Heat Exchanger Header Stiffening Element Design

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Solution Overview

Problem

Heat exchangers experience bending or flexing due to thermal expansion variations between heat exchanger tubes, leading to increased stress and potential leakage at tube-header junctions.

Innovation Solution

A stiffening element is integrated into the header tank of the heat exchanger, featuring a stiffening wall extending from one longitudinal side to the opposing side, enhancing the bending stiffness and resistance to thermal expansion-induced deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If the header is made thinner to reduce weight and material cost, then manufacturing cost is reduced, but bending stiffness decreases leading to increased flexing under thermal expansion

Engineering Contradiction:

Improveheader weightVSAvoidheader bending stiffness

Core Design Contradiction:

Weight of stationary objectVSStability of the object's composition

Solution Approach 1:

The stiffening element is divided into multiple ribs extending from the front surface to the rear surface of the header. These ribs segment the header structure into multiple stiffened zones, providing enhanced bending stiffness throughout the header while maintaining overall thinness and weight reduction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stiffening element adds structural reinforcement in the third dimension by extending ribs from the front surface through to the rear surface of the header. This dimensional addition increases the area moment of inertia and bending stiffness without increasing the header's planar dimensions or weight significantly

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stability of the object's composition

If the header is made thicker to increase bending stiffness, then resistance to thermal expansion-induced flexing is improved, but manufacturing cost and weight increase

Engineering Contradiction:

Improveheader bending stiffnessVSAvoidheader weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of stationary object

Solution Approach 1:

Instead of uniformly thickening the header, the stiffening element segments the reinforcement into multiple ribs that provide localized stiffness where needed. This segmented approach achieves the required bending stiffness while minimizing material usage and weight compared to a uniformly thicker header

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stiffening element forms a composite structure with the header, combining the base header material with the integrated stiffening ribs. This composite configuration optimizes the strength-to-weight ratio by providing reinforcement only where structurally necessary, rather than uniformly increasing thickness throughout

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the header is made thicker to increase bending stiffness, then resistance to thermal expansion-induced flexing is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveheader bending stiffnessVSAvoidheader manufacturing

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The stiffening element is merged with the header as an integrated component, forming a single unified structure. This merging eliminates the need for separate manufacturing and assembly steps for additional stiffening components, simplifying manufacturing while achieving the required bending stiffness

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stiffening element serves multiple functions: it increases bending stiffness, resists thermal expansion-induced flexing, and maintains a streamlined profile. This multi-functionality achieves structural reinforcement without adding complex manufacturing processes or increasing header thickness

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 stiffening element effectively prevents header deformation and reduces the risk of leakage by increasing the area moment of inertia, ensuring the header remains stable under varying thermal conditions.

Implementation Method 1

increasing the area moment of inertia, ensuring the header remains stable under varying thermal conditions

Methodology Applied

Scientific EffectArea moment of inertia: Moment of Inertia

Implementation Method 2

These variations in temperature can result in the first and second sets of the heat exchanger tubes experiencing different degrees of thermal expansion in the longitudinal direction of each of the tubes

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11073345B2Heat exchanger header with stiffening element

Publication Date: 2021.07.27 HANON SYST CO LTD

AI summary

A header tank for a heat exchanger comprises a casing having a hollow interior and a header assembly coupled to the casing. The header assembly comprises a header having a plurality of tube openings formed therein and a stiffening element coupled to the header. The stiffening element includes a stiffening wall extending from a first longitudinal side of the header to an opposing second longitudinal side of the header to provide additional bending stiffness to the header assembly.