Air conditioner and method of manufacturing the same

Abstract

The application provides an air conditioner and a manufacturing method thereof, the manufacturing method comprising the following steps: installing a silencing device into a fluid path of a compression refrigeration cycle system in an outdoor unit; detecting a peak noise frequency corresponding to a peak noise occurring in the outdoor unit when a compressor in the compression refrigeration cycle system is working; determining a proportioning scheme of a refrigerant to be filled in the compression refrigeration cycle system according to the peak noise frequency, wherein the refrigerant to be filled is a mixed refrigerant composed of R32 refrigerant and R125 refrigerant, and a functional relationship between the peak noise frequency y and an R32 proportion x in the mixed refrigerant satisfies y=450x+550, wherein 0x<1; and filling the refrigerant with the determined proportioning scheme into the compression refrigeration cycle system. The application has the advantages of effectively solving the problem of narrow-band frequency noise of the air conditioner, reducing the narrow-band frequency noise, and improving the comfort experience of users.

Description

Technical Field

[0001] This invention relates to the field of air conditioning technology, and in particular to an air conditioner and its manufacturing method. Background Technology

[0002] In recent years, with the continuous development of technology and the improvement of living standards, users have placed higher demands on the comfort of air conditioners. Existing air conditioners, especially those using R134a refrigerant, often exhibit high noise levels at narrow frequency bands during operation. While single-expansion silencers are effective at reducing broadband noise, they are ineffective at reducing narrow frequency noise. Even when integrated into a compression refrigeration cycle, they cannot effectively solve the noise problem, leading to frequent user complaints and severely impacting brand reputation. Therefore, improvements are needed. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides an air conditioner and its manufacturing method to solve the issue of high narrowband frequency noise in air conditioners using R32 refrigerant, thereby reducing the narrowband frequency noise of the air conditioner and improving the user's comfort experience.

[0004] According to a first aspect of the present invention, the present invention provides a method for manufacturing an air conditioner, the air conditioner including a compression refrigeration cycle system partially located within the outdoor unit of the air conditioner, the method comprising:

[0005] Silencing device installation steps: Install the silencer into the fluid path of the compression refrigeration cycle system inside the outdoor unit;

[0006] Peak noise detection steps: Detect the peak noise frequency corresponding to the peak noise that occurs in the outdoor unit when the compressor in the compression refrigeration cycle system is working. The definition of peak noise is: for the working noise generated by the compressor in the range of (550Hz~1000Hz) during operation, if its maximum peak intensity is at least 20% greater than its average intensity, then the working noise point corresponding to the maximum peak intensity is the peak noise.

[0007] Refrigerant ratio determination steps: Determine the refrigerant ratio scheme to be charged into the compression refrigeration cycle system based on the peak noise frequency, wherein...

[0008] The refrigerant to be charged is a mixture of R32 and R125 refrigerants. The functional relationship between the peak noise frequency y and the proportion x of R32 in the mixture satisfies:

[0009] y = 450x + 550, where: 0 < x < 1;

[0010] Refrigerant charging steps: Charge the refrigerant with the determined ratio into the compression refrigeration cycle system.

[0011] Optionally, the manufacturing method further includes:

[0012] Compressor operating program setting steps: Set the compressor operating program so that the compressor discharge temperature is set to 80℃~90℃ and the discharge pressure is set to 3.8Mpa~4.2Mpa.

[0013] Optionally, in the silencing device installation step, the silencing device is selected as a micro-perforated silencer, which is connected between the exhaust end of the compressor and any heat exchanger of the compression refrigeration cycle system.

[0014] Optionally, the micro-perforated silencer is configured to include an expansion tube and a connecting pipe passing through the expansion tube, with both ends of the connecting pipe connected to refrigerant lines in the compression refrigeration cycle system; and

[0015] The connecting tube has several micropores on its inner wall inside the expansion tube.

[0016] Optionally, the ratio of the inner diameter of the expansion tube to the inner diameter of the connecting tube is 1.5:1 to 2.5:1.

[0017] Optionally, during the refrigerant charging step, the refrigerant charging amount and charging pressure are controlled such that the normal pipeline pressure of the compression refrigeration cycle system in non-operational state is ≤5.0 MPa.

[0018] Optionally, the peak noise detection step includes:

[0019] Acquire noise data from the outdoor unit when the compressor is operating;

[0020] Analyze the noise data to obtain the noise spectrum data;

[0021] The presence of peak noise is determined based on the spectral data of the noise data; if it exists, its corresponding peak noise frequency is further determined.

[0022] Optionally, noise data is measured using an acoustic microphone; and / or

[0023] The spectrum data is generated by a spectrum analyzer.

[0024] According to a second aspect of the present invention, an air conditioner is provided, which is manufactured by any of the manufacturing methods described above.

[0025] According to a third aspect of the present invention, an air conditioner is provided, comprising:

[0026] The compression refrigeration cycle system is partially located inside the outdoor unit of the air conditioner. This system is filled with a mixture of R32 and R125 refrigerants. The refrigerant mix ratio is selected based on the peak noise frequency observed inside the outdoor unit when the compressor is operating.

[0027] The functional relationship between peak noise frequency y and the proportion of R32 in the mixed refrigerant x satisfies:

[0028] y = 450x + 550, where: 0 < x < 1; and

[0029] A micro-perforated silencer is connected between the compressor's exhaust end and any heat exchanger in the compression refrigeration cycle system.

[0030] The manufacturing method for an air conditioner according to this invention first involves installing a silencer device into the fluid path of the compression refrigeration cycle system inside the outdoor unit. Then, the peak noise frequency corresponding to the peak noise level observed when the compressor in the compression refrigeration cycle system is operating is detected. Next, the refrigerant ratio to be charged into the compression refrigeration cycle system is determined based on the peak noise. Finally, the refrigerant with the determined ratio is charged into the compression refrigeration cycle system. This innovative method alters the proportions of different components of R32 and R125 refrigerants to change the density of the mixture, thereby increasing the resistance loss of the silencer device and maximizing the reduction of air conditioner noise.

[0031] The above and other objects, advantages and features of the present invention will become more apparent to those skilled in the art from the following detailed description of specific embodiments of the invention in conjunction with the accompanying drawings. Attached Figure Description

[0032] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0033] Figure 1 This is a schematic diagram of the structure of an air conditioner according to an embodiment of the present invention;

[0034] Figure 2 This is a schematic diagram of the structure of a micro-perforated silencer according to an embodiment of the present invention;

[0035] Figure 3 This is a flowchart of an air conditioner control method according to an embodiment of the present invention;

[0036] Figure 4This is a comparison diagram of the noise reduction curves of a micro-perforated silencer and a single-expansion silencer according to an embodiment of the present invention;

[0037] Figure 5 The diagram shows the noise reduction characteristics of a micro-perforated silencer under different refrigerant ratio schemes according to an embodiment of the present invention.

[0038] Figure 6 This is a flowchart of peak noise detection according to an embodiment of the present invention. Detailed Implementation

[0039] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0040] This invention first provides an air conditioner 10. Figure 1 This is a schematic diagram of the structure of an air conditioner 10 according to an embodiment of the present invention, with reference to... Figure 1 The air conditioner 10 can be a split-type air conditioner 10, which generally includes an indoor unit 110, an outdoor unit 120 and a compression refrigeration cycle system 200, which is partially located in the outdoor unit 120 of the air conditioner 10.

[0041] The air conditioner 10 of the present invention further includes a micro-perforated silencer 300, which is connected between the discharge end of the compressor 210 and any heat exchanger 220 of the compression refrigeration cycle system 200. In this embodiment, a four-way valve 240 is provided at the discharge end of the compressor 210, and the micro-perforated silencer 300 can be connected in series on the refrigerant pipeline 230 between the discharge end of the compressor 210 and the four-way valve 240.

[0042] Figure 2 This is a schematic diagram of the structure of a micro-perforated muffler 300 according to an embodiment of the present invention, with reference to... Figure 2 The micro-perforated silencer 300 is configured to include an expansion tube 310 and a connecting tube 320 passing through the expansion tube 310. The two ends of the connecting tube 320 are respectively connected to the refrigerant pipeline 230 in the compression refrigeration cycle system 200, and the connecting tube 320 has a plurality of micro-holes 321 on the tube wall inside the expansion tube 310.

[0043] Actual testing of the prototype samples revealed that the micro-perforated muffler 300 has a good noise reduction effect on narrow-band frequency noise (550Hz to 1000Hz). After replacing the traditional single-expansion muffler and installing it in the compression refrigeration cycle system 200, it can significantly reduce the narrow-band frequency noise of the air conditioner 10.

[0044] Specifically, the refrigerant charged in the compression refrigeration cycle system 200 needs to be selected according to the peak noise frequency inside the outdoor unit 120 when the compressor 210 is running. The charged refrigerant is a mixture of R32 and R125 refrigerants, and the functional relationship between the peak noise frequency y and the proportion of R32 in the mixture x satisfies:

[0045] y = 450x + 550, where: 0 < x < 1;

[0046] In the manufacturing process of the air conditioner 10 of this invention, the refrigerant ratio scheme needs to be selected according to the peak noise frequency that appears in the outdoor unit 120 when the compressor 210 is working, so as to improve the resistance loss of the micro-perforated silencer 300, thereby minimizing the operating noise of the air conditioner 10 and improving the user's comfort experience.

[0047] The present invention also provides a method for manufacturing an air conditioner 10. It should be noted that the air conditioner 10 of the above embodiments can be manufactured by, but is not limited to, this manufacturing method. Figure 3 This is a flowchart of a method for manufacturing an air conditioner 1010 according to an embodiment of the present invention, with reference to... Figure 3 The manufacturing method includes at least the following:

[0048] S102 Silencing Device Installation Steps: Install the silencing device into the fluid path of the compression refrigeration cycle system 200 inside the outdoor unit 120.

[0049] S104 Peak Noise Detection Steps: Detect the peak noise frequency corresponding to the peak noise that occurs inside the outdoor unit 120 when the compressor 210 in the compression refrigeration cycle system 200 is working.

[0050] In this step, peak noise is defined as follows: for the operating noise generated by compressor 210 in the range of (550Hz to 1000Hz) during operation, if its maximum peak intensity is at least 20% greater than its average intensity, then the operating noise point corresponding to the maximum peak intensity is the peak noise.

[0051] S106 Refrigerant Proportion Determination Steps: Determine the refrigerant proportion scheme to be charged within 200 cycles of the compression refrigeration cycle system based on the peak noise frequency, whereby...

[0052] The refrigerant to be charged is a mixture of R32 and R125 refrigerants. The functional relationship between the peak noise frequency y and the proportion x of R32 in the mixture satisfies:

[0053] y = 450x + 550, where: 0 < x < 1;

[0054] S108 Refrigerant Charging Procedure: Charge the refrigerant with the determined ratio into the compression refrigeration cycle system 200.

[0055] The manufacturing method for an air conditioner 10 according to an embodiment of the present invention first installs a silencer device into the fluid path of a compression refrigeration cycle system 200 inside the outdoor unit 120. Then, it detects the peak noise frequency corresponding to the peak noise occurring inside the outdoor unit 120 when the compressor 210 in the compression refrigeration cycle system 200 is operating. Next, it determines the refrigerant ratio to be charged into the compression refrigeration cycle system 200 based on the peak noise. Finally, it charges the refrigerant with the determined ratio into the compression refrigeration cycle system 200. This innovative method changes the different component ratios of R32 and R125 refrigerants to alter the density of the mixture, increasing the resistance loss of the silencer device and thus minimizing the noise of the air conditioner 10.

[0056] In an optional embodiment, the manufacturing method further includes a compressor 210 operating program setting step (S110). This step can set the operating program of the compressor 210 such that the discharge temperature is set to 80°C–90°C and the discharge pressure is set to 3.8 MPa–4.2 MPa. It is understood that this step is an electrically controlled step, which can be executed at any stage without affecting the execution of steps S102 to S108.

[0057] In step S102, the silencer is selected as a micro-perforated silencer 300, which is connected between the exhaust end of the compressor 210 and any heat exchanger 220 of the compression refrigeration cycle system 200. Specifically, in this embodiment, it is connected between the exhaust end of the compressor 210 and the four-way valve 240 of the compression refrigeration cycle system 200. As mentioned earlier, the micro-perforated silencer 300 has a good noise reduction effect on narrowband frequency noise, effectively reducing the narrowband frequency noise of the air conditioner 10 during operation.

[0058] The ratio of the inner diameter of the expansion tube 310 to the inner diameter of the connecting tube 320 of the micro-perforated muffler 300 can be 1.5:1 to 2.5:1, for example 2:1. In this embodiment, the inner diameter of the expansion tube 310 can be 16 mm, the inner diameter of the connecting tube 320 can be 8 mm, the diameter of the micro-hole 321 can be 0.8 mm, and the distance between adjacent micro-holes 321 can be 1.5 mm.

[0059] The resistance loss of the silencer can be calculated using a CAE acoustic simulation analysis platform. Figure 4 This is a comparison chart of the noise reduction curves of a micro-perforated muffler 300 and a single-expansion muffler according to an embodiment of the present invention. Figure 4 As can be seen, the single-expansion muffler has a good noise reduction effect on broadband frequency noise, but its noise reduction effect on narrowband frequency noise is poor. In contrast, the micro-perforated muffler 300 has a very strong noise reduction characteristic for narrowband frequency noise, with a noise reduction amount more than three times that of the expansion cavity muffler. Therefore, for the air conditioner 10, where narrowband frequency noise is relatively significant, using the micro-perforated muffler 300 will have a more obvious noise reduction effect.

[0060] Figure 5 The diagram illustrates the noise reduction characteristic curves of a micro-perforated silencer under different refrigerant ratios according to an embodiment of the present invention. For the micro-perforated silencer 300 of this embodiment, a mixture of R32 and R125 refrigerant is used. By changing the proportion of R32 refrigerant in the mixture, noise in the narrow band frequency range of 550Hz-1000Hz can be eliminated to the maximum extent. The functional relationship between the noise reduction frequency y and the proportion x of R32 in the mixture, fitted from the noise reduction characteristic curve, basically satisfies:

[0061] y = 450x + 550 where: 0 < x < 1.

[0062] Under the premise that the structure of the micro-perforated silencer 300 remains unchanged, if there is narrow-band frequency noise in the 5500-1000Hz frequency band, the optimal refrigerant ratio can be obtained according to the above formula.

[0063] It should be noted that, considering the practicalities of the project and the storage cost of the refrigerant, several refrigerant formulations can be selected and optimized in conjunction with the structural design of the micro-perforated silencer 300 to achieve the best noise reduction effect and cost.

[0064] In the S108 refrigerant charging step, the refrigerant charging amount and charging pressure are controlled to ensure that the normal pipeline pressure of the compression refrigeration cycle system 200 in non-operating state is ≤5.0Mpa.

[0065] Figure 6 This is a flowchart of peak noise detection according to an embodiment of the present invention, with reference to... Figure 6 The S104 peak noise detection step may include:

[0066] S1041, acquire noise data inside outdoor unit 120 when compressor 210 is working.

[0067] In this step, noise data can be measured using an acoustic microphone.

[0068] S1042, Analyze the noise data to obtain the spectral data of the noise data.

[0069] In this step, the spectrum data can be generated by a spectrum analyzer.

[0070] S1043, determine whether peak noise exists based on the spectral data of the noise data.

[0071] If S1044 exists, then its corresponding peak noise frequency is further determined.

[0072] In summary, during the manufacturing process of air conditioner 10, to address the issue of high narrow-band frequency noise during compressor 210 operation, a micro-perforated silencer 300 can be directly integrated into the compression refrigeration cycle system 200, with the refrigerant ratio selected accordingly based on the peak noise frequency. For already sold air conditioners 10, addressing user feedback regarding excessive noise, a micro-perforated silencer 300 can replace the original single-expansion silencer; however, this method is slightly more expensive. A preferred approach is to use a mixed refrigerant consisting of R32 and R125 refrigerants, selected according to the peak noise frequency ratio, to replace the original R32 refrigerant. This method can essentially resolve the issue of high narrow-band frequency noise in air conditioner 10 causing problems for users.

[0073] Therefore, those skilled in the art should recognize that although numerous exemplary embodiments of the present invention have been shown and described in detail herein, many other variations or modifications conforming to the principles of the present invention can be directly determined or derived from the disclosure of the present invention without departing from the spirit and scope of the invention. Thus, the scope of the present invention should be understood and construed as covering all such other variations or modifications.

Claims

1. A method for manufacturing an air conditioner, the air conditioner comprising a compression refrigeration cycle system partially located within an outdoor unit of the air conditioner, the manufacturing method comprising: Silencing device installation steps: Install the silencer into the fluid path of the compression refrigeration cycle system inside the outdoor unit; Peak noise detection steps: Detect the peak noise frequency corresponding to the peak noise that occurs in the outdoor unit when the compressor in the compression refrigeration cycle system is working. The peak noise is defined as follows: For the working noise generated by the compressor in the range of (550Hz~1000Hz) during operation, if its maximum peak intensity is at least 20% greater than its average intensity, then the working noise point corresponding to the maximum peak intensity is the peak noise. Refrigerant ratio determination steps: Determine the refrigerant ratio scheme to be charged into the compression refrigeration cycle system based on the peak noise frequency, wherein... The refrigerant to be charged is a mixture of R32 and R125 refrigerants, and the functional relationship between the peak noise frequency y and the proportion x of R32 in the mixture satisfies: y = 450x + 550, where: 0 < x < 1; Refrigerant charging steps: Charge the refrigerant with the determined ratio into the compression refrigeration cycle system; In the installation step of the silencing device, the silencing device is selected as a micro-perforated silencer, which is connected between the exhaust end of the compressor and any heat exchanger of the compression refrigeration cycle system.

2. The manufacturing method according to claim 1 further includes: Compressor operating program setting steps: Set the operating program of the compressor so that the discharge temperature of the compressor is set to 80℃~90℃ and the discharge pressure is set to 3.8Mpa~4.2Mpa.

3. The manufacturing method according to claim 1, wherein The micro-perforated silencer is configured to include an expansion tube and a connecting tube passing through the expansion tube, with both ends of the connecting tube connected to refrigerant lines in the compression refrigeration cycle system; and The connecting tube has several micropores on its inner wall inside the expansion tube.

4. The manufacturing method according to claim 3, wherein The ratio of the inner diameter of the expansion tube to the inner diameter of the connecting tube is 1.5:1 to 2.5:

1.

5. The manufacturing method according to claim 1, wherein In the refrigerant charging step, the refrigerant charging amount and charging pressure are controlled so that the normal pipeline pressure of the compression refrigeration cycle system in the non-operating state is ≤5.0 MPa.

6. The manufacturing method according to claim 1, wherein The peak noise detection step includes: Obtain noise data from the outdoor unit when the compressor is operating; The noise data is analyzed to obtain the spectral data of the noise data; The presence of the peak noise is determined based on the spectral data of the noise data; if it exists, the corresponding peak noise frequency is further determined.

7. The manufacturing method according to claim 6, wherein The noise data was measured using an acoustic microphone; and / or The spectrum data is generated by a spectrum analyzer.

8. An air conditioner manufactured by the manufacturing method according to any one of claims 1-7.

9. An air conditioner, comprising: A compression refrigeration cycle system is partially located inside the outdoor unit of the air conditioner. This system is filled with a mixture of R32 and R125 refrigerants. The refrigerant mix ratio is selected based on the peak noise frequency observed inside the outdoor unit when the compressor in the compression refrigeration cycle system is operating. The functional relationship between the peak noise frequency y and the R32 content x in the mixed refrigerant satisfies: y = 450x + 550, where: 0 < x < 1; as well as A micro-perforated silencer is connected between the exhaust end of the compressor and any heat exchanger of the compression refrigeration cycle system.

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