Condenser and collector for condenser
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Solution Overview
Problem
Existing collectors for condensers are complex and costly to produce, with inefficient thermal decoupling and assembly processes.
Innovation Solution
A one-piece extruded collector with a tubular wall and lateral extension for attachment to adjacent pipes, featuring overflow openings and recessed areas for thermal decoupling, and increased wall thickness for secure closure, allowing for simplified assembly and optimized thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a collector is designed as a one-piece welded tube with soldered-on covers, then the structural integrity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The collector is designed as a one-piece extruded component where the tubular wall, lateral projection for manifold connection, and closure structures are all formed in a single manufacturing operation. This eliminates the need for welding tubes together or soldering separate covers, thereby reducing manufacturing complexity while maintaining structural integrity through the continuous extruded structure.
Solution Approach 2:
The single extruded collector structure serves multiple functions simultaneously: it provides the collection chamber, includes integrated lateral projections for manifold connections, incorporates closure structures for the open end, and provides thermal decoupling features. This multi-functionality in a single component reduces assembly steps and manufacturing complexity.
2Ease of manufacture
If multiple separate components are used to form the collector, then the ease of manufacture is improved, but the assembly complexity increases
Solution Approach 1:
Multiple functional elements that would traditionally be separate components (tubular wall, lateral projections, closure structures) are merged into a single extruded collector body. This eliminates assembly steps while the extrusion process itself remains relatively simple and cost-effective for producing the complex geometry.
3Strength
If the lateral connection is continuous, then the structural strength is improved, but the thermal decoupling performance worsens
Solution Approach 1:
The lateral connection projection is segmented into spaced-off sections rather than being continuous. These discrete sections provide sufficient structural connection to the manifold while creating gaps that enable thermal decoupling, reducing unwanted heat transfer between the collector and manifold while maintaining mechanical strength.
Solution Approach 2:
The collector structure has different properties in different locations: the lateral connection areas provide structural strength where needed, while the recessed areas between connection sections provide thermal insulation. This local variation in structural density optimizes both strength and thermal performance.
4Ease of manufacture
If the wall thickness is uniform, then the manufacturing simplicity is improved, but the closure security worsens
Solution Approach 1:
The extruded collector features a localized increase in wall thickness at the open end area where closure is required. This thicker section provides enhanced structural support for secure closure while the rest of the collector maintains uniform, thin-walled construction for manufacturing efficiency and material savings.
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 enables cost-effective production, improved thermal decoupling, and a simplified assembly process, enhancing the efficiency and design of condenser collectors.
Implementation Method 1
The lateral connection is divided into spaced-off sections, with one section extending axially adjacent to the closed pipe end and/or another extending axially adjacent to the open end. This allows for good thermal decoupling in addition to the connection to the manifold.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The battery (107) has a tubular wall that is provided to form an inner space with a closed end of a tube (103), and an open and closable end of the tube for insertion of an insert. The two overflow openings are provided for fluid communication of the interior of the header with an interior of the manifold. The battery is formed from a flow pressed portion. The overflow openings are formed in the lateral approach (110,111). The lateral projection is provided with a concave portion which serves for engagement with an adjacent manifold.