, as the bar or sheet material strengthens the thermal link between pipes, allowing for efficient heat transfer even when pipe gaps exceed specified limits.
Implementation Method 1
both pipes are satisfactorily linked thermally via the above bar
Implementation Method 2
the above pipes and bar are subjected to brazing
Data Source
AI summary
The provision of a pipe-type heat exchange device wherein solder can be reliably filled between pipes attached together, resulting in a high heat transfer efficiency, comprising two pipes attached to each other through which fluids with differing temperatures are passed respectively, wherein a bar is attached to the pipes and wherein the pipes and the bar are subjected to brazing.