Air conditioner with flow direction changing mechanism
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Solution Overview
Problem
Conventional microchannel heat exchangers face challenges in uniformly distributing refrigerant across refrigerant tubes due to varying flow resistance and swirling issues, leading to inefficient heat exchange, especially with fluctuating flow rates and complex separating plate configurations, which also increase costs.
Innovation Solution
A header design with a main header chamber and sub header chambers, featuring a flow direction changing mechanism that redirects refrigerant from a horizontal inlet to a vertical flow, ensuring uniform distribution of gas-liquid mixed refrigerant across refrigerant tubes, reducing internal volume, and eliminating the need for brazing, thus promoting even heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flat tubes are projected into the header, then refrigerant distribution is intended to be improved, but flow resistance varies and swirling occurs causing non-uniform refrigerant flow
Solution Approach 1:
The header is divided into multiple distribution chambers, each serving specific flat tubes. This segmentation allows independent optimization of refrigerant distribution in each chamber, reducing the negative effects of flow resistance variation and swirling by confining them to localized areas rather than affecting the entire header system.
Solution Approach 2:
Different regions of the header are designed with different structural characteristics. The distribution chambers have varying configurations tailored to the specific refrigerant flow requirements of adjacent flat tubes, creating local optimizations that compensate for flow resistance variations and prevent widespread swirling effects.
2Manufacturing precision
If separating plates are added to the header, then refrigerant distribution uniformity is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The distribution chamber walls serve dual functions as both structural separators and refrigerant distribution guides. By merging the separating function with the distribution function, the need for additional dedicated separating plates is eliminated, reducing manufacturing cost and device complexity while maintaining refrigerant distribution uniformity.
Solution Approach 2:
The distribution chambers are designed to perform multiple functions: they separate refrigerant flow paths, guide refrigerant distribution, and structurally support the flat tubes. This multi-functionality eliminates the need for separate separating plates, achieving both cost reduction and improved refrigerant distribution uniformity.
3Manufacturing precision
If sub header pipes are branched horizontally from a vertical main header, then refrigerant distribution is intended to be uniform, but liquid refrigerant accumulates in lower tubes and gas refrigerant in upper tubes
Solution Approach 1:
The distribution chambers are arranged in a horizontal plane rather than extending vertically from the main header. This dimensional change allows refrigerant to distribute laterally across all flat tubes simultaneously, preventing gravitational separation where liquid accumulates in lower tubes and gas in upper tubes, thereby achieving uniform refrigerant distribution regardless of vertical position.
4Stability of the object's composition
If the main header chamber volume is reduced, then gas-liquid mixing is promoted, but refrigerant flow distribution may be affected
Solution Approach 1:
The compact main header chamber is segmented into multiple distribution chambers that extend the refrigerant flow path laterally. This segmentation allows sufficient residence time for gas-liquid mixing within the reduced volume while maintaining effective refrigerant distribution to all flat tubes through the distributed chamber structure.
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 achieves uniform refrigerant distribution and improved heat exchange efficiency by preventing excessive refrigerant accumulation and promoting gas-liquid mixing, enhancing the reliability and cost-effectiveness of the heat exchanger.
Implementation Method 1
a flow direction changing mechanism provided to collide with the refrigerant flowing out from the refrigerant inlet port, and configured to change a flow direction of the refrigerant from the horizontal direction to the vertical direction
Implementation Method 2
a header that can evenly distribute refrigerant in a gas-liquid mixing state to each of a plurality of refrigerant tubes that are provided side by side in a vertical direction
Data Source
AI summary
An air conditioner includes a header for introducing refrigerant into a plurality of refrigerant tubes provided in parallel in a vertical direction. The header includes a main header chamber extending in the vertical direction and a plurality of sub header chambers branched in the horizontal direction from the main header chamber and provided in parallel in the vertical direction. The main header chamber includes a refrigerant inlet port configured to introduce the refrigerant in a gas-liquid mixing state in a horizontal direction into an inside of the main header chamber; and a flow direction changing mechanism provided to collide with the refrigerant ejected from the refrigerant inlet port, and configured to change a flow direction of the refrigerant from the horizontal direction to the vertical direction.