CLIAMS:1. A condenser configured to use in an air-conditioning system, the condenser comprising:
a first tank formed using a first header plate and a second header plate, wherein the first header plate comprises at least one opening for exchanging refrigerant with at least one component of the air-conditioning system and the second header plate comprises a plurality of slots for receiving a plurality of tubes for condensing the refrigerant; and
a coupling unit configured to connect the at least one component with the first header plate; wherein the coupling unit comprises a first hole and a second hole; the first hole is disposed over the at least one opening within the first header plate; the second hole is disposed on a side facing toward the first header plate and is configured to receive a fastening element so as to fasten the first header plate with the coupling unit.

2. The condenser as claimed in claim 1, wherein the coupling unit comprises a third hole configured to receive a male connector corresponding to the at least one component.

3. The condenser as claimed in claim 1, wherein the second hole is a blind hole and has an opening on the side facing toward the first header plate.

4. The condenser as claimed in claim 1, wherein the fastening element is inserted within the second hole from a rear portion of the first header plate.

5. The condenser as claimed in claim 1, wherein the fastening element comprises at least one of a rivet and a screw.

6. The condenser as claimed in claim 5, wherein the rivet comprises a rivet head and a mandrel made of at least of aluminium, steel and combination thereof.

7. The condenser as claimed in claim 1, wherein a diameter of the second hole is 0.1 to 0.8 mm greater than a diameter of the fastening element.

8. The condenser as claimed in claim 1, wherein the at least one component is a tube configured to connect the condenser to at least one of a compressor, and an evaporator of the air-conditioning system.

9. The condenser as claimed in claim 1 further comprises a second tank, wherein the first tank is connected to a compressor or evaporator or both and the second tank is connected to a receiver drier tank and / or compressor or evaporator of the air conditioning system.

10. The condenser as claimed in claim 1, wherein a bracket is coupled to the first header plate using a closed end rivet or solid rivet.

11. The condenser as claimed in claim 10, wherein a diameter of a hole required for inserting the closed end rivet is 0.1 to 0.8 mm greater than a diameter of the closed end rivet.

12. A coupling unit configured to connect a tank of the condenser comprising a first header plate and a second header plate with at least one component of an air conditioning system, the coupling unit comprising:
a first hole disposed over an at least one opening within the first header plate;
a second hole disposed on a side facing toward the first header plate and is configured to receive a fastening element so as to fasten the first header plate with the coupling unit; and
a third hole configured to receive a male connector corresponding to the at least one component.

13. The condenser as claimed in claim 12, wherein the second hole is a blind hole and has an opening on the side facing toward the first header plate.

14. The condenser as claimed in claim 12, wherein the fastening element is inserted within the second hole from a rear portion of the first header plate.

15. A method for connecting a tank of the condenser comprising a first header plate and a second header plate with an at least one component of an air conditioning system, the method comprising:
aligning a blind hole of a coupling unit on at least one opening of the first header plate, wherein the blind hole is facing toward a front portion of the first header plate;
riveting the first header plate with the coupling unit through an insertion of a blind rivet within the blind hole from a rear portion of the first header plate;
facilitating seal between the front portion of the first header plate with the coupling unit through brazing process.
,TagSPECI:TECHNICAL FIELD
[001] This present disclosure relates to refrigeration systems, and more specifically, to a coupling unit configured to be installed in a condenser of an air-conditioning system.
BACKGROUND
[002] Our environment is sensitive to the types of refrigerant used in an air-conditioning system. Any leakage of the refrigerant from one or more components of the air-conditioning system contributes in rise in global warming. As a result, the components of the air-conditioning system are sealed in order to avoid any leakage of the refrigerant thereof.
[003] Condenser is one of the primary components of the air-conditioning system. Normally the condenser receives high pressure refrigerant in a gaseous form from a compressor, condenses the refrigerant to a liquid state and directs the high pressure refrigerant in the liquid state to an evaporator in the air-conditioning system. Although, the condenser is built as an integrated unit to perform condensation of the refrigerant, the condenser is required to include connectors in order to be coupled to other components of the air-conditioning system.
[004] As illustrated in FIG. 1, a prior art condenser 100 includes a header plate 102 upon which a connector 104 and a bracket 106 is disposed. The connector 104 is attached to the plate header 102 through joints using tungsten insert gas (TIG) welding process and the bracket 106 is attached to the plate header 102 through joints using metal inert gas (MIG) welding process. Other methods of attaching the connector 104 with the plate header 102 includes bush caulking or wire winding.
[005] The attachments, plate header 102 and other components of the condenser 100 are passed through a brazing process in order to seal any openings so that refrigerant may not leak during functioning of the condenser. The prior art methods for attaching the connector or bracket with the header plate have several drawbacks. For example, TIG or MIG welding based methods depend on the skill level of the operators and consequently, quality of the products vary substantially on the operator’s skill. Further, the TIG or MIG based methods reduces the aesthetic effectiveness of the condenser. In addition, there exists a relatively higher chance of leakage in the wire winding method due to inconsistent holes concentricity at the mating surface.
[006] Therefore there exists a need to provide a leakage proof, secure and efficient method and apparatus for attaching the connector or bracket with the header plate of the condenser. .
SUMMARY
[007] Embodiments of the present disclosure disclose a coupling unit configured to be installed in a condenser of an air-conditioning system. The condenser includes a first tank formed using a first header plate and a second header plate. The first header plate includes at least one opening for exchanging refrigerant with at least one component of the air-conditioning system and the second header plate includes a plurality of slots for receiving a plurality of tubes for condensing the refrigerant. The condenser includes a coupling unit configured to connect the at least one component with the first header plate. The coupling unit includes a first hole and a second hole such that the first hole is disposed over the at least one opening within the first header plate and the second hole is disposed on a side facing toward the first header plate and is configured to receive a fastening element so as to fasten the first header plate with the coupling unit.
[008] In an embodiment, a coupling unit configured to connect a tank of the condenser comprising a first header plate and a second header plate with at least one component of an air conditioning system is disclosed. The coupling unit includes a first hole, a second hole and a third hole. The first hole is disposed over at least one opening within the first header plate. The second hole is disposed on a side facing toward the first header plate and is configured to receive a fastening element so as to fasten the first header plate with the coupling unit. The third hole is configured to receive a male connector corresponding to the at least one component.
[009] In another embodiment, a method for connecting a tank of the condenser comprising a first header plate and a second header plate with at least one component of an air conditioning system is disclosed. The method includes aligning a blind hole of a coupling unit on at least one opening of the first header plate, wherein the blind hole is facing toward a front portion of the first header plate; riveting the first header plate with the coupling unit through an insertion of a blind rivet within the blind hole from a rear portion of the first header plate; and facilitating seal between the front portion of the first header plate with the coupling unit through a brazing process.
[0010] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.
[0011] It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
[0013] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
[0014] FIG. 1 illustrates a prior art condenser including a connector and a bracket;
[0015] FIG. 2 illustrates a partial and an exploded view of a condenser comprising a coupling unit in accordance with an embodiment of the disclosure;
[0016] FIGs. 3A-C illustrate perspective views of the coupling unit attached to a header plate of the condenser in accordance with an embodiment of the disclosure;
[0017] FIG. 4 illustrates a sectional view of the coupling unit in accordance with an embodiment of the disclosure;
[0018] FIG. 5 illustrates a process for attaching the coupling unit with the header plate of the condenser in accordance with an embodiment of the disclosure;
[0019] FIGs. 6A-B illustrate sectional views of the coupling unit when attached to the header plate of the condenser in accordance with an embodiment of the disclosure;
[0020] FIGs. 7A-B illustrate sectional views of a bracket when attached to the header plate of the condenser in accordance with an embodiment of the disclosure; and
[0021] FIG. 8 illustrates steps of a method for connecting a tank of the condenser comprising a first header plate and a second header plate with at least one component of an air conditioning system.
[0022] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0023] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0024] Referring to FIG. 2, a partial and an exploded view of a condenser 200 of an air-conditioning system is illustrated. The condenser 200 can be configured to use in a vehicle or home air-conditioning system. The condenser 200 includes a first header plate 202 and a second header plate 204 which are parts of a substantially cylindrical tank 206 of the condenser 200. A front portion of the first header plate 202 forms an outer portion of the tank 206 and a rear portion of the first header plate 202 forms a part of an inner portion of the tank 206.
[0025] The second header plate 204 includes a plurality of tube slots 208 for receiving ends of a plurality of tubes 210 which are used for condensing high pressure refrigerant obtained in a gaseous state from a compressor of the air-conditioning system. The opposite ends of the plurality of tubes 210 are supported by a second tank (not shown in FIG. 2) of the condenser 200. In addition, secondary heat transfer units (e.g., fins) can be inserted within the plurality of tubes 210 for effective heat transfer from the refrigerant flowing through the plurality of tubes 210.
[0026] The condenser 200 is further configured to include first and second side plates 212 so as to support the plurality of tubes 210. The second header plate 204 is configured to receive the ends of the first and second side plates 212 whereas the opposite ends of the first and second side plates 212 are supported by another tank of the condenser 200. In addition, the condenser 200 is configured to include end caps 214 for sealing the opposite ends of the tank 206.
[0027] The condenser 200 is configured to include one or more coupling units 222 and brackets 242. The coupling unit 222 can be configured to connect the condenser 200 with connecting tubes utilized for exchanging refrigerant with other respective components of the air-conditioning system. In an embodiment, the components of the air-conditioning system can include a compressor, an evaporator, an expansion device and a receiver drier. For example, the first tank 206 is connected to the compressor through the coupling unit 222 and the second tank is connected to the evaporator through the receiver drier for exchanging refrigerant.
[0028] Further, the bracket 242 is configured to provide support for the condenser 200 which is to be disposed for example, in an automotive vehicle air-conditioning system. A closed end rivet / solid rivet 252 is used so as to securely attach the bracket 242 to the front portion of the first header plate 202.
[0029] In an embodiment, the coupling unit 222 is configured to attach with the first header plate 202 through a fastening element 232. As illustrated, the fastening element 232 is a rivet and is configured to insert within a blind hole (not shown in FIG. 2) which is facing toward the front portion of the first header plate 202.
[0030] The rivet based connection between the first header plate 202 and the coupling unit 222 is strong enough to withstand the thermal expansion that may happen during the brazing process performed on the condenser 200. In an embodiment, the coupling unit 222 is designed in such a way that the thermal expansion coefficient of the rivet 232 and the coupling unit 222 are in opposite direction. As a result, the joint between the coupling unit 222 and the first header plate 202 remain strengthen even at high temperature during the brazing process.
[0031] The method of connecting the coupling unit 222 to the first header plate 202 as disclosed herein does not require the skill as generally required during the TIG welding process. As a result, the present disclosure provides an efficient process of connecting the coupling unit and increases the quality of manufacturing the condenser 200 even at large scale level.
[0032] FIGs. 3A and 3B illustrate perspective views of the coupling unit 222 attached to the first header plate 202 of the condenser 200. The coupling unit 222 includes a first hole 224 disposed over an opening 234 on the front portion of the first header plate 202. The first hole 224 is configured to receive a component (e.g., a tube) to exchange the refrigerant between the condenser 200 and a compressor or an expansion device of the air-conditioning system.
[0033] The coupling unit further includes a second hole 226 disposed on a side facing toward the first header plate 202 of the condenser 200. As illustrated in FIG. 3B, the second hole 226 is a blind hole and has an opening on the side facing toward the first header plate.
[0034] The second hole 226 is used for attaching the coupling unit 222 with the first header plate 202 through a fastening element for example, the rivet 232. An opening 236 is created on the first header plate 202 and the rivet 232 is inserted within the second hole 226 through the opening 236. In an embodiment, the rivet 232 includes a rivet head and a mandrel made of at least of aluminium, steel and combination thereof. FIG. 3C illustrates a perspective view of a rear portion of the first header plate 202 when the coupling unit 222 is attached to the first header plate 202 through the rivet 232.
[0035] In an embodiment, the coupling unit 222 includes a third hole 228 configured to receive a stud or bolt to fasten the male connector corresponding to the at least one component. For example, when the condenser 200 is connected to the compressor through the coupling unit 222, the first hole 224 is configured to receive an end of a tubular pipe whose other end is coupled to the compressor and the third hole 228 is configured to receive a stud or bolt to fasten the male connector (e.g., a threaded screw) so as to firmly connect the tubular pipe with the condenser 200.
[0036] FIG. 4 illustrates a sectional view of the coupling unit 222 in accordance with an embodiment of the disclosure. The first hole 224 and the third hole 228 are on same side of the coupling unit 222 and the second hole 226 is on the opposite side.
[0037] FIG. 5 illustrates a process for attaching the coupling unit 222 with the first header plate 202 of the condenser 200. The second hole 226 (i.e., the blind hole) of the coupling unit 222 is aligned with the opening 236 of the first header plate 202. The rivet 232 is inserted within the second hole 226 from the rear portion of the first header plate 202 and a force is applied using a rivet gun 238 so as to securely fix the coupling unit 222 with the first header plate 202. In an embodiment, the rivet gun 238 can be a pneumatic, hydraulic, electric, plunger spring type gun. The rivet gun 238 is configured to apply a pulling force on the rivet mandrel which deforms the rivet shank. The rivet mandrel breaks at the break notch and a joint is created between the coupling unit 222 and the first header plate 202.
[0038] In an embodiment, a diameter of the second hole 226 is 0.1 to 0.8 mm greater than a diameter of the fastening element (i.e., the rivet 232). In an embodiment, a roughness of the second hole 226 wall is greater than 2.5 microns to achieve more strength in the joint. Further, the tolerance of the second hole 226 is considered as ± 0.1 unit.
[0039] Further, the condenser 200 including this attached combination of the coupling unit 222 and the first header plate 202 is passed through a furnace at high temperature during the brazing process. Such process seals the condenser 200 in order to prevent the refrigerant leakage from these joints.
[0040] FIGs. 6A and 6B illustrate sectional views of the coupling unit 222 when attached to the first header plate 202 of the condenser 200. FIG. 6A indicates that the rivet 232 is used as the fastening element for connecting the coupling unit 222 with the first header plate 202. In another embodiment, a screw 240 is used as fastening element for connecting the coupling unit 222 with the first header plate 202.
[0041] FIGs. 7A and 7B illustrate sectional views of the bracket 242 when attached to the first header plate 202 of the condenser 200. FIG. 7A indicates that the closed end rivet / solid rivet 252 is used as the fastening element for connecting the bracket 242 with the first header plate 202. In an embodiment, a diameter of a hole required to be created on the first header plate 202 for inserting the closed end rivet 252 is 0.1 to 0.8 mm greater than a diameter of the closed end rivet 252. FIG. 7B illustrates usage of a threaded screw 262 for connecting the bracket 242 with the first header plate 202. The closed end rivet 252 used for holding the bracket 242 ensures the leak proof joint between the bracket 242 and the first header plate 202.
[0042] FIG. 8 illustrates steps of a method 800 for connecting a tank of the condenser with at least one coupling unit. The tank includes a first header plate and a second header plate. At step 802, the method 800 aligns a blind hole of a coupling unit on an opening of the first header plate. The blind hole is facing toward a front portion of the first header plate.
[0043] At step 804, the first header plate is riveted with the coupling unit through an insertion of a blind rivet within the blind hole from a rear portion of the first header plate. At step 806, a seal is facilitated between the front portion of the first header plate and the coupling unit through brazing process.
[0044] The present disclosure offers several advantages. For example, the method for connecting the coupling unit 222 with the first header plate 202 provides strength of more than 30 Newton which prevents any failure of this attachment during the brazing process. The attachment method as disclosed herein validates an external corrosion durability of the condenser 200 for joints associated with the coupling unit 222 and the bracket 242 when checked during Copper Accelerated Acetic Acid Salt Spray Test (CASS Test) as per Japanese Industry Standard (JIS) H 8681 standard.
[0045] Further, the joint between the coupling unit 222 and the first header plate 202 as disclosed herein validates vibration durability as required in JIS D 1601. Furthermore, the condenser comprising the coupling unit 222 connected to the first header plate 202 conform to various industry requirements such as pressure pulsation durability, burst strength durability, and joint strength.
[0046] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.