Additive Heat Exchanger Header With Integral Flange
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Solution Overview
Problem
Existing heat exchanger headers face challenges due to welded flanges, which can cause warping and complicate the attachment of sub-components, making the manufacturing process difficult and prone to errors.
Innovation Solution
An additively manufactured header with a base, tube, and flange formed in a layer-by-layer process, where the tube and flange are integrated with the header body, allowing for tighter tolerances and reduced weld joints, enhancing structural integrity and simplifying the attachment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flanges are welded onto the header, then the header can be assembled with sub-components, but warping occurs and manufacturing becomes more difficult
Solution Approach 1:
The flange is merged with the header body through additive manufacturing, creating an integral structure where the flange is formed as part of the header fabrication process rather than being welded separately. This eliminates the welding operation and associated warping issues while maintaining the functional connection between the flange and header.
2Ease of operation
If flanges are welded onto the header, then the header can be assembled with sub-components, but the attachment process becomes more complex and error-prone
Solution Approach 1:
The flange and header are combined into a single additively manufactured component, eliminating the separate welding operation. This reduces the number of assembly steps and potential error sources while simplifying the overall manufacturing process.
3Strength
If welded flanges are used on headers, then traditional manufacturing methods can be employed, but structural integrity is compromised due to warping
Solution Approach 1:
The welding process is replaced with additive manufacturing technology. Instead of joining separate components through welding (which causes warping), the flange and header are fabricated as an integrated structure using layer-by-layer material deposition, eliminating the harmful thermal effects of welding while maintaining structural integrity.
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 improves manufacturing tolerances and reduces failure modes, providing a more robust and efficient assembly process by integrating the header, tube, and flange through additive manufacturing, thus addressing the warping and attachment issues of traditional welded headers.
Implementation Method 1
The header body, the tube, and the flange are all additively manufactured together
Implementation Method 2
The header body, the tube, and the flange are each formed in a layer-by-layer process
Data Source
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AI summary
An additively manufactured header (13A, 13B) for a heat exchanger includes a header body (14A, 14B). The header body includes a base (16A, 16B) and a top (18A, 18B) opposite the base. The base (16A, 16B) is open and configured for connection to a heat exchanger core. The additively manufactured header further includes a tube (20A, 20B) extending from the top of the header body and a flange (26A, 26B) formed on the tube. The header body (14A, 14B), the tube (20A, 20B), and the flange (26A, 26B) are all additively manufactured together.