Stacked Gutter-Shaped Headers for Size-Adjustable Heat Exchangers
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Solution Overview
Problem
Conventional heat exchangers face challenges in maximizing heat exchange area relative to size due to the size and structure of headers, which limits flexibility in adjusting the heat exchanger's size to fit installation spaces and reduces heat exchange performance.
Innovation Solution
A heat exchanger design featuring gutter-shaped headers with stacked header members and modular construction, allowing for flexible size adjustment by changing the number of stacked modules, and incorporating inclined heat exchanger tubes for improved water drainage and enhanced heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the dimension of the heat exchanger tube in the width direction is increased to enlarge the heat exchange area, then the heat exchange area is increased, but the dimension of the header across the width of the tube must be increased, leading to increased header thickness and volume, which reduces the heat exchange area relative to the overall size
Solution Approach 1:
The header is divided into multiple header members stacked in the width direction of the heat exchanger tube. Each header member has a smaller cross-sectional dimension, allowing the heat exchanger tube to be inserted between them. This segmentation enables the header to accommodate wider heat exchanger tubes without increasing the overall header volume, thus maintaining a high heat exchange area to overall size ratio.
2Adaptability or versatility
If the conventional header structure with holes along the longitudinal direction is used, then the header can accommodate heat exchanger tubes, but the header dimension across the width must be greater than the tube dimension, increasing header volume and reducing heat exchange efficiency
Solution Approach 1:
Instead of accommodating heat exchanger tubes by increasing the header's width dimension, the invention stacks header members in the width direction of the heat exchanger tube (creating a new dimensional arrangement). This allows the header to accommodate tubes of various widths without proportionally increasing header volume, as the accommodation is achieved through stacking rather than lateral expansion.
3Adaptability or versatility
If the heat exchanger tubes are stacked along the longitudinal direction of the header, then the heat exchanger size can be adjusted by changing the number of tubes, but a new header with changed length is needed every time, making size adjustment difficult
Solution Approach 1:
The header is segmented into multiple stackable header members. By changing the number of header members stacked in the width direction of the heat exchanger tube, the heat exchanger size can be adjusted without requiring a completely new header design. This modular segmentation enables flexible size adjustment while maintaining the same header member configuration.
4Strength
If the header thickness is increased to maintain pressure strength with larger dimensions, then the pressure strength is maintained, but the header volume is increased, reducing the heat exchange area relative to the overall size
Solution Approach 1:
The header is divided into multiple thin header members stacked together. Each individual header member can be made thinner than a conventional single header, reducing the overall header volume. The stacked configuration maintains pressure strength through the cumulative effect of multiple members, allowing the heat exchange area to be enlarged without proportionally increasing header volume.
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
The design enhances heat exchange area and performance while facilitating easy size adjustment to fit installation spaces, improving water drainage, and maintaining structural integrity with minimal weight and cost increase.
Implementation Method 1
performs a heat exchange between heat medium such as a refrigerant flowing through the heat exchanger tubes and fluid (for example, air) around the heat exchanger tubes, via the surfaces of the heat exchanger tubes
Implementation Method 2
performs a heat exchange between heat medium such as a refrigerant flowing through the heat exchanger tubes and fluid (for example, air) around the heat exchanger tubes
Implementation Method 3
improving water drainage
Data Source
AI summary
A heat exchanger includes a pair of headers, and a plurality of heat exchanger tubes stacked between the pair of headers. Each of the headers includes header members each having a gutter-shaped cross section and including an open part and a bottom part. The header members are stacked in a staking direction of the heat exchanger tubes in such a way that the bottom part of one header member closes the open part of another header member. A fitted hole into which an end of a heat exchanger tube is fitted is provided in a side part of the header member.