Heat Exchanger Support Cuts for Thermal Load Tube Protection
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Solution Overview
Problem
Existing heat exchangers face issues with tube damage due to thermal load, particularly in single-row configurations, where stress concentration at joint portions occurs, and increasing the number of saw-cuts to alleviate this damage leads to higher production costs.
Innovation Solution
A heat exchanger design featuring a combination of I-shaped and Z-shaped cut portions on the support, with the I-shaped cut at the center and symmetrically placed Z-shaped cuts at the ends, which enhances thermal load suppression without requiring additional manufacturing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of saw-cuts on the support is increased to suppress tube damage from thermal load, then tube damage is reduced, but manufacturing cost increases due to additional equipment requirements
Solution Approach 1:
The support is divided into multiple segments through saw-cuts, creating expansion gaps that allow each segment to move independently during thermal expansion. This segmentation reduces stress concentration on tubes while maintaining structural integrity, solving the reliability issue without requiring excessive cuts that would increase manufacturing complexity
Solution Approach 2:
The patent optimizes the number and positioning of saw-cuts to achieve the minimum effective configuration. By carefully selecting parameters such as cut depth, spacing, and location, the design achieves adequate thermal expansion accommodation with a limited number of cuts, avoiding the need for additional manufacturing equipment while still suppressing tube damage
2Stability of the object's composition
If the support maintains a fixed distance between header tanks, then structural stability is improved, but stress concentration on tube joints increases during thermal expansion
Solution Approach 1:
The support transitions from a completely rigid structure to a semi-dynamic structure with controlled flexibility. The saw-cuts create gaps that allow the support to dynamically adjust its configuration during thermal expansion, absorbing stress while maintaining overall positional stability between header tanks
Solution Approach 2:
The patent incorporates thermal expansion gaps through saw-cuts in the support structure. These gaps allow the header tanks and connected components to expand thermally without generating excessive stress, as the support can accommodate the dimensional changes while still maintaining structural integrity
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 effectively suppresses tube damage by allowing flexible deformation and reducing stress concentration, while maintaining structural integrity and avoiding increased production costs by utilizing existing equipment.
Implementation Method 1
when thermal expansion occurs due to the formation of a high-temperature environment, during the expansion process of the tank and tubes, respectively, stress is concentrated at the joint portions therebetween
Data Source
AI summary
The present disclosure is directed to provide a heat exchanger and a method of manufacturing the same, which are capable of, in a high-temperature environment, improving the effect of suppressing tube damage caused by the heat load by improving the shape of a saw-cut formed on a support to suppress tube damage caused by a heat load while also allowing the heat exchanger to be manufactured using existing equipment, thereby preventing an increase in the production costs. More specifically, an object of the present disclosure is to provide a heat exchanger and a method of manufacturing the same, in which the shape of the saw-cut formed on the support is formed of two types, an I-shaped cut portion and a Z-shaped cut portion, and the I-shaped cut portion is formed at the center, while a pair of Z-shaped cut portions are formed symmetrically and biased toward the both ends.