Heat exchange assembly for a compressor

Abstract

The application discloses a heat exchange assembly for a compressor, comprising a shell and a cover plate, further comprising: a heating assembly accommodated in a space formed by the shell and the cover plate; the heating assembly comprises a plate-shaped ceramic base and a resistor arranged on the plate-shaped ceramic base, and a heat conduction structure is arranged on both sides of the heating assembly, the heat conduction structure has a plurality of protrusions extending towards the heating assembly, and a guide flow channel is formed between adjacent protrusions; the protrusions of the heat conduction structure are in contact with the surface of the plate-shaped ceramic base to clamp and fix the plate-shaped ceramic base. The shell and the cover plate are integrated with the heating assembly to eliminate the redundant structure of traditional external heating, the protrusions in the heat conduction structure directly clamp the ceramic base, the space occupied by the independent support is avoided, the volume is significantly reduced under the same power, and the heat exchange assembly is suitable for narrow installation environment.

Description

Technical Field

[0001] This invention relates to the field of compressor manufacturing technology, and in particular to a heat exchange component for a compressor. Background Technology

[0002] As a core component of a refrigeration system, the compressor's low-temperature start-up performance directly impacts system reliability. In cold environments, the increased viscosity of the internal lubricating oil leads to lubrication failure, and refrigerant migration poses a risk of liquid slugging. The traditional solution is to attach an independent heating device to the outside of the compressor housing. Common forms include wound resistance heating strips or adhesive heating elements, which indirectly heat the housing via external power. This type of heating method suffers from low thermal efficiency; heat must penetrate the housing to reach the interior, and the limited contact area between the heating strip and the housing easily leads to localized overheating or uneven heating. Furthermore, external heating devices require additional fixing structures (such as clamps or adhesive), making installation complex and prone to displacement or detachment due to vibration during long-term operation, affecting heating stability.

[0003] To improve heat transfer efficiency, some existing solutions attempt to embed heating elements into mounting feet at the bottom of the compressor or within the casing. While this design shortens the heat transfer path, limitations in installation space and structural strength restrict the density and coverage of the heating elements, making it difficult to achieve a uniform temperature distribution. Furthermore, the electrical insulation layer of the heating elements is directly exposed to the compressor's vibration environment, and after long-term operation, the insulation material is prone to micro-cracks due to mechanical fatigue, posing a safety hazard of decreased insulation performance. Another approach uses an independent heating element mounted tightly against the casing. Although this improves heat transfer by increasing the contact area, it requires a separate temperature sensor linked to the controller. The sensor wiring must traverse the compressor's external space, increasing assembly complexity and making the cables susceptible to damage from external forces, potentially leading to temperature control failure.

[0004] The main drawbacks of existing technologies are that the dispersed layout of heating units, insulation structures, fixing components, and electrical connection terminals results in a loose overall structure. This leads to low heat transfer efficiency, poor temperature uniformity, complex installation procedures, insufficient mechanical stability, decreased insulation reliability, and vulnerability of temperature control signal lines. These structural defects restrict the synergistic improvement of heating efficiency and safety, necessitating a highly integrated heating device design that optimizes the spatial arrangement and connection relationships between components to achieve efficient heat conduction and reliable assembly while ensuring insulation safety.

[0005] Existing technologies have proposed some solutions that can partially solve the above problems. For example, Chinese Patent CN120384858A discloses "An Integrated Structure of MCH Heating and Compressor," which includes a compressor pump body and a heating mechanism. The heating mechanism includes a cast aluminum flow channel, an inlet pipe, and an outlet pipe. The cast aluminum flow channel is installed at the bottom of the controller. The inlet pipe and outlet pipe are sequentially installed on the side of the surface of the cast aluminum flow channel and are connected to the cast aluminum flow channel. An end cap is fixedly connected to the middle of the top of the cast aluminum flow channel. A ceramic heating tube is installed at the bottom of the inner cavity of the cast aluminum flow channel, and the ceramic heating tube is connected to the bottom of the cast aluminum flow channel. The sealed installation involves extending the bottom of the cast aluminum flow channel to its base. A heating core pressure plate is fixedly mounted at the bottom of the cast aluminum flow channel, and a PCB connecting board is fixedly mounted at the bottom of the heating core pressure plate, achieving uniform heating and integrating the heating and compressor into one unit. While this solution effectively improves the integration of the compressor heating device, it lacks assembly stability and cannot balance thermal conductivity and installation structural stability under vibration conditions. Summary of the Invention

[0006] The primary objective of this invention is to address the problems of long heat transfer paths, poor installation stability, and susceptibility to failure under vibration in compressor heating devices. This is achieved by using a sealed space formed by the outer shell and cover plate to house the heating assembly. A heat-conducting structure with protrusions is installed on the inner wall of the outer shell, using these protrusions to clamp and fix the plate-shaped ceramic substrate, thus achieving integrated heating unit and heat conduction path. This integrates the physical chain of heat generation → conduction → diffusion within a single enclosed space, eliminating the assembly gap thermal resistance of traditional distributed layouts. Simultaneously, mechanical clamping counteracts vibration displacement, resulting in improved thermal efficiency and structural reliability.

[0007] The second objective of this invention is to solve the problem of localized overheating caused by the uniform fluid state of the heat dissipation fins under high-frequency vibration of the compressor. By using a discontinuous staggered toothed structure and a guide lip to achieve directional guidance of turbulent flow, the heat dissipation efficiency can be improved.

[0008] The third objective of this invention is to eliminate the risk of sealing failure at the ceramic-metal interface due to expansion differences under thermal cycling conditions, and to maintain dynamic sealing of the component by using an adaptive deformation seal.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: A heat exchange assembly for a compressor includes a housing and a cover plate, and further includes a heating assembly housed within a space formed by the closure of the housing and the cover plate; the heating assembly includes a plate-shaped ceramic substrate and a resistive element disposed thereon, and heat-conducting structures are provided on both sides of the heating assembly, the heat-conducting structures having multiple protrusions extending toward the heating assembly, and guiding channels forming between adjacent protrusions; the protrusions of the heat-conducting structures contact the surface of the plate-shaped ceramic substrate to clamp and fix it, and turbulent guiding channels are formed between adjacent protrusions.

[0010] In this design, the outer shell and cover plate form a sealed space to house the heating components, avoiding external environmental interference and improving mechanical protection. The heat-conducting structure is fixed to the inner wall of the outer shell, with multiple protrusions directly contacting the surface of the plate-shaped ceramic substrate. This multi-point contact clamps and fixes the ceramic substrate, suppressing displacement caused by compressor vibration; it also establishes an efficient heat conduction path, rapidly transferring heat generated by the resistor through the protrusions → heat-conducting structure → outer shell to the compressor housing. The ceramic substrate possesses both insulation and heat resistance. The resistor integrated into the ceramic substrate surface enables electrothermal conversion. The guide channels formed between adjacent protrusions allow refrigerant to pass through and achieve efficient heat exchange. Depending on the structure of the protrusions on both sides, the guide channels can guide the formation of accelerated turbulence or turbulent flow, thereby optimizing refrigerant heat exchange efficiency. This design abandons the traditional externally wrapped heating tape or independent heating package mode. Through spatial reconstruction, the heating unit, heat-conducting unit, and outer shell form a compact whole, solving the problems of long heat transfer paths, poor installation stability, and susceptibility to failure under vibration in traditional solutions, ensuring that heat exchange efficiency and structural reliability meet higher standards.

[0011] Preferably, the heat-conducting structure is a fin formed by stamping on a single-piece substrate, and the protrusion is a toothed structure of the fin. The stamped finned heat-conducting structure is integrally formed through plastic processing, with the toothed protrusion serving as an extension of the fin, maximizing the contact area while ensuring structural strength. Compared to welded or bolted heat dissipation fins, the stamping process reduces costs and avoids thermal resistance at the connection interface. The toothed structure directly abuts against the ceramic substrate, optimizing discrete contact points into continuous line contact or small-area contact, significantly improving the heat conduction efficiency from the ceramic substrate to the heat-conducting structure, while simultaneously enhancing the mechanical constraint on the substrate and suppressing high-frequency fretting wear.

[0012] Preferably, the fins have a discontinuous, staggered tooth structure, with guide lips formed on both sides of the tooth structure, and several through-holes are formed on the sheet-like substrate. The discontinuous, staggered distribution of the tooth structure breaks the laminar boundary layer of the fluid flow, creating turbulence between the fins to enhance gas disturbance and increase the heat exchange intensity between the air inside the shell and the fins. The guide lips direct the airflow along the surface of the tooth structure, reducing eddy current energy loss. The micropores on the sheet-like substrate balance the air pressure inside and outside the shell, preventing thermal expansion from causing sealing failure, while simultaneously promoting natural convection exchange between the internal hot air and the external environment. This solution optimizes the heat dissipation environment through feature synergy, avoiding thermal stress cracking of the ceramic substrate caused by localized temperature accumulation.

[0013] Preferably, the heating assembly further includes a mounting flange disposed at the head of the plate-shaped ceramic substrate, with a sealing element inserted between the mounting flange and the head of the plate-shaped ceramic substrate. The mounting flange is fitted onto the head of the ceramic substrate, and the insertion-type sealing element achieves a dynamic seal between the flange and the substrate. The mounting flange can solve the interfacial stress problem caused by the difference in thermal expansion coefficients between the ceramic substrate and the metal shell: when the temperature changes, the sealing element allows for slight relative displacement between the substrate and the flange, preventing brittle fracture of the ceramic. The flange structure also provides a mechanical support platform for the electrode leads, providing a stable interface for electrical connections.

[0014] Preferably, the sealing element is an elastic sealing body, which is a bimetallic ring composed of two metal sheets with different coefficients of thermal expansion. The bimetallic ring utilizes the difference in thermal expansion between the two metals to achieve adaptive sealing: at low temperatures, the bimetallic ring maintains its initial clamping force; at high temperatures, the bimetallic sheets undergo directional deformation due to the difference in expansion, compensating for the thermal displacement difference between the ceramic and metal flanges and maintaining a constant pressure at the sealing interface. Compared to a single elastic sealing ring, the bimetallic structure is less prone to aging and failure under the high-temperature operating conditions of the compressor, significantly improving long-term sealing stability.

[0015] Preferably, the mounting flange is a metal-ceramic gradient composite material component, whose material composition gradually changes along its thickness direction, with the ceramic proportion gradually increasing closer to the plate-like ceramic matrix. The gradual change in composition along the thickness direction of the metal-ceramic gradient composite material results in a higher proportion of ceramic phase near the ceramic matrix and a higher proportion of metallic phase near the external environment. This material optimization eliminates stress concentration at the traditional hard metal / ceramic interface, while simultaneously utilizing the better thermal compatibility of the ceramic phase and the better mechanical strength of the metallic phase to prevent interface delamination failure under thermal cycling. Furthermore, the gradient transition layer optimizes the lateral diffusion path of heat from the ceramic matrix to the external environment.

[0016] Furthermore, the resistive element is a resistive paste layer printed and sintered on at least one surface of the plate-shaped ceramic substrate; the plate-shaped substrate is bonded to the outside of the resistive paste layer. The resistive paste layer is printed and sintered onto the ceramic substrate to achieve integrated manufacturing, avoiding assembly errors common in traditional heating wires.

[0017] Preferably, the system also includes an electrode lead-out component. The head of the electrode lead-out component passes through the mounting flange and inserts into both sides of the head of the plate-shaped ceramic substrate. The elastic sealing body engages and fixes the electrode lead-out component, and the tail of the electrode lead-out component protrudes through the cover plate. The electrode lead-out component's head is inserted into both sides of the ceramic substrate with positive and negative terminals, and is fixed by the elastic sealing body, thus decoupling the electrical connection from the mechanical fixation. The elastic sealing body absorbs vibration energy and compensates for assembly tolerances, ensuring no rigid friction between the electrode and the substrate. The tail protruding through the cover plate simplifies the structural complexity of external wiring and avoids stress concentration caused by direct welding of wires to the heating element in traditional solutions.

[0018] Preferably, the power supply area of ​​the resistive slurry layer is covered with a layer of metal fiber braided mesh, and the electrode lead is electrically connected to the metal fiber braided mesh via an elastic pin. The metal fiber braided mesh covers the power supply area and provides protection. Mechanically, it disperses electrode contact stress to prevent slurry layer peeling; electrically, it reduces contact resistance and homogenizes current distribution; thermally, it acts as a heat dissipation layer to suppress localized overheating, and the porous structure of the braided mesh ensures heat dissipation and breathability, effectively avoiding the reduced heat dissipation efficiency caused by a closed coating. The elastic pin connects the electrode lead to the metal fiber braided mesh, using the axial expansion and contraction of the pin to compensate for dimensional changes caused by thermal expansion and contraction, maintaining stable contact pressure. Point contact effectively reduces contact resistance, and the elastic buffer prevents the risk of open circuit due to fretting wear at the connection point under vibration conditions, making it particularly suitable for the impact conditions during compressor start-up and shutdown.

[0019] Preferably, both the cover plate and the outer shell have positioning strips on the side facing the heat-conducting structure. These positioning strips interlock with the toothed gaps in the sheet-like substrate. A sealing strip, which is annular, is provided at the joint between the cover plate and the outer shell. The positioning strips fix the sheet-like substrates on both sides of the plate-like ceramic substrate, ensuring that the sheet-like substrates are tightly attached to the plate-like ceramic substrate and its resistive slurry layer. The annular sealing strip fills the joint surface between the cover plate and the outer shell, preventing external oil and moisture intrusion and disorderly internal heat leakage. The continuous annular seal avoids seams, providing a stable working environment for the internal heating-heat conduction system and ensuring long-term component reliability.

[0020] Therefore, the present invention has the following beneficial effects: The heating components integrated into the outer shell and cover eliminate the redundant structure of traditional external heating. The heat-conducting structure has embedded protrusions that directly clamp the ceramic substrate, avoiding the space occupied by independent brackets. This significantly reduces the volume for the same power, making it suitable for narrow installation environments.

[0021] The finned tooth structure increases the contact area with the ceramic substrate, and the staggered distribution enhances airflow disturbance. After eliminating the thermal resistance of the assembly gap, the thermal efficiency is significantly improved.

[0022] The plate-shaped ceramic substrate has double-sided printed resistive paste layers, which, together with the internal airflow organization design of the shell, enables simultaneous heating of the medium on both sides. This doubles the heat exchange efficiency compared to the single-sided thick film solution and shortens the preheating time at low temperatures.

[0023] The sealing element maintains the seal by adaptive deformation to compensate for thermal deformation, and the elastic pin anti-vibration design ensures stable electrical connection, thus jointly solving the failure problem caused by vibration / thermal cycling. Attached Figure Description

[0024] Figure 1 This is an exploded view of the present invention in Example 1.

[0025] Figure 2 This is a front view of the heat-conducting structure of the present invention in Example 2.

[0026] Figure 3 This is a side sectional view of the present invention in Example 2.

[0027] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0028] In the diagram: 1. Cover plate, 11. Positioning strip, 2. Fin, 21. Toothed structure, 211. Toothed surface, 212. Toothed groove, 22. Flow guide channel, 23. Resistor, 24. Micropore, 3. Sealing strip, 4. Mounting flange, 5. Sealing element, 51. First metal ring, 52. Second metal ring, 6. Electrode lead-out, 7. Ceramic substrate, 8. Metal fiber braided mesh, 9. Outer shell, 91. Liquid inlet, 92. Liquid outlet. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Examples of the embodiments are shown in the drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout.

[0030] Example 1 like Figure 1As shown, this embodiment discloses a heat exchange assembly for a compressor, including a housing 9 and a cover plate 1. A heating assembly is installed within the space formed by the closed housing and cover plate. The cover plate and housing are locked together by screws arranged along the periphery of the cover plate. The housing is also provided with an inlet port 91 and an outlet port 92. The heating assembly includes a plate-shaped ceramic substrate 7 and a resistor 23 disposed thereon. The protruding toothed surface 211 of the heat-conducting structure contacts the surface of the plate-shaped ceramic substrate to clamp and fix it. The heat-conducting structure is installed on both sides of the plate-shaped ceramic substrate and has multiple protrusions extending towards the heating assembly, with turbulent flow channels formed between adjacent protrusions. Specifically, the heat-conducting structure is a fin 2 stamped onto a sheet-like substrate. The protrusion is a toothed structure 21 of the fin, which includes a toothed surface 211 and a toothed groove 212. The toothed surface abuts against the surface of the sheet-like ceramic substrate to ensure high heat exchange efficiency; the toothed groove, in conjunction with the gap between the fins, forms a liquid flow channel to ensure the refrigerant passes through and achieves heat exchange. Since the edge of the toothed surface is an inclined plane that slopes away from the toothed surface, and the two inclined planes of adjacent toothed surfaces are set to converge towards the direction of refrigerant flow, the refrigerant forms an accelerated turbulent flow when passing through the inclined plane, thereby improving the refrigerant transfer speed. The heating assembly also includes a mounting flange 4 fitted onto the head of the sheet-like ceramic substrate, and a sealing element 5 is inserted between the mounting flange and the head of the sheet-like ceramic substrate. The mounting flange is fitted onto the head of the ceramic substrate, and the dynamic seal between the flange and the substrate is achieved through the inserted sealing element. The mounting flange is a metal-ceramic gradient composite material component, and its material composition ratio gradually changes along its thickness direction, with the ceramic ratio gradually increasing closer to the sheet-like ceramic substrate. Metal-ceramic gradient composites exhibit a gradual change in composition along the thickness direction, resulting in a higher proportion of ceramic phase in regions closer to the ceramic matrix and a higher proportion of metal phase in regions closer to the external environment.

[0031] In this design, the outer shell and cover plate form a sealed space to house the heating components, avoiding external environmental interference and improving mechanical protection. The heat-conducting structure is fixed to the inner wall of the outer shell, with multiple protrusions directly contacting the surface of the plate-shaped ceramic substrate. This multi-point contact clamps and fixes the ceramic substrate, suppressing displacement caused by compressor vibration; it also establishes an efficient heat conduction path, rapidly transferring heat generated by the resistor through the protrusions → heat-conducting structure → outer shell to the compressor housing. The ceramic substrate possesses both insulation and heat resistance, and the resistor integrated into its surface enables electrothermal conversion. This design abandons the traditional externally wrapped heating tape or independent heating package approach. By reconfiguring the internal layout of the outer shell, the heating unit, heat-conducting unit, and outer shell form a compact whole, effectively solving the problems of long heat transfer paths, poor installation stability, and susceptibility to failure under vibration in traditional solutions. This ensures that heat exchange efficiency and structural reliability meet higher standards.

[0032] The stamped finned heat-conducting structure is integrally formed through plastic processing. The serrated protrusions, acting as extensions of the fins, maximize the contact area while ensuring structural strength. Compared to welded or bolted heat dissipation fins, the stamping process reduces costs and avoids interfacial thermal resistance. The serrated structure directly abuts against the ceramic substrate, optimizing discrete contact points into continuous line contact or small-area contact, significantly improving the heat transfer efficiency from the ceramic substrate to the heat-conducting structure. Simultaneously, it enhances the mechanical constraint on the substrate, suppressing high-frequency fretting wear. The mounting flange solves the interfacial stress problem caused by the difference in thermal expansion coefficients between the ceramic substrate and the metal shell: when the temperature changes, the sealing element allows for slight relative displacement between the substrate and the flange, preventing brittle fracture of the ceramic. The flange structure also provides a mechanical support platform for the electrode leads, providing a stable interface for electrical connections.

[0033] The mounting flange eliminates stress concentration at the traditional metal / ceramic hard connection interface, while taking advantage of the better thermal matching of the ceramic phase and the better mechanical strength of the metal phase to avoid interface delamination failure under thermal cycling. At the same time, the gradient transition layer can also optimize the lateral diffusion path of heat from the ceramic matrix to the external environment.

[0034] The heat exchange assembly for the compressor also includes an electrode lead-out 6. The head of the electrode lead-out passes through the mounting flange and inserts into both sides of the head of the plate-shaped ceramic substrate. The sealing element engages and fixes the electrode lead-out, and the tail of the electrode lead-out protrudes through the cover plate. The head of the electrode lead-out is inserted into both sides of the ceramic substrate with positive and negative terminals, and is fixed by an elastic sealing body, thus decoupling the electrical connection from the mechanical fixation. The elastic sealing body absorbs vibration energy and compensates for assembly tolerances, ensuring no rigid friction between the electrode and the substrate. The tail protruding through the cover plate simplifies the structural complexity of external wiring and avoids stress concentration caused by direct welding of wires to the heating element in traditional solutions. Both the cover plate and the outer shell have positioning strips on the side facing the heat-conducting structure. The positioning strips interlock with the toothed structure gaps of the plate-shaped substrate. A sealing strip 3, which is annular, is provided at the joint between the cover plate and the outer shell. Positioning strips secure the sheet-like substrates on both sides of the plate-like ceramic substrate, ensuring they adhere tightly to the ceramic substrate and its resistive slurry layer. An annular sealing strip fills the interface between the cover plate and the outer shell, preventing external oil and moisture intrusion and uncontrolled internal heat leakage. This continuous annular seal eliminates seams, providing a stable operating environment for the internal heating and heat conduction system and ensuring long-term component reliability.

[0035] Specifically, the heat exchange assembly for the compressor uses closed-loop thermal management as its core technology. The main structure consists of a shell, cover plate, heating element, and heat-conducting structure forming the basic framework. The shell and cover plate are joined at the edges to form a rigid, sealed cavity. This cavity serves as the core working area for heat exchange, providing both mechanical protection and environmental isolation. The heating element, as the heat source generation unit, has a plate-shaped ceramic substrate at its core. This substrate is an alumina ceramic base with high insulation strength and thermal stability. A resistive paste layer is applied to both sides of the substrate using a screen printing process to form a resistive element, enabling the direct conversion of electrical energy into heat energy when energized. The heat-conducting structure uses stamped metal fins, preferably made of aluminum alloy 1060. The fins are plastically deformed to form an array of toothed structures on the plate-shaped substrate. Each toothed unit includes a toothed surface in contact with the ceramic substrate and guide grooves formed between adjacent toothed surfaces. Two symmetrical fins are attached to the front and back of the ceramic substrate respectively. Their toothed surfaces form surface contact with the substrate surface through elastic preload, which not only achieves mechanical clamping and fixation of the substrate, but also creates a highly efficient heat-conducting interface.

[0036] The mounting flange, serving as the transition interface between the ceramic substrate and the external structure, is made of a metal-ceramic gradient composite material. In this embodiment, the mounting flange is an Al2O3 / Cu component, with its material composition gradually changing along the thickness direction: the ceramic phase volume fraction near the ceramic substrate reaches over 70% to achieve thermal expansion matching, while the metal phase proportion near the external environment exceeds 80% to ensure structural strength. A sealing plug is installed in the gap between the flange inner hole and the head of the ceramic substrate to generate radial clamping force. The sealing plug can be made of a negative thermal expansion material such as tungsten zirconate to achieve adaptive deformation compensation. The electrode lead-out component is made of molybdenum-copper alloy rod, with its head designed as a forked pin structure, penetrating the flange and contacting the power supply areas on both sides of the ceramic substrate; an elastic pin is embedded in the end of the pin, maintaining a constant contact pressure with the power supply area through axial elastic deformation. ABS engineering plastic positioning strips are installed on the cover plate and the inner wall of the outer shell, with their raised teeth interlocking with the fin grooves to limit the lateral displacement of the fins; the mating surface is filled with a fluororubber annular sealing strip, achieving static sealing through compression and rebound.

[0037] Once the components are assembled, they form a tight coupling of space and function. The outer shell and cover plate constitute a sealed cavity, isolating external oil and moisture. The ceramic substrate serves as a heat source carrier, and the resistive slurry layer generates heat when energized. The fin toothed surface rapidly conducts heat from the substrate through continuous pressure contact, which diffuses through the sheet-like substrate to the continuously flowing refrigerant within the sealed cavity. The positioning strip constrains the fin position to ensure that the contact interface remains secure, effectively maintaining the preset heat exchange area and efficiency, especially under vibration conditions. The mounting flange coordinates the thermal deformation of the ceramic and metal shells, while the electrode leads use elastic pins to offset vibration impacts and maintain a stable electrical connection. Compared to traditional solutions, this embodiment achieves several innovative optimizations: First, the finned tooth structure transforms discrete support points into continuous heat-conducting surfaces, reducing contact thermal resistance to less than 1 / 5 of that of welded structures; second, the double-sided fin layout increases the effective heat exchange area to more than 1.8 times that of single-sided heating solutions, and the toothed grooves create turbulent flow to enhance heat transfer and convection efficiency; finally, the deformation-adaptive scheme of gradient materials and sealing plugs reduces the peak stress of the ceramic matrix under thermal cycling from -40℃ to 150℃, effectively avoiding the risk of brittle fracture.

[0038] In this embodiment, the operator places the stamped fins in a special fixture, ensuring that the tooth groove distribution direction is consistent with the design requirements. The plate-shaped ceramic substrate, after being sintered with resistance slurry, is transferred between the two fins, and a precision guiding mechanism ensures that the substrate surface and the fin tooth surface are precisely fitted. Vertical pressure is applied, causing elastic deformation of the tooth surface, creating a continuous clamping force on the ceramic substrate. At this point, surface contact is established between the fin tooth surface and the plate-shaped ceramic substrate. When installing the metal-ceramic gradient flange, the electrode lead is first inserted into the pre-cooled sealing plug and pre-installed as a whole within the mounting flange. Then, the mounting flange is fitted onto the head of the ceramic substrate. After returning to room temperature, the sealing plug expands and seals the gap between the mounting flange and the electrode lead. The electrode lead pins pass through the flange mounting holes, and the fasteners are tightened so that the elastic pins at the ends of the pins press against the resistance slurry layer contact point to ensure power supply. Finally, the cover plate positioning strip is inserted into the fin tooth groove gap, the annular sealing strip is embedded, and the cover plate bolts are locked to form a complete sealed cavity.

[0039] When the heat exchange component proposed in this embodiment is applied to a compressor, the component is fixed to the wall of the liquid storage tank via the outer casing mounting surface. After power is applied, the resistance slurry layer heats up rapidly, and the heat is conducted through the ceramic substrate to the contact area of ​​the fin tooth surface. The elongation characteristics of the tooth structure increase the heat conduction area, and the heat diffuses laterally along the fin substrate to the inner wall of the outer casing. The discontinuous staggered tooth groove layout further disrupts the laminar flow state and promotes the turbulent movement of the internal refrigerant; the guide lip guides the fluid to flow along the tooth surface direction, enhancing the convective heat transfer efficiency. The double-sided heating mode allows the refrigerant to contact the positive and negative heating surfaces of the substrate simultaneously, significantly shortening the low-temperature preheating cycle. The high-frequency vibration generated by the compressor operation is absorbed by the multi-layer structure: the elastic clamping of the fin tooth surface allows for slight displacement of the substrate; the elastic pins buffer vibration impact and maintain stable electrical connection.

[0040] In this embodiment, the mass production process employs a continuous stamping process to form the finned tooth structure, resulting in better material utilization than traditional machining. The ceramic substrate undergoes double-sided resistive paste patterning via an automated printing line, and the gradient flange utilizes hot-pressing sintering to achieve compositional gradients. After assembly, the entire unit undergoes sealing tests and thermal cycling durability verification to ensure long-term reliability under typical compressor operating conditions.

[0041] Example 2 like Figure 3 As shown, compared to Embodiment 1, this embodiment further optimizes the heat exchange component for the compressor in terms of heat transfer efficiency, sealing reliability, and electrical stability. The outer shell and cover plate continue the sealed cavity design, with the internal space accommodating the heating component and heat-conducting structure. The plate-shaped ceramic substrate of the heating component is made of alumina ceramic, and a resistance paste layer is formed on both sides of the substrate through screen printing as the heat source. The heat-conducting structure consists of two symmetrically arranged metal fins, which are formed into a toothed array on the plate-shaped substrate through a stamping process. Figure 2 As shown, the toothed unit includes a heat-conducting toothed surface in contact with the ceramic substrate, a flow-guiding lip extending arcuately from the edge of the toothed surface, and a turbulence channel formed between the teeth. The toothed structure is discontinuously staggered, with adjacent tooth rows offset by one tooth pitch, guiding turbulence to form a novel turbulence channel through the staggered structure; micropores 24 are uniformly opened on the surface of the sheet-like substrate, with the pore diameter and tooth height dimensions coordinated. In this embodiment, the mounting flange is fitted onto the head of the ceramic substrate, and a bimetallic sealing ring is added in the gap between the inner wall of the flange and the substrate. This ring is composed of composite metal sheets with significantly different coefficients of thermal expansion. The electrode area of ​​the resistive slurry layer is covered with a stainless steel metal fiber braided mesh 8, and the electrode lead-out pins are in contact with the braided mesh through beryllium copper alloy elastic pins.

[0042] Once integrated, the fin teeth fully adhere to the ceramic substrate, forming the dominant thermal path. The discontinuous, staggered toothed layout causes abrupt changes in airflow direction through the fin gaps, disrupting laminar flow and creating vortices. The curved surface of the guide lip guides the vortices along the tooth surface normal, reducing lateral kinetic energy dissipation. A network of micropores permeates the cavity, balancing pressure fluctuations caused by thermal expansion. At low temperatures, the bimetallic sealing ring provides initial sealing force through material elasticity; at high temperatures, the expansion difference between the dissimilar metals drives radial deformation of the ring, dynamically compensating for thermal displacement between the ceramic and metal flanges. The metal braided mesh disperses electrode contact stress, and its mesh structure promotes heat diffusion in the electrode area. Elastic pins compensate for thermal expansion and contraction through axial extension and contraction, while spherical contacts maintain a constant contact pressure with the braided mesh.

[0043] Specifically, in this embodiment, the innermost plate-shaped ceramic substrate of the compressor heat exchange assembly serves as the heat generation carrier. It is made of high thermal conductivity alumina ceramic, and its front and back surfaces are screen-printed with a serpentine resistive paste layer. This paste layer generates Joule heat when energized, and the heat is symmetrically conducted to both sides through the ceramic substrate. Adhering closely to the substrate surface are two metal fins, which are precision-stamped into an array of tooth-like structures. Each tooth unit contains three key parts: a planar tooth surface in direct contact with the ceramic substrate, used to establish a heat conduction channel; a flow guiding channel extending arcuately from the edge of the tooth surface, with a lip structure whose radius of curvature is coordinated with the tooth height; and a guiding channel formed between adjacent tooth surfaces, which in this embodiment can guide turbulence because the tooth structure adopts a discontinuous staggered layout, with adjacent tooth rows offset by half a tooth pitch to a full tooth pitch along the airflow direction, forming staggered fluid channels. Micropores are uniformly distributed on the surface of the fin-shaped substrate, with the pore size proportional to the tooth height.

[0044] A metal-ceramic gradient flange is fitted over the ceramic substrate head. A sealing element is inserted between the mounting flange and the plate-shaped ceramic substrate head. Below the sealing element, an elastic sealing body is added. This elastic sealing body is a bimetallic ring composed of two metal sheets with different coefficients of thermal expansion. The bimetallic ring utilizes the difference in thermal expansion between the two metals to achieve adaptive sealing: at low temperatures, the bimetallic ring maintains its initial clamping force; at high temperatures, the bimetallic sheets undergo directional deformation due to the difference in expansion, compensating for the thermal displacement difference between the ceramic and the metal-ceramic gradient flange, maintaining a constant pressure at the sealing interface. Compared to a single elastic sealing ring, the bimetallic structure is less prone to aging and failure under the high-temperature conditions of the compressor, significantly improving long-term sealing stability. Figure 4As shown, the first metal ring 51 has a V-shaped opening in its cross-section. The inner side of the V-shape is attached to the surface of the ceramic substrate, and the outer side abuts against the inner wall of the flange. The second metal ring 52 is perpendicular to the first metal ring 51 and is clamped to the outside of the V-shaped opening of the first metal ring, thereby controlling the opening angle of the first metal ring 51. Although both the first and second metal rings expand when the temperature rises, the two metal materials are different. In this embodiment, the first metal ring is made of copper, with an average coefficient of thermal expansion of approximately 0.0000177°C. The second metal ring is made of an iron-nickel alloy. Made of Invar alloy, with an average coefficient of thermal expansion of approximately 0.0000016 / °C, the second metal ring has a much smaller expansion rate than the first metal ring. Therefore, as the ambient temperature rises, the second metal ring exerts a contraction effect on the first metal ring, which has a larger expansion rate. This causes the V-shaped first metal ring to significantly extend radially, effectively "flattening" itself. This fills the gap between the ceramic substrate and the metal-ceramic gradient flange caused by temperature changes, ensuring a consistent seal at the joint between the mounting flange and the plate-shaped ceramic substrate. Compared to using a single metal sealing ring directly, this solution utilizes the second metal ring, with its smaller coefficient of thermal expansion, to "actively extend" the first metal ring twice. This results in a greater radial extension volume than the volume compensated for by temperature-induced expansion, achieving a tighter dynamic seal.

[0045] The silver electrode area of ​​the resistive slurry layer is covered with a stainless steel metal fiber woven mesh, which is metallurgically bonded to the electrode through high-temperature sintering. The electrode lead is electrically connected to the metal fiber woven mesh via an elastic pin. The lead pin penetrates the flange mounting hole, and a beryllium copper alloy elastic pin is embedded at the end of the pin. The pin head has a spherical contact structure. The metal fiber woven mesh covers the power supply area and forms a protective layer. Mechanically, it can disperse electrode contact stress and prevent slurry layer peeling; electrically, it can reduce contact resistance and homogenize current distribution; thermally, it can act as a heat dissipation layer to suppress local overheating. The porous structure of the woven mesh ensures heat dissipation and breathability, effectively avoiding the reduction in heat dissipation efficiency caused by a closed coating. The elastic pin connects the electrode lead to the metal fiber woven mesh, using the axial expansion and contraction of the pin to compensate for dimensional changes caused by thermal expansion and contraction, maintaining stable contact pressure. Point contact can effectively reduce contact resistance, and elastic buffering prevents the risk of open circuit caused by fretting wear at the connection point under vibration environment, especially suitable for the impact conditions during compressor start-up and shutdown.

[0046] In summary, the fins feature a discontinuous, staggered tooth structure, with flow-guiding channels formed on both sides of the tooth structure serving as flow-guiding lips. The sheet-like substrate has several through-holes. This discontinuous, staggered tooth structure breaks the laminar boundary layer of the fluid flow, creating turbulence between the fins to enhance fluid disturbance and increase the heat exchange intensity between the internal air and the fins. The flow-guiding lips direct airflow along the surface of the tooth structure, reducing eddy current energy loss. The micropores on the sheet-like substrate balance the internal and external air pressures, preventing thermal expansion from causing seal failure, while simultaneously promoting natural convection exchange between the internal hot air and the external environment. This solution optimizes the heat dissipation environment through feature synergy, avoiding thermal stress cracking of the ceramic substrate caused by localized temperature accumulation.

[0047] After the heat exchange assembly is assembled, the heat conduction path is first established through the surface contact between the finned tooth surface and the ceramic substrate. The staggered layout of the toothed structure causes a sudden change in the direction of the airflow passing through the tooth grooves, forming local vortices between adjacent tooth rows and disrupting the laminar boundary layer. The arc-shaped surface of the guide lip guides the vortices to move in a direction perpendicular to the tooth surface, reducing energy dissipation. The micropore group balances the pressure difference between the inside and outside of the shell, preventing thermal expansion from causing seal failure. At low temperatures, the bimetallic ring relies on the elasticity of the V-shaped structure to provide the initial sealing force. At high temperatures, the low expansion characteristics of the iron-nickel alloy cause the V-angle to narrow, automatically compensating for the radial displacement difference between the ceramic and the metal flange. The metal braided mesh disperses the mechanical stress at the electrode contact points, and its mesh structure accelerates the diffusion of heat from the electrode area. The elastic pin absorbs thermal expansion and contraction deformation through axial extension and contraction, and the spherical contact point penetrates the oxide layer to maintain stable electrical contact.

[0048] In this embodiment, the toothed groove turbulence and lip guidance work together to improve the convective heat transfer efficiency; the thermal adaptive characteristics of the bimetallic ring ensure the reliability of the seal; and the combination of braided mesh and elastic pin suppresses electrical connection failure under vibration.

Claims

1. A heat exchange assembly for a compressor, comprising a housing and a cover plate, characterized in that, Also includes: A heating component is housed within a space formed by the enclosure and the cover plate. The heating component includes a plate-shaped ceramic substrate and a resistor disposed thereon. Heat-conducting structures are provided on both sides of the heating component. The heat-conducting structures have multiple protrusions extending toward the heating component, and guide channels are formed between adjacent protrusions. The protrusions of the thermally conductive structure contact the surface of the plate-shaped ceramic substrate to clamp and fix it. The heat-conducting structure is fixed to the inner wall of the outer shell; the heat-conducting structure is a fin formed by stamping on a sheet-like substrate, and several through micropores are opened on the sheet-like substrate; the tooth-like structure of the fin is discontinuously staggered. The protrusions are fin-like toothed structures, including toothed surfaces and toothed grooves. The toothed surfaces abut against the surface of the plate-shaped ceramic substrate, and the toothed surfaces form surface contact with the substrate surface through elastic pre-tightening force. The toothed grooves cooperate with the gaps between the fins to form liquid flow channels. Positioning strips are provided on the side of the cover plate and the outer shell facing the heat conduction structure. The positioning strips are inserted into the gaps of the protrusions of the heat conduction structure, and the positioning strips fix the plate-shaped substrates on both sides of the plate-shaped ceramic substrate.

2. The heat exchange assembly for a compressor according to claim 1, characterized in that, The tooth-like structure has guide lips formed on both sides.

3. The heat exchange assembly for a compressor according to claim 1, characterized in that, The heating assembly also includes a mounting flange fitted onto the head of the plate-shaped ceramic substrate, and a sealing element is inserted between the mounting flange and the head of the plate-shaped ceramic substrate.

4. The heat exchange assembly for a compressor according to claim 3, characterized in that, The sealing element is an elastic sealing body, which is a bimetallic ring composed of two metal sheets with different coefficients of thermal expansion.

5. The heat exchange assembly for a compressor according to claim 3, characterized in that, The mounting flange is a metal-ceramic gradient composite material component, the proportion of which gradually changes along its thickness direction, with the proportion of ceramic gradually increasing closer to the plate-shaped ceramic matrix.

6. The heat exchange assembly for a compressor according to claim 3, characterized in that, The resistor is a resistive paste layer printed and sintered on at least one surface of the plate-shaped ceramic substrate; the sheet-shaped substrate is attached to the outside of the resistive paste layer.

7. The heat exchange assembly for a compressor according to claim 6, characterized in that, It also includes an electrode lead-out component, the head of which passes through the mounting flange and is inserted into the resistive slurry layer on both sides of the head of the plate-shaped ceramic substrate. The sealing element engages and fixes the electrode lead-out component, and the tail of the electrode lead-out component protrudes through the cover plate.

8. The heat exchange assembly for a compressor according to claim 7, characterized in that, The power supply area of ​​the resistive paste layer is covered with a layer of metal fiber braided mesh, and the electrode lead is electrically connected to the metal fiber braided mesh through an elastic pin.

9. The heat exchange assembly for a compressor according to any one of claims 1-8, characterized in that, A sealing strip is provided at the joint between the cover plate and the outer shell, and the sealing strip is ring-shaped.

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