Layered header, heat exchanger, and air conditioner
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Solution Overview
Problem
The stacking-type header faces issues with excess brazing material entering refrigerant passages, causing blockages due to the large volume of brazing material used in the brazing process, which affects the distribution of refrigerant in heat exchangers.
Innovation Solution
The design includes second plates with openings that communicate with the atmosphere, preventing excess brazing material from entering the distribution junction passage by allowing it to flow into a low-pressure atmospheric space, thus reducing the likelihood of blockages and improving the brazing process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large amount of brazing material is used to ensure complete joining of plates, then the joining strength is improved, but excess brazing material enters the refrigerant passages and causes blockages
Solution Approach 1:
The header is divided into multiple plates that are joined together through brazing. By segmenting the structure into discrete plates with controlled brazing areas, the design allows for precise control of brazing material placement, ensuring strong joints while preventing excess material from entering refrigerant passages.
Solution Approach 2:
Different regions of the plates have different properties: some areas have brazing material applied for joining strength, while other areas (refrigerant passages) are kept clear. The opening in the second plate creates a local region where excess brazing material can be contained without affecting the refrigerant flow paths, demonstrating local quality differentiation.
2Reliability
If the amount of brazing material is increased to ensure complete coverage of plate surfaces, then the brazing reliability is improved, but the brazing time increases
Solution Approach 1:
The brazing material is pre-applied only to specific areas where joining is required, rather than covering entire plate surfaces. This preliminary, targeted application reduces the total amount of material that needs to be heated and processed, thereby reducing brazing time while maintaining reliable joints.
Solution Approach 2:
Instead of applying brazing material excessively across all surfaces, the invention uses partial action by limiting the material application to only the necessary joining areas. The opening provides a controlled space that accepts any slight excess without requiring complete surface coverage, optimizing the balance between reliability and processing time.
3Strength
If more brazing material is used to ensure complete joining, then the joint strength is improved, but the weight and thermal capacity of the header increase
Solution Approach 1:
The brazing material is concentrated only in the local areas where joints are needed between plates, rather than being distributed throughout the entire header structure. This localized application maintains joint strength while minimizing the total weight and thermal capacity of the header.
Solution Approach 2:
The design extracts the brazing material from the refrigerant passages by providing an alternative space (the opening) where excess material can be contained. This separation ensures that brazing material is taken out of the critical refrigerant flow paths, maintaining joint strength without adding unnecessary weight to the functional areas.
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 configuration effectively prevents blockages in the refrigerant passages, reduces the weight and thermal capacity of the stacking-type header, and shortens the brazing time by minimizing the amount of brazing material used and ensuring it does not enter the distribution junction passage.
Implementation Method 1
The brazing process involves heating a brazing material, serving as clad layers, on the surfaces of the plates to melt the brazing material and forming fillets on side surfaces of the plates and inner surfaces of openings of the plates using surface tension to join the plates
Implementation Method 2
An excess of brazing material entering the opening upon brazing can flow toward a relatively low pressure atmospheric space
Data Source
Figure 1
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Figure 3
AI summary
A stacking-type header according to the present invention includes a plurality of first plates and a plurality of second plates stacked on one another and brazed together such that each of the plurality of second plates is disposed between adjoining two of the plurality of first plates. The plurality of first plates include a first end plate that is an outermost one of the plurality of first plates in a stacking direction of the plurality of first plates and that has a first through hole, and a second end plate that is another outermost one of the plurality of first plates in the stacking direction of the plurality of first plates and that has a plurality of second through holes. The plurality of first plates and the plurality of second plates have a communication hole that connects the first through hole of the first end plate and the plurality of second through holes of the second end plate. The plurality of second plates each have at least one opening formed at other than the communication hole. The opening communicates with atmosphere.