Condenser structure capable of realizing deep supercooling

Abstract

This invention pertains to the field of automotive air conditioning and relates to a condenser structure capable of deep subcooling, comprising a top plate, a core body, and a bottom plate, which are assembled sequentially from top to bottom. The top plate has pipe mounting holes at both ends for fixing inlet / outlet water pipes. The bottom plate has a compressor refrigerant inlet to the condenser and a refrigerant outlet to the condenser and liquid receiver tank on one side, and a refrigerant outlet to the liquid receiver tank for return and subcooling exit on the other side. The core body is composed of multiple layers of plates, forming interconnected water flow chambers and refrigerant flow chambers. The system includes a flow cavity; water passages at both ends of the plate, and refrigerant passages at the four corners. Two refrigerant passages on one side connect to the condensing zone, and the other side connects to the subcooling zone. Two water pipes connect to the flow cavity via the water passages at both ends. The compressor refrigerant inlet to the condenser and the refrigerant outlet from the condenser to the liquid receiver tank connect to the upper condensing zone via the condensing zone connection holes at both ends. The refrigerant outlet from the liquid receiver tank and the refrigerant outlet after subcooling from the condenser connect to the lower subcooling zone via the subcooling zone connection holes at both ends. This invention improves the refrigerant subcooling.

Description

Technical Field

[0001] This invention belongs to the field of automotive air conditioning technology, specifically relating to a condenser structure that can achieve deep subcooling. Background Technology

[0002] In traditional vapor compression refrigeration cycles, the core function of the condenser is to condense the high-temperature, high-pressure gaseous refrigerant discharged from the compressor into a liquid state. With increasingly stringent global energy efficiency standards (such as EU EURO VII and China's GB27999-2020) and ever-increasing energy conservation and environmental protection requirements, subcooling technology has become one of the core means to improve the performance of refrigeration systems. The typical structure of existing subcooled condensers suffers from mutual interference between the subcooling and condensing flow channels, uneven refrigerant distribution, and limited heat exchange area in the subcooling region, making it impossible to achieve deep subcooling. This results in the subcooling degree failing to meet design requirements, limited improvement in system energy efficiency, and flash gas generation under certain operating conditions, affecting the stability of the expansion valve. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention proposes a condenser structure capable of deep subcooling that achieves the comprehensive goals of improved subcooling efficiency, simplified structure, and enhanced adaptability to operating conditions.

[0004] The above-mentioned objective of this invention is achieved through the following technical solution: A water-cooled condenser structure capable of achieving deep subcooling requirements, the condenser structure being an integrally welded structure, including a top plate, a bottom plate, a core body, an inlet pipe, and an outlet pipe; the top plate, the core body, and the bottom plate are assembled sequentially from top to bottom. Pipe mounting holes are provided at the middle of both ends of the top plate. One end of the water inlet pipe and one end of the water outlet pipe are respectively inserted and fixed into the pipe mounting holes at both ends. The bottom plate has a compressor refrigerant inlet to the condenser and a refrigerant outlet from the condenser to the liquid storage tank at the two ends near one side, and a refrigerant outlet from the liquid storage tank and a refrigerant subcooled outlet from the condenser at the two ends near the other side. The core body is composed of multiple layers of plates. Water passages are located at the center of both ends of the plates, and refrigerant passages are located near the four corners of the plates. Two refrigerant passages on one side of the two water passages are condensation zone connection passages, and two refrigerant passages on the other side are subcooling zone connection passages. A water flow chamber and a refrigerant flow chamber are formed inside the core body, connected by a partition. The inlet and outlet pipes are connected to the water flow chamber via the water passages at both ends. The refrigerant flow chamber is divided into an upper condensation zone and a lower subcooling zone. The compressor refrigerant inlet to the condenser and the refrigerant outlet from the condenser to the liquid storage tank are connected to the upper condensation zone via the condensation zone connection passages at both ends. The refrigerant outlet from the liquid storage tank and the refrigerant outlet after subcooling from the condenser are connected to the lower subcooling zone via the subcooling zone connection passages at both ends.

[0005] Furthermore, the upper condensation zone adopts a three-pass flow channel structure; the core body includes a long guide tube, a short guide tube, a first main plate, a second main plate, a first partition plate, a second partition plate, a third partition plate, and a fourth partition plate; The long conduit is inserted from bottom to top into the condensation zone connection hole at one end of the core body near the outlet pipe, and the short conduit is inserted from bottom to top into the condensation zone connection hole at the other end of the core body; the second baffle plate is disposed between the first and second flow sections of the condensation zone to isolate the first and second flow sections; the third baffle plate is disposed between the second and third flow sections of the condensation zone to act as a baffle between the second and third flow sections; the fourth baffle plate is disposed between the condensation zone and the subcooled zone to act as a baffle between the condensation zone and the subcooled zone; within the three flow sections of the condensation zone, the first baffle plate and the second main plate are arranged in alternating vertical layers; within the subcooled zone, the first main plate and the second main plate are arranged in alternating vertical layers.

[0006] Furthermore, the first motherboard has water isolation protrusions on the front of the two water passages and refrigerant isolation protrusions on the back of the four refrigerant passages. The height of the water isolation protrusions is twice the height of the refrigerant isolation protrusions. The second motherboard has refrigerant isolation protrusions on the front of the four refrigerant passages.

[0007] Furthermore, the first partition plate adopts a structure in which a water isolation boss is provided on the front and a refrigerant isolation boss is provided on the back, and a sealing component is fixed in the through hole connecting the two subcooled zones.

[0008] Furthermore, the second partition plate adopts a structure with a water isolation boss on the front and a refrigerant isolation boss on the back, and a sealing component is fixed in the two subcooled zone connecting holes. The condensation zone connecting hole that is fitted with the long conduit is a front-flanged small hole with the same diameter as the outer diameter of the long conduit. The front-flanged small hole on the second partition plate is fitted with the upper end of the long conduit.

[0009] Furthermore, the third partition plate adopts a structure in which a water isolation boss is provided on the front and a refrigerant isolation boss is provided on the back, and sealing components are fixed in the connecting holes of the two subcooled zones and the connecting holes of the condensation zone corresponding to the short conduit.

[0010] Furthermore, the fourth partition plate adopts a structure with a water isolation boss on the front and a refrigerant isolation boss on the back. The condensation zone connection holes at both ends adopt small flanged holes on the front. The diameter of the flanged holes at both ends is consistent with the outer diameter of the long conduit and the outer diameter of the short conduit, respectively. The two flanged holes are inserted and fixed to the lower part of the long conduit and the upper part of the short conduit, respectively.

[0011] Furthermore, the height of the flanged holes on the two partition plates is between 1.5mm and 2mm.

[0012] Furthermore, the top plate is composed of an upper top plate and a top plate arranged vertically; the bottom plate is composed of a bottom plate and a mounting plate arranged vertically.

[0013] The advantages and positive effects of this invention are as follows: 1. Significantly improves subcooling efficiency, thereby greatly enhancing the energy efficiency of the refrigeration system. This invention achieves uniform distribution of refrigerant and pure liquid phase heat exchange in the subcooling section through an independent subcooling section flow channel design combined with an external high-efficiency gas-liquid separation structure. It completely solves the problems of flow channel interference and gas-liquid mixing heat exchange in traditional structures, and can stably increase the refrigerant subcooling degree to a deep subcooling range of 10~15℃, improving the subcooling efficiency by more than 30% compared with traditional structures. The improvement in subcooling degree increases the COP (coefficient of performance) of the refrigeration system by 8%~15%, while significantly reducing the amount of refrigerant flash gas after the throttling device, and increasing the effective cooling capacity of the evaporator by about 20%.

[0014] 2. Optimize the structural layout to achieve the dual goals of compactness and low flow resistance. This invention adopts an integrated layout of condensing and subcooling sections, eliminating the complex connecting pipes of traditional external structures. While ensuring the heat exchange area, the overall volume of the equipment is reduced by 15% to 25%, and the weight is reduced by 10% to 20%, making it suitable for use in compact installation spaces such as automotive engine compartments and small heat pump units. In addition, the four-hole design on the refrigerant side separates the flow channels of the subcooling and condensing zones, effectively reducing the flow resistance of the refrigerant within the equipment. Pressure loss is reduced by more than 40% compared to traditional structures, avoiding increased compressor power consumption due to excessive flow resistance, and further improving the overall operating efficiency of the system.

[0015] 3. Simplify manufacturing processes and reduce production and usage costs. The subcooled condenser structure of this invention is applicable to modular integrated structures, which can be integrated with components such as refrigerant flow channels and plate heat exchangers through welding, reducing the number of parts by more than 30%, significantly reducing mold development costs and production process difficulty, and increasing production efficiency by about 40%. At the same time, the simplified structure reduces welding and sealing nodes in the equipment assembly process, reduces the risk of refrigerant leakage by more than 60%, increases material utilization by 25%, and reduces the manufacturing cost per unit heat exchange area by 20% to 30%. In addition, the equipment has no redundant vulnerable parts, and subsequent maintenance only requires routine cleaning, which significantly reduces the user's use and maintenance costs and enhances the product's industrial competitiveness. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall appearance of the water-cooled condenser structure that can achieve deep subcooling requirements according to the present invention. Figure 2 This is an exploded view of the water-cooled condenser structure that can meet the deep subcooling requirements of the present invention; Figure 3 This is a bottom view of the water-cooled condenser structure of the present invention, which can meet the requirements of deep subcooling. Figure 4 This is a top view of the water-cooled condenser structure that can meet the deep subcooling requirements of the present invention. Figure 5 This is a schematic diagram of the first partition plate; Figure 6 This is a schematic diagram of the second partition plate; Figure 7 This is a schematic diagram of the third partition plate; Figure 8 This is a schematic diagram of the fourth partition plate; Figure 9 This is a schematic diagram of the first motherboard chip; Figure 10 This is a schematic diagram of the second motherboard chip; Figure 11 This is a schematic diagram illustrating the refrigerant flow principle of the present invention and its components; Figure 12 This is a schematic diagram showing the refrigerant flow inside the condensation zone of the structure of the present invention; Figure 13 This is a schematic diagram showing the flow of coolant inside the structure of the present invention; Figure 14 This is a schematic diagram showing the refrigerant flow through the subcooled zone inside the structure of the present invention; The components are: 1. Top plate; 2. Top plate; 3. First partition plate; 4. Second partition plate; 5. Third partition plate; 6. Fourth partition plate; 7. First main plate; 8. Base plate; 9. Mounting plate; 10. Short conduit; 11. Long conduit; 12. Second main plate; 13. Water outlet pipe; 14. Water inlet pipe; 15. Compressor refrigerant inlet to condenser; 16. Refrigerant outlet from condenser to liquid storage tank; 17. Refrigerant outlet from liquid storage tank return port; 18. Refrigerant subcooled outlet from condenser; 19. Sealing component; 20. Flanged small hole. Detailed Implementation

[0017] The structure of the present invention will be further described below with reference to the accompanying drawings and embodiments. It should be noted that these embodiments are descriptive and not limiting.

[0018] For a water-cooled condenser structure that can meet deep subcooling requirements, please refer to [link / reference]. Figures 1-14The invention features that the condenser structure is an integrally welded structure, including a top plate, a bottom plate, a core body, an inlet pipe, and an outlet pipe; the top plate, the core body, and the bottom plate are assembled sequentially from top to bottom. Pipe mounting holes are provided at the middle of both ends of the top plate. One end of the water inlet pipe and one end of the water outlet pipe are respectively inserted and fixed into the pipe mounting holes at both ends. The bottom plate has a compressor refrigerant inlet to the condenser and a refrigerant outlet from the condenser to the liquid storage tank at the two ends near one side, and a refrigerant outlet from the liquid storage tank and a refrigerant subcooled outlet from the condenser at the two ends near the other side. The core body is composed of multiple layers of plates. Water passages are located at the center of both ends of each plate, and refrigerant passages are located near the four corners of each plate. Two refrigerant passages on one side of the two water passages connect to the condensing zone, while the refrigerant passages on the other side connect to the subcooling zone. The core body internally forms a water flow chamber and a refrigerant flow chamber connected by partitions. The inlet and outlet pipes are connected to the water flow chamber via the water passages at both ends. The refrigerant flow chamber is divided into an upper condensing zone and a lower subcooling zone. The compressor refrigerant inlet to the condenser and the refrigerant outlet from the condenser to the liquid storage tank are connected to the upper condensing zone via the condensing zone connection holes at both ends. The refrigerant outlet from the liquid storage tank and the refrigerant outlet after subcooling from the condenser are connected to the lower subcooling zone via the subcooling zone connection holes at both ends.

[0019] The number of flow paths in the upper condensation zone of the water-cooled condenser structure of this invention is not limited; a multi-pass or single-pass flow path structure can be adopted. Example 1: In this embodiment, the upper condensation zone adopts a three-pass flow channel structure. Specifically, the structure is as follows: Please refer to section 1 for details. Figure 14 The top plate consists of an upper top plate 1 and a top plate 2, located on the upper part of the core body. Its main function is to strengthen the core support and connect the inlet pipe 14 and the outlet pipe 13. The bottom plate consists of a bottom plate 8 and a mounting plate 9. The mounting plate is located at the bottom of the core and mainly serves to strengthen the core support and connect to the outside. It has four small holes: a compressor refrigerant inlet 15, a refrigerant outlet from the condenser to the liquid storage tank 16, a refrigerant outlet from the liquid storage tank return port 17, and a refrigerant subcooled outlet from the condenser 18. Figure 3 As shown.

[0020] The core body includes a long conduit 11, a short conduit 10, a first main board plate 7, a second main board plate 12, a first partition plate 3, a second partition plate 4, a third partition plate 5, and a fourth partition plate 6.

[0021] The long conduit is inserted from bottom to top into the condensation zone connection hole at the end of the core body near the outlet pipe, and the short conduit is inserted from bottom to top into the condensation zone connection hole at the other end of the core body. The second baffle plate is positioned between the first and second flow sections of the condensation zone to isolate them. The third baffle plate is positioned between the second and third flow sections of the condensation zone to act as a baffle between them. The fourth baffle plate is positioned between the condensation zone and the subcooled zone to act as a baffle between them. Within the three flow sections of the condensation zone, the first baffle plate and the second main plate are arranged in alternating vertical layers. Within the subcooled zone, the first main plate and the second main plate are arranged in alternating vertical layers.

[0022] The specific structural forms of the above six types of plates are as follows: Water isolation protrusions are provided on the front periphery of the two water passages on the first main board plate, and refrigerant isolation protrusions are provided on the back periphery of the four refrigerant passages on the first main board plate. The height of the water isolation protrusions is twice the height of the refrigerant isolation protrusions. Refrigerant isolation protrusions are provided on the front periphery of the four refrigerant passages on the second main board plate. The first, second, third, and fourth partition plates are all formed by partial sealing and modification of the first main board plate, specifically: The first partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back, and a sealing element 19 is fixed in the two subcooled zone connecting holes. The second partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back, and a sealing element is fixed in the two subcooled zone connecting holes. The condensation zone connecting hole that mates with the long conduit is a small flanged hole on the front, and the diameter of the flanged hole is the same as the outer diameter of the long conduit. The flanged hole on the second partition plate mates with the upper end of the long conduit. The third partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back, and a sealing element is fixed in the two subcooled zone connecting holes and the condensation zone connecting hole corresponding to the short conduit. The fourth partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back. The condensation zone connection holes at both ends are small flanged holes on the front, with the diameters of the flanged holes matching the outer diameters of the long and short conduits, respectively. These two flanged holes are inserted and fixed into the lower part of the long conduit and the upper part of the short conduit, respectively. In this invention, the long and short conduits are of equal diameter. The height of the flanged holes on the two partition plates is between 1.5mm and 2mm. To facilitate the fit between the two guide rails and the corresponding flanged holes, the upper ends of the two conduits are chamfered for installation with the flanged holes. A flanged platform is provided at the lower end, which is welded to the base plate. The diameter of the flanged platform is 1.5mm to 2mm larger than the conduit diameter to ensure welding sealing strength.

[0023] In the manufacturing process of this invention, the various parts are first assembled. After the assembly of each component is completed, the entire assembly is brazed or vacuum welded to finally form the water-cooled condenser structure described in this invention. The refrigerant flow principle and coolant flow principle are as follows.

[0024] The condenser structure is divided into a coolant side and a refrigerant side. The coolant participates in the heat exchange of the entire heat exchanger core and flows through the internal partitions of the core. Figure 13 As shown. The refrigerant side is divided into a condensing zone and a subcooling zone, and its internal flow is as follows: Figure 12 , 14 As shown.

[0025] The heat exchange principle between the coolant side and the refrigerant side condensation zone, subcooling zone, and external storage tank is as follows: Figure 11 As shown: The coolant flows through the inlet and outlet pipes within the core, exchanging heat with the condensation zone and subcooling zone respectively.

[0026] The compressor refrigerant flows through the compressor refrigerant inlet on the mounting plate, through a long conduit, into the condensing zone inside the core, where it exchanges heat with the coolant. After the heat exchange, the gas-liquid mixture enters the receiver tank through a short conduit. Inside the receiver tank, the refrigerant is dried and filtered, then returns to the subcooling zone inside the heat exchanger core through the refrigerant outlet on the mounting plate. In the subcooling zone, the coolant exchanges heat with the coolant, ultimately achieving deep subcooling of the refrigerant. After being subcooled again on the mounting plate, the refrigerant exits the condenser and enters the expansion valve or other heat exchangers.

[0027] This achieves the deep subcooling requirement of the refrigerant and improves system performance.

[0028] It should be emphasized that the number of subcooling zones should be set according to the subcooling requirements of the system design, generally 3 to 8 layers.

[0029] The plate shown in the accompanying drawings is a simplified structural form. In actual products, heat exchange ribs or fins are provided on the main surface of the plate to enhance heat exchange.

[0030] Example 2: In this embodiment, the upper condensation zone adopts a single-pass flow channel structure. This structure can also achieve a single-pass refrigerant arrangement. Based on the three-pass flow channel configuration of Example 1, in this embodiment, the two conduits are short pipes of equal length, and the condensing zone and the filtering zone are separated by a fourth partition plate. Within the entire condensing zone, the first partition plate and the second main partition plate are arranged in alternating vertical layers; within the subcooling zone, the first main partition plate and the second main partition plate are also arranged in alternating vertical layers. This achieves a single-pass refrigerant arrangement.

[0031] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A water-cooled condenser structure capable of achieving deep subcooling requirements, wherein the condenser structure is an integrally welded structure, characterized in that: It includes a top plate, a bottom plate, a core body, an inlet pipe, and an outlet pipe; the top plate, the core body, and the bottom plate are assembled in a vertical sequence. Pipe mounting holes are provided at the middle of both ends of the top plate. One end of the water inlet pipe and one end of the water outlet pipe are respectively inserted and fixed into the pipe mounting holes at both ends. The bottom plate has a compressor refrigerant inlet to the condenser and a refrigerant outlet from the condenser to the liquid storage tank at the two ends near one side, and a refrigerant outlet from the liquid storage tank and a refrigerant subcooled outlet from the condenser at the two ends near the other side. The core body is composed of multiple layers of plates. Water passages are located at the center of both ends of the plates, and refrigerant passages are located near the four corners of the plates. Two refrigerant passages on one side of the two water passages are condensation zone connection passages, and two refrigerant passages on the other side are subcooling zone connection passages. A water flow chamber and a refrigerant flow chamber are formed inside the core body, connected by a partition. The inlet and outlet pipes are connected to the water flow chamber via the water passages at both ends. The refrigerant flow chamber is divided into an upper condensation zone and a lower subcooling zone. The compressor refrigerant inlet to the condenser and the refrigerant outlet from the condenser to the liquid storage tank are connected to the upper condensation zone via the condensation zone connection passages at both ends. The refrigerant outlet from the liquid storage tank and the refrigerant outlet after subcooling from the condenser are connected to the lower subcooling zone via the subcooling zone connection passages at both ends.

2. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 1, characterized in that: The upper condensation zone adopts a three-pass flow channel structure; the core body includes a long guide tube, a short guide tube, a first main plate, a second main plate, a first partition plate, a second partition plate, a third partition plate, and a fourth partition plate; The long conduit is inserted from bottom to top into the condensation zone connection hole at one end of the core body near the outlet pipe, and the short conduit is inserted from bottom to top into the condensation zone connection hole at the other end of the core body; the second baffle plate is disposed between the first flow section and the second flow section of the condensation zone to isolate the first flow section and the second flow section; the third baffle plate is disposed between the second flow section and the third flow section of the condensation zone to act as a partition between the second flow section and the third flow section; The fourth partition plate is disposed between the condensing zone and the subcooling zone to separate the condensing zone and the subcooling zone; in the three process sections of the condensing zone, the first partition plate and the second main plate are arranged in alternating layers; in the subcooling zone, the first main plate and the second main plate are arranged in alternating layers.

3. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 2, characterized in that: The first motherboard has water isolation protrusions on the front of the two water passages and refrigerant isolation protrusions on the back of the four refrigerant passages. The height of the water isolation protrusions is twice the height of the refrigerant isolation protrusions. The second motherboard has refrigerant isolation protrusions on the front of the four refrigerant passages.

4. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 3, characterized in that: The first partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back, and a sealing component is fixed in the through hole connecting the two subcooled zones.

5. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 3, characterized in that: The second partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back. A sealing component is fixed in the connecting hole between the two subcooled zones. The connecting hole between the condensing zone and the long conduit is a small hole with a flange on the front. The diameter of the small hole with a flange on the front is the same as the outer diameter of the long conduit. The small hole with a flange on the second partition plate is inserted into the upper end of the long conduit.

6. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 3, characterized in that: The third partition plate has a structure with a water isolation boss on the front and a refrigerant isolation boss on the back. It is also equipped with sealing components in the connecting holes of the two subcooled zones and the connecting holes of the condensation zone corresponding to the short conduit.

7. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 5, characterized in that: The fourth partition plate adopts a structure with a water isolation boss on the front and a refrigerant isolation boss on the back. The condensation area connection holes at both ends adopt small flanged holes on the front. The diameter of the flanged holes at both ends is consistent with the outer diameter of the long conduit and the outer diameter of the short conduit, respectively. The two flanged holes are inserted and fixed to the lower part of the long conduit and the upper part of the short conduit, respectively.

8. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 7, characterized in that: The height of the flange holes on the two partition plates is between 1.5mm and 2mm.

9. The water-cooled condenser structure capable of achieving deep subcooling requirements according to claim 1, characterized in that: The top plate consists of an upper top plate and a top plate arranged vertically; the bottom plate consists of a bottom plate and a mounting plate arranged vertically.

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