Heat Exchanger Header Structure for Lower Refrigerant Volume
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Solution Overview
Problem
Conventional heat exchangers with flat pipes and header collecting pipes do not effectively reduce volume or refrigerant usage, leading to inefficiencies in air conditioning systems.
Innovation Solution
A heat exchanger design featuring flat pipes with a header collecting pipe that includes a flat pipe-side curved portion and an opposite-side curved portion with a smaller inner diameter, along with an intermediate-side header forming member to create a loop structure, reducing the internal space volume and ensuring pressure resistance while minimizing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the header collecting pipe uses a conventional structure with flat pipe-side curved portion and opposite-side curved portion, then the heat exchanger can be assembled with flat pipes, but the volume of the heat exchanger is large and refrigerant saving is not achieved
Solution Approach 1:
The patent changes the inner diameter parameter of the opposite-side curved portion, making it smaller than the inner diameter of the flat pipe-side curved portion. This parameter modification reduces the internal space volume of the header collecting pipe, thereby reducing the overall heat exchanger volume and achieving refrigerant saving while maintaining functional performance
Solution Approach 2:
The patent introduces asymmetry in the header collecting pipe structure by making the inner diameter of the opposite-side curved portion different from (smaller than) the inner diameter of the flat pipe-side curved portion. This asymmetric design optimizes space utilization and reduces the overall volume while ensuring proper refrigerant flow and pressure resistance
2Volume of stationary object
If the inner diameter of the opposite-side curved portion is made smaller than the inner diameter of the flat pipe-side curved portion, then the volume of the internal space is reduced, but the pressure resistance may be compromised
Solution Approach 1:
The patent applies different inner diameter specifications to different portions of the header collecting pipe: the flat pipe-side curved portion has a larger inner diameter to ensure proper connection and flow, while the opposite-side curved portion has a smaller inner diameter to reduce volume. This localized quality differentiation optimizes both volume reduction and pressure resistance in respective areas
Data Source
AI summary
A heat exchanger includes: flat pipes each including a passage for refrigerant that are arranged side by side in a predetermined step direction; and a header collecting pipe extending along the predetermined step direction that is connected to the flat pipes. The header collecting pipe includes: a flat pipe-side header forming member; and an opposite-side header forming member facing the flat pipe-side header forming member. The flat pipes are inserted in the flat pipe-side header forming member and an internal space exists between the flat pipe-side header forming member and the opposite-side header forming member. When viewed along the predetermined step direction: the flat pipe-side header forming member has a flat pipe-side curved portion protruding toward the flat pipes and the opposite-side header forming member has an opposite-side curved portion protruding toward a side away from the flat pipes.