Heat exchanger assembly
A heat exchanger assembly includes a first single-piece manifold and a second single-piece manifold spaced from and parallel to the first single-piece manifold. Each of the first and second single-piece manifolds has a tubular wall defining a flow path. A plurality of flow tubes extend in parallel between the first and second single-piece manifolds and are in fluid communication with the flow paths. An insert having a distribution surface is slidably disposed in the flow path of the first single-piece manifold to establish a distribution chamber within the first single-piece manifold. A series of orifices defined in the distribution surface of the insert are in fluid communication with the flow path and the distribution chamber for uniformly distributing a heat exchange fluid between the flow path and the flow tubes.
1. Field of the Invention
The present invention generally relates to a heat exchanger assembly. More specifically, the present invention relates to a heat exchanger assembly including an insert for uniformly distributing and directing a heat exchange fluid within the heat exchanger assembly.
2. Description of the Related Art
Heat exchanger assemblies currently used in automobiles are being further developed and refined for use in commercial and residential heat pump systems due to their desirable high heat exchange performance. Typically, the heat exchanger assemblies used in automobiles include a pair of spaced and parallel manifolds with a series of parallel flow tubes extending therebetween. The flow tubes communicate a heat exchange fluid, i.e., a refrigerant, between the two manifolds. Air fins are disposed between the flow tubes to add surface area to the heat exchanger assembly for further aiding in heat transfer to or from ambient air passing over the flow tubes. The heat exchanger assemblies include an inlet and an outlet for transferring the refrigerant to and from the heat exchanger assembly in a continuous closed-loop system.
In downflow, crossflow, and one-pass heat exchanger assemblies, the inlet is disposed in one manifold, and the outlet is disposed in the other manifold. Typically, the inlet and the outlet are kitty-corner each other, attempting to fully utilize all of the flow tubes between the manifolds. However, due to poor internal distribution of the refrigerant, and temperature and pressure differences within the manifolds and the flow tubes, some of the flow tubes receive more or less of the refrigerant than the other flow tubes, causing an unequal heat transfer burden on each one of the flow tubes, which decreases heat exchange performance of the heat exchanger assembly.
Conversely, in a multi-pass heat exchanger assembly, both the inlet and the outlet may be spaced apart and disposed in the same manifold. Typically, the heat exchanger assemblies used in commercial or residential heat pump system are multi-pass. A plurality of separator plates, i.e., baffles, are disposed within each of the manifolds to form a plurality of passes with each of the passes including a group of flow tubes. In a typical heat exchange loop, the refrigerant enters through the inlet into one of the manifolds, flows through all of the passes between the manifolds, and then exits one of the manifolds through the outlet. The baffles and the passes alleviate some of the distribution problems of the refrigerant within the heat exchanger assembly. However, there is still uneven distribution of the refrigerant between each of the individual flow tubes within each of the passes.
Typically, the heat exchanger assemblies used in commercial or residential heat pump systems are two to three times larger than the heat exchanger assemblies used in automobiles. This increased size magnifies the aforementioned distribution problems of the refrigerant within the heat exchanger assembly, and further adds to manufacturing costs due to the increased difficulty of properly locating and fixing the baffles within each of the manifolds to form the passes.
Typically, the heat exchanger assemblies can function as a condenser in cooling mode or an evaporator in heating mode for respectively cooling or heating a commercial or residential building. Velocity and distribution of the refrigerant within the heat exchanger assembly varies between the cooling and heating modes and can further decrease heat exchange performance of the heat exchanger.
For example, in heating mode, a two-phase refrigerant comprising a liquid and gas phase enters the inlet of the heat exchanger assembly, i.e., the evaporator, and flows through the passes. While traveling through the passes, the two-phase refrigerant absorbs heat from the ambient air passing over the flow tubes and air fins, which causes the liquid phase to further evaporate and the gas phase to further expand. Momentum effects due to large mass differences between the liquid and gas phases causes separation of the two-phase refrigerant. Separation of the phases adds to the already present distribution problem within the passes, which further decreases overall heat exchange performance of the evaporator. Separation of the two-phase refrigerant can also cause localized icing or frosting of individual or groups of flow tubes within the evaporator, causing plugging of the flow tubes and yet further lowering the heat exchange performance of the evaporator.
To increase heat exchange performance, a distributor tube can be used to improve refrigerant distribution within the evaporator. U.S. Pat. No. 1,684,083 to Bloom (the '083 patent), discloses a distributor tube disposed within a manifold of a refrigerating coil. The distributor tube includes a series of orifices and is attached to an inlet for distributing a refrigerant from the inlet to a group of flow tubes attached to the manifold. The distributor tube essentially extends a length of the manifold and acts as an extension of the inlet, with each of the orifices communicating a portion of the refrigerant to each of the flow tubes. However, the distributor tube in the '083 patent is welded in place, and therefore is not movable or removable from the manifold. Due to the distributor tube requiring welding to remain in place within the manifold, manufacture of the refrigerating coil is difficult due to demands of properly locating and welding the distributor tube in place within the manifold. In addition, the distributor tube is limited to a one-pass configuration, due to the distributor tube extending the length of the manifold. U.S. Pat. No. 5,836,382 to Dingle et al., and WO 94/14021 to Conry, disclose similar distributor tubes for a shell and tube evaporator and a plate type heat exchanger, respectively. However, both the shell and tube evaporator and the plate type heat exchanger are limited to the same '083 patent one-pass configuration limitation.
U.S. Pat. No. 5,941,303 (the '303 patent) to Gowan et al., discloses an extruded manifold. The extruded manifold includes integral partitions for distributing a refrigerant to a plurality of multi-passage flow tubes. However, extruded manifolds are typically expensive when compared to typical welded manifolds. In addition, the integral partitions limit the extruded manifold to one flow configuration.
U.S. Pat. No. 5,203,407 (the '407 patent) to Nagasaka, discloses a multi-pass heat exchanger assembly including internal walls in a pair of manifolds for distributing a refrigerant to passes. The passes include groups of flow tubes within the heat exchanger assembly. However, as in the '083 patent and the '303 patent, the internal walls are fixed and integral in the manifolds, thereby limiting the heat exchanger to one flow configuration. In addition, the '407 patent suffers from distribution problems among each of the individual flow tubes within each of the passes.
Thus, there remains a need to develop a heat exchanger assembly having an insert that provides a cost effective, flexible, and efficient solution for uniformly distributing a heat exchange fluid to a plurality of flow tubes within the heat exchanger assembly.
SUMMARY OF THE INVENTION AND ADVANTAGESThe present invention is a heat exchanger assembly. The heat exchanger assembly includes a first single-piece manifold and a second single-piece manifold spaced from and parallel to the first single-piece manifold. Each of the first and second single-piece manifolds has a tubular wall defining a flow path. A plurality of flow tubes extend in parallel between the first and second single-piece manifolds and are in fluid communication with the flow paths. An insert having a distribution surface is slidably disposed in the flow path of the first single-piece manifold to establish a distribution chamber within the first single-piece manifold. A series of orifices defined in the distribution surface of the insert are in fluid communication with the flow path and the distribution chamber for uniformly distributing a heat exchange fluid between the flow path and the flow tubes.
Accordingly, the present invention provides a heat exchanger assembly including an insert that provides a cost effective, flexible, and efficient solution for uniformly distributing and directing a heat exchange fluid to a plurality of flow tubes within the heat exchanger assembly. Uniform distribution of the heat exchange fluid prevents separation and distribution problems encountered in previous heat exchanger assemblies while increasing heat exchange performance of the heat exchanger assembly. The insert may include various configurations of the orifices. For example, the orifices may be different in size, shape and spacing. The insert may be made into any length for spanning a length or a portion of the length of the first single-piece manifold. The insert may easily be slid into, within, and from the first single-piece manifold for forming a plurality of configurations and passes within the heat exchanger assembly. The orifices and the distribution chamber efficiently and uniformly distribute the heat exchange fluid to each one of the flow tubes for increasing heat exchange performance of the heat exchanger assembly.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a heat exchanger assembly is shown generally at 20.
Referring to
The tubular wall 26 may be formed by a suitable process as is known in the art. For example, the tubular wall 26 may be formed by an extrusion process or a welding process such as a roll forming and welding process. In one embodiment, as best shown in
The heat exchanger assembly 20 further includes a first tube end 30 and a second tube end 32 spaced from the first tube end 30. In one embodiment, as best shown in
The heat exchanger assembly 20 further includes at least one port 96 in fluid communication with the flow path FP. The port 96 may be of any size and shape. In one embodiment, the first single-piece manifold 22 defines the port 96. For example, one of the tube ends 30, 32 may define the port 96. As another example, and as shown in
As best shown in
The heat exchanger assembly 20 may include a plurality of end caps 38. In one embodiment, as shown in
The heat exchanger assembly 20 further includes a series of apertures 42 disposed in the tubular wall 26 of the first and second single-piece manifolds 22, 24. In one embodiment, as best shown in
As best shown in
The flow tubes 44 may be formed by any method or process as is known in the art. For example, the flow tubes 44 may be formed by an extrusion process or a welding process. In one embodiment, as shown in
The heat exchanger assembly 20 may further include a plurality of air fins 48. In one embodiment, the airs fins 48 are disposed on each one of the flow tubes 44. In another embodiment, as best shown in
The heat exchanger assembly 20 may further include at least two indentations 50. In one embodiment, as shown in
The heat exchanger assembly 20 further includes an insert 52 having a distribution surface 54. As best shown in
The insert 52 may be formed by any method or process as is known in the art. For example, the insert 52 may be formed by an extrusion process, a welding process, a stamping process, a roll-forming process, or other methods and processes known to those skilled in the art. The insert 52 may be of any thickness.
As best shown in
Referring to
The insert 52 may be oriented in any suitable position in the flow path FP. As best shown in
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The heat exchanger assembly 20 may further include a groove 68. In one embodiment, as shown in
The heat exchanger assembly 20 may further include a pair of side flanges 72 extending opposite each other from the distribution surface 54 of the insert 52 toward and along the tubular wall 26 of the first single-piece manifold 22. In one embodiment, as shown in
The heat exchanger assembly 20 may further include a pair of tips 74 with each tip 74 spaced from and opposite the other with one of the tips 74 curving to extend from one of the side flanges 72 parallel to the distribution surface 54 of the insert 52 and the other of the tips 74 curving to extend from the other of the side flanges 72 parallel to the distribution surface 54 of the insert 52. As shown in
The heat exchanger assembly 20 may further include at least one partial separator 76 integrally extending from the distribution surface 54 of the insert 52 outwardly toward the tubular wall 26 of the first single-piece manifold 22 such that the partial separator 76 obstructs a portion of the width W of the first single-piece manifold 22. In one embodiment, as shown in
The heat exchanger assembly 20 may further include at least one full separator 80 integrally extending from the distribution surface 54 of the insert 52 outwardly toward and to the tubular wall 26 of the first single-piece manifold 22 such that the full separator 80 obstructs an entirety of the width W of the first single-piece manifold 22. In one embodiment, as shown in
As shown in
As shown in
The baffles 82, 92 may define a notch 140. In one embodiment, as shown in
The heat exchanger assembly 20 may further include a coupler 98 disposed in the port 96. In one embodiment, as shown in
The heat exchanger assembly 20 may include a plurality of passes for forming a multi-pass configuration within the heat exchanger assembly 20. In one embodiment, as shown in
Sometimes, the first pass 84 may be relatively controlled because the heat exchange fluid is freshly introduced into the inlet 34 and tends to flood the first pass 84 such that the heat exchange fluid is distributed among the flow tubes 44. However, as the heat exchange fluid changes temperature, shifts phases, and begins to separate due to mass differences between the phases, uniform distribution of the heat exchange fluid to each of the flow tubes 44 in later passes, i.e., the second pass 86, is difficult. As already discussed, the insert 52 is slidably disposed in the flow path FP of either the first or second single-piece manifold 22, 24 for uniformly distributing the heat exchange fluid to the flow tubes 44. As such, the insert 52, and optionally, the second insert 62, may be used to control distribution of the heat exchange fluid in each of the passes 84, 86. As best shown in
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. As is now apparent to those skilled in the art, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.
Claims
1. A heat exchanger assembly comprising:
- a first single-piece manifold;
- a second single-piece manifold spaced from and parallel to said first single-piece manifold;
- each of said first and second single-piece manifolds having a tubular wall defining a flow path;
- a plurality of flow tubes extending in parallel between said first and second single-piece manifolds and in fluid communication with said flow paths;
- an insert having a distribution surface and slidably disposed in said flow path of said first single-piece manifold to establish a distribution chamber within said first single-piece manifold; and
- a series of orifices defined in said distribution surface of said insert and in fluid communication with said flow path and said distribution chamber for uniformly distributing a heat exchange fluid between said flow path and said flow tubes.
2. A heat exchanger assembly as set forth in claim 1 wherein said orifices are in alignment with said flow tubes with one of said orifices aligned per at least one of said flow tubes.
3. A heat exchanger assembly as set forth in claim 1 wherein said flow tubes are grouped into a plurality of flow tube groups.
4. A heat exchanger assembly as set forth in claim 3 wherein said orifices are in alignment with said flow tube groups with one of said orifices aligned per at least one of said flow tube groups.
5. A heat exchanger assembly as set forth in claim 1 further comprising;
- a second insert having a distribution surface and slidably disposed in said flow path of one of said first and second single-piece manifolds to establish a distribution chamber within one of said first and second single-piece manifolds, and
- a series of orifices defined in said distribution surface of said second insert and in fluid communication with said flow path and said distribution chamber for uniformly distributing a heat exchange fluid between said flow path and said flow tubes.
6. A heat exchanger assembly as set forth in claim 5 wherein said second insert is slidably disposed in said flow path of said first single-piece manifold along with said insert.
7. A heat exchanger assembly as set forth in claim 5 said second insert is slidably disposed in said flow path of said second single-piece manifold.
8. A heat exchanger assembly as set forth in claim 1 wherein said insert is removable from said flow path of said first single-piece manifold.
9. A heat exchanger assembly as set forth in claim 1 further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one partial separator integrally extending from said distribution surface of said insert outwardly toward said tubular wall of said first single-piece manifold such that said partial separator obstructs a portion of said width of said first single-piece manifold for directing the heat exchange fluid to said orifices.
10. A heat exchanger assembly as set forth in claim 1 further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one full separator integrally extending from said distribution surface of said insert outwardly toward and to said tubular wall of said first single-piece manifold such that said full separator obstructs an entirety of said width of said first single-piece manifold for directing the heat exchange fluid to said flow tubes.
11. A heat exchanger assembly as set forth in claim 1 further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one partial baffle slidably disposed in said flow path and having a perimeter with only a portion of said perimeter contacting said tubular wall such that said at least one partial baffle obstructs a portion of said width of said first single-piece manifold for directing the heat exchange fluid to said orifices.
12. A heat exchanger assembly as set forth in claim 1 further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one full baffle slidably disposed in said flow path and having a perimeter with an entirety of said perimeter contacting said tubular wall such that said at least one full baffle obstructs an entirety of said width of said first single-piece manifold for directing the heat exchange fluid to said flow tubes.
13. A heat exchanger assembly as set forth in claim 1 wherein each of said tubular walls of said first and second single-piece manifolds includes a pair of longitudinal ends adjacent and joined to each other such that each of said first and second single-piece manifolds are unitary.
14. A heat exchanger assembly as set forth in claim 1 wherein said first single-piece manifold includes a first tube end and a second tube end spaced from said first tube end, said flow path extends between said tube ends of said first single-piece manifold, and said heat exchanger assembly further comprises an axis extending centrally within said flow path of said first single-piece manifold, and a center plane intersecting said axis between said tubular wall of said first single-piece manifold.
15. A heat exchanger assembly as set forth in claim 14 wherein said distribution surface of said insert is spaced from and parallel to said center plane.
16. A heat exchanger assembly as set forth in claim 14 wherein said distribution surface of said insert includes a first insert end and a second insert end spaced from said first insert end and an insert length extending between said insert ends, and said insert length is equal to or less than said flow path of said first single-piece manifold.
17. A heat exchanger assembly as set forth in claim 14 wherein said distribution surface of said insert includes a first insert end and a second insert end spaced from said first insert end and an insert length extending between said insert ends, and said insert length is equal to or greater than said flow path of said first single-piece manifold.
18. A heat exchanger assembly as set forth in claim 14 further comprising a pair of side flanges extending opposite each other from said distribution surface of said insert toward and along said tubular wall of said first single-piece manifold for orienting and securing said insert in said flow path of said first single-piece manifold.
19. A heat exchanger assembly as set forth in claim 18 wherein said side flanges are curved and said tubular wall is complimentary curved such that said side flanges mechanically engage said tubular wall.
20. A heat exchanger assembly as set forth in claim 19 wherein each of said side flanges extend from said distribution surface along said tubular wall toward and across said center plane for orienting and securing said insert in said flow path of said first single-piece manifold.
21. A heat exchanger assembly as set forth in claim 18 wherein said tubular wall of said first single-piece manifold defines at least two indentations with each indentation spaced from and opposite the other with said side flanges mechanically engaging said at least two indentations for orienting and securing said insert in said flow path of said first single-piece manifold.
22. A heat exchanger assembly as set forth in claim 18 further comprising a pair of tips with each tip spaced from and opposite the other with one of said tips curving to extend from one of said side flanges parallel to said distribution surface of said insert and the other of said tips curving to extend from the other of said side flanges parallel to said distribution surface of said insert.
23. A heat exchanger assembly as set forth in claim 22 wherein said flow tubes extend toward said center plane and mechanically engage said tips of said insert.
24. A heat exchanger assembly as set forth in claim 14 further comprising a center line parallel to said axis extending along said distribution surface of said insert.
25. A heat exchanger assembly as set forth in claim 24 wherein said orifices are spaced from each other and from said center line of said distribution surface of said insert.
26. A heat exchanger assembly as set forth in claim 24 wherein said orifices are spaced from each other along said center line of said distribution surface of said insert.
27. A heat exchanger assembly as set forth in claim 26 wherein said orifices are equally spaced from each other along said center line of said distribution surface of said insert.
28. A heat exchanger assembly as set forth in claim 24 wherein a portion of said distribution surface is concave and forms a groove therein bounded by a bottom surface spaced from said tubular wall of said first single-piece manifold.
29. A heat exchanger assembly as set forth in claim 28 wherein said orifices are defined in said bottom surface along said groove of said distribution surface of said insert.
30. A heat exchanger assembly as set forth in claim 29 wherein said groove is defined along said center line of said distribution surface of said insert.
31. A heat exchanger assembly as set forth in claim 29 wherein said groove is offset from said center line of said distribution surface of said insert.
32. A heat exchanger assembly as set forth in claim 1 wherein said first single-piece manifold defines at least one port in fluid communication with at least one of said flow path and said distribution chamber, and at least one coupler disposed in said at least one port and in fluid communication with at least one of said flow path and said distribution chamber through said at least one port for coupling an external tube to said first single-piece manifold.
33. A heat exchanger assembly as set forth in claim 32 wherein said first single-piece manifold includes a first tube end and a second tube end spaced from said first tube end, and further comprising an end cap disposed adjacent said first tube end wherein said at least one port is defined by said end cap.
Type: Application
Filed: Jul 25, 2006
Publication Date: Jan 31, 2008
Inventors: Henry Earl Beamer (Middleport, NY), Robert Michael Runk (N. Tonawanda, NY)
Application Number: 11/492,477
International Classification: F28F 9/02 (20060101);