Air heat exchanger and preparation method thereof

Abstract

The invention discloses an air heat exchanger and a preparation method thereof. The air heat exchanger comprises a honeycomb plate and a heat exchange pipe. The honeycomb plate comprises a plurality of air holes penetrating in the first direction and mounting grooves located in at least one surface arranged in the first direction, and the mounting grooves extend in the second direction perpendicular to the first direction. The heat exchange pipe comprises a heat exchange pipe body which is located in the installation groove. The air heat exchanger comprises a honeycomb plate and heat exchange pipes, and part of the heat exchange pipes are arranged in the honeycomb plate in a penetrating mode and make close contact with the honeycomb plate. The honeycomb plate provides a heat exchange area with a huge unit volume, and a very short heat conduction path is created by combining the vertical penetrating design of the heat exchange tubes, so that the volume of the heat exchanger can be reduced by more than 30% compared with that of a traditional finned tube type heat exchanger under the same heat exchange amount, and real high efficiency and compactness are realized.

Description

Technical Field

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

[0002] Air heat exchangers are widely used in air conditioning, ventilation, and waste heat recovery systems to achieve heat exchange between air and fluids (such as refrigerants and water). Traditional finned tube heat exchangers increase the heat exchange area on the air side by stringing fins together on the heat exchange tubes. However, this structure has problems such as high airflow resistance, limited heat exchange efficiency, and potentially large contact thermal resistance between the fins and the tube wall.

[0003] In view of this, the present invention provides an improved air heat exchanger and its manufacturing method to solve one of the above-mentioned technical problems. Summary of the Invention

[0004] The present invention aims to provide an air heat exchanger with a compact structure, high heat exchange efficiency, and low contact thermal resistance, as well as its manufacturing method, to overcome the shortcomings of the prior art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides an air heat exchanger, comprising: a honeycomb panel including a plurality of air holes extending along a first direction and a mounting groove located on at least one surface arranged along the first direction, the mounting groove extending along a second direction perpendicular to the first direction; and a heat exchange tube including a heat exchange tube located within the mounting groove.

[0006] In an optional embodiment, at least half of the heat exchange tube is located within the mounting groove along the circumferential direction.

[0007] In an optional embodiment, the opening size of the mounting groove is larger than the inner size of the groove, or the mounting groove is Ω-shaped.

[0008] In an optional embodiment, the honeycomb panel is an aluminum honeycomb panel, and / or the cross-sectional shape of the air pores after being cut perpendicular to the first direction is hexagonal; and / or, the heat exchange tube is a copper tube.

[0009] In an optional embodiment, the heat exchange tube further includes an inlet pipe and an outlet pipe. The inlet pipe and the outlet pipe are respectively located on both sides of the honeycomb plate, and a plurality of heat exchange tubes are connected in parallel between the inlet pipe and the outlet pipe. Alternatively, the inlet pipe and the outlet pipe are located on the same side of the honeycomb plate, and the heat exchange tube further includes a transfer pipe located on the other side of the honeycomb plate, with some of the heat exchange tubes connected in parallel between the inlet pipe and the transfer pipe, and other heat exchange tubes connected in parallel between the outlet pipe and the transfer pipe. Alternatively, the inlet pipe and the outlet pipe are respectively located on both sides of the honeycomb plate, and the heat exchange tube further includes a distributor connected to the inlet pipe, with a plurality of heat exchange tubes connected in parallel between the distributor and the outlet pipe.

[0010] Secondly, the present invention also provides a method for preparing an air heat exchanger, comprising the following steps: forming a pre-compression groove on at least one surface of a folded honeycomb panel arranged along a first direction, the first direction being perpendicular to the folding direction, the pre-compression groove extending and penetrating along the folding direction; unfolding the honeycomb panel, forming air holes penetrating along the first direction on the honeycomb panel, and deforming the pre-compression groove into an installation groove penetrating along the unfolding direction, the installation groove being Ω-shaped; placing a heat exchange tube in the installation groove; expanding the heat exchange tube, or welding the heat exchange tube to the honeycomb panel, so that the heat exchange tube and the honeycomb panel are in close contact.

[0011] In an optional embodiment, the pre-compression groove has a different cross-sectional shape from the mounting groove, and the cross-sectional shape of the mounting groove is consistent with a portion of the cross-sectional shape of the heat exchange tube.

[0012] Thirdly, the present invention also provides a method for preparing an air heat exchanger, comprising the following steps: a honeycomb panel having pores extending along a first direction; pre-pressing an installation groove on at least one surface of the honeycomb panel arranged along the first direction, wherein the opening size of the installation groove is larger than the inner size of the groove; placing a heat exchange tube in the installation groove; and welding the heat exchange tube to the honeycomb panel so that the heat exchange tube is in close contact with the honeycomb panel.

[0013] In an optional embodiment, the heat exchange tube is placed in the mounting groove in a direction perpendicular to the surface, or the heat exchange tube is inserted into the mounting groove in its unfolding direction. And / or, the mounting groove is configured to accommodate at least half of the heat exchange tube circumferentially.

[0014] In an optional embodiment, the method for preparing the air heat exchanger further includes the following step: before or after placing the heat exchange tube into the mounting groove, covering the edge of the honeycomb panel with a frame.

[0015] In an optional embodiment, the method for preparing the air heat exchanger further includes the following step: connecting an inlet pipe and an outlet pipe to the end of the heat exchange tube.

[0016] In an optional embodiment, an inlet pipe is connected to the same end of all heat exchange tubes along the unfolding direction, and an outlet pipe is connected to the other end of all heat exchange tubes along the unfolding direction.

[0017] In an optional embodiment, a distributor is connected to the same end of all heat exchange tubes along the unfolding direction, an inlet pipe is connected to the inlet of the distributor, and an outlet pipe is connected to the other end of all heat exchange tubes along the unfolding direction.

[0018] In an optional embodiment, the inlet pipe is connected to a portion of the heat exchange tubes on the same end side along the unfolding direction, and the outlet pipe is connected to the other heat exchange tubes; a transfer pipe is connected to the other end side along the unfolding direction of all heat exchange tubes.

[0019] Compared with existing technologies, the present invention has significant advantages: The air heat exchanger of this invention comprises a honeycomb panel and heat exchange tubes, with some of the heat exchange tubes embedded in mounting grooves on the surface of the honeycomb panel and in close contact with it. The honeycomb panel provides a large heat exchange area per unit volume, and combined with the vertical through-hole design of the heat exchange tubes, it creates an extremely short heat conduction path. This allows the heat exchanger to be more than 30% smaller in volume than traditional finned tube heat exchangers for the same heat exchange capacity, achieving true high efficiency and compactness. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of an air heat exchanger according to one embodiment of the present invention.

[0021] Figure 2 for Figure 1 A diagram from another angle.

[0022] Figure 3 for Figure 1 A diagram from another angle.

[0023] Figure 4 This is a three-dimensional structural diagram of an air heat exchanger according to one embodiment of the present invention.

[0024] Figure 5 for Figure 4 A diagram from another angle.

[0025] Figure 6 for Figure 4 A diagram from another angle.

[0026] Figure 7 This is a three-dimensional structural diagram of an air heat exchanger according to one embodiment of the present invention.

[0027] Figure 8 for Figure 7 A diagram from another angle.

[0028] Figure 9 for Figure 7 A diagram from another angle.

[0029] Figure 10 This is a three-dimensional structural diagram of an air heat exchanger according to one embodiment of the present invention.

[0030] In the diagram: 1. Honeycomb panel; 11. Vents; 12. Frame; 2. Heat exchange tube; 21. Liquid inlet pipe; 22. Heat exchange tube; 23. Liquid outlet pipe; 24. Transfer pipe; 25. Dispenser. Detailed Implementation

[0031] The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0032] The terms first, second, third, fourth, etc., used in this invention are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0033] like Figures 1 to 10 The image shows an air heat exchanger according to a preferred embodiment of the present invention. The air heat exchanger includes a honeycomb plate 1 and heat exchange tubes 2. The honeycomb plate 1 includes a plurality of pores 11 extending along a first direction, pore walls surrounding the pores 11, and mounting grooves located on at least one surface arranged along the first direction. The mounting grooves extend along a second direction perpendicular to the first direction, and the heat exchange tubes 22 of the heat exchange tubes 2 are located within the mounting grooves and in close contact with the pore walls.

[0034] The heat exchange tube 2 forms a fluid channel through which heated or cooled fluid flows. The heat of the fluid is rapidly transferred to the honeycomb plate 1 through the tube wall of the heat exchange tube 2, and then exchanges heat with the air through the honeycomb plate 1. The heat transfer path between the air and the fluid is: air → wall of the pore 11 → tube wall of the heat exchange tube 22 → internal fluid.

[0035] The honeycomb panel 1 forms a large, continuous heat exchange area through the pores 11. Due to the very thin pore walls and their tight connection with the tube walls, the heat conduction path is extremely short, and the thermal resistance is significantly reduced. The close contact between the honeycomb panel 1 and the heat exchange tube 22 creates an extremely short heat conduction path, achieving efficient coupling of heat exchange between the air side and the fluid side, and significantly improving the overall heat transfer coefficient (K value).

[0036] A number of parallel, straight, and regularly arranged vents 11 form a regular and smooth airflow channel, providing a smoother airflow path. Compared with traditional staggered and complex fin arrays, the number of vents 11 is continuous along the first direction, which can significantly reduce the pressure loss (pressure drop) when air flows through the heat exchanger. Thus, under the premise of obtaining the same amount of heat exchange, it is possible to achieve heat exchange without a fan and rely solely on natural flow, or to select a lower power fan, thereby reducing system energy consumption and noise.

[0037] In addition, the pore walls of the honeycomb panel 1 have a continuous network structure, forming a highly efficient heat exchanger that can rapidly conduct and diffuse the heat (or cold) on the surface of the heat exchange tube 22 along its planar direction (i.e., the direction of the honeycomb panel 1), making the outlet air temperature more uniform and improving the heat exchange efficiency.

[0038] The heat exchange tube 22 is embedded in the mounting groove on the surface of the honeycomb panel 1, giving the air heat exchanger the characteristics of high performance, lightweight and compactness. This makes it not only suitable for traditional household air conditioners, commercial air conditioners, and fresh air heat recovery, but also has great application potential in cutting-edge fields with higher requirements for energy efficiency, weight and space, such as new energy vehicle thermal management (battery cooling, air conditioning), data centers, aerospace environmental control systems, and high-end equipment heat dissipation.

[0039] In some embodiments, the honeycomb panel 1 is an aluminum honeycomb panel 1. Aluminum's thermal conductivity (approximately 237 W / (m·K)) is much higher than most engineering alloys and steel, enabling it to rapidly transfer heat from the heat exchange tubes 2 to the walls of each pore 11 of the honeycomb panel 1, fully utilizing its expanded heat exchange surface. Simultaneously, aluminum has a low density (approximately 2.7 g / cm³), which is a decisive advantage for applications requiring lightweight construction. Furthermore, a dense alumina protective film easily forms on the surface of aluminum, providing excellent resistance to atmospheric corrosion. This allows the air heat exchanger composed of the aluminum honeycomb panel 1 and the heat exchange tubes 2 to operate stably for extended periods in normal temperature and humidity environments, resulting in a long service life.

[0040] In addition, aluminum foil has good ductility and plastic deformation ability. In the folded state, aluminum foil can be easily rolled or stamped to form a pre-pressed groove with precise shape and no tearing; during the unfolding process, aluminum can undergo plastic deformation smoothly, so that the pre-pressed groove can be stably and regularly transformed into the installation groove required by the design, while the honeycomb pore structure 11 is perfectly formed.

[0041] In some embodiments, the cross-sectional shape of the pores 11 after being cut perpendicular to the first direction is hexagonal. In a two-dimensional plane, a regular hexagon can enclose the largest area with the least perimeter. Therefore, for a honeycomb panel 1 of the same volume, the hexagonal pores 11 can provide the largest pore wall surface area (i.e., air-side heat transfer area), thus maximizing the heat transfer area. The regular hexagonal parallel flow channels guide the air to form a stable and uniform flow. When the air flows in it, the boundary layer development is relatively stable, and the tendency of flow separation is small. It can provide a huge heat transfer surface while maintaining a relatively low air flow resistance (pressure drop), achieving a balance between high efficiency and low energy consumption.

[0042] Furthermore, the air heat exchanger also includes a frame 12 that covers the edge of the honeycomb panel 1. The frame 12 covers the edge of the honeycomb panel 1 and is connected to the internal heat exchange tubes 2 by mechanical or welding methods, together forming a rigid frame structure. This greatly enhances the bending and torsional resistance of the entire air heat exchanger, completely solving the problem of the bare honeycomb panel 1 being easily damaged at the edge and having poor integrity. It can effectively resist physical damage to the fragile honeycomb panel 1 edges caused by collisions and scratches that may occur during transportation, installation, and use.

[0043] In one embodiment, the frame 12 is an aluminum frame 12 or a steel frame 12.

[0044] The heat exchange tube 22 is assembled with the honeycomb panel 1 in such a way that at least half of the heat exchange tube 22 is located within the mounting groove along the circumferential direction. That is, radially, the mounting groove encloses at least half of the heat exchange tube 22. Based on this assembly method, the stability of the connection between the heat exchange tube 22 and the honeycomb panel 1 can be guaranteed, ensuring effective heat transfer between the two.

[0045] In some alternative embodiments, the opening size of the mounting slot is larger than the inner size of the slot. The heat exchange tube 22 can be directly inserted into the mounting slot from a direction perpendicular to the surface of the honeycomb panel 1, without having to be inserted from the side of the honeycomb panel 1, which greatly simplifies the operation and is particularly suitable for production processes where the heat exchange tube 2 needs to be assembled with other components as a whole before being assembled with the honeycomb panel 1.

[0046] After the heat exchange tube 22 is placed into the mounting groove, a good space for brazing filler metal is formed between the shoulder of the groove and the tube wall. During welding (especially brazing), the molten brazing filler metal can evenly fill the entire gap under capillary action, which easily forms a full, full-circumferential weld, thereby achieving a metallurgical bond with high strength and high sealing performance.

[0047] In some alternative embodiments, the mounting slots are Ω-shaped. The heat exchange tubes 22 slide parallel to the extension direction of the mounting slot (i.e., the second direction). This assembly method is extremely smooth and particularly suitable for automated, continuous production. The production line can be designed to fix the honeycomb panel 1, and a robotic arm grips long tubes or tube bundles and inserts them horizontally into multiple parallel Ω-shaped slots in one go, resulting in high production efficiency.

[0048] The Ω-shaped mounting groove has a large contact area with the heat exchange tube 22, which can prevent the heat exchange tube 22 from detaching from the direction perpendicular to the surface. Therefore, the heat exchange tube 22 and the honeycomb panel 1 can be tightly contacted by tube expansion or welding processes.

[0049] In some embodiments, the heat exchange tube 22 is made of copper. Copper has a high thermal conductivity, approximately 400 W / (m·K), ensuring heat exchange on the fluid side. Copper also has good plasticity and ductility, resulting in uniform deformation and minimal springback during mechanical expansion, easily achieving a tight interference fit with the mounting groove wall of the aluminum honeycomb panel 1, and the expanded joint has high fatigue strength. Furthermore, there are mature welding processes available for copper materials and aluminum plates, ensuring close contact between the two.

[0050] In one specific embodiment, a plurality of heat exchange tubes 22 are located on one surface of the honeycomb panel 1. The air heat exchanger is a thin layer with low airflow resistance and can also serve as the outer shell wall of the equipment, optimizing the installation space.

[0051] In other embodiments, the heat exchange tubes 22 may also be disposed on two surfaces of the honeycomb panel 1. Air flows sequentially through the two rows of tube bundles, exchanging heat with each row of heat exchange tubes 22, and its temperature is changed progressively and gradually. This allows the heat exchanger to achieve a larger total air-side temperature difference, or to require a shorter total length of heat exchange tubes 22 for the same air temperature change requirements.

[0052] The heat exchange tube 2 also includes an inlet pipe 21 and an outlet pipe 23, with several heat exchange tubes 22 connected in series or in parallel between the inlet pipe 21 and the outlet pipe 23. The air heat exchanger can be directly connected to an air conditioner, etc., through the inlet pipe 21 and the outlet pipe 23.

[0053] In one optional implementation, please refer to Figures 1 to 3 As shown, the inlet pipe 21 and the outlet pipe 23 are located on both sides of the honeycomb plate 1, and several heat exchange pipes 22 are connected in parallel between the inlet pipe 21 and the outlet pipe 23.

[0054] Fluid is distributed from the inlet pipe 21 on one side into several heat exchange pipes 22, and flows through each heat exchange pipe 22 along the shortest straight path before merging into the outlet pipe 23 on the other side. The flow path length of the heat exchange pipe 22 is approximately equal to the dimension of the honeycomb panel 1 in the second direction, thus minimizing the overall flow path of the fluid and reducing the flow resistance along the path.

[0055] In this embodiment, several heat exchange tubes 22 are arranged in parallel. By utilizing the excellent lateral thermal conductivity and temperature uniformity of the honeycomb plate 1, the local temperature difference caused by uneven flow in each heat exchange tube 22 is effectively compensated, so that the temperature of the entire heat exchange surface tends to be uniform, and this simplest structure can still achieve a stable and good overall heat exchange effect.

[0056] Specifically, the inlet pipe 21 and the outlet pipe 23 both extend in a direction perpendicular to the second direction, and the inlet pipe 21 and the outlet pipe 23 are located on both sides of the honeycomb plate 1 in the second direction. The heat exchange pipe 22 is perpendicularly connected to the inlet pipe 21 and the outlet pipe 23, and the path impedance of each heat exchange is basically the same, so that the flow of fluid in each heat exchange tends to be basically the same.

[0057] In one optional implementation, please refer to Figures 4 to 6 As shown, the inlet pipe 21 and the outlet pipe 23 are located on the same side of the honeycomb plate 1. The heat exchange tube 2 also includes a transfer pipe 24 located on the other side of the honeycomb plate 1. Some heat exchange tubes 22 are connected in parallel between the inlet pipe 21 and the transfer pipe 24, and other heat exchange tubes 22 are connected in parallel between the outlet pipe 23 and the transfer pipe 24.

[0058] In this embodiment, the inlet pipe 21 and the outlet pipe 23 are concentrated on the same side of the honeycomb panel 1, which facilitates installation in the system. For example, when the air heat exchanger is integrated into a limited space such as an air conditioning unit or equipment compartment, the inlet pipe 21 and the outlet pipe 23 can be connected on one side, which simplifies the external piping design, saves installation space, and makes maintenance and repair more convenient.

[0059] The various parts of heat exchange tube 2 collectively define a U-shaped flow path. Fluid enters from the inlet pipe 21 on one side, flows through the first section of heat exchange tube 22 to the transfer pipe 24 on the other side, then flows back through the second section of heat exchange tube 22, and finally exits from the outlet pipe 23 on the same side. Its total flow path length is approximately twice the width of the honeycomb plate 1. The longer flow path doubles the contact time between the fluid and air, allowing for greater temperature changes (larger temperature rises or falls), thus increasing the heat exchanger's capacity.

[0060] In one embodiment, the number of heat exchange tubes 22 connected to the inlet pipe 21 is greater than the number of heat exchange tubes 22 connected to the outlet pipe 23. Since the temperature difference between the fluid and air in the heat exchange tubes 22 connected to the inlet pipe 21 is large, increasing the area of ​​this portion of the heat exchange tubes 22 and reducing the flow velocity in this portion with the large temperature difference is more conducive to improving heat exchange performance.

[0061] In one embodiment, the inlet pipe 21 and the outlet pipe 23 are the same pipe, separated by a partition. Typically, they are formed by welding two pipes to the partition.

[0062] In one optional implementation, please refer to Figures 7 to 10 As shown, the inlet pipe 21 and the outlet pipe 23 are located on both sides of the honeycomb plate 1, and the heat exchange tube 2 also includes a distributor 25 connected to the inlet pipe 21, and several heat exchange tubes 22 are connected in parallel between the distributor 25 and the outlet pipe 23.

[0063] In this embodiment, the fluid is evenly distributed to each parallel heat exchange tube 22 by the distributor 25, ensuring that the flow rate of each tube is consistent to the best, avoiding some heat exchange tubes 22 being idle or overloaded, and fundamentally eliminating the problem of uneven distribution caused by the length of the tubes.

[0064] With uniform flow distribution, each heat exchange tube 22 operates in the same state, releasing or absorbing consistent amounts of heat. This prevents individual heat exchange tubes 22 from overheating (in heating mode) or frosting (in cooling mode) due to insufficient flow, greatly improving the operational stability and long-term reliability of the air heat exchanger and the entire thermal management system under harsh conditions. Combined with the temperature uniformity characteristics of the honeycomb panel 1, the temperature field of the entire heat exchange surface can reach the theoretically most uniform state.

[0065] With the distributor 25 ensuring uniform flow rate of each heat exchange tube 22, several heat exchange tubes 22 can be arranged in an array on a non-planar aluminum honeycomb plate 1, thereby reducing the volume of the air heat exchanger while ensuring the heat exchange area.

[0066] The air heat exchanger of this invention, based on the cooperation of heat exchange tube 2 and honeycomb plate 1, can achieve efficient heat exchange. Therefore, it can be used independently without a fan. Even if a fan is provided, it is not necessary to bind the fan to the air heat exchanger; the fan can simply be placed within the space where the air heat exchanger is located. The main purpose of the fan is to agitate the airflow, allowing the air to naturally pass through the vents 11 to achieve heat exchange. Furthermore, it can reduce the power consumption of the accompanying fan and improve the overall system's coefficient of performance (COP).

[0067] The inventors discovered that while the honeycomb panel 1 structure has significant advantages in heat exchange applications due to its large surface area and good structural rigidity per unit volume, how to efficiently, stably, and with low thermal resistance integrate the heat exchange tube 2 with the honeycomb panel 1 remains a challenge for existing technologies.

[0068] If a plate is used as an intermediary to bond a plate to the surface of the honeycomb panel 1, and then the heat exchange tube 22 is welded to the plate, the plate may affect the airflow and reduce the heat exchange performance. If the mounting groove for installing the heat exchange tube 22 is directly formed on the surface of the honeycomb panel 1, the pore walls of the honeycomb panel 1 are very thin and have low strength, making it impossible to form a mounting groove that matches the heat exchange tube 22 on the unfolded honeycomb panel 1 through processes such as rolling and drilling.

[0069] The inventors further discovered that in the folded honeycomb panel 1, the hole walls fit together tightly and are not easily deformed, making it easy to fix and perform high-precision stamping, drilling, or laser cutting. This invention chooses to create the grooves in the folded state, avoiding the difficulty of machining mounting grooves on the unfolded three-dimensional structure.

[0070] This invention provides a method for manufacturing an air heat exchanger, comprising the following steps: S1 Forming a pre-compression groove on at least one surface of a folded honeycomb plate 1 arranged along a first direction, the first direction being perpendicular to the folding direction, the pre-compression groove extending and penetrating along the folding direction. S2 Unfolding the honeycomb plate 1, forming air holes 11 penetrating along the first direction on the honeycomb plate 1, and deforming the pre-compression groove into an installation groove penetrating along the unfolding direction, the installation groove being Ω-shaped. S3 Placing a heat exchange tube 22 into the installation groove. S4 Expanding the heat exchange tube 22, or welding the heat exchange tube 22 to the honeycomb plate 1, so that the heat exchange tube 22 and the honeycomb plate 1 are in close contact.

[0071] S1 to S4 do not represent a unique sequence of steps; other steps may be included between adjacent steps.

[0072] When the honeycomb panel 1 is in a folded state, a pre-pressing groove is processed on the honeycomb panel 1. This can make full use of the structural rigidity of the honeycomb panel 1 after folding, avoid the problem of easy deformation of thin-walled structure in unfolded state, and improve the processing accuracy and consistency of the groove.

[0073] When the folded honeycomb panel 1 is unfolded, it changes from a compressed state to a stretched state, and the internal pore walls undergo complex spatial position changes, forming pores 11 that extend along the first direction inside. Correspondingly, the edge of the pre-compression groove is stretched and rotated, and its geometry is deformed to form an installation groove suitable for the installation of the heat exchange tube 22.

[0074] This invention uses software simulation and calculation to determine the changes in the mounting groove when the honeycomb panel 1 is folded and unfolded. Based on the shape of the mounting groove used to match the heat exchange tube 22 in the unfolded state, the shape of the pre-compression groove corresponding to the mounting groove when the honeycomb panel 1 is folded is deduced. A pre-compression groove is formed on the folded honeycomb panel 1. When the honeycomb panel 1 is unfolded, the pre-compression groove can accurately and predictably deform into the mounting groove of the target shape.

[0075] The present invention forms a pre-compression groove on the surface of the folded honeycomb panel 1, and then unfolds the honeycomb panel 1 to deform the pre-compression groove into an installation groove, and places the heat exchange tube 22 in the installation groove. This invention perfectly solves this long-standing manufacturing bottleneck and makes it possible to mass-produce high-performance honeycomb panel 1 heat exchangers, so as to achieve low-cost, high-quality mass production.

[0076] After placing the heat exchange tube 22 into the mounting groove, the tube is expanded slightly to increase its diameter, generating uniform radial pressure on the wall of the mounting groove and achieving an interference fit. This ensures that the heat exchange tube 22 is in close contact with the honeycomb panel 1. The large-area micro-adhesion between the tube wall and the honeycomb wall greatly eliminates air gaps, reduces contact thermal resistance, and allows heat to be conducted between the tube wall and the honeycomb panel 1 with almost no loss.

[0077] Alternatively, after placing the heat exchange tube 22 in the mounting groove, weld the heat exchange tube 22 to the honeycomb panel 1 so that the contact surfaces of the two are fused together to achieve tight contact. After welding, the heat exchange tube 22 and the honeycomb panel 1 are connected as one unit, with high connection strength and good heat conduction performance.

[0078] Whether it's the interference fit and clamping force generated by mechanical tube expansion or the metallurgical bond formed by welding, the connection between the heat exchange tube 22 and the honeycomb plate 1 is very strong. This connection method has good vibration resistance and can effectively prevent contact loosening and increased thermal resistance caused by thermal expansion and contraction or vibration during long-term operation, resulting in a long service life and high reliability.

[0079] This invention forms a pre-compression groove on the folded honeycomb panel 1, which facilitates high-speed, automated, and high-precision continuous production. Unfolding the honeycomb panel 1, preventing heat exchange tubes 22 from expanding, or welding can also be designed as an assembly line operation. This process route offers high repeatability and minimal quality fluctuations, making it highly suitable for industrial mass production.

[0080] Precisely forming the pre-compression groove is crucial for ensuring the successful assembly of the heat exchange tube 22 and the honeycomb panel 1. This invention can employ, but is not limited to, the following grooving processes: CNC milling, stamping, laser cutting, ultrasonic cutting, etc.

[0081] Preferably, the preload groove is prepared using CNC milling. A milling cutter with a size smaller than the mounting groove is used to form the preload groove.

[0082] In an optional embodiment, the pre-compression groove and the installation groove have different cross-sectional shapes, and the cross-sectional shape of the installation groove is consistent with a portion of the cross-sectional shape of the heat exchange tube 22.

[0083] When the mounting slot is Ω-shaped, the heat exchange tube 22 is inserted into the mounting slot along the unfolding direction. The production line can be designed to fix the honeycomb panel 1, and the robot arm clamps the long tube or tube bundle and inserts it horizontally into multiple parallel Ω-shaped mounting slots at one time, which results in high production efficiency.

[0084] The Ω-shaped mounting groove has a large contact area with the heat exchange tube 22, naturally wrapping around most of the circumference of the heat exchange tube 22 and playing a role in pre-positioning the heat exchange tube 22. Tight contact between the two can be achieved by tube expansion or welding processes.

[0085] In one embodiment, the heat exchange tube 22 is expanded to achieve tight contact between the heat exchange tube 22 and the honeycomb plate 1. The Ω-shaped arc profile closely matches the shape of the circular heat exchange tube 2. During tube expansion, the tube wall expands outward uniformly, making surface contact with the arc-shaped inner wall of the Ω-shaped groove. This results in low stress concentration, uniform contact pressure, and a stable and reliable interference fit.

[0086] In this invention, the tube expander can be a mechanical expander, a hydraulic expander, or a pneumatic expander. The pressure can be adjusted adaptively according to the material, shape, etc. of the heat exchange tube 22.

[0087] In one specific embodiment, hydraulic expansion is used. When the heat exchange tube 22 is made of copper with an outer diameter of 4 mm and an inner diameter of 3 mm, the pressure range is from 40 MPa to 45 MPa.

[0088] The preparation method of the air heat exchanger also includes the following steps: before or after the heat exchange tube 22 is placed into the mounting groove, the edge of the honeycomb plate 1 is covered with the frame 12 to protect the edge of the honeycomb plate 1.

[0089] In one embodiment, a frame 12 is placed before the heat exchange tube 22 is placed in the mounting slot. The frame 12 provides a protective frame and positioning reference for the honeycomb panel 1, enhances the overall rigidity of the honeycomb panel 1, effectively prevents the honeycomb panel 1 from deforming under stress in subsequent processes, and ensures the consistency of the manufacturing process and the yield rate.

[0090] In another embodiment, the frame 12 is covered after the heat exchange tube 22 is placed in the mounting groove. Preferably, the frame 12 is covered after the tube is expanded or welded. Before covering the frame, the connection between the heat exchange tube 22 and the honeycomb panel 1 can be visually inspected or non-destructively tested without obstruction. If defects are found, they can be repaired directly without removing the frame 12, greatly reducing rework costs.

[0091] Additionally, the frame 12 has through holes corresponding to the mounting groove, through which the heat exchange tube 22 passes. The manufacturing method of the present invention also includes a step of welding the heat exchange tube 22 to the frame 12 to increase the stability of the product.

[0092] The method for preparing an air heat exchanger also includes the following steps: connecting an inlet pipe 21 and an outlet pipe 23 to the end of the heat exchange tube 22. Connecting the inlet pipe 21 and the outlet pipe 23 forms an air heat exchanger with a complete fluid passage function, which can be directly integrated into an air conditioning, refrigeration, or heating system.

[0093] In one embodiment, an inlet pipe 21 is connected to the same end of all heat exchange tubes 22 along the unfolding direction, and an outlet pipe 23 is connected to the other end of all heat exchange tubes 22 along the unfolding direction, forming a... Figures 1 to 3 The air heat exchanger shown.

[0094] In one embodiment, at the same end of all heat exchange tubes 22 along the unfolding direction, an inlet pipe 21 is connected to a portion of the heat exchange tubes 22, and an outlet pipe 23 is connected to the other heat exchange tubes 22. A transfer pipe 24 is connected to the other end of all heat exchange tubes 22 along the unfolding direction, forming a configuration as follows: Figures 4 to 6 The air heat exchanger shown.

[0095] In one embodiment, a distributor 25 and an inlet pipe 21 are connected to the same end of all heat exchange tubes 22 along the unfolding direction, and an outlet pipe 23 is connected to the other end of all heat exchange tubes 22 along the unfolding direction, forming a... Figures 7 to 10 The air heat exchanger shown.

[0096] The present invention also provides a method for manufacturing an air heat exchanger, wherein an mounting groove is formed directly on an unfolded honeycomb panel 1. The manufacturing method includes the following steps: P1 The honeycomb panel has pores extending along a first direction, and a mounting groove is pre-pressed to form on at least one surface of the honeycomb panel arranged along the first direction, wherein the opening size of the mounting groove is larger than the inner size of the groove. P2 Heat exchange tubes 22 are placed in the mounting groove. P3 The heat exchange tubes 22 are welded to the honeycomb panel 1 to ensure close contact between the heat exchange tubes 22 and the honeycomb panel 1.

[0097] P1 to P3 do not represent a unique sequence of steps; other steps may be included between adjacent steps.

[0098] In one embodiment, the mounting groove is formed by pre-pressing the unfolded honeycomb panel 1 onto its surface using a molding roller that matches the shape of the mounting groove. The hole walls of the honeycomb panel 1 are bent during pre-pressing, which increases the contact area with the heat exchange tube 22 and ensures the stability of the welding.

[0099] In an optional embodiment, the mounting groove is configured to accommodate at least half of the heat exchange tube 22 circumferentially. That is, the mounting groove encloses at least half of the heat exchange tube 22. For welding processes, a larger contact area allows for a more continuous and robust weld, improving the mechanical strength and long-term thermal reliability of the connection.

[0100] When the opening size of the mounting slot is larger than the inner size of the slot, the heat exchange tube 22 is placed in the mounting slot in a direction perpendicular to the surface, and the heat exchange tube 22 is welded to the honeycomb panel 1. The operation process is simple. Alternatively, the heat exchange tube 22 can be threaded through the mounting slot. The production line can be designed to fix the honeycomb panel 1, and a robotic arm can grip long tubes or tube bundles and thread them horizontally into multiple parallel Ω-shaped mounting slots in one go, resulting in high production efficiency.

[0101] To ensure welding quality, solder is applied to the mounting groove before the heat exchange tube 22 is placed in the furnace for welding. Alternatively, solder can be applied directly to the heat exchange tube 22.

[0102] The preparation method also includes steps such as frame 12, connecting inlet pipe 21 and outlet pipe 23, which are the same as the above method and will not be described again here.

[0103] The air heat exchanger of the present invention achieves lightweight, low-cost, and high-efficiency heat exchange by assembling the heat exchange tube 22 into the mounting groove on the surface of the honeycomb panel 1. This structure enables pre-processing in a folded state, solving the problem of precision assembly in a molded honeycomb structure and realizing a high-quality, low-cost, and mass-producible manufacturing path.

[0104] The following specific embodiments will be provided to illustrate the air heat exchanger and its preparation method of the present invention in detail.

[0105] Example 1.

[0106] Reference Figures 1 to 3 The air heat exchanger in this embodiment includes a honeycomb plate 1 and a heat exchange tube 2.

[0107] The honeycomb panel 1 is an aluminum honeycomb panel 1, which has a large number of regular hexagonal pores 11 that extend along a first direction inside. Multiple semi-circular mounting grooves 12 extending along a second direction and extending through the surface of the honeycomb panel 1 are formed.

[0108] The heat exchange tube 2 includes multiple parallel heat exchange tubes 22, a liquid inlet pipe 21, and a liquid outlet pipe 23. The heat exchange tubes 22 are inserted into corresponding semi-circular mounting grooves 12, with half of their circular tube bodies being enclosed by the mounting grooves. The liquid inlet pipe 21, heat exchange tubes 22, and liquid outlet pipe 23 are all made of copper.

[0109] The inlet pipe 21 and outlet pipe 23 are located on both sides of the honeycomb panel 1 (the upper and lower sides in the figure), respectively. All heat exchange tubes 22 are connected in parallel between the inlet pipe 21 and the outlet pipe 23. Each heat exchange tube 22 passes through the honeycomb panel 1 along a second direction perpendicular to the first direction. The tube wall of the heat exchange tube 22 is tightly bonded to the hole wall of the honeycomb panel 1 by welding, forming a low thermal resistance connection.

[0110] During operation, the refrigerant or liquid enters through the inlet pipe 21 and is evenly distributed to each heat exchange tube 22. As it flows through the heat exchange tube 22, it exchanges heat with the air flowing through the vent 11 through the tube wall, and finally converges into the outlet pipe 23 and flows out. The air in the vent 11 is in full contact with the outer wall of the heat exchange tube 22, resulting in high heat exchange efficiency.

[0111] Aluminum honeycomb panels can be precisely pre-processed in a folded state and undergo controllable plastic deformation after unfolding to form the target shape of the mounting groove. They are also resistant to springback or cracking, ensuring a high success rate and consistency in the process. Copper tubes and aluminum honeycomb panels can achieve a tight mechanical bond through a mature expansion joint process, or a reliable metallurgical bond through welding.

[0112] Example 2 Reference Figures 4 to 6The main difference between this embodiment and embodiment 1 is the connection method of the liquid inlet pipe 21, the liquid outlet pipe 23, and the heat exchange pipe 22.

[0113] In this embodiment, the inlet pipe 21 and the outlet pipe 23 are located on the same side of the honeycomb plate 1, and a transfer pipe 24 is provided on the other side. A portion of the heat exchange pipes 22 are connected between the inlet pipe 21 and the transfer pipe 24, and another portion of the heat exchange pipes 22 are connected between the outlet pipe 23 and the transfer pipe 24, forming a series flow path, which can increase the flow rate of the fluid in the pipe and the heat exchange time.

[0114] Example 3 The main difference between this embodiment and Embodiment 1 is that a distributor 25 is added to the side of the inlet pipe 21. The inlet pipe 21 is connected to the inlet of the distributor 25, and the multiple outlets of the distributor 25 are respectively connected to one end of multiple heat exchange tubes 22. The other ends of these heat exchange tubes 22 are connected in parallel to the outlet pipe 23.

[0115] The distributor 25 ensures that the flow distribution of multiple parallel heat exchange tubes 22 is uniform, which helps to further improve the heat exchange uniformity.

[0116] Example 4 Design of the pre-compression groove: The cross-sectional shape of the mounting groove on the surface of the honeycomb panel 1 (unfolded state) is determined based on the shape of the heat exchange tube 22. The shape of the pre-compression groove corresponding to the transition of the mounting groove from the unfolded state to the folded state is simulated and calculated. Specifically, taking the circular heat exchange tube 22 as an example, the shape of the mounting groove is Ω-shaped, and the shape of the pre-compression groove is arc-shaped, specifically a part of an ellipse.

[0117] Forming pre-compression grooves: By taking a piece of aluminum honeycomb panel 1 in a folded state, several pre-compression grooves are formed on one surface of it in the first direction using a CNC milling cutter.

[0118] Unfolding and forming: The folded blank with pre-compression grooves is unfolded to form a honeycomb panel 1 with regular hexagonal pores 11. During this process, the pre-compression grooves undergo plastic deformation as the material unfolds, becoming mounting grooves that extend along the second direction.

[0119] Assemble the heat exchange tubes 22: Insert multiple copper heat exchange tubes 22 sequentially into each mounting groove 12 along the second direction.

[0120] Fixed connection: Each heat exchange tube 22 is expanded using a hydraulic tube expansion process, causing it to expand slightly and fit tightly against the inner wall of the mounting groove 12, generating a certain clamping force.

[0121] Add frame 12 and piping: Wrap and fix aluminum frame 123 around the honeycomb panel 1. Finally, according to... Figure 1In this method, one end of all the heat exchange tubes 22 is assembled and welded to the liquid inlet pipe 21, and the other end is assembled and welded to the liquid outlet pipe 23, thus completing the preparation of the air heat exchanger.

[0122] Example 5 Forming the mounting groove: Using a pressure roller that matches the shape of the mounting groove, pressure is applied to the surface of the unfolded honeycomb panel 1 to form the mounting groove.

[0123] Assemble the heat exchange tubes 22: Insert multiple copper heat exchange tubes 22 sequentially into each mounting groove 12 along the second direction, or place them directly in the mounting groove on the vertical surface.

[0124] Fixed connection: The heat exchange tube 22 and the aluminum honeycomb panel 1 are integrally brazed using a vacuum brazing furnace to form a metallurgical bond at the mounting groove 12.

[0125] Add frame 12 and piping: Wrap and fix aluminum frame 123 around the honeycomb panel 1. Finally, according to... Figure 1 In this method, one end of all the heat exchange tubes 22 is assembled and welded to the liquid inlet pipe 21, and the other end is assembled and welded to the liquid outlet pipe 23, thus completing the preparation of the air heat exchanger.

[0126] In summary, in the air heat exchanger of the present invention, some heat exchange tubes 2 are embedded in a surface of the honeycomb plate 1 and are in close contact with the honeycomb plate 1. The honeycomb plate 1 provides a huge heat exchange area per unit volume. Combined with the vertical through-through design of the heat exchange tubes 22, an extremely short heat conduction path is created, so that the volume of the heat exchanger can be reduced by more than 30% compared with the traditional finned tube heat exchanger under the same heat exchange capacity, achieving true high efficiency and compactness.

[0127] The above description, based on the embodiments shown in the figures, details the structure, features, and effects of the present invention. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.

Claims

1. An air heat exchanger, characterized in that, include: A honeycomb panel includes a plurality of air holes penetrating along a first direction and a mounting groove located on at least one surface arranged along the first direction, the mounting groove extending along a second direction perpendicular to the first direction. A heat exchange tube, including a heat exchange tube, is located within the mounting groove.

2. The air heat exchanger according to claim 1, characterized in that: At least half of the heat exchange tube is located within the mounting groove along its circumferential direction.

3. The air heat exchanger according to claim 1, characterized in that: The opening size of the mounting groove is larger than the inner size of the groove, or the mounting groove is Ω-shaped.

4. The air heat exchanger according to claim 1, characterized in that: The honeycomb panel is an aluminum honeycomb panel, and / or the cross-sectional shape of the air pores after being cut perpendicular to the first direction is hexagonal; and / or the heat exchange tube is a copper tube.

5. The air heat exchanger according to any one of claims 1 to 4, characterized in that: The heat exchange tube also includes a liquid inlet pipe and a liquid outlet pipe; wherein The inlet pipe and the outlet pipe are located on both sides of the honeycomb plate, and a number of heat exchange pipes are connected in parallel between the inlet pipe and the outlet pipe. Alternatively, the inlet pipe and the outlet pipe are located on the same side of the honeycomb plate, and the heat exchange tube also includes a transfer pipe located on the other side of the honeycomb plate. Some of the heat exchange tubes are connected in parallel between the inlet pipe and the transfer pipe, and other heat exchange tubes are connected in parallel between the outlet pipe and the transfer pipe. Alternatively, the inlet pipe and the outlet pipe are located on both sides of the honeycomb plate, and the heat exchange tube also includes a distributor connected to the inlet pipe, with a plurality of heat exchange tubes connected in parallel between the distributor and the outlet pipe.

6. A method for preparing an air heat exchanger, characterized in that: Includes the following steps: A pre-compression groove is formed on at least one surface of the folded honeycomb panel arranged along a first direction, the first direction being perpendicular to the folding direction, and the pre-compression groove extending and penetrating along the folding direction. Unfold the honeycomb panel, form air holes that extend along the first direction on the honeycomb panel, and deform the pre-compression groove into an installation groove that extends along the unfolding direction, the installation groove being Ω-shaped; Place the heat exchange tube into the mounting slot; The heat exchange tube is expanded or welded to the honeycomb plate to ensure close contact between the heat exchange tube and the honeycomb plate.

7. The method for preparing an air heat exchanger according to claim 6, characterized in that: The pre-compression groove has a different cross-sectional shape than the mounting groove, and the cross-sectional shape of the mounting groove is consistent with a portion of the cross-sectional shape of the heat exchange tube.

8. A method for preparing an air heat exchanger, characterized in that: Includes the following steps: The honeycomb panel has pores that extend along the first direction, and a mounting groove is pre-pressed on at least one surface of the honeycomb panel arranged along the first direction, wherein the opening size of the mounting groove is larger than the inner size of the groove. Place the heat exchange tube into the mounting slot; The heat exchange tube is welded to the honeycomb panel to ensure close contact between the heat exchange tube and the honeycomb panel.

9. The method for preparing an air heat exchanger according to claim 8, characterized in that: The heat exchange tube is placed in the mounting groove in a direction perpendicular to the surface, or the heat exchange tube is inserted into the mounting groove in the unfolding direction. And / or, the mounting slot is configured to accommodate at least half of the heat exchange tube in the circumferential direction.

10. The method for preparing an air heat exchanger according to any one of claims 6 to 9, characterized in that: It also includes the following steps: before or after placing the heat exchange tube into the mounting groove, covering the edge of the honeycomb panel with a frame; Alternatively, it may include the following steps: connecting an inlet pipe and an outlet pipe to the end of the heat exchange tube; wherein Connect the inlet pipe to the same end of all heat exchange tubes along the expansion direction, and connect the outlet pipe to the other end of all heat exchange tubes along the expansion direction. Alternatively, a distributor can be connected to the same end of all heat exchange tubes along the unfolding direction, an inlet pipe can be connected to the inlet of the distributor, and an outlet pipe can be connected to the other end of all heat exchange tubes along the unfolding direction. Alternatively, on the same end side along the unfolding direction of all heat exchange tubes, the inlet pipe is connected to a portion of the heat exchange tubes, and the outlet pipe is connected to the other heat exchange tubes; Connect the transfer pipe to the other end of all heat exchange tubes along the unfolding direction.

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