Triple-Sealing High Pressure Coupling for CO2 Air Conditioning
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Solution Overview
Problem
Current sealing systems for high-pressure hoses in air conditioning circuits, particularly with carbon dioxide as the refrigerant, experience unacceptable leaks due to extreme pressures and temperatures, leading to inefficiencies and environmental concerns.
Innovation Solution
A connector system featuring two O-rings in peripheral grooves of the male part and a face sealing part made of soft metal coated with an elastomeric material, such as a fluorinated terpolymer, ensures a triple-sealing mechanism that includes a centering mechanism to maintain perfect alignment and sealing efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single O-ring or face sealing part is used in the connector, then the device complexity is reduced, but the sealing reliability deteriorates under high pressure and temperature conditions
Solution Approach 1:
The sealing system is divided into three independent sealing lines: two O-rings in peripheral grooves and one face sealing part with elastomeric coating. Each sealing line operates independently to provide redundant sealing, ensuring that if one sealing line fails, the others maintain the seal integrity under high pressure and temperature conditions.
Solution Approach 2:
The triple-sealing mechanism provides preemptive protection against sealing failures. By incorporating three sealing lines before operation begins, the system compensates for potential degradation or failure of individual sealing elements during high-pressure CO2 operation, ensuring continuous reliable sealing.
2Quantity of substance
If the refrigerant mass varies by more than 20g, then the ease of operation is improved, but the loss of substance increases and operating conditions deteriorate
Solution Approach 1:
The triple-sealing connector system provides feedback through its redundant sealing mechanism, allowing operators to verify sealing integrity during connection. This ensures that no refrigerant is lost during the filling operation, enabling precise control of refrigerant mass within the required 20g tolerance.
Solution Approach 2:
The multiple sealing lines prevent refrigerant leakage before it can occur during the filling operation. By establishing three independent sealing barriers prior to refrigerant introduction, the system prevents any potential loss of substance during the critical filling phase.
3Object-affected harmful factors
If carbon dioxide is used as refrigerant, then the environmental harm is reduced, but the operating pressure and temperature increase significantly
Solution Approach 1:
The connector employs composite sealing materials including elastomeric coatings on metal face sealing parts and O-rings made of pressure-resistant elastomers. These composite materials are specifically selected to withstand the high pressures and temperatures generated by CO2 refrigerant operation while maintaining sealing integrity.
Solution Approach 2:
The sealing system is designed with parameters optimized for high-pressure operation, including reinforced O-ring grooves, thickened face sealing parts, and elastomeric materials with high pressure and temperature resistance. These parameter changes enable the connector to function reliably under CO2 operating conditions of up to 150 bars and 180°C.
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 proposed sealing system significantly reduces leaks to acceptable levels, achieving a leakage rate of 1.5 g/year under 90 bars and 120°C conditions, meeting the stringent requirements for air conditioning circuits.
Implementation Method 1
a face sealing part made of a soft metal and coated with an elastomeric material, which is plated against the fixing flange
Implementation Method 2
two O-rings housed in two peripheral grooves of the tubular element of the male part of the connection connector
Data Source
Figure 1~2
Figure 3
AI summary
The connectics has a male part (3) made in a single piece with a tube of a high pressure hose and comprising a mounting clip extended by a rigid tubular unit (15). A female part is formed in a reception unit (7) with a housing (20) arranged in a flat side of the unit (7), where the housing receives the tubular unit. A sealing system has two sealing lines in the form of o-ring joints (32) housed in peripheral grooves of the male part. A third sealing line is formed by a face sealing piece (35), that is coated by an elastomer material, plated against the clip, and on which the side is supported.