Air conditioner and method of manufacturing the same

Abstract

An air conditioner and a method of manufacturing the same are disclosed. The air conditioner includes an indoor heat exchanger and an outdoor heat exchanger, each including a plurality of refrigerant pipes and at least one connection pipe for interconnecting the refrigerant pipes, a brazing hole formed in the connection pipe by punching, and a brazing ring mounted over the brazing hole, wherein portions of the refrigerant pipes are inserted into the connection pipe through inlet ends of the connection pipe, the brazing hole is located between ends of the refrigerant pipes and the inlet ends of the connection pipe, and the connection pipe is bonded to the refrigerant pipes by heating at least one selected from between the refrigerant pipes and the brazing ring.

Claims

1. An air conditioner comprising: an indoor heat exchanger and an outdoor heat exchanger, each comprising a plurality of refrigerant pipes and at least one connection pipe connected to the refrigerant pipes; and a plurality of brazing holes defined along a circumference of the connection pipe, the connection pipe extending in a longitudinal direction, wherein the connection pipe comprises inlet ends comprising a first inlet end that receives a portion of a first refrigerant pipe among the refrigerant pipes, and a second inlet end that receives a portion of a second refrigerant pipe among the refrigerant pipes, wherein the plurality of brazing holes comprise: a first group of brazing holes that are located between an end of the first refrigerant pipe and the first inlet end, the first group of brazing holes being located closer to the end of the first refrigerant pipe than to the first inlet end in the longitudinal direction, and a second group of brazing holes that are located between an end of the second refrigerant pipe and the second inlet end, the second group of brazing holes being located closer to the end of the second refrigerant pipe than to the second inlet end in the longitudinal direction, wherein the connection pipe is bonded to each of the refrigerant pipes by a sealing material that fills a gap between one of the refrigerant pipes and one of the inlet ends of the connection pipe, and wherein each of the plurality of brazing holes has a circumferential width in a circumference direction of the connection pipe and a longitudinal width in the longitudinal direction, the circumferential width being greater than the longitudinal width.

2. The air conditioner according to claim 1, wherein the plurality of brazing holes are arranged at predetermined intervals along the circumference of the connection pipe.

3. The air conditioner according to claim 1, wherein the refrigerant pipes and the connection pipe are arranged so as to be perpendicular to a surface of one of the indoor heat exchanger or the outdoor heat exchanger, and the connection pipe is located so as to be more distant from the surface of the one of the indoor heat exchanger or the outdoor heat exchanger than the refrigerant pipes.

4. The air conditioner according to claim 1, wherein the refrigerant pipes and the connection pipe are arranged so as to be perpendicular to a surface of one of the indoor heat exchanger or the outdoor heat exchanger, and the connection pipe is located so as to be more distant from the surface of the one of the indoor heat exchanger or the outdoor heat exchanger than the refrigerant pipes.

5. The air conditioner according to claim 1, wherein each of the plurality of brazing holes is configured to receive a brazing ring in a liquid state based on the brazing ring being liquefied along the circumference of the connection pipe, the sealing material being solidified from the brazing ring in the liquid state.

Description

DESCRIPTION OF DRAWINGS

(1) The accompanying drawings, which are included to provide a further understanding of the invention, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention.

(2) In the drawings:

(3) FIG. 1 is a view showing the general structure of a heat exchanger provided in an air conditioner;

(4) FIG. 2 is a view showing the structure of an indoor heat exchanger or an outdoor heat exchanger;

(5) FIG. 3 is a view showing a conventional method of brazing a connection pipe to refrigerant pipes;

(6) FIG. 4 is a view showing another conventional method of brazing a connection pipe to refrigerant pipes;

(7) FIG. 5 is a view showing a method of brazing a connection pipe to refrigerant pipes in accordance with an embodiment of the present invention;

(8) FIG. 6 is a view showing brazing holes formed in a connection pipe according to an embodiment of the present invention;

(9) FIG. 7 is a bottom perspective view showing a brazing ring provided on the connection pipe; and

(10) FIG. 8 is a flowchart showing a method of brazing a connection pipe to refrigerant pipes.

BEST MODE

(11) Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It should be noted herein that these embodiments are only for illustrative purposes and the protection scope of the invention is not limited thereto. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

(12) FIG. 2 is a view showing a heat exchanger 10. The heat exchanger 10 may be the indoor heat exchanger 6 or the outdoor heat exchanger 3 shown in FIG. 1. The heat exchanger 10 includes a plurality of refrigerant pipes 12, in which high-temperature or lower-temperature refrigerant flows to increase or decrease the temperature of air, and a plurality of fins 13 for increasing heat exchange between the refrigerant flowing in the refrigerant pipes 12 and external air.

(13) As shown in FIG. 2, the refrigerant pipes 12 may be arranged parallel to each other, and the fins 13 may be arranged at predetermined intervals so as to be perpendicular to the refrigerant pipes 12. Each refrigerant pipe 12 may be an elongated hollow pipe. Each fin 13 may be a thin metal sheet. Air may be introduced into gaps between the respective fins 13 to improve the efficiency of heat exchange between the refrigerant and the air.

(14) Each fin 13 may have various shapes. In order to further improve the efficiency of heat exchange between the refrigerant and the air, a plurality of holes (not shown) may be formed in each fin 13 such that the air flows through the holes. The shapes of each fin 13 are well known in the art to which the present invention pertain; therefore, a detailed description thereof will be omitted.

(15) The refrigerant pipes 12 are arranged parallel to each other, and are connected to each other using connection pipes 11 and 14. One connection pipe 11 or 14 may interconnect ends of two refrigerant pipes 12. A plurality of refrigerant pipes 12 is connected to each other via a plurality of connection pipes 11 and 14 in order to constitute a plurality of long channels. The refrigerant flows in the long channels, which are formed by the refrigerant pipes 12 and the connection pipes 11 and 14, and passes perpendicularly through the fins 13 in a serpentine fashion to exchange heat with external air. The long channels, which are formed by the connection pipes 11 and 14 and the refrigerant pipes 12, extend through the fins 13, thereby improving the efficiency of heat exchange.

(16) The connection pipes 11 and 14 may include Y-shaped connection pipes 11 and U-shaped connection pipes 14. The Y-shaped connection pipes 11 serve as inlets, through which the refrigerant is introduced into the heat exchanger 10, or outlets, through which the refrigerant is discharged from the heat exchanger 10. The U-shaped connection pipes 14 interconnect ends of the refrigerant pipes 12 such that the refrigerant passes along the refrigerant pipes 12 in the heat exchanger 10.

(17) The refrigerant flows as follows. After reaching the heat exchanger 10, the refrigerant is introduced into the refrigerant pipes 12 through the Y-shaped connection pipes 11. Subsequently, the refrigerant passes perpendicularly through the fins 13. At this time, heat exchange is performed. The refrigerant introduced into one end of the heat exchanger 10 flows to the other end of the heat exchanger 10 along the refrigerant pipes 12, and then passes perpendicularly through the fins 13 via the U-shaped connection pipes 14 provided at the ends of the refrigerant pipes 12. After flowing several times in a serpentine fashion, the refrigerant flows to the other end of the heat exchanger 10. The refrigerant is discharged from the other end of the heat exchanger 10 through the Y-shaped connection pipes 11 provided at the ends of the refrigerant pipes 12. After being discharged through the Y-shaped connection pipes 11, the refrigerant flows to a compressor or an expansion valve.

(18) Referring to FIGS. 3 to 6, one Y-shaped connection pipe 11 is shown as being connected to two refrigerant pipes 12 for the convenience of description. Of course, one U-shaped connection pipe 14 may be connected to two refrigerant pipes 12. Hereinafter, therefore, the Y-shaped connection pipe 11 and the U-shaped connection pipe 14 will simply be referred to as a connection pipe 11. In addition, a portion of the heat exchanger 10 from which the refrigerant is discharged after exchanging heat will be described as an embodiment. Consequently, the inlet ends of the connection pipe 11, which will be described below, indicate portions of the connection pipe 11 that are connected to the refrigerant pipes 12, and the ends of the refrigerant pipes 12 indicate portions of the refrigerant pipes 12 that are connected to the connection pipe 11.

(19) FIGS. 3 and 4 are views showing conventional methods of brazing the connection pipe 11 to the refrigerant pipes 12. In order to easily perform the brazing process, the connection pipe 11 may be generally coupled to the refrigerant pipes 12 in the state in which the refrigerant pipes 12 are arranged so as to be perpendicular to the ground. That is, brazing is performed in the state in which the refrigerant pipes 12 are disposed on the ground and the connection pipe 11 is disposed on the refrigerant pipes 12. However, the positional relationship between the connection pipe 11 and the refrigerant pipes 12 is not limited thereto.

(20) Referring to FIG. 3, ends of the refrigerant pipes 12 are expanded, and the connection pipe 11 is inserted into the expanded ends of the refrigerant pipes 12. Brazing rings 15 are mounted to the connection pipe 11 in advance, and then the connection pipe 11 is inserted into the refrigerant pipes 12. After being set as shown in FIG. 3, the brazing rings 15 come into contact with the ends of the refrigerant pipes 12. In this state, the brazing rings 15 are heated using a torch, with the result that the liquid-state brazing rings 15 flow into gaps between the connection pipe 11 and the refrigerant pipes 12. Consequently, the connection pipe 11 is brazed to the refrigerant pipes 12.

(21) In FIG. 3, however, the channel is suddenly narrowed, since the connection pipe 11 is inserted into the refrigerant pipes 12. As a result, pressure loss occurs, and the refrigerant does not flow smoothly. In addition, during brazing, the liquid-phase brazing rings 15 may flow under the connections between the refrigerant pipes 12 and the connection pipe 11. If the liquid-phase brazing rings 15 leak into the refrigerant pipes 12, the brazing rings 15 disturb the flow of the refrigerant in the refrigerant pipes 12. Furthermore, the heat exchanger 10 may be damaged due to imbalance in pressure between the refrigerant pipes 12 having the brazing rings 15 therein and the refrigerant pipes 12 having no brazing rings 15.

(22) Referring to FIG. 4, the refrigerant pipes 12 are inserted into the connection pipe 11. In this case, it is possible to prevent pressure loss caused as the result of the channel being suddenly narrowed and imbalance in flow of the refrigerant, which occur in the case shown in FIG. 3. In FIG. 4, brazing rings 15 are mounted to the refrigerant pipes 12, and then the refrigerant pipes 12 are inserted into the connection pipe 11. After the insertion is completed, the brazing rings 15 are in contact with the inlet ends of the connection pipe 11.

(23) In this state, the brazing rings 15 are heated using a torch, with the result that the liquid-state brazing rings 15 enter gaps between the connection pipe 11 and the refrigerant pipes 12 according to a capillary phenomenon.

(24) In FIG. 4, however, the liquid-phase brazing rings 15 do not entirely enter the gaps between the connection pipe 11 and the refrigerant pipes 12, but a portion of each of the liquid-phase brazing rings 15 flows down along the refrigerant pipes 12 due to gravity.

(25) FIG. 5 shows an embodiment of the present invention that solves the problems caused in FIGS. 3 and 4. The refrigerant pipes 12 are inserted into the connection pipe 11 in the same manner as shown in FIG. 4. In the embodiment of the present invention shown in FIG. 5, brazing holes 16 may be formed in the connection pipe 11. The brazing holes 16 may be formed in the connection pipe 11 by punching. The inside and outside of the connection pipe 11 communicate with each other through the brazing holes 16. When the brazing rings 15 are heated, the liquid-phase brazing rings 15 enter the brazing holes 16.

(26) The brazing holes 16 may be formed in a portion of the connection pipe 11 that faces the refrigerant pipes 12 after the refrigerant pipes 12 are inserted into the connection pipe 11. That is, the brazing holes 16 may be formed in a portion of the connection pipe 11 between the ends of the refrigerant pipes 12 and the inlet ends of the connection pipe 11 after the refrigerant pipes 12 are inserted into the connection pipe 11 such that the liquid-phase brazing rings 15 are uniformly distributed in the gaps between the connection pipe 11 and the refrigerant pipes 12.

(27) A plurality of brazing holes 16 may be formed along the circumference of the connection pipe 11. The brazing holes 16 may be arranged at predetermined intervals such that the liquid-phase brazing rings 15 uniformly enter the brazing holes 16. In addition, the brazing holes 16 are arranged along the circumference of an arbitrary section of the connection pipe 11 in the longitudinal direction of the connection pipe 11, since each of the brazing rings 15 is formed in a ring shape.

(28) As shown in FIG. 5, the refrigerant pipes 12 are inserted into the connection pipe 11 more deeply than the brazing rings 15 in the state in which the brazing rings 15 are mounted over the brazing holes 16 formed in the connection pipe 11. In this state, the brazing rings 15 are heated using a torch, with the result that the liquid-state brazing rings 15 enter gaps between the connection pipe 11 and the refrigerant pipes 12 through the brazing holes 16. The liquid-phase brazing rings 15 flow both upward and downward according to a capillary phenomenon, and enter the gaps between the connection pipe 11 and the refrigerant pipes 12.

(29) The brazing rings 15 are affected by gravity in the downward direction. As a result, a larger amount of liquid-phase brazing rings 15 enters more quickly the gaps between the connection pipe 11 and the refrigerant pipes 12 in the downward direction. For this reason, the brazing holes 16 may be formed so as to be closer to the ends of the refrigerant pipes 12 than to the inlet ends of the connection pipe 11 such that the liquid-phase brazing rings 15 uniformly enter the gaps between the connection pipe 11 and the refrigerant pipes 12.

(30) Meanwhile, the width of each of the brazing holes 16 in the longitudinal direction of the connection pipe 11 may be slightly smaller than that of each of the brazing rings 15 in the longitudinal direction of the connection pipe 11 such that the brazing rings 15 are easily mounted over the brazing holes 16.

(31) FIGS. 6 and 7 are views showing the state before the refrigerant pipes 12 are inserted into the connection pipe 11. FIG. 6 is a view showing the connection pipe 11 before the brazing rings 15 are mounted thereto. The shape and number of brazing holes 16 may be changed as long as the characteristics of the brazing holes 16 are not deteriorated.

(32) FIG. 8 is a flowchart showing a manufacturing method according to an embodiment of the present invention. Specifically, FIG. 8 is a flowchart showing a method of manufacturing an air conditioner including an indoor heat exchanger or an outdoor heat exchanger including a plurality of refrigerant pipes 12 and at least one connection pipe 11 for interconnecting the refrigerant pipes 12, a compressor, and an expansion valve. The manufacturing method includes a punching step (S100) of punching a portion of the connection pipe 11 to form brazing holes 16 in the connection pipe 11, a mounting step (S200) of mounting brazing rings 15 to the punched portion of the connection pipe 11, an insertion step (S300) of inserting the refrigerant pipes 12 into the connection pipe 11 through inlet ends of the connection pipe 11, and a brazing step (S400) of brazing the connection pipe 11 to the refrigerant pipes 12.

(33) At the punching step (S100), the brazing holes 16 may be formed in a portion of the connection pipe 11 into which the refrigerant pipes 12 can be inserted. The brazing holes 16 formed at the punching step (S100) are formed in a portion of the connection pipe 11 between the inlet ends of the connection pipe 11 and the ends of the refrigerant pipes 12 in order to reduce the brazing defect rate at the brazing step (S400).

(34) At the punching step (S100), a plurality of brazing holes 16 may be formed along the circumference of one side of the connection pipe 11. The brazing holes 16 are formed by punching so as to be arranged at predetermined intervals such that the brazing rings 15 uniformly enter the brazing holes 16 at the brazing step (S400).

(35) The width of each of the brazing holes 16 formed at the punching step (S100) in the longitudinal direction of the connection pipe 11 may be slightly smaller than that of each of the brazing rings in the longitudinal direction of the connection pipe 11 such that the brazing rings 15 are easily mounted over the brazing holes 16.

(36) The diameter of each of the brazing rings 15 mounted at the mounting step (S200) is larger than that of the connection pipe 11. The reason for this is that the brazing defect rate is minimized when the brazing rings 15 enter the inside of the connection pipe 11 from the outside of the connection pipe 11, since the refrigerant pipes 12 are inserted into the connection pipe 11.

(37) The brazing holes 16, provided between the inlet ends of the connection pipe 11 and the ends of the refrigerant pipes 12, may be formed so as to be closer to the ends of the refrigerant pipes 12. When the brazing rings 15 are heated at the brazing step (S400), the liquid-state brazing rings 15 enter gaps between the connection pipe 11 and the refrigerant pipes 12 through the brazing holes 16 formed at the punching step (S100) according to a capillary phenomenon. In an embodiment of the present invention, however, the refrigerant pipes 12 are arranged so as to be perpendicular to the ground, and the connection pipe 11 is provided on the refrigerant pipes 12. During brazing, therefore, gravity is further applied to the liquid-state brazing rings 15. As a result, a larger amount of liquid-phase brazing rings 15 enters the gaps between the connection pipe 11 and the refrigerant pipes 12 in the downward direction. For this reason, the brazing holes 16 may be formed so as to be closer to the ends of the refrigerant pipes 12 than to the inlet ends of the connection pipe 11.

(38) After the punching step (S100), the mounting step (S200), and the insertion step (S300) are performed, the brazing step (S400) is finally performed. At the brazing step (S400), the brazing rings 15 are heated using a torch.

(39) The brazing step (S400) includes a preheating step of preheating the refrigerant pipes 12 and a heating step of heating the brazing rings 15. When the brazing rings 15 are melted using the torch, the molten brazing rings 15 tend to flow in the state of clinging to the high-temperature portion. When the preheating step is performed, therefore, the liquid-state brazing rings 15 more smoothly enter the gaps between the connection pipe 11 and the refrigerant pipes 12 through the brazing holes 16.

Mode for Invention

(40) Various embodiments have been described in the best mode for carrying out the invention.

INDUSTRIAL APPLICABILITY

(41) The present invention provides an air conditioner, wherein brazing rings smoothly enter gaps between refrigerant pipes and a connection pipe during brazing, thereby reducing the brazing defect rate, and a method of manufacturing the same.

(42) It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.