Condenser Header Tank Layout for Leak-Safe Multi-Path Condensation
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Solution Overview
Problem
The existing condenser for car air conditioners has a high number of brazing areas, leading to increased leakage risk and inadequate condensation performance due to the requirement of brazing between header tanks and a liquid receiver, and it only has one heat exchange path for condensation.
Innovation Solution
A condenser design with multiple heat exchange paths and separate header tanks, where the flow direction of refrigerant in each path is opposite to adjacent paths, eliminating the need for a liquid receiver and allowing for improved gas-liquid separation using gravitational force, thereby reducing brazing areas and enhancing condensation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a liquid receiver is brazed to one header tank, then the condenser can collect liquid refrigerant, but the number of brazing areas increases and leakage risk increases
Solution Approach 1:
The liquid receiver function is merged into the second header tank by providing a lower header section that serves dual purposes: connecting heat exchange tubes and collecting liquid refrigerant through gas-liquid separation. This eliminates the need for a separate liquid receiver component and its associated brazing connections.
Solution Approach 2:
The second header tank is designed with multi-functionality: it serves as both a connection point for heat exchange tubes and a gas-liquid separation chamber. The lower header section acts as both a structural component and a liquid collection zone, reducing the overall component count.
2Reliability
If only one heat exchange path is provided, then the structure is simpler, but condensation performance is insufficient
Solution Approach 1:
The condensation system is segmented into multiple parallel heat exchange paths (upper and lower paths) within the header tanks. Each path consists of multiple heat exchange tubes arranged vertically, allowing refrigerant to flow through multiple routes simultaneously, thereby increasing total condensation capacity.
Solution Approach 2:
Heat exchange paths are arranged in both vertical and horizontal dimensions. The upper and lower paths are positioned at different vertical levels, and multiple paths are juxtaposed horizontally within the header tanks, creating a three-dimensional heat exchange network that maximizes condensation efficiency.
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 decreases the likelihood of leakage and improves condensation performance by providing multiple refrigerant condensation paths and efficient gas-liquid separation within the second header tank, preventing re-gasification of liquid-phase refrigerant and allowing for effective separation of gas-liquid mixed phases.
Implementation Method 1
the second header tank has a gas-liquid separation function making use of gravitational force
Data Source
AI summary
A condenser includes a first header tank which is provided on one side of the condenser, a second header tank which is provided on the one side of the condenser and which has a gas-liquid separation function, and a third header tank provided on another side of the condenser opposite to the one side. First heat exchange tubes extend in an extending direction between the first header tank and the third header tank to connect the first header tank and the third header tank. Second heat exchange tubes are provided below the first heat exchange tubes and extend in the extending direction between the second header tank and the third header tank to connect the second header tank and the third header tank. The second heat exchange tubes are longer than the first heat exchange tubes in the extending direction.