Heat Exchanger Header with Segmented Tube Insertion Spaces
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Solution Overview
Problem
Existing heat exchangers face challenges in maintaining the integrity of flat tubes within the header structure, particularly during brazing, which can lead to disconnection and filling of perforated tubes with brazing alloy, limiting flexibility in tube arrangement and assembly.
Innovation Solution
A heat exchanger design featuring a header composed of multiple members, including a first member with through holes, a second member defining insertion spaces, and a third member facing the tube ends, with integrated side plates and partition plates to separate and stabilize the insertion spaces, allowing for staggered tube arrangements and enhanced assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If flat tubes are inserted directly into the header without separate insertion spaces, then the header structure is simpler, but the flat tubes may disconnect during brazing and perforated tubes may be filled with brazing alloy
Solution Approach 1:
The header is segmented into a body portion and a separate insertion portion (second member) that defines distinct insertion spaces for each flat tube. This segmentation isolates the tubes within individual spaces during brazing, preventing disconnection and brazing alloy intrusion into perforated tubes, while maintaining overall structural integrity.
2Ease of manufacture
If flat tubes are arranged in fixed positions within the header, then assembly is simpler, but flexibility in tube arrangement is reduced
Solution Approach 1:
The insertion portion is prepared in advance with pre-defined insertion spaces that guide flat tube placement. This preliminary configuration of the header allows for flexible tube arrangements to be easily achieved during assembly, as the insertion spaces are already positioned to accommodate various tube configurations without requiring complex alignment procedures.
3Productivity
If multiple flat tubes are inserted into the header simultaneously without separate insertion spaces, then the manufacturing process is faster, but deformation of tubes and header occurs
Solution Approach 1:
The insertion portion divides the header interior into multiple separate insertion spaces, each accommodating a flat tube individually. This segmentation allows multiple tubes to be inserted simultaneously while maintaining precise positional control and preventing mutual interference and deformation, as each tube is confined to its own dedicated space during the brazing process.
Data Source
AI summary
A heat exchanger includes: heat transfer tubes disposed along a predetermined direction; and a header that retains longitudinal ends of the heat transfer tubes. The header includes: a first member including a main wall portion that has through holes through which the longitudinal ends respectively pass; a second member defining insertion spaces that communicate with the heat transfer tubes at the longitudinal ends; and a third member facing the longitudinal ends. The second member includes: a pair of side plates disposed in a width direction of the header and that define the insertion spaces therebetween; and a partition plate connected to the pair of side plates and that separates adjacent ones of the insertion spaces.