Heat Exchanger Header With Transverse Channels
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Solution Overview
Problem
Existing heat exchanger headers are inefficient due to material duplication, leading to increased weight, cost, and pressure losses, particularly in high-pressure refrigerant systems like CO2 gas coolers.
Innovation Solution
A two-part collector tube design with a base and lid, featuring transverse and longitudinal channels that allow for fluid flow and pressure compensation, reducing weight and pressure losses while maintaining high-pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If a two-part manifold design is used, then weight and cost are reduced, but pressure losses may increase due to potential blockage of flow channels
Solution Approach 1:
The invention relocates the flow channels from the traditional horizontal plane to the vertical dimension by forming them in the cover plate. This dimensional change allows the channels to pass through the cover thickness, creating unobstructed flow paths that avoid blockage by flat tubes while maintaining the lightweight two-part manifold structure.
Solution Approach 2:
The manifold is divided into two separate parts (base and cover) that are joined together. This segmentation allows the cover to incorporate vertical flow channels that would be difficult to implement in a monolithic structure, thereby reducing weight while preventing pressure losses through proper channel positioning.
2Weight of stationary object
If material duplication is avoided in heat exchanger design, then weight and cost are reduced, but manufacturing complexity increases
Solution Approach 1:
The heat exchanger is segmented into modular components: flat tubes, a base plate with openings, and a cover plate with integrated flow channels. This segmentation eliminates material duplication while maintaining manufacturing simplicity through standardized joining methods (soldering, brazing, or mechanical connections) between the modular parts.
Solution Approach 2:
The cover plate serves multiple functions: it closes the manifold structure, provides vertical flow channels for refrigerant distribution, and acts as a support structure. This multi-functionality reduces the need for separate components, thereby reducing weight and material duplication while keeping manufacturing straightforward.
3Strength
If traditional manifold designs are used in CO2 gas coolers, then structural simplicity is maintained, but they cannot withstand higher pressure levels
Solution Approach 1:
The cover plate is designed with a curved or domed shape instead of a flat configuration. This curvature provides structural strength to withstand high CO2 pressure levels while using minimal material, thereby increasing pressure resistance without significantly increasing device complexity. The curved geometry naturally distributes stress more effectively than flat surfaces.
Solution Approach 2:
The manifold uses composite construction combining the base plate and cover plate made from materials suitable for high-pressure CO2 applications. This composite approach allows optimization of each component for its specific function while achieving overall high pressure resistance, balancing strength requirements with manageable complexity.
Data Source
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AI summary
A header for a heat exchanger, which comprises a plurality of flat tubes arranged in a longitudinal direction. The header has a bottom and a lid. The bottom has a plurality of openings for coupling the header to the plurality of flat tubes. The lid is arranged opposite of the bottom and connected to the lid, at least at the edges extending in the longitudinal direction, in a fluid-tight manner. The lid has a plurality of transverse channels on a side facing the bottom, which are arranged opposite of the plurality of openings, and a longitudinal channel extending in the longitudinal direction.