Modular Heat Exchanger Headers for Mold-Free Tube Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current heat exchanger manufacturing processes are inefficient due to slow manufacturing speed, high costs, and the need for specific molds, with issues related to brazing tolerances and the difficulty of forming precise inlets for tube insertion.
Innovation Solution
A heat exchanger design featuring a modular header structure with elongated insertion holes and coupling blocks that allow for flexible customization without specific molds, reducing brazing tolerance and improving manufacturing speed and cost efficiency by eliminating the need for slotting or wire cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slotting or wire cutting is performed on the header to form insertion holes, then tubes can be inserted into the header, but the manufacturing speed decreases and mass production efficiency is deteriorated
Solution Approach 1:
The insertion holes are formed in the header block before the tube panels are inserted. This preliminary formation of insertion holes allows for precise positioning and eliminates the need for subsequent slotting or wire cutting operations, thereby improving manufacturing speed while maintaining precision
Solution Approach 2:
The header is divided into multiple header blocks that are stacked to form the complete header structure. Each header block contains pre-formed insertion holes, allowing parallel processing and assembly, which significantly improves manufacturing efficiency compared to forming all holes in a single header piece
2Manufacturing precision
If specific molds are used for manufacturing heat exchangers according to sizes, then precise dimensions can be achieved, but the manufacturing efficiency is deteriorated due to mold changes
Solution Approach 1:
The header blocks are designed as universal, standardized components that can be stacked in different configurations to create heat exchangers of various sizes. This modular approach eliminates the need for specific molds for each size, allowing the same header blocks to serve multiple functions and specifications, thereby improving manufacturing efficiency
Solution Approach 2:
The heat exchanger configuration becomes dynamic and adaptable through the stacking of standardized header blocks. Instead of being fixed to specific mold-based sizes, the system can be dynamically adjusted by adding or removing header blocks to match different product specifications, improving both efficiency and flexibility
3Strength
If components are coupled through brazing, then strong joints can be formed, but brazing apertures are generated due to tolerance of machining equipment or between inlet and tube
Solution Approach 1:
The invention replaces the brazing process with a mechanical interference fit system. The tube panels are inserted into the header blocks and secured through precise mechanical coupling without requiring brazing, thereby eliminating brazing apertures while maintaining joint strength through the interference fit and retention mechanisms
Solution Approach 2:
The header blocks and tube panels are designed with self-aligning features that automatically compensate for machining tolerances during assembly. The elongated insertion holes and retention structures allow the components to self-adjust and self-lock, eliminating the need for precise pre-brazing alignment and preventing brazing aperture formation
4Ease of manufacture
If the blade of machining equipment is used to form inlets, then insertion holes can be created, but the blade becomes worn out and must be frequently replaced
Solution Approach 1:
The insertion holes are pre-formed in the header blocks using precise molding or drilling processes during header block manufacturing, rather than being created later by blade-based machining. This preliminary formation eliminates the need for subsequent blade operations and frequent blade replacements, saving time and resources
Data Source
AI summary
The present disclosure relates to a heat exchanger. The heat exchanger includes: a plurality of tube panels including a tube elongated in one direction; a pair of header modules coupled to both ends of the plurality of tube panels; and a pair of header cases having an open side, providing a space therein, and having the header module inserted in the space such that the tube panels communicate with the spaces, in which the header modules is composed of a plurality of header blocks stacked and coupled to each other, and an insertion hole in which the tube panel is inserted is formed at each of the plurality of header blocks. Accordingly, it is possible to increase the efficiency of manufacturing a heat exchanger, manufacture a heat exchanger flexibly in a custom-made type in accordance with the size of a product having the heat exchanger, reduce tolerance due to brazing, and improve stability of a product.