US20060042309A1 - Condenser assembly having a mounting rib - Google Patents
Condenser assembly having a mounting rib Download PDFInfo
- Publication number
- US20060042309A1 US20060042309A1 US10/932,865 US93286504A US2006042309A1 US 20060042309 A1 US20060042309 A1 US 20060042309A1 US 93286504 A US93286504 A US 93286504A US 2006042309 A1 US2006042309 A1 US 2006042309A1
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- Prior art keywords
- dryer
- receiver
- mounting rib
- manifold
- condenser assembly
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/001—Casings in the form of plate-like arrangements; Frames enclosing a heat exchange core
- F28F9/002—Casings in the form of plate-like arrangements; Frames enclosing a heat exchange core with fastening means for other structures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B39/00—Evaporators; Condensers
- F25B39/04—Condensers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2339/00—Details of evaporators; Details of condensers
- F25B2339/04—Details of condensers
- F25B2339/044—Condensers with an integrated receiver
- F25B2339/0441—Condensers with an integrated receiver containing a drier or a filter
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2339/00—Details of evaporators; Details of condensers
- F25B2339/04—Details of condensers
- F25B2339/044—Condensers with an integrated receiver
- F25B2339/0442—Condensers with an integrated receiver characterised by the mechanical fixation of the receiver to the header
Definitions
- the present invention relates generally to air conditioning systems for motor vehicles and, more specifically, to a condenser with an integral receiver/dryer for an air conditioning system in a motor vehicle and a method of assembling the condenser.
- Condenser assemblies for automotive vehicle air conditioning systems typically include a pair of headers and a core having a plurality of tubes, through which refrigerant flows, disposed horizontally between the two headers.
- An inlet is disposed near an upper portion of one of the headers and an outlet is disposed at the lower portion of either the same or the other header.
- partitions may be provided to divide the interior space of the headers into more than one fluidly separate spaces. As a result, the refrigerant is caused to flow in a serpentine fashion making more than one path through the tubes between the headers.
- a receiver typically attached to one of the headers and in fluid communication therewith is a receiver.
- Refrigerant condensed in the core flows into the receiver where it is separated into gas and liquid portions.
- a dryer is often associated with or located within the receiver. The dryer is located within the receiver so that the dryer is in contact with the liquid portion of the refrigerant facilitating the removal of water from the refrigerant.
- the dryer may itself be comprised of a bag or cartridge containing dryer granulates such as desiccant.
- a receiver/dryer structure to provide a manifold structure, and then connect the respective structures.
- the manifold and the receiver/dryer are typically connected via a brazing method. More specifically, the manifold is positioned in desired location with respect to the receiver/dryer such that a portion of the manifold engages a portion of the receiver/dryer.
- the respective engaging portions are fixedly connected via a brazing method, such as a brazing oven.
- the manifold and the receiver/dryer may become partially or completely disengaged from each other before or during the brazing process, leading to an insufficient or an incomplete connection between the respective components.
- a condenser assembly for a vehicle air conditioning system comprising: a core including first and second ends and a plurality of tubes extending therebetween, a first header located adjacent to the first end of the core, and a second header located adjacent to the second end of the core.
- the second header includes a receiver/dryer having a receiver/dryer chamber, a manifold cooperating with the receiver/dryer to define a manifold chamber being in fluid communication with the flow passages in the tubes, and a mounting rib unitarily formed with at least one of the receiver/dryer and the manifold.
- the mounting rib includes a first portion extending away from the at least one of the receiver/dryer and the manifold in a first direction and a second portion extending away from the first portion in a second direction that is substantially nonparallel with the first direction.
- first direction and the second direction cooperate to define an angle being greater than 45° and being less than 135°.
- the first direction and the second direction may be generally perpendicular with each other.
- the mounting rib further includes a weakened line connecting the first portion and the second portion.
- the weakened line may be an arcuate groove.
- the receiver/dryer includes a top end and a bottom end, and the mounting rib extends substantially continuously from the top end to the bottom end in a direction generally perpendicularly to the plurality of tubes.
- the condenser assembly further comprises a second mounting rib unitarily formed with the at least one of the receiver/dryer and the manifold.
- the mounting rib and the second mounting rib and the second mounting rib are each unitarily formed with the receiver/dryer.
- the manifold includes a flange and a second flange, the mounting rib engages the flange of the manifold, and the second mounting rib engages the second flange of the manifold.
- the mounting rib is a deformable mounting rib and the second mounting rib is a fixed mounting rib.
- the condenser assembly further comprises a third mounting rib and a fourth mounting rib, each unitarily formed with the receiver/dryer.
- the third mounting rib and the fourth mounting rib engage a mounting bracket coupled to the vehicle.
- the third mounting rib is a deformable mounting rib and the fourth mounting rib is a fixed mounting rib.
- the first header is connected to the core such that the first header is in fluid communication with the tubes in the core.
- the manifold is connected to the core such that the manifold chamber and the receiver/dryer chamber are in fluid communication with the tubes.
- a mounting rib is formed on at least one of the receiver/dryer and the manifold for coupling the manifold and the receiver/dryer with each other. The mounting rib may be brazed in order to further connect the manifold and the receiver/dryer with each other.
- FIG. 1 shows a condenser having a manifold and a pair of mounting brackets coupled with a receiver/dryer and embodying the principles of the present invention
- FIG. 2 is a cross-sectional view of the condenser taken along line 2 - 2 in FIG. 1 , showing the manifold, the receiver/dryer, and one of the mounting brackets being coupled by deformable mounting ribs and a fixed mounting rib; and
- FIG. 3 is a cross-sectional view taken along line 2 - 2 in FIG. 1 , showing the deformable ribs in an undeformed state.
- FIG. 1 shows a condenser assembly 10 embodying the principals of the present invention.
- the condenser assembly 10 includes a core 12 , a first header 14 , and a second header 16 .
- the headers 14 and 16 are located at opposing ends of the core 12 , as further mentioned below.
- the condenser 10 further includes a pair of brackets 13 in order to mount the condenser 10 to a mounting portion of the vehicle (not shown) during use in an air conditioning system (not shown).
- the core 12 is a tube stack comprising a series of tubes 18 extending between the headers 14 , 16 . More specifically, a first end 15 of the core 12 extends into the first header 14 and a second end 17 of the core 12 extends into the second header 16 .
- the tubes 18 are generally parallel to each other and are vertically stacked with respect to each other. Adjacent tubes 18 are generally evenly-spaced apart from one another such that a space 20 is located therebetween.
- the tubes 18 themselves may be of any appropriate construction. In one preferred embodiment, the tubes are generally flat and include portions defining one or more flow channels 21 longitudinally through the tube.
- a fin 22 for increasing heat transfer between the tubes 18 and an airflow intersecting the condenser assembly 10 .
- the fins 22 exhibit a generally corrugated shape comprising a series of convolutes as is commonly known in the industry.
- the fins 22 generally extend completely across the space 20 contacting both the tube located thereabove and therebelow.
- the details of the shape of the fins 22 are not illustrated in significant detail since those skilled in this technology will readily appreciate such a construction.
- the fins 22 are preferably provided with a series of louvers on each corrugation in order to aid in the heat transfer efficiency from the tubes, to the fins and to the air passing therethrough.
- the fins 22 are provided in such a manner that the overall length of the tubes 18 is greater than the overall length of the fins 22 and that the ends 24 and 26 of the tubes 18 extend beyond the end of the fins 22 .
- These first and second ends 24 , 26 of the tubes are respectively received within the first and second headers 14 , 16 and, as further discussed below, are in fluid communication with the first and second headers 14 , 16 .
- the first header 14 (hereinafter the “inlet/outlet header” or “I/O header”) is shown on the left-hand side of FIG. 1 .
- the I/O header 14 is preferably constructed of a cylindrical body or member 28 that has a constant cross-sectional profile, round in the preferred embodiment, over its length.
- the top and bottom ends 30 , 32 of the cylindrical body 28 are respectively engaged and closed by top and bottom caps 34 , 36 .
- a partition or baffle 40 is preferably located within the cylindrical body 28 so as to cooperate with the cylindrical body and the upper cap 34 in order to define an upper chamber 42 , which will be discussed in more detail below.
- an additional partition 44 may be provided to define a middle chamber 46 and a lower chamber 48 .
- the lower chamber 48 is often referred to as the super-cooled region.
- the I/O header 14 includes an inlet aperture 49 that communicates with an inlet bore 50 defined in an inlet block 52 . Similarly, the I/O header 14 includes an outlet aperture 54 that is in communication with an outlet bore 56 defined in an outlet block 58 mounted to the cylindrical body 28 of the I/O header 14 .
- refrigerant enters into the condenser assembly 10 via the inlet block 52 and exits from the condenser assembly 10 via the outlet block 58 .
- the end 24 of each tube 18 is received through a tube aperture 60 defined in one side of the cylindrical body 28 .
- the remaining header 16 of the condenser assembly 10 is generally illustrated on the right hand side of FIG. 1 .
- This header 16 is hereinafter referred to as the “receiver/dryer header” or “RID header”.
- the R/D header 16 is preferably an integrated structure made up of two components, a receiver/dryer 62 and a manifold 64 , which will now be discussed in more detail.
- the receiver/dryer 62 preferably includes a cylindrical body or member 66 having top and bottom ends 67 , 69 respectively closed by top and bottom caps 68 , 70 . Therefore, the top and bottom caps 68 , 70 cooperate with the cylindrical body 66 to define a R/D chamber 72 within the R/D header 16 .
- the cylindrical body 66 preferably exhibits a substantially constant cross-sectional profile along its length. More preferably, the cylindrical body 66 includes a generally round cross-sectional profile along its length having a longitudinal axis 71 shown in FIG. 1 .
- the R/D chamber 72 is in fluid connection with the manifold chamber 74 via a first opening 75 a and a second opening 75 b in the receiver/dryer 62 .
- the R/D chamber 72 preferably includes a drying element, such as a dryer 73 .
- the dryer 73 shown in FIG. 1 comprises a dryer bag containing a liquid-absorbing component, such as desiccant material. Any water in the refrigerant is absorbed by the dryer 73 in order to improve the performance and structural integrity of the air conditioning system.
- the manifold 64 and the cylindrical body 66 cooperate to define a manifold chamber 74 .
- the second header 16 preferably includes at least one partition and at least two caps in order to divide the manifold chamber 74 into a plurality of chambers.
- an upper partition 76 , a lower partition 78 , a top cap 77 , and a bottom cap 79 are located within the manifold chamber 74 in order to form respective substantially fluid-tight seals with the manifold 64 and the receiver dryer 62 .
- the upper partition 76 cooperates with the manifold 64 , the receiver dryer 62 , and the top cap 77 in order to define an upper chamber 80 .
- the upper partition 76 cooperates with the manifold 64 , the receiver dryer 62 , and the lower partition 78 in order to define a middle chamber 82 and the lower partition 78 cooperates with the manifold 64 , the receiver dryer 62 , and the bottom cap 79 in order to define a lower chamber 84 .
- the respective components 62 , 64 are preferably brazed together by being exposed to relatively high temperatures as is known in the art. As discussed above, it is advantageous for respective components to be engaged with each other during the brazing process in order to form a robust connection. Therefore, it may be advantageous to provide engaging component(s) to engage the manifold 64 and the receiver/dryer 62 with each other before and during the brazing process. Similarly, the engaging components may be used as an alternative to the brazing process.
- a first mounting rib 86 is provided in order to engage the manifold 64 and the receiver/dryer 62 with each other.
- the mounting rib 86 in FIG. 2 is unitarily formed with the receiver/dryer 62 and engages a flange 88 of the manifold 64 .
- the mounting rib 86 may alternatively be formed with the manifold 64 in order to engage a flange of the receiver/dryer 62 .
- the flange 88 preferably extends along and parallel to the outer surface of the receiver/dryer 62 in order to increase the contact surface area between the respective components 62 , 64 .
- the mounting rib 86 preferably includes a first portion 90 extending away from the receiver/dryer 62 in a first direction 91 and a second portion 92 extending obliquely away from the first portion in a second direction 93 . More specifically, the first direction 91 and the second direction 93 form an angle 94 that is preferably greater than 45° and less than 135°. More preferably, the first direction 91 and the second direction 93 are generally perpendicular to each other such that the first portion 90 and the second portion 92 each engage a respective portion of the flange 88 . However, any appropriate angles may be formed by the first and second portions 90 , 92 .
- a second mounting rib 96 similar to the first mounting rib 86 , is provided in order to further engage the manifold 64 and the receiver/dryer 62 with each other.
- the second mounting rib 96 is unitarily formed with the receiver/dryer 62 in order to engage a second flange 98 of the manifold 64 .
- the second flange 98 preferably extends along the receiver/dryer 62 similarly to the first flange 88 .
- the second mounting rib 96 includes a first portion 100 extending away from the receiver/dryer 62 in a first direction 101 and a second portion 102 extending away from the first portion in a second direction 103 at an angle 104 that is preferably greater than 45° and less than 135°. More preferably, the first direction 101 and the second direction 103 are generally perpendicular to each other.
- the mounting ribs 86 , 96 preferably extend continuously from the top end 67 to the bottom end 69 of the receiver/dryer 62 , but other configurations may be used. In particular, the mounting ribs 86 , 96 may extend along a portion of the length of the receiver/dryer 62 . Additionally, a plurality of first mounting ribs 86 may be longitudinally separated from each other and a plurality of second mounting ribs 96 may be similarly longitudinally separated from each other.
- the first and second mounting ribs 86 , 96 may be deformable mounting ribs, fixed mounting ribs, or a combination thereof.
- Deformable mounting ribs are defined as mounting ribs that are designed to be bent along a line in order to engage the respective manifold flanges 88 , 98 .
- the first and/or second mounting ribs 86 , 96 may include a weakened line extending along the length of the mounting ribs 86 , 96 .
- the weakened line is preferably located between the first portion 90 , 100 and the second portion 92 , 102 of the respective mounting ribs 86 , 96 such that the first portion 90 , 100 and the second portion 92 , 102 each engage respective portions of the flanges 88 , 98 .
- first mounting rib 86 and the second mounting rib 96 are each shown in an undeformed position, such that the respective second portions 92 , 102 are not engaged with the flanges 88 , 98 when the mounting ribs 86 , 96 are undeformed. More specifically, the first direction 91 , 101 of each of the first portions 90 , 100 remains the same as shown in FIG. 2 , but the second portions 92 , 102 extend from the first portions 90 , 100 at respective second directions 93 ′, 103 ′ that are preferably not the same as the second directions 93 , 103 shown in FIG. 2 .
- angles 94 ′, 104 ′ that are preferably greater than the angles 94 , 104 shown in FIG. 2 .
- the angles 94 ′, 104 ′ of the first and second mounting ribs 86 , 96 shown in FIG. 3 permit the manifold 64 to be easily inserted between the respective mounting ribs 86 , 96 .
- each mounting rib 86 , 96 is a groove 106 , 108 having a thickness less than that of the respective first portions 90 , 100 and second portions 92 , 102 .
- the reduced thickness of the grooves 106 , 108 cause the mounting ribs 86 , 96 to have a tendency to bend along the grooves 106 , 108 .
- the grooves 106 , 108 preferably have an arcuate shape in order to simplify manufacturing.
- the bracket 13 includes a first portion 110 to be connected to the receiver/dryer 62 and a second portion 112 to be connected to a mounting portion of the vehicle.
- the first portion 110 of the bracket 13 preferably includes a pair of flanges 118 , 128 which will be discussed in further detail below.
- the second portion 112 of the bracket 13 preferably includes at least one mounting hole 114 in order to receive a fastener or other appropriate connection means.
- the condenser assembly 10 may include a pair of mounting brackets 13 .
- a third mounting rib 116 is provided in order to engage the bracket 13 and the receiver/dryer 62 with each other.
- the third mounting rib 116 in FIG. 2 is unitarily formed with the receiver/dryer 62 and engages the flange 118 of the bracket 13 .
- the third mounting rib 116 may alternatively be formed with the bracket 13 in order to engage a flange of the receiver/dryer 62 .
- the flange 118 preferably extends along and parallel to the outer surface of the receiver/dryer 62 in order to increase the contact surface area between the respective components 13 , 62 .
- the mounting rib 86 preferably includes a first portion 120 extending away from the receiver/dryer 62 in a first direction 121 and a second portion 122 extending away from the first portion in a second direction 123 that is nonparallel with the first direction 121 . More specifically, the first direction 121 and the second direction 123 form an angle 124 that is preferably greater than 45° and less than 135°. More preferably, the first direction 121 and the second direction 123 are generally perpendicular to each other such that the first portion 120 and the second portion 122 each engage a respective portion of the flange 118 . However, any appropriate angles may be formed by the first and second portions 120 , 122 .
- a fourth mounting rib 126 is also preferably provided in order to further engage the bracket 13 and the receiver/dryer 62 with each other.
- the fourth mounting rib 126 is unitarily formed with the receiver/dryer 62 in order to engage the second flange 128 of the bracket 13 .
- the second flange 128 preferably extends along the receiver/dryer 62 similarly to the first flange 118 .
- the fourth mounting rib 126 includes a first portion 130 extending away from the receiver/dryer 62 in a first direction 131 and a second portion 132 extending away from the first portion in a second direction 133 at an angle 134 that is preferably greater than 45° and less than 135°. More preferably, the first direction 131 and the second direction 133 are generally perpendicular to each other.
- the third and fourth mounting ribs 116 , 126 preferably extend continuously from the top end 67 to the bottom end 69 of the receiver/dryer 62 , but other configurations may be used. In particular, the third and fourth mounting ribs 116 , 126 may extend along a portion of the length of the receiver/dryer 62 . Additionally, a plurality of third mounting ribs 116 may be longitudinally separated from each other and a plurality of fourth mounting ribs 126 may be similarly longitudinally separated from each other.
- the third and fourth mounting ribs 116 , 126 may be deformable mounting ribs, fixed mounting ribs, or a combination thereof. Similarly to the first and second mounting ribs 86 , 96 described above, the third and fourth mounting ribs 116 , 126 may include a weakened line extending along the length of the mounting ribs 116 , 126 . The weakened line is preferably located between the first portion 120 , 130 and the second portion 122 , 132 of the respective mounting ribs 116 , 126 .
- the fourth mounting rib 126 is shown in an undeformed position, such that the second portion 132 is not engaged with the flange 128 when the fourth mounting rib 126 is undeformed. More specifically, the first direction 131 of the first portion 130 remains the same as shown in FIG. 2 , but the second portion 132 extends from the first portions 130 at a second direction 133 ′ that is preferably not the same as the second direction 133 shown in FIG. 2 .
- the first direction 131 and the second direction 133 ′ in FIG. 3 form an angle 134 ′ that is preferably greater than the angle 134 shown in FIG. 2 .
- the weakened portion of the fourth mounting rib 126 is a groove 136 having a thickness less than that of the first portion 130 and second portion 132 .
- the reduced thickness of the groove 136 causes the fourth mounting rib 126 to have a tendency to bend along the groove 136 .
- the groove 136 preferably has an arcuate shape in order to simplify manufacturing.
- the third mounting rib 116 shown in FIGS. 2 and 3 is a fixed mounting rib that is preferably pre-formed to have the angle 124 . Therefore, the third mounting rib 116 is shown as having the same angle 124 in both FIGS. 2 and 3 .
- the third mounting rib 116 may be or may not include a weakened line in order to cause the bent portion of the third mounting rib 116 to be precisely-located.
- both of the third and fourth mounting ribs 116 , 126 may be deformable ribs or may be fixed ribs.
- at least one of the third and fourth mounting ribs 126 , 136 is preferably a deformable mounting rib.
- the refrigerant flows into the upper chamber 42 of the first header 14 via the inlet block 52 as described above.
- the refrigerant is typically substantially gaseous when it flows through the inlet block 52 .
- the refrigerant flows through the tubes 18 , undergoing heat exchange with cross-flowing air, which promotes condensation of the refrigerant.
- the refrigerant then exits the tubes into the upper chamber 80 of the manifold 64 .
- the refrigerant then flows back across the tubes 18 , undergoing further heat exchange, and exits into the middle chamber 46 of the first header 14 .
- the refrigerant makes yet another pass across the core 12 and into the middle chamber 82 of the manifold 64 .
- the refrigerant enters the R/D chamber 72 via the first opening 75 a .
- the refrigerant is typically a 3-part fluid at this point in the system: gaseous refrigerant, liquid refrigerant, and water.
- the gaseous refrigerant rises to the top portion of the RID chamber 72 in order to undergo further condensation.
- the liquid refrigerant enters the lower chamber 84 of the manifold 64 via the second opening 75 b and flows into the tubes 18 , where it exits the condenser 10 via the outlet block 58 as described above.
- the water is preferably substantially absorbed by the dryer in order to minimize the amount of water degradating the performance of the refrigerant.
- the manifold 64 is engaged with the receiver/dryer 62 such that the flanges 88 , 98 engage the outer surface of the receiver/dryer 62 as shown in FIG. 3 .
- the deformable ribs 86 , 96 are then bent towards the flanges 88 , 98 in order to form an engagement therewith.
- the bracket 13 is engaged with the receiver/dryer 62 such that the flanges 118 , 128 engage the outer surface of the receiver/dryer 62 as shown in FIG. 3 . More specifically, the first flange 118 is preferably first inserted into the third mounting rib 116 such that the first portion 120 and the second portion 122 of the third mounting rib 116 each engage a portion of the first flange 118 of the bracket 13 .
- the second flange 128 of the bracket 13 is moved such as to engage first portion 130 of the fourth mounting rib 126 and the outer surface of the receiver/dryer 62 , as shown in FIG. 3 . Then, the second portion 132 of the fourth mounting rib 126 is deformed in order to engage the second flange 128 .
- the bracket 13 may simultaneously engage the third and fourth mounting ribs 116 , 126 by sliding the bracket 13 between the respective ribs 116 , 126 in a direction generally parallel with the longitudinal axis 71 .
- the respective components 62 , 64 are preferably brazed together in order to form substantially fluid-tight connections.
- the components may be brazed using a known process, such as a brazing oven. Alternatively, the brazing process is not used, and the mounting ribs 86 , 96 , 116 , 126 form substantially fluid-tight connections between the and the second header 16 are each preferably manifold 64 and the receiver/dryer 62 .
Abstract
Description
- 1. Field of the Invention
- The present invention relates generally to air conditioning systems for motor vehicles and, more specifically, to a condenser with an integral receiver/dryer for an air conditioning system in a motor vehicle and a method of assembling the condenser.
- 2. Related Technology
- Condenser assemblies for automotive vehicle air conditioning systems typically include a pair of headers and a core having a plurality of tubes, through which refrigerant flows, disposed horizontally between the two headers. An inlet is disposed near an upper portion of one of the headers and an outlet is disposed at the lower portion of either the same or the other header. Within the headers, partitions may be provided to divide the interior space of the headers into more than one fluidly separate spaces. As a result, the refrigerant is caused to flow in a serpentine fashion making more than one path through the tubes between the headers.
- Typically attached to one of the headers and in fluid communication therewith is a receiver. Refrigerant condensed in the core flows into the receiver where it is separated into gas and liquid portions. Because the presence of water in the refrigerant will degrade the performance and structural integrity of the air conditioning system, a dryer is often associated with or located within the receiver. The dryer is located within the receiver so that the dryer is in contact with the liquid portion of the refrigerant facilitating the removal of water from the refrigerant. The dryer may itself be comprised of a bag or cartridge containing dryer granulates such as desiccant.
- More recent designs of condenser assemblies have integrated the receiver/dryer with one of the headers mentioned above. One process of doing this has been to locate a plate within the header so as to divide the header into a manifold portion and a receiver/dryer portion. One drawback of this construction is that the design requires, for structural integrity of the system, a center line alignment of the core and the header containing the integrated receiver/dryer. Another drawback of this construction is that the joint between the manifold portion and the receiver/dryer portion cannot be inspected after brazing from the outside of the header.
- Therefore, it may be desirable to provide a receiver/dryer structure, to provide a manifold structure, and then connect the respective structures. The manifold and the receiver/dryer are typically connected via a brazing method. More specifically, the manifold is positioned in desired location with respect to the receiver/dryer such that a portion of the manifold engages a portion of the receiver/dryer. The respective engaging portions are fixedly connected via a brazing method, such as a brazing oven. However, the manifold and the receiver/dryer may become partially or completely disengaged from each other before or during the brazing process, leading to an insufficient or an incomplete connection between the respective components.
- Therefore, it is desirable to provide an assembly and a method of assembly in order to sufficiently engage the manifold and the receiver/dryer.
- In one configuration of the present invention, a condenser assembly for a vehicle air conditioning system is provided, comprising: a core including first and second ends and a plurality of tubes extending therebetween, a first header located adjacent to the first end of the core, and a second header located adjacent to the second end of the core. The second header includes a receiver/dryer having a receiver/dryer chamber, a manifold cooperating with the receiver/dryer to define a manifold chamber being in fluid communication with the flow passages in the tubes, and a mounting rib unitarily formed with at least one of the receiver/dryer and the manifold. The mounting rib includes a first portion extending away from the at least one of the receiver/dryer and the manifold in a first direction and a second portion extending away from the first portion in a second direction that is substantially nonparallel with the first direction.
- In another configuration, the first direction and the second direction cooperate to define an angle being greater than 45° and being less than 135°. The first direction and the second direction may be generally perpendicular with each other.
- In yet another configuration, the mounting rib further includes a weakened line connecting the first portion and the second portion. The weakened line may be an arcuate groove.
- In another configuration, the receiver/dryer includes a top end and a bottom end, and the mounting rib extends substantially continuously from the top end to the bottom end in a direction generally perpendicularly to the plurality of tubes.
- In yet another configuration, the condenser assembly further comprises a second mounting rib unitarily formed with the at least one of the receiver/dryer and the manifold. The mounting rib and the second mounting rib and the second mounting rib are each unitarily formed with the receiver/dryer. Additionally, the manifold includes a flange and a second flange, the mounting rib engages the flange of the manifold, and the second mounting rib engages the second flange of the manifold. The mounting rib is a deformable mounting rib and the second mounting rib is a fixed mounting rib.
- In another configuration, the condenser assembly further comprises a third mounting rib and a fourth mounting rib, each unitarily formed with the receiver/dryer. The third mounting rib and the fourth mounting rib engage a mounting bracket coupled to the vehicle. The third mounting rib is a deformable mounting rib and the fourth mounting rib is a fixed mounting rib.
- The first header is connected to the core such that the first header is in fluid communication with the tubes in the core. Furthermore, the manifold is connected to the core such that the manifold chamber and the receiver/dryer chamber are in fluid communication with the tubes. A mounting rib is formed on at least one of the receiver/dryer and the manifold for coupling the manifold and the receiver/dryer with each other. The mounting rib may be brazed in order to further connect the manifold and the receiver/dryer with each other.
-
FIG. 1 shows a condenser having a manifold and a pair of mounting brackets coupled with a receiver/dryer and embodying the principles of the present invention; -
FIG. 2 is a cross-sectional view of the condenser taken along line 2-2 inFIG. 1 , showing the manifold, the receiver/dryer, and one of the mounting brackets being coupled by deformable mounting ribs and a fixed mounting rib; and -
FIG. 3 is a cross-sectional view taken along line 2-2 inFIG. 1 , showing the deformable ribs in an undeformed state. - Referring now to the drawings,
FIG. 1 shows acondenser assembly 10 embodying the principals of the present invention. Thecondenser assembly 10 includes acore 12, afirst header 14, and asecond header 16. Theheaders core 12, as further mentioned below. Thecondenser 10 further includes a pair ofbrackets 13 in order to mount thecondenser 10 to a mounting portion of the vehicle (not shown) during use in an air conditioning system (not shown). - The
core 12 is a tube stack comprising a series oftubes 18 extending between theheaders first end 15 of thecore 12 extends into thefirst header 14 and asecond end 17 of thecore 12 extends into thesecond header 16. Thetubes 18 are generally parallel to each other and are vertically stacked with respect to each other.Adjacent tubes 18 are generally evenly-spaced apart from one another such that aspace 20 is located therebetween. Thetubes 18 themselves may be of any appropriate construction. In one preferred embodiment, the tubes are generally flat and include portions defining one ormore flow channels 21 longitudinally through the tube. - Located within the
space 20 between eachadjacent tube 18 is afin 22 for increasing heat transfer between thetubes 18 and an airflow intersecting thecondenser assembly 10. Thefins 22 exhibit a generally corrugated shape comprising a series of convolutes as is commonly known in the industry. Thefins 22 generally extend completely across thespace 20 contacting both the tube located thereabove and therebelow. In the figures, the details of the shape of thefins 22 are not illustrated in significant detail since those skilled in this technology will readily appreciate such a construction. Additionally, thefins 22 are preferably provided with a series of louvers on each corrugation in order to aid in the heat transfer efficiency from the tubes, to the fins and to the air passing therethrough. Thefins 22 are provided in such a manner that the overall length of thetubes 18 is greater than the overall length of thefins 22 and that the ends 24 and 26 of thetubes 18 extend beyond the end of thefins 22. These first and second ends 24, 26 of the tubes are respectively received within the first andsecond headers second headers - The first header 14 (hereinafter the “inlet/outlet header” or “I/O header”) is shown on the left-hand side of
FIG. 1 . The I/O header 14 is preferably constructed of a cylindrical body ormember 28 that has a constant cross-sectional profile, round in the preferred embodiment, over its length. The top and bottom ends 30, 32 of thecylindrical body 28 are respectively engaged and closed by top and bottom caps 34, 36. A partition or baffle 40 is preferably located within thecylindrical body 28 so as to cooperate with the cylindrical body and theupper cap 34 in order to define anupper chamber 42, which will be discussed in more detail below. Furthermore, anadditional partition 44 may be provided to define amiddle chamber 46 and alower chamber 48. Thelower chamber 48, as will be discussed in more detail below, is often referred to as the super-cooled region. - The I/
O header 14 includes aninlet aperture 49 that communicates with an inlet bore 50 defined in aninlet block 52. Similarly, the I/O header 14 includes anoutlet aperture 54 that is in communication with an outlet bore 56 defined in anoutlet block 58 mounted to thecylindrical body 28 of the I/O header 14. - During operation of the air conditioner, refrigerant enters into the
condenser assembly 10 via theinlet block 52 and exits from thecondenser assembly 10 via theoutlet block 58. In order for the cavity 38 of the I/O header 14 to fluidly communicate with thetubes 18, theend 24 of eachtube 18 is received through atube aperture 60 defined in one side of thecylindrical body 28. - The remaining
header 16 of thecondenser assembly 10 is generally illustrated on the right hand side ofFIG. 1 . Thisheader 16 is hereinafter referred to as the “receiver/dryer header” or “RID header”. The R/D header 16 is preferably an integrated structure made up of two components, a receiver/dryer 62 and a manifold 64, which will now be discussed in more detail. - The receiver/
dryer 62 preferably includes a cylindrical body ormember 66 having top and bottom ends 67, 69 respectively closed by top and bottom caps 68, 70. Therefore, the top and bottom caps 68, 70 cooperate with thecylindrical body 66 to define a R/D chamber 72 within the R/D header 16. Thecylindrical body 66 preferably exhibits a substantially constant cross-sectional profile along its length. More preferably, thecylindrical body 66 includes a generally round cross-sectional profile along its length having alongitudinal axis 71 shown inFIG. 1 . - The R/
D chamber 72 is in fluid connection with themanifold chamber 74 via afirst opening 75 a and asecond opening 75 b in the receiver/dryer 62. The R/D chamber 72 preferably includes a drying element, such as adryer 73. Thedryer 73 shown inFIG. 1 comprises a dryer bag containing a liquid-absorbing component, such as desiccant material. Any water in the refrigerant is absorbed by thedryer 73 in order to improve the performance and structural integrity of the air conditioning system. - The manifold 64 and the
cylindrical body 66 cooperate to define amanifold chamber 74. Thesecond header 16 preferably includes at least one partition and at least two caps in order to divide themanifold chamber 74 into a plurality of chambers. As shown inFIG. 1 , anupper partition 76, alower partition 78, atop cap 77, and abottom cap 79 are located within themanifold chamber 74 in order to form respective substantially fluid-tight seals with the manifold 64 and thereceiver dryer 62. More specifically, theupper partition 76 cooperates with the manifold 64, thereceiver dryer 62, and thetop cap 77 in order to define anupper chamber 80. Similarly, theupper partition 76 cooperates with the manifold 64, thereceiver dryer 62, and thelower partition 78 in order to define amiddle chamber 82 and thelower partition 78 cooperates with the manifold 64, thereceiver dryer 62, and thebottom cap 79 in order to define alower chamber 84. - In order to form a substantially fluid-tight seal between the manifold 64 and the receiver/
dryer 62, therespective components dryer 62 with each other before and during the brazing process. Similarly, the engaging components may be used as an alternative to the brazing process. - Referring now to
FIG. 2 , a first mountingrib 86 is provided in order to engage the manifold 64 and the receiver/dryer 62 with each other. The mountingrib 86 inFIG. 2 is unitarily formed with the receiver/dryer 62 and engages aflange 88 of the manifold 64. However, the mountingrib 86 may alternatively be formed with the manifold 64 in order to engage a flange of the receiver/dryer 62. Theflange 88 preferably extends along and parallel to the outer surface of the receiver/dryer 62 in order to increase the contact surface area between therespective components - The mounting
rib 86 preferably includes afirst portion 90 extending away from the receiver/dryer 62 in afirst direction 91 and asecond portion 92 extending obliquely away from the first portion in asecond direction 93. More specifically, thefirst direction 91 and thesecond direction 93 form anangle 94 that is preferably greater than 45° and less than 135°. More preferably, thefirst direction 91 and thesecond direction 93 are generally perpendicular to each other such that thefirst portion 90 and thesecond portion 92 each engage a respective portion of theflange 88. However, any appropriate angles may be formed by the first andsecond portions - A second mounting
rib 96, similar to the first mountingrib 86, is provided in order to further engage the manifold 64 and the receiver/dryer 62 with each other. The second mountingrib 96 is unitarily formed with the receiver/dryer 62 in order to engage asecond flange 98 of the manifold 64. Thesecond flange 98 preferably extends along the receiver/dryer 62 similarly to thefirst flange 88. The second mountingrib 96 includes afirst portion 100 extending away from the receiver/dryer 62 in afirst direction 101 and asecond portion 102 extending away from the first portion in asecond direction 103 at anangle 104 that is preferably greater than 45° and less than 135°. More preferably, thefirst direction 101 and thesecond direction 103 are generally perpendicular to each other. - The mounting
ribs top end 67 to thebottom end 69 of the receiver/dryer 62, but other configurations may be used. In particular, the mountingribs dryer 62. Additionally, a plurality of first mountingribs 86 may be longitudinally separated from each other and a plurality of second mountingribs 96 may be similarly longitudinally separated from each other. - The first and second mounting
ribs respective manifold flanges ribs ribs first portion second portion ribs first portion second portion flanges - Referring now to
FIG. 3 , the first mountingrib 86 and the second mountingrib 96 are each shown in an undeformed position, such that the respectivesecond portions flanges ribs first direction first portions FIG. 2 , but thesecond portions first portions second directions 93′, 103′ that are preferably not the same as thesecond directions FIG. 2 . Thefirst directions second directions 93′, 103′ inFIG. 3 formrespective angles 94′, 104′ that are preferably greater than theangles FIG. 2 . Thus, theangles 94′, 104′ of the first and second mountingribs FIG. 3 permit the manifold 64 to be easily inserted between the respective mountingribs - Also shown in
FIG. 3 , the weakened portion of each mountingrib groove first portions second portions grooves ribs grooves grooves - Alternatively to the first and second mounting
ribs FIG. 3 , at least one fixed mounting rib may be used instead of a deformable mounting rib. However, in order to simplify the connection between the manifold 64 and the receiver/dryer 62, at least one of the first and second mountingribs - Referring back to
FIG. 2 , the connection between the receiver/dryer 62 and thebracket 13 will now be discussed. Thebracket 13 includes afirst portion 110 to be connected to the receiver/dryer 62 and asecond portion 112 to be connected to a mounting portion of the vehicle. Thefirst portion 110 of thebracket 13 preferably includes a pair offlanges second portion 112 of thebracket 13 preferably includes at least one mountinghole 114 in order to receive a fastener or other appropriate connection means. As shown inFIG. 1 , thecondenser assembly 10 may include a pair of mountingbrackets 13. - In order to engage the
bracket 13 with the receiver/dryer 62, a third mountingrib 116 is provided in order to engage thebracket 13 and the receiver/dryer 62 with each other. The third mountingrib 116 inFIG. 2 is unitarily formed with the receiver/dryer 62 and engages theflange 118 of thebracket 13. However, the third mountingrib 116 may alternatively be formed with thebracket 13 in order to engage a flange of the receiver/dryer 62. Theflange 118 preferably extends along and parallel to the outer surface of the receiver/dryer 62 in order to increase the contact surface area between therespective components - The mounting
rib 86 preferably includes afirst portion 120 extending away from the receiver/dryer 62 in afirst direction 121 and asecond portion 122 extending away from the first portion in asecond direction 123 that is nonparallel with thefirst direction 121. More specifically, thefirst direction 121 and thesecond direction 123 form anangle 124 that is preferably greater than 45° and less than 135°. More preferably, thefirst direction 121 and thesecond direction 123 are generally perpendicular to each other such that thefirst portion 120 and thesecond portion 122 each engage a respective portion of theflange 118. However, any appropriate angles may be formed by the first andsecond portions - A fourth mounting
rib 126 is also preferably provided in order to further engage thebracket 13 and the receiver/dryer 62 with each other. The fourth mountingrib 126 is unitarily formed with the receiver/dryer 62 in order to engage thesecond flange 128 of thebracket 13. Thesecond flange 128 preferably extends along the receiver/dryer 62 similarly to thefirst flange 118. The fourth mountingrib 126 includes afirst portion 130 extending away from the receiver/dryer 62 in afirst direction 131 and asecond portion 132 extending away from the first portion in asecond direction 133 at anangle 134 that is preferably greater than 45° and less than 135°. More preferably, thefirst direction 131 and thesecond direction 133 are generally perpendicular to each other. - The third and fourth mounting
ribs top end 67 to thebottom end 69 of the receiver/dryer 62, but other configurations may be used. In particular, the third and fourth mountingribs dryer 62. Additionally, a plurality of third mountingribs 116 may be longitudinally separated from each other and a plurality of fourth mountingribs 126 may be similarly longitudinally separated from each other. - The third and fourth mounting
ribs ribs ribs ribs first portion second portion ribs - Referring now to
FIG. 3 , the fourth mountingrib 126 is shown in an undeformed position, such that thesecond portion 132 is not engaged with theflange 128 when the fourth mountingrib 126 is undeformed. More specifically, thefirst direction 131 of thefirst portion 130 remains the same as shown inFIG. 2 , but thesecond portion 132 extends from thefirst portions 130 at asecond direction 133′ that is preferably not the same as thesecond direction 133 shown inFIG. 2 . Thefirst direction 131 and thesecond direction 133′ inFIG. 3 form anangle 134′ that is preferably greater than theangle 134 shown inFIG. 2 . - Also shown in
FIG. 3 , the weakened portion of the fourth mountingrib 126 is agroove 136 having a thickness less than that of thefirst portion 130 andsecond portion 132. The reduced thickness of thegroove 136 causes the fourth mountingrib 126 to have a tendency to bend along thegroove 136. Thegroove 136 preferably has an arcuate shape in order to simplify manufacturing. - The third mounting
rib 116 shown inFIGS. 2 and 3 is a fixed mounting rib that is preferably pre-formed to have theangle 124. Therefore, the third mountingrib 116 is shown as having thesame angle 124 in bothFIGS. 2 and 3 . The third mountingrib 116 may be or may not include a weakened line in order to cause the bent portion of the third mountingrib 116 to be precisely-located. - Alternatively to the third and fourth mounting
ribs FIG. 3 , both of the third and fourth mountingribs bracket 13 and the receiver/dryer 62, at least one of the third and fourth mountingribs - During operation of the
condenser assembly 10, the refrigerant flows into theupper chamber 42 of thefirst header 14 via theinlet block 52 as described above. The refrigerant is typically substantially gaseous when it flows through theinlet block 52. Next, the refrigerant flows through thetubes 18, undergoing heat exchange with cross-flowing air, which promotes condensation of the refrigerant. The refrigerant then exits the tubes into theupper chamber 80 of the manifold 64. The refrigerant then flows back across thetubes 18, undergoing further heat exchange, and exits into themiddle chamber 46 of thefirst header 14. The refrigerant makes yet another pass across thecore 12 and into themiddle chamber 82 of the manifold 64. - From the
middle chamber 82, the refrigerant enters the R/D chamber 72 via thefirst opening 75 a. The refrigerant is typically a 3-part fluid at this point in the system: gaseous refrigerant, liquid refrigerant, and water. The gaseous refrigerant rises to the top portion of theRID chamber 72 in order to undergo further condensation. The liquid refrigerant enters thelower chamber 84 of the manifold 64 via thesecond opening 75 b and flows into thetubes 18, where it exits thecondenser 10 via theoutlet block 58 as described above. The water is preferably substantially absorbed by the dryer in order to minimize the amount of water degradating the performance of the refrigerant. - A method of assembling the manifold 64 and the receiver/
dryer 62 will now be discussed. The manifold 64 is engaged with the receiver/dryer 62 such that theflanges dryer 62 as shown inFIG. 3 . Thedeformable ribs flanges - Additionally, the
bracket 13 is engaged with the receiver/dryer 62 such that theflanges dryer 62 as shown inFIG. 3 . More specifically, thefirst flange 118 is preferably first inserted into the third mountingrib 116 such that thefirst portion 120 and thesecond portion 122 of the third mountingrib 116 each engage a portion of thefirst flange 118 of thebracket 13. - Next, the
second flange 128 of thebracket 13 is moved such as to engagefirst portion 130 of the fourth mountingrib 126 and the outer surface of the receiver/dryer 62, as shown inFIG. 3 . Then, thesecond portion 132 of the fourth mountingrib 126 is deformed in order to engage thesecond flange 128. Alternatively, thebracket 13 may simultaneously engage the third and fourth mountingribs bracket 13 between therespective ribs longitudinal axis 71. - After the manifold 64 and the receiver/
dryer 62 have been engaged and the deformable ribs have been deformed, therespective components ribs second header 16 are each preferablymanifold 64 and the receiver/dryer 62. - It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.
Claims (12)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/932,865 US7007499B1 (en) | 2004-09-02 | 2004-09-02 | Condenser assembly having a mounting rib |
DE102005042708A DE102005042708A1 (en) | 2004-09-02 | 2005-09-01 | Capacitor assembly with a mounting rib |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/932,865 US7007499B1 (en) | 2004-09-02 | 2004-09-02 | Condenser assembly having a mounting rib |
Publications (2)
Publication Number | Publication Date |
---|---|
US20060042309A1 true US20060042309A1 (en) | 2006-03-02 |
US7007499B1 US7007499B1 (en) | 2006-03-07 |
Family
ID=35941092
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/932,865 Expired - Fee Related US7007499B1 (en) | 2004-09-02 | 2004-09-02 | Condenser assembly having a mounting rib |
Country Status (2)
Country | Link |
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US (1) | US7007499B1 (en) |
DE (1) | DE102005042708A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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EP1906114A1 (en) * | 2006-09-27 | 2008-04-02 | Behr France Hambach S.A.R.L. | Heat exchanger, especially condenser |
WO2010097392A1 (en) * | 2009-02-25 | 2010-09-02 | Kn Interlektuell Propertys Ug | Condenser |
US20150314665A1 (en) * | 2012-12-20 | 2015-11-05 | Valeo Systemes Thermiques | Securing clamp for a heat exchanger bottle, notably motor vehicle air conditioning circuit condenser |
CN110773999A (en) * | 2019-11-14 | 2020-02-11 | 浙江兰通空调设备有限公司 | Intelligent production line for parallel flow condenser of automobile air conditioner |
Families Citing this family (5)
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DE102004037688A1 (en) * | 2003-08-05 | 2005-05-25 | Behr Gmbh & Co. Kg | Heat exchanger for use in road vehicle has collection or distribution manifold with two molded parts fitted together to form two flow channels side-by-side with openings for ends of heat exchanger tubes |
JP4774238B2 (en) * | 2004-05-20 | 2011-09-14 | 昭和電工株式会社 | Refrigeration cycle refrigerant distribution part connection structure |
CN103090695B (en) * | 2008-12-15 | 2015-08-19 | 康奈可关精株式会社 | Heat exchanger |
FR2951817B1 (en) * | 2009-10-22 | 2012-04-13 | Valeo Systemes Thermiques | COLLECTOR FOR HEAT EXCHANGER, HEAT EXCHANGER AND ASSOCIATING METHOD |
AT516942B1 (en) * | 2015-04-28 | 2016-10-15 | Euler-Rolle Thomas Dipl Ing | Cooler station for connection of a liquid cooler |
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Cited By (4)
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---|---|---|---|---|
EP1906114A1 (en) * | 2006-09-27 | 2008-04-02 | Behr France Hambach S.A.R.L. | Heat exchanger, especially condenser |
WO2010097392A1 (en) * | 2009-02-25 | 2010-09-02 | Kn Interlektuell Propertys Ug | Condenser |
US20150314665A1 (en) * | 2012-12-20 | 2015-11-05 | Valeo Systemes Thermiques | Securing clamp for a heat exchanger bottle, notably motor vehicle air conditioning circuit condenser |
CN110773999A (en) * | 2019-11-14 | 2020-02-11 | 浙江兰通空调设备有限公司 | Intelligent production line for parallel flow condenser of automobile air conditioner |
Also Published As
Publication number | Publication date |
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US7007499B1 (en) | 2006-03-07 |
DE102005042708A1 (en) | 2006-03-23 |
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