Heat Exchanger Header Box with Inverted Flared Collars

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Solution Overview

Problem

Existing heat exchanger manifolds with flat or rounded bottoms face challenges in tube insertion due to insufficient flare in inverted collars, leading to internal pressure drops and increased pumping power requirements, especially in high-pressure applications.

Innovation Solution

A manifold with an at least partially rounded shape and corrugations forming inverted collars with a substantially flared shape directed opposite to the volume, facilitating tube insertion and reducing pressure drops by providing a tulip-shaped inlet opening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If tubes protrude into the manifold volume to ensure proper brazing, then brazing quality is improved, but internal pressure drop increases

Engineering Contradiction:

Improvebrazing qualityVSAvoidinternal pressure drop

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The collar is inverted relative to conventional design, with the flare directed inward toward the tube insertion direction rather than outward. This inversion allows the tube to be properly guided and secured for brazing while preventing protrusion into the manifold volume, thereby eliminating the pressure drop issue while maintaining brazing quality

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If inverted collars with low flare are used, then tube insertion difficulty is reduced, but collar strength is insufficient

Engineering Contradiction:

Improvetube insertion easeVSAvoidcollar strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The collar design implements local quality differentiation: the inner surface has a flared geometry to facilitate easy tube insertion, while the outer surface maintains sufficient thickness and structural integrity. This localized differentiation of geometric properties allows the collar to simultaneously provide insertion ease and structural strength

Inventive Principle:

Principle #3Local quality

3Strength

If standard collars are used with rounded bottom manifold, then structural integrity is maintained, but tube insertion becomes difficult

Engineering Contradiction:

Improvemanifold structural integrityVSAvoidtube insertion ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The collar geometry is inverted compared to conventional designs, with the flare directed inward toward the tube insertion direction. This inversion creates a tulip-shaped inlet that guides tubes easily into the manifold while the collar base maintains attachment to the rounded bottom structure, preserving structural integrity

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP3080542B1Header box and corresponding heat exchanger

Publication Date: 2020.09.02 VALEO SYST THERMIQUES SAS

Figure 1~3
Figure 4a~6

AI summary

The invention relates to a collection box (1) for a heat exchanger comprising a collector (5) having an at least partially rounded shape and including: a plurality of openings (7) for passing a plurality of heat-exchange tubes (3) of the heat exchanger, and a plurality of collars (9) surrounding the openings (7). According to the invention, the collector (5) comprises a plurality of corrugations (11), and the collars (9) are formed at the corrugations (11) of the collector (5) and have a substantially flared shape, respectively, in the direction of the side opposite the space defined by the collection box (1).