Integrated Tank Assembly Manifolds for Heat Exchanger Packaging
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Solution Overview
Problem
Conventional tank assemblies for heat exchangers face packaging, connection, and routing issues due to the presence of inlet and outlet conduits, which lead to energy losses, pressure drops, and increased complexity.
Innovation Solution
A tank assembly configuration that eliminates the need for inlet and outlet conduits by integrating a tank cover and header to form manifolds and a connection system on the same side of the heat exchanger core, utilizing fluid flow passages to establish fluid communication between the manifolds and the heat exchanger core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inlet and outlet conduits are used to connect manifolds to the heat exchanger core, then fluid communication is established, but packaging space is increased and routing complexity arises
Solution Approach 1:
The patent merges the connection system with the tank assembly by integrating the inlet and outlet directly into the tank cover and header structures. The fluid flow passages are formed as integral parts of the tank cover and header, eliminating the need for separate inlet and outlet conduits. This consolidation reduces the overall packaging space while maintaining fluid communication functionality.
2Ease of manufacture
If inlet and outlet conduits are used to connect manifolds to the heat exchanger core, then fluid communication is established, but pressure losses and energy losses occur
Solution Approach 1:
The patent merges the connection system with the tank assembly, creating direct fluid flow passages within the tank cover and header. This integration eliminates intermediate connection points and reduces the length of fluid flow paths, thereby minimizing pressure losses and energy losses that would occur in conventional conduit-based systems.
3Ease of manufacture
If manifolds are disposed on opposite sides of the heat exchanger core, then fluid distribution is achieved, but connection complexity and routing issues arise
Solution Approach 1:
The patent merges both manifolds onto the same side of the heat exchanger core by integrating them into the tank assembly structure. The tank cover and header are configured to form both the first and second manifolds on the same side, eliminating the need for opposite-side manifold placement and the associated routing complexity.
4Ease of manufacture
If separate connection conduits are used for inlet and outlet, then fluid communication is established, but the structure becomes more complex and less reliable
Solution Approach 1:
The patent merges the inlet and outlet connection systems into a single integrated tank assembly structure. The tank cover and header together form both connection points and the fluid flow passages between them, eliminating the need for separate connection conduits and reducing structural complexity while maintaining fluid communication functionality.
Data Source
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AI summary
A tank assembly (100) includes a tank cover (10) and a header (20). The tank cover (10) includes longitudinally extending first channels (10a) and (10b). The header (20) includes portions (20a) and (20b) that in conjunction with the first channels (10a) and (10b) defines a first and a second manifold (30a) and (30b). The header (20) further includes apertures (22a) and (22b) that receive the corresponding first set of tubular elements (42a) and second set of tubular elements (42b). At least one of the tank cover (10) and the header (20) includes an extension portion (10c, 20c) extending therefrom beyond the heat exchanger core (40) to form a connection system. The connection system includes an inlet (50a), an outlet (50b) and fluid flow passages (30c) and (30d) configuring fluid communication between the inlet (50a) and the outlet (50b) and the respective first and second manifolds (30a) and (30b).