Nested Header Tank Condenser for Compact Gas-Liquid Separation
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Solution Overview
Problem
Conventional car air conditioner condensers require a large space due to the size of the first header tank, which hinders the installation of other devices and has inadequate gas-liquid separation performance.
Innovation Solution
A condenser design with a first header tank positioned outside a second header tank, featuring projecting portions on the heat exchange tubes and a corrosion prevention member to prevent pitting corrosion, allowing for a more compact installation and improved gas-liquid separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first header tank is made considerably larger than the second header tank to improve gas-liquid separation performance, then the gas-liquid separation efficiency is improved, but the installation space required increases
Solution Approach 1:
The second header tank is positioned inside the first header tank, creating a nested configuration. This allows the first header tank to provide the necessary large internal volume for effective gas-liquid separation while the overall external dimensions are reduced, as the second header tank occupies the central space rather than requiring additional external space.
2Reliability
If the first header tank is made considerably larger than the second header tank to improve gas-liquid separation performance, then the gas-liquid separation efficiency is improved, but other devices cannot be installed in the vicinity
Solution Approach 1:
The nested configuration of the second header tank within the first header tank reduces the overall external footprint of the condenser assembly. This compact design creates sufficient space around the condenser for installing other automotive components such as radiators, improving installation flexibility and adaptability in the vehicle engine compartment.
3Use of energy by moving object
If heat exchange tubes are connected over the entire length of the first header tank to maximize heat exchange efficiency, then the heat exchange performance is improved, but the gas-liquid separation performance deteriorates
Solution Approach 1:
The connection between heat exchange tubes and the first header tank is segmented rather than continuous. The heat exchange tubes are connected at specific discrete positions along the length of the first header tank, creating distinct zones. This segmentation allows certain regions to be optimized for gas-liquid separation while other regions facilitate heat exchange, resolving the conflict between these two functions.
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 required installation space and enhances gas-liquid separation efficiency while preventing refrigerant leakage through sacrificial corrosion protection.
Implementation Method 1
a liquid receiver which separates gas and liquid from each other by making use of gravitational force and stores the separated liquid
Implementation Method 2
a corrosion prevention member which prevents pitting corrosion of the first heat exchange tube
Data Source
AI summary
A first header tank to which first heat exchange tubes of third and fourth heat exchange paths are connected and a second header tank to which second heat exchange tubes of first and second heat exchange paths are connected are provided at one end of a condenser. The upper end of the first header tank is located above the lower end of the second header tank. The first header tank has a function of separating gas and liquid and storing the liquid. The first heat exchange tubes have projecting portions at their ends located on the side toward the first header tank. A corrosion prevention member having a function of corroding sacrificially for the first heat exchange tubes is disposed in a clearance between the projecting portion of the upper-end first heat exchange tube and the lower end of the second header tank.