A full-plastic gas-liquid separator for a vehicle air conditioning system

Abstract

The utility model relates to the technical field of automobile air conditioner, disclose a kind of full plastic gas-liquid separator of vehicle air conditioning system, including jar body and end cap, the side of end cap away from jar body is provided with air inlet and air outlet, the inside of end cap is provided with baffle and air inlet pipe, the air inlet pipe includes concentrically arranged first air inlet pipe and second air inlet pipe, first air inlet pipe is sleeved in the outside of second air inlet pipe, the utility model is by using full plastic structure design, jar body and end cap are made of high-strength engineering plastic material, compared with traditional metal gas-liquid separator, the overall weight is significantly reduced, the whole vehicle light weight is realized, manufacturing cost and assembly difficulty are reduced, while having excellent corrosion resistance and fatigue resistance, meet the use requirement of new energy automobile and traditional automobile air conditioning system.

Description

Technical Field

[0001] This utility model relates to the field of automotive air conditioning technology, and in particular to an all-plastic gas-liquid separator for automotive air conditioning systems. Background Technology

[0002] The gas-liquid separator is a key component of automotive air conditioning systems. It is typically installed between the evaporator outlet and the compressor suction port. Its main function is to separate the refrigerant into gas and liquid phases, while also serving as a liquid storage, drying, and filter. In the automotive air conditioning refrigeration cycle, the refrigerant from the evaporator outlet is in a gas-liquid mixed state. If this mixture is not fully separated, the liquid refrigerant entering the compressor can easily cause "liquid slugging," leading to compressor damage and affecting the reliability and lifespan of the entire vehicle's air conditioning system.

[0003] In existing technologies, metal separators are prone to stress concentration or weld fatigue under compressor suction conditions due to the large internal and external pressure difference and limited internal structural rigidity, affecting sealing performance. Furthermore, their internal gas-liquid separation efficiency is limited by the baffle structure and flow field distribution, resulting in unsatisfactory separation and back-suction of liquid refrigerant and lubricating oil. Some oil is carried into the compressor suction end along with the gaseous refrigerant, causing not only unstable lubrication but also affecting the system's heat exchange efficiency. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing an all-plastic gas-liquid separator for automotive air conditioning systems.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A vehicle air conditioning system all-plastic gas-liquid separator includes a tank and an end cap. The end cap has an air inlet and an air outlet on the side away from the tank. The end cap has a baffle and an air inlet pipe inside. The air inlet pipe includes a first air inlet pipe and a second air inlet pipe arranged concentrically. The first air inlet pipe is sleeved on the outside of the second air inlet pipe. The end of the second air inlet pipe extending outside the first air inlet pipe passes through the baffle and extends into the air outlet. The end of the first air inlet pipe near the baffle is the air inlet, and the end of the second air inlet pipe extending into the air outlet is the air outlet. A bracket is provided at the end of the air inlet pipe away from the end cap. A liquid suction plate is assembled and connected inside the bracket.

[0007] Preferably, a gap is left between the side of the baffle away from the tank body and the inner wall of the end cap, a gap is left between the side of the baffle close to the tank body and the opening of the air inlet, and a gap is left between the inner wall of the first air inlet and the outer wall of the second air inlet.

[0008] Preferably, the liquid suction plate has liquid suction holes on its side, and the support has a filter screen on its side.

[0009] Preferably, the second air inlet pipe is provided with an assembly buckle at one end near the air outlet, and a pressure equalization hole is provided on the side wall of the second air inlet pipe near the air outlet.

[0010] Preferably, the outer wall of the end cap is provided with an end cap reinforcing structure and a pre-embedded nut, and the outside of the tank is provided with an external tank reinforcing structure.

[0011] Preferably, the outer wall of the first air inlet pipe is provided with a molecular sieve, and the inner wall of the tank is provided with an internal tank reinforcement structure.

[0012] Preferably, the tank body and the end cap are connected by rotary friction welding.

[0013] Preferably, the tank body and the end cap are connected by hot gas welding.

[0014] Preferably, the tank head is a spherical head structure, and the outer wall of the tank is provided with a mounting bracket structure.

[0015] Preferably, the mounting bracket structure includes a mounting frame, a rubber pad, and a steel bushing.

[0016] The beneficial effects of this utility model are as follows:

[0017] 1. By adopting an all-plastic structure design, the tank body and end caps are made of high-strength engineering plastic materials, which significantly reduces the overall weight compared to traditional metal gas-liquid separators, achieving vehicle lightweighting, reducing manufacturing costs and assembly difficulty, while possessing excellent corrosion resistance and fatigue resistance, meeting the usage requirements of air conditioning systems in new energy vehicles and traditional vehicles.

[0018] 2. This utility model proposes an all-plastic gas-liquid separator for automotive air conditioning systems. Through the internal design of baffles, a double-layered concentric intake pipe, a liquid suction plate, and a filter, it achieves efficient separation of gaseous refrigerant and liquid refrigerant, preventing liquid refrigerant from entering the compressor and causing liquid slugging, while ensuring stable oil backflow circulation. The pressure equalization orifice effectively balances the pressure inside and outside the intake pipe, reducing pressure fluctuations and ensuring stable liquid suction flow.

[0019] 3. The present invention proposes an all-plastic gas-liquid separator for a vehicle air conditioning system. The tank body and the end cap are connected by rotary friction welding or hot gas welding. The weld is dense and has high air tightness, avoiding the leakage problem of traditional metal welding.

[0020] 4. The all-plastic gas-liquid separator for vehicle air conditioning system proposed in this utility model has a mounting bracket with a suspension vibration reduction design using rubber pads and steel bushings, which reduces vibration transmission and improves operational stability and durability. Attached Figure Description

[0021] Figure 1This is a schematic diagram of the structure of an all-plastic gas-liquid separator for an automotive air conditioning system according to Embodiment 1 of this utility model;

[0022] Figure 2 This is a schematic diagram of the structure of the tank and end cap of an all-plastic gas-liquid separator for an automotive air conditioning system, as proposed in Embodiment 1 of this utility model, which are obtained by rotary welding.

[0023] Figure 3 This is a schematic diagram of the air inlet pipe structure of an all-plastic gas-liquid separator for an automotive air conditioning system according to Embodiment 1 of this utility model;

[0024] Figure 4 This is a cross-sectional view of the bracket, air inlet pipe, and liquid suction plate structure of an all-plastic gas-liquid separator for an automotive air conditioning system according to Embodiment 1 of this utility model;

[0025] Figure 5 This is a schematic diagram of the end cap structure of an all-plastic gas-liquid separator for an automotive air conditioning system according to Embodiment 1 of this utility model;

[0026] Figure 6 This is a schematic diagram of the external structure of one end of the tank of an all-plastic gas-liquid separator for an automotive air conditioning system according to Embodiment 1 of this utility model;

[0027] Figure 7 This is a schematic diagram of the structure of the tank and end cap of an all-plastic gas-liquid separator for an automotive air conditioning system, as proposed in Embodiment 2 of this utility model, which are welded by hot gas welding.

[0028] Figure 8 This is a side view of the tank and mounting bracket of an all-plastic gas-liquid separator for an automotive air conditioning system, as proposed in Embodiment 3 of this utility model.

[0029] Figure 9 This is a schematic diagram of the mounting bracket, rubber pad, and steel bushing structure of an all-plastic gas-liquid separator for an automotive air conditioning system according to Embodiment 3 of this utility model;

[0030] Figure 10 This is a cross-sectional view of the mounting bracket, rubber pad, and steel bushing structure of an all-plastic gas-liquid separator for an automotive air conditioning system, as proposed in Embodiment 3 of this utility model.

[0031] In the diagram: 1-Tank body, 2-Support, 3-Liquid suction plate, 4-Air inlet pipe, 41-First air inlet pipe, 42-Second air inlet pipe, 43-Air inlet pipe inlet, 44-Air inlet pipe outlet, 5-Baffle plate, 6-Embedded nut, 7-End cap, 8-Molecular sieve, 9-Internal reinforcement structure of tank body, 10-Assembly buckle, 11-Equalizing hole, 12-Filter screen, 13-Liquid suction hole, 14-End cap reinforcement structure, 15-Air inlet, 16-Air outlet, 17-External reinforcement structure of tank body, 18-Mounting bracket, 19-Rubber pad, 20-Steel bushing. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0033] Example 1: Refer to Figures 1 to 6 A vehicle air conditioning system all-plastic gas-liquid separator includes a tank body 1 and an end cap 7. The end cap 7 has an air inlet 15 and an air outlet 16 on the side away from the tank body 1. The end cap 7 has a baffle 5 and an air inlet pipe 4 inside. The air inlet pipe 4 includes a first air inlet pipe 41 and a second air inlet pipe 42 arranged concentrically. The first air inlet pipe 41 is sleeved on the outside of the second air inlet pipe 42. The end of the second air inlet pipe 42 extending outside the first air inlet pipe 41 passes through the baffle 5 and extends into the air outlet 16. The end of the first air inlet pipe 41 near the baffle 5 is the air inlet 43, and the end of the second air inlet pipe 42 extending into the air outlet 16 is the air outlet 44. The end of the air inlet pipe 4 away from the end cap 7 is provided with a bracket 2. A liquid suction plate 3 is assembled and connected inside the bracket 2.

[0034] When the air conditioning system is running, the gas-liquid mixture of refrigerant from the evaporator outlet enters the separator cavity through the inlet 15. At this time, the mixture contains a small amount of incompletely vaporized liquid refrigerant and engine oil. The baffle 5 guides the mixture to the inner wall of the gas-liquid separator, changing the airflow direction. Under the action of gravity and inertia, the liquid refrigerant and engine oil in the mixture fall along the inner wall and settle at the bottom of the tank 1. The gaseous refrigerant in the mixture rises under the guidance of the baffle, achieving preliminary gas-liquid separation. The baffle 5 here plays a combined separation role of inertial separation and gravity settling. The liquid refrigerant deposited at the bottom of the tank 1 contains a small amount of engine oil, which is then processed by the compressor. Under the suction action, a certain negative pressure difference is formed inside the separator. The pressure at the bottom of the intake pipe 4 is lower than the pressure at the bottom of the separator cavity. Driven by this pressure difference, the oil at the bottom of the tank 1 is sucked into the intake pipe 4 through the liquid suction plate 3 on the bracket 2, realizing the oil return circulation. The gaseous refrigerant enters the first intake pipe 41 through the intake pipe inlet 43. When the gaseous refrigerant flows into the second intake pipe 42 through the gap between the first intake pipe 41 and the second intake pipe 42, the gaseous refrigerant mixes with the oil in the intake pipe 4 and is then transported to the compressor suction end through the intake pipe outlet 44 and the outlet 16. This ensures the circulation of the compressor lubricating oil and prevents the liquid refrigerant from directly entering the compressor.

[0035] In a preferred embodiment of this utility model, a gap is left between the side of the baffle 5 away from the tank body 1 and the inner wall of the end cover 7, so that the baffle 5 can change the flow direction without completely cutting off the upper space, thereby forming a smooth bypass channel and buffer cavity in the end cover 7. A gap is left between the side of the baffle 5 near the tank body 1 and the opening of the inlet 43 of the air inlet pipe, which can ensure the continuity and smoothness of the flow line when transitioning from the cavity to the inlet 43 of the air inlet pipe, and avoid "jet collision" and local high shear secondary atomization caused by the baffle and the inlet being too close. A gap is left between the inner wall of the first air inlet pipe 41 and the outer wall of the second air inlet pipe 42, forming an annular gap channel of concentric tubes. When the gaseous refrigerant enters the second air inlet pipe 42 through this annular gap, the flow cross section is reasonably enlarged and the pressure drop distribution is more uniform, which reduces the axial velocity gradient and suppresses vortex separation caused by abrupt changes in cross section, making the airflow entering the second air inlet pipe 42 more stable.

[0036] In a preferred embodiment of this utility model, the suction plate 3 has a suction hole 13 on its side, and the support 2 has a filter screen 12 on its side for filtering impurities from the oil entering the intake pipe 4. After passing through the filter screen 12, the oil enters the suction hole 13, achieving the intake of pure lubricating oil and preventing impurity particles from entering the intake pipe 4 along with the oil, thus preventing blockage of the intake passage or wear on the compressor's suction end components, thereby improving the reliability and lifespan of the entire machine. The amount of oil drawn in is controlled by the interaction between the size of the suction hole 13 and the pressure equalization hole 11 on the second intake pipe 42. Together, they form a self-balancing flow regulation system, ensuring that the amount of oil drawn back is sufficient to maintain compressor lubrication while avoiding the risk of excessive intake leading to liquid slugging inside the compressor.

[0037] In a preferred embodiment of this utility model, the bracket 2 and the liquid suction plate 3 are made of high-strength PA6+GF30 material, and the filter screen 12 is made of nylon. The filter screen 12 is pre-embedded in the side wall of the bracket 2 during the injection molding process. The liquid suction plate 3 is assembled onto the bracket 2 by means of dimensional fit and snap-fit, and the bracket 2 is assembled and connected to the lower end of the air inlet pipe 4 by means of interference fit, thereby achieving overall structural sealing and mechanical fixation.

[0038] In a preferred embodiment of the present invention, the second air inlet pipe 42 is provided with a mounting buckle 10 at one end near the air outlet 16, and a pressure equalization hole 11 is provided on the side wall of the second air inlet pipe 42 near the air outlet 16.

[0039] When gaseous refrigerant flows inside the intake pipe 4, a certain pressure difference will form between the first intake pipe 41 and the second intake pipe 42 due to changes in fluid dynamic pressure and the influence of internal local resistance. This will lead to pressure fluctuations between the intake pipe inlet 43 and the intake pipe outlet 44. If this pressure difference fluctuation is too large, it will cause the instantaneous flow rate at the suction hole 13 to be unstable, resulting in pulsation of the bottom oil intake with changes in system load, affecting the balance of lubricating oil back suction and the smoothness of compressor suction. The equalizing hole 11 connects the inside of the second intake pipe 42 with its external cavity, thereby achieving pressure self-balancing during system operation: when the pressure inside the pipe increases, excess gas can flow to the external cavity through the equalizing hole 11; conversely, when the pressure inside the pipe decreases, gas from the external cavity can be replenished through the equalizing hole 11, thereby adjusting the pressure difference between the two sides in real time and maintaining a stable airflow environment inside the pipe.

[0040] The equalizing orifice 11 also plays a "rectifying" role in the flow field structure to a certain extent. Since gaseous refrigerant tends to form vortices or uneven velocity distribution when flowing in the annular channel between the first inlet pipe 41 and the second inlet pipe 42, the presence of the equalizing orifice 11 allows some fluid to be released or replenished, thereby weakening the secondary eddy effect and making the fluid more stable and uniform before entering the outlet 16. This design not only improves the flow stability of the gaseous refrigerant but also further reduces noise and vibration, making the entire system operate more quietly and reliably.

[0041] In a preferred embodiment of this utility model, the outer wall of the end cap 7 is provided with an end cap reinforcing structure 14 and a pre-embedded nut 6, and the outer side of the tank body 1 is provided with an external tank body reinforcing structure 17. The end cap reinforcing structure 14 is arranged on the outer wall of the end cap 7, and is generally in the form of radial or annular ribs. This structure is mainly used to enhance the rigidity and sealing reliability of the end cap under pressure differential.

[0042] In a preferred embodiment of this utility model, a molecular sieve 8 is provided on the outer wall of the first inlet pipe 41, and an internal reinforcing structure 9 is provided on the inner wall of the tank body 1. The internal reinforcing structure 9 is provided on the inner wall of the tank body 1 and is usually in the form of annular ribs or longitudinal ribs, arranged along the axis or circumference of the tank body. Its function is to improve the tank body's resistance to expansion and shape stability when subjected to the refrigerant pressure inside the system, and to prevent radial bulging or local deformation under the action of internal pressure. The internal reinforcing structure 9 and the external reinforcing structure 17 provided on the outer wall of the tank body 1 form a double-layer reinforcement system that echoes each other.

[0043] Molecular sieve 8 is used to adsorb moisture and impurities in the refrigerant in the system, thereby preventing moisture from freezing at low temperatures or reacting chemically with the lubricating oil during the circulation process, which could cause system blockage, corrosion, or deterioration of lubricating oil performance.

[0044] The internal reinforcing structure 9, the end cap reinforcing structure 14, and the external reinforcing structure 17 of the tank together constitute the structural reinforcement system of this all-plastic gas-liquid separator. While ensuring a lightweight design, they improve the overall mechanical strength, deformation resistance, and sealing reliability from different directions. Since the tank body 1 and end cap 7 of this invention are both made of engineering plastic materials (such as PA66+GF30, PA-GF50, etc.), although plastic materials have advantages such as light weight, corrosion resistance, and flexible molding, their elastic modulus and stress resistance are relatively lower than those of metal materials. Therefore, it is necessary to compensate for their insufficient mechanical properties through the design of reinforcing structures, thereby ensuring that the separator remains stable and safe under high pressure and vibration conditions.

[0045] In a preferred embodiment of this utility model, the tank body 1 and the end cap 7 are connected by rotary friction welding.

[0046] Example 2: Refer to Figure 7 The difference between this embodiment and embodiment 1 is that the tank body 1 and the end cap 7 are connected by hot gas welding.

[0047] In a preferred embodiment of this utility model, the overflow material generated during hot gas welding of the outer wall is removed by a processing and grinding method;

[0048] The materials for the tank body 1 and the end cap 7 can be high-strength plastics with good welding performance, such as PA66+GF30, PA-GF50, PA66+PA6I / 6T, GF50, PA66+GF20+CF10.

[0049] Example 3: Reference Figures 8 to 10 The difference between this embodiment and embodiment 1 is that the end cap of tank 1 is a spherical end cap structure. The spherical end cap structure is more uniformly stressed and can increase the burst pressure of the separator. The burst pressure of the separator is greater than 4 MPa.

[0050] In a preferred embodiment of this utility model, the outer wall of the tank 1 is provided with a mounting bracket structure for securely installing the gas-liquid separator onto the pipeline of the automotive air conditioning system or the vehicle body structure. This mounting bracket structure not only supports and fixes the separator but also withstands stresses caused by vibration, impact, and temperature changes during vehicle operation.

[0051] In a preferred embodiment of the present invention, the mounting bracket structure includes a mounting frame 18, a rubber pad 19, and a steel bushing 20. The steel bushing 20 is disposed inside the rubber pad 19 and has no direct contact with the mounting frame 18. After locking, the steel bushing 20 compresses the rubber pad 19 to fix the separator in a suspended manner, thereby achieving vibration isolation.

[0052] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A full plastic gas-liquid separator for a vehicle air conditioning system, comprising a tank body (1) and an end cover (7), characterized in that, The end cap (7) is provided with an air inlet (15) and an air outlet (16) on the side away from the tank body (1). The end cap (7) is provided with a baffle (5) and an air inlet pipe (4). The air inlet pipe (4) includes a first air inlet pipe (41) and a second air inlet pipe (42) arranged concentrically. The first air inlet pipe (41) is sleeved on the outside of the second air inlet pipe (42). The end of the second air inlet pipe (42) extending to the outside of the first air inlet pipe (41) passes through the baffle (5) and extends to the inside of the air outlet (16). The end of the first air inlet pipe (41) near the baffle (5) is the air inlet pipe (43). The end of the second air inlet pipe (42) extending to the inside of the air outlet (16) is the air outlet pipe (44). The end of the air inlet pipe (4) away from the end cap (7) is provided with a bracket (2). The inside of the bracket (2) is fitted with a liquid suction plate (3).

2. The all-plastic gas-liquid separator of claim 1, wherein There is a gap between the side of the baffle (5) away from the tank (1) and the inner wall of the end cap (7), a gap between the side of the baffle (5) close to the tank (1) and the opening of the air inlet (43), and a gap between the inner wall of the first air inlet pipe (41) and the outer wall of the second air inlet pipe (42).

3. The all-plastic gas-liquid separator of claim 1, wherein The side of the liquid suction plate (3) is provided with a liquid suction hole (13), and the side of the bracket (2) is provided with a filter screen (12) for filtering impurities from the oil entering the intake pipe (4).

4. The all-plastic gas-liquid separator of claim 1, wherein The second air inlet pipe (42) is provided with a mounting buckle (10) at one end near the air outlet (16), and a pressure equalization hole (11) is provided on the side wall of the second air inlet pipe (42) near the air outlet (16).

5. The all-plastic gas-liquid separator of claim 1, wherein The outer wall of the end cap (7) is provided with an end cap reinforcing structure (14) and a pre-embedded nut (6), and the outer side of the tank body (1) is provided with an external tank reinforcing structure (17).

6. The all-plastic gas-liquid separator of claim 1, wherein The outer wall of the first air inlet pipe (41) is provided with a molecular sieve (8), and the inner wall of the tank (1) is provided with an internal tank reinforcement structure (9).

7. The all-plastic gas-liquid separator of claim 1, wherein The tank body (1) and the end cap (7) are connected by rotary friction welding.

8. The all-plastic gas-liquid separator of claim 1, wherein, The tank body (1) and the end cap (7) are connected by hot gas welding.

9. The all-plastic gas-liquid separator of claim 1, wherein The tank (1) has a spherical head structure and an installation bracket structure on the outer wall of the tank (1).

10. The all-plastic gas-liquid separator of claim 9, wherein The mounting bracket structure includes a mounting frame (18), a rubber pad (19), and a steel bushing (20).

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