Snap-lock Packing Element Assembly for Heat Exchangers
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Solution Overview
Problem
Current snap-lock packing elements for contact assemblies in heat exchange systems require complex assembly processes and tools, leading to high storage and shipping costs due to their nesting height, and there is a need for a more efficient and cost-effective method to connect and disconnect these elements without compromising their structural integrity.
Innovation Solution
The development of lattice packing elements with snap-lock connectors featuring post members and segmented truncated dome members that can be easily assembled by hand without tools, using a simple fixture, which reduces the nesting height and allows for secure connection and disconnection by aligning the elements 180° and inserting post members into dome members, ensuring the connection is strong enough to prevent separation without damaging the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mechanical fastening with crimping tools is used to connect packing elements, then the connection strength is improved, but the assembly complexity and tool requirements increase
Solution Approach 1:
The connection system is segmented into two distinct components: a post member with legs and a dome member with corresponding features. This segmentation allows each component to be independently molded and then assembled through simple insertion, eliminating the need for complex crimping tools while maintaining connection strength through the interlocking geometry of the segmented parts
Solution Approach 2:
The post and dome members are designed to self-align and self-secure through their geometric features. The legs of the post member fit into the dome member's opening, and the complementary shapes provide automatic alignment and secure connection without requiring external crimping tools or complex assembly procedures
2Strength
If packing elements are designed for secure mechanical connection, then the structural integrity is improved, but the nesting height increases leading to higher storage and shipping costs
Solution Approach 1:
The post member is designed to nest within the dome member when packing elements are stacked for storage and shipping. The post's legs fit inside the dome's opening, allowing compact nesting that reduces height. The nesting geometry is designed so that the connection features do not prevent compact stacking, thereby reducing storage and shipping costs while maintaining structural integrity when assembled
3Reliability
If strong mechanical connections are used to prevent separation, then the reliability is improved, but the ease of disassembly deteriorates
Solution Approach 1:
The connection system transitions from a static, permanent mechanical fasten to a dynamic, reversible insertion. The post member can be easily inserted into the dome member for assembly and can be removed by applying force in the opposite direction. The geometric interlocking provides reliable connection during operation while allowing simple disassembly when needed, achieving both reliability and ease of operation
Data Source
AI summary
A packing element has components that form snap-lock connections with like packing elements used to form a contact assembly. The packing elements can be readily and easily assembled together using little force by connecting the packing elements with connectors in a snap-lock manner. The packing elements are retained by the snap-lock connectors in the contact assembly such that the packing elements cannot be separated without such force that the material forming at least one of components of the snap-lock connections or the packing element will fail to the extent that a contact assembly made using the packing elements would not be functional.