Dual-Header Heat Exchanger Layout for Uniform Refrigerant Flow
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Solution Overview
Problem
Existing air conditioners face challenges in efficiently alternating the passage of refrigerant in heat exchange units, leading to uneven heat transfer and potential frost concentration during cooling and heating operations.
Innovation Solution
The air conditioner design incorporates a heat exchanger with a first and second header pipe, a bypass pipe, and alternately coupled header branch pipes, allowing for efficient refrigerant flow and thermal exchange in both cooling and heating modes, preventing frost concentration by ensuring uniform refrigerant passage through the heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional heat exchanger with single header pipe is used, then the structure is simple, but the refrigerant flow is uneven causing frost concentration
Solution Approach 1:
The heat exchanger is divided into multiple heat exchange units (first, second, third units) with separate refrigerant flow paths. Each unit has its own header branch pipes connected to first and second header pipes, creating segmented flow paths that distribute refrigerant more uniformly across different sections of the heat exchanger, preventing frost concentration in specific areas.
Solution Approach 2:
The patent introduces a dual-header pipe configuration (first header pipe and second header pipe) with alternating branch connections to create a three-dimensional flow distribution pattern. The odd-numbered and even-numbered heat exchange units are connected to different header pipes, creating a spatial alternation that promotes uniform refrigerant distribution across the heat exchanger surface.
2Productivity
If refrigerant passage is not alternated in heat exchange units, then the flow path is simple, but heat transfer efficiency is reduced and frost concentrates
Solution Approach 1:
The refrigerant flow alternates periodically between different heat exchange units through the dual header pipe system. Odd-numbered units receive refrigerant from the first header pipe while even-numbered units receive from the second header pipe, creating a periodic flow pattern that ensures all units are actively engaged in heat exchange, improving overall heat transfer efficiency and preventing frost accumulation.
3Adaptability or versatility
If bypass pipe is not included, then the cooling operation is simple, but defrosting capability is insufficient
Solution Approach 1:
The bypass pipe serves multiple functions: during cooling operation, it allows refrigerant to bypass the heat exchange unit for direct flow; during defrosting operation, it enables reverse flow of refrigerant through the heat exchange unit to melt accumulated frost. This multi-functional design enhances the system's adaptability without requiring separate dedicated piping for defrosting.
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 ensures uniform refrigerant flow and thermal exchange, preventing frost concentration during cooling and heating operations, and facilitates efficient defrosting by ensuring refrigerants pass through different paths, enhancing the overall performance and efficiency of the air conditioner.
Implementation Method 1
a heat exchange unit (143) coupled to the first header pipe (141a) and configured to thermally exchange the refrigerant with air
Implementation Method 2
a heat exchange unit (143) coupled to the first header pipe (141a) and configured to thermally exchange the refrigerant with air
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An air conditioner includes a compressor and a heat exchanger. The heat exchanger includes a first header pipe to have a refrigerant compressed by the compressor to flow therein, a heat exchange unit including a plurality of first refrigeration tubes and a plurality of second refrigeration tubes to thermally exchange the refrigerant with air, a plurality of first header branch pipes coupling the first header pipe with corresponding first refrigeration tubes in the heat exchange unit, a bypass pipe to have the refrigerant, thermally exchanged in the heat exchange unit, passing therethrough in the air cooling operation, and a second header pipe to have the refrigerant passing through the bypass pipe to flow therein. A plurality of second header branch pipes couples the second header pipe with corresponding second refrigeration tubes in the heat exchange unit, where at least two first refrigeration tubes have at least one second refrigeration tube therebetween.