Refrigerant Circuit Welding Spatter Containment
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Solution Overview
Problem
Conventional refrigerant circuit components face issues with spatter leakage during projection welding, as existing designs fail to reliably seal spatter within the welding space, leading to potential contamination of the refrigerant circuit.
Innovation Solution
A joint structure for refrigerant circuit components is developed, featuring a metallic connecting member and casing part joined by projection welding with strategically placed gaps and crimped portions to contain spatter within a defined space, preventing it from entering the refrigerant circuit. This includes cylindrical and convex portions with gaps, and surface layer removal methods like cutting, press working, or polishing to enhance sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the inner projection is made shorter to prevent spatter from flowing into the refrigerant circuit, then spatter containment is improved, but the welding strength is reduced due to insufficient welding width
Solution Approach 1:
The connecting member is divided into two distinct projection structures: an outer projection for welding and an inner projection for sealing. This segmentation allows each projection to be optimized independently - the outer projection provides sufficient welding width for strong joints, while the inner projection creates an effective seal to contain spatter, resolving the contradiction between welding strength and spatter containment.
Solution Approach 2:
The welded portion acts as an intermediary structure that bridges the casing part and connecting member. By forming a welded portion with specific dimensional relationships (outer projection extending beyond inner projection), it creates a dual-function zone that simultaneously ensures welding strength and spatter containment, mediating between the conflicting requirements.
2Strength
If the welding power is increased to ensure welding strength, then welding strength is improved, but spatter is generated and may flow into the pipe
Solution Approach 1:
The invention converts the harmful spatter generation during welding into a beneficial containment system. The outer projection is designed to extend beyond the inner projection, creating a protective barrier that channels and contains spatter within the connecting member. This transforms the harmful effect of spatter generation into a controlled process where spatter is contained rather than allowed to flow into the refrigerant circuit.
Solution Approach 2:
The inner projection is pre-configured as a sealing element that creates a barrier against spatter flow before welding occurs. By designing the inner projection to extend inward and create a seal against the casing part, the system establishes preliminary protection that prevents spatter from entering the refrigerant circuit, countering the potential harmful effect before it can occur.
3Object-affected harmful factors
If a gap is maintained between the inner projection and lid member to seal spatter, then spatter containment is improved, but the reliability of sealing is insufficient
Solution Approach 1:
The sealing function is localized to specific regions through the dual-projection design. The inner projection creates a localized seal zone against the casing part, concentrating the sealing function in a specific area. This localized approach enhances sealing reliability by ensuring that the critical sealing function is performed at the precise location where spatter containment is most needed, rather than relying on a general gap throughout the structure.
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 solution effectively seals spatter within the welding space, preventing it from entering the refrigerant circuit and enhancing the rigidity of the welded joint, thus ensuring reliable operation and preventing adverse effects on pressure-sensitive devices or valve systems.
Implementation Method 1
The metallic connecting member (1) and the metallic casing part (2) are joined to each other by projection welding
Implementation Method 2
The lid member 1 is diffusion-joined with the coupling 2 by projection welding (resistance welding)
Implementation Method 3
An opening end of one of the casing part and the connecting member around the inner hole is crimped to an opening end of the other to pressure-join them
Data Source
AI summary
In a refrigerant circuit component or valve device, the present invention projection-welds a connector to a cap member and prevents intrusion of spatter into a refrigerant circuit. A-cylinder section in which an inside hole of the connector is open is inserted in an inside hole formed in the center of the cap member. The area between the A-cylinder section and a projection of the connector is used as a spatter generation space. The projection of the connector abuts against the cap member and is projection-welded to form a welded part. The open end of the inside hole of the A-cylinder section is crimped to pressure-join the open end to the open end of the inside hole of the cap member. Spatter is sealed inside the spatter generation space. A portion of the surface layer to which the generated spatter adheres may be removed by machining to provide a spatter-removed structure.