Heat Exchanger Block Detachable Header Connection
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Solution Overview
Problem
Existing heat exchanger blocks face challenges in assembling and connecting heat exchangers of different sizes and configurations, as well as thermal interference between adjacent units, which complicates the assembly process and hampers the development of standardized joining techniques.
Innovation Solution
A heat exchanger block design featuring pairs of longitudinal headers with recessed portions and flanges, along with oblong holes and fasteners that allow for detachable connections and accommodate thermal expansion, while maintaining a compact and standardized structure, and optionally incorporating low thermal conductivity inserts and shroud attachments for thermal isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional connection methods are used to assemble heat exchangers of different sizes, then the heat exchanger block can be assembled, but additional frames or rails are required, increasing device complexity
Solution Approach 1:
The connection means are integrated directly into the headers of the heat exchangers. One header includes a recessed portion while the adjacent header includes a flange, and these components are formed as part of the header structure itself rather than being separate external fixtures. This merging eliminates the need for additional frames or rails, reducing device complexity while maintaining adaptability.
Solution Approach 2:
The standardized connection means (recessed portion and flange with matching holes) provide a universal interface that can accommodate heat exchangers of different sizes and configurations. The same connection mechanism works for various heat exchanger dimensions, making the system multi-functional and adaptable without requiring different connection methods for different sizes.
2Stability of the object's composition
If heat exchangers are thermally connected to adjacent heat exchangers, then structural stability is improved, but thermal separation is lost, causing unwanted heat transfer between different temperature ranges
Solution Approach 1:
The connection structure is segmented into distinct thermal zones. The recessed portion and flange connection creates a physical separation that interrupts thermal conduction paths between adjacent heat exchangers. This segmentation allows each heat exchanger to maintain its own thermal environment while still being structurally connected, preventing unwanted heat transfer between different temperature ranges.
3Device complexity
If detachable connections are made stable without additional frame parts, then device complexity is reduced, but the connection difficulty increases for heat exchangers of different sizes
Solution Approach 1:
The connection interface uses asymmetric geometry with a recessed portion on one header and a protruding flange on the adjacent header. This asymmetric design provides inherent alignment guidance that simplifies the connection process, making it easier to assemble heat exchangers of different sizes without requiring complex alignment procedures or additional positioning fixtures.
Solution Approach 2:
The flange acts as an intermediary component that facilitates the connection between headers of different sizes. The flange with its matching holes provides a standardized interface that mediates the connection process, making it easier to join different sized heat exchangers without direct complex interfacing between the headers themselves.
4Ease of manufacture
If common collecting tanks or headers are used for all heat exchangers, then manufacturing is simplified, but adaptability to different heat exchanger sizes is reduced
Solution Approach 1:
Instead of using a single common collecting tank design for all heat exchangers, the patent applies local quality by providing each header with connection means tailored to its specific size and function. Each header has its own recessed portion or flange dimensions optimized for its role, allowing the system to manufacture headers with standardized processes while adapting the local connection geometry to accommodate different heat exchanger sizes.
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
Facilitates the assembly of heat exchanger blocks with varying sizes and configurations without additional support frames, while ensuring secure connections and minimizing thermal interference, allowing for flexible and cost-effective manufacturing and use in diverse applications.
Implementation Method 1
oblong holes for fasteners, allowing for relative movement and thermal expansion
Implementation Method 2
an intermediate insert is between the tubes of the adjacent headers, the insert having a low thermal conductivity
Data Source
AI summary
A heat exchanger block including at least two heat exchangers each including a pair of longitudinal headers with tubes extending between the headers, at least some of which are aluminum cast parts. Adjacent heat exchangers are detachably connected at adjacent ends of their headers wherein one of the adjacent headers includes a recessed portion in the adjacent end and the other of the adjacent headers includes a flange receivable in the recess of the one header. Matching holes extend through the flange and the one header end, and a fastener extends through the matching holes in the ends of at least one set of adjacent headers. Shroud attachments are along a longitudinal wall of at least one of the longitudinal headers.