Segmented Coupling Header Design for Large Multi-Tier Heat Exchangers
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Solution Overview
Problem
As the size of heat exchangers in the tube tier direction increases due to the number of flat tube tiers, the coupling header becomes longer, requiring high dimensional precision and making the manufacturing process more difficult due to the need for long intermediate plates and increased joining complexity.
Innovation Solution
A coupling header configuration using a two-types-of-members structure, where second members with through holes are joined to a first member to form coupling passages, allowing for lengthening of the header while maintaining pressure resistance and reducing the thickness of coupling passage partition portions where necessary, and incorporating incorrect assembly prevention features to ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of flat tube tiers is increased to accommodate larger heat exchanger sizes, then the heat exchanger capacity is improved, but the coupling header becomes longer and requires high dimensional precision making manufacturing more difficult
Solution Approach 1:
The coupling header is divided into multiple segments (first coupling header segment, second coupling header segment, third coupling header segment) connected in series along the tube tier direction. This segmentation allows each segment to be manufactured with standard lengths and then assembled to form the complete coupling header, reducing the dimensional precision requirements for individual components while accommodating larger heat exchanger capacities.
Solution Approach 2:
The coupling header structure transitions from a single long component to a multi-segment assembly where segments are connected through coupling passages. This dimensional reconfiguration allows the system to achieve the required length for large heat exchangers through assembly rather than single-piece manufacturing, thereby reducing precision requirements.
2Productivity
If the coupling header is lengthened to accommodate more tube tiers, then larger heat exchanger sizes are achieved, but the manufacturing process becomes more difficult due to increased joining complexity
Solution Approach 1:
The coupling header is segmented into multiple standardized sections that can be manufactured independently and then assembled. Each segment contains coupling passages that align with corresponding passages in adjacent segments, creating a modular assembly process that reduces overall manufacturing complexity compared to producing a single long coupling header.
Solution Approach 2:
The coupling passages are pre-formed within each coupling header segment during the segment manufacturing process. This preliminary formation of connection pathways allows for standardized production of individual segments that can be readily assembled, reducing the complexity of the overall manufacturing process.
3Adaptability or versatility
If intermediate plates are made longer to connect more tube tiers, then larger heat exchanger configurations are achieved, but the joining complexity and manufacturing difficulty increase
Solution Approach 1:
The intermediate plates are segmented and integrated into the multi-segment coupling header structure. Each coupling header segment contains its own intermediate plate portions that are joined to form the complete coupling header. This segmentation reduces the length of individual intermediate plates and simplifies the joining process while accommodating various heat exchanger configurations.
Solution Approach 2:
The coupling header segments are designed with universal coupling passages and connection features that can accommodate different numbers and arrangements of flat tube tiers. This multi-functional design allows the same basic segment structure to be used in various heat exchanger configurations, reducing joining complexity while maintaining adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration accommodates larger heat exchanger sizes by simplifying the manufacturing process, ensuring pressure resistance and reducing the risk of incorrect assembly, thus enhancing the overall performance and reliability of the heat exchanger.
Implementation Method 1
one end portions in the longitudinal direction of the flat tubes adjacent to each other in the tube row direction communicate with each other via a coupling header
Implementation Method 2
the header plate is fitted into the plate fitting portion and brazed with respect to side walls, and the closing plate is fitted into the closing plate fitting portion and brazed with respect to the tank member and header plate
Data Source
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AI summary
A coupling header (74) is configured by joining, in a tube tier direction to a first member (80) in which are formed plural through holes (82) through which pass one end portions in a longitudinal direction of plural flat tubes (61), plural second members (90, 90a to 90g) that, when joined to the first member (80), form plural coupling passages (75) where the one end portions in the longitudinal direction of the flat tubes (61) adjacent to each other in a tube row direction communicate with each other.