An arc surface bonding and welding structure of a condenser header and a pipe of an automobile
By adopting an arc-surface bonding welding structure at the connection between the automobile condenser manifold and the pipeline, the problems of poor bonding and insufficient sealing of traditional connection structures are solved, achieving higher welding stability and sealing performance, which is suitable for the complex working conditions of new energy vehicles.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- FOSHAN NANHAI LEI TE AUTOMOTIVE PARTS CO LTD
- Filing Date
- 2025-06-17
- Publication Date
- 2026-06-23
AI Technical Summary
The connection structure between the manifold and pipe of the traditional automotive condenser has problems such as poor fit, insufficient sealing and weak welding stability, which makes it difficult to meet the reliability requirements, especially under the complex operating conditions of new energy vehicles.
The structure adopts a curved surface bonding welding structure. By designing a hyperboloidal contact between the outer convex arc surface and the inner concave arc surface at the connection between the manifold and the pipeline, the contact area and weld length are increased. A continuous and sealed annular weld is formed by laser welding.
It improves the stability and sealing of the weld, reduces the risk of incomplete or missing welds, and can better withstand vehicle vibration and stress, thus extending the service life of the condenser.
Smart Images
Figure CN224398452U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automotive air conditioning system technology, and in particular to an arc-shaped welded structure for automotive condenser manifold and pipe. Background Technology
[0002] In automotive air conditioning systems, the condenser is a key component for heat exchange, and the reliability of its connection between the manifold and the refrigerant inlet / outlet pipes and the liquid receiver pipe directly affects the system's sealing performance and service life. Traditional connection structures typically employ a direct welding method between flat and curved surfaces, where the manifold opening edge is curved and the pipe connection end is flat, with welding performed through the contact between the two surfaces.
[0003] However, this traditional structure has significant drawbacks: First, the fit between the flat and curved surfaces is poor, making complete tight contact difficult and prone to forming gaps; second, the weld area only involves linear contact at the edge of the flat surface, resulting in a small contact area, large weld gaps, and insufficient weld stability; third, the sealing performance depends on the welding quality, and any incomplete or missed welds can easily lead to refrigerant leakage, affecting the performance of the air conditioning system. Especially in the field of new energy vehicles, the complex operating conditions (such as high-frequency vibration and alternating high and low temperatures) place higher demands on the reliability of the condenser connection structure, which traditional connection structures can no longer meet.
[0004] In existing technologies, some solutions attempt to improve sealing by adding sealant or optimizing welding processes, but these do not fundamentally solve the problem of defects in the bonding surface structure. Furthermore, adding sealant increases costs and may introduce other reliability risks. Therefore, we propose an arc-surface bonding welding structure for automotive condenser manifolds and pipes. Utility Model Content
[0005] To address the aforementioned problems, this utility model provides an arc-shaped welded structure for the manifold and pipe of an automotive condenser, which improves upon the poor fit, insufficient sealing, and weak welding stability of existing flat-to-circular pipe connection structures.
[0006] The technical solution of this utility model is:
[0007] A curved surface welded structure for an automotive condenser manifold and pipe includes two manifolds. Multiple flat pipes are arranged between the two manifolds, forming a square structure. A refrigerant inlet / outlet pipe is installed at the top of the manifold, with a refrigerant inlet / outlet at one end. A liquid storage tank is installed at the bottom of the manifold, with a liquid storage tank inlet / outlet pipe at one end. The connection ends of the liquid storage tank inlet / outlet pipe and the refrigerant inlet / outlet pipe are respectively equipped with a connecting end curved surface structure and a liquid storage tank pipe connecting end curved surface structure. The radii of curvature of the connecting end curved surface structure and the liquid storage tank pipe connecting end curved surface structure are precisely matched to the outer diameter of the manifold. Refrigerant outlet openings and refrigerant inlet openings are provided on the two manifolds at positions corresponding to the refrigerant inlet / outlet pipes and the liquid storage tank inlet / outlet pipes.
[0008] In a further technical solution, condenser guard plates are installed on both sides of the square structure, and manifold seals are installed at the four corners of the square structure.
[0009] In a further technical solution, the edges of the refrigerant outlet opening and the refrigerant inlet opening in the pipe wall are machined with concave arc chamfers to increase the contact area and fit of the device.
[0010] In a further technical solution, the arc-shaped structure at the connecting end and the arc-shaped structure at the connecting end of the liquid storage tank pipeline form a hyperboloid contact with the corresponding manifold wall, and the refrigerant inlet and outlet pipelines and the liquid storage tank inlet and outlet pipelines are respectively fixed to the corresponding manifold by welding.
[0011] In a further technical solution, a mounting flange is welded and fixed to one end of the bottom manifold.
[0012] In a further technical solution, the depth of the concave arc chamfer is 0.2mm and the angle is 20°.
[0013] In a further technical solution, the outer diameter of the manifold is 20mm, the diameters of the refrigerant inlet / outlet pipes and the liquid storage tank inlet / outlet pipes are 12.5mm and 8mm respectively, the radius of curvature R of the arc surface structure at the connecting end satisfies the relationship R = 0.5D ± 0.02D with respect to the outer diameter D of the manifold, and the central angle of the arc surface structure at the connecting end is 25°-30°.
[0014] In a further technical solution, the manifold, refrigerant inlet and outlet pipes, and liquid storage tank inlet and outlet pipes are all made of aluminum alloy.
[0015] In a further technical solution, the surface roughness of the connecting end arc surface structure and the concave arc surface chamfer is controlled to be below Ra3.2 micrometers.
[0016] The beneficial effects of this utility model are:
[0017] By using a hyperboloidal surface with a chamfered inner concave arc, the contact area is increased, resulting in a longer and thicker weld. This allows for more complete filling of the molten metal, reducing the risk of incomplete or missed welds. The tensile and shear strength of the welded joint is improved, enabling it to better withstand vibrations and stresses during vehicle operation and extending the service life of the condenser. The hyperboloidal surface fit eliminates the gaps of traditional planar connections, forming a continuous and sealed annular weld after welding, eliminating the need for additional sealing. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model;
[0019] Figure 2 This is a schematic diagram of the connection between the manifold and the refrigerant inlet and outlet pipes in an embodiment of this utility model;
[0020] Figure 3 This is a schematic diagram of the connection between the manifold and the inlet / outlet pipes of the storage tank in an embodiment of this utility model;
[0021] Figure 4 This is a comparative schematic diagram of the traditional flat-curved surface connection (left a, c, e) and the hyperboloid connection of this utility model (right b, d, f);
[0022] Figure 5 This is a schematic diagram of the chamfered edge of the opening in an embodiment of this utility model;
[0023] Figure 6 This is a side cross-sectional view of the manifold according to an embodiment of the present invention.
[0024] Explanation of reference numerals in the attached figures:
[0025] 1. Manifold; 101. Refrigerant outlet opening in pipe wall; 102. Refrigerant inlet opening in pipe wall; 103. Chamfered inner concave arc surface; 2. Refrigerant inlet and outlet; 201. Refrigerant inlet and outlet pipes; 202. Arc surface structure of connection end; 3. Condenser guard plate; 4. Flat pipe; 5. Manifold seal; 6. Liquid storage tank; 601. Liquid storage tank inlet and outlet pipes; 602. Arc surface structure of liquid storage tank pipe connection end; 7. Mounting flange. Detailed Implementation
[0026] The embodiments of this utility model will be further described below with reference to the accompanying drawings.
[0027] Example:
[0028] like Figures 1-6As shown, an arc-face welded structure for an automotive condenser manifold and pipe includes two manifolds 1. Multiple flat pipes 4 are arranged in the middle of the two manifolds 1, forming a square structure. A refrigerant inlet / outlet pipe 201 is installed at the top of the top manifold 1, and a refrigerant inlet / outlet 2 is installed at one end of the refrigerant inlet / outlet pipe 201. A liquid storage tank 6 is installed at the bottom of the bottom manifold 1, and a liquid storage tank inlet / outlet pipe 601 is installed at one end of the liquid storage tank 6. An arc-faced connection structure 202 and a liquid storage tank pipe are respectively installed at the connection ends of the liquid storage tank inlet / outlet pipe 601 and the refrigerant inlet / outlet pipe 201. The arc surface structure 602 at the connection end of the pipeline, the arc surface structure 202 at the connection end of the pipeline and the arc surface structure 602 at the connection end of the liquid storage tank pipeline are precisely matched with the outer diameter of (1). The pipeline connection end of the liquid storage tank inlet and outlet pipeline 601 and the refrigerant inlet and outlet pipeline 201 is processed into an outwardly convex arc surface structure by using a die stamping process. The radius of curvature is detected by a coordinate measuring machine to ensure that it matches the outer diameter of the manifold. The two manifolds 1 are provided with pipe wall refrigerant outlet opening 101 and pipe wall refrigerant inlet opening 102 at the positions corresponding to the refrigerant inlet and outlet pipeline 201 and the liquid storage tank inlet and outlet pipeline 601, such as Figure 1 As shown, the upper manifold 1 has a refrigerant outlet opening 101 and a refrigerant inlet opening 102, with the inlet opening having a diameter of 12.5 mm and the outlet opening having a diameter of 8 mm; the lower manifold has two liquid storage tank pipe openings, each with a diameter of 8 mm, as shown. Figure 6 As shown, the manifold 1 is made of aluminum alloy, with an outer diameter D of 20 mm and a wall thickness b of 2 mm.
[0029] In another embodiment, such as Figure 1 As shown, condenser guard plates 3 are installed on both sides of the square structure, and manifold seals 5 are installed at the four corners of the square structure.
[0030] In another embodiment, such as Figure 5 As shown, the edges of the refrigerant outlet opening 101 and the refrigerant inlet opening 102 on the pipe wall are milled to form an inner concave arc chamfer 103. The chamfer size is precisely controlled by a CNC machining center, and the curvature is adapted to the outer convex arc surface of the pipe to ensure that the double curved surfaces fit tightly, increasing the contact area and fit of the device.
[0031] In another embodiment, such as Figure 1As shown, the arc-shaped structure 202 at the connecting end and the arc-shaped structure 602 at the connecting end of the liquid storage tank pipeline form a hyperboloid contact with the corresponding manifold 1 pipe wall. The refrigerant inlet / outlet pipeline 201 and the liquid storage tank inlet / outlet pipeline 601 are respectively fixed to the corresponding manifold 1 by welding. The convex arc-shaped structure at the pipe connecting end of the refrigerant inlet / outlet pipeline 201 and the liquid storage tank inlet / outlet pipeline 601 is attached to the outer surface of the manifold 1, so that the convex arc-shaped structure contacts the concave arc-shaped chamfer 103 and is completely attached to the outer wall of the manifold 1. Laser welding is used, and the weld formed after welding evenly covers the hyperboloid contact area, which enhances the welding stability.
[0032] In another embodiment, such as Figure 1 As shown, a mounting flange 7 is welded and fixed to one end of the bottom manifold 1.
[0033] In another embodiment, such as Figure 5 As shown, the depth of the concave arc chamfer 103 is 0.2mm and the angle is 20°.
[0034] In another embodiment, such as Figure 6 As shown, the outer diameter of the manifold 1 is 20mm, the diameters of the refrigerant inlet / outlet pipe 201 and the liquid storage tank inlet / outlet pipe 601 are 12.5mm and 8mm respectively, the radius of curvature R of (202) and the outer diameter D of the manifold satisfy the relationship R=0.5D±0.02D, and the central angle of the arc surface structure 202 at the connection end is 25°-30°.
[0035] In another embodiment, such as Figure 1 As shown, the manifold 1, the refrigerant inlet and outlet pipes 201, and the liquid storage tank inlet and outlet pipes 601 are all made of aluminum alloy.
[0036] In another embodiment, such as Figure 5 and Figure 6 As shown, the surface roughness of the connecting end arc surface structure 202 and the concave arc surface chamfer 103 are both controlled below Ra 3.2 micrometers.
[0037] 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. An arc surface bonding and welding structure of an automobile condenser header and pipe, comprising two headers (1), characterized in that: Multiple flat tubes (4) are arranged in the middle of the two manifolds (1) to form a square structure. A refrigerant inlet / outlet pipe (201) is installed at the top of the manifold (1), and a refrigerant inlet / outlet (2) is installed at one end of the refrigerant inlet / outlet pipe (201). A liquid storage tank (6) is installed at the bottom of the manifold (1), and a liquid storage tank inlet / outlet pipe (601) is installed at one end of the liquid storage tank (6). The liquid storage tank inlet / outlet pipe (601) and the refrigerant inlet / outlet pipe (2) The connecting ends of 01) are respectively equipped with a connecting end arc surface structure (202) and a liquid storage tank pipeline connecting end arc surface structure (602). The curvature radius of the connecting end arc surface structure (202) and the liquid storage tank pipeline connecting end arc surface structure (602) is precisely matched with the outer diameter of (1). The two manifolds (1) are provided with pipe wall refrigerant outlet opening (101) and pipe wall refrigerant inlet opening (102) at the positions corresponding to the refrigerant inlet and outlet pipelines (201) and the liquid storage tank inlet and outlet pipelines (601).
2. The arc surface bonding and welding structure of the automobile condenser header and the pipe according to claim 1, characterized in that: Condenser guard plates (3) are installed on both sides of the square structure, and manifold seals (5) are installed at the four corners of the square structure.
3. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 1, characterized in that: The refrigerant outlet opening (101) and refrigerant inlet opening (102) in the pipe wall are machined with concave arc chamfers (103) at the opening edges to increase the contact area and fit of the device.
4. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 1, characterized in that: The arc-shaped structure (202) at the connecting end and the arc-shaped structure (602) at the connecting end of the liquid storage tank pipeline form a hyperboloid contact with the wall of the corresponding manifold (1). The (201) and the inlet and outlet pipes (601) of the liquid storage tank are respectively fixed to the corresponding manifold (1) by welding.
5. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 1, characterized in that: A mounting flange (7) is welded and fixed to one end of the bottom manifold (1).
6. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 3, characterized in that: The depth of the concave arc chamfer (103) is 0.2 mm and the angle is 20°.
7. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 1, characterized in that: The outer diameter of the manifold (1) is 20 mm, the diameters of the refrigerant inlet / outlet pipe (201) and the liquid storage tank inlet / outlet pipe (601) are 12.5 mm and 8 mm respectively, the radius of curvature R of the connecting end arc surface structure (202) and the outer diameter D of the manifold satisfy the relationship R = 0.5D ± 0.02D, and the central angle of the connecting end arc surface structure (202) is 25°-30°.
8. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 1, characterized in that: The manifold (1), refrigerant inlet and outlet pipes (201), and liquid storage tank inlet and outlet pipes (601) are all made of aluminum alloy.
9. The arc-surface welded structure of the automobile condenser manifold and the pipeline according to claim 1, characterized in that: The surface roughness of the connecting end arc surface structure (202) and the concave arc surface chamfer (103) is controlled to be below Ra3.2 micrometers.