At KAK, we design and manufacture professional-grade copper header and manifold assemblies engineered for uniform refrigerant distribution and collection. Utilizing high-purity, seamless copper tubing, our header components are widely specified for commercial, residential, and industrial HVAC/R heat exchangers, ensuring maximum heat transfer efficiency and pressure integrity.
Key Advantages of KAK Copper Headers
- Premium Materials: Fabricated from 99.9% pure TP2 (C12200) seamless copper, offering exceptional thermal conductivity and outstanding resistance to corrosion.
- Advanced Forming Technologies: We offer two high-precision extrusion methods for branched outlets: Friction Drilling (T-Drilling) for a completely chipless, ultra-clean interior, and Automated Mechanical Punching & Flanging for deep-drawn, rigid collars that offer extended contact area.
- Precision Branch Welding: Advanced automated brazing on perfectly formed collars guarantees robust, leak-proof joints, eliminating potential micro-leakage at connection ports under high operating pressures.
- Custom Engineering: Fully customizable pipe lengths, outer diameters (OD), wall thicknesses (up to 2.0mm for high-pressure R32/R410A systems), and branch counts as per your Technical Purchase Specifications (TPS).
- Smooth Internal Flow: Cleaned and deburred internally to reduce fluid friction, pressure drops, and prevent system contamination or oil trapping.
Technical Specifications
| Technical Parameter | Standard Options & Capabilities |
|---|---|
| Main Pipe Material | TP2 / C12200 Deoxidized High-Phosphorus Copper |
| Main Body OD Range | Ø12.7mm up to Ø54mm or fully customized size |
| Branch Forming Process | Friction Drilling (T-Drill Chipless Process) / CNC Mechanical Flanging |
| Working Pressure Rating | Designed to safely manage up to 30 bar to 45 bar applications |
Our copper header manifolds are the ideal choice for high-end HVAC original equipment manufacturers (OEMs) and engineering contractors looking for reliable fluid control solutions in advanced Environmental Control Units (ECUs) and VRF networks.
Frequently Asked Questions (FAQ)
Q1: What is the difference between your T-Drilling and Mechanical Punching options?
Our Friction Drilling (T-Drilling) process uses thermal friction to soften the copper and form a collar without creating any copper cuttings, guaranteeing 100% internal cleanliness to protect compressors. Our Mechanical Punching & Flanging process utilizes precise automated tooling to pull out deep, rigid collars, which provides a highly stable mechanical fit and superior capillary support for high-volume OEM productions.
Q2: Can you manufacture headers with a wall thickness of 2.0mm for high-pressure systems?
Yes. To satisfy modern high-pressure demands (such as eco-friendly R32, R410A, or R513A systems requiring stable 30-bar holding conditions), KAK can upgrade the main pipe and branch tube wall thicknesses up to 2.0mm. This prevents physical warping and tube distortion during extreme thermal cycles and heavy vibration.
Q3: What leak detection procedures do your copper manifolds undergo?
Quality is our top priority. Every single custom copper header assembly undergoes rigorous factory pressure hold tests and underwater pneumatic bubble testing. We ensure that every brazed branch joint achieves 100% airtightness before the products are packaged and shipped to international markets.
Q4: Do you accept production based on customized blueprints or OEM designs?
Absolutely. KAK specializes in custom manufacturing. You can provide your CAD engineering drawings detailing the exact branch spacing, hole sizes, and tail lengths. Our engineering team will review your parameters to offer an accurate commercial proposal and tiered pricing based on your annual volumes.