Vehicle condenser
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vehicle condenser supports with protruding portions are prone to melting the radiation fins during brazing, leading to increased failure rates and reduced efficiency, and the manufacturing process is inefficient due to the need for separate molds for different lengths and arbitrary adjustment limitations.
Innovation Solution
The vehicle condenser design features a notch portion or through-hole in the coupling parts of the supports that extend inward from the tip, preventing the radiation fins from melting during brazing and allowing for efficient manufacturing regardless of the support manufacturing method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protruding portion is formed on the support to facilitate brazing and prevent separation of radiation fins, then the brazing process is improved, but the radiation fins may melt when the clad on the header melts during brazing and flows along the protruding portion
Solution Approach 1:
The harmful protruding portion that causes molten clad to flow onto radiation fins is removed. Instead, a flat coupling part is used that provides sufficient brazing surface area without creating channels for molten metal flow, thereby eliminating the source of the harmful effect while maintaining brazing functionality
Solution Approach 2:
The design converts the potential harm of molten clad flow by using the flat coupling part geometry to redirect molten clad away from radiation fins. The coupling part's flat surface allows brazing to occur effectively while the geometry naturally prevents molten metal from reaching and damaging the radiation fins
2Adaptability or versatility
If the starting point of the protruding portion is randomly formed on the support, then manufacturing flexibility is improved, but the clad on the header melts the radiation fin during brazing, increasing the failure rate of the condenser
Solution Approach 1:
The flat coupling part design serves multiple functions: it provides a standardized brazing surface, prevents molten clad flow onto radiation fins, and works with supports of various lengths using the same geometry. This universal design eliminates the need for random protruding portion positioning while maintaining manufacturing flexibility through standardized components
3Adaptability or versatility
If the press mold is changed to adjust the starting point of the protruding portion for different support lengths, then manufacturing adaptability is improved, but the time and cost for manufacturing the support increase
Solution Approach 1:
A single flat coupling part geometry is used for all support lengths, eliminating the need for multiple specialized press molds. The standardized design allows the same mold to produce coupling parts for supports of various lengths, significantly reducing manufacturing time and cost while maintaining adaptability
Solution Approach 2:
Instead of changing the geometry (protruding portion position) to adapt to different support lengths, the invention changes only the length parameter of the support while keeping the coupling part geometry constant. This parameter-based adaptation maintains manufacturing efficiency
4Ease of manufacture
If the support is designed without a protruding portion to simplify manufacturing, then manufacturing complexity is reduced, but the radiation fin separation during assembly increases
Solution Approach 1:
The support is segmented into distinct functional parts: a flat coupling part for brazing that provides sufficient surface area for strong attachment, and the support body for structural function. This segmentation allows simplification of the coupling interface while maintaining attachment strength through optimized brazing surface geometry
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 design reduces the failure rate of the condenser, maintains the original state of the radiation fins, and enhances the condenser's efficiency and aesthetic appearance by preventing melting and supporting efficient assembly and manufacturing processes.
Implementation Method 1
a condenser performs a function that exchanges heat between the high-temperature and high-pressure gas refrigerant discharged from the compressor and outside air so that the refrigerant is condensed into a liquid phase
Implementation Method 2
a condenser performs a function that exchanges heat between the high-temperature and high-pressure gas refrigerant discharged from the compressor and outside air so that the refrigerant is condensed into a liquid phase
Implementation Method 3
the clad on a header of a header tank is melted during the brazing of the radiation fins
Implementation Method 4
the clad on a header of a header tank is melted during the brazing of the radiation fins
Data Source
AI summary
A vehicle condenser in which a notch portion of each coupling part of a pair of supports installed at the outermost sides of radiation fins extends so as to have a certain length from the tip of a body part to the inside end of the notch portion, or a through-hole is formed so as to be spaced by a predetermined distance toward the inside of the body part from the tip thereof, thereby preventing the radiation fins from melting when the clad on a header of a header tank is melted during the brazing of the radiation fins and flows along an embossing part, regardless of a method for manufacturing the supports. Consequently, it is possible to reduce the failure rate of the condenser and increase the efficiency of the condenser by maintaining the original state of the radiation fins.