Integrated refrigerant plate of air energy heat pump

Abstract

The invention relates to the technical field of air energy heat pumps, and discloses an integrated refrigerant plate of an air energy heat pump, which comprises a compressor, a four-way valve, a condenser, an economizer, an evaporator, a first integrated refrigerant plate and a second integrated refrigerant plate, a main flow channel and an enhanced vapor injection branch flow channel are formed in the first integrated refrigerant plate; the main flow channel is used for realizing sequential communication among the compressor, the four-way valve, the condenser and the economizer; and the enhanced vapor injection branch flow channel shunts from the main flow channel. Complex external welding copper pipes among core components such as the compressor, the four-way valve, the condenser and the economizer are all integrated in precise flow channels in the first integrated refrigerant plate and the second integrated refrigerant plate, so that the number of connecting welding spots of the whole system can be greatly reduced, potential quality hazards such as insufficient welding and sand holes in traditional pipeline welding are fundamentally eliminated, and the welding quality of the whole system is improved. The risk of refrigerant leakage is greatly reduced, and the long-term reliability of system operation is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of air source heat pump technology, specifically to an integrated refrigerant plate for an air source heat pump. Background Technology

[0002] As a highly efficient and energy-saving heat transfer device, the performance and reliability of air source heat pumps depend heavily on the refrigerant circulation system among core components such as the compressor, four-way valve, condenser, evaporator, and economizer. For a long time, the standard practice in this field has been to use separate copper pipes, connecting these components in series by welding to form a complete refrigerant flow path.

[0003] In existing technologies, the aforementioned components are primarily connected by complex, independent copper pipe welding. The entire system requires multiple independent pipe sections connected in series, with all connection nodes between components using welding. A single system often has more than 20 weld points. Welding quality is unstable, prone to incomplete welds, pinholes, or cracks, leading to a high risk of refrigerant leakage. The large amount of copper pipe used and the numerous processing steps result in high material and labor costs. The complex piping layout increases system flow resistance, leading to energy efficiency losses. Furthermore, installation and maintenance are cumbersome and troubleshooting is difficult. Although attempts have been made to use flanges or quick couplings to reduce weld points, their sealing and durability are insufficient due to the high-pressure operating conditions of the system. Therefore, traditional piping connection methods have become a key bottleneck restricting the reliability, economy, and energy efficiency improvement of air source heat pumps. Summary of the Invention

[0004] In view of the shortcomings of the integrated refrigerant plate of the existing air source heat pump mentioned in the background art, the present invention provides an integrated refrigerant plate for air source heat pumps, which solves the problems of high risk of weld point leakage, high cost, complex installation and maintenance and large system flow resistance caused by decentralized welded pipelines.

[0005] This invention provides the following technical solution: an integrated refrigerant plate for an air source heat pump, comprising a compressor, a four-way valve, a condenser, an economizer, an evaporator, and an air source heat pump, and further comprising a first integrated refrigerant plate and a second integrated refrigerant plate; the first integrated refrigerant plate has a main flow channel and a vapor injection enthalpy-increasing branch flow channel formed inside, the main flow channel being used to realize sequential connection between the compressor, the four-way valve, the condenser, and the economizer; the vapor injection enthalpy-increasing branch flow channel is diverted from the main flow channel and is used to connect to the compressor's air inlet after passing through the economizer; the second integrated refrigerant plate has a branch flow channel and a converging flow channel formed inside, the branch flow channel being used to distribute the main refrigerant from the first integrated refrigerant plate to the evaporator, and the converging flow channel being used to collect the refrigerant from the evaporator and send it back to the first integrated refrigerant plate; wherein, within the first integrated refrigerant plate, a first throttling device and a second throttling device are respectively integrated on the vapor injection enthalpy-increasing branch flow channel and the main flow channel leading to the second integrated refrigerant plate.

[0006] Preferably, the first integrated refrigerant plate has the following on its body: a first interface for connecting the compressor's exhaust port, a second interface for connecting the compressor's inlet port, and a third interface for connecting the compressor's suction port; a fourth interface, a fifth interface, a sixth interface, and a seventh interface for connecting the four-way valve; an eighth interface for connecting the condenser's inlet and a ninth interface for connecting the condenser's outlet; and a tenth interface for connecting the economizer's main inlet, an eleventh interface for connecting the economizer's main outlet, a twelfth interface for connecting the economizer's enthalpy-increasing branch inlet, and a thirteenth interface for connecting the economizer's enthalpy-increasing branch outlet.

[0007] Preferably, the main flow channel includes: a first flow channel, a second flow channel, a third flow channel, a fourth flow channel, a fifth flow channel, and a sixth flow channel; the first flow channel connects the first interface and the fourth interface; the second flow channel connects the fifth interface and the eighth interface; the third flow channel connects the ninth interface and the tenth interface; one end of the fourth flow channel connects to the eleventh interface, and the other end leads to the second integrated refrigerant plate; one end of the fifth flow channel connects to the sixth interface, and the other end leads to the second integrated refrigerant plate; the sixth flow channel connects the seventh interface and the third interface.

[0008] Preferably, the internal flow channel of the first integrated refrigerant plate further includes a jet enthalpy-increasing branch, which includes a seventh flow channel and an eighth flow channel. The inlet of the seventh flow channel and the inlet of the fourth flow channel are connected to the eleventh interface, and its outlet is connected to the twelfth interface. The eighth flow channel connects the thirteenth interface and the second interface.

[0009] Preferably, the first throttling device is located on the seventh flow channel.

[0010] Preferably, the second throttling device is disposed on the fourth flow channel.

[0011] Preferably, the second integrated refrigerant plate has a fourteenth interface group for connecting multiple inlets of the evaporator and a fifteenth interface group for connecting multiple outlets; the diversion channel is a ninth channel, which connects the other end of the fourth channel to the fourteenth interface group; the confluence channel is a tenth channel, which connects the fifteenth interface group to the other end of the fifth channel.

[0012] Preferably, both the first integrated refrigerant plate and the second integrated refrigerant plate are integrally formed from metal materials.

[0013] Preferably, the metal material is an aluminum alloy.

[0014] The present invention has the following beneficial effects: 1. This invention integrates all the complex externally welded copper pipes between core components such as the compressor, four-way valve, condenser, and economizer into the precision flow channels inside the first and second integrated refrigerant plates. This significantly reduces the number of connection welds in the entire system, fundamentally eliminating quality hazards such as false welds and pinholes in traditional pipe welding, greatly reducing the risk of refrigerant leakage, and significantly improving the long-term reliability of the system.

[0015] 2. This invention uses aluminum alloy and other materials to integrally manufacture the refrigerant plate, replacing a large number of independent copper pipes, elbows and joints with internally processed flow channels. This reduces raw material costs and eliminates the cutting, bending and welding processes of traditional pipeline systems, significantly improving production efficiency and product economy. At the same time, the optimized flow channel design reduces local flow resistance, which helps to improve the overall energy efficiency of the system.

[0016] 3. By directly integrating throttling devices such as electronic expansion valves into the main circuit and jet enthalpy-increasing branch circuit inside the first integrated refrigerant plate, the present invention enables an extremely compact system layout, eliminates external valves and their additional connecting pipes, not only further reduces potential leakage points, but also simplifies the pipe routing, which is conducive to reducing refrigerant flow resistance and improving energy efficiency and control centralization.

[0017] 4. Through modular design and standardized interfaces, this invention enables clear interface docking between various components and refrigerant panels, simplifying the on-site installation process from cumbersome measurement, pipe cutting, and welding to efficient alignment, connection, and fastening. This greatly reduces reliance on the welding skills of operators, shortens installation time from several hours to less than one hour, and facilitates quick location of problematic interfaces during later maintenance. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall connection of the integrated refrigerant panel system of the present invention; Figure 2 This diagram shows the interface connections between the integrated refrigerant board, compressor, and four-way valve. Figure 3 Functional diagram of internal piping and throttling components for integrated refrigerant panels; Figure 4 Diagram showing the piping connections between the integrated refrigerant plate, condenser, and economizer; Figure 5 This is a diagram showing the connection function between the integrated refrigerant plate and the evaporator.

[0019] In the diagram: 1. Compressor; 2. Four-way valve; 3. Condenser; 4. Economizer; 5. Evaporator; 6. Air source heat pump; 7. First integrated refrigerant panel; 8. Second integrated refrigerant panel; 101. First interface; 102. Second interface; 103. Third interface; 201. Fourth interface; 202. Fifth interface; 203. Sixth interface; 204. Seventh interface; 301. Eighth interface; 302. Ninth interface; 401. Tenth interface; 40 2. Eleventh Interface; 403. Twelfth Interface; 404. Thirteenth Interface; 501. Fourteenth Interface Group; 502. Fifteenth Interface Group; M1. First Flow Channel; M2. Second Flow Channel; M3. Third Flow Channel; M4. Seventh Flow Channel; M5. Eighth Flow Channel; M6. Fourth Flow Channel; M7. Fifth Flow Channel; M8. Sixth Flow Channel; M9. Ninth Flow Channel; M10. Tenth Flow Channel; M41. First Throttling Device; M61. Second Throttling Device. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see Figure 1 An integrated refrigerant plate for an air source heat pump replaces the traditional distributed welded copper pipe network with a highly integrated refrigerant plate module. It mainly includes a first integrated refrigerant plate 7 and a second integrated refrigerant plate 8. The first integrated refrigerant plate 7 serves as the central flow path hub of the system, connecting to the compressor 1, four-way valve 2, condenser 3, and economizer 4 via multiple standardized interfaces integrated on its plate. The second integrated refrigerant plate 8 serves as a dedicated connection module for the evaporator, connecting to the first integrated refrigerant plate 7 at one end and to the evaporator 5 at the other end via multiple interfaces. Through a dual-plate modular design, most of the external connection pipes of the air source heat pump's main cooling / heating cycle and the vapor injection enthalpy-increasing branch are integrated into the internal flow channels of the two refrigerant plates, thereby optimizing the system structure.

[0022] Please see Figure 2-4The first integrated refrigerant plate 7 is made of metal, preferably aluminum alloy, and is integrally molded. Its internal sealed flow channels are formed through casting or machining. The first integrated refrigerant plate 7 has all necessary external connection interfaces: the compressor interface group includes a first interface 101 connecting to the exhaust port of compressor 1, a second interface 102 connecting to the air supply port, and a third interface 103 connecting to the suction port. The four-way valve interface group includes a fourth interface 201, a fifth interface 202, a sixth interface 203, and a seventh interface 204 connecting to the four ports of four-way valve 2 respectively. The condenser interface group includes an eighth interface 301 connecting to the inlet of condenser 3 and a ninth interface 302 connecting to the outlet. The economizer interface group includes a tenth interface 401 connecting to the main inlet of economizer 4, an eleventh interface 402 connecting to the main outlet, a twelfth interface 403 connecting to the inlet of the enthalpy-increasing branch, and a thirteenth interface 404 connecting to the outlet of the enthalpy-increasing branch.

[0023] Please see Figure 3 The aforementioned interfaces are interconnected through precision flow channels integrated within the board, and also integrate key control components. The main flow channels form the main refrigerant circulation path. The first flow channel M1 connects the first interface 101 and the fourth interface 201. The second flow channel M2 connects the fifth interface 202 and the eighth interface 301. The third flow channel M3 connects the ninth interface 302 and the tenth interface 401. One end of the fourth flow channel M6 connects to the eleventh interface 402, and the other end leads to the second integrated refrigerant plate 8. One end of the fifth flow channel M7 connects to the sixth interface 203, and the other end leads to the second integrated refrigerant plate 8. The sixth flow channel M8 connects the seventh interface 204 and the third interface 103.

[0024] The jet enthalpy-enhancing branch channel branches off from the main channel to improve the system's performance at low temperatures. The seventh channel M4 branches off from the path of the fourth channel M6 and connects to the twelfth interface 403. The eighth channel M5 connects the thirteenth interface 404 and the second interface 102.

[0025] To achieve precise refrigerant throttling control, two electronic expansion valves are directly integrated inside the first integrated refrigerant plate 7 as throttling devices. Among them, the first throttling device M41 is installed on the seventh flow channel M4 and is used to control the refrigerant flow in the jet enthalpy-increasing branch; the second throttling device M61 is installed on the fourth flow channel M6 and is used to control the refrigerant flow from the main line to the evaporator.

[0026] Please see Figure 5The second integrated refrigerant plate 8 is designed for efficient connection of the multi-flow evaporator 5. Its body is also manufactured using a unibody metal forming process. The plate body has a fourteenth interface group 501 and a fifteenth interface group 502. The fourteenth interface group 501 contains multiple independent interfaces for connecting to multiple inlets of the evaporator 5; the fifteenth interface group 502 also contains multiple interfaces for connecting to multiple outlets of the evaporator 5. This multi-interface design facilitates uniform distribution of refrigerant within the evaporator, improving heat exchange efficiency.

[0027] The second integrated refrigerant plate 8 has two main flow channels: the ninth flow channel M9 and the tenth flow channel M10. The ninth flow channel M9 diverts the refrigerant from the fourth flow channel M6 of the first integrated refrigerant plate 7 and distributes it evenly to each interface of the fourteenth interface group 501. The tenth flow channel M10 collects the return gas from the evaporator 5 from the fifteenth interface group 502 and centrally delivers it to the fifth flow channel M7 of the first integrated refrigerant plate 7.

[0028] The two integrated refrigerant plates can be manufactured using metal die casting, brazing, or 3D printing.

[0029] Metal die casting can achieve one-piece molding and is suitable for light metal materials such as aluminum alloys. Based on the final three-dimensional structure of the first and second integrated refrigerant plates, a special high-strength steel mold is designed and manufactured. The cavity of the mold can accurately form all the interface bosses and mounting structures on the outside of the refrigerant plate. Through the correspondingly designed dissolvable core or core pulling mechanism, a cavity with complex internal flow channels is left in the cavity. The mold must have high precision and high surface finish to ensure that the molded part is dimensionally accurate and the inner wall of the flow channel is smooth, reducing flow resistance.

[0030] Brazing-type integral welding process is suitable for scenarios using copper or stainless steel. The main body of the refrigerant plate is divided into three layers or similar structures: an upper cover plate, a lower cover plate, and an intermediate flow channel plate. The upper and lower surfaces of the intermediate flow channel plate are processed with grooves that can form a complete flow channel network when they are attached to the upper and lower cover plates through etching, machining, or molding. The upper cover plate, intermediate flow channel plate, and lower cover plate are precisely stacked and aligned, and brazing material is placed between each contact surface. Then, the whole assembly is placed in a vacuum brazing furnace or a protective atmosphere brazing furnace for connection. After cooling, it forms a non-removable integral structure with a sealed internal flow channel and a complete metal block on the outside. It has high connection strength and excellent sealing performance.

[0031] 3D printing technology enables rapid prototyping and small-batch customized production. It is based directly on a three-dimensional digital model of a refrigerant plate and uses metal additive manufacturing equipment. Under the protection of high-purity inert gas, the equipment uses aluminum-silicon alloy powder or stainless steel powder as raw materials, and precisely deposits them by scanning and melting layer by layer with laser or electron beam.

[0032] The working principle of the method of using this invention is as follows: Combination Figures 1 to 5 The refrigerant circulation path of the system in heating mode is as follows: Main Circulation: High-temperature, high-pressure gaseous refrigerant is discharged from the compressor 1 exhaust port, enters the first interface 101 of the first integrated refrigerant plate 7 through an external pipeline, reaches the fourth interface 201 through the first flow channel M1, and then enters the four-way valve 2 through an external pipeline. After being guided by the four-way valve 2, the refrigerant enters the first integrated refrigerant plate 7 from the fifth interface 202, flows out from the eighth interface 301 through the second flow channel M2, and enters the condenser 3 for heat release and condensation. The condensed liquid refrigerant returns from the condenser 3 outlet to the ninth interface 302 of the first integrated refrigerant plate 7, flows out from the tenth interface 401 through the third flow channel M3, and enters the main circuit of the economizer 4 for further cooling. The subcooled liquid refrigerant flowing out of the main circuit outlet of the economizer 4 returns to the eleventh interface 402 of the first integrated refrigerant plate 7, enters the fourth flow channel M6, and flows through the second throttling device M61 integrated on this flow channel for throttling and pressure reduction. After throttling, the gas-liquid two-phase refrigerant leaves the first integrated refrigerant plate 7 and enters the ninth flow channel M9 of the second integrated refrigerant plate 8. It is then evenly distributed to the fourteenth interface group 501 and enters the evaporator 5 for heat absorption and evaporation. The evaporated low-temperature, low-pressure gaseous refrigerant flows from the evaporator 5 outlet through the fifteenth interface group 502 into the tenth flow channel M10 of the second integrated refrigerant plate 8, and is then transported back to the fifth flow channel M7 of the first integrated refrigerant plate 7. The refrigerant flows out from the fifth flow channel M7 through the sixth interface 203, enters the four-way valve 2 through an external pipeline, and after reversing, enters the first integrated refrigerant plate 7 through the seventh interface 204. Finally, it returns to the compressor 1 suction port through the sixth flow channel M8 and the third interface 103, completing the main cycle.

[0033] Jet enthalpy-increasing branch circulation: When the subcooled liquid refrigerant from the main outlet of the economizer 4 flows back to the eleventh interface 402 of the first integrated refrigerant plate 7, the refrigerant is divided into two parallel paths. The main stream enters the fourth flow channel M6 as described above; the other path enters the dedicated seventh flow channel M4, i.e., the jet enthalpy-increasing branch. The refrigerant in this branch immediately flows through the first throttling device M41 integrated on the seventh flow channel M4. This device is an electronic expansion valve, which performs the first throttling and pressure reduction, turning it into a low-temperature and low-pressure gas-liquid two-phase mixture. The throttled low-temperature refrigerant flows out of the first integrated refrigerant plate 7 through the twelfth interface 403 and enters the enthalpy-increasing branch inlet of the economizer 4. Inside the economizer, this low-temperature refrigerant undergoes efficient heat exchange with the high-temperature liquid refrigerant from the condenser flowing through the main economizer circuit. It absorbs heat from the main circuit refrigerant and completely evaporates into a low-temperature gas, simultaneously increasing the subcooling of the main circuit refrigerant and enhancing its cooling / heating potential. After completing the heat exchange and becoming a low-temperature, medium-pressure gaseous refrigerant, it flows out from the enthalpy-increasing branch outlet of the economizer 4 and returns to the thirteenth interface 404 of the first integrated refrigerant plate 7. Subsequently, the refrigerant flows through the eighth channel M5, exits the integrated plate from the second interface 102, and is finally introduced into the medium-pressure injection port of the compressor 1.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0035] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An integrated refrigerant plate of an air-to-energy heat pump comprising a compressor (1), a four-way valve (2), a condenser (3), an economizer (4), an evaporator (5), and an air-to-energy heat pump (6), characterized in that: Also comprising a first integrated refrigerant plate (7) and a second integrated refrigerant plate (8); the first integrated refrigerant plate (7) is internally formed with a main path flow channel and a jet augmenting branch flow channel, the main path flow channel is used to realize the sequential communication between the compressor (1), the four-way valve (2), the condenser (3) and the economizer (4); the jet augmenting branch flow channel is branched from the main path flow channel, and is used to be communicated to the air injection port of the compressor (1) after passing through the economizer (4); the second integrated refrigerant plate (8) is internally formed with a branched flow channel and a converging flow channel, the branched flow channel is used to distribute the main path refrigerant from the first integrated refrigerant plate (7) to the evaporator (5), and the converging flow channel is used to converge the refrigerant from the evaporator (5) and send it back to the first integrated refrigerant plate (7); wherein, in the first integrated refrigerant plate (7), a first throttling device (M41) and a second throttling device (M61) are respectively integrated on the jet augmenting branch flow channel and the main path flow channel leading to the second integrated refrigerant plate (8).

2. An integrated refrigerant panel of an air-to-heat pump according to claim 1, characterized in that: The plate body of the first integrated refrigerant plate (7) is provided with: a first interface (101) for connecting the exhaust port of the compressor (1), a second interface (102) for connecting the air injection port, and a third interface (103) for connecting the air suction port; a fourth interface (201), a fifth interface (202), a sixth interface (203) and a seventh interface (204) for connecting the four-way valve (2); an eighth interface (301) for connecting the inlet of the condenser (3) and a ninth interface (302) for connecting the outlet; a tenth interface (401) for connecting the main path inlet of the economizer (4), an eleventh interface (402) for connecting the main path outlet, a twelfth interface (403) for connecting the augmenting branch inlet, and a thirteenth interface (404) for connecting the augmenting branch outlet.

3. An integrated refrigerant panel of an air-to-heat pump according to claim 2, characterized in that: The main path flow channel comprises: a first flow channel (M1), a second flow channel (M2), a third flow channel (M3), a fourth flow channel (M6), a fifth flow channel (M7) and a sixth flow channel (M8); the first flow channel (M1) communicates the first interface (101) and the fourth interface (201); the second flow channel (M2) communicates the fifth interface (202) and the eighth interface (301); the third flow channel (M3) communicates the ninth interface (302) and the tenth interface (401); one end of the fourth flow channel (M6) communicates the eleventh interface (402), and the other end leads to the second integrated refrigerant plate (8); one end of the fifth flow channel (M7) communicates the sixth interface (203), and the other end leads to the second integrated refrigerant plate (8); the sixth flow channel (M8) communicates the seventh interface (204) and the third interface (103).

4. An integrated refrigerant panel of an air-to-heat pump according to claim 3, characterized in that: The internal flow channel of the first integrated refrigerant plate (7) further comprises a jet augmenting branch, which comprises a seventh flow channel (M4) and an eighth flow channel (M5), the inlet of the seventh flow channel (M4) is in common communication with the inlet of the fourth flow channel (M6) to the eleventh interface (402), and the outlet thereof is in communication with the twelfth interface (403); the eighth flow channel (M5) is in communication with the thirteenth interface (404) and the second interface (102).

5. An integrated refrigerant panel of an air-to-heat pump according to claim 4, characterized in that: The first throttling device (M41) is arranged on the seventh flow channel (M4).

6. An integrated refrigerant panel of an air-to-heat pump according to claim 3, characterized in that: The second throttling device (M61) is arranged on the fourth flow channel (M6).

7. An integrated refrigerant panel of an air-to-heat pump according to claim 3, characterized in that: The plate body of the second integrated refrigerant plate (8) is provided with a fourteenth interface group (501) for connecting a plurality of inlets of the evaporator (5) and a fifteenth interface group (502) for connecting a plurality of outlets; the shunt flow channel is a ninth flow channel (M9) in communication with the other end of the fourth flow channel (M6) and the fourteenth interface group (501); and the converging flow channel is a tenth flow channel (M10) in communication with the fifteenth interface group (502) and the other end of the fifth flow channel (M7).

8. An integrated refrigerant panel of an air-to-heat pump according to any of claims 1-7, characterized in that: The first integrated refrigerant plate (7) and the second integrated refrigerant plate (8) are both integrally formed of a metal material.

9. An integrated refrigerant panel of an air-to-heat pump according to claim 8, characterized in that: The metal material is an aluminum alloy.

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