Integrated Fin Set Heat Exchanger for Low-Noise Sealed Assembly
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Solution Overview
Problem
Existing multi-fold heat exchangers in air conditioners have low production efficiency, high costs, large working noise, and low heat exchange efficiency due to the need for splicing and the use of sponges and snap rings for sealing.
Innovation Solution
A heat exchanger design featuring a fin set with notches and connection members, allowing for efficient stacking and bending to form integral fins with non-zero included angles, reducing the need for splicing and eliminating the use of sponges and snap rings, thereby improving manufacturing efficiency and heat exchange performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-fold heat exchanger is formed by splicing multiple single heat exchangers with sponges and snap rings, then sealing is achieved, but production efficiency is low and cost is high
Solution Approach 1:
The patent merges multiple spliced heat exchanger units into a single integrated heat exchanger structure. The fin set is designed as one piece with continuous fins extending through the refrigerant pipe, eliminating the need for multiple separate units to be spliced together. This integration maintains sealing performance while dramatically improving production efficiency by reducing assembly steps and components.
Solution Approach 2:
The patent extracts and eliminates the sealing components (sponges and snap rings) from the heat exchanger structure. By designing the fin set as an integrated single piece, the patent removes the need for these additional sealing parts, thereby reducing production complexity and cost while maintaining the necessary sealing function through the continuous fin structure.
2Reliability
If a multi-fold heat exchanger is formed by splicing multiple single heat exchangers, then sealing is achieved, but production cost is high
Solution Approach 1:
The patent combines multiple heat exchanger units into a single integrated structure where the fin set is formed as one continuous piece. This merging eliminates the need for multiple separate components and their associated sealing elements (sponges, snap rings), thereby reducing material costs and assembly complexity while maintaining effective sealing through the continuous fin design.
Solution Approach 2:
The patent removes the expensive sealing components (sponges and snap rings) from the design by extracting their function. The sealing performance is achieved through the continuous fin structure itself, eliminating the need for additional sealing parts and reducing overall production cost.
3Reliability
If a multi-fold heat exchanger uses sponges and snap rings for sealing, then sealing performance is achieved, but working noise is large
Solution Approach 1:
The patent extracts and removes the sponge and snap ring components from the heat exchanger structure. By designing the fin set as a single integrated piece, the patent eliminates these sealing components that generate working noise during operation. The continuous fin structure provides sealing without the mechanical contact and friction that cause noise in spliced designs.
4Reliability
If a multi-fold heat exchanger is formed by splicing multiple units, then sealing is achieved, but heat exchange efficiency is low
Solution Approach 1:
The patent merges multiple spliced units into a single integrated heat exchanger with continuous fins. This integration eliminates the gaps and discontinuities created by splicing multiple units together, improving thermal contact and heat transfer efficiency. The continuous fin structure ensures better thermal conductivity and reduces energy loss while maintaining effective sealing.
Data Source
AI summary
A heat exchanger includes a fin set formed by a plurality of fins stacked together and a refrigerant pipe set passing through the fin set. The fin set includes a connection member, and a first fin member and a second fin member connected to each other via the connection member. An included angle between the first fin member and the second fin member is larger than zero. The first fin member and the second fin member are arranged at two sides, respectively, of a notch of the fin set. The notch is located at an air input side and/or an air output side of the connection member.