Header Box Recessed Holes for Compact Heat Exchangers
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Solution Overview
Problem
In automotive air conditioning systems, there is a need to minimize the height of the header box of heat exchangers while maintaining or increasing heat exchange capacity, and for CO2 refrigeration systems, high pressure resistance is required due to high operating pressures.
Innovation Solution
The design includes a header box with a bottom plate and cover plate, featuring recessed holes for fluid distribution and a casing with a core of flat tubes for efficient heat exchange, along with a cover plate that blocks openings to prevent solder clogging and enhance welding strength, allowing for improved flow rates and heat exchange efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the height of the header box is reduced to increase heat exchange capacity, then the volume of the heat exchange core increases, but the structural complexity of the bottom plate increases due to recessed holes
Solution Approach 1:
The bottom plate is segmented into multiple functional zones with recessed holes distributed across its surface. These recessed holes create localized channels that divide and direct fluid flow through different regions of the heat exchange core, enabling complex flow patterns within a compact header box structure.
Solution Approach 2:
The recessed holes in the bottom plate create three-dimensional flow channels within the otherwise planar structure. By recessing holes into the bottom plate surface, the design adds vertical dimensionality to fluid distribution, allowing multi-level flow paths without increasing the overall header box height.
2Productivity
If the header box height is minimized to increase heat exchange capacity, then more space is available for the heat exchange core, but the manufacturing precision requirements increase for the recessed holes
Solution Approach 1:
The recessed holes are pre-formed in the bottom plate during manufacturing, establishing the fluid distribution network before assembly. This preliminary formation of flow channels ensures that the precise geometry required for optimal fluid distribution is built-in during production, rather than requiring post-assembly adjustments.
3Reliability
If the cover plate blocks openings to prevent solder clogging, then the reliability of fluid flow is improved, but the welding strength requirements increase
Solution Approach 1:
The cover plate acts as an intermediary component between the header box and the fluid distribution system. By positioning the cover plate over the recessed holes and blocking their openings, it serves as a protective barrier that prevents solder and other contaminants from entering and clogging the fluid channels, while still allowing for secure welding connections.
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 reduces the height of the header box, increases heat exchange capacity, and provides high pressure resistance suitable for CO2 refrigeration systems, enhancing the overall efficiency and stability of the heat exchanger.
Implementation Method 1
The heat exchanger can be used for heat exchange between a refrigerant and the outside air, and can also be used for heat exchange between the refrigerant and a cooling liquid
Implementation Method 2
the first hole is communicated with the at least two second holes, so that fluid flowing through the first hole is capable of being distributed to the at least two second holes
Data Source
AI summary
A header box includes a first bottom plate and an unperforated cover plate. The first bottom plate includes a first surface and a second surface opposite to the first surface. The first bottom plate is of a one-piece configuration. The first surface is recessed inwardly to form a straight first hole extending along a length direction. The second surface is recessed inwardly to form at least two straight second holes extending along a width direction perpendicular to the length direction. The first hole is communicated with the at least two second holes. The cover plate is connected to the first surface to block an opening of the first hole on the first surface. A heat exchanger having the header box is also disclosed.