Compact Heat Exchanger Casing Manifold Integration
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Solution Overview
Problem
Existing heat exchangers have large overall dimensions due to the need for crimping mechanisms to hold fluid manifolds, which increases their external volume and reduces compactness.
Innovation Solution
The fluid manifold is directly held by the casing, eliminating the need for crimping mechanisms on the header plate, and the manifold and casing are either welded, brazed, or crimped together to form a compact structure, with stiffening means on the header plate to maintain mechanical strength and precise hole dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the header plate includes crimping means to hold the fluid manifold, then the manifold is securely held, but the external volume of the exchanger increases
Solution Approach 1:
The patent merges the manifold support function into the casing structure by providing internal support surfaces and positioning features on the casing itself. This eliminates the need for separate crimping means on the header plate, thereby securing the manifold without increasing the exchanger's external volume.
2Strength
If the manifold is held by the header plate with crimping means, then the assembly is mechanically secure, but the overall dimensions of the exchanger increase
Solution Approach 1:
The support function previously separated in the header plate is merged into the casing structure. The casing now provides both containment and manifold support through integrated support surfaces, maintaining mechanical strength while reducing overall dimensions.
Solution Approach 2:
The patent transitions from a planar support approach on the header plate to a three-dimensional support structure within the casing. The casing provides support surfaces at multiple spatial positions, distributing the manifold support function throughout the volume rather than concentrating it on a single plate.
3Reliability
If crimping mechanisms are added to the header plate, then the manifold is securely positioned, but manufacturing complexity increases
Solution Approach 1:
The patent combines the positioning and support functions into the casing structure itself. The casing includes integrated support surfaces and positioning features that eliminate the need for separate crimping mechanisms on the header plate, thereby simplifying the header plate design while maintaining positioning accuracy.
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 results in a more compact heat exchanger with improved mechanical strength and reduced overall dimensions, facilitating easier manufacturing and storage, while maintaining efficient fluid flow and heat exchange capabilities.
Implementation Method 1
the manifold and the casing are welded or brazed
Implementation Method 2
the manifold and the casing are welded or brazed
Implementation Method 3
the manifold and the casing are crimped. In this case, the casing includes at least one lug for crimping on to the manifold
Data Source
AI summary
The heat exchanger has exchange and fluid flow components (2, 2′), at least one fluid manifold (11) into which the exchange components (2, 2′) open, at least one header plate (10) for holding the exchange components (2, 2′), and a casing (4) for accommodating the exchange components (2, 2′). According to the invention, the fluid manifold (11) is held directly by the casing (4). A compact heat exchanger is produced.