Automotive Condenser Header Layout for Gas-Liquid Separation

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Solution Overview

Problem

Conventional car air conditioner condensers require a large space due to the size of the first header tank, which hinders the installation of other devices like radiators and compromises gas-liquid separation performance.

Innovation Solution

The condenser design features a first header tank offset from a second header tank, with heat exchange tubes bent in the same direction about a common vertical line, allowing for a smaller footprint and improved gas-liquid separation using gravitational force without increasing the thickness of the first header tank.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the first header tank is made considerably larger than the second header tank to improve gas-liquid separation, then the gas-liquid separation performance is improved, but the space required for installing the condenser increases and hinders installation of other devices

Engineering Contradiction:

Improvegas-liquid separation performanceVSAvoidspace required for condenser installation

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent changes the spatial arrangement from a horizontal placement (where the first header tank would extend horizontally and block radiator installation) to a vertical placement (where the first header tank is positioned above the second header tank). This dimensional change allows the condenser to achieve adequate gas-liquid separation volume without increasing the horizontal footprint, thereby resolving the conflict between separation performance and installation space.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent positions the first header tank vertically above the second header tank, creating a nested-like vertical stacking arrangement. The heat exchange tubes connect these tanks vertically, with the tubes bent about a common vertical line. This nesting approach allows both tanks to occupy overlapping horizontal space while maintaining sufficient internal volume for gas-liquid separation, reducing the overall horizontal footprint.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

Engineering Contradiction:

Improvegas-liquid separation performanceVSAvoidthickness of the first header tank

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

Instead of increasing the thickness (horizontal dimension) of the first header tank, the patent extends the tank vertically in the vertical dimension. The first header tank is positioned above the second header tank, and the heat exchange tubes connect them vertically with bends about a common vertical line. This dimensional transformation allows sufficient internal volume for gas-liquid separation without increasing the horizontal thickness that would interfere with radiator installation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If heat exchange tubes are connected over substantially the entire length of the first header tank, then the structural integrity is improved, but the gas-liquid separation performance becomes unsatisfactory

Engineering Contradiction:

Improvestructural integrityVSAvoidgas-liquid separation performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent segments the connection points of heat exchange tubes to the first header tank, concentrating connections at specific locations (with tubes bent about a common vertical line) rather than distributing them along the entire length. This segmentation creates sufficient uninterrupted internal space within the first header tank for effective gas-liquid separation while maintaining structural integrity through properly positioned connection points.

Inventive Principle:

Principle #1Segmentation

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

This design enables space-saving installation without hindering adjacent devices and enhances gas-liquid separation efficiency, preventing re-vaporization of liquid-phase refrigerant and allowing for efficient condensation and super-cooling processes.

Implementation Method 1

a first header tank... having a function of separating gas and liquid from each other by making use of gravitational force and storing the liquid

Methodology Applied

Scientific EffectGravitational force: Gravitation

Implementation Method 2

a plurality of heat exchange tubes disposed in parallel... and fins each disposed between heat exchange tubes

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 3

heat exchange tubes... for condensing refrigerant

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8991479B2Condenser

Publication Date: 2015.03.31 MAHLE INT GMBH

AI summary

A first header tank to which first heat exchange tubes of second and third heat exchange paths are connected and a second header tank to which second heat exchange tubes of a first heat exchange path are connected are provided at the left end of a condenser such that the former is located on the outer side of the latter with respect to a left-right direction and is offset from the latter in an air passage direction. The upper end of the first header tank is located above the lower end of the second header tank. The first header tank has a function of separating gas and liquid and storing the liquid. The first and second heat exchange tubes and side plates are bent in the same direction about a common vertical line. This condenser is suitable for use in a car air conditioner mounted on an automobile.