Method of manufacturing a header and heat exchanger comprising a corresponding header obtained by such a method.
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Solution Overview
Problem
The existing methods for manufacturing headers in heat exchangers result in a reduction of brazing material thickness, leading to shifts in plate-shaped bodies and potential refrigerant leakage due to the melting of brazing materials, which compromises the structural integrity and efficiency of the heat exchanger.
Innovation Solution
A method involving a first member with no brazing material on its surface, a second member also without brazing material, and a third member with brazing material applied, where the brazing material from the third member enters the gap between the first and second members during heating, eliminating the need for excessive brazing material and reducing the likelihood of refrigerant leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing material is applied to surfaces before assembly, then bonding strength is improved, but the brazing material thickness reduces during melting causing plate shift and refrigerant leakage
Solution Approach 1:
The brazing material is applied in advance to the third member (intermediate plate) before assembly. During furnace heating, this pre-applied brazing material melts and naturally flows into the gaps between the first and second members, achieving reliable bonding without requiring the brazing material to be present between the first and second members during the bonding process, thus preventing plate shift
Solution Approach 2:
The third member (intermediate plate) with pre-applied brazing material serves as an intermediary that facilitates bonding between the first and second members. The brazing material on the third member acts as a mediator that flows into gaps and bonds the first and second members together, eliminating the need to apply brazing material directly to the first and second members
2Stability of the object's composition
If excessive brazing material is applied to prevent plate shift, then position stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Brazing material is applied locally and selectively only to the third member (intermediate plate) rather than to all members. This localized application simplifies the manufacturing process while still achieving the desired position stability, as the brazing material on the third member is sufficient to prevent plate shift during bonding
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 configuration ensures stable bonding between the members without preliminary brazing material, reducing the risk of refrigerant leakage and maintaining structural integrity while minimizing costs by eliminating the need for additional brazing steps.
Implementation Method 1
The first member, the second member, and the third member are heated in a furnace, and the brazing material applied to the third surface thus enters a gap between the first surface and the second surface
Implementation Method 2
the brazing material applied to the third surface enters the gap between the first surface and the second surface to bond the first surface and the second surface with each other
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An outdoor heat exchanger (13) includes a liquid side header (52) and a heat transfer tube (53). The liquid side header (52) guides a refrigerant. The heat transfer tube (53) is connected to the liquid side header (52) and causes heat exchange between the refrigerant and a medium. The liquid side header (52) includes an inner board (62), an inner board (63), and an outer board (61). The inner board (62) has a surface (622). The inner board (63) has a surface (631) facing the surface (622). The outer board (61) has a surface (614). The surface (614) crosses the surface (622) and the surface (631), and is bonded to the inner board (62) and the inner board (63). The surface (622) and the surface (631) are bonded by a brazing material having a first thickness. The surface (614) and the inner board (62) are bonded by a brazing material having a second thickness. The surface (614) and the inner board (63) are bonded by a brazing material having a third thickness. The first thickness is less than the second thickness. The first thickness is less than the third thickness. The first thickness is 0.2 mm or less.