Integral Heat Exchanger Manifold Fabrication
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Solution Overview
Problem
Existing heat exchanger manifolds are expensive and laborious to manufacture due to the need for welding two pieces together, which is undesirable for current manufacturing expectations.
Innovation Solution
A method of fabricating a heat exchanger manifold by bending a sheet of material to form a distributor conduit and header, where the header radially surrounds the distributor conduit, and orifices are formed along the leading edge for fluid communication, allowing for a single integral sheet to define the manifold with sealed edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a manifold is constructed by welding two pieces together (distributor conduit and header), then the structural integrity is ensured, but the manufacturing cost and labor requirements increase
Solution Approach 1:
The patent combines the distributor conduit and header into a single integral manifold structure formed from one continuous piece of material. This eliminates the need for welding separate components together, reducing manufacturing complexity and cost while maintaining structural integrity through the monolithic construction.
2Strength
If a manifold is constructed by welding two pieces together, then the structural integrity is ensured, but the manufacturing time and process complexity increase
Solution Approach 1:
The manifold is formed as a single integrated component from one continuous piece of material through forming operations, eliminating the sequential steps of manufacturing separate parts and welding them together. This single-step forming process significantly reduces manufacturing time while ensuring structural integrity.
3Strength
If a manifold is constructed by welding two pieces together, then the structural integrity is ensured, but the production efficiency decreases
Solution Approach 1:
The integral manifold design allows for continuous forming operations without interruption for welding processes. The single-piece construction enables faster production cycles and higher throughput while maintaining the structural requirements through the unified geometry of the formed component.
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 method reduces manufacturing costs and complexity by eliminating the need for welding, resulting in a more efficient and cost-effective production process for heat exchanger manifolds while maintaining effective fluid communication and flow.
Implementation Method 1
bending a sheet of material about an axis to form a distributor conduit and a header
Implementation Method 2
The edges are sealed to the sheet axially therealong
Data Source
AI summary
A manifold for a heat exchanger includes a header radially surrounding and in spaced relationship to an axially extending distributor conduit. The distributor conduit is formed by bending the sheet along the leading edge, and the header is formed by bending a remainder of the sheet including a trailing edge about an axis in radially spaced relationship to the distributor conduit. The cross sections are completed and closed by placing the leading and trailing edges into contact with, and sealing the edges to the sheet.