Integrated Internal Heat Exchanger With Threaded Tube Sealing
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Solution Overview
Problem
Current internal heat exchanger designs for refrigerant circuits in HVAC systems are costly and inefficient due to complex geometries, expensive metallurgical joining methods, and susceptibility to damage, which complicates manufacturing and increases material costs.
Innovation Solution
A combined internal heat exchanger and accumulator design featuring a tubular outer cylinder, cover plate, and bottom plate, with a minimized heat-conducting accumulator and finned tube, where the finned tube is sealed to the cover and bottom plates using threaded joints, eliminating the need for expensive metallurgical connections and allowing for efficient manufacturing and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallurgical joining methods (welding, brazing, soldering) are used to connect tube ends to container covers, then connection strength and reliability are improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent replaces metallurgical joining methods (welding, brazing, soldering) with mechanical joining methods (threaded connections, snap-fit connections, or bayonet connections). This substitution eliminates the need for complex metallurgical processes while maintaining connection reliability through properly designed mechanical interfaces that are easier and cheaper to manufacture.
Solution Approach 2:
The patent segments the heat exchanger into modular components (container, cover, tube assembly) that can be connected through simple mechanical interfaces. This segmentation allows each component to be manufactured separately using standard processes, then assembled through straightforward mechanical connections rather than requiring integrated metallurgical joining.
2Ease of operation
If tube coils are led through the external case and sealed from the interior, then connection accessibility is improved, but the case geometry becomes intricate and manufacturing complexity increases
Solution Approach 1:
Instead of leading tubes through the case from the exterior and sealing them from the interior, the patent inverts the approach by providing connection points on the exterior surface of the container. This allows direct external access for connections without requiring tubes to penetrate through the case wall, thereby maintaining simple case geometry while improving connection accessibility.
3Strength
If thicker walls or higher-grade materials are used to compensate for heat input during metallurgical joining, then mechanical properties are improved, but manufacturing cost increases
Solution Approach 1:
By replacing metallurgical joining with mechanical joining, the patent eliminates the need for heat input during the joining process. This prevents heat-affected zone issues and allows the use of thinner walls and lower-grade materials while maintaining mechanical strength, thereby reducing manufacturing costs.
4Adaptability or versatility
If intricate container geometries are used to integrate heat exchanger and accumulator functions, then functional integration is improved, but manufacturing efficiency decreases
Solution Approach 1:
The patent segments the heat exchanger and accumulator into separate but integrated components, with the heat exchanger tube coil positioned within the accumulator container. This segmentation allows both components to be manufactured using standard, efficient processes for simple geometries, then assembled together to achieve functional integration, thereby maintaining manufacturing efficiency while providing versatility.
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 minimizes manufacturing costs and space requirements while enhancing efficiency, reducing weight and heat input to the accumulator, thus improving the overall performance and reliability of the refrigeration system.
Implementation Method 1
a finned tube for transmitting the refrigerant at high pressure, wherein the finned tube is disposed in a gap formed between the accumulator and the outer cylinder
Implementation Method 2
a finned tube for transmitting the refrigerant at high pressure
Implementation Method 3
an accumulator substantially concentrically disposed in the main body for transmitting a liquid refrigerant at low pressure
Implementation Method 4
a first end of the finned tube is sealed to the cover plate and a second end of the finned tube is sealed to the bottom plate
Data Source
AI summary
An internal heat exchanger including an integrated accumulator is disclosed, wherein the heat exchanger is used in refrigerant circuits, particularly in motor vehicle heating, ventilation, and air conditioning systems.