Pipeline Integrated Module with Sandwich Layer for Brazing Gap Filling
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Solution Overview
Problem
The existing pipeline integrated modules in air conditioner outdoor units suffer from gaps in the cavity formed by stamped chafers, which cannot be effectively filled, leading to reduced pressure-bearing and anti-fatigue performance due to incomplete brazing seams.
Innovation Solution
A sandwich layer is introduced between the plate-like components, partially located within the gap, connected to both components, and filled with brazing material to enhance the filling of the gap, improving the brazing seam thickness and reducing stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two plate bodies are butt-joined and welded to form a sealed cavity using stamping process, then the cavity structure is formed, but a gap is formed at the opening of the groove due to stamped chamfer, resulting in incomplete brazing seam and reduced pressure-bearing performance
Solution Approach 1:
A filler plate is introduced as an intermediary component between the two plate bodies. The filler plate is positioned in the gap formed by the stamped chamfers and is connected to both plate bodies through brazing, serving as a mediator to bridge the gap and enable complete brazing seam formation, thereby resolving the manufacturing precision issue while maintaining the stamping process advantage
2Device complexity
If the gap in the cavity is not effectively filled, then the brazing process is simplified, but the pressure-bearing performance and anti-fatigue performance of the cavity are reduced
Solution Approach 1:
The cavity structure is segmented into three components: the two original plate bodies and the added filler plate. This segmentation allows the filler plate to specifically address the gap filling requirement without complicating the overall brazing process, as the filler plate can be independently positioned and brazed to both plate bodies, thereby improving pressure-bearing performance while maintaining relatively simple device complexity
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 solution significantly increases the filling volume of the gap, enhancing the anti-pressure and anti-fatigue performance of the cavity, while maintaining uniform flatness and facilitating effective brazing seam formation.
Implementation Method 1
The sandwich layer is connected to both the first plate-like component and the second plate-like component through a brazing material layer
Data Source
AI summary
A pipeline integrated module includes: a first plate-like component having a first groove that has a first stamped chamfer at an opening of the first groove, a second plate-like component having a second groove that has a second stamped chamfer at an opening of the second groove, and a sandwich layer disposed between and connected to the first plate-like component and the second plate-like component. The first plate-like component and the second plate-like component cover each other. The second groove and the first groove correspond to each other and together enclose a cavity. The cavity has a gap between the first stamped chamfer and the second stamped chamfer. The sandwich layer has an end portion facing towards the cavity and located within the gap.