Air conditioner piping system and method of producing the same
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Solution Overview
Problem
Conventional air conditioner piping systems using metal materials face issues such as increased complexity and cost due to vibration sensitivity, deformation, and pressure loss, along with quality defects from brazing and caulking methods.
Innovation Solution
The system uses plastic materials for the refrigerant pipe, connection flange, and charging port, bonded by laser welding to maintain consistent diameter, reduce weight, and isolate vibrations, preventing damage and pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials (aluminum) are used for refrigerant pipe and connection flange, then strength and durability are improved, but vibration sensitivity increases and requires additional vibration isolation components
Solution Approach 1:
The patent changes the material parameter from metal (aluminum) to plastic, fundamentally altering the vibration characteristics. Plastic materials inherently provide vibration isolation properties, eliminating the need for separate vibration isolation components while maintaining structural integrity for refrigerant piping applications
Solution Approach 2:
The patent employs plastic material as a composite solution that combines multiple functions: structural strength for piping, inherent vibration isolation properties, and laser weldability. This single material replacement addresses multiple requirements simultaneously, eliminating the need for separate vibration isolation hoses and reducing system complexity
2Strength
If caulking method or brazing method is used to connect refrigerant pipe and flange, then connection strength is improved, but diameter deformation and step occurrence increase causing pressure loss
Solution Approach 1:
The patent replaces mechanical connection methods (caulking, brazing, soldering) with laser welding. This substitution eliminates the mechanical deformation and thermal distortion associated with traditional methods, maintaining consistent pipe diameter throughout the connection and preventing pressure loss while achieving strong connections
Solution Approach 2:
The patent changes the connection process parameters by using laser welding instead of mechanical or thermal-brazing methods. Laser welding provides precise control over heat input and connection formation, preventing diameter deformation and step occurrence that plague traditional connection methods
3Strength
If brazing welding is used to connect refrigerant pipe, connection flange, and charging port, then connection strength is improved, but temperature control difficulty increases causing damage or puncture
Solution Approach 1:
The patent replaces the brazing process with laser welding, substituting a process requiring high temperature and filler material with a direct energy beam welding process. Laser welding provides superior temperature control through precise energy delivery, eliminating the risk of excessive heat causing damage or puncture while maintaining strong connections
4Object-affected harmful factors
If vibration isolation hose is added to cover refrigerant pipe, then vibration isolation effect is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the vibration isolation function into the refrigerant pipe material itself by using plastic. This consolidation eliminates the need for separate vibration isolation hoses, reducing the number of components and simplifying the overall system while maintaining effective vibration isolation
Solution Approach 2:
The plastic material serves multiple functions simultaneously: it provides the structural conduit for refrigerant flow, inherent vibration isolation properties, and laser weldability for connections. This multi-functionality eliminates the need for separate specialized components, reducing system complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides weight reduction, vibration isolation, and minimizes pressure loss while ensuring strong connections without deformation or damage, maintaining consistent diameter and improving electrical insulation.
Implementation Method 1
connecting the refrigerant pipe, the connection flange, and the charging port through laser welding
Data Source
AI summary
An air conditioning piping system of the disclosure includes a refrigerant pipe made of a plastic material and configured to provide a fluid flow between components constituting an air conditioning system; at least one connection flange made of the plastic material and configured to provide a connection between the refrigerant pipe and components constituting the air conditioner system; and at least one charging port made of the plastic material and having a charging valve configured to inject a refrigerant into the refrigerant pipe.