Dual-Circuit Condenser Manifold Segmentation for Tube Stress Relief
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Solution Overview
Problem
Dual circuit refrigerant condensers with shared manifolds experience stress on refrigerant conveying tubes due to temperature differences between circuits, leading to potential fractures at the braze joints, particularly when one circuit is inactive and the other is active with a significant temperature differential.
Innovation Solution
Incorporating three or more separators within the manifold to segregate refrigerant between the two circuits, with additional separators defining a third volume to reduce stress on tubes by managing temperature differentials and preventing refrigerant mixing in case of leaks, thereby reducing the stress on tubes at the braze joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shared manifold with a separator is used to create dual circuit condenser, then system cost is reduced and a single fan can be used, but stress on refrigerant conveying tubes increases when temperature differential between circuits is significant
Solution Approach 1:
The manifold is segmented into multiple isolated volumes (first volume, second volume, and intermediate third volume) using three or more separators. This segmentation prevents direct thermal coupling between the first and second circuits, reducing temperature differential stress on the tubes while maintaining the cost benefits of a shared manifold structure.
Solution Approach 2:
An intermediate third volume is introduced between the first and second circuit volumes, acted upon by two or more separators. This intermediate volume serves as a thermal buffer and mediator, isolating the two circuits thermally while allowing both to share the same manifold structure, thereby reducing stress on refrigerant tubes during temperature transients.
2Reliability
If separators are added to reduce stress on tubes, then tube fracture risk is reduced, but device complexity increases
Solution Approach 1:
The manifold is divided into multiple isolated volumes using three or more separators, creating a first volume, second volume, and intermediate third volume. This segmentation provides thermal isolation to protect tubes from stress while maintaining a relatively simple integrated manifold structure that does not require additional external components.
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 solution effectively reduces stress on the tubes by 18.9% at the braze joints, preventing fractures and ensuring that refrigerant from one circuit does not contaminate the other in case of a leak, while allowing for easier manufacturing and operation of the condenser.
Implementation Method 1
The manifold includes three or more separators interposed between the first volume and the second volume to segregate refrigerant in the first circuit from refrigerant in the second circuit
Implementation Method 2
a dual circuit condenser for a cooling system. The condenser is configured to cool refrigerant passing through the condenser
Implementation Method 3
with additional separators defining a third volume to reduce stress on tubes by managing temperature differentials
Data Source
AI summary
A dual circuit condenser for a cooling system is configured to cool refrigerant passing through the condenser. Operation of a first circuit of the system establishes a first temperature at a first area of the condenser, and operation of a second circuit of the system establishes a second temperature at a second area of the condenser. The condenser includes a manifold. The manifold is configured to receive a plurality of tubes. The manifold is further configured to define a first volume that is part of the first circuit and a second volume that is part of the second circuit. The manifold includes three or more separators interposed between the first volume and the second volume to segregate refrigerant in the first circuit from refrigerant in the second circuit.