Condenser Filling Component Design to Reduce Refrigerant Volume
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Solution Overview
Problem
Existing condensers require a large filling amount of refrigerant to maintain a specific liquid level, which increases costs and resource consumption.
Innovation Solution
Incorporating recyclable processing residues as filling components within the condensation accommodating cavity, which do not chemically react with the refrigerant, to occupy a portion of the cavity volume and prevent exit through the condenser outlet, thereby reducing the required refrigerant amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large filling amount of refrigerant is used to maintain a specific liquid level, then the liquid level stability is improved, but the refrigerant consumption and cost increase
Solution Approach 1:
The patent introduces a filling component as an intermediary substance (water or other liquids) to replace part of the refrigerant in the lower portion of the evaporator. This intermediary substance maintains the liquid level and provides thermal mass without consuming refrigerant, thereby resolving the contradiction between liquid level stability and refrigerant consumption
Solution Approach 2:
The patent changes the physical parameter of the filling material from refrigerant (high cost, regulated substance) to water or other inexpensive liquids. This parameter change allows the system to maintain the same functional requirements (liquid level stability, thermal inertia) while dramatically reducing refrigerant quantity requirements
2Ease of manufacture
If recyclable processing residues are used as filling components, then material cost and waste utilization are improved, but potential chemical reactivity with refrigerant becomes a concern
Solution Approach 1:
The patent specifies that the filling component material must be chemically inert toward the refrigerant, creating an inert environment where no harmful chemical reactions occur. This allows the use of inexpensive recyclable materials (metal shavings, plastic scraps) without compromising system safety or refrigerant integrity
3Quantity of substance
If filling components are added to occupy cavity volume, then refrigerant amount is reduced, but device complexity increases
Solution Approach 1:
The patent employs filling components that are self-contained and require no active control, pumping, or regulation mechanisms. The materials (water, metal shavings, plastic) passively occupy volume and provide thermal mass without adding operational complexity, thereby reducing refrigerant amount while maintaining simple device architecture
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
Reduces the filling amount of refrigerant needed while maintaining the same liquid level, thus saving costs and resources by utilizing recyclable materials effectively.
Implementation Method 1
The liquid refrigerant in the condensation accommodating cavity is arranged to be maintained at a specific level. The filling component occupies volume and displaces refrigerant, reducing the total refrigerant quantity needed while maintaining the same liquid level in the condensation accommodating cavity.
Implementation Method 2
A gaseous refrigerant can enter the condensation accommodating cavity through the condenser inlet, condenses into a liquid refrigerant in the condensation accommodating cavity, and is discharged through the condenser outlet.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A condenser, comprising a condenser shell (102) and at least one filling component (160), wherein a condensation accommodating cavity (132) defined by the condenser shell (102) is configured to accommodate a refrigerant; the filling component (160) is arranged in the condensation accommodating cavity (132) and can occupy some of the volume of the condensation accommodating cavity (132); and the filling component (160) is a recyclable processing residue, does not chemically react with the refrigerant, and can decrease a filling amount of the refrigerant.