Folded Header Heat Exchanger for Faster Brazed Assembly
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Solution Overview
Problem
Existing heat exchanger manufacturing processes face issues with poor brazing tolerance, specific mold requirements, decreased manufacturing speed, and reduced efficiency in mass production due to the need for slotting or wire cutting to form inlets for tube insertion.
Innovation Solution
A heat exchanger with a folding-type header structure that eliminates the need for separate slotting or wire cutting, featuring a tube panel module with alternately arranged first and second tube panels, and header panel modules that are bent and bonded to reduce brazing apertures and improve manufacturing flexibility without specific molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If slotting or wire cutting is performed to form inlets for tube insertion, then tubes can be inserted into the header, but brazing tolerance deteriorates and manufacturing precision decreases
Solution Approach 1:
The invention extracts and eliminates the harmful inlets formed by slotting or wire cutting from the header. Instead of creating separate inlet holes for tube insertion, the design integrates tube connections directly into the header structure through bending and bonding, removing the source of brazing tolerance problems while maintaining tube insertion capability
Solution Approach 2:
The invention merges the functions of the header and tube support structures. The header panels are bent to form integrated support structures that directly hold tubes without requiring separate inlet holes, combining the distribution and support functions into a single unified structure that eliminates brazing tolerance issues
2Manufacturing precision
If specific molds are used for manufacturing heat exchangers according to sizes, then manufacturing precision can be maintained, but device complexity increases and manufacturing flexibility decreases
Solution Approach 1:
The invention creates a universal header structure that can be adapted to different heat exchanger sizes without requiring specific molds for each size. The folding-type header panels and bending processes can be standardized and scaled, allowing the same basic manufacturing approach to produce various sizes of heat exchangers while maintaining precision
Solution Approach 2:
The invention uses parameter changes in the bending and folding processes to adapt the header structure to different sizes. By adjusting bending angles, panel dimensions, and folding configurations rather than changing the fundamental manufacturing method or requiring different molds, the system maintains manufacturing precision across various product sizes
3Ease of operation
If slotting is performed on one header by the number of tubes, then tubes can be inserted, but manufacturing speed decreases and productivity is reduced
Solution Approach 1:
The invention extracts and eliminates the time-consuming slotting operation from the manufacturing process. By removing the need for slotting or wire cutting to create inlets, the process directly proceeds to bending and bonding operations, significantly reducing manufacturing steps and increasing production speed while maintaining tube insertion capability
Solution Approach 2:
The header panels are designed and prepared in advance with bending zones and folding structures that enable direct tube insertion without on-demand slotting. The support structures are pre-formed through bending, eliminating the need for time-consuming slotting operations during assembly and improving overall manufacturing efficiency
4Ease of manufacture
If the blade of machining equipment is used for slotting, then inlets can be formed, but the blade becomes worn and requires frequent replacement
Solution Approach 1:
The invention extracts and eliminates the slotting operation that requires blade machining from the manufacturing process. By replacing slotting with bending and folding operations, the harmful blade wear and frequent replacement issues are completely removed, while the functional capability to accommodate tubes is maintained through the integrated header structure
Solution Approach 2:
The invention replaces the mechanical blade slotting system with a bending and folding system. Instead of using a blade to cut inlets, the process uses bending zones and folding structures to create integrated support structures, substituting a wear-prone mechanical cutting system with a more durable forming process
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 solution decreases brazing tolerance, enhances product stability, and increases manufacturing speed and cost efficiency, allowing for flexible customization of heat exchanger sizes and improved mass production efficiency.
Implementation Method 1
the first tube panel is formed by bonding a first panel and a second panel
Implementation Method 2
the second tube panel is formed by bonding a third panel and a fourth panel
Implementation Method 3
a first header panel formed by bending both ends of the first panel and the second panel in opposite directions
Implementation Method 4
a second header panel formed by bending both ends of the third panel and the fourth panel in opposite directions
Implementation Method 5
bonded to the first header panel between every first tube panel and second tube panel
Data Source
AI summary
A heat exchanger is provided that includes a tube panel module elongated in a vertical direction and including a plurality of first tube panels and a plurality of second tube panels that are alternately arranged in a lateral direction; header panel modules respectively formed at an upper end and a lower end of the tube panel module and elongated in the lateral direction; and a header case having an open one side, providing a space therein, and covered on the one side by the header panel module such that the plurality of first tube panels and the plurality of second tube panels communicate with the space. Each first tube panel is formed by bonding a first panel and a second panel, and each second tube panel is formed by bonding a third panel and a fourth panel. The header panel modules include a first header panel formed by bending both ends of the first panel and the second panel in opposite directions, and a second header panel formed by bending both ends of the third panel and the fourth panel in opposite directions and bonded to the first header panel between every first tube panel and second tube panel.