Header-Tank Communication Hole Layout for Uniform Heat Exchange
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Solution Overview
Problem
The existing heat exchanger designs face challenges in optimizing the position and size of communication holes, leading to increased manufacturing costs, non-uniform temperature distribution, and reduced durability due to complex structures and dead zones in refrigerant flow.
Innovation Solution
A heat exchanger design with communication holes strategically positioned between the baffle and the end of the header-tank, with a controlled surface area ratio and spacing, to simplify the structure and enhance refrigerant flow uniformity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If communication holes are formed at every tube in the header-tank, then refrigerant flow path is established, but device complexity increases and manufacturing cost increases
Solution Approach 1:
Multiple communication holes that were previously formed at each tube are merged into a single communication hole formed at the partition wall. This consolidation reduces the number of holes from multiple per tube to one shared hole, simplifying the overall structure and reducing manufacturing complexity while maintaining the refrigerant flow function.
Solution Approach 2:
The single communication hole at the partition wall serves as a universal communication path for refrigerant flow between multiple tubes and header-tanks, replacing the need for individual communication holes at each tube location. This multi-functional design reduces device complexity without compromising flow path establishment.
2Manufacturing precision
If communication holes are positioned without optimization, then refrigerant flow is established, but temperature distribution becomes non-uniform and heat exchange performance deteriorates
Solution Approach 1:
The position parameter of the communication hole is optimized to be located at a specific region between the baffle and the end of the header-tank, rather than at arbitrary or uniform positions. This parameter optimization ensures uniform temperature distribution and maximizes heat exchange performance by improving refrigerant flow distribution.
Solution Approach 2:
The communication hole is strategically positioned in a specific local region of the partition wall where it can most effectively influence refrigerant distribution. This localized optimization creates non-uniform flow patterns that result in more uniform temperature distribution across the heat exchanger, improving overall heat exchange performance.
3Reliability
If communication hole structure is complex, then refrigerant flow control is precise, but durability decreases due to stress concentration
Solution Approach 1:
The communication hole function is extracted from the complex tube-level structure and relocated to the partition wall structure. This extraction simplifies the communication hole structure while maintaining its essential function of controlling refrigerant flow, and simultaneously improves durability by reducing stress concentration points.
4Adaptability or versatility
If communication holes are redesigned according to fin standards, then flow path is optimized, but manufacturing inconvenience increases
Solution Approach 1:
The single communication hole at the partition wall serves as a universal flow path for multiple tubes and header-tanks, eliminating the need for separate communication holes at each tube location. This universal design maintains flow path optimization while significantly improving manufacturing convenience by reducing the number of features that need to be designed and manufactured.
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 simplifies the manufacturing process, reduces costs, and improves heat exchange performance by ensuring uniform refrigerant distribution and preventing stress concentration, thereby enhancing the durability of the heat exchanger.
Implementation Method 1
the fin 30 is interposed between the tubes 20 to enhance heat exchange performance
Implementation Method 2
the gaseous refrigerant introduced from the evaporator to the compressor is compressed at a high pressure and high temperature, and the compressed gaseous refrigerant radiates liquefaction heat to a peripheral portion while passing through the condenser so as to be liquefied
Implementation Method 3
a communication hole 15 is formed on the partition wall 11 that is positioned at a region disposed between the baffle 12 and one end of the header-tank 10 adjacent to the baffle 12
Data Source
AI summary
One or more embodiments of the present invention relates to a heat exchanger. The heat exchanger comprises a pair of header-tanks having at least one partition wall and at least one baffle; a plurality of tubes; and a plurality of fins. A communication hole is formed on the partition wall that is positioned at a region disposed between the baffle and one end of the header-tank adjacent to the baffle. Given that a distance from the baffle to the one end of the header-tank is 100%, 1˜4 communication holes are formed at positions on the partition wall which corresponds to an extent of 0˜50%, 65˜100%, or an extent of 0˜50% and an extent of 65˜100%.