Axial Groove Header Assembly for Heat Exchanger Miniaturization
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Solution Overview
Problem
Conventional header assemblies in heat exchangers have a large volume and weight due to their design, which is influenced by the size of the through groove, leading to increased refrigerant charge and fluid resistance, and are difficult to miniaturize due to strength and manufacturing constraints.
Innovation Solution
A header assembly with a new structure featuring through grooves that extend in the same direction as the main header sections, allowing for reduced hydraulic diameter, weight, and volume, and improved refrigerant distribution, while maintaining strength and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the header assembly uses a conventional radial groove design, then the flat tube can be properly accommodated and welded, but the outer diameter and thickness of the header assembly must be large, resulting in increased volume and weight
Solution Approach 1:
The groove is reoriented from a radial direction to an axial direction (parallel to the header axis). This dimensional change allows the groove to extend along the length of the header rather than across its diameter, enabling the flat tube to be accommodated with a much smaller outer diameter while maintaining adequate wall thickness for strength.
2Ease of manufacture
If the header assembly outer diameter is increased to accommodate the flat tube width, then the flat tube can be properly installed, but the volume and weight of the header assembly increase significantly
Solution Approach 1:
By changing the groove orientation from radial to axial, the design allows the flat tube to be installed through a groove that runs parallel to the header axis. This enables the header to have a much smaller outer diameter since the groove depth (along the axis) does not constrain the radial dimension as much as a radial groove would.
3Strength
If the header assembly thickness is increased to ensure strength, then the structural integrity is maintained, but the volume and weight of the header assembly increase
Solution Approach 1:
The axial groove orientation allows the header wall thickness to be optimized independently of the outer diameter. Since the groove runs parallel to the axis, the required wall thickness for strength can be maintained at a minimal value (0.5-1.5mm) without needing to increase the outer diameter to accommodate deeper radial grooves.
4Volume of stationary object
If the through groove size is reduced to minimize header assembly volume, then the refrigerant charge decreases, but the hydraulic diameter may be affected in conventional designs
Solution Approach 1:
The axial groove orientation decouples the groove dimensions from the header's hydraulic diameter. The groove extends along the axis rather than radially, so its cross-sectional area (which affects hydraulic diameter) remains small while its length (which affects volume) can be optimized independently. This allows minimal refrigerant charge in the header while maintaining adequate flow characteristics.
Data Source
AI summary
A header assembly and a heat exchanger having the same are provided. The header assembly includes at least one header group, the header group includes a plurality of main header sections, the main header section is provided with at least one through groove, the through groove extends in a same direction as an axis of the main header section, and the plurality of main header sections in the header group are communicated with one another. In the header group, the main header section extends along a first direction, and the plurality of main header sections are sequentially arranged along a second direction. An included angle between the first direction and the second direction is greater than 0°.