Segmented Coupling Header for Multi-Tier Flat Tube Heat Exchangers
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Solution Overview
Problem
As heat exchangers with multiple tiers of flat tubes grow in size, the coupling header's length increases, requiring high dimensional precision and complicating the manufacturing process due to the need for long intermediate plates, leading to difficulties in assembly and increased risk of joining issues.
Innovation Solution
A coupling header configuration using a two-types-of-members structure, where second members are joined to a first member with through holes, forming coupling passages, and featuring adjustable thickness coupling passage partition portions and incorrect assembly prevention features to ensure pressure resistance and correct assembly, allowing for lengthening without unnecessary thickness increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of tiers of flat tubes is increased to accommodate larger heat exchanger sizes, then the heat exchanger capacity is improved, but the coupling header length increases requiring high dimensional precision and complicating the manufacturing process
Solution Approach 1:
The coupling header is divided into multiple intermediate plates joined together in the tube tier direction. Each intermediate plate has a manageable thickness with standard dimensional tolerances, but together they form a long coupling header that accommodates many tiers of flat tubes. This segmentation allows the heat exchanger capacity to be increased without requiring each individual plate to have excessive dimensional precision.
2Length of stationary object
If long intermediate plates are used to accommodate larger heat exchanger sizes, then the coupling header can span more tiers, but the difficulty of actual work of inserting intermediate plates increases
Solution Approach 1:
Instead of using one or two very long intermediate plates that are difficult to manufacture and insert, the coupling header is segmented into multiple shorter intermediate plates of standard length. These shorter plates can be easily manufactured with standard tolerances and inserted into the square pipe-shaped main plate without excessive difficulty, while collectively providing the necessary long coupling header span.
3Adaptability or versatility
If the coupling header is lengthened to accommodate more tiers, then larger heat exchanger sizes are supported, but the level of difficulty of actual work becomes higher
Solution Approach 1:
The coupling header is segmented into multiple standardized intermediate plates that can be easily joined together. Each intermediate plate is a simple component with through holes for flat tubes and coupling passages for communication. The modular segmented design allows the coupling header to be adapted to various heat exchanger sizes by simply changing the number of intermediate plates, without significantly increasing assembly complexity.
4Reliability
If intermediate plates are joined to form a long coupling header, then the two-types-of-members structure advantages are maintained, but joining problems may occur
Solution Approach 1:
The coupling header is segmented into multiple intermediate plates that are joined together using the same reliable two-types-of-members structure (intermediate plates joined to main plate). While this increases the number of joints compared to a single-piece construction, each joint uses the proven reliable connection method, and the segmentation allows each joint to be independently manufactured and quality-checked, potentially improving overall reliability through distributed risk.
Data Source
AI summary
A heat exchanger includes a plurality of flat tubes and a coupling header. The flat tubes are disposed in multiple tiers along a predetermined tube tier direction and in multiple rows so as to be adjacent to each other in a tube row direction intersecting the tube tier direction and the longitudinal direction of the flat tubes. The coupling header is formed by joining a first member to a plurality of second members in the tube tier direction. The first member has a plurality of through holes through which pass the first end portions of the flat tubes. The second members when joined to the first member forming a plurality of coupling passages where the first end portions of the flat tubes adjacent to each other in the tube row direction communicate with each other.