Thermoplastic Condenser Base Plate Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing condensers with parallel tubes are inefficient in connecting the free ends of the tubes to a base plate, as they require complex and potentially flawed manufacturing processes.
Innovation Solution
A method involving a trough with grid-patterned bores for pipe sockets, filled with thermoplastic granulate, and centering pins with a frustoconical section to securely attach the tubes to a base plate, ensuring a sealing and compact connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex manufacturing processes are used to connect tube ends to base plate, then connection reliability may be improved, but manufacturing complexity and time increase
Solution Approach 1:
The base plate is pre-formed with recesses and the tubes are pre-positioned in these recesses before the thermoplastic material is applied. This preliminary arrangement ensures proper alignment and positioning, eliminating the need for complex adjustment processes during assembly and reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
A thermoplastic material serves as an intermediary substance that fills the recesses and bonds the tube ends to the base plate. This intermediate material simplifies the connection process by providing a versatile bonding medium that can accommodate slight variations in positioning, thereby maintaining reliability without requiring complex precision alignment procedures.
2Manufacturing precision
If precise alignment of tube ends to base plate is performed, then sealing integrity is improved, but manufacturing time increases
Solution Approach 1:
The base plate is pre-formed with recesses that are pre-positioned to receive the tube ends. This preliminary positioning ensures that when the thermoplastic material is applied, the tubes are already aligned in the correct positions, achieving sealing integrity without requiring time-consuming precise alignment operations during assembly.
Solution Approach 2:
The thermoplastic material undergoes a phase change from solid granules to melted state, allowing it to flow and fill the recesses, then solidify to create a sealed connection. This parameter change enables the material to adapt to slight positioning variations while maintaining sealing integrity, reducing the need for extremely precise alignment and thereby decreasing manufacturing time.
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
Facilitates a simple and effective connection of tube ends to a base plate, enhancing the manufacturing efficiency and sealing integrity of the condenser.
Implementation Method 1
A thermoplastic granulate is then filled into the tub 1 and melted. After the granules have melted, a stamp can be placed on it until it rests on the free surfaces of the pipe sockets 2
Implementation Method 2
This unit can then cool down, the melted granules forming a base plate which receives the free ends of the tubes 5 in a sealing manner
Implementation Method 3
Centering pins 4 are then introduced from above into the pipe sockets 2 while pushing out the filling pins 3, the outer diameter of the shank of the centering pins corresponding to the inner diameter of the pipe sockets 2 and a truncated cone-shaped centering section corresponding to the inner diameter of the pipes
Data Source
Figure 1~2
AI summary
A method for producing a capacitor, which is provided with a plurality of pipes (5) extending parallel to each other and disposed in a defined grid, the ends of said pipes being held by a base plate, characterized by the following chronologically consecutive steps: providing a pan (1), the base surface of which has a plurality of bores disposed in a defined grid and pipe sockets (2) aligned with the bores, introducing filling pins (3) into the pipe sockets (2), introducing thermoplastic granules into the pan (1), melting the granules in the pan (1), introducing centering pins (4) into the pipe sockets (2) while pushing out the filling pins (3), sliding the pan (1) comprising the molten granules onto the free ends of the pipes (5), cooling the molten granules while forming a base plate receiving the free ends of the pipes (5) in a gas-tight manner, said base plate being made of thermoplastic material, and subsequently pulling the pan (1) and the centering pins (4) off the connection of the base plate and pipes (5).