Heat Exchanger Header Structure for Tube Retention During Assembly
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Solution Overview
Problem
Existing heat exchangers face issues with heat transfer tubes being extracted from the header during assembly, leading to assembly challenges and potential failures, especially when the insertion length is not appropriately managed.
Innovation Solution
A heat exchanger design featuring a header with a tubular shape, including a base portion and protruding portions that create a space for the heat transfer tubes, with a communication hole for uniform insertion and temporary fixing, preventing extraction during assembly and brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insertion length of heat transfer tubes is not appropriately provided, then the heat transfer tube may be extracted from the header during assembly, but increasing the insertion length makes assembly more difficult and time-consuming
Solution Approach 1:
The header is pre-formed with protruding portions that extend into the heat transfer tubes before assembly occurs. These protruding portions are positioned to contact the inner circumference of the heat transfer tubes, preventing extraction during assembly without requiring long insertion lengths or complex assembly procedures.
Solution Approach 2:
The protruding portions act as an intermediary mechanical feature between the header and heat transfer tubes. They provide a positive stop that prevents tube extraction while allowing for simple insertion, serving as a mediator that resolves the conflict between retention reliability and assembly simplicity.
2Reliability
If the heat transfer tube insertion length is increased to prevent extraction, then reliability improves, but the complexity of the header structure increases
Solution Approach 1:
The header structure is segmented by adding protruding portions that divide the internal space. These protruding portions are distributed around the header circumference and each independently prevents extraction of heat transfer tubes, allowing the structure to achieve high reliability through distributed simple features rather than a single complex mechanism.
Solution Approach 2:
Rather than making the entire header structure complex, the invention applies local quality by adding protruding portions only at specific locations where heat transfer tubes are inserted. The protruding portions have specific dimensions (extending in the thickness direction) that are optimized for their local function of preventing tube extraction, while the rest of the header maintains its simple tubular structure.
3Ease of operation
If the heat transfer tube insertion length is appropriately controlled, then assembly ease improves, but the risk of tube extraction during assembly increases
Solution Approach 1:
The protruding portions are pre-configured in the header to apply preliminary anti-action against the heat transfer tubes. By extending into the tube path before assembly, they create a predetermined barrier that prevents extraction, allowing the tube insertion length to be kept short while maintaining reliability.
Data Source
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AI summary
Provided is a heat exchanger that excels in ease of assembly. A heat exchanger (100) includes a header (10) that extends in a first direction (dr1) and a plurality of heat transfer tubes (60) that extend in a second direction (dr2) crossing the first direction (dr1). One end of each of the heat transfer tubes (60) is connected to the header (10). The plurality of heat transfer tubes (60) are arranged in the first direction (dr1) at intervals. The header (10) includes a header body (20) having a tubular shape, a header first member (30) through which one end of each of the heat transfer tubes (60) extend, and a header second member (40). The header second member (40) is positioned between the header body (20) and the header first member (30) in the second direction (dr2). The header second member (40) includes a base portion (41) and a plurality of protruding portions (45). The base portion (41) extends in the first direction (dr1). The protruding portions (45) extend from the base portion (41) toward the header first member (30) in the second direction (dr2).