Composite Refrigeration Line Set With Aluminum Barrier for Burst Pressure

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Solution Overview

Problem

Existing refrigeration line sets face challenges in achieving high burst pressure and temperature resistance, which are essential for reliable performance in refrigeration systems.

Innovation Solution

A composite refrigeration line set is designed with a structure that includes an inner polyethylene of raised temperature tube, adhesive layers, an aluminum layer (AL 3005-O) with specific thickness ranges, and an outer polyethylene of raised temperature layer, which provides enhanced strength and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a composite structure with multiple layers is used, then strength and burst pressure resistance are improved, but device complexity increases

Engineering Contradiction:

Improveburst pressure resistanceVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs a composite structure consisting of an inner polyethylene layer, an intermediate aluminum layer, and an outer polyethylene layer. This multi-material composite design provides enhanced burst pressure resistance (exceeding 1950 psi) while maintaining a manageable structural complexity through standardized layering and adhesive bonding.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The pipe is divided into distinct functional layers: the inner polyethylene layer provides corrosion resistance and fluid compatibility, the aluminum intermediate layer provides structural strength and rigidity, and the outer polyethylene layer provides environmental protection. This segmentation allows each layer to be optimized for its specific function while collectively achieving high burst pressure resistance.

Inventive Principle:

Principle #1Segmentation

2Strength

If aluminum layer thickness is increased, then strength and durability are improved, but manufacturing cost and material usage increase

Engineering Contradiction:

ImprovedurabilityVSAvoidaluminum material usage

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The aluminum layer is applied with specific thickness ranges optimized for each pipe size (e.g., 0.014-0.02 inches for 1/4 inch pipe, 0.028-0.045 inches for 5/8 inch pipe). This local optimization ensures sufficient strength and durability for each application while minimizing unnecessary material usage and manufacturing cost.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12320449B2Multilayer composite pipe and pipe assemblies including reflective insulation

Publication Date: 2025.06.03 TITEFLEX

AI summary

One aspect of the invention provides a composite refrigeration line set including at least one selected from the group consisting of: a suction line and a return line, characterized in that one or more of the suction line and the return line are a composite refrigeration line set tube include: an inner plastic tube; a first adhesive layer positioned about the inner plastic tube; an aluminum layer positioned about the first adhesive layer and coupled to the inner plastic tube via the first adhesive layer; a second adhesive layer positioned about the aluminum layer; and an outer plastic layer positioned about the aluminum layer coupled to the aluminum layer via the second adhesive layer. The inner plastic tube is polyethylene of raised temperature. The outer plastic tube is polyethylene of raised temperature. The aluminum layer comprises AL 3005-O.