High-performance light-weight automobile parallel flow condenser

Abstract

This utility model discloses a high-performance, lightweight automotive parallel-flow condenser, belonging to the technical field of automotive air conditioning heat exchangers. The condenser includes a manifold, refrigerant inlet and outlet, multiple rows of flat tubes, corrugated finned windows, upper and lower clamps, an integrated liquid receiver dryer, and mounting clips. The inner wall of the manifold has spiral grooves to guide the refrigerant into a swirling flow, while simultaneously reducing overall weight. The two ends of the flat tubes are flat tube arc surfaces, seamlessly fitting the inner wall of the manifold. The corrugated finned windows are brazed to the flat tubes, increasing the heat exchange area. The liquid receiver dryer is integrated into the top of the right-side manifold, with a built-in dryer core, simplifying the piping structure. The upper and lower clamps are made of aluminum alloy. Through multi-component collaborative design, uniform refrigerant distribution, reduced flow pressure loss, and lightweight structure are achieved, resulting in reduced overall weight and improved heat exchange efficiency. It also enhances vibration resistance and installation reliability, making it suitable for automotive air conditioning systems.

Description

Technical Field

[0001] This utility model relates to the field of automotive air conditioning heat exchanger technology, and in particular to a high-performance, lightweight automotive parallel flow condenser, which is especially suitable for electric vehicle air conditioning systems that are sensitive to heat dissipation performance, space layout, and weight. Background Technology

[0002] Traditional automotive parallel flow condensers suffer from structural redundancy (such as thick-walled manifolds and high-density fins), uneven refrigerant distribution (rough manifold channels and high pressure loss at the flat tube inlet), poor installation reliability (rigid bolt connections are prone to loosening), and low system integration (independent liquid receiver dryers occupy space and pose a high risk of leakage). These defects result in problems such as heavy weight, low heat exchange efficiency (loss of more than 15%), and short lifespan (corrosion in coastal environments reduces lifespan by 30-40%).

[0003] Existing improvement solutions, such as microchannel flat tubes and carbon fiber manifolds, still face technical bottlenecks such as soaring pressure loss and poor reliability of welding dissimilar materials, making it difficult to meet the stringent requirements of automobiles for efficient and lightweight thermal management systems. To address this, we propose a high-performance and lightweight automotive parallel flow condenser. Utility Model Content

[0004] To address the aforementioned issues, this invention provides a high-performance, lightweight automotive parallel-flow condenser that improves the overall performance of traditional condensers while ensuring efficient heat exchange through lightweight structural design, optimized flow channels, highly reliable installation, and integrated functional components.

[0005] The technical solution of this utility model is:

[0006] A high-performance, lightweight automotive parallel-flow condenser includes two manifolds disposed on both sides;

[0007] The refrigerant outlet and refrigerant inlet are located on one side of the manifold, communicating with the inner wall of the manifold, and are fixed to the manifold by laser welding.

[0008] A flat tube is installed in the middle of two manifolds, and multiple flat tubes are installed.

[0009] The mounting clip is located on one side of the outer wall of the manifold.

[0010] Fins are inserted into the gaps between multiple flat tubes;

[0011] Upper and lower clamping plates are respectively set at the top and bottom of the structure composed of multiple flat tubes;

[0012] The liquid dryer is integrated on the top of the manifold on the other side.

[0013] In a further technical solution, the inner wall of the manifold is uniformly distributed with spiral grooves, and the interior is divided into an inlet section, a middle section, and an outlet section by a partition. Both ends of the manifold are welded and fixed with manifold sealing ports.

[0014] In a further technical solution, the manifold wall thickness is 1-1.5mm, the internal spiral groove has a spiral angle of 30°, a groove depth of 0.5mm, and a spacing of 4mm between adjacent spiral grooves.

[0015] In a further technical solution, the partition is roughly circular in cross-section and made of aluminum alloy. Depending on the flow sequence of the refrigerant and the state of the refrigerant, the length of the inlet section divided by the partition accounts for 20-30%, the length of the middle section accounts for 40-60%, and the length of the outlet section accounts for 20-30%.

[0016] In a further technical solution, a plurality of flat tube mounting grooves are evenly provided on the inner side of the manifold, and a partition mounting groove is also provided on one side of the manifold.

[0017] In a further technical solution, the flat tube has flat tube arc surfaces at both ends, and the shape of the flat tube arc surfaces is designed with a circular arc transition. The tube body is covered with a hydrophilic coating, and the hydrophilic coating is only applied to the outer surface of the flat tube, while the inner wall remains smooth.

[0018] In a further technical solution, the fins have a corrugated window structure and are brazed to the flat tube at multiple points.

[0019] In a further technical solution, the mounting buckle is a flat protruding structure made of aluminum alloy, which is connected to the outer wall of the manifold by laser welding. The protrusions on both ends of the buckle cooperate with other devices, and the connecting contact surface is provided with concave and convex rubber pads to suppress the transmission of high-frequency vibration.

[0020] In a further technical solution, the liquid storage dryer is equipped with a molecular sieve and a metal filter screen. The liquid storage dryer and the manifold on one side have two connection ports, located at the inlet section and the middle section of the manifold, respectively, and are fixedly connected by laser welding. The internal cylindrical body of the liquid storage dryer is equipped with a dryer core for storing refrigerant, filtering impurities and absorbing moisture, and is threadedly connected to the outer tube of the dryer.

[0021] In a further technical solution, the upper and lower clamping plates are generally arc-shaped, with positioning grooves at both ends and a circular through hole in the middle section.

[0022] The beneficial effects of this utility model are:

[0023] Compared with existing technologies, this device achieves uniform refrigerant distribution, reduced flow pressure loss, and lightweight structure through multi-component collaborative design, resulting in reduced overall weight and improved heat exchange efficiency. It also enhances vibration resistance and installation reliability, making it suitable for air conditioning systems in new energy vehicles. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0025] Figure 2 This is a schematic diagram of the manifold structure of this utility model;

[0026] Figure 3 This is a schematic diagram of the flat tube structure of this utility model;

[0027] Figure 4 This is a schematic diagram of the buckle structure of this utility model.

[0028] Figure 5 This is a schematic diagram of the fin structure of this utility model;

[0029] Figure 6 This is a schematic diagram of the clamping plate structure of this utility model;

[0030] Figure 7 This is a schematic diagram of the liquid storage dryer structure of this utility model.

[0031] In the diagram: 1. Manifold; 101. Manifold sealing port; 102. Flat tube mounting groove; 103. Partition mounting groove; 104. Partition; 105. Spiral groove; 106. Inlet section; 107. Intermediate section; 108. Outlet section; 2. Refrigerant outlet; 3. Flat tube; 301. Flat tube arc surface; 4. Mounting clip; 401. Concave-convex rubber pad; 5. Refrigerant inlet; 6. Upper and lower clamps; 601. Circular through hole; 602. Positioning groove; 7. Liquid receiver dryer; 701. Dryer core; 702. Connecting port; 8. Fins. Detailed Implementation

[0032] The embodiments of this utility model will be further described below with reference to the accompanying drawings.

[0033] Example:

[0034] like Figures 1-7As shown, a high-performance, lightweight automotive parallel-flow condenser includes a manifold 1, a refrigerant inlet 5, a refrigerant outlet 2, a flat tube 3, fins 8, upper and lower clamping plates 6, and a liquid receiver dryer 7. The inner walls of the manifolds on both sides are evenly distributed with spiral grooves 105, and the interior is divided into an inlet section 106, a middle section 107, and an outlet section 108 by a partition 104. The outer wall of the manifolds is provided with mounting clips 4, and the inner wall has a flat tube mounting groove 102. The flat tubes have curved ends 301 and are coated with a hydrophilic coating. The liquid receiver dryer 7 is integrated on the outer side of the right-side manifold and contains a molecular sieve and a metal filter 701. The upper and lower clamping plates 6 have positioning grooves 602 at both ends and a circular through-hole 601 in the middle section.

[0035] In this embodiment, the manifold 1 is made of aluminum alloy extrusion molding with a wall thickness of 1-1.5mm. The spiral groove inside has a spiral angle of 105° of 30°, a groove depth of 0.5mm, and a spacing of 4mm between adjacent spiral grooves.

[0036] In this embodiment, the refrigerant inlet 5 and the refrigerant outlet 2 are located on the left manifold and communicate with the inner wall of the manifold. They are fixed to the manifold by laser welding.

[0037] In this embodiment, the partition 104 has a roughly circular cross-section and is made of aluminum alloy. Depending on the refrigerant flow sequence and the refrigerant state, the length of the inlet section separated by the partition accounts for 20-30%, the length of the middle section accounts for 40-60%, and the length of the outlet section accounts for 20-30%.

[0038] In this embodiment, the flat tube mounting grooves 102 are evenly opened on the inner side of the manifold 1, and the shape of the flat tube arc surfaces 301 at both ends is designed with a rounded transition, with an interval of 6.8mm between adjacent mounting grooves.

[0039] In this embodiment, the hydrophilic coating is applied only to the outer surface of the flat tube, while the inner wall remains smooth.

[0040] In this embodiment, the fin 8 has a corrugated window structure with a crest spacing of 2mm, and is connected to the flat tube by multi-point brazing.

[0041] In this embodiment, the mounting buckle 4 is a flat protrusion structure made of aluminum alloy. It is connected to the outer wall of the manifold by laser welding. The protrusions on both ends of the buckle can easily cooperate with other devices, and the connecting contact surface is provided with concave and convex rubber pads 401 to suppress the transmission of high-frequency vibration, so that the fit is tight and the installation is stable.

[0042] In this embodiment, the liquid storage dryer 7 has two connection ports 702 with one side of the manifold, located at the inlet section 106 and the middle section 107 of the manifold, respectively, and are fixedly connected by laser welding.

[0043] In this embodiment, the dryer core is located inside the cylindrical body of the liquid storage dryer and is used to store refrigerant, filter impurities, and absorb moisture. It is threadedly connected to the outer tube of the dryer and can be disassembled and replaced separately.

[0044] The working principle and usage process of this utility model are as follows: During assembly, firstly, the various devices on the manifold 1, such as the partition 104, refrigerant inlet 5, refrigerant outlet 2, mounting buckle 4, and end caps 101, are welded and fixed to the manifold 1; then, the upper and lower clamps 6 are welded to the manifolds 1 on both sides to form an overall frame; the flat tubes 3 are inserted into the mounting grooves 102 of the left and right manifolds and fixed by high-frequency brazing; the corrugated fins 8 are inserted into the gaps between adjacent flat tubes 3 and formed by brazing to form an air side flow channel; the integrated liquid receiver dryer 7 is laser welded to the right manifold to reduce the number of pipe connection points; the mounting buckles 4 on the manifolds 1 on both sides are embedded into other devices of the automotive air conditioning system and fit tightly, and the rubber damping layer suppresses vibration transmission. During operation, the high-temperature refrigerant enters from the left manifold and is rapidly and evenly distributed to the flat tube 3 via the spiral guide groove 108. The streamlined flat tube cross-section 301 greatly reduces the obstruction and interference to the refrigerant, enabling efficient gas-liquid phase change heat dissipation with the fins 8. Afterward, the liquid refrigerant is filtered and dried by the liquid storage dryer 7 and enters the middle section 107. Then, it enters the right manifold through the flat tube 3 via the left manifold and finally enters the output section 108, exiting from the refrigerant outlet 102 at the bottom of the left manifold. The overall refrigerant flow path is S-shaped and flows rapidly, enabling efficient heat exchange and lightweight operation of the parallel flow condenser.

[0045] The above embodiments merely illustrate specific implementations of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model.

Claims

1. A high performance light weight automotive parallel flow condenser characterized by: Includes two manifolds (1) located on both sides; The refrigerant outlet (2) and refrigerant inlet (5) are set on one side of the manifold (1) and communicate with the inner wall of the manifold (1). They are fixed to the manifold by laser welding. A flat tube (3) is set in the middle of two manifolds (1), and multiple flat tubes (3) are provided; Install the buckle (4), which is set on one side of the outer wall of the manifold (1); Fins (8) are inserted into the gaps between multiple flat tubes (3); Upper and lower clamping plates (6) are respectively set at the top and bottom of the structure composed of multiple flat tubes (3); The liquid storage dryer (7) is integrated on the top of the manifold (1) on the other side.

2. The high performance light weight automotive parallel flow condenser as claimed in claim 1 wherein: The inner wall of the manifold (1) is evenly distributed with spiral grooves (105), and the interior is divided into an inlet section (106), a middle section (107), and an outlet section (108) by a partition (104). The manifold (1) is welded and fixed with manifold sealing ports (101) at both ends.

3. A high-performance, lightweight automotive parallel-flow condenser according to claim 2, characterized in that: The manifold (1) has a wall thickness of 1-1.5 mm, and the spiral groove (105) inside has a spiral angle of 30°, a groove depth of 0.5 mm, and a spacing of 4 mm between adjacent spiral grooves.

4. A high-performance, lightweight automotive parallel-flow condenser according to claim 2, characterized in that: The partition (104) has a roughly circular cross section and is made of aluminum alloy. Depending on the flow sequence of the refrigerant and the state of the refrigerant, the length of the inlet section separated by the partition accounts for 20-30%, the length of the middle section accounts for 40-60%, and the length of the outlet section accounts for 20-30%.

5. A high-performance, lightweight automotive parallel-flow condenser according to claim 2, characterized in that: The inner side of the manifold (1) is provided with a plurality of flat tube mounting grooves (102), and the side of the manifold (1) is also provided with a partition mounting groove (103).

6. A high-performance, lightweight automotive parallel-flow condenser according to claim 1, characterized in that: The flat tube (3) has flat tube arc surfaces (301) at both ends. The flat tube arc surfaces (301) are designed with a rounded transition shape. The tube body of the flat tube (3) is covered with a hydrophilic coating. The hydrophilic coating is only applied to the outer surface of the flat tube, while the inner wall remains smooth.

7. A high-performance, lightweight automotive parallel-flow condenser according to claim 1, characterized in that: The fin (8) has a wavy window structure and is brazed to the flat tube (3) at multiple points.

8. A high-performance, lightweight automotive parallel-flow condenser according to claim 1, characterized in that: The mounting buckle (4) is a flat protrusion structure made of aluminum alloy. It is connected to the outer wall of the manifold by laser welding. The protrusions on both ends of the buckle cooperate with other devices, and the contact surface is provided with concave and convex rubber pads (401) to suppress the transmission of high frequency vibration.

9. A high-performance, lightweight automotive parallel-flow condenser according to claim 1, characterized in that: The liquid storage dryer (7) is equipped with a molecular sieve and a metal filter screen. The liquid storage dryer (7) and the one-side manifold (1) have two connection ports (702), located at the inlet section (106) and the middle section (107) of the manifold, respectively. They are fixedly connected by laser welding. The liquid storage dryer (7) has a dryer core (701) in the inner cylindrical body, which is used to store refrigerant, filter impurities and absorb moisture. It is threadedly connected to the outer tube of the dryer.

10. A high-performance, lightweight automotive parallel-flow condenser according to claim 1, characterized in that: The upper and lower clamps (6) are generally arch-shaped, with positioning grooves (602) at both ends and a circular through hole (601) in the middle section.

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