Heat Exchanger Header Partition Wall with Auxiliary Communication Holes
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Solution Overview
Problem
Current heat exchangers in vehicle cooling systems face challenges in achieving high efficiency and cost-effectiveness due to structural limitations, particularly in withstanding high temperatures and pressures, as well as ensuring reliable refrigerant flow and heat exchange performance.
Innovation Solution
The proposed heat exchanger design includes a configuration with a first and second header tank, a core part with tubes and fins, and a throttle system, featuring a specific partition wall structure with main and auxiliary communication holes, and a baffle system to enhance flow paths and prevent leakage, optimizing the area ratio of these components to improve heat dissipation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat exchanger uses a conventional structure with simple header tanks, then the manufacturing cost is lower and the structure is simpler, but the heat exchange performance and reliability under high temperature and pressure are insufficient
Solution Approach 1:
The header tank is segmented into a first header tank and a second header tank that are spatially separated and connected through communication holes in the partition wall. This segmentation allows independent optimization of each header tank's function while improving overall reliability under high temperature and pressure conditions.
Solution Approach 2:
The partition wall is designed with different types of communication holes (main communication hole and auxiliary communication hole) at different locations, creating local quality variations. The main communication hole has a larger area ratio for primary refrigerant flow, while the auxiliary communication hole has a smaller area ratio (3-7%) for secondary flow control, optimizing heat exchange performance in different regions.
2Productivity
If the heat exchanger uses a conventional single header tank design, then the device complexity is lower, but the heat exchange efficiency and flow path optimization are insufficient
Solution Approach 1:
The single header tank is divided into two separate header tanks (first and second header tanks) with distinct functions. The first header tank receives refrigerant from the evaporator while the second header tank supplies refrigerant to the expansion valve, enabling parallel heat exchange operations and improving overall productivity.
Solution Approach 2:
The header tanks are arranged in a vertical dimension with the first header tank positioned above the second header tank, connected through vertical communication holes in the partition wall. This dimensional arrangement optimizes space utilization while enabling efficient refrigerant flow paths.
3Quantity of substance
If the auxiliary communication hole area ratio is too large, then the refrigerant flow is improved, but the pressure control and flow stability deteriorate
Solution Approach 1:
The area ratio of the auxiliary communication hole is precisely controlled within the range of 3-7% of the main communication hole area. This parameter optimization ensures sufficient refrigerant flow quantity while maintaining pressure control stability, balancing flow rate and pressure regulation functions.
4Volume of moving object
If the throttle is positioned close to the header tank, then the space utilization is better, but the flow control precision and leakage prevention are reduced
Solution Approach 1:
The throttle is positioned at a predetermined distance from the second header tank, creating a buffer zone that allows preliminary flow regulation before refrigerant enters the expansion valve. This preliminary action improves flow control precision and enables better leakage prevention through controlled pressure gradients.
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 reduces manufacturing costs, enhances the prevention of leakage and fastening force, and increases heat exchange performance, achieving improved efficiency and durability compared to conventional heat exchangers.
Implementation Method 1
a core part that is disposed between the first header tank and the second header tank and includes a plurality of tubes and fins
Implementation Method 2
the refrigerant absorbs heat from the surroundings in the heat exchanger
Implementation Method 3
the liquid refrigerant absorbs the amount of heat as much as the heat of vaporization in the surroundings and is vaporized
Implementation Method 4
the refrigerant absorbs heat from the surroundings in the heat exchanger, resulting in high temperature and high pressure
Data Source
AI summary
A heat exchanger including a first header tank and a second header tank that are disposed to be spaced apart a predetermined distance in a height direction and a core part that is disposed between the first header tank and the second header tank and includes a plurality of tubes and fins, the first header tank including a first header plate, a first tank, and a first partition wall that divides a space formed by a combination of the first header plate and the first tank to form a plurality of flow paths, the first partition wall being provided with a main communication hole and an auxiliary communication hole, and an area ratio of the auxiliary communication hole being 3 to 7% of an area of the main communication hole.