Header box assembly
By introducing bypass channels into the header assembly of the heat exchanger, the uneven fluid flow and dead zone problems caused by insufficient pressure difference at both ends of the tubular element are solved, the heat exchange efficiency is improved and the thermal stress is reduced, and the uniform distribution and simple manufacturing of the fluid are achieved.
Patent Information
- Application Number
- CN202380091050.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-01-10
- Filing Date
- 2023-12-05
- Publication Date
- 2025-08-05
AI Technical Summary
In existing heat exchangers, uneven fluid flow and dead zone formation due to insufficient pressure difference at both ends of the tubular element, which affects heat exchange efficiency and performance and may cause heat stress problems.
The bypass channel is introduced into the header assembly of the heat exchanger, forming a fluid communication between the tubular element with insufficient pressure difference at both ends and the outlet nozzle, ensuring uniform distribution of the fluid through the bypass channel to prevent the formation of dead zones.
The uniform fluid distribution in the heat exchanger is achieved, the heat exchange efficiency is improved, the formation of dead zones is prevented, and the thermal stress problem is reduced. The structure is simple and easy to manufacture.
Smart Images
Figure CN120435640A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a header box assembly, and in particular, to a header box assembly for a vehicle heat exchanger. Background Art
[0002] Typically, a heat exchanger, such as a radiator, includes a header assembly that arranges a first manifold 2 and a second manifold 4 on opposite sides of a heat exchanger core 6, which is defined by tubular elements 6a separated by fins 6b. The first manifold 2 and the second manifold 4 include inlet nozzles 2c and outlet nozzles 4c, respectively, for the inflow and outflow of a first heat exchange fluid relative to the heat exchanger 1. The first manifold 2 distributes the first heat exchange fluid received therefrom to the tubular elements, particularly to one end of the tubular element 6a. The second manifold 4 collects the first heat exchange fluid from the other end of the tubular element 6a after the first heat exchange fluid has exchanged heat with a second heat exchange fluid, such as air, that flows through the tubular element 6a as the first fluid passes through the tubular element 6a. More specifically, the tubular element 6a provides fluid communication between the first manifold 2 and the second manifold 4, thereby forming a fluid flow path between the first manifold 2 and the second manifold 4.
[0003] However, given the positions of inlet nozzle 2c and outlet nozzle 4a, as well as the configuration of first and second tanks 2a and 4a of the first and second header tank assemblies, the pressure differential across some tubular elements is insufficient, particularly across tubular element 6e located distal from the inlet nozzle. This insufficient pressure differential across the end portions of multiple tubular elements 6e restricts fluid flow therethrough and creates dead zones within these end tubular elements 6e, leading to insufficient heat exchange and adversely affecting the efficiency and performance of heat exchanger 1. None of the prior art solutions address the problem of uneven fluid flow and the formation of dead zones within the tubular elements caused by the insufficient pressure differential across the end portions of the multiple tubular elements.
[0004] Therefore, there is a need for a header assembly for a heat exchanger that ensures uniform fluid distribution within the tubular elements of the heat exchanger, thereby preventing dead zones within the heat exchanger. Furthermore, there is a need for a header assembly for a heat exchanger that promotes efficient heat exchange and ensures improved performance of the heat exchanger. Furthermore, there is a need for a header assembly for a heat exchanger that prevents problems such as thermal stress caused by high temperature gradients due to uneven fluid flow within the tubular elements of the heat exchanger.
[0005] Another object of the present invention is to provide a header box assembly for a heat exchanger, which has a simple structure and is easy to manufacture.
[0006] In this specification, some elements or parameters may be indexed, such as "first element" and "second element." In this case, unless otherwise specified, such indexing is used solely to distinguish and name similar, but not identical, elements. No notion of priority should be inferred from such indexing, as these terms can be interchanged without departing from the present invention. Furthermore, such indexing does not imply any order of installation or use of the elements of the present invention. Summary of the Invention
[0007] A header box assembly includes a header and a box, the header and box being assembled to define a manifold that supplies a heat exchange fluid to a bundle of tubular elements or collects the heat exchange fluid from the tubular elements after the heat exchange fluid undergoes heat exchange while passing through the tubular elements. At least one of the header box assemblies includes at least one bypass channel that establishes fluid communication between a tubular element having an insufficient pressure differential across its ends and corresponding inlet and outlet nozzles.
[0008] Typically, the bypass channel provides fluid communication between at least one end tubular element distal to the outlet nozzle and the outlet nozzle.
[0009] Specifically, the bypass passage is provided along at least one of an inner side and an outer side of the tank of the second header tank assembly.
[0010] Preferably, the bypass channel comprises at least one inlet and at least one outlet, wherein the at least one inlet collects fluid from at least one of the tubular elements and the at least one outlet delivers the fluid to the outlet nozzle, the at least one inlet passing through the at least one tubular element with insufficient pressure difference at both ends.
[0011] Typically, the inlets are evenly spaced relative to each other.
[0012] Specifically, the bypass channel is formed integrally with the tank during the formation of the tank through a molding process.
[0013] Furthermore, the bypass channel has a uniform cross-section along its length.
[0014] More specifically, the bypass channel is provided along at least one of the side walls and the top wall of the tank.
[0015] According to one embodiment of the present invention, the inner side of the tank is provided with guide ribs to guide the fluid to flow toward the inlet of the bypass channel.
[0016] According to one embodiment of the present invention, a plurality of bypass channels form a fluid connection between the tubular element with insufficient pressure difference at both ends and the at least one outlet nozzle.
[0017] Typically, the flow through the bypass channel is based on the pressure difference between the tank outlet nozzle and the outlet of the tubular element.
[0018] According to one embodiment of the present invention, a bypass channel is formed in the first header assembly for defining fluid communication between the inlet nozzle and the tubular element having an insufficient pressure difference across both ends.
[0019] According to one embodiment, the at least one outlet creates a pressure difference across the at least one outlet to promote the flow of fluid from the bypass channel to the nozzle.
[0020] According to another embodiment, the header assembly includes a connection portion at a junction between the bypass passage and the nozzle to facilitate fluid flow from the bypass passage to the nozzle.
[0021] A heat exchanger according to an embodiment of the present invention is also disclosed. The heat exchanger includes a first header assembly, a plurality of tubular elements, and a second header assembly. The first header assembly receives fluid therein via an inlet nozzle. The plurality of tubular elements are in fluid communication with the first header assembly to receive the fluid distributed by the first header assembly. The second header assembly collects fluid from the tubular elements for discharge through outlet nozzles formed therein. The second header assembly also includes at least one bypass channel that establishes fluid communication between the outlet nozzle and the tubular elements, where the pressure differential between the two ends is insufficient. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Other features, details, and advantages of the present invention can be inferred from the following description of the invention. A more complete understanding of the present invention and its many attendant advantages will be readily obtained, and the present invention and its many attendant advantages will become better understood, by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:
[0023] FIG1 shows a cross-sectional view depicting the internal details of a conventional header box assembly;
[0024] Figure 2 shows an isometric view of a heat exchanger configured with the header box assembly of the present invention;
[0025] Figure 3 A cross-sectional view of a heat exchanger according to one embodiment is shown showing internal details of a header assembly thereof, wherein a bypass channel is formed inside a manifold;
[0026] Figure 4 Shown Figure 3 a cross-sectional view of a box of a header box assembly;
[0027] Figure 5 shows a cross-sectional view of a heat exchanger according to another embodiment, illustrating internal details of a header assembly thereof, wherein a bypass channel is formed outside the manifold;
[0028] Figure 6 Shown Figure 5 a cross-sectional view of the box; depicting an enlarged view of the inlet and outlet of the bypass channel;
[0029] Figure 7 shows an isometric view of a header box assembly according to one embodiment, the header box assembly having a single outlet;
[0030] Figure 8 Shown Figure 7 a cross-sectional view of a header box assembly;
[0031] Figure 9 shows an isometric view of a header box assembly having multiple outlets according to one embodiment;
[0032] Figure 10 Shown Figure 9 a cross-sectional view of a header box assembly;
[0033] Figure 11 A schematic diagram of a header box assembly according to another embodiment is shown, wherein the outlet nozzle is positioned in the middle of the box.
[0034] It must be noted that the accompanying drawings disclose the invention in sufficient detail to enable it to be implemented and, if necessary, to help better define the invention. However, the invention should not be limited to the embodiments disclosed in the specification. DETAILED DESCRIPTION
[0035] Although the present invention is explained in the following description and accompanying drawings using a header assembly for a radiator as an example, wherein the outlet manifold of the radiator is provided with at least one bypass channel that establishes fluid communication between a tubular element having an insufficient pressure difference at both ends and an outlet nozzle to ensure air removal and uniform distribution of the heat exchange fluid throughout the tubular element, the present invention is also applicable to any header assembly for a heat exchanger in a vehicular or non-vehicular environment.
[0036] Reference Figure 2, shows a heat exchanger 100 configured with a header assembly according to an embodiment of the present invention. More specifically, heat exchanger 100 (e.g., a radiator) includes header assemblies 10 and 30, which are configured with first and second manifolds on opposite sides of a heat exchanger core defined by tubular elements 20 separated by fins. The first and second manifolds include inlet nozzles 10a and outlet nozzles 30a, respectively, for the flow of a first heat exchange fluid into and out of heat exchanger 100. The first manifold distributes the first heat exchange fluid received thereby to tubular elements 20 at one end of the tubular elements. After the first heat exchange fluid exchanges heat with a second heat exchange fluid flowing through tubular elements 20 (e.g., air flowing through the tubular elements 20 as the first fluid passes through the tubular elements 20), the second manifold collects the first heat exchange fluid from the other end of the tubular elements 20. More specifically, the tubular elements 20 establish fluid communication between the first and second manifolds, forming a fluid flow path between the first and second manifolds.
[0037] The present invention Figures 3 to 10 , the assembly includes at least one bypass channel 40 that provides fluid communication between tubular elements 20a with insufficient pressure differential across the tubular elements 20a and corresponding outlet nozzles 30a. The bypass channel 40 is configured to create a sufficient pressure differential across the tubular elements 20a proximal to the inlet 42 of the bypass channel 40 to allow fluid to flow therethrough and achieve uniform fluid flow through all tubular elements 20. Specifically, the bypass channel 40 provides fluid communication between at least one of the tubular elements 20a distal to the outlet nozzle 30a and the outlet nozzle 30a. The bypass channel 40 has a varying cross-section; in particular, the bypass channel 40 converges toward the outlet nozzle 30a to facilitate fluid flow through the bypass channel 40. Furthermore, the inner side 32a of the box 32 is provided with features, such as guide ribs, to direct fluid flow toward the inlet 42 of the bypass channel 40. In the case where the outlet nozzle 30a is provided at one end of the header assembly 30, the inlet 42 to the bypass passage 40 is provided near the other end of the header assembly 30 opposite the outlet nozzle 30a. In the case where the outlet nozzle 30a is provided in the middle of the header assembly 20, there may be two bypass passages, referred to as a first bypass passage 40a and a second bypass passage 40b, which extend toward opposite sides of the outlet nozzle 30a, as shown in FIG. Figure 11 As shown. Specifically, the first bypass channel 40a and the second bypass channel 40b receive fluid from respective first inlet 42a and second inlet 42b and deliver it to the outlet nozzle 30a. In this configuration, the first inlet 42a leading to the first bypass channel 40a is located proximate one end of the header assembly 30, and the second inlet 42b leading to the second bypass channel 40b is located proximate the other end of the header assembly 30.
[0038] According to one embodiment, the bypass passage 40 is provided along at least one of the inner side and the outer side of the box 32. The bypass passage 40 is provided along the inner side 32a of the box 32, as shown in FIG. Figure 3 and Figure 4 As shown, or set along the outer side 32b of the box 32, as shown in the accompanying drawings Figures 5 to 8 As shown. Specifically, the bypass channel 40 can be provided along at least one of the side walls and the top wall of the box 32. Typically, the bypass channel 40 is integrally formed with the box 32 during the molding process. This bypass channel configuration can be easily manufactured in a single step. Alternatively, the bypass channel 40 can be separated from the box 32 and secured to the box 32 using a snap-fit connection or any other connecting means, such as screws and bolts.
[0039] According to one embodiment of the present invention, the bypass channel 40 has a uniform cross-section along its length. Alternatively, the bypass channel 40 may have a non-uniform cross-section along its length. Furthermore, there may be multiple bypass channels 40, each of which provides fluid communication between the tubular element 20a with an insufficient pressure differential across its ends and the outlet nozzle 30a. However, the present invention is not limited to the configuration, arrangement, or number of bypass channels disposed within or outside the manifold, as long as the bypass channels provide fluid communication between the tubular element with an insufficient pressure differential across its ends and the corresponding outlet nozzle.
[0040] Typically, the bypass passage 40 includes at least one inlet 42 and at least one outlet 44. The inlet 42 collects fluid from at least one of the end tubular elements 20a, and the outlet 44 delivers the fluid to the outlet nozzle 30a, as shown. Figure 6 According to one embodiment, the bypass channel 40 includes a plurality of inlets 42, such as Figure 7 and Figure 8 As shown. When the bypass channel 40 includes multiple inlets 42, the multiple inlets 42 form a fluid flow path A indicated by an arrow leading to the bypass channel 40. The inlets 42 are provided proximal to the multiple tubular elements 20a with insufficient pressure difference between the ends to collect fluid from these tubular elements 20a, and the outlets 44 forming a fluid flow path B leading to the outlet nozzle 30a deliver the fluid collected from the multiple inlets 42 to the outlet nozzle 30a through the outlets 44. Thus, the bypass channel establishes fluid communication between the tubular elements 20a with insufficient pressure difference between the ends and the outlet nozzle 30a.
[0041] According to another embodiment of the present invention, the bypass channel 40 includes a plurality of outlets 44. The inlets 42 are evenly spaced relative to one another, each corresponding to an area of the interior of the header assembly near the tubular element 20a where the pressure differential between the ends is insufficient. However, the present invention is not limited to any particular configuration, position, and spacing between the inlets, so long as the inlets are capable of collecting fluid within the bypass channel 40 from the area of the header assembly near the tubular element 20a where the pressure differential between the ends is insufficient. Similarly, the outlets 44 can be evenly spaced relative to one another. However, the present invention is not limited to any particular configuration, position, and spacing between the outlets, so long as the outlets are capable of delivering the fluid received in the bypass channel to the outlet nozzle. The flow through the bypass 40 is based on the pressure differential between the tank outlet nozzle 30a and the outlet of the tubular elements 20, 20a.
[0042] A heat exchanger 100 according to an embodiment of the present invention is also disclosed. The heat exchanger includes a first header assembly 10, a plurality of tubular elements 20, and a second header assembly 30. The first header assembly 10 receives fluid therein via an inlet nozzle 10a. The plurality of tubular elements 20 are in fluid communication with the first header assembly 10 to receive the fluid distributed by the first header assembly 10. The second header assembly 30 collects the fluid from the tubular elements 20 for discharge through outlet nozzles 30a formed therein. The second header assembly 30 also includes at least one bypass channel 40 that establishes fluid communication between the outlet nozzles 30a and the tubular elements 20a, where the pressure difference between the two ends is insufficient.
[0043] According to another embodiment, a bypass passage 40 may be formed in the first header assembly 10 for defining fluid communication between the inlet nozzle 10 a and the tubular element 20 a having an insufficient pressure difference between both ends.
[0044] According to one embodiment, the at least one outlet 44 generates a pressure difference at both ends thereof to promote the flow of fluid from the bypass channel 40 to the nozzles 10a, 30a. More specifically, the bypass channel converges toward the at least one outlet 44 in the direction of fluid flow.
[0045] According to another embodiment, the header assembly 10, 30 includes a connecting portion 50 at the junction between the bypass passage 40 and the nozzle 10a. This facilitates fluid flow from the bypass passage 40 to the nozzle 10a, 30a. The connecting portion 50 connects between the bypass passage 40 and the nozzle 10a, 30a and establishes fluid communication between the bypass passage 40 and the nozzle 10a, 30a. More specifically, the connecting portion 50 gradually diverges in the direction of fluid flow away from the at least one outlet 44.
[0046] This arrangement of the bypass channel 40, the at least one outlet 44 and the connection portion connecting and configuring fluid communication between the bypass channel 40 and the nozzles 10a, 30a achieves the dual purpose of uniform distribution of fluid through the core and outflow of fluid (particularly coolant with bubbles or coolant with entrained air / air-saturated coolant) from the heat exchanger.
[0047] In any case, the present invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments are possible. The present invention should extend to any equivalent means and any combination of means that operate technically.
Claims
1. A header box assembly (10, 30) comprising a header (12, 32) and a box (14, 34), the header (12, 32) and the box (14, 34) being assembled with each other to define a manifold (16, 36), the manifold (16, 36) supplying a heat exchange fluid to a bundle of tubular elements (20) or collecting the heat exchange fluid from the tubular elements (20) after the heat exchange fluid has undergone heat exchange during passage through the tubular elements (20), It is characterized by: At least one of the header box assembly (10) and the header box assembly (30) includes at least one bypass channel (40), wherein the bypass channel (40) forms a fluid connection between a tubular element (20a) with insufficient pressure difference between both ends and the corresponding inlet nozzle (10a) and outlet nozzle (30a).
2. The header box assembly (10, 30) according to claim 1, wherein: The bypass channel (40) establishes fluid communication between at least one of the end tubular elements (20a) distal to the outlet nozzle (30a) and the outlet nozzle (30a).
3. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The bypass passage (40) is provided along at least one of an inner side (32a) and an outer side (32b) of the tank (32) of the second header tank assembly (30).
4. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The bypass channel (40) includes at least one inlet (42) and at least one outlet (44), wherein the at least one inlet (42) is adapted to collect fluid from at least one of the tubular elements (20a) having insufficient pressure difference at both ends, and the at least one outlet (44) is adapted to deliver the fluid to the outlet nozzle (30a).
5. The header box assembly (10, 30) according to claim 4, wherein: The inlets (42) are evenly spaced relative to each other.
6. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The bypass channel (40) is formed integrally with the box (32) during the process of forming the box (32) through a molding process.
7. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The bypass channel (40) has a uniform cross-section along its length.
8. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The bypass channel (40) is provided along at least one of a side wall and a top wall of the box (32).
9. The header box assembly (10, 30) according to claim 3, wherein: The inner side (32a) of the box (32) is provided with guide ribs to guide the fluid to flow toward the inlet (42) of the bypass channel (40).
10. The header box assembly (10, 30) according to any one of the preceding claims, comprising a plurality of bypass channels (40) forming a fluid connection between the tubular element (20a) with insufficient pressure difference across the two ends and the at least one outlet nozzle (30a).
11. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The flow through the bypass (40) is based on the pressure difference between the tank outlet nozzle (30a) and the outlet of the tubular element (20, 20a).
12. A header box assembly (10, 30) according to any one of the preceding claims, wherein: The bypass channel (40) is formed in the first header assembly (10) for establishing fluid communication between the inlet nozzle (10a) and the tubular element (20a) with insufficient pressure difference between both ends.
13. The header box assembly (10, 30) according to claim 4, wherein: The at least one outlet (44) is adapted to generate a pressure difference across the outlet to promote the flow of fluid from the bypass channel to the nozzle (10a, 30a).
14. The header box assembly (10, 30) according to any one of the preceding claims, further comprising a connecting portion (50) located at a junction between the bypass channel (40) and the nozzle (10a, 30), the connecting portion (50) being adapted to facilitate fluid flow from the bypass channel to the nozzle (10a, 30a).
15. A heat exchanger (100), comprising: • a first header box assembly (10) adapted to receive fluid therein via an inlet nozzle (10a); • a plurality of tubular elements (20) adapted to be in fluid communication with the first header assembly (10) to receive fluid distributed by the first header assembly (10); • a second header assembly (30) adapted to collect fluid from the tubular element (20) to flow out through the outlet nozzle (30a) formed on the tubular element (20), It is characterized in that the second header box assembly (30) further includes at least one bypass channel (40), and the at least one bypass channel (40) forms a fluid connection between the tubular element (20a) with insufficient pressure difference at both ends and the outlet nozzle (30a).