Heat Exchanger Header Cover Deflector Flow Distribution

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Solution Overview

Problem

Existing heat exchanger header covers in automotive vehicles experience fluid flow-related issues such as erosion and leakage due to high-speed coolant flow, leading to resistance problems and incorrect fluid distribution among tubes, particularly with mechanical and brazed assembly types.

Innovation Solution

A header cover design featuring a vault with angled deflectors and a rounded hump, where the deflectors are oriented to spread the fluid uniformly among tubes, reducing flow-induced damage and optimizing fluid distribution, and can be used for both input and output fluid management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-speed coolant flow is used in the header cover, then heat exchanger productivity is improved, but fluid flow-induced erosion and damage to tubes increases

Engineering Contradiction:

Improveheat exchanger performanceVSAvoidfluid flow-induced erosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The header cover interior is segmented into multiple flow paths using deflectors that direct coolant flow toward the nozzle opening. This segmentation distributes the high-speed flow across multiple directions rather than allowing concentrated erosion at tube ends, while maintaining high overall flow velocity for productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Deflectors are introduced as intermediary elements between the coolant flow and the tube ends. These deflectors mediate the interaction by redirecting the high-speed flow away from direct impact with tube ends, reducing erosion while preserving the high flow rates needed for heat exchanger productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If high-speed coolant flow is used in the header cover, then heat exchanger productivity is improved, but incorrect fluid distribution among tubes occurs

Engineering Contradiction:

Improveheat exchanger performanceVSAvoidfluid distribution uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the header cover are given different flow characteristics through strategically positioned deflectors. The deflectors create localized flow patterns that ensure uniform distribution across all tubes while maintaining high overall flow velocity for productivity.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If deflectors are added to spread fluid flow, then fluid distribution is improved, but device complexity increases

Engineering Contradiction:

Improvefluid distribution uniformityVSAvoidheader cover structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The deflectors are integrated directly into the header cover structure as a single piece, merging the flow distribution function with the header cover body. This integration achieves uniform fluid distribution while minimizing the increase in device complexity by avoiding separate, detachable components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The header cover structure serves multiple functions: it contains the coolant, distributes the flow uniformly through integrated deflectors, and provides structural support. This multi-functionality reduces overall device complexity by combining several functions into a single component rather than requiring separate elements for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design effectively reduces fluid flow-induced damage and ensures uniform distribution, enhancing the structural integrity and efficiency of heat exchanger performance by minimizing pressure drops and leakage risks.

Implementation Method 1

The header cover comprises a plurality of deflectors superimposed on one side of the vault, opposite to the opening of the nozzle, in an axis defining an angle, especially a right-angle, with a plane defined by an opening of the vault on the heat exchanger core. The deflectors are oriented to spread the fluid uniformly among tubes

Methodology Applied

Scientific EffectFluid flow distribution:

Implementation Method 2

The vault of the header cover comprises a rounded hump, higher than the apex of the vault, said rounded hump comprising two opposite sides and defining a volume at the location of the nozzle

Methodology Applied

Scientific EffectFlow turbulence reduction:

Data Source

PatentEP2474805B1A header cover, in particular for a heat exchanger

Publication Date: 2019.06.26 VALEO AUTOSYSTY

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AI summary

Header cover (10), in particular for heat exchangers of automotive vehicles, comprising a vault (11) and a fluid input and/or output nozzle opening out into the header cover through a side (12) of said vault. The header cover is configured for conveying a fluid to or from a plurality of tubes (32) of circulation of a heat exchanger core (30). The vault of the header cover is configured to open out on the heat exchanger core. The header cover comprises a plurality of deflectors (15) superimposed on one side (14) of the vault, opposite to the opening of the nozzle, in an axis defining an angle with a plane (18) defined by an opening of the vault on the heat exchanger core.