Condenser Header Tank Layout for Gas-Liquid Separation
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Solution Overview
Problem
Conventional car air conditioner condensers require a large installation space due to the size of the first header tank, which hinders the installation of other devices and has inadequate gas-liquid separation performance.
Innovation Solution
A condenser design with a spacer between the first and second header tanks, allowing the first header tank to extend upward without increasing its thickness, reducing overall space requirements and enhancing gas-liquid separation by gravitational force, while also preventing corrosion through proper clearance maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the internal volume of the first header tank is increased to improve gas-liquid separation performance, then the gas-liquid separation performance is improved, but the thickness of the first header tank becomes considerably larger, which increases the installation space requirement
Solution Approach 1:
The first header tank is repositioned from a horizontal arrangement to a vertical arrangement, extending in the vertical direction rather than increasing in thickness horizontally. This dimensional change allows the tank to achieve the necessary internal volume for effective gas-liquid separation while maintaining a compact horizontal footprint that does not interfere with radiator installation.
2Reliability
If the thickness of the first header tank is increased to improve gas-liquid separation, then the gas-liquid separation performance is improved, but the space for installing other devices such as radiator is hindered
Solution Approach 1:
The first header tank is oriented vertically to extend in the up-down direction, utilizing the vertical space within the engine compartment. This allows the tank to achieve sufficient internal volume for gas-liquid separation without increasing its horizontal footprint, thereby preserving installation flexibility for other components like the radiator.
3Reliability
If the first header tank is positioned to extend upward beyond the second header tank, then the internal volume is increased for better gas-liquid separation, but the clearance between header tanks may cause corrosion issues
Solution Approach 1:
A spacer is introduced as an intermediary component between the first header tank and the second header tank. This spacer maintains an appropriate clearance between the two tanks, preventing direct contact that could lead to galvanic corrosion or other harmful interactions, while still allowing the first header tank to extend upward to achieve the necessary internal volume for effective gas-liquid separation.
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 design achieves space savings and improved gas-liquid separation efficiency, along with suppressed corrosion of the header tanks, by optimizing the internal volume and positioning of the header tanks within the condenser.
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 separated liquid
Implementation Method 2
preventing corrosion through proper clearance maintenance
Implementation Method 3
a plurality of heat exchange tubes disposed in parallel... All the heat exchange paths serve as refrigerant condensation paths for condensing refrigerant
Implementation Method 4
All the heat exchange paths serve as refrigerant condensation paths for condensing refrigerant
Data Source
AI summary
A first header tank to which first heat exchange tubes of third and fourth heat exchange paths are connected and a second header tank to which second heat exchange tubes of first and second heat exchange paths are connected are provided at one end of a condenser. 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 from each other and storing the liquid. A spacer is disposed between the first header tank and the second header tank. The spacer includes a first portion which comes into contact with and is brazed to the first header tank, and a second portion which comes into contact with and is brazed to the second header tank.