Heat Exchanger Pipe Joint Structure for Welding Heat Balance
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Solution Overview
Problem
Welding defects occur in heat exchangers due to heat capacity imbalances between refrigerant pipes and distribution pipes with different cross-sectional thicknesses, leading to issues during the manufacturing process.
Innovation Solution
A heat exchanger design that includes a connecting member with a specific thickness range and configuration, allowing for automatic welding of refrigerant and bending pipes, followed by manual welding of the distribution pipe, to manage heat capacity differences and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the distribution pipe has a greater thickness than the refrigerant pipe, then the distribution pipe has sufficient strength and heat capacity, but welding defects occur due to heat capacity imbalance between the pipes
Solution Approach 1:
A connecting member is introduced as an intermediary component between the refrigerant pipe and the distribution pipe. This connecting member has a thickness within 95%-105% of the distribution pipe thickness (second thickness), which balances the heat capacity during welding while the distribution pipe maintains its greater thickness (second thickness > first thickness) for structural strength. The connecting member acts as a thermal buffer that prevents welding defects caused by heat capacity imbalance.
2Productivity
If automatic welding is used for refrigerant and bending pipes, then manufacturing efficiency is improved, but the process complexity increases due to multiple welding steps required
Solution Approach 1:
The welding process is segmented into distinct stages: automatic welding for the refrigerant pipe and connecting member, followed by manual welding for the distribution pipe to the connecting member. This segmentation allows each welding operation to be optimized independently, with automatic welding handling the more critical refrigerant pipe connections and manual welding allowing flexibility for the distribution pipe connection.
3Reliability
If the connecting member thickness is within 95%-105% of the distribution pipe thickness, then heat capacity balance is achieved during welding, but the manufacturing precision requirement increases
Solution Approach 1:
The thickness parameter of the connecting member is specifically controlled to fall within the range of 95%-105% of the distribution pipe thickness (second thickness). This parameter control ensures that the heat capacity of the connecting member is sufficient to balance the welding process with the distribution pipe, preventing welding defects while maintaining manufacturability through a reasonable tolerance range.
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 reduces the probability of overheating and non-melting during welding, improving the manufacturing process efficiency and quality by ensuring consistent heat capacity across components.
Implementation Method 1
the connecting member is positioned between the refrigerant pipe and the distribution pipe so that a refrigerant is flowable through the connecting member between the refrigerant pipe and the distribution pipe, and has a thickness in a range of 95% or more and 105% or less of the second thickness
Data Source
AI summary
A heat exchanger including a heat exchange fin; a refrigerant pipe passing through the heat exchange fin, the refrigerant pipe having a first thickness; a connecting member coupled to the refrigerant pipe; and a distribution pipe coupled to the connecting member at an outside of the heat exchange fin, the distribution pipe having a second thickness greater than the first thickness, wherein the connecting member is positioned between the refrigerant pipe and the distribution pipe so that a refrigerant is flowable through the connecting member between the refrigerant pipe and the distribution pipe, and has a thickness in a range of 95% or more and 105% or less of the second thickness.