Heat Exchanger with Segmented Headers for Bend-Friendly Manufacturing
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Solution Overview
Problem
Conventional heat exchangers face challenges in bending configurations due to constrained headers, leading to increased manufacturing costs and reduced productivity, as the bending process requires re-brazing, which is inefficient and can damage the material.
Innovation Solution
A heat exchanger design where one header is common for multiple rows and separate headers are used for each heat exchange unit on the other end, allowing the bend section to be formed after brazing, reducing the need for multiple brazing processes and improving flexibility in bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If headers are provided on both ends of the heat exchange unit group in common for multiple rows, then the structural simplicity and manufacturing ease are improved, but the ability to form bend sections after brazing deteriorates due to constrained positions
Solution Approach 1:
The header on the downstream side is divided into multiple separate headers corresponding to individual heat exchange units, while the upstream side maintains a common header. This segmentation allows each separate header to be independently positioned after bending, enabling the heat exchange unit group to form bend sections while maintaining proper header connections.
2Reliability
If the heat exchange unit group is brazed to headers first and then bent, then the structural integrity is improved, but the manufacturing cost increases and productivity decreases due to required re-brazing
Solution Approach 1:
The common header and separate headers are pre-positioned at their final locations before the heat exchange unit group is brazed and bent. This preliminary positioning ensures that the headers remain properly aligned throughout the bending process, eliminating the need for re-brazing and maintaining both structural integrity and manufacturing efficiency.
3Adaptability or versatility
If re-brazing is performed after bending to connect headers, then the bending flexibility is improved, but the manufacturing cost increases and material reliability deteriorates due to thermal damage
Solution Approach 1:
The headers are pre-positioned before brazing, allowing the entire assembly to be brazed in one process before bending. This eliminates subsequent re-brazing operations that would expose the material to additional thermal stress and potential damage, while still achieving the required bending flexibility through the separate header configuration.
4Reliability
If multiple brazing processes are required for header connection, then the connection reliability is improved, but the manufacturing complexity and time consumption increase
Solution Approach 1:
The positioning and brazing of all headers are merged into a single integrated process step performed before bending. The common upstream header and multiple separate downstream headers are simultaneously positioned and brazed to the heat exchange unit group, reducing the process from multiple separate brazing operations to one unified operation.
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, increases productivity, and enhances the reliability of the heat exchanger by allowing for efficient bending without damaging the material, while also improving heat exchange efficiency and reducing the amount of refrigerant needed.
Implementation Method 1
a plurality of heat transfer tubes configured to allow refrigerant to pass therethrough
Implementation Method 2
a plurality of fins stacked to allow air to pass in the air flow direction
Implementation Method 3
the heat transfer tube and the fin may be brazed to form the heat exchange unit group
Data Source
AI summary
A heat exchanger includes: a heat exchange unit group made up of a plurality of heat exchange units arranged in a row direction, the heat exchange units including a plurality of heat transfer tubes configured to allow refrigerant to pass therethrough, the heat transfer tubes being arrayed in a level direction, the level direction being perpendicular to the direction of air flow, and a plurality of fins stacked to allow air to pass therethrough in the air flow direction; and headers, disposed on both ends of the heat exchange unit group, the headers being connected with ends of the plurality of heat transfer tubes, the heat exchange unit group including one or more bend sections bent in the row direction, the headers including one header provided on one end of the heat exchange unit group in common for the plurality of rows of the heat exchange units, and a plurality of separate headers provided separately for the heat exchange units on the other end of the heat exchange unit group, the plurality of separate headers being arranged at positions different between adjacent rows, the positions being different in a fin-stacking direction in which the plurality of fins are stacked.