Heat Exchanger Header With Forking Channels for Low Pressure Drop
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Solution Overview
Problem
Existing headers for heat exchangers are customized for specific applications, leading to high costs and long lead times, and are limited by manufacturing methods, resulting in complex and labor-intensive processes with potential leakage and limited design flexibility.
Innovation Solution
A header design featuring an array of throughgoing slits and a forking section with partitioned channels, manufactured via additive manufacturing, allowing for customizable and efficient fluid distribution across multiple paths, reducing thermal boundary build-up and enabling complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If headers are customized for specific applications, then adaptability is improved, but manufacturing cost and lead time increase
Solution Approach 1:
The patent applies universality by designing a standardized header geometry that can serve multiple applications through parametric customization. The header uses a universal forking section design with configurable parameters (number of channels, channel dimensions, slit arrangements) that can be adjusted via software to meet different application requirements while maintaining the same manufacturing process and tooling, thus achieving adaptability without increasing lead time.
2Manufacturing precision
If traditional manufacturing methods are used, then manufacturing precision is achieved, but device complexity and labor intensity increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. The header's complex geometry including the forking section, slits, and channels are all created in one integrated build process, eliminating the need for separate welding, brazing, or gluing operations. This reduces manufacturing complexity while maintaining precision through the inherent accuracy of additive manufacturing technology.
3Strength
If welding or brazing is used to join components, then structural strength is improved, but leakage risk and manufacturing complexity increase
Solution Approach 1:
The patent eliminates joining operations by merging the entire header structure into a single monolithic component manufactured via additive manufacturing. The forking section, channels, and slits are all integrated into one continuous structure without welds, brazes, or adhesives, thereby completely eliminating leakage risks associated with joint failures while maintaining structural strength through the inherent integrity of the additive manufacturing process.
4Ease of manufacture
If rectangular header designs are used, then ease of manufacture is improved, but adaptability and thermal transfer efficiency worsen
Solution Approach 1:
The patent transitions from traditional 2D rectangular header designs to a 3D additive manufacturing approach, enabling complex spatial geometries including curved surfaces, varying thickness profiles, and integrated forking sections. This dimensional change allows the header to adapt to complex heat exchanger configurations while maintaining manufacturing simplicity through the digital nature of additive manufacturing, where complex 3D geometries are as easy to produce as simple 2D shapes.
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 improved thermal transfer, low weight, and low pressure drop, with reduced manufacturing complexity and minimized leakage risk, enabling adaptable and efficient heat exchanger systems.
Implementation Method 1
A header design featuring an array of throughgoing slits and a forking section with partitioned channels, manufactured via additive manufacturing, allowing for customizable and efficient fluid distribution across multiple paths, reducing thermal boundary build-up
Implementation Method 2
Heat exchangers are used to transfer energy between outgoing and ingoing fluid flow in various applications such as ventilation, drying, cooling etc.
Data Source
Figure 1~2
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AI summary
A header (1) comprising an inlet/outlet section (3), comprising an array of throughgoing slits (4), and a forking section (5), comprising a matrix of throughgoing channels (6) arranged in a plurality of rows and columns. A housing (14) encloses said inlet/outlet section (3) and forking section (5). A first part (5a) of said forking section (5) is directly connected to said inlet/outlet section (3) at an interface (I), such that each throughgoing slit (4) is fluidly connected to throughgoing channels (6) from at least two rows and at least two columns. A second part (5b) of said forking section (5) is configured such that each throughgoing channel (6) of said matrix comprises at least one partition wall (7) dividing said throughgoing channel (6) into at least two sub-channels (6a, 6b), each subchannel (6a, 6b) being configured to fluidly connect with one cell (8) of a heat exchanger body (2).