Heat Exchanger Frames with Stress-Absorption Zones for High Pressure
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Solution Overview
Problem
Existing heat exchangers fail to withstand high pressures, particularly those used in motor vehicles with refrigerant fluids like CO2, due to limitations in mechanical strength and efficiency, and face challenges in compact design and fluid circulation configurations.
Innovation Solution
A heat exchanger design featuring a bundle of heat exchange tubes with stress-absorbing frames that include recesses and arch-shaped edges for mechanical stress absorption, allowing for efficient fluid circulation and brazing, and a configuration of alternating frames for improved mechanical strength and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional plate heat exchangers are used, then the structure is simple, but they cannot withstand high pressures greater than 100 bars
Solution Approach 1:
The heat exchanger is divided into multiple modules, each comprising a stack of tubes interconnected by collectors. This modular segmentation allows each unit to withstand high pressures independently while maintaining overall structural simplicity and ease of assembly.
Solution Approach 2:
The heat exchanger employs composite construction combining tube bundles with collector assemblies, creating a structurally robust design capable of withstanding pressures greater than 100 bars while maintaining manufacturing simplicity through standardized connection points.
2Strength
If a stack of tubes with collectors is used to withstand high pressure, then pressure resistance improves, but the architecture becomes complex to produce with multiple brazing points
Solution Approach 1:
The collectors serve multiple functions: they interconnect tube bundles, provide structural support for high-pressure containment, and facilitate fluid distribution. This multi-functionality reduces the number of separate components and brazing points required, simplifying manufacturing while maintaining pressure resistance.
3Productivity
If traditional tube collectors are used, then pressure containment is achieved, but the tube height cannot be reduced below 2 mm limiting efficiency
Solution Approach 1:
The design shifts from vertical tube stacking to a planar arrangement where tubes are interconnected through collectors in a two-dimensional configuration. This allows efficient heat exchange surface area while maintaining compact overall dimensions and enabling tube heights below 2 mm without compromising structural integrity or heat transfer efficiency.
4Ease of manufacture
If cross flow configuration is used, then construction is simplified, but counter-current circulation cannot be provided reducing efficiency
Solution Approach 1:
The collector design enables flexible fluid flow configuration, allowing the system to operate in counter-current mode when efficiency is prioritized or cross-flow mode when construction simplicity is needed. The interconnected collector structure dynamically adapts to different operational requirements without compromising manufacturing ease.
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
The design enhances mechanical strength and resistance to high pressures, enables efficient heat exchange, and simplifies construction while allowing for compact size and efficient fluid circulation, addressing the limitations of prior art heat exchangers.
Implementation Method 1
the first frames for receiving the heat exchange tubes respectively comprise at least one stress absorption zone, arranged on at least one edge facing one end of a heat exchange tube and capable of withstanding mechanical stresses
Implementation Method 2
heat exchanger comprising a heat exchange bundle with a plurality of heat exchange tubes defining circulation channels for a fluid
Implementation Method 3
heat exchangers assembled by brazing
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a heat exchanger, in particular for a motor vehicle, said exchanger comprising a heat-exchanger core with a plurality of heat-exchanger tubes (5) defining channels for circulating a fluid. According to the invention: the heat-exchanger core comprises a plurality of first frames (13) for receiving heat-exchanger tubes (5); and the first frames (13) for receiving heat-exchanger tubes respectively comprise at least one stress-absorption area (133), arranged on at least one edge (13A, 13B) opposite one end of a heat-exchanger tube (5) and capable of withstanding mechanical stress.