Machined Heat Exchanger Header Box for High Pressure
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Solution Overview
Problem
Existing heat exchanger manifolds designed for high-pressure refrigerant fluids, such as CO2, are complex and expensive to manufacture due to the need for multiple assembly operations and components.
Innovation Solution
A heat exchanger header box with a machined metal bar cover featuring grooved distribution channels that communicate with the collector plate, eliminating the need for additional components and simplifying the manufacturing process while withstanding high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple stacked plates and intermediate components are used to ensure fluid distribution and withstand high pressure, then the pressure resistance is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions into a single cover component: the cover integrates fluid distribution channels, pressure containment, and structural support functions that were previously separated across multiple stacked plates and intermediate components. This merging reduces the number of parts while maintaining pressure resistance through a monolithic structure with integrated grooves for fluid distribution.
Solution Approach 2:
The cover is designed as a multi-functional component that simultaneously serves as a pressure containment vessel, a fluid distribution manifold with integrated channels, and a structural support element. This universal design eliminates the need for separate distribution plates and intermediate components, reducing device complexity while maintaining all required functions.
2Manufacturing precision
If multiple assembly operations and intermediate components are used to ensure proper fluid distribution, then the fluid distribution precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The fluid distribution channels are integrated directly into the cover structure as grooves, combining the distribution function with the cover component itself. This eliminates the need for separate distribution plates and multiple assembly operations, simplifying manufacturing while maintaining precise fluid distribution through the integrated groove geometry.
3Strength
If a thick metal bar with machined grooves is used for the cover, then the pressure resistance is improved, but the manufacturing time increases
Solution Approach 1:
The cover is manufactured from a thick metal bar with machined grooves rather than thin plates, changing the dimensional parameters to increase pressure resistance. The groove geometry and metal bar thickness are optimized to provide sufficient structural strength while accommodating fluid distribution channels.
Data Source
Figure 1
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Figure 7~10
AI summary
The box has a collector plate (26) comprising openings (28) for inserting heat exchange tubes (18). A cover (44) is formed by machining a metal bar and comprises an internal surface (72) and external surface. Distribution channels (70) e.g. groove, are formed in the metal bar by emerging on the internal surface while permitting material of the bar to close a volume of the cover at the level of longitudinal ends of the cover, where the channels communicate with the heat exchange tubes. An independent claim is also included for a method for fabricating a collector box.