Modular Heat Exchanger Headers for Rapid Assembly
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Solution Overview
Problem
Existing heat exchangers face challenges such as lengthy manufacturing times due to numerous weldings or brazings, complex maintenance and cleaning processes, limited flexibility in size and capacity production, and reliability issues with liquid leakage and flow rate pressures, particularly when used in applications beyond the automotive industry.
Innovation Solution
A heat exchanger design featuring modular headers with removable dome-shaped modular members and partitions that allow for easy assembly and disassembly, enabling quick adaptations in size and capacity, and the use of various materials like copper, aluminum, and steel, with improved sealing and structural strength through gaskets and a thin metal strengthening plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If U-shaped pipe unions and welding/brazing are used to connect tubes, then fluid connection between tube rows is achieved, but manufacturing time increases significantly
Solution Approach 1:
The header is divided into modular components: a support structure with tube-receiving apertures and removable cover members that can be independently assembled and disassembled. This segmentation eliminates the need for welding/brazing U-shaped unions between tubes, as tubes are simply inserted into the modular header sections.
Solution Approach 2:
The complex welding/brazing process for creating U-shaped pipe unions is extracted and replaced by a simpler insertion mechanism. Tubes are taken out from the requirement of being welded into unions and are instead directly received by the modular header apertures, significantly reducing manufacturing time.
2Reliability
If rigorous testing of weldings/brazings is performed, then leak-resistance and strength are verified, but manufacturing time and equipment requirements increase
Solution Approach 1:
The design uses removable cover members sealed with gaskets instead of permanent welded joints. This allows for simpler, less time-consuming testing procedures since the modular construction with elastomeric seals inherently provides leak resistance without requiring the complex pressure testing and inspection needed for welded joints.
3Ease of manufacture
If copper materials are used for tubes and unions, then ease of welding is achieved, but weight and cost increase
Solution Approach 1:
The modular header design with removable cover members and gasket seals is universally applicable to different tube materials (copper, aluminum, steel) without requiring material-specific welding expertise. This universal connection method eliminates the need to choose copper specifically for welding ease, allowing selection of lighter, cheaper materials like aluminum while maintaining ease of assembly through the modular design.
4Weight of moving object
If aluminum tubes are used instead of copper, then weight and cost are reduced, but welding and brazing difficulties increase
Solution Approach 1:
The mechanical welding/brazing system is replaced with a mechanical insertion and sealing system. Aluminum tubes are simply inserted into the modular header apertures and sealed with elastomeric gaskets, eliminating the need for difficult aluminum welding or brazing operations while maintaining connection reliability.
5Ease of operation
If complete disassembly is performed for maintenance, then cleaning access is achieved, but maintenance complexity increases
Solution Approach 1:
The header is segmented into removable cover members that can be independently accessed and removed. This allows maintenance personnel to access specific tube rows for cleaning without disassembling the entire heat exchanger, reducing both the complexity and time required for maintenance operations.
Solution Approach 2:
The header transitions from a fixed, permanent construction to a dynamic, reconfigurable structure with removable covers. This dynamic design allows the header to be easily opened and closed for maintenance operations, providing cleaning access while maintaining operational integrity when assembled.
6Stability of the object's composition
If headers are rigidly sized for specific heat exchanger sizes, then structural fit is achieved, but adaptability to different sizes is lost
Solution Approach 1:
The header is segmented into modular support sections and removable cover members that can be independently configured. This allows the same modular components to be assembled in different quantities and arrangements to accommodate various heat exchanger sizes and capacities while maintaining structural stability through standardized connection interfaces.
Solution Approach 2:
The modular header components are designed as universal parts that can serve multiple configurations. The same support structure with standardized apertures and cover members can be adapted to different heat exchanger sizes by simply adjusting the number and arrangement of modular sections, eliminating the need for custom-sized headers for each application.
Data Source
Figure 1
Figure 2
AI summary
The present invention refers to a heat exchanger provided with modular headers. A heat exchanger, in particular of the finned-pack type, made according to the present invention comprises a plurality of tubes (1) that extend between a plurality of hollow interspaces (2); at least a header (4) comprising a support (5) provided with a plurality of first apertures (6) adapted to accommodate an extremity region (7, 8) of the tubes (1); and a cover (9) associated to said support (5). The heat exchanger is characterized in that each one of said support (5) and said cover (9) comprises a plurality of modular members (10, 18) that are removably associated to each other by means of conjugate surfaces (11a, 11b; 19a, 19b).