Heat exchanger and home appliance including the same

Abstract

A home appliance may include: a housing; and a heat exchanger disposed inside the housing, the heat exchanger including: a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum, a second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor, and a filler metal configured to couple the first pipe and the second pipe together, At least of a portion of the first pipe or a portion of the second pipe includes a zinc diffusion layer. An electrical potential difference between any two of the filler metal, the first pipe, and the second pipe is 50 mV or less.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation application of International Application No. PCT / KR2025 / 012993 filed on Aug. 26, 2025, in the Korean Intellectual Property Receiving Office, which claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2024-0136157, filed on Oct. 8, 2024, in the Korean Intellectual Property Office, the disclosure of which are incorporated by reference herein in their entireties.TECHNICAL FIELD

[0002] An embodiment of the disclosure relates to a heat exchanger disposed inside a home appliance.BACKGROUND ART

[0003] A heat exchanger is a device that performs heat exchange between two fluids separated by a solid wall, and generally exchanges heat between two process flows without phase change. The heat exchanger may include, e.g., a cooler and a condenser.

[0004] Heat exchangers are widely used for heating, air conditioning, power generation, cooling and waste heat recovery. In general, a heat exchanger used as a component of a home appliance is an important component that determines the performance and lifespan of the home appliance. Aluminum alloy materials are widely used in heat exchangers considering price competitiveness and heat conduction characteristics.

[0005] When a sensor holder (e.g., a pipe) equipped with a sensor such as a thermistor and a pipe providing a refrigerant flow path are welded to each other in the heat exchanger, the pipes may be easily separated by corrosion due to a potential difference therebetween. Accordingly, a design is discussed which may prevent easy separation between pipes due to corrosion and may maintain a strong joint.DISCLOSURE OF INVENTIONSolution to Problems

[0006] In accordance with the present disclosure, a home appliance may include a housing, and a heat exchanger disposed inside the housing, the heat exchanger may include a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum, a second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor, and a filler metal configured to couple the first pipe and the second pipe together. At least of a portion of the first pipe or a portion of the second pipe may include a zinc diffusion layer. An electrical potential difference between any two of the filler metal, the first pipe, and the second pipe may be 50 mV or less.

[0007] In accordance with the present disclosure, a heat exchanger may include a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum, a second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor, and a filler metal configured to couple the first pipe and the second pipe together. At least of a portion of the first pipe or a portion of the second pipe may include a zinc diffusion layer. The filler metal is an alloy including zinc and aluminum, with zinc present at 10 to 90 wt % relative to a total weight of the alloy.

[0008] In accordance with the present disclosure, a home appliance may include a housing, and a heat exchanger disposed inside the housing, the heat exchanger may include a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum, and a second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor. The first pipe and the second pipe may be directly bonded so as to be integrally formed. A bonding width of a bonding portion of the first pipe and the second pipe directly bonded may be smaller than a thickness of the first pipe or a thickness of the second pipe.

[0009] The disclosure is not limited to the foregoing embodiments but various modifications or changes may rather be made thereto without departing from the spirit and scope of the disclosure.BRIEF DESCRIPTION OF DRAWINGS

[0010] FIG. 1 is a view illustrating one side of a heat exchanger according to an embodiment of the disclosure;

[0011] FIG. 2 is an enlarged perspective view illustrating a portion of a heat exchanger according to an embodiment of the disclosure:

[0012] FIG. 3 is a perspective view illustrating a heat exchanger with a partial area of FIG. 2 enlarged, according to an embodiment of the disclosure:

[0013] FIG. 4 is a top view illustrating a heat exchanger with a partial area of FIG. 2 enlarged, according to an embodiment of the disclosure:

[0014] FIG. 5 is a side view illustrating a heat exchanger with a partial area of FIG. 2 enlarged, according to an embodiment of the disclosure:

[0015] FIG. 6 is a graph illustrating potential values according to the composition of a filler material of the heat exchanger according to an embodiment of the disclosure:

[0016] FIG. 7 is a view illustrating a zinc diffusion layer of a first pipe and / or a second pipe of a heat exchanger according to an embodiment of the disclosure:

[0017] FIG. 8 is an enlarged view illustrating a zinc diffusion layer of a first pipe and / or

[0018] a second pipe of a heat exchanger according to an embodiment of the disclosure:

[0019] FIG. 9A is a view illustrating a structure in which a first pipe and a second pipe of a heat exchanger are coupled, according to an embodiment of the disclosure, viewed from one direction:

[0020] FIG. 9B is a view illustrating a structure in which a first pipe and a second pipe of a heat exchanger are coupled, according to an embodiment of the disclosure, viewed from another direction:

[0021] FIG. 10 is a cross-sectional view illustrating a coupling area before and after coupling of a first pipe and a second pipe of a heat exchanger according to an embodiment of the disclosure:

[0022] FIG. 11 is an enlarged view illustrating a coupling area before and after coupling of a first pipe and a second pipe of a heat exchanger according to an embodiment of the disclosure:

[0023] FIG. 12 is a view schematically illustrating a configuration related to a refrigerant cycle including a heat exchanger of an air conditioner according to an embodiment of the disclosure:

[0024] FIG. 13A is a perspective view illustrating an appearance of an indoor unit of an air conditioner according to an embodiment of the disclosure; and

[0025] FIG. 13B is a perspective view illustrating an appearance of an outdoor unit of an air conditioner according to an embodiment of the disclosure.MODE FOR THE INVENTION

[0026] It should be appreciated that various embodiments of the disclosure and the terms used therein are not intended to limit the technological features set forth herein to particular embodiments and include various changes, equivalents, or replacements for a corresponding embodiment.

[0027] With regard to the description of the drawings, similar reference numerals may be used to refer to similar or related elements.

[0028] It is to be understood that a singular form of a noun corresponding to an item may include one or more of the things, unless the relevant context clearly indicates otherwise.

[0029] As used herein, each of such phrases as “A or B,”“at least one of A and B,”“at least one of A or B,”“A, B, or C,”“at least one of A, B, and C,” and “at least one of A, B, or C,” may include all possible combinations of the items enumerated together in a corresponding one of the phrases.

[0030] In the disclosure, the term “and / or” may denote a combination(s) of a plurality of related components as listed or any of the components.

[0031] In the disclosure, such terms as “1st” and “2nd,” or “first” and “second” may be used to simply distinguish a corresponding component from another, and does not limit the components in other aspect (e.g., importance or order).

[0032] In the disclosure, the terms ‘front surface,’‘rear surface,’‘upper surface,’‘side surface,’‘left side,’‘right side,’‘upper portion,’ and ‘lower portion’ are defined with respect to the drawings, and the shape and position of each component are not limited by the terms.

[0033] It is to be understood that if an element (e.g., a first element) is referred to, with or without the term “operatively” or “communicatively”, as “coupled with,”“coupled to,”“connected with,” or “connected to” another element (e.g., a second element), it means that the element may be coupled with the other element directly (e.g., wiredly), wirelessly, or via a third element.

[0034] It will be further understood that the terms “comprise” and / or “have,” as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0035] It will be understood that when a component is referred to as “connected to,”“coupled to”, “supported on,” or “contacting” another component, the components may be connected to, coupled to, supported on, or contact each other directly or via a third component.

[0036] Throughout the specification, when one component is positioned “on” another component, the first component may be positioned directly on the second component, or other component(s) may be positioned between the first and second component.

[0037] FIG. 1 is a view illustrating one side of a heat exchanger according to an embodiment of the disclosure.

[0038] FIG. 2 is an enlarged perspective view illustrating a portion of a heat exchanger according to an embodiment of the disclosure.

[0039] Referring to FIGS. 1 and 2, the heat exchanger 10 may be disposed in a home appliance, such as an air conditioner (e.g., the air conditioner 1 of FIGS. 12 and 13), a refrigerator, or a dryer, to provide heat exchange.

[0040] According to an embodiment, the heat exchanger of the air conditioner may include an indoor evaporator and an outdoor condenser. The evaporator of the indoor unit may cool indoor air. For example, as indoor air passes through the evaporator, the refrigerant evaporates to absorb heat, and cold air may be sent indoors to lower the temperature. The condenser of the outdoor unit may discharge heat absorbed indoors to the outside. For example, as the refrigerant loses heat in the condenser and returns to the liquid state, the heat inside the room may be discharged to the outside.

[0041] According to an embodiment, the heat exchanger of the refrigerator may include an evaporator and a condenser. The evaporator may be disposed inside the refrigerator to form a moving path through which the refrigerant flows. The refrigerant absorbs heat while evaporating to cool the air inside the refrigerator. For example, the evaporator may absorb heat from the inside of the refrigerator to keep food fresh. The condenser is positioned at the rear of the refrigerator, and may discharge heat changed to a high-temperature state by compressing the refrigerant to the outside. For example, the condenser may release heat absorbed from the inside of the refrigerator to the outside to maintain a constant internal temperature.

[0042] According to an embodiment, the heat exchanger of the dryer is disposed in the heat pump and may exchange heat with a refrigerant circulating through the heat pump. Air discharged from the heat pump may be understood as high-temperature dry air. The compressor of the dryer compresses the refrigerant into a high-temperature and high-pressure state and discharges it, and the discharged refrigerant may flow into the condenser. The condenser may condense the compressed refrigerant and release heat to the surroundings through a condensation process. Further, an expansion device (e.g., an electronic expansion valve (EEV), hereinafter referred to as an expansion valve) in the heat pump may expand a high-temperature, high-pressure refrigerant condensed in the condenser into a low-pressure state. The evaporator may evaporate the expanded refrigerant and remove heat from the surroundings through the evaporation process.

[0043] According to an embodiment, a home appliance (e.g., air conditioner, refrigerator, or dryer) may include a housing (e.g., housing 410, 510 of FIGS. 13A and 13B), a heat exchanger 10 disposed inside the housing, and a fan (e.g., the outdoor blower 108 or indoor blower 109 of FIG. 12) which is disposed adjacent to the heat exchanger 10 to discharge air to the outside of the housing. The fan may be disposed at a position capable of exchanging heat with the outside.

[0044] According to an embodiment, the heat exchanger 10 may include a refrigerant pipe 100 including a plurality of pipes, fins 200 (e.g., radiating fins) coupled to the outer circumferential surface of the refrigerant pipe 100, and a cover portion 300 covering the refrigerant pipe 100 and the fins 200.

[0045] According to an embodiment, the refrigerant pipe 100 of the heat exchanger 10 may provide a refrigerant flow path. For example, a channel is formed inside the refrigerant pipe 100 so that the refrigerant may move. The refrigerant pipe 100 may have a serpentine (or zigzag) shape to increase the contact area between the refrigerant and the external space (e.g., to increase the heat exchange area with external air).

[0046] According to an embodiment, the refrigerant pipe 100 may include a plurality of straight pipes 100a and a connection pipe 100b (e.g., an U-pipe) connecting the plurality of straight pipes 100a. The plurality of straight pipes 100a may be disposed parallel to each other.

[0047] According to an embodiment, a plurality of fins 200 of the heat exchanger 10 may be provided, and may be positioned between the plurality of straight pipes 100a so that the refrigerant flowing along the channel formed inside the straight pipes 100a may efficiently exchange heat with the external air. When the straight pipes 100a of the refrigerant pipe 100 are disposed side by side in the first direction, the fins 200 may be disposed side by side in the second direction perpendicular to the first direction. For example, the plurality of fins 200 may be disposed to contact the straight pipes 100a in the heat exchange space. For example, the plurality of fins 200 may be provided along the outer circumferential surface of the straight pipes 100a in the length direction of the straight pipes 100a. The plurality of fins 200 may be disposed to be spaced apart from each other at a predetermined distance to limit (e.g., prevent) corrosion of the refrigerant pipe 100.

[0048] According to an embodiment, the cover portion 300 of the heat exchanger 10 may support the refrigerant pipes 100 and cover the refrigerant pipes 100 and the fins 200 so as not to be exposed to the outside. The cover portion 300 may be referred to as an evaporation portion providing a heat exchange function, and may maintain the shape of the heat exchanger by fixing the refrigerant pipes 100.

[0049] According to an embodiment, a sensor holder (hereinafter, referred to as the second pipe 120) configured to receive a sensor (e.g., a thermistor) may be disposed on some of the connection pipes 100b of the refrigerant pipe 100. Hereinafter, the coupling structure of the first pipe 110 and the second pipe 120 is described in detail.

[0050] FIG. 3 is a perspective view illustrating a heat exchanger with a partial area S of FIG. 1 or 2 enlarged, according to an embodiment of the disclosure.

[0051] FIG. 4 is a top view illustrating a heat exchanger with a partial area S of FIG. 1 or 2 enlarged, according to an embodiment of the disclosure.

[0052] FIG. 5 is a side view illustrating a heat exchanger with a partial area S of FIG. 1 or 2 enlarged, according to an embodiment of the disclosure.

[0053] According to an embodiment, a home appliance (e.g., a refrigerator, an air conditioner, or a dryer) may include a heat exchanger 10. The heat exchanger 10 may include a first pipe 110, a second pipe 120 disposed adjacent to the first pipe 110 and configured to receive a sensor (e.g., a thermistor), and a filler metal400 configured to couple the first pipe 110 and the second pipe 120.

[0054] According to an embodiment, the first pipe 110 of the heat exchanger 10 may be a portion of a refrigerant pipe (e.g., the refrigerant pipe 100 of FIGS. 1 and 2) that provides a refrigerant flow path. For example, the first pipe 110 may be one of connection pipes (e.g., the connection pipes 100b of FIGS. 1 and 2) connecting parallel straight pipes (e.g., the straight pipes 100a of FIGS. 1 and 2) in the refrigerant pipe 100. For example, the first pipe 110 may include a U-shaped pipe. However, the shape of the first pipe 110 is not limited thereto, and may be one of various shapes of connection pipes 100b positioned adjacent to the sensor 127.

[0055] According to an embodiment, the first pipe 110 has a shape that provides a passage through which the refrigerant moves, and the pipe may be named as at least one of a pipe, a pipeline, a tube, a conduit, or a line.

[0056] According to an embodiment, the first pipe 110 has a cylindrical shape, and may include a first wall 111 having a predetermined thickness formed to surround a space in which the refrigerant moves, and / or a rim portion 112 protruding from the outside of the first wall 111. The first wall 111 has a U-shape, and may include parallel portions and a curved portion for connecting with different straight pipes 100a. The rim portion 112 is a portion for fixing a position connected (e.g., fitted-coupled) to each of the different straight pipes 100a, and may be formed adjacent to an end portion of each of the parallel portions.

[0057] According to an embodiment, the first wall 111 of the first pipe 110 may include a first surface 111a facing the outside and a first core portion 111b forming the inside of the first wall 111. A portion of the first surface 111a may contact the second pipe 120 or may be coupled to the second pipe 120 by the filler metal 400. The coupling area of the first surface 111a coupled to the second pipe 120 may be positioned on a curved portion.

[0058] According to an embodiment, the second pipe 120 of the heat exchanger 10 provides a space for mounting the sensor (e.g., a thermistor) 127, and may be disposed on one side of the first pipe 110. For example, the sensor 127 may sense (e.g., monitor in real-time) the temperature of the refrigerant flowing through the first pipe 110. When the sensor 127 transfers the detected temperature to a system controller (not illustrated), the controller may control the operation of the compressor or the fan as necessary.

[0059] According to an embodiment, the second pipe 120 of the heat exchanger 10 is a straight pipe and may be designed to facilitate mounting of the cylindrical sensor 127. The second pipe 120 has a cylindrical shape, and may include a second wall 121 having a predetermined thickness formed to surround the space in which the sensor 127 is inserted and seated, and / or a stopper portion 122 extending from the second wall 121 and restricting movement of the sensor 127. The stopper portion 122 may be formed to surround a space having an area smaller than that of the space formed by the second wall 121, thereby preventing the sensor 127 from further moving linearly in one direction. However, the shape of the second pipe 120 is not limited thereto, and may be design-changed into various shapes for mounting the sensor 127.

[0060] According to an embodiment, the second pipe 120 has a shape that provides a space for disposing the sensor 127, and the pipe may be named as at least one of a pipe, a pipeline, a tube, a conduit, or a line.

[0061] According to an embodiment, the second wall 121 of the second pipe 120 may include a second surface 121a facing the outside and a second core portion 121b forming the inside of the second wall 121. A portion of the second surface 121a may contact the first pipe 110 or may be coupled to the first pipe 110 by the filler metal 400. The second surface 121a may be disposed to face the curved portion of the first pipe 110.

[0062] According to an embodiment, the first pipe 110 and the second pipe 120 may include the same alloy material. The first pipe 110 and the second pipe 120 may include aluminum (Al). For example, the first pipe 110 and the second pipe 120 may be one of A3xxx-based aluminum or A1xx-based aluminum. Since the first pipe 110 and the second pipe 120 are manufactured to have different shapes through the same process, when the first pipe 110 includes A3xxx-based aluminum, the second pipe 120 may also include A3xxx-based aluminum. When the first pipe 110 includes A1xxx-based aluminum, the second pipe 120 may also include A1xxx-based aluminum.

[0063] According to an embodiment, the first pipe 110 and / or the second pipe 120 may include a zinc diffusion layer (e.g., the zinc diffusion layer 115, 125 of FIG. 7). For example, the first pipe 110 and / or the second pipe 120 may form a zinc diffusion layer 115, 125 when coupled by the filler metal 400 to prevent the sacrificially corroded surface (e.g., the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120). For example, the first pipe 110 may include a first zinc diffusion layer 115, 125, and the second pipe 120 may include a second zinc diffusion layer 115, 125.

[0064] According to an embodiment, the first zinc diffusion layer (e.g., the zinc diffusion layer 115 of FIG. 7) of the first pipe 110 may be formed through a heat treatment process after arc-spraying zinc (Zn) on the first surface 111a. In the heat treatment process, the zinc (Zn) disposed on the first surface 111a may penetrate into the first core portion 111b and may be diffused. Through arc-spraying, zinc (Zn) has a content of 1 wt % or more relative to the total weight, and in the heat treatment process, the first zinc diffusion layer 115 may form a layer having a depth (or thickness) of about 10 μm.

[0065] According to an embodiment, the second zinc diffusion layer (e.g., the zinc diffusion layer 125 of FIG. 7) of the second pipe 120 may be formed through a heat treatment process after arc-spraying zinc (Zn) on the second surface 121a. In the heat treatment process, the zinc (Zn) disposed on the second surface 121a may penetrate into the second core portion 121b and may be diffused. Through arc-spraying, zinc (Zn) has a content of 1 wt % or more relative to the total weight, and in the heat treatment process, the second zinc diffusion layer 125 may form a layer having a depth (or thickness) of about 10 μm.

[0066] According to an embodiment, the zinc diffusion layer 115, 125 of the first pipe 110 and / or the second pipe 120 may be designed so that the potential difference between the filler metals 400 does not differ by a predetermined value or more due to the zinc (Zn) included in the filler metal 400 when coupled by the filler metal 400. This design may limit (e.g., reduce or prevent) decoupling between the first pipe 110, the second pipe 120, and the filler metal 400 by preventing a potential difference from occurring between the first pipe 110, the second pipe 120, and the filler metal 400.

[0067] According to an embodiment, the first pipe 110 and the second pipe 120 may be coupled to be misaligned with each other. For example, when viewed from above the second pipe 120 in a state in which the second pipe 120 is coupled on the curved portion of the first pipe 110, the angle between the center line L of the curved portion of the first pipe 110 and the center line L′ of the second pipe 120 may constitute an acute angle. For example, the curved portion of the first pipe 110 and the second pipe 120 may be disposed not to be parallel to each other. For example, the angle of the center line L′ of the second pipe 120 with respect to the center line L of the curved portion of the first pipe 110 may have a value of about 15 degrees or less. However, the angle between the first pipe 110 and the second pipe 120 is an angle to avoid interference with the surrounding components, and various design changes are possible between 0 and 90 degrees according to the presence or position of a surrounding component.

[0068] According to an embodiment, the filler metal 400 of the heat exchanger 10 may be configured to couple the first pipe 110 and the second pipe 120. The filler metal 400 is an auxiliary material used for welding the first pipe 110 and the second pipe 120, and melts during welding to couple the first pipe 110 and the second pipe 120, and after welding, the first pipe 110 and the second pipe 120 may form one component (e.g., a monolithic structure).

[0069] According to an embodiment, when welding the surfaces of the first pipe 110 and the second pipe 120, the filler metal 400 may fill the joint between the first pipe 110 and the second pipe 120 so that the first pipe 110 and the second pipe 120 are strongly coupled to each other. According to an embodiment, when welding the surfaces of the first pipe 110 and the second pipe 120, the filler metal 400 may increase the strength of the welding portion to ensure that the heat exchanger 10 is firmly maintained for a long time. For example, the filler metal 400 may provide the necessary physical properties so that the welding portion is stronger than the original metal (e.g., Al). According to an embodiment, the filler metal 400 may supplement the durability or thermal performance of the welding portion. For example, the filler metal 400 may use a material resistant to corrosion or adjust the coefficient of thermal expansion in the welding portion.

[0070] According to an embodiment, the filler metal 400 may include al alloy of aluminum (Al) and zinc (Zn). For example, the filler metal 400 may include aluminum (Al) and zinc (Zn) as the main content materials, and may include other impurities.

[0071] According to an embodiment, zinc (Zn) of the filler metal 400 may include about 10 to 90 wt % relative to the total weight, and may have substantially the same (or similar) potential value as the zinc diffusion layer 115, 125 of the first pipe 110 and the second pipe 120. For example, zinc (Zn) of the filler metal 400 may include about 40 to 70 wt % relative to the total weight.

[0072] According to an embodiment, potential values between the filler metal 400, the first pipe 110, and the second pipe 120 may be substantially the same. For example, the potential difference between the filler metal 400, the first pipe 110, and the second pipe 120 may be about 50 mV or less. For example, the potential difference between the filler metal 400, the first pipe 110, and the second pipe 120 may be about 30 mV or less. For example, a portion having substantially the same potential value as the filler metal 400 may be the surface of the first pipe 110 and / or the surface of the second pipe 120. In general, even when the filler metal 400, the first pipe 110, and the second pipe 120 include the same material (e.g., including Al, and Zn), a potential difference may occur according to the composition deviation of the alloy element. The heat exchanger 10 of the disclosure may limit (e.g., reduce or prevent) the separation between components by minimizing (e.g., substantially the same) the potential difference between the filler metal 400, the first pipe 110, and the second pipe 120 by adjusting the content of the alloy elements of the filler metal 400. The potential difference may be defined as a difference between the potential value of the material having the highest potential value among the filler metal 400, the first pipe 110, and the second pipe 120 and the potential value of the material having the lowest potential value among the filler metal 400, the first pipe 110, and the second pipe 120.

[0073] According to an embodiment, the filler metal 400 may adjust the potential value by adding impurities such as copper (Cu) or silicon (Si) to have a value identical or similar to the potential value of the first pipe 110 and the second pipe 120. For example, if the potential value of the filler metal 400 is relatively significantly decreased compared to the potential values of the first pipe 110 and the second pipe 120, the content of impurities such as copper (Cu) or silicon (Si) may be increased. As the content of impurities such as copper (Cu) or silicon (Si) in the filler metal 400 increases, the potential value of the filler metal 400 may be increased.

[0074] According to an embodiment, when a potential difference occurs between the filler metal 400, the first pipe 110, and the second pipe 120 in the heat exchanger 10, the potential value of the filler metal 400 may be designed to be lower than those of the first pipe 110 and the second pipe 120. For example, by setting the potential value of the filler material 400, which has a relatively larger volume (e.g., size) among the filler material 400, the first pipe 110, and the second pipe 120, to a lower value, it may limit (e.g., reduce or prevent) the separation between each component.

[0075] According to an embodiment, when comparing the potential values between the filler metal 400, the first surface 111a of the first pipe 110, the first core portion 111b of the first pipe 110, the second surface 121a of the second pipe 120, and the second core portion 121b of the second pipe 120 in the heat exchanger 10, the potential value of the filler metal 400 may be smaller than the potential value of the first core portion 111b of the first pipe 110 and the potential value of the second core portion 121b of the second pipe 120. The potential value of the first surface 111a of the first pipe 110 may be smaller than the potential value of the first core portion 111b of the first pipe 110 and the potential value of the second core portion 121b of the second pipe 120. The potential value of the second surface 121a of the second pipe 120 may be smaller than the potential value of the first core portion 111b of the first pipe 110 and the potential value of the second core portion 121b of the second pipe 120. The potential value of the filler metal 400 may be larger than or equal to the potential value of the first surface Illa of the first pipe 110 and the potential value of the second surface 121a of the second pipe 120.

[0076] FIG. 6 is a graph illustrating potential values according to the composition of a filler material of the heat exchanger according to an embodiment of the disclosure.

[0077] According to an embodiment, the heat exchanger 10 may include a first pipe 110, a second pipe 120 disposed adjacent to the first pipe 110 and configured to receive a sensor (e.g., a thermistor), and a filler metal 400 configured to couple the first pipe 110 and the second pipe 120.

[0078] According to an embodiment, the configuration of the filler metal 400 for coupling the first pipe 110 and the second pipe 120 of the heat exchanger 10 of FIG. 6 may be identical in whole or part to the configuration of the filler metal 400 for coupling the first pipe 110 and the second pipe 120 of the heat exchanger 10 of FIGS. 1 to 5.

[0079] The embodiment of FIG. 6 may selectively be combined with the embodiments of FIGS. 1 to 5, and FIGS. 7 to 13B.

[0080] According to an embodiment, the filler metal 400 may include al alloy of aluminum (Al) and zinc (Zn). For example, the filler metal 400 may include aluminum (Al) and zinc (Zn) as the main content materials, and may include other impurities.

[0081] Hereinafter, Table 1 is a table showing an alloy ratio between aluminum (Al) and zinc (Zn) of the filler metal 400.TABLE 1wt. %AlZnpotential [mV]990.05 or less−723991−822973−931955−9529010−10108020−11157030−12106040−12855050−13304060−13853070−14602080−15151090−1572

[0082] Referring to Table 1, it may be identified that the potential value mV decreases as the content of zinc (Zn) in the filler metal 400 increases.

[0083] According to an embodiment, when the zinc (Zn) of the filler metal 400 includes a content of about 10 to 90 wt % relative to the total weight, it may be designed to have substantially the same (or similar) potential value as the zinc diffusion layer (e.g., the zinc diffusion layer 115 of FIG. 7) of the first pipe 110 and the second pipe 120. When the zinc (Zn) of the filler metal 400 has a content of about 10 to 90 wt % relative to the total weight, the potential value of the filler metal 400 may be about −1010 mV to −1572 mV.

[0084] According to an embodiment, when the zinc (Zn) of the filler metal 400 includes a content of about 40 to 70 wt % relative to the total weight, the zinc diffusion layer (e.g., the zinc diffusion layer 115, 125 of FIG. 7) of the first pipe 110 and the second pipe 120 may have substantially the same (or similar) potential value. When the zinc (Zn) of the filler metal 400 has a content of about 40 to 70 wt % relative to the total weight, the potential value of the filler metal 400 may be about −1210 mV to −1385 mV. The zinc diffusion layer 115, 125 may be generated by heat treatment after arc-spraying zinc on the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120 so that the zinc constitutes about 3-7% relative to the total weight. The potential value of the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120 including the zinc diffusion layer 115 (or 125) may be about −1160 mV to −1335 mV. As the potential value of the filler metal 400 and the potential difference between the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120 are substantially the same (e.g., a difference of about 50 mV or less), separation between each component may be limited (e.g., decreased or prevented) after the first pipe 110 and the second pipe 120 are coupled.

[0085] FIG. 7 is a view illustrating a zinc diffusion layer of a first pipe and / or a second pipe of a heat exchanger according to an embodiment of the disclosure.

[0086] FIG. 8 is an enlarged view illustrating a zinc diffusion layer of a first pipe and / or a second pipe of a heat exchanger according to an embodiment of the disclosure.

[0087] According to an embodiment, the heat exchanger 10 may include a first pipe 110, a second pipe 120 disposed adjacent to the first pipe 110 and configured to receive a sensor (e.g., a thermistor), and a filler metal (e.g., the filler metal 400 of FIG. 5) configured to couple the first pipe 110 and the second pipe 120.

[0088] According to an embodiment, the configuration of the first pipe 110, the second pipe 120, and the filler metal 400 of the heat exchanger 10 of FIGS. 7 and 8 may be identical in whole or part to the configuration of the first pipe 110, the second pipe 120, and the filler metal 400 of the heat exchanger 10 of FIGS. 1 to 6. The embodiments of FIGS. 7 and 8 may be selectively combined with the embodiments of FIGS. 1 to 6, and 9 to 13B.

[0089] According to an embodiment, the first pipe 110 and / or the second pipe 120 may include a zinc diffusion layer 115, 125. The first pipe 110 and / or the second pipe 120 may form a zinc diffusion layer 115, 125 when coupled by the filler metal 400 to prevent the sacrificially corroded surface (e.g., the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120). As the zinc diffusion layer 115, 125 maintains substantially the same (or similar) potential value as the filler metal 400 including zinc (Zn), separation between the first pipe 110 and / or the second pipe 120 may be restricted (e.g., decreased or prevented) after welding.

[0090] According to an embodiment, the zinc diffusion layer 115, 125 may be formed through a heat treatment process after arc-spraying zinc on the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120. The arc-sprayed zinc may have a content of about 3 to 7 wt % relative to the total weight of the first pipe 110 and / or the second pipe 120.

[0091] According to an embodiment, after arc-spraying, during the heat treatment process, the zinc diffusion layer 115, 125 may form a layer as it diffuses from the first surface 111a of the first pipe 110 (and / or the second surface 121a of the second pipe 120) into the first core portion 111b of the first pipe 110 (and / or the second core portion 121b of the second pipe 120). After the heat treatment process is completed, the zinc diffusion layers 115 and 125 may be formed to have a depth (or thickness) of about 10 μm. For example, the zinc diffusion layers 115 and 125 may be formed to have a depth (or thickness) of about 100 μm.

[0092] According to an embodiment, the zinc diffusion layer 115, 125 may provide layers of various shapes. For example, the zinc diffusion layer 115, 125 may be formed to have a layer with an irregular thickness based on the different speeds of zinc (Zn) diffusion toward the first core portion 111b of the first pipe 110 (and / or the second core portion 121b of the second pipe 120. For example, the zinc diffusion layer 115, 125 may form layers with different thicknesses for each section (or position) as the content of zinc diffused toward the first core portion 111b of the first pipe 110 (and / or the second deep 121b of the second pipe 120 sequentially decreases.

[0093] Hereinafter, Table 2 illustrates the contents of compositions according to the depth of the zinc diffusion layer 115, 125 of the first pipe 110 and / or the second pipe 120.TABLE 2Composition [Weight %]Elements①②③④Mg0.260.250.310.35Al93.5295.9597.7098.67Si1.45———Mn0.770.430.650.64Zn4.003.381.350.34Total100.00

[0094] Referring to FIG. 8 and Table 2, the first pipe 110 and / or the second pipe 120 may include at least one of aluminum (Al), zinc (Zn), silicon (Si), manganese (Mn), and magnesium (Mg). The thickness of 100 μm disclosed in FIG. 8 is an example, and the area where zinc (Zn) is diffused may be variously design-changed considering the sizes of the first pipe 110 and / or the second pipe 120. The area 1) (area denoted by (1)) of FIG. 8 represents an area where zinc (Zn) is diffused, and it may be identified as the area close to the surface. The area (2) of FIG. 8 (area indicated by (2) represents the area where zinc (Zn) is diffused through the area 1, and it may be identified as the area under the area (1). The area 3 of FIG. 8 (area indicated by 3) represents the area where zinc (Zn) is diffused through the area (2), and it may be identified as the area under the area (2). The area 4) of FIG. 8 (area indicated by 4)) represents the area where zinc (Zn) is diffused through the area 3, and it may be identified as the area under the area 3). The zinc diffusion layer 115, 125 forms a thickness along the area 1, the area (2), the area (3) and the area 4), and may have a length of about 100 μm.

[0095] According to an embodiment, it may be identified that the zinc diffusion layer 115, 125 sequentially decreases as zinc (Zn) is diffused from the surface of the first pipe 110 and / or the second pipe 120 to the core portion. For example, zinc (Zn) included in the area (1) may have a content of about 4.0 wt % relative to the total weight. Zinc (Zn) included in the area 2 may have a content of about 3.38 wt % relative to the total weight. Zinc (Zn) included in the area 3 may have a content of about 1.35 wt % relative to the total weight. Zinc included in the area 44 may have a content of about 0.34 wt % relative to the total weight. As zinc (Zn) decreases from the surface of the first pipe 110 and / or the second pipe 120 to the core portion, the potential value of each area may increase.

[0096] According to an embodiment, the zinc diffusion layer 115, 125 of the first pipe 110 and / or the second pipe 120 may be designed so that the potential difference does not differ by a predetermined value or more due to the zinc (Zn) included in the filler metal 400 when coupled by the filler metal 400. This design may limit (e.g., reduce or prevent) decoupling between the first pipe 110, the second pipe 120, and the filler metal 400 by preventing a potential difference from occurring between the first pipe 110, the second pipe 120, and the filler metal 400.

[0097] FIG. 9A is a view illustrating a structure in which a first pipe and a second pipe of a heat exchanger are coupled, according to an embodiment of the disclosure, viewed from one direction.

[0098] FIG. 9B is a view illustrating a structure in which a first pipe and a second pipe of a heat exchanger are coupled, according to an embodiment of the disclosure, viewed from another direction.

[0099] FIG. 10 is a cross-sectional view illustrating the bonding portion before and after coupling of a first pipe and a second pipe of a heat exchanger according to an embodiment of the disclosure.

[0100] FIG. 11 is a cross-sectional view illustrating the bonding portion before and after coupling of a first pipe and a second pipe of a heat exchanger according to an embodiment of the disclosure.

[0101] According to an embodiment, the heat exchanger 10 may include a first pipe 110 and a second pipe 120 disposed adjacent to the first pipe 110 and configured to receive a sensor (e.g., a thermistor). The first pipe 110 and the second pipe 120 may provide a monolithic structure through direct coupling. The direct coupling may be at least one of laser coupling, fiber coupling, electrical coupling, magnetic coupling, optical coupling, or acoustic coupling. The following description focuses primarily on laser coupling.

[0102] According to an embodiment, the configuration of the first pipe 110 and the second pipe 120 of the heat exchanger 10 of FIGS. 9A to 11 may be identical in whole or part to the configuration of the first pipe 110 and the second pipe 120 of the heat exchanger 10 of FIGS. 1 to 8. The embodiments of FIGS. 9A to 11 may be selectively bonded with the embodiments of FIGS. 1 to 8.

[0103] Hereinafter, the embodiments of FIGS. 9A to 11 regard, rather than coupling of the first pipe 110 and the second pipe 120 through a filler metal, coupling of the first pipe 110 and the second pipe 120 through a laser, without using a filler metal. Hereinafter, laser coupling is described in detail.

[0104] According to an embodiment, as the first pipe 110 and the second pipe 120 are directly bonded using a laser, potential difference corrosion caused by the filler metal component may be limited (e.g., decreased or prevented).

[0105] According to an embodiment, the coupling structure of the heat exchanger 10 may be a structure in which the first pipe 110 and the second pipe 120 are brought into contact with each other, and then a high-power laser beam is radiated to the contact area between the first pipe 110 and the second pipe 120 to locally heat and melt the bonding portion A (e.g., the coupling area), and is then solidified to strongly couple the first pipe 110 and the second pipe 120.

[0106] According to an embodiment, the laser used in the coupling structure of the heat exchanger 10 may be at least one of a carbon dioxide (COU) laser, a fiber laser, a diode laser, and an Nd laser (neodymium:yittrium-aluminum-ganet laser).

[0107] By the welding process of the coupling structure of the heat exchanger 10, a surface treatment process may be performed on the first pipe 110 and the second pipe 120 before welding. For instance, the presence of impurities like oxide may deteriorate the quality of laser welding. Therefore, the surfaces of the first and second pipes 110 and 120 may undergo thorough cleaning to eliminate these impurities. Subsequently, as the first pipe 110 and the second pipe 120 to be welded should be aligned with precision, the first pipe 110 or the second pipe 120 may be secured using a jig or clamp to maintain a fixed position. For example, when a curved pipe (e.g., the first pipe 110) is included, precise position adjustment may be required. Then, the operator-selected laser may produce an appropriate output, locally heating the connection portion, such as the connection portion (e.g., the bonding portion A) between the first pipe 110 and the second pipe 120. For example, the high-power laser may instantly melt and bond the surfaces of the first pipe 110 and the second pipe 120. The first pipe 110 and the second pipe 120 which are metallic are melted at the portion radiated with the laser to form a melt pool, and the melt pool may form a welding line at the bonding portion A. The laser welding machine may perform welding along the entire bonding line between the first pipe 110 and the second pipe 120 at an accurate speed.

[0108] Then, the first pipe 110 and the second pipe 120 melted by the laser are cooled after welding, and in this process, the first pipe 110 and the second pipe 120 are coupled with each other to form a strong bonding portion A. Thereafter, when welding is completed, welding quality may be identified through a non-destructive inspection (NDT) technology. For example, ultrasound, X-ray, or video endoscopy may be employed to examine cracks, pores, or incomplete welding in the welding area of the heat exchanger 10.

[0109] According to an embodiment, in the coupling structure of the heat exchanger 10, a portion of the first pipe 110 and a portion of the second pipe 120 may form a bonding portion A where they overlap each other. The bonding portion A may be a portion in which a portion of the first pipe 110 and a portion of the second pipe 120 are melted and coupled. The partial length of the bonding portion A may have a value smaller than the thickness of each of the first pipe 110 or the second pipe 120. Referring to the cross-section of the coupling structure of the heat exchanger 10 of FIG. 10, the length in the direction from the bonding portion A toward the first center O1 of the first pipe 110 and / or the second center O2 of the second pipe 120 may be defined as a first width t3 of the bonding portion A, and the length perpendicular to the first width t3 may be defined as a first length L1 of the bonding portion A. The first thickness t1 of the first pipe 110 may be defined as a difference between the outer diameter and the inner diameter of the first pipe 110. The second thickness t2 of the second pipe 120 may be defined as a difference between the outer diameter and the inner diameter of the second pipe 120.

[0110] According to an embodiment, in the coupling structure of the heat exchanger 10, the first width t3 of the bonding portion A may be smaller than the first thickness t1 of the first pipe 110 or the second thickness t2 of the second pipe 120. For example, the first width t3 of the bonding portion A may be equal to or smaller than ½ of the first thickness t1 of the first pipe 110 or the second thickness t2 of the second pipe 120. For example, when the first thickness t1 of the first pipe 110 or the second thickness t2 of the second pipe 120 is about 1 mm, the first width t3 of the bonding portion A may be about 0.5 mm or less.

[0111] According to an embodiment, in the coupling structure of the heat exchanger 10, the first length L1 of the bonding portion A may be smaller than the outer diameter (or inner diameter) of the first pipe 110 or the outer diameter (or inner diameter) of the second pipe 120. For example, the first length L1 of the bonding portion A may have a size equal to or smaller than ½ of the outer diameter of the first pipe 110 or the outer diameter of the second pipe 120. For example, when the outer diameter of the first pipe 110 or the outer diameter of the second pipe 120 is about 7±0.05 mm, the first length L1 of the bonding portion A may be about 2 to 4 mm.

[0112] In one embodiment, the coupling structure of heat exchanger 10 may benefit from the bonding portion A for fast processing and mass production by minimizing the welding portion of the first pipe 110 and the second pipe 120 using a laser (e.g., reducing thermal deformation of the pipe material with localized heating) while maintaining strong bonding.

[0113] According to an embodiment, the coupling structure of heat exchanger 10 allows the first pipe 110 and the second pipe 120 to have an aesthetically pleasing joint (e.g., a welding portion) by using a laser. According to an embodiment, the first pipe 110 and the second pipe 120 may form a monolithic structure. The first pipe 110 and the second pipe 120 may be formed of the same material.

[0114] According to an embodiment, the first pipe 110 and the second pipe 120 may be a monolithic support body, and the bonding portion A of the monolithic support body may have a structure that is exposed to the outside of the heat exchanger 10 and seamlessly extends from the first pipe 110 to the second pipe 120.

[0115] According to an embodiment, the first pipe 110 and / or the second pipe 120 may include a zinc diffusion layer 115, 125. The zinc diffusion layer 115, 125 may be formed through a heat treatment process after arc-spraying zinc (Zn) on the first surface 111a of the first pipe 110 and / or the second surface 121a of the second pipe 120. The arc-sprayed zinc may have a content of about 3 to 7 wt % relative to the total weight of the first pipe 110 and / or the second pipe 120.

[0116] According to an embodiment, the first pipe 110 of the heat exchanger 10 may be a portion of a refrigerant pipe (e.g., the refrigerant pipe 100 of FIGS. 1 and 2) that provides a refrigerant flow path. For example, the first pipe 110 may include a U-shaped pipe.

[0117] According to an embodiment, the first wall 111 of the first pipe 110 may include a first surface 111a facing the outside and a first core portion 111b forming the inside of the first wall 111. A portion of the first surface 111a may contact the second pipe 120, or may form a bonding portion A by a laser to be coupled to the second pipe 120. The coupling area of the first surface 111a coupled to the second pipe 120 may be positioned on the curved portion.

[0118] According to an embodiment, the second pipe 120 of the heat exchanger 10 provides a space for mounting a sensor (e.g., a thermistor), and may be disposed on one side of the first pipe 110. For example, the sensor 127 may detect (e.g., monitor in real-time) the temperature of the refrigerant flowing through the first pipe 110.

[0119] According to an embodiment, the second wall 121 of the second pipe 120 may include a second surface 121a facing the outside and a second core portion 121b forming the inside of the second wall 121. A portion of the second surface 121a may contact the first pipe 110, or may form the bonding portion A by a laser to be coupled to the first pipe 110. The second surface 121a may be disposed to face the curved portion of the first pipe 110.

[0120] According to an embodiment, the first pipe 110 and the second pipe 120 may not cause a potential difference therebetween by performing laser coupling on the same material. It is possible to limit (e.g., reduce or prevent) decoupling between the first pipe 110 and the second pipe 120.

[0121] FIG. 12 is a view schematically illustrating a configuration related to a refrigerant cycle including a heat exchanger of an air conditioner according to an embodiment of the disclosure.

[0122] FIG. 13A is a perspective view illustrating an appearance of an indoor unit of an air conditioner according to an embodiment of the disclosure.

[0123] FIG. 13B is a perspective view illustrating an appearance of an outdoor unit of an air conditioner according to an embodiment of the disclosure.

[0124] FIGS. 12 to 13B illustrate a structure of an air conditioner as an example of a home appliance including a heat exchanger. Referring to FIG. 12, the configuration of the heat exchanger of the air conditioner may be identical in whole or part to the configuration of the heat exchanger 10 of FIGS. 1 to 11. The embodiments of FIGS. 12 to 13B may be selectively combined with the embodiments of FIGS. 1 to 11.

[0125] According to an embodiment, the air conditioner 1 may include a compressor 101 that compresses the refrigerant to change it to a high-temperature and high-pressure state, an outdoor heat exchanger 102 that performs heat exchange between the outdoor air and the refrigerant, an expansion device 103 that expands the refrigerant to change it to a low-temperature and low-pressure state, and an indoor heat exchanger 104 that performs heat exchange between the indoor air and the refrigerant. The air conditioner 1 may include a refrigerant pipe 105 (e.g., the refrigerant pipe 100 of FIGS. 1 and 2) connecting the compressor 101, the outdoor heat exchanger 102, the expansion device 103, and the indoor heat exchanger 104. In an example, the refrigerant may circulate in the order of the compressor 101, the outdoor heat exchanger 102, the expansion device 103, and the indoor heat exchanger 104 through the refrigerant pipe 105. In an example, the refrigerant may circulate in the order of the compressor 101, the indoor heat exchanger 104, the expansion device 103, and the outdoor heat exchanger 102.

[0126] According to an embodiment, the air conditioner 1 may include a flow path switching valve 106 for switching the circulation path of the refrigerant through the refrigerant pipe 105. The flow path switching valve 106 may include, e.g., a four-way valve. The flow path switching valve 106 may be connected to the suction unit 101a of the compressor 101. The flow path switching valve 106 may be connected to the discharge unit 101b of the compressor 101. The flow path switching valve 106 may be connected to the outdoor heat exchanger 102. The flow path switching valve 106 may be connected to the indoor heat exchanger 104. The flow path switching valve 106 may switch the circulation path of the refrigerant depending on the operation mode (e.g., a cooling operation mode or a heating operation mode) of the air conditioner 1. The flow path switching valve 106 may allow the high-temperature and high-pressure refrigerant discharged through the discharge unit 101b from the compressor 101 to flow to the outdoor heat exchanger 102 or the indoor heat exchanger 104 according to the operation mode of the air conditioner 1. The flow path switching valve 106 may allow the refrigerant from the indoor heat exchanger 104 or the outdoor heat exchanger 102 to flow to the suction unit 101a of the compressor 101 according to the operation mode of the air conditioner 1.

[0127] According to an embodiment, the air conditioner 1 may include an accumulator 107. One end of the accumulator 107 may be connected to the suction unit 101a of the compressor 101. The other end of the accumulator 107 may be connected to the flow path switching valve 106. Through the flow path switching valve 106, a low-temperature and low-pressure refrigerant from the indoor heat exchanger 104 or the outdoor heat exchanger 102 may flow into the accumulator 107. When the refrigerant in which a refrigerant liquid and a refrigerant gas are mixed is introduced, the accumulator 107 may separate the refrigerant gas from the refrigerant liquid and provide the refrigerant gas from which the refrigerant liquid is separated to the suction unit 101a of the compressor 101.

[0128] According to an embodiment, the compressor 101 may suck the refrigerant gas through the suction unit 101a and compress the sucked refrigerant gas and convert it into a high-temperature and high-pressure state. The compressor 101 may discharge the high-temperature and high-pressure refrigerant gas through the discharge unit 101b. The compressor 101 is a capacitive variable compressor, and may vary the capacitance by changing the frequency according to a driving control command.

[0129] According to an embodiment, the outdoor heat exchanger 102 may be typically disposed outdoors. In the outdoor heat exchanger 102, heat exchange between the refrigerant and outdoor air may be achieved by a phase change (e.g., condensation or evaporation) of the refrigerant passing through the outdoor heat exchanger 102. For example, during cooling mode operation, the outdoor heat exchanger 102 may condense the high-temperature and high-pressure refrigerant introduced from the compressor 101. During cooling mode operation, latent heat may be discharged to outdoor air while the high-temperature and high-pressure refrigerant is condensed while passing through the outdoor heat exchanger 102. During the heating mode operation, in the outdoor heat exchanger 102, the low-temperature and low-pressure refrigerant may be evaporated, and latent heat may be absorbed from the outdoor air while the refrigerant is evaporated. Although not illustrated in FIG. 1, in an example, one or more temperature sensors for temperature detection of outdoor air may be disposed at an adjacent position of the outdoor heat exchanger 102.

[0130] According to an embodiment, the air conditioner 1 may include an outdoor blower 108 that generates forced circulation of outdoor air so that heat exchange in the outdoor heat exchanger 102 is smooth. The outdoor blower 108 may be disposed adjacent to the outdoor heat exchanger 102. Although not illustrated in detail, the outdoor blower 108 may include one or more blower fans and fan motors. The fan motor of the outdoor blower 108 may provide a driving force to the blower fan through the shaft.

[0131] According to an embodiment, the expansion device 103 may lower the pressure and temperature of the refrigerant condensed in the outdoor heat exchanger 102 when operating in the cooling mode. The expansion device 103 may lower the pressure and temperature of the refrigerant introduced from the indoor heat exchanger 104 during the heating mode operation. In an example, the expansion device 103 may lower the temperature and pressure of the refrigerant using the throttling effect. The expansion device 103 may include an orifice capable of reducing the cross-sectional area of the flow path. The temperature and pressure of the refrigerant passing through the orifice may be lowered. In an example, the expansion device 103 may be implemented as an electronic expansion valve that may adjust the opening ratio (an electronic expansion valve that may adjust the ratio of the cross-sectional area of the valve's flow path in a partially opened state to the cross-sectional area of the valve's flow path in a fully opened state). In such a case, the amount of refrigerant passing through the expansion device 103 may be controlled depending on the opening ratio of the electromagnetic expansion valve. In an example, the expansion device 103 may be implemented as a capillary device.

[0132] According to an embodiment, the indoor heat exchanger 104 may be disposed indoors. In the indoor heat exchanger 104, heat exchange between the refrigerant and indoor air may be achieved by a phase change (e.g., evaporation or condensation) of the refrigerant passing through the indoor heat exchanger 104. For example, during cooling mode operation, the refrigerant passing through the expansion device 103 may flow into the indoor heat exchanger 104 and evaporate from the indoor heat exchanger 104. While the refrigerant evaporates in the indoor heat exchanger 104, latent heat may be absorbed from the surrounding air, thereby cooling the surrounding air. When operating in the heating mode, the high-temperature and high-pressure refrigerant from the compressor 101 may be introduced into the indoor heat exchanger 104 and condensed, and latent heat may be released into indoor air. Although not illustrated in FIG. 1, the indoor heat exchanger 104 may include a refrigerant flow path through which refrigerant flows and a plurality of heat exchange fins provided to increase the heat exchange area.

[0133] In the cooling mode operation, water vapor contained in the air may be condensed and liquefied on the surface of the indoor heat exchanger 104 by heat exchange between the surrounding indoor air and the refrigerant performed in the indoor heat exchanger 104. The condensate formed on the surface of the indoor heat exchanger 104 may fall downward. Although not illustrated in FIG. 12, the air conditioner 1 may include a drain tray disposed under the indoor heat exchanger 104 to collect condensate falling from the indoor heat exchanger 104. Condensate accommodated in the drain tray may be drained to the outside through a drain hose. The drain tray may be provided to support the indoor heat exchanger 104 from below, but is not limited thereto.

[0134] According to an embodiment, the air conditioner 1 may include an indoor blower 109 that generates forced circulation of indoor air so that heat exchange in the indoor heat exchanger 104 is smooth. The indoor blower 109 may be disposed adjacent to the indoor heat exchanger 104. Although not specifically illustrated, in an example, the indoor blower 109 may be disposed downstream of the indoor heat exchanger 104 with respect to the air flow direction in the space where the indoor blower 109 is installed, but the disclosure is not limited thereto. The indoor blower 109 may include one or more blower fans and fan motors. The fan motor of the indoor blower 109 may provide a driving force to the blower fan through the shaft. In an example, the blower fan may include one of an axial fan that sucks air in the rotation axis direction of the fan motor and discharges air in the rotation axis direction, a diagonal fan that sucks air in the rotation axis direction of the fan motor and discharges air in a direction between the axial direction and the radial direction, a centrifugal fan and cross flow fan that suck air in the rotation axis direction of the fan motor and discharges the air in the circumferential direction, but the disclosure is not limited thereto.

[0135] In the disclosure, the description focuses primarily on the case where the air conditioner 1 has cooling cycle-related components, but the disclosure is not limited thereto. In an example, the air conditioner may be configured using a thermoelectric element. The thermoelectric element may cool or heat the surrounding air through heat generation and cooling through the Peltier effect.

[0136] According to an embodiment, the air conditioner 1 may include one or more outdoor units installed outdoors and one or more indoor units installed indoors. In an example, the compressor 101, the outdoor heat exchanger 102, and the expansion device 103 described above may be disposed in the outdoor unit. In an example, the above-described indoor heat exchanger 104 may be disposed in the indoor unit. However, the disposition position of each of the above-described components is not limited. For example, the position of the expansion device 103 is not limited to the outdoor unit, but may be disposed in the indoor unit as necessary.

[0137] The description in the disclosure focuses on the case where the air conditioner 1 is of a separate type with an outdoor unit installed outdoors and an indoor unit installed indoors, respectively, but the disclosure is not limited to this. In an example, the air conditioner 1 may be configured as an integrated type in which a compressor 101, an outdoor heat exchanger 102, an expansion device 103, and an indoor heat exchanger 104 are disposed in a single case placed indoors.

[0138] In the case of the separated air conditioner 1, the outdoor unit may be connected to the indoor unit to allow fluid communication through the refrigerant pipe. The outdoor unit may be communicatively connected to the indoor unit. In an example, control information (or command) of the air conditioner 1 input by the user or received from the outside may be transferred from the indoor unit to the outdoor unit.

[0139] In the case of an air conditioner including a plurality of indoor units, some of the indoor units may be operated in the cooling mode and the rest of the indoor units may be simultaneously individually in the heating mode. When operating the plurality of indoor units, in order to effectively respond to the cooling or heating load according to the number of indoor units operated, the air conditioner may be used with connecting the plurality of compressors or the plurality of outdoor units connected in parallel with each other.

[0140] According to an embodiment, the air conditioner 1 may be classified according to the installation type / position of the indoor unit. For example, air conditioners may be divided into a standing type in which the indoor unit is placed upright in an indoor space, a wall-mounted type installed to be attached to the wall, and a ceiling-mounted type installed on the ceiling. In an example, the air conditioner 1 includes a plurality of indoor units, some indoor units may be configured in the standing type, and some indoor units may be configured in the wall-mounted type, but the disclosure is not limited to a specific form.

[0141] Referring to FIGS. 13A and 13B, the indoor unit 20 of the air conditioner 1 may include a housing 410 forming the outer appearance. The housing 410 may include a front frame 412 covering the front of the housing 410, a rear frame 414 covering the rear, and a center frame 416 disposed therebetween. According to an embodiment, each of the front frame 412 and the rear frame 414 may be detachable from the center frame 416 but the disclosure is not limited thereto.

[0142] According to an embodiment, a front panel 418 may be disposed on the front frame 412.

[0143] According to an embodiment, the front panel 418 may include an input unit 420. According to an embodiment, the input unit 420 includes any type of user input means including a button, a switch, and a touch pad, and setting data (e.g., desired temperature, cooling / dehumidifying / air purifying operation mode settings, and air volume settings) may be input by the user through the input unit 420.

[0144] According to an embodiment, the front panel 418 may include a display module 422. The display module 422 may display information (e.g., desired temperature, air volume setting, and / or driving mode setting) inputted from the user through the input unit 420.

[0145] According to an embodiment, the display module 422 may display various pieces of sensing information (e.g., current indoor temperature measured by a temperature sensor), the current air volume or operation state of the air conditioner 1, and / or various warning messages on the air conditioner 1.

[0146] According to an embodiment, the display module 422 may be provided at various positions of the air conditioner 1. For example, according to the embodiment of FIG. 13A, the display module 422 is illustrated as being provided on the front panel 418, but is not limited thereto.

[0147] According to an embodiment, the outdoor unit 30 may include a housing 510, internal components (e.g., the compressor 101, outdoor heat exchanger 102, expansion device 103, and / or flow path switching valve 106 of FIGS. 1 and 2) disposed in the housing 510, and an outdoor blower 108 that generates forced air blowing for heat exchange between the outdoor heat exchanger 102 and outdoor air. The outdoor blower 108 may include one or more blower fans 108a and a fan motor, and the fan motor of the outdoor blower 108 may provide a driving force to the blower fan 108a through a shaft.

[0148] According to an embodiment, the housing 510 may form the outer appearance of the outdoor unit 30 and accommodate various components therein. The housing 510 may have an overall hexahedral shape. For example, the housing 510 may include a front frame 511 substantially covering the front surface (e.g., +X-axis direction), a rear frame 512 substantially covering the rear surface (e.g., −X-axis direction), a side frame 513, 514 substantially covering the side surface (e.g., +Y-axis and / or −Y-axis direction), and an upper or lower frame 515, 516 substantially covering the upper surface (e.g., +Z-axis direction) and / or the lower surface (e.g., −Z-axis direction). Frames facing two or more surfaces among the frames (e.g., the front, rear, side, upper, and lower frames 511, 512, 513, 514, 515, and 516) of the housing 510 may be integrally formed.

[0149] According to an embodiment, an inlet (not illustrated) through which external air is suctioned may be formed in one area of the side frame 513, 514 and / or the rear frame 512 of the housing 510, and an outlet 511c through which the suctioned external air is discharged may be formed in one area of the front frame 511. As the blower fan 108a is disposed adjacent to the outlet 511c and is rotated by a fan motor rotating based on a control command, the blower fan 108a may forcibly suction the external air. By the rotation of the blower fan 108a of the outdoor blower (e.g., the outdoor blower 108 of FIG. 12), the air flow and heat exchange around the outdoor heat exchanger (e.g., the outdoor heat exchanger 102 of FIG. 1) of the air conditioner 1 may be smoothly performed.

[0150] In general, an aluminum heat exchanger of an electronic device (e.g., a home appliance) includes a sensor holder, which is coupled to a refrigerant pipe using a filler metal and may use the same material as the refrigerant pipe. For example, when welding to couple the Al 3xxx-based refrigerant pipe and the Al 3xxx-based sensor holder, brazing may be used using an Al 4xxx-based filler metal. In this case, the potential value of the filler metal is relatively high compared to the potential values of the refrigerant pipe and the sensor holder, and a large potential difference may occur between components. This potential difference may cause sacrificial corrosion on a portion of the surface of the refrigerant pipe, and the sensor holder may be easily separated from the refrigerant pipe.

[0151] In the home appliance according to an embodiment of the disclosure, the heat exchanger may ensure a stable coupling between the refrigerant pipe, the sensor holder, and the filler metal.

[0152] In the home appliance according to an embodiment of the disclosure, the heat exchanger may limit (e.g., reduce or prevent) the separation of the sensor holder from the refrigerant pipe by forming the filler metal with an alloy (e.g., a Zn—Al alloy) including aluminum and zinc to reduce or equalize the potential difference between the refrigerant pipe, the sensor holder, and the filler metal.

[0153] In the home appliance according to an embodiment of the disclosure, the heat exchanger may be designed to minimize or substantially equalize the potential differences from the filler metal by forming the refrigerant pipe and the sensor holder with the same aluminum material, arc-spraying zinc onto the surfaces of the refrigerant pipe and the sensor holder, and then conducting heat treatment thereon.

[0154] In the home appliance according to an embodiment of the disclosure, the heat exchanger may form a zinc diffusion layer that prevents sacrificial corrosion to the refrigerant pipe or the sensor holder.

[0155] In the home appliance according to an embodiment of the disclosure, the heat exchanger may limit (e.g., reduce or prevent) sacrificial corrosion due to a potential difference from the filler metal through laser coupling between the refrigerant pipe and the sensor holder.

[0156] In home appliances according to an embodiment of the disclosure, a heat exchanger formed by direct coupling (e.g., laser coupling, fiber coupling, and electrical coupling) between refrigerant pipes and sensor holders may provide a clean appearance and provide mass production due to high-speed work.

[0157] Effects obtainable from the disclosure are not limited to the above-mentioned effects, and other effects not mentioned may be apparent to one of ordinary skill in the art from the following description.

[0158] A home appliance according to an embodiment of the disclosure may comprise a housing 410, 510, and a heat exchanger 10 disposed inside the housing. The heat exchanger may comprise a first pipe 110 providing a flow path along which a refrigerant is flowable, and including aluminum, a second pipe 120 adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor 127, and a filler metal 400 configured to couple the first pipe and the second pipe together. At least one of a portion of the first pipe or a portion of the second pipe may include a zinc diffusion layer 115, 125. An electrical potential difference between any two of the filler metal, the first pipe, and the second pipe may be 50 mV or less.

[0159] According to an embodiment, the filler metal 400 may be an alloy including zinc and aluminum, and the alloy includes 10 to 90 wt % zinc relative to a total weight of the alloy.

[0160] According to an embodiment, the filler metal 400 may be an alloy including including zinc and aluminum, and the alloy includes 40 to 70 wt % zinc relative to the total weight of the alloy.

[0161] According to an embodiment, the zinc diffusion layer 115, 125 may include a layer extending from a surface of the first pipe or the second pipe to a core portion thereof by a thickness of 10 μm or more.

[0162] According to an embodiment, the zinc diffusion layer 115 may be formed to have a layer with an irregular thickness by arc-spraying Zn zinc onto a surface of the first pipe and diffusing the Zn into a core portion of the first pipe by heat treatment.

[0163] According to an embodiment, the zinc diffusion layer 125 may be formed to have a layer with an irregular thickness by arc-spraying Zn zinc onto a surface of the second pipe and diffusing the Zn into a core portion of the second pipe by heat treatment.

[0164] According to an embodiment, the electrical potential difference between any two of the filler metal, the first pipe, and the second pipe may be 30 mV or less.

[0165] According to an embodiment, an electrical potential value of the filler metal may be configured to be less than or equal to a surface potential value of the first pipe or a surface potential value the second pipe.

[0166] According to an embodiment, a core portion of the first pipe may be have an electrical potential value that is higher than an electrical potential value of a surface of the first pipe, and a core portion of the second pipe may be have an electrical potential value that is higher an electrical potential value of a surface of the second pipe. The filler metal may be configured to have an electrical potential value that is lower than the electrical potential value of the core portion of the first pipe and / or the electrical potential value of the second pipe.

[0167] According to an embodiment, a material of the first pipe includes A3xxx series or A1xxx series aluminum, and a material of the second pipe includes A3xxx series or A1xxx series aluminum.

[0168] According to an embodiment, a portion of the first pipe may include a bent portion, and the second pipe may be coupled on the bent portion by the filler metal.

[0169] According to an embodiment, the first pipe may include the zinc diffusion layer and the zinc diffusion layer may include 3 to 7 wt % zinc relative to a total weight of the first pipe.

[0170] According to an embodiment, the second pipe may include the zinc diffusion layer and the zinc diffusion layer may include 3 to 7 wt % zinc relative to a total weight of the second pipe.

[0171] According to an embodiment, the zinc diffusion layer may have a thickness of 100 μm or more from a surface of the first pipe or the second pipe to a core portion thereof. A content of Zn zinc in the zinc diffusion layer may gradually decrease from the surface to the core portion.

[0172] According to an embodiment, in a state where the second pipe is coupled on the bent portion of the first pipe, when viewed from above the second pipe, a designated angle may be formed between a center line L of the bent portion and a center line L′ of the second pipe.

[0173] A heat exchanger according to an embodiment of the disclosure may comprise a first pipe 110 providing a flow path along which a refrigerant is flowable, and including aluminum, a second pipe 120 adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor 127, and a filler metal 400 configured to couple the first pipe and the second pipe together. At least one of a portion of the first pipe or a portion of the second pipe may include a zinc diffusion layer 115, 125. The filler metal 400 may be an alloy including zinc and aluminum, with zinc present at 10 to 90 wt % relative to a total weight of the alloy.

[0174] According to an embodiment, an electrical potential difference between any two of the filler metal, the first pipe, and the second pipe may be 50 mV or less.

[0175] According to an embodiment, the alloy of the metal may include 40 to 70 wt % zinc relative to the total weight of the alloy.

[0176] A home appliance according to an embodiment of the disclosure may comprise a housing 410, 510, and a heat exchanger 10 disposed inside the housing. The heat exchanger may comprise a first pipe 110 providing a flow path along which is a refrigerant is flowable, and including aluminum, and a second pipe 120 adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor 127. The first pipe and the second pipe may be directly bonded so as to be integrally formed. A bonding width t3 of a bonding portion A of the first pipe and the second pipe may be smaller than a thickness of the first pipe or a thickness of the second pipe.

[0177] According to an embodiment, the first pipe may have a first thickness t1, and the second pipe may have a second thickness t2 corresponding to the first thickness. The bonding width t3 of the bonding portion A may be ½ or less of the first thickness or the second thickness.

[0178] A bonding length L1 perpendicular to the bonding width t3 of the bonding portion A may be larger than a thickness of the first pipe or the second pipe.

[0179] According to an embodiment, the first pipe and the second pipe may be a monolithic support body extending seamlessly, and the monolithic support body may be exposed to the outside of the heat exchanger.

Claims

1. A home appliance, comprising:a housing; anda heat exchanger disposed inside the housing, the heat exchanger including:a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum,a second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor, anda filler metal configured to couple the first pipe and the second pipe together,wherein at least of a portion of the first pipe or a portion of the second pipe includes a zinc diffusion layer, andwherein an electrical potential difference between any two of the filler metal, the first pipe, and the second pipe is 50 mV or less.

2. The home appliance of claim 1, whereinthe filler metal is an alloy including zinc and aluminum, andthe alloy includes 10 to 90 wt % zinc relative to a total weight of the alloy.

3. The home appliance of claim 1, whereinthe filler metal is an alloy including zinc and aluminum, andthe alloy includes 40 to 70 wt % zinc relative to a total weight of the alloy.

4. The home appliance of claim 1, whereinthe zinc diffusion layer includes a layer extending from a surface of the first pipe or the second pipe to a core portion thereof by a thickness of 10 μm or more.

5. The home appliance of claim 1, wherein the zinc diffusion layer has an irregular thickness as a result of:zinc having been arc-sprayed onto a surface of the first pipe and diffused into a core portion of the first pipe by heat treatment, and / orzinc having been arc-sprayed onto a surface of the second pipe and diffused into a core portion of the second pipe by heat treatment.

6. The home appliance of claim 1, wherein the electrical potential difference between any two of the filler metal, the first pipe, and the second pipe is 30 mV or less.

7. The home appliance of claim 1, wherein an electrical potential value of the filler metal is configured to be less than or equal to a surface potential value of the first pipe or a surface potential value the second pipe.

8. The home appliance of claim 1, whereina core portion of the first pipe has an electrical potential value that is higher than an electrical potential value of a surface of the first pipe,a core portion of the second pipe has an electrical potential value that is higher than an electrical potential value of a surface of the second pipe, andthe filler metal is configured to have an electrical potential value that is lower than the electrical potential value of the core portion of the first pipe and / or the electrical potential value of the second pipe.

9. The home appliance of claim 1, whereina material of the first pipe includes A3xxx series aluminum or A1xxx series aluminum, anda material of the second pipe includes A3xxx series aluminum or A1xxx series aluminum.

10. The home appliance of claim 1, whereina portion of the first pipe includes a bent portion, andthe second pipe is coupled on the bent portion by the filler metal.

11. The home appliance of claim 1, whereinthe first pipe includes the zinc diffusion layer and the zinc diffusion layer includes 3 to 7 wt % zinc relative to a total weight of the first pipe, and / orthe second pipe includes the zinc diffusion layer and the zinc diffusion layer includes 3 to 7 wt % zinc relative to a total weight of the second pipe.

12. The home appliance of claim 1, whereinthe zinc diffusion layer has a thickness of 100 μm or more from a surface of the first pipe or the second pipe to a core portion thereof, and wherein a content of Zn (zinc) in the zinc diffusion layer gradually decreases from the surface to the core portion.

13. The home appliance of claim 1, whereinin a state where the second pipe is coupled on the bent portion of the first pipe, when viewed from above the second pipe, a designated angle is formed between a center line (L) of the bent portion and a center line (L′) of the second pipe.

14. A heat exchanger comprising:a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum;a second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor; anda filler metal configured to couple the first pipe and the second pipe together,wherein at least of a portion of the first pipe or a portion of the second pipe includes a zinc diffusion layer wherein the filler metal is an alloy including zinc and aluminum, with zinc present at 10 to 90 wt % relative to a total weight of the alloy.

15. The heat exchanger of claim 14, wherein an electrical potential difference between any two of the filler metal, the first pipe, and the second pipe is 50 mV or less.

16. The heat exchanger of claim 14, whereinthe alloy of the filler metal includes 40 to 70 wt % zinc relative to the total weight of the alloy.

17. A home appliance, comprising:a housing; anda heat exchanger disposed inside the housing, the heat exchanger including:a first pipe providing a flow path along which a refrigerant is flowable, and including aluminum, anda second pipe adjacent to the first pipe, the second pipe including aluminum, and configured to receive a sensor,wherein the first pipe and the second pipe are directly bonded so as to be integrally formed, andwherein a bonding width of a bonding portion of the first pipe and the second pipe is smaller than a thickness of the first pipe or a thickness of the second pipe.

18. The home appliance of claim 17, whereinthe first pipe has a first thickness (t1), and the second pipe has a second thickness (t2) corresponding to the first thickness, andwherein the bonding width (t3) of the bonding portion (A) is ½ or less of the first thickness or the second thickness.

19. The home appliance of claim 17, whereina bonding length (L1) perpendicular to the bonding width (t3) of the bonding portion (A) is larger than a thickness of the first pipe or the second pipe.

20. The home appliance of any one of claim 17, wherein the first pipe and the second pipe are a monolithic support body that result from having been bonded by a laser.

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