Bridging Header Structure to Prevent Corrugated Sheet Deformation
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Solution Overview
Problem
The existing heat exchangers with corrugated sheets in bridging headers face challenges due to deformation under refrigerant pressure, leading to reduced design flexibility and interference with heat transfer tubes.
Innovation Solution
A heat exchanger design featuring a bridging header with a corrugated sheet that is suppressed from deformation by a covering plate, allowing for adjustable placement and number of heat transfer tubes without thickening the corrugated sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the corrugated sheet is thickened to prevent deformation under refrigerant pressure, then the strength and reliability of the bridging header is improved, but the corrugated sheet interferes with heat transfer tube insertion and reduces design flexibility
Solution Approach 1:
The covering plate is installed beforehand to press the corrugated sheet toward the base, preventing deformation before refrigerant pressure acts on the system. This preliminary support allows the use of thinner corrugated sheets without compromising structural integrity under pressure.
Solution Approach 2:
The covering plate acts as an intermediary element between the refrigerant pressure and the corrugated sheet. By introducing this intermediate component, the corrugated sheet does not need to directly withstand high pressures, allowing it to remain thin and flexible while still maintaining system reliability.
2Reliability
If the corrugated sheet is thickened to maintain structural integrity, then the reliability is improved, but the region in the base for heat transfer tube insertion is reduced
Solution Approach 1:
The covering plate provides preliminary support to the corrugated sheet, ensuring structural integrity is maintained before refrigerant pressure is applied. This allows the design to use thinner sheets that occupy less space in the base region, thereby increasing the available area for heat transfer tube insertion while maintaining reliability.
3Ease of manufacture
If the corrugated sheet is made thinner to increase design flexibility, then the ease of manufacture and design freedom is improved, but the corrugated sheet deforms under refrigerant pressure
Solution Approach 1:
The covering plate is installed in advance to provide support to the thin corrugated sheet, preventing deformation when refrigerant pressure is applied. This allows manufacturers to use thinner, more flexible sheets that are easier to manufacture and install, while the covering plate ensures structural stability during operation.
Solution Approach 2:
The covering plate serves as a protective intermediary that shields the thin corrugated sheet from direct exposure to high refrigerant pressures. This mediator allows the use of thinner materials that would otherwise deform, thereby improving ease of manufacture while maintaining operational stability.
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 enhances design flexibility by allowing adjustments in the number and spacing of heat transfer tubes while maintaining structural integrity against refrigerant pressure.
Implementation Method 1
a covering plate covering the corrugated sheet and pressing the corrugated sheet toward the base
Implementation Method 2
a fin provided on the heat transfer tubes and facilitating heat exchange between refrigerant flowing inside the heat transfer tubes and air
Data Source
AI summary
A heat exchanger has: a heat transfer tube group made up of plural heat transfer tubes each of which has, inside the heat transfer tube, a flow passage through which refrigerant flows; a fin provided on the heat transfer tubes; and a bridging header into which end portions of the heat transfer tubes are inserted and that causes refrigerant to flow between the heat transfer tubes. The bridging header has a base having a flat plate shape. The bridging header also has a corrugated sheet forming, between the corrugated sheet and the base, a header flow passage, through which refrigerant flows. The bridging header also has a covering plate covering the corrugated sheet and pressing the corrugated sheet toward the base.