Integrated Heat Exchanger Headers for Compact Core Geometry
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Solution Overview
Problem
Traditional heat exchangers require separate components for headers and turnaround tanks, which increase the footprint and reduce the effective size or length of the core, necessitating post-processing steps like machining and welding.
Innovation Solution
The integration of headers with the heat exchanger core via additive manufacturing, using the core passages as support material, eliminates the need for separate components and reduces the overall footprint while enhancing thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are used for headers and turnaround tanks, then the heat exchanger can be assembled using traditional manufacturing methods, but the footprint increases and the effective core size decreases
Solution Approach 1:
The patent merges the headers and turnaround tanks into a single integrally formed component manufactured via additive manufacturing. This eliminates the need for separate components and their associated supporting structures, thereby reducing the overall footprint while maintaining manufacturing feasibility through advanced additive processes.
Solution Approach 2:
The integrally formed header component performs multiple functions simultaneously: it serves as a header, a turnaround tank, and a structural support element. This multi-functionality eliminates the need for separate dedicated components, reducing the footprint while maintaining ease of manufacture through a single additive manufacturing process.
2Ease of manufacture
If separate components are used for headers and turnaround tanks, then the assembly can be constructed using conventional methods, but the effective core length is reduced
Solution Approach 1:
By merging the headers and turnaround tanks into one integrally formed component, the patent eliminates the space required for separate components and their supporting structures. This increases the effective core length available for heat exchange while maintaining ease of manufacture through additive manufacturing.
Solution Approach 2:
The patent extracts the non-essential supporting and joining structures from the traditional multi-component design. By removing these extraneous elements, the effective core length is maximized while the essential header and turnaround functions are retained in an integrated form.
3Ease of manufacture
If traditional manufacturing methods are used with separate components, then the assembly process is straightforward, but post-processing steps such as machining and welding are required
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process that produces the integrally formed header. This eliminates the need for subsequent machining and welding operations, thereby increasing productivity while maintaining ease of manufacture through the straightforward additive process.
Solution Approach 2:
The additive manufacturing process itself performs all necessary manufacturing operations in one step, making the system self-sufficient. The integrally formed header requires no additional machining or welding, as the additive process directly produces the final functional component with all necessary features already incorporated.
4Ease of manufacture
If separate components are used for headers and turnaround tanks, then the design can be implemented using traditional manufacturing, but the overall footprint and complexity increase
Solution Approach 1:
The patent merges multiple separate components (headers, turnaround tanks, and supporting structures) into a single integrally formed component. This reduces device complexity by eliminating the need for multiple parts and their associated assembly requirements, while traditional manufacturing is replaced with additive manufacturing to maintain ease of manufacture.
Solution Approach 2:
The integrally formed header serves multiple functions that previously required separate components, thereby reducing the total number of parts and simplifying the overall device design. This multi-functional component maintains ease of manufacture through additive manufacturing while significantly reducing device complexity.
Data Source
AI summary
A fluid circuit of a heat exchanger includes a core and a first header. The core is configured to receive a fluid and includes a plurality of conduits. Each of the plurality of conduits extends along a longitudinal axis from a first end portion to a second end portion. The first header is integrally formed with and fluidly connecting the plurality of conduits. Outer walls of the plurality of conduits taper outward relative to the longitudinal axes to join the first header.