Cylindrical Heat Exchanger Header with Bead
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Solution Overview
Problem
Heat exchangers with tube and fin construction face increased cost and complexity due to secondary joining operations after brazing, which can compromise the integration of fluid ports and mounting features, especially in cylindrical header designs that aim to avoid these operations.
Innovation Solution
A header design featuring two cylindrical portions with a circumferential bead, where tube receiving slots are strategically located close to the bead, allowing for secure retention and integration of the headers within a cooling module using retention features and an attachment bracket, eliminating the need for additional mounting parts and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a formed component is joined to the header after brazing to create a tank, then fluid ports and mounting features can be integrated into the formed component, but the cost and complexity increase due to the secondary joining operation
Solution Approach 1:
The patent merges the tank and header into a single integrated header structure where the tank is formed as an integral part of the header body. This eliminates the need for secondary joining operations between separate tank and header components, while still providing integrated fluid ports and mounting features directly on the header.
Solution Approach 2:
The header is designed to perform multiple functions: it serves as both the structural header component and the tank for fluid storage, while also integrating fluid ports and mounting features. This multi-functionality reduces the number of separate components needed and eliminates secondary joining operations.
2Device complexity
If the header is made cylindrical to avoid secondary joining operations, then manufacturing complexity is reduced, but fluid ports and mounting features cannot be directly integrated
Solution Approach 1:
The header maintains a generally cylindrical shape for manufacturing efficiency, but incorporates localized variations in geometry to integrate fluid ports and mounting features. The tank portion and feature integrations are strategically placed at specific locations where they do not compromise the overall cylindrical form or manufacturing simplicity.
3Strength
If tube slots are located far from the circumferential bead, then structural integrity is maintained, but retention features cannot securely restrain the header
Solution Approach 1:
The retention feature engages the header in multiple dimensions: radially (through the circumferential bead), axially (through the tube slot proximity), and circumferentially (through the bead geometry). This multi-dimensional engagement provides secure restraint while maintaining structural integrity through proper positioning relative to the tube slots.
Data Source
Figure 1
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AI summary
A header for a heat exchanger includes a first and a second cylindrical portion. The first cylindrical portion has a first diameter, and extends over a first length portion of the header. The second cylindrical portion has a second diameter that is smaller than the first diameter, and extends over a second length portion of the header. Tube receiving slots are arranged along the first length portion. An end cap is received into an open end of the first cylindrical portion, and is joined thereto to seal a first end of the header. An open end of the second cylindrical portion is arranged at a second end of the header opposite the first end to allow for fluid flow into or out of the header. A circumferential bead is located between the first and second cylindrical portions, and extends radially outward of the first cylindrical portion.