Heat exchanger and home appliance comprising same

Abstract

A home appliance according to one embodiment of the present disclosure may comprise a housing and a heat exchanger disposed inside the housing. The heat exchanger can include: a first pipe providing a refrigerant flow path and including aluminum (Al); a second pipe, which is adjacent to the first pipe, includes an Al material, and accommodates a sensor; and filler metal for coupling the first pipe and the second pipe to each other. A portion of the first pipe and / or a portion of the second pipe can include a zinc diffusion layer. The potential difference between random constituent elements from among the filler metal, the first pipe and the second pipe can be 50 mV or less.

Description

Heat exchangers and home appliances including the same

[0001] One embodiment of the present disclosure relates to a heat exchanger placed inside a home appliance.

[0002] A heat exchanger is a device that performs heat exchange between two fluids separated by a solid wall, and is generally a device that exchanges heat between two process flows without phase change. A heat exchanger may include, for example, a cooler and a condenser.

[0003] Heat exchangers are widely used for heating, air conditioning, power generation, cooling, and waste heat recovery. Generally, heat exchangers used as components in home appliances are critical parts that determine the performance and lifespan of the appliances. Aluminum alloy materials are widely used for heat exchangers due to their cost competitiveness and thermal conductivity characteristics.

[0004] In heat exchangers, when a sensor holder (e.g., piping) equipped with a sensor such as a thermistor is welded to a pipe providing the refrigerant flow path, the two pipes can easily separate due to corrosion caused by the potential difference between them. Therefore, a design is discussed that can maintain a strong bond without easily causing separation between the pipes due to corrosion.

[0005] According to one embodiment of the present disclosure, a home appliance may include a housing and a heat exchanger disposed inside the housing. The heat exchanger may include a first pipe comprising Al (aluminum) that provides a flow path for a refrigerant, a second pipe adjacent to the first pipe comprising Al and configured to accommodate a sensor, and a filler material configured to connect the first pipe and the second pipe to each other. At least one of the first pipe or the second pipe may include a zinc diffusion layer. The potential difference between any two components among the filler material, the first pipe, and the second pipe may be 50 mV or less.

[0006] According to one embodiment of the present disclosure, a heat exchanger may include a first pipe comprising Al (aluminum) that provides a flow path for a refrigerant, a second pipe adjacent to the first pipe comprising Al and configured to accommodate a sensor, and a filler material configured to connect the first pipe and the second pipe together. At least one of the first pipe or the second pipe may include a zinc diffusion layer. The filler material is an alloy comprising Zn and Al, wherein Zn may be 10 to 90 weight (wt) % relative to the total weight of the alloy.

[0007] According to one embodiment of the present disclosure, a home appliance may include a housing and a heat exchanger disposed inside the housing. The heat exchanger may include a first pipe comprising Al (aluminum) that provides a flow path for a refrigerant, and a second pipe adjacent to the first pipe that comprises Al and is configured to accommodate a sensor. The first pipe and the second pipe may be directly joined to form an integral. The width of the joint area where the first pipe and the second pipe are joined may be smaller than the thickness of the first pipe or the thickness of the second pipe.

[0008] However, the problems to be solved in this disclosure are not limited to those mentioned above, and may be determined in various ways without departing from the spirit and scope of this disclosure.

[0009] FIG. 1 is a view of one side of a heat exchanger according to one embodiment of the present disclosure.

[0010] FIG. 2 is an enlarged perspective view of a portion of a heat exchanger according to one embodiment of the present disclosure.

[0011] FIG. 3 is a perspective view of a heat exchanger with an enlarged portion of FIG. 2 according to one embodiment of the present disclosure.

[0012] FIG. 4 is a top view of a heat exchanger with an enlarged portion of FIG. 2 according to one embodiment of the present disclosure.

[0013] FIG. 5 is a side view of a heat exchanger with an enlarged portion of FIG. 2 according to one embodiment of the present disclosure.

[0014] FIG. 6 is a graph showing potential values ​​according to the composition of the filler material of a heat exchanger according to one embodiment of the present disclosure.

[0015] FIG. 7 is a drawing showing a zinc diffusion layer of a first pipe and / or a second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0016] FIG. 8 is an enlarged view of the zinc diffusion layer of the first pipe and / or second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0017] FIG. 9a is a view from one direction of a structure in which a first pipe and a second pipe of a heat exchanger are combined, according to one embodiment of the present disclosure.

[0018] FIG. 9b is a drawing of a structure in which a first pipe and a second pipe of a heat exchanger are combined, according to one embodiment of the present disclosure, viewed from a different direction.

[0019] FIG. 10 is a cross-sectional view showing the connection area before and after the connection of the first pipe and the second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0020] FIG. 11 is an enlarged view of the connection area before and after the connection of the first pipe and the second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0021] FIG. 12 is a schematic diagram illustrating a configuration related to a refrigerant cycle including a heat exchanger of an air conditioner (e.g., air conditioner) according to one embodiment of the present disclosure.

[0022] FIG. 13a is a perspective view showing the exterior of an indoor unit of an air conditioner according to one embodiment of the present disclosure.

[0023] FIG. 13b is a perspective view showing the exterior of an outdoor unit of an air conditioner according to one embodiment of the present disclosure.

[0024] The various embodiments of this document and the terms used therein are not intended to limit the technical features described in this document to specific embodiments, and should be understood to include various modifications, equivalents, or substitutions of said embodiments.

[0025] In relation to the description of the drawings, similar reference numerals may be used for similar or related components.

[0026] The singular form of the noun corresponding to the item may include one or multiple items, unless the relevant context clearly indicates otherwise.

[0027] In this document, each of the phrases such as "A or B", "at least one of A and B", "at least one of A or B", "A, B or C", "at least one of A, B and C", and "at least one of A, B, or C" may include any one of the items listed together in the corresponding phrase, or all possible combinations thereof.

[0028] In this document, the term “and / or” includes a combination of multiple related described components or any of the multiple related described components.

[0029] In this document, terms such as "first," "second," or "first" or "second" may be used simply to distinguish a component from another component and do not limit the components in any other aspect (e.g., importance or order).

[0030] In this document, terms such as "front," "rear," "top," "bottom," "side," "left," "right," "top," and "bottom" are defined based on the drawings, and the shape and location of each component are not limited by these terms.

[0031] Where any (e.g., 1st) component is referred to as "coupled" or "connected" to another (e.g., 2nd) component, with or without the terms "functionally" or "communicationly," it means that said any component may be connected to said other component directly (e.g., via a wire), wirelessly, or through a third component.

[0032] Terms such as "include" or "have" are intended to specify the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in this document, and do not preclude the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0033] When it is said that a component is "connected," "combined," "supported," or "in contact" with another component, this includes not only cases where the components are directly connected, combined, supported, or in contact, but also cases where they are indirectly connected, combined, supported, or in contact through a third component.

[0034] When it is said that a component is located "on" another component, this includes not only cases where one component is in contact with the other, but also cases where another component exists between the two components.

[0035] FIG. 1 is a view of one side of a heat exchanger according to one embodiment of the present disclosure.

[0036] FIG. 2 is an enlarged perspective view of a portion of a heat exchanger according to one embodiment of the present disclosure.

[0037] Referring to FIGS. 1 and 2, the heat exchanger (10) can be placed inside a home appliance, such as an air conditioner (e.g., see air conditioner (1) in FIGS. 12 and 13), a refrigerator, or a dryer, to provide heat exchange.

[0038] According to one embodiment, the heat exchanger of the air conditioner may include an indoor evaporator and an outdoor condenser. The evaporator of the indoor unit can cool the indoor air. For example, as the indoor air passes through the evaporator, the refrigerant evaporates to absorb heat, and the cooled air can be sent into the room to lower the temperature. The condenser of the outdoor unit can release the heat absorbed from the room to the outside. For example, as the refrigerant loses heat in the condenser and returns to a liquid state, the heat from the room can be released to the outside air.

[0039] According to one embodiment, the heat exchanger of a refrigerator may include an evaporator and a condenser. The evaporator may be positioned inside the refrigerator to form a path for the flow of refrigerant. The refrigerant may absorb heat while evaporating to cool the air inside the refrigerator. For example, the evaporator may absorb heat from inside the refrigerator to keep food fresh. The condenser is located at the rear of the refrigerator and may release heat to the outside, which has been converted to a high-temperature state by compressing the refrigerant. For example, the condenser may release heat absorbed from inside the refrigerator to the outside to maintain a constant internal temperature.

[0040] According to one embodiment, the heat exchanger of the dryer is placed within the heat pump and can exchange heat with the refrigerant circulating through the heat pump. The air discharged from the heat pump can be understood as high-temperature dry air. The compressor of the dryer compresses the refrigerant to a high-temperature, high-pressure state and discharges it, and the discharged refrigerant can flow into the condenser. The condenser condenses the compressed refrigerant and can release heat to the surroundings through the condensation process. Additionally, an expansion device within the heat pump (e.g., an electronic expansion valve (EEV, hereinafter referred to as the expansion valve)) can expand the refrigerant in a high-temperature, high-pressure state condensed in the condenser to a low-pressure state. The evaporator evaporates the expanded refrigerant and can absorb heat from the surroundings through the evaporation process.

[0041] According to one embodiment, a home appliance (e.g., an air conditioner, a refrigerator, or a dryer) may include a housing (e.g., the housing (410; 510) of FIG. 13a and 13b), a heat exchanger (10) disposed inside the housing, and a fan (e.g., the outdoor fan (108), indoor fan (109) of FIG. 12) disposed adjacent to the heat exchanger (10) and for discharging air to the outside of the housing. The fan may be disposed in a position where heat exchange with the outside is possible.

[0042] According to one embodiment, the heat exchanger (10) may include a refrigerant pipe (100) comprising a plurality of pipes, a fin (200) (e.g., a heat dissipation fin) coupled to the outer surface of the refrigerant pipe (100), and a cover portion (300) covering the refrigerant pipe (100) and the fin (200).

[0043] According to one embodiment, the refrigerant pipe (100) of the heat exchanger (10) can provide a flow path for the refrigerant. For example, the refrigerant pipe (100) may have a channel formed inside so that the refrigerant can move. The refrigerant pipe (100) may have a winding (or zigzag) shape to increase the contact area between the refrigerant and the external space (e.g., to expand the heat exchange area with the external air).

[0044] According to one embodiment, the refrigerant piping (100) may include a plurality of straight pipes (100a) and a connecting pipe (100b) (e.g., a U-pipe) connecting the plurality of straight pipes (100a). The plurality of straight pipes (100a) may be arranged in parallel with each other.

[0045] According to one embodiment, the fins (200) of the heat exchanger (10) are provided in a plurality and may be positioned between the plurality of straight pipes (100a) so that the refrigerant flowing along the channel formed inside the straight pipe (100a) of the refrigerant piping (100) and the external air can efficiently exchange heat. When the straight pipes (100a) of the refrigerant piping (100) are arranged in a first direction, the fins (200) may be arranged in a second direction perpendicular to the first direction. For example, the plurality of fins (200) may be arranged to be in contact with the straight pipes (100a) in the heat exchange space. For example, the plurality of fins (200) may be provided along the outer surface of the straight pipes (100a) in the longitudinal direction of the straight pipes (100a). The plurality of fins (200) may be arranged spaced apart at regular intervals to limit (e.g., prevent) corrosion of the refrigerant piping (100).

[0046] According to one embodiment, the cover portion (300) of the heat exchanger (10) supports the refrigerant pipes (100) and can cover the refrigerant pipes (100) and fins (200) so that they are not exposed to the outside. The cover portion (300) may be named an evaporator that provides a heat exchange function and can maintain the shape of the heat exchanger (10) by fixing the refrigerant pipes (100).

[0047] According to one embodiment, a sensor holder (hereinafter referred to as a second pipe (120)) configured to accommodate a sensor (e.g., a thermistor) may be disposed on some of the connecting pipes (100b) of the refrigerant pipe (100) (hereinafter referred to as a first pipe (110)). The combined structure of the first pipe (110) and the second pipe (120) will be described in detail below.

[0048] FIG. 3 is a perspective view of a heat exchanger in which a portion of FIG. 1 or FIG. 2 (S) is enlarged, according to one embodiment of the present disclosure.

[0049] FIG. 4 is a top view of a heat exchanger in which a portion of FIG. 1 or FIG. 2 (S) is enlarged, according to one embodiment of the present disclosure.

[0050] FIG. 5 is a side view of a heat exchanger in which a portion of FIG. 1 or FIG. 2 (S) is enlarged, according to one embodiment of the present disclosure.

[0051] According to one embodiment, a home appliance (e.g., refrigerator, air conditioner, or dryer) may include a heat exchanger (10). The heat exchanger (10) may include a first pipe (110), a second pipe (120) positioned adjacent to the first pipe (110) and configured to accommodate a sensor (e.g., a thermistor) (127), and a filler material (400) configured to connect the first pipe (110) and the second pipe (120).

[0052] According to one embodiment, the first pipe (110) of the heat exchanger (10) may be part of a refrigerant pipe (e.g., the refrigerant pipe (100) of FIGS. 1 and 2) that provides a flow path for the refrigerant. For example, the first pipe (110) may be one of the connecting pipes (e.g., the connecting pipe (100b) of FIGS. 1 and 2) that connect straight pipes (e.g., the straight pipe (100a) of FIGS. 1 and 2) that are parallel to each other among the refrigerant pipes (100). For example, the first pipe (110) may include a U-shaped pipe. However, the shape of the first pipe (110) is not limited thereto and may be one of the connecting pipes (100b) of various shapes located adjacent to the sensor (127).

[0053] According to one embodiment, the first pipe (110) is shaped to provide a passage for the refrigerant to travel through, and the pipe may be named at least one of a pipe, a pipeline, a tube, a duct, or a line.

[0054] According to one embodiment, the first pipe (110) may be cylindrical in shape and may include a first wall (111) of a constant thickness formed to surround a space through which a refrigerant travels, and / or a rim portion (112) protruding on the outer side of the first wall (111). The first wall (111) may be U-shaped and may include parallel portions and a curved portion for connecting to different straight pipes (100a). The rim portion (112) may be formed adjacent to each end of the parallel portions as a portion for fixing the position where each of the different straight pipes (100a) is connected (e.g., by fitting).

[0055] According to one embodiment, the first wall (111) of the first pipe (110) may include a first surface (111a) facing outward and a first core (111b) forming the interior of the first wall (111). A portion of the first surface (111a) may come into contact with the second pipe (120) or be joined to the second pipe (120) by a filler material (400). The joining area of ​​the first surface (111a) that is joined to the second pipe (120) may be located on a curved portion.

[0056] According to one embodiment, the second pipe (120) of the heat exchanger (10) provides a space for mounting a sensor (e.g., a thermistor) (127) and may be positioned on one side of the first pipe (110). For example, the sensor (127) can detect (e.g., real-time monitoring) the temperature of the refrigerant flowing in the first pipe (110). When the sensor (127) transmits the detected temperature to a system control unit (not shown), the control unit can control the operation of the compressor or fan as needed.

[0057] According to one embodiment, the second pipe (120) of the heat exchanger (10) may be designed as a straight pipe to facilitate mounting of a cylindrical sensor (127). The second pipe (120) may have a cylindrical shape and may include a second wall (121) of a certain thickness formed to surround a space into which the sensor (127) is inserted and seated, and / or a stopper portion (122) extending from the second wall (121) to restrict movement of the sensor (127). The stopper portion (122) may be formed to surround a space with an area smaller than the space formed by the second wall (121) so that the sensor (127) can no longer move linearly in one direction. However, the shape of the second pipe (120) is not limited thereto and may be designed to be changed to various shapes for mounting the sensor (127).

[0058] According to one embodiment, the second pipe (120) is shaped to provide a space for a sensor (127) to be placed, and the pipe may be named at least one of a pipe, a pipeline, a tube, a duct, or a line.

[0059] According to one embodiment, the second wall (121) of the second pipe (120) may include a second surface (121a) facing outward and a second core (121b) forming the interior of the second wall (121). A portion of the second surface (121a) may be in contact with the first pipe (110) or may be joined to the first pipe (110) by a filler material (400). The second surface (121a) may be positioned facing a curved portion of the first pipe (110).

[0060] According to one embodiment, the first pipe (110) and the second pipe (120) may include the same alloy material. The first pipe (110) and the second pipe (120) may include an Al (aluminum) material. For example, the first pipe (110) and the second pipe (120) may be either A3xxx-series aluminum or A1xxx-series aluminum. Since the first pipe (110) and the second pipe (120) are manufactured with only different shapes through the same process, if the first pipe (110) includes A3xxx-series aluminum, the second pipe (120) may also include A3xxx-series aluminum. If the first pipe (110) includes A1xxx-series aluminum, the second pipe (120) may also include A1xxx-series aluminum.

[0061] According to one embodiment, the first pipe (110) and / or the second pipe (120) may include a zinc diffusion layer (e.g., the zinc diffusion layer (115; 125) of FIG. 7). For example, the first pipe (110) and / or the second pipe (120) may form a zinc diffusion layer (115; 125) to prevent sacrificial corrosion of surfaces (e.g., the first surface (111a) of the first pipe (110), and / or the second surface (121a) of the second pipe (120)) when joined by a filler material (400). For example, the first pipe (110) may include a first zinc diffusion layer (115; 125), and the second pipe (120) may include a second zinc diffusion layer (115; 125).

[0062] According to one embodiment, a first zinc diffusion layer (e.g., the zinc diffusion layer (115) of FIG. 7) of a first pipe (110) can be formed by arc spraying zinc (Zn) onto a first surface (111a) and then performing a heat treatment process. In the heat treatment process, the zinc (Zn) placed on the first surface (111a) can penetrate and diffuse into the first core (111b). Through the arc spraying, the zinc (Zn) has a content of at least 1 wt% relative to the total weight, and in the heat treatment process, the first zinc diffusion layer (115) can form a layer with a depth (or thickness) of approximately 10 μm.

[0063] According to one embodiment, a second zinc diffusion layer of the second pipe (120) (e.g., the zinc diffusion layer (125) of FIG. 7) can be formed by arc spraying zinc (Zn) onto the second surface (121a) and then performing a heat treatment process. In the heat treatment process, the zinc (Zn) placed on the second surface (121a) can penetrate and diffuse into the second core (121b). Through the arc spraying, the zinc (Zn) has a content of at least 1 wt% relative to the total weight, and in the heat treatment process, the second zinc diffusion layer (125) can form a layer with a depth (or thickness) of approximately 10 μm.

[0064] According to one embodiment, when the zinc diffusion layer (115; 125) of the first pipe (110) and / or the second pipe (120) is joined by the filler material (400), the potential difference between the filler materials (400) can be designed so that the potential difference between the filler materials (400) does not exceed a certain value due to the zinc (Zn) contained in the filler material (400). This design prevents the occurrence of a potential difference between the first pipe (110), the second pipe (120), and the filler material (400), thereby limiting (e.g., reducing or preventing) the separation of the first pipe (110), the second pipe (120), and the filler material (400).

[0065] According to one embodiment, the first pipe (110) and the second pipe (120) may be joined so as to be offset from each other. For example, when the second pipe (120) is joined to the curved portion of the first pipe (110), the angle between the center line (L') of the second pipe (120) and the center line (L1) of the curved portion of the first pipe (110) when viewed from above the second pipe (120) may form an acute angle. For example, the curved portion of the first pipe (110) and the second pipe (120) may be arranged so as not to be parallel to each other. For example, the angle between the center line (L') of the second pipe (120) and the center line (L1) of the curved portion of the first pipe (110) may have a value of approximately 15 degrees or less. However, the angle between the first pipe (110) and the second pipe (120) is an angle to avoid interference with surrounding parts, and depending on the presence or location of surrounding parts, the design can be varied between 0 and 90 degrees.

[0066] According to one embodiment, the filler material (400) of the heat exchanger (10) may be configured to join the first pipe (110) and the second pipe (120). The filler material (400) is an auxiliary material used when welding the first pipe (110) and the second pipe (120), and melts during welding to join the first pipe (110) and the second pipe (120), and after welding, the first pipe (110) and the second pipe (120) can form a single part (e.g., an integrated structure).

[0067] According to one embodiment, the filler material (400) can fill the joint between the first pipe (110) and the second pipe (120) when welding the surfaces of the first pipe (110) and the second pipe (120) so that the first pipe (110) and the second pipe (120) are strongly bonded to each other. According to one embodiment, the filler material (400) can increase the strength of the welded portion when welding the surfaces of the first pipe (110) and the second pipe (120) so that the heat exchanger (10) remains sturdy for a long time. For example, the filler material (400) can provide the necessary physical properties to ensure that the welded portion remains stronger than the original metal (e.g., Al). According to one embodiment, the filler material (400) can complement the durability or thermal performance of the welded portion. For example, the filler material (400) can use a corrosion-resistant material for the welded portion or control the coefficient of thermal expansion.

[0068] According to one embodiment, the filler material (400) may include an aluminum (Al) and zinc (Zn) alloy. For example, the filler material (400) may include aluminum (Al) and zinc (Zn) as the main materials and may include other impurities.

[0069] According to one embodiment, the zinc (Zn) of the filler material (400) may contain approximately 10 to 90 wt% of the total weight, so as to have a potential value substantially the same (or similar) as the zinc diffusion layer (115; 125) of the first pipe (110) and the second pipe (120). For example, the zinc (Zn) of the filler material (400) may contain approximately 40 to 70 wt% of the total weight.

[0070] According to one embodiment, the potential values ​​between the filler material (400), the first pipe (110), and the second pipe (120) may be substantially the same. For example, the potential difference between the filler material (400), the first pipe (110), and the second pipe (120) may be approximately 50 mV or less. For example, the potential difference between the filler material (400), the first pipe (110), and the second pipe (120) may be approximately 30 mV or less. For example, a portion having a potential value substantially the same as that of the filler material (400) may be the surface of the first pipe (110) and / or the surface of the second pipe (120). Generally, even if the filler material (400), the first pipe (110), and the second pipe (120) contain the same material (e.g., Al and Zn), a potential difference may occur depending on the compositional variation of the alloy elements. The heat exchanger (10) of the present disclosure can limit (e.g., reduce or prevent) separation between the filler material (400), the first pipe (110), and the second pipe (120) by controlling the content of alloy elements of the filler material (400) to minimize (e.g., substantially identical). The potential difference may be defined as the difference between the potential value of the material with the highest potential value among the filler material (400), the first pipe (110), and the second pipe (120) and the potential value of the material with the lowest potential value among the filler material (400), the first pipe (110), and the second pipe (120).

[0071] According to one embodiment, the filler material (400) can have its potential value adjusted to be equal to or similar to the potential value of the first pipe (110) and the second pipe (120) by adding impurities such as Cu (copper) or Si (silicon). For example, if the potential value of the filler material (400) is relatively significantly reduced compared to the potential values ​​of the first pipe (110) and the second pipe (120), the content of impurities such as Cu (copper) or Si (silicon) can be increased. As the content of impurities such as Cu (copper) or Si (silicon) in the filler material (400) increases, the potential value of the filler material (400) can be increased.

[0072] According to one embodiment, when a potential difference occurs between the filler material (400), the first pipe (110), and the second pipe (120) in the heat exchanger (10), the potential value of the filler material (400) can be designed to be lower than that of the first pipe (110) and the second pipe (120). For example, the potential value of the filler material (400), which has a relatively larger volume (e.g., size) among the filler material (400), the first pipe (110), and the second pipe (120), can be set lower to limit (e.g., reduce or prevent) the separation between each part.

[0073] According to one embodiment, when comparing potential values ​​between the filler material (400), the first surface (111a) of the first pipe (110), the first core (111b) of the first pipe (110), the second surface (121a) of the second pipe (120), and the second core (121b) of the second pipe (120) in the heat exchanger (10), the potential value of the filler material (400) may be smaller than the potential value of the first core (111b) of the first pipe (110) and the potential value of the second core (121b) of the second pipe (120). The potential value of the first surface (111a) of the first pipe (110) may be smaller than the potential value of the first core (111b) of the first pipe (110) and the potential value of the second core (121b) of the second pipe (120). The potential value of the second surface (121a) of the second pipe (120) may be smaller than the potential value of the first core (111b) of the first pipe (110) and the potential value of the second core (121b) of the second pipe (120). The potential value of the filler material (400) may have a value greater than the potential value of the first surface (111a) of the first pipe (110) and the potential value of the second surface (121a) of the second pipe (120).

[0074] FIG. 6 is a graph showing potential values ​​according to the composition of the filler material of a heat exchanger according to one embodiment of the present disclosure.

[0075] According to one embodiment, the heat exchanger (10) may include a first pipe (110), a second pipe (120) positioned adjacent to the first pipe (110) and configured to accommodate a sensor (e.g., a thermistor), and a filler material (400) configured to connect the first pipe (110) and the second pipe (120).

[0076] According to one embodiment, the configuration of the filler material (400) for joining the first pipe (110) and the second pipe (120) of the heat exchanger (10) of FIG. 6 may be partially or entirely the same as the configuration of the filler material (400) for joining the first pipe (110) and the second pipe (120) of the heat exchanger (10) of FIG. 1 to FIG. 5.

[0077] The embodiment of FIG. 6 can be optionally combined with the embodiments of FIG. 1 to 5 and FIG. 7 to 13b.

[0078] According to one embodiment, the filler material (400) may include an aluminum (Al) and zinc (Zn) alloy. For example, the filler material (400) may include aluminum (Al) and zinc (Zn) as the main materials and may include other impurities.

[0079] Below, [Table 1] is a table showing the alloy ratio between aluminum (Al) and zinc (Zn) of the filler material (400).

[0080]

[0081] Referring to [Table 1], it can be seen that as the zinc (Zn) content of the filler material (400) increases, the potential value (mV) decreases.

[0082] According to one embodiment, when the zinc (Zn) of the filler material (400) contains approximately 10 to 90 wt% of the total weight, it can be designed to have a potential value substantially the same (or similar) as the zinc diffusion layer of the first pipe (110) and the second pipe (120) (e.g., zinc diffusion layer (115; 125) of FIG. 7). When the zinc (Zn) of the filler material (400) contains approximately 10 to 90 wt% of the total weight, the potential value of the filler material (400) may be approximately -1010 mV to -1572 mV.

[0083] According to one embodiment, when the zinc (Zn) of the filler material (400) contains approximately 40 to 70 wt% of the total weight, it may have a potential value substantially the same (or similar) as the zinc diffusion layer of the first pipe (110) and the second pipe (120) (e.g., zinc diffusion layer (115; 125) of FIG. 7). When the zinc (Zn) of the filler material (400) contains approximately 40 to 70 wt% of the total weight, the potential value of the filler material (400) may be approximately -1210 mV to -1385 mV. A zinc diffusion layer (115; 125) can be produced by arc spraying on the first surface (111a) of the first pipe (110) and / or the second surface (121a) of the second pipe (120) such that zinc (Zn) is approximately 3 to 7% of the total weight, followed by heat treatment. The potential value of the first surface (111a) of the first pipe (110) and / or the second surface (121a) of the second pipe (120) containing the zinc diffusion layer (115; 125) can be approximately -1160 mV to -1335 mV. As the potential value of the filler material (400) and the potential difference between the first surface (111a) of the first pipe (110) and / or the second surface (121a) of the second pipe (120) are substantially the same (e.g., difference of approximately 50 mV or less), the separation between each part can be limited (e.g., reduced or prevented) after the first pipe (110) and the second pipe (120) are joined.

[0084] FIG. 7 is a drawing showing a zinc diffusion layer of a first pipe and / or a second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0085] FIG. 8 is an enlarged view of the zinc diffusion layer of the first pipe and / or second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0086] According to one embodiment, the heat exchanger (10) may include a first pipe (110), a second pipe (120) positioned adjacent to the first pipe (110) and configured to accommodate a sensor (e.g., a thermistor), and a filler material (e.g., filler material (400) of FIG. 5) configured to connect the first pipe (110) and the second pipe (120).

[0087] According to one embodiment, the configuration of the first pipe (110), the second pipe (120), and the filler material (400) of the heat exchanger (10) of FIGS. 7 and 8 may be partially or entirely identical to the configuration of the first pipe (110), the second pipe (120), and the filler material (400) of the heat exchanger (10) of FIGS. 1 to 6. The embodiment of FIGS. 7 and 8 may be optionally combined with the embodiment of FIGS. 1 to 6 and FIGS. 9 to 13b.

[0088] According to one embodiment, the first pipe (110) and / or the second pipe (120) may include a zinc diffusion layer (115; 125). The first pipe (110) and / or the second pipe (120) may form a zinc diffusion layer (115; 125) to prevent sacrificial corrosion of surfaces (e.g., a first surface (111a) of the first pipe (110) and / or a second surface (121a) of the second pipe (120)) when joined by a filler material (400). The zinc diffusion layer (115; 125) may limit (e.g., reduce or prevent) separation between the first pipe (110) and / or the second pipe (120) after welding, as the potential value is maintained substantially the same (or similar) with the filler material (400) containing zinc (Zn).

[0089] According to one embodiment, a zinc diffusion layer (115; 125) can be formed by arc spraying zinc (Zn) onto a first surface (111a) of a first pipe (110) and / or a second surface (121a) of a second pipe (120), followed by a heat treatment process. The arc-sprayed zinc may have a content of approximately 3 to 7 wt% relative to the total weight of the first pipe (110) and / or the second pipe (120).

[0090] According to one embodiment, the zinc diffusion layer (115; 125) may be formed as it diffuses from the first surface (111a) of the first pipe (110) (and / or the second surface (121a) of the second pipe (120)) to the first core (111b) of the first pipe (110) (and / or the second core (121b) of the second pipe (120)) during a heat treatment process after being sprayed. After the heat treatment process is completed, the zinc diffusion layer (115; 125) may be formed to have a depth (or thickness) of approximately 10 μm. For example, the zinc diffusion layer (115; 125) may be formed to have a depth (or thickness) of approximately 100 μm.

[0091] According to one embodiment, the zinc diffusion layer (115; 125) may provide a layer of various shapes. For example, the zinc diffusion layer (115; 125) may be formed to have a layer of irregular thickness based on the different rates at which zinc (Zn) diffuses toward the first core (111b) of the first pipe (110) (and / or the second core (121b) of the second pipe (120). For example, the zinc diffusion layer (115; 125) may form a layer with different thicknesses at each section (or location) as the content of zinc (Zn) diffused toward the first core (111b) of the first pipe (110) (and / or the second core (121b) of the second pipe (120)) decreases sequentially.

[0092] Below, [Table 2] is a table showing the content of compositions according to the depth of the zinc diffusion layer (115; 125) of the first pipe (110) and / or the second pipe (120).

[0093]

[0094] Referring to FIG. 8 and [Table 2], the first pipe (110) and / or the second pipe (120) may comprise at least one of aluminum (Al), zinc (Zn), silicon (Si), manganese (Mn), or magnesium (Mg). The thickness of 100 μm disclosed in FIG. 8 is an example, and the region where zinc (Zn) is diffused may be designed in various ways considering the size of the first pipe (110) and / or the second pipe (120). Region ① in FIG. 8 (region referred to as ①) represents the region where zinc (Zn) is diffused, and it can be confirmed that it is a region close to the surface. Region ② in FIG. 8 (region referred to as ②) represents the region where zinc (Zn) is diffused through region ①, and it can be confirmed that it is a region below region ①. Region ③ in FIG. 8 (region referred to as ③) represents the region where zinc (Zn) is diffused through region ②, and it can be confirmed that it is a region below region ②. Region ④ of FIG. 8 (the region referred to by ④) represents the region where zinc (Zn) has diffused through region ③, and it can be confirmed that it is the region below region ③. The zinc diffusion layer (115; 125) forms a thickness along regions ①, ②, ③, and ④, and can have a length of approximately 100 μm.

[0095] According to one embodiment, the zinc diffusion layer (115; 125) can be seen to decrease sequentially as zinc (Zn) diffuses from the surface of the first pipe (110) and / or the second pipe (120) into the depth. For example, the zinc (Zn) contained in area ① may have a content of approximately 4.0 wt% relative to the total weight. The zinc (Zn) contained in area ② may have a content of approximately 3.38 wt% relative to the total weight. The zinc (Zn) contained in area ③ may have a content of approximately 1.35 wt% relative to the total weight. The zinc (Zn) contained in area ④ may have a content of approximately 0.34 wt% relative to the total weight. As the zinc (Zn) decreases from the surface of the first pipe (110) and / or the second pipe (120) into the depth, the potential value of each area may increase.

[0096] According to one embodiment, the zinc diffusion layer (115; 125) of the first pipe (110) and / or the second pipe (120) can be designed so that when joined by the filler material (400), the potential difference due to the zinc (Zn) contained in the filler material (400) does not exceed a certain value. This design prevents a potential difference from occurring between the first pipe (110), the second pipe (120), and the filler material (400), thereby limiting (e.g., reducing or preventing) the separation of the first pipe (110), the second pipe (120), and the filler material (400).

[0097] FIG. 9a is a view from one direction of a structure in which a first pipe and a second pipe of a heat exchanger are combined, according to one embodiment of the present disclosure.

[0098] FIG. 9b is a drawing of a structure in which a first pipe and a second pipe of a heat exchanger are combined, according to one embodiment of the present disclosure, viewed from a different direction.

[0099] FIG. 10 is a cross-sectional view showing the joint portion before joining and the joint portion after joining of the first pipe and the second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0100] FIG. 11 is a cross-sectional view showing the joint portion before and after joining of the first pipe and the second pipe of a heat exchanger according to one embodiment of the present disclosure.

[0101] According to one embodiment, the heat exchanger (10) may include a first pipe (110) and a second pipe (120) positioned adjacent to the first pipe (110) and configured to accommodate a sensor (e.g., a thermistor). The first pipe (110) and the second pipe (120) may provide an integrated structure joined through direct coupling. The direct coupling may be at least one of laser coupling, fiber coupling, electrical coupling, magnetic coupling, optical coupling, or acoustic coupling. Hereinafter, laser coupling will be described with focus.

[0102] According to one embodiment, the configuration of the first pipe (110) and the second pipe (120) of the heat exchanger (10) of FIGS. 9a to 11 may be partially or entirely identical to the configuration of the first pipe (110) and the second pipe (120) of the heat exchanger (10) of FIGS. 1 to 8. The embodiment of FIGS. 9a to 11 may be optionally combined with the embodiment of FIGS. 1 to 8.

[0103] Hereinafter, the embodiments of FIGS. 9a to 11 are joined by a laser rather than by a filler material, so the filler material may be excluded. The laser joining will be described in detail below.

[0104] According to this, since the first pipe (110) and the second pipe (120) are directly joined using a laser, potential difference corrosion caused by the filler material components can be limited (e.g., reduced or prevented).

[0105] According to one embodiment, the heat exchanger (10) coupling structure may be a structure in which the first pipe (110) and the second pipe (120) are strongly coupled by bringing the first pipe (110) and the second pipe (120) into contact, and then irradiating the contact area of ​​the first pipe (110) and the second pipe (120) with a high-power laser to locally heat and melt the joint area (A) (e.g., the joint area) and then solidify it.

[0106] According to one embodiment, the laser used in the heat exchanger (10) coupling structure may be at least one of a CO2 laser (carbon dioxide laser), a fiber laser, a diode laser, or an Nd laser (neodymium:yttrium-aluminum-garnet laser).

[0107] According to the welding process of the heat exchanger (10) joint structure, a surface treatment process can be performed on the first pipe (110) and the second pipe (120) before welding. For example, if there are impurities such as oxides, the laser welding quality may be degraded, so the surfaces of the first pipe (110) and the second pipe (120) can be cleaned thoroughly to remove them. Afterward, since the first pipe (110) and the second pipe (120) to be welded must be accurately aligned, the first pipe (110) or the second pipe (120) can be fixed by a jig or clamp so that they do not move while fixed. For example, if a curved pipe (e.g., the first pipe (110)) is included, precise positioning may be required. Afterward, a laser selected by the operator is emitted at an appropriate output, and the connection part (e.g., the joint part (A)) of the first pipe (110) and the second pipe (120) can be locally heated. For example, a high-power laser can instantaneously melt and join the surfaces of the first pipe (110) and the second pipe (120). In the area where the laser is irradiated, the metal of the first pipe (110) and the second pipe (120) melts to form a melt pool, and the melt pool can form a weld line at the joining area (A). The laser welding machine can perform welding along the entire joining line of the first pipe (110) and the second pipe (120) at an accurate speed.

[0108] Afterward, the first pipe (110) and the second pipe (120), which were melted by a laser, are cooled after welding. During this process, the first pipe (110) and the second pipe (120) are joined together, and a strong joint (A) can be formed. Afterward, once the welding is completed, the quality of the weld can be verified using non-destructive testing (NDT) techniques. For example, ultrasonic testing, X-ray testing, or video endoscopy may be used to inspect for cracks, pores, or incomplete welding in the welded area of ​​the heat exchanger (10).

[0109] According to one embodiment, in a heat exchanger (10) coupling structure, a portion of the first pipe (110) and a portion of the second pipe (120) may form a joint portion (A) that overlaps with each other. The joint portion (A) may be a portion where the portion of the first pipe (110) and the portion of the second pipe (120) are melted and joined. The length of the portion of the joint portion (A) may have a value smaller than the thickness of each of the first pipe (110) or the second pipe (120). Referring to the cross-section of the heat exchanger (10) coupling structure of FIG. 10, the length in the direction toward the first center (O1) of the first pipe (110) and / or the second center (O2) of the second pipe (120) at the joint portion (A) may be defined as the first width (t3) of the joint portion (A), and the length perpendicular to the first width (t3) may be defined as the first length (L1) of the joint portion (A). The first thickness (t1) of the first pipe (110) can be defined as the difference between the outer diameter and the inner diameter of the first pipe (110). The second thickness (t2) of the second pipe (120) can be defined as the difference between the outer diameter and the inner diameter of the second pipe (120).

[0110] According to one embodiment, in a heat exchanger (10) coupling structure, the first width (t3) of the joint portion (A) may be smaller than the first thickness (t1) of the first pipe (110) or the second thickness (t2) of the second pipe (120). For example, the first width (t3) of the joint portion (A) may have a size of less than or equal to half the first thickness (t1) of the first pipe (110) or the second thickness (t2) of the second pipe (120). For example, if the first thickness (t1) of the first pipe (110) or the second thickness (t2) of the second pipe (120) is approximately 1 mm, the first width (t3) of the joint portion (A) may be approximately 0.5 mm or less.

[0111] According to one embodiment, in the heat exchanger (10) coupling structure, the first length (L1) of the joint portion (A) may be smaller than the outer diameter (or inner diameter) of the first pipe (110) or the outer diameter (or inner diameter) of the second pipe (120). For example, the first length (L1) of the joint portion (A) may have a size of less than or equal to half the outer diameter of the first pipe (110) or the outer diameter of the second pipe (120). For example, if the outer diameter of the first pipe (110) or the outer diameter of the second pipe (120) is approximately 7 ± 0.05 mm, the first length (L1) of the joint portion (A) may be approximately 2 to 4 mm.

[0112] According to one embodiment, in the heat exchanger (10) joint structure, the joint area (A) can be advantageous for fast operation and mass production as the welding area of ​​the first pipe (110) and the second pipe (120) is minimized (e.g., less thermal deformation of the pipe material due to localized heating) and a strong bond is maintained using a laser.

[0113] According to one embodiment, in a heat exchanger (10) combined structure, the first pipe (110) and the second pipe (120) can have a beautiful appearance at the joint (e.g., welded part) using a laser. According to one embodiment, the first pipe (110) and the second pipe (120) can form an integrated structure. The first pipe (110) and the second pipe (120) can be made of the same material.

[0114] According to one embodiment, the first pipe (110) and the second pipe (120) are a monolithic support body, and the joint portion (A) of the monolithic support body may be exposed to the outside of the heat exchanger (10) and may be a structure that extends seamlessly from the first pipe (110) to the second pipe (120).

[0115] According to one embodiment, the first pipe (110) and / or the second pipe (120) may include a zinc diffusion layer (115; 125). The zinc diffusion layer (115; 125) may be formed by arc spraying zinc (Zn) onto the first surface (111a) of the first pipe (110) and / or the second surface (121a) of the second pipe (120), followed by a heat treatment process. The arc-sprayed zinc may have a content of approximately 3 to 7 wt% relative to the total weight of the first pipe (110) and / or the second pipe (120).

[0116] According to one embodiment, the first pipe (110) of the heat exchanger (10) may be part of a refrigerant pipe (e.g., the refrigerant pipe (100) of FIG. 1 and FIG. 2) that provides a flow path for the refrigerant. For example, the first pipe (110) may include a U-shaped pipe.

[0117] According to one embodiment, the first wall (111) of the first pipe (110) may include a first surface (111a) facing outward and a first core (111b) forming the interior of the first wall (111). A portion of the first surface (111a) may come into contact with the second pipe (120), or a bonding area (A) may be formed by a laser to bond with the second pipe (120). The bonding area of ​​the first surface (111a) that bonds with the second pipe (120) may be located on a curved portion.

[0118] According to one embodiment, the second pipe (120) of the heat exchanger (10) provides a space for mounting a sensor (e.g., a thermistor) and may be positioned on one side of the first pipe (110). For example, the sensor (127) can detect (e.g., real-time monitoring) the temperature of the refrigerant flowing in the first pipe (110).

[0119] According to one embodiment, the second wall (121) of the second pipe (120) may include a second surface (121a) facing outward and a second core (121b) forming the interior of the second wall (121). A portion of the second surface (121a) may be in contact with the first pipe (110), or a joint portion (A) may be joined to the first pipe (110) by a laser. The second surface (121a) may be positioned facing the curved portion of the first pipe (110).

[0120] According to one embodiment, the first pipe (110) and the second pipe (120) may not have a potential difference between them due to laser coupling of the same material. This may limit (e.g., reduce or prevent) the separation of the first pipe (110) and the second pipe (120).

[0121] FIG. 12 is a schematic diagram illustrating a configuration related to a refrigerant cycle including a heat exchanger of an air conditioner (e.g., air conditioner) according to one embodiment of the present disclosure.

[0122] FIG. 13a is a perspective view showing the exterior of an indoor unit of an air conditioner according to one embodiment of the present disclosure.

[0123] FIG. 13b is a perspective view showing the exterior of an outdoor unit of an air conditioner according to one embodiment of the present disclosure.

[0124] FIGS. 12 to 13b illustrate the structure of an air conditioner as an example of a home appliance including a heat exchanger. Referring to FIG. 12, the heat exchanger of an air conditioner (e.g., air conditioner) may have a configuration that is partly or entirely identical to the heat exchanger (10) of FIGS. 1 to 11. The embodiments of FIGS. 12 to 13b may be optionally combined with the embodiments of FIGS. 1 to 11.

[0125] According to one embodiment, an air conditioner (1) may include a compressor (101) that compresses the refrigerant to change it to a high-temperature, high-pressure state, an outdoor heat exchanger (102) that enables heat exchange between the outdoor air and the refrigerant, an expansion device (103) that expands the refrigerant to change it to a low-temperature, low-pressure state, and an indoor heat exchanger (104) that enables heat exchange between the indoor air and the refrigerant. The air conditioner (1) may include a refrigerant pipe (105) (e.g., the refrigerant piping (100) of FIGS. 1 and 2) connecting the compressor (101), the outdoor heat exchanger (102), the expansion device (103), and the indoor heat exchanger (104). In one example, the refrigerant may circulate through the refrigerant pipe (105) in the order of the compressor (101), the outdoor heat exchanger (102), the expansion device (103), and the indoor heat exchanger (104). In one example, the refrigerant can circulate in the order of the compressor (101), indoor heat exchanger (104), expansion device (103), and outdoor heat exchanger (102).

[0126] According to one embodiment, the air conditioner (1) may include a flow switching valve (106) that switches the circulation path of the refrigerant through the refrigerant pipe (105). The flow switching valve (106) may include, for example, a four-way valve. The flow switching valve (106) may be connected to the suction part (101a) of the compressor (101). The flow switching valve (106) may be connected to the discharge part (101b) of the compressor (101). The flow switching valve (106) may be connected to an outdoor heat exchanger (102). The flow switching valve (106) may be connected to an indoor heat exchanger (104). The flow switching valve (106) may switch the circulation path of the refrigerant depending on the operating mode of the air conditioner (1) (e.g., cooling operation or heating operation mode). The flow switching valve (106) can allow high-temperature, high-pressure refrigerant discharged by the compressor (101) through the discharge section (101b) to flow to an outdoor heat exchanger (102) or an indoor heat exchanger (104) depending on the operating mode of the air conditioner (1). The flow switching valve (106) can allow refrigerant from the indoor heat exchanger (104) or the outdoor heat exchanger (102) to flow to the suction section (101a) of the compressor (101) depending on the operating mode of the air conditioner (1).

[0127] According to one embodiment, the air conditioner (1) may include an accumulator (107). One end of the accumulator (107) may be connected to the suction part (101a) of the compressor (101). The other end of the accumulator (107) may be connected to a flow path switching valve (106). Through the flow path switching valve (106), low-temperature, low-pressure refrigerant from an indoor heat exchanger (104) or an outdoor heat exchanger (102) may be introduced into the accumulator (107). When a refrigerant mixed with liquid refrigerant and refrigerant gas is introduced, the accumulator (107) may separate the refrigerant gas and the liquid refrigerant, and provide the refrigerant gas from which the liquid refrigerant has been separated to the suction part (101a) of the compressor (101).

[0128] According to one embodiment, the compressor (101) can suck in refrigerant gas through the suction part (101a) and compress the sucked refrigerant gas to change it to a high temperature and high pressure state. The compressor (101) can discharge the high temperature and high pressure refrigerant gas through the discharge part (101b). The compressor (101) is a variable capacity compressor and can vary its capacity by changing the frequency according to a drive control command.

[0129] According to one embodiment, the outdoor heat exchanger (102) may typically be placed outdoors. In the outdoor heat exchanger (102), heat exchange between the refrigerant and the outdoor air may occur through a phase change (e.g., condensation or evaporation) of the refrigerant passing through the outdoor heat exchanger (102). For example, when operating in cooling mode, the outdoor heat exchanger (102) may condense the high-temperature, high-pressure refrigerant introduced from the compressor (101). When operating in cooling mode, latent heat may be released to the outdoor air while the high-temperature, high-pressure refrigerant condenses as it passes through the outdoor heat exchanger (102). When operating in heating mode, the low-temperature, low-pressure refrigerant may evaporate in the outdoor heat exchanger (102), and latent heat may be absorbed from the outdoor air while the refrigerant evaporates. Although not shown in FIG. 1, in one example, one or more temperature sensors for detecting the temperature of the outdoor air may be placed at a location adjacent to the outdoor heat exchanger (102).

[0130] According to one embodiment, the air conditioner (1) may include an outdoor blower (108) that generates forced circulation of outdoor air so that heat exchange in the outdoor heat exchanger (102) is smooth. The outdoor blower (108) may be positioned adjacent to the outdoor heat exchanger (102). Although not specifically illustrated, the outdoor blower (108) may include one or more blower fans and fan motors. The fan motor of the outdoor blower (108) may provide driving force to the blower fan through a shaft.

[0131] According to one embodiment, the expansion device (103) can lower the pressure and temperature of the refrigerant condensed in the outdoor heat exchanger (102) during cooling mode operation. The expansion device (103) can lower the pressure and temperature of the refrigerant introduced from the indoor heat exchanger (104) during heating mode operation. In one example, the expansion device (103) can lower the temperature and pressure of the refrigerant by utilizing a throttling effect. The expansion device (103) may include an orifice capable of reducing the cross-sectional area of ​​the flow path. The refrigerant passing through the orifice may have its temperature and pressure lowered. In one example, the expansion device (103) may be implemented as an electronic expansion valve capable of adjusting the opening ratio (an electronic expansion valve capable of adjusting the ratio of the cross-sectional area of ​​the flow path of the valve in a partially open state to the cross-sectional area of ​​the flow path of the valve in a fully open state). In such a case, the amount of refrigerant passing through the expansion device (103) can be controlled depending on the opening ratio of the electronic expansion valve. In one example, the expansion device (103) can be implemented as a capillary device.

[0132] According to one embodiment, an indoor heat exchanger (104) may be placed indoors. In the indoor heat exchanger (104), heat exchange between the refrigerant and the indoor air may occur through a phase change (e.g., evaporation or condensation) of the refrigerant passing through the indoor heat exchanger (104). For example, during operation in cooling mode, the refrigerant passing through the expansion device (103) may flow into the indoor heat exchanger (104) and may evaporate in the indoor heat exchanger (104). While the refrigerant evaporates in the indoor heat exchanger (104), latent heat may be absorbed from the surrounding air, thereby cooling the surrounding air. During operation in heating mode, high-temperature, high-pressure refrigerant from the compressor (101) may flow into the indoor heat exchanger (104), condense, and release latent heat to the indoor air. Although not illustrated in FIG. 1, the indoor heat exchanger (104) may include a refrigerant flow path through which the refrigerant flows and a plurality of heat exchange fins arranged to increase the heat exchange area.

[0133] When operating in cooling mode, due to the heat exchange between the surrounding indoor air and the refrigerant in the indoor heat exchanger (104), water vapor contained in the air may condense and liquefy on the surface of the indoor heat exchanger (130). The condensed water formed on the surface of the indoor heat exchanger (104) may fall downward. Although not shown in FIG. 12, the air conditioner (1) may include a drain tray positioned below the indoor heat exchanger (104) to collect the condensed water falling from the indoor heat exchanger (104). The condensed water contained in the drain tray may be drained to the outside through a drain hose. The drain tray may be provided to support the indoor heat exchanger (104) from below, but is not limited thereto.

[0134] According to one embodiment, the air conditioner (1) may include an indoor blower (109) that generates forced circulation of indoor air so that heat exchange in the indoor heat exchanger (104) is smooth. The indoor blower (109) may be positioned adjacent to the indoor heat exchanger (104). Although not specifically illustrated, in one example, the indoor blower (109) may be positioned downstream of the indoor heat exchanger (104) based on the direction of air flow in the space where the indoor blower (109) is installed, and the present document is not limited thereto. The indoor blower (109) may include one or more blower fans and fan motors. The fan motor of the indoor blower (109) may provide driving force to the blower fan through a shaft. In one example, the blower fan may include one of an axial flow fan that draws in air in the direction of the fan motor's rotation axis and discharges air in the direction of the rotation axis, a cross-flow fan that draws in air in the direction of the fan motor's rotation axis and discharges air between the axial and radial directions, a centrifugal fan that draws in air in the direction of the fan motor's rotation axis and discharges air in the circumferential direction, and a cross-flow fan, but the present document is not limited thereto.

[0135] In this document, the air conditioner (1) is described primarily in the case where it is equipped with components related to a refrigeration cycle, but this document is not limited thereto. In one example, the air conditioner may be configured using a thermoelectric element. The thermoelectric element can cool or heat the surrounding air through heat generation and cooling action via the Peltier effect.

[0136] According to one embodiment, the air conditioner (1) may include one or more outdoor units installed outdoors and one or more indoor units installed indoors. In one example, the aforementioned compressor (101), outdoor heat exchanger (102), and expansion device (103) may be placed in the outdoor unit. In one example, the aforementioned indoor heat exchanger (104) may be placed in the indoor unit. However, the placement locations of each of the aforementioned components are not limited. For example, the location of the expansion device (103) is not limited to the outdoor unit and may be placed in the indoor unit as needed.

[0137] In this document, the air conditioner (1) is described primarily as a separated type having an outdoor unit installed separately outdoors and an indoor unit installed indoors, but this document is not limited thereto. In one example, the air conditioner (1) may be configured as an integrated type in which a compressor (101), an outdoor heat exchanger (102), an expansion device (103), and an indoor heat exchanger (104) are placed inside a single case located indoors.

[0138] In the case of a split-type air conditioner (1), the outdoor unit can be connected to the indoor unit via a refrigerant pipe so as to be fluidly connected. The outdoor unit can be communicated to the indoor unit. In one example, control information (or commands) of the air conditioner (1) entered by a user or received from the outside can be transmitted from the indoor unit to the outdoor unit.

[0139] In the case of an air conditioner containing multiple indoor units, some of the indoor units can be operated individually in cooling mode and the remaining indoor units in heating mode simultaneously. When operating multiple indoor units, to effectively respond to cooling or heating loads based on the number of indoor units in operation, the air conditioner may use multiple compressors or multiple outdoor units connected in parallel.

[0140] According to one embodiment, the air conditioner (1) can be classified according to the installation type / location of the indoor unit. For example, the air conditioner can be classified into a stand type in which the indoor unit is placed upright in an indoor space, a wall-mounted type installed to be attached to a wall, and a ceiling type installed on the ceiling. In one example, the air conditioner (1) may include a plurality of indoor units, some of which may be configured as a stand type and some of which may be configured as a wall-mounted type, and the present document is not limited to a specific form.

[0141] Referring to FIG. 13a and FIG. 13b, the indoor unit (20) of the air conditioner (1) may include a housing (410) forming an exterior. The housing (410) may include a front frame (412) covering the front of the housing (410), a rear frame (414) covering the rear, and a center frame (416) disposed between them. According to one embodiment, each of the front frame (412) and the rear frame (414) may be detachable from the center frame (416), but the present disclosure is not limited thereto.

[0142] According to one embodiment, the front frame (412) may have a front panel (418) placed on it.

[0143] According to one embodiment, the front panel (418) may include an input unit (420). According to one embodiment, the input unit (420) includes any type of user input means including a button, a switch, and a touchpad, and setting data by a user (e.g., desired temperature, setting of operating mode for cooling / dehumidification / air purification, and setting of airflow) may be input through the input unit (420).

[0144] According to one embodiment, the front panel (418) may include a display module (422). The display module (422) may display information input by a user through the input unit (420) (e.g., desired temperature, airflow setting, and / or operating mode setting). According to one embodiment, the display module (422) may display various sensing information on the air conditioner (1) (e.g., current indoor temperature measured by a temperature sensor), the current airflow or operating status of the air conditioner (1), and / or various warning messages.

[0145] According to one embodiment, the display module (422) may be provided at various locations on the air conditioner (1). For example, according to one embodiment in FIG. 13a, the display module (422) is illustrated as being provided on the front panel (418), but is not limited thereto.

[0146] According to one embodiment, the outdoor unit (30) may include a housing (510), internal components disposed within the housing (510) (e.g., a compressor (101) of FIG. 1 and 2, an outdoor heat exchanger (102), an expansion device (103), and / or a flow switching valve (106)), and an outdoor blower (108) that generates forced air for heat exchange between the outdoor heat exchanger (102) and the outdoor air. The outdoor blower (108) may include one or more blower fans (108a) and fan motors, and the fan motor of the outdoor blower (108) may provide driving force to the blower fans (108a) through a shaft.

[0147] According to one embodiment, the housing (510) forms the exterior of the outdoor unit (30) and can accommodate various components inside. The housing (510) may have an overall cuboidal shape. For example, the housing (510) may include a front frame (511) substantially covering the front (e.g., +X-axis direction), a rear frame (512) substantially covering the rear (e.g., -X-axis direction), side frames (513, 514) substantially covering the sides (e.g., +Y-axis and / or -Y-axis direction), and upper and lower frames (515, 516) substantially covering the upper side (e.g., +Z-axis direction) and / or lower side (e.g., -Z-axis direction). Frames facing two or more of the respective frames of the housing (510) (e.g., front, rear, side, top, and bottom frames (511, 512, 513, 514, 515, 516)) may be formed as a single unit.

[0148] According to one embodiment, an intake port (not shown) for drawing in outside air may be formed in a region of the side frame (513, 514) and / or rear frame (512) of the housing (510), and an exhaust port (511c) for discharging the drawn-in outside air may be formed in a region of the front frame (511). A blower fan (108a) is positioned adjacent to the exhaust port (511c) and can forcibly draw in outside air by being rotated by a fan motor that rotates based on a control command. By rotating the blower fan (108a) of the outdoor blower (e.g., outdoor blower (108) of FIG. 12), air flow and heat exchange around the outdoor heat exchanger (e.g., outdoor heat exchanger (102) of FIG. 12) of the air conditioner (1) can be smoothly achieved.

[0149] Generally, aluminum heat exchangers in electronic devices (e.g., home appliances) include a sensor holder, and the sensor holder is joined to the refrigerant piping using a filler material, and the same material as the refrigerant piping can be used. For example, when welding to join Al 3xxx-based refrigerant piping and Al 3xxx-based sensor holders, brazing can be performed using Al 4xxx-based filler material. In this case, the potential value of the filler material is relatively higher compared to the potential values ​​of the refrigerant piping and the sensor holder, and a large potential difference may occur between the components. This potential difference may cause sacrificial corrosion on a part of the surface of the refrigerant piping, and the sensor holder may easily detach from the refrigerant piping.

[0150] In a home appliance according to one embodiment of the present disclosure, the heat exchanger can ensure that the connection between the refrigerant piping, the sensor holder, and the filler material is stably maintained.

[0151] In a home appliance according to one embodiment of the present disclosure, the heat exchanger can limit (e.g., reduce or prevent) the detachment of the sensor holder from the refrigerant piping by designing the filler material to be formed from an alloy including aluminum and zinc (e.g., Zn-Al alloy) and reducing or equalizing the potential difference between the refrigerant piping, the sensor holder, and the filler material.

[0152] In a home appliance according to one embodiment of the present disclosure, the heat exchanger can be designed such that the refrigerant pipe and the sensor holder are manufactured from aluminum of the same material, and after zinc spraying on the surface of the refrigerant pipe and the sensor holder, heat treatment is performed to reduce or substantially equal the potential difference with the filler material.

[0153] In a home appliance according to one embodiment of the present disclosure, the heat exchanger can form a zinc diffusion layer that prevents sacrificial corrosion in the refrigerant piping or sensor holder.

[0154] In a home appliance according to one embodiment of the present disclosure, the heat exchanger can limit (e.g., reduce or prevent) the sacrificial corrosion phenomenon caused by the potential difference with the filler material through laser coupling between the refrigerant piping and the sensor holder.

[0155] In a home appliance according to one embodiment of the present disclosure, a heat exchanger formed by a direct coupling (e.g., laser coupling, fiber coupling, electrical coupling) between a refrigerant pipe and a sensor holder can provide a neat appearance and enable mass production due to high-speed operation.

[0156] The effects obtainable from the present disclosure are not limited to those mentioned above, and other unmentioned effects will be clearly understood by those skilled in the art to which the present disclosure belongs from the description below.

[0157] A home appliance according to one embodiment of the present disclosure may include a housing (410; 510) and a heat exchanger (10) disposed inside the housing. The heat exchanger may include a first pipe (110) comprising Al (aluminum) and providing a flow path for a refrigerant, a second pipe (120) adjacent to the first pipe and comprising Al material and configured to accommodate a sensor (127), and a filler material (400) configured to connect the first pipe and the second pipe to each other. At least one of the first pipe or the second pipe may include a zinc diffusion layer (115; 125). The potential difference between any two components among the filler material, the first pipe, and the second pipe may be 50 mV or less.

[0158] According to one embodiment, the filler material (400) is an alloy containing Zn and Al, and the alloy may contain 10 to 90 weight (wt) % of Zn relative to the total alloy weight.

[0159] According to one embodiment, the filler material (400) is an alloy containing Zn and Al, and the alloy may contain 40 to 70 weight (wt) % of Zn relative to the total alloy weight.

[0160] According to one embodiment, the zinc diffusion layer (115; 125) may include a layer extending from the surface of the first pipe or the second pipe to a depth with a thickness of 10 μm or more.

[0161] According to one embodiment, the zinc diffusion layer (115) can be formed to have a layer of irregular thickness as the Zn (zinc) is arc sprayed onto the surface of the first pipe and then diffused into the core of the first pipe by heat treatment.

[0162] According to one embodiment, the zinc diffusion layer (125) can be formed to have a layer of irregular thickness as the Zn (zinc) is arc sprayed onto the surface of the second pipe and then diffused into the core of the second pipe by heat treatment.

[0163] According to one embodiment, the potential difference between at least two components among the filler material, the first pipe, and the second pipe may be 30 mV or less.

[0164] According to one embodiment, the potential value of the filler material may be less than or equal to the potential value of the surface of the first pipe or the potential value of the surface of the second pipe.

[0165] According to one embodiment, the potential value of the core of the first pipe is higher than the potential value of the surface of the first pipe, the potential value of the core of the second pipe is higher than the potential value of the surface of the second pipe, and the filler material may be configured to have a potential value lower than the potential value of the core of the first pipe and / or the potential value of the core of the second pipe.

[0166] According to one embodiment, the material of the first pipe may include A3xxx series or A1xxx series Al (aluminum), and the material of the second pipe may include A3xxx series or A1xxx series Al (aluminum).

[0167] According to one embodiment, a portion of the first pipe includes a curved portion, and the second pipe can be joined to the curved portion by the filler material.

[0168] According to one embodiment, the first pipe comprises the zinc diffusion layer, and the zinc diffusion layer may comprise 3 to 7 weight (wt) % of Zn (zinc) relative to the total weight of the first pipe.

[0169] According to one embodiment, the third pipe comprises the zinc diffusion layer, and the zinc diffusion layer may comprise 3 to 7 weight (wt) % of Zn (zinc) relative to the total weight of the third pipe.

[0170] According to one embodiment, the zinc diffusion layer has a thickness of 100 μm or more from the surface of the first pipe or the second pipe to the depth, and the content of Zn (zinc) in the zinc diffusion layer may be configured to gradually decrease from the surface to the depth.

[0171] According to one embodiment, when the second pipe is joined to the curved portion of the first pipe, when viewed from above the second pipe, the center line (L') of the second pipe can form a designated angle with respect to the center line (L) of the curved portion.

[0172] A heat exchanger according to one embodiment of the present disclosure may include a first pipe (110) comprising Al (aluminum) and providing a flow path for a refrigerant, a second pipe (120) adjacent to the first pipe and comprising Al and configured to accommodate a sensor (127), and a filler material (400) configured to connect the first pipe and the second pipe together. At least one of the first pipe or the second pipe may include a zinc diffusion layer (115; 125). The filler material (400) is an alloy comprising Zn and Al, wherein Zn may be 10 to 90 weight (wt) % relative to the total alloy weight.

[0173] According to one embodiment, the potential difference between any two components among the filler material, the first pipe, and the second pipe may be 50 mV or less.

[0174] According to one embodiment, the alloy of the filler material may contain 40 to 70 (wt) % of Zn relative to the total alloy weight.

[0175] A home appliance according to one embodiment of the present disclosure may include a housing (410; 510) and a heat exchanger (10) disposed inside the housing. The heat exchanger may include a first pipe (110) comprising Al (aluminum) and providing a flow path for a refrigerant, and a second pipe (120) adjacent to the first pipe, comprising Al, and configured to accommodate a sensor (127). The first pipe and the second pipe may be directly joined to form an integral. The joint width (t3) of the joint portion (A) of the first pipe and the second pipe may be smaller than the thickness of the first pipe or the thickness of the second pipe.

[0176] According to one embodiment, the first pipe may have a first thickness (t1), and the second pipe may have a second thickness (t2) corresponding to the first thickness. The joint width (t3) of the joint portion (A) may be less than or equal to half of the first thickness or the second thickness.

[0177] According to one embodiment, the joint length (L1) perpendicular to the joint width (t3) of the joint portion (A) may be greater than the thickness of the first pipe or the second pipe.

[0178] According to one embodiment, the first pipe and the second pipe are a seamlessly extended monolithic support body, and the monolithic support body may be exposed to the outside of the heat exchanger.

Claims

1. Housing (410; 510); and It includes a heat exchanger (10) disposed inside the above housing, and the heat exchanger, A first pipe (110) providing a flow path for the refrigerant and containing Al (aluminum); A second pipe (120) adjacent to the first pipe, containing Al, and configured to accommodate a sensor (127); and It includes a filler material (400) configured to combine the first pipe and the second pipe together, and At least one of the first pipe portion or the second pipe portion comprises a zinc diffusion layer (115; 125), and A home appliance in which the potential difference between any two components among the above filler material, the above first pipe, and the above second pipe is 50 mV or less.

2. In Paragraph 1, The above filler material (400) is an alloy containing Zn and Al, and the alloy contains 10 to 90 wt% of Zn relative to the total alloy weight, in a home appliance.

3. In Paragraph 1 or 2, The above filler material (400) is an alloy containing Zn and Al, and the alloy contains 40 to 70 wt% of Zn relative to the total alloy weight, in a home appliance.

4. In any one of paragraphs 1 to 3, The above zinc diffusion layer (115; 125) comprises a layer extending from the surface of the first pipe or the second pipe to a depth with a thickness of 10 μm or more, in a home appliance.

5. In any one of paragraphs 1 to 3, The zinc diffusion layer (115; 125) is formed to have a layer of irregular thickness as the Zn (zinc) diffuses into the core of the first pipe by heat treatment after arc spraying Zn (zinc) onto the surface of the first pipe, or The above zinc diffusion layer (115; 125) is formed to have a layer of irregular thickness as the Zn (zinc) diffuses into the core of the second pipe by heat treatment after arc spraying Zn (zinc) onto the surface of the second pipe.

6. In any one of paragraphs 1 through 5, A home appliance in which the potential difference between any two components among the above filler material, the above first pipe, and the above second pipe is 30 mV or less.

7. In any one of paragraphs 1 through 6, A home appliance in which the potential value of the above-mentioned filler material is less than or equal to the potential value of the surface of the first pipe or the potential value of the surface of the second pipe.

8. In any one of paragraphs 1 through 6, The potential value of the deep part of the first pipe is higher than the potential value of the surface of the first pipe, and The potential value of the core of the second pipe is higher than the potential value of the surface of the second pipe, and A home appliance configured such that the above filler material has a potential value lower than the potential value of the core of the first pipe and / or the potential value of the core of the second pipe.

9. In any one of paragraphs 1 through 8, The material of the first pipe above includes A3xxx series or A1xxx series Al (aluminum) A home appliance in which the material of the second pipe above includes A3xxx series or A1xxx series Al (aluminum).

10. In any one of paragraphs 1 through 9, A home appliance, wherein a portion of the first pipe includes a curved portion, and the second pipe is joined to the curved portion by the filler material.

11. In any one of paragraphs 1 through 10, The first pipe comprises the zinc diffusion layer, and the zinc diffusion layer comprises 3 to 7 weight (wt) % of Zn (zinc) relative to the total weight of the first pipe, or A home appliance, wherein the second pipe comprises the zinc diffusion layer, and the zinc diffusion layer comprises 3 to 7 weight (wt) % of Zn (zinc) relative to the total weight of the second pipe.

12. In any one of paragraphs 1 through 11, A home appliance configured such that the zinc diffusion layer has a thickness of 100 μm or more from the surface of the first pipe or the second pipe to the depth, and the content of Zn (zinc) in the zinc diffusion layer gradually decreases from the surface to the depth.

13. In any one of paragraphs 10 to 12, A home appliance in which, when viewed from above, the center line (L') of the second pipe forms a designated angle with respect to the center line (L) of the curved portion, while the second pipe is joined to the curved portion of the first pipe.

14. In a heat exchanger, A first pipe (110) providing a flow path for the refrigerant and containing Al (aluminum); A second pipe (120) adjacent to the first pipe, containing Al, and configured to accommodate a sensor (127); and It includes a filler material (400) configured to combine the first pipe and the second pipe together, and At least one of the first pipe portion or the second pipe portion comprises a zinc diffusion layer (115; 125), and The above filler material (400) is an alloy containing Zn and Al, and is a heat exchanger in which Zn is 10 to 90 wt% of the total alloy weight.

15. In Paragraph 14, A heat exchanger in which the potential difference between any two components among the above filler material, the above first pipe and the above second pipe is 50 mV or less.

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