INTEGRATED COUNTER CROSS FLOW CONDENSER

A heat exchanger includes a leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium, a windward condenser core positioned adjacent and in fluid communication with the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium, a header plate securing the windward condenser core to the leeward condenser core, the header plate forming at least a portion of a first tank in fluid communication with each of the first fluid conduits and a second tank in fluid communication with each of the second fluid conduits, a first cap disposed on the header plate to form the first tank, and a second cap disposed on the header plate to form the second tank.

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Description
FIELD OF THE INVENTION

The present invention relates to a condenser. More particularly, the invention is directed to an integrated dual plane condenser.

BACKGROUND OF THE INVENTION

In recent years, heat exchangers have been developed that incorporate structural improvements aimed at maximizing a heat transfer efficiency of the heat exchangers. For example, parallel flat tubes and corrugated fins have been used to increase a surface area over which air flows, thereby maximizing a heat transfer efficiency. Similarly, duplex heat exchangers including two unit heat exchangers configured in parallel with one another in a direction of airflow have been developed to maximize the heat transfer efficiency over past multi-flow type heat exchangers. However, the problem persists that insufficient condensing capacity for heat exchanging systems results from any substantial decrease in packaging space.

U.S. Pat. No. 6,021,846 describes a duplex heat exchanger including a plurality of unit heat exchangers. Each unit heat exchanger includes a plurality of tubes arranged parallel with each other, fins interposed between the tubes, and a pair of hollow headers. The combination of the plurality of tubes, fins, and headers is said to improve efficiency and reduce the scatter of water condensed on the exchanger. The heat exchanger of U.S. Pat. No. 6,021,846 is disadvantageous in that the separate headers for each unit heat exchanger require additional space, additional material, and separate installation and coupling.

U.S. Pat. No. 7,503,382 B2 discloses a heat exchanger including a heat exchange section having a plurality of flat tubes arranged parallel to one another. At least some of the flat tubes are bent outside the heat exchange section and connect to a header. The disclosed heat exchanger is said to distribute fluid to the flat tubes more equally and, thus, improve the heat exchange efficiency. However, the heat exchanger of U.S. Pat. No. 7,549,465 requires additional material, additional space resulting from an awkward shape, and additional installation and or coupling.

U.S. Pat. No. 7,013,952 B2 describes a stack type heat exchanger including a plurality of unit frames stacked on one another. The heat exchanger further includes tubes that form a path for a coolant, fins between the stacked tubes, and inlet and outlet pipes through which refrigerant may enter and exit. The heat exchanger of U.S. Pat. No. 7,013,952 is said to uniformly distribute refrigerant but is disadvantageous in that the inlet and outlet pipes for entry and exiting of the refrigerant occupy additional space and additional material, and the separate unit frames require additional installation and coupling.

It would be desirable to develop a dual plane heat exchanger that integrates a pair of condensers and maximizes a heat transfer efficiency without increasing material usage and packaging space.

SUMMARY OF THE INVENTION

Consonant with the present invention, a dual plane heat exchanger that integrates the two planes and maximizes a heat transfer efficiency without increasing material usage and packaging space, has surprisingly been discovered.

In one embodiment, a heat exchanger comprises: a leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium; a windward condenser core positioned adjacent and in fluid communication with the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium; a header plate securing the windward condenser core to the leeward condenser core, the header plate forming at least a portion of a first tank in fluid communication with each of the first fluid conduits and a second tank in fluid communication with each of the second fluid conduits; a first cap disposed on the header plate to form the first tank; and a second cap disposed on the header plate to form the second tank.

In another embodiment, a leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium, each of the first fluid conduits having a first width; a windward condenser core positioned adjacent the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium, each of the second fluid conduits having a second width; and a plurality of fins disposed adjacent each of the first fluid conduits and the second fluid conduits, each of the fins interposed between adjacent ones of each of the first fluid conduits and the second fluid conduits and having a fin width greater than the first width and the second width combined.

In yet another embodiment, a leeward condenser core having a first total face area, the leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium, each of the first fluid conduits having a first width; a windward condenser core having a second total face area, the windward condenser core positioned adjacent the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium, each second fluid conduit having a second width; and at least one circuit pass extending at least partially through the first flow circuit, the at least one circuit pass including at least a portion of the first total face area, wherein the portion of the first total face area is at least 42.7 percent of the first total face area and second total face area combined.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiment when considered in the light of the accompanying drawings in which;

FIG. 1 is a perspective view of a dual plane heat exchanger according to an embodiment of the present invention;

FIG. 2 is a fragmentary, exploded perspective view of two condenser cores of the heat exchanger of FIG. 1;

FIG. 3 is a fragmentary, partially exploded perspective view of a header portion of the heat exchanger of FIG. 1;

FIG. 4 is a fragmentary top plan view of a pair of separate fins of the heat exchanger of FIG. 1 showing an end fin removed, each of the fins disposed adjacent a fluid conduit to form each of the condenser cores;

FIG. 5 is a fragmentary top plan view of a heat exchanger including a common fin according to another embodiment of the present invention, with an end fin removed;

FIG. 6 is a front elevational view of a leeward condenser core of the heat exchanger of FIG. 1 showing a first pass of fluid therethrough; and

FIG. 7 is a front elevational view of a windward condenser core of the heat exchanger of FIG. 1 showing three passes of fluid therethrough.

 DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

FIGS. 1-4 illustrate a heat exchanger 10 according to an embodiment of the present invention. As shown, the heat exchanger 10 includes a leeward condenser core 12 and a windward condenser core 14, the windward condenser core 14 positioned adjacent and facing the leeward condenser core 12. The leeward condenser core 12 and the windward condenser core 14 are connected and secured to one another by, and are in fluid communication with, at least one header 16.

The leeward condenser core 12 includes a plurality of fluid conduits 18 arranged in parallel with one another. In certain embodiments, the fluid conduits 18 are stacked on top of one another with a gap or interval defining a pitch between each adjacent fluid conduit 18. The size of the gaps between each of the adjacent fluid conduits 18 can be uniform or different. The fluid conduits 18 are typically formed from aluminum. However, any material conducive to heat transfer and capable of withstanding a pressure of a fluid passing therethrough can be used.

As a non-limiting example, the fluid conduits 18 are generally flat tubes, the shape of which maximizes a heat exchanging area of the fluid conduits 18. However, the fluid conduits 18 can be any appropriate shape for facilitating a heat exchange. The fluid conduits 18 can have the same length extending from one end of the leeward condenser core 12 or varying lengths. Each of the fluid conduits 18 has a narrow side disposed between and connecting two wider, flattened sides of the fluid conduit 18 that directly faces an air flow as the air flow passes through the heat exchanger 10 substantially perpendicular to the condenser cores 12, 14. The narrow side of each fluid conduit 18 defines a face area of the fluid conduit 18. The face area of each fluid conduit 18 can be the same or different.

The leeward condenser core 12 further includes a plurality of fins 20 interposed between the fluid conduits 18. The fins 20 facilitate additional heat exchange between the fluid circulating through the fluid conduits 18 and the air flowing thereby. The fins 20 are typically corrugated and can be arranged in any manner, serpentine or otherwise, to optimize a heat transfer from the fluid conduits 18. The fins 20 can be formed from aluminum or any other thermally conductive material. The fins 20 can be brazed or otherwise secured to the adjacent fluid conduits 18. Each of the fins 20 can extend the length of the fluid conduits 18 or any length greater than or less than the length of the fluid conduits 18. The length of each of the fins 20 can be identical or different. The fins 20 can have the same width or different widths. Each of the fins 20 has an edge defining a face area that directly faces the air flow passing through the heat exchanger 10 substantially perpendicular to the face of the condenser cores 12, 14. The face area of each fin 20 can be the same or different. Likewise, a fin pitch, defined as the space between each adjacent fin 20, can be the same or different depending on the size of the gap between each of the adjacent fluid conduits 18 and the arrangement and/or pattern of the fins 20. It is understood that the total face area of the leeward condenser core 12 includes the face area of the fluid conduits 18 and the face area of the fins 20.

The windward condenser core 14 includes a plurality of fluid conduits 22 typically arranged in parallel with one another. The fluid conduits 22 are stacked on top of one another with a gap or interval defining the pitch between each adjacent fluid conduit 22. The size of the gaps between each of the adjacent fluid conduits 22 can be uniform or different. The fluid conduits 22 are typically formed from aluminum. However, other thermally conductive materials capable of withstanding the pressure of the fluid passing therethrough can be used.

In certain embodiments, the fluid conduits 22 are flat tubes, the shape of which maximizes the heat exchanging area of the fluid conduits 22. However, the fluid conduits 22 can be any appropriate shape for facilitating a heat exchange. The fluid conduits 22 can have the same length extending from one end of the windward condenser core 14 or varying lengths. Each fluid conduit 22 has a narrow side disposed between and connecting two wider, flattened sides of the fluid conduit 22 that directly faces an air flow passing through the heat exchanger 10 substantially perpendicular to the condenser cores 12, 14. The narrow side of each fluid conduit 22 defines a face area of the fluid conduit 22. The face area of each fluid conduit 22 can be the same or different.

A width w1 of the fluid conduits 18 included in the leeward condenser core 12 can be substantially equal to a width w2 of the fluid conduits 22 included in the windward condenser core 14, as illustrated in FIG. 1, or they can be different. As a non-limiting example, the width w1′ of each of the fluid conduits 18 in the leeward condenser core 12 can be less than the tube width w2 of each of the fluid conduits 22 in the windward condenser core 14 (see FIG. 4). However, any relative arrangement can be used. Likewise, the shape of the fluid conduits 18, 22 included in the condenser cores 12, 14 can be identical or different. As a further non-limiting example, a distance between the fluid conduits 18 of the leeward condenser core 12 and each of the adjacent fluid conduits 22 of the windward condenser core 14 can vary from about 0 to 14 mm.

The windward condenser core 14 further includes a plurality of fins 24 interposed between the fluid conduits 22. The fins 24 facilitate additional heat exchange between the fluid circulating through the fluid conduits 22 and the air flowing thereby. The fins 24 are typically corrugated and can be arranged in any manner, serpentine or otherwise, to optimize a heat transfer from the fluid conduits 22. The fins 24 can be made from aluminum or any other thermally conductive material. The fins 24 can be brazed or otherwise secured to the adjacent fluid conduits 22. Each of the fins 24 can extend the length of the fluid conduits 22 or any length greater than or less than the length of the fluid conduits 22. The length of each of the fins 24 can be identical or different. The fins 24 can have the same width or different widths. Each of the fins 24 has an end defining a face area that directly faces the air flow passing through the heat exchanger 10 substantially perpendicular to the face of the condenser cores 12, 14. The face area of each fin 24 can be the same or different. Likewise, a fin pitch, defined as the space between each adjacent fin 24, can be the same or different depending on the size of the gap between each of the adjacent fluid conduits 22 and the arrangement and/or pattern of the fins 24. It is understood that the total face area of the windward condenser core 14 includes the face area of the fluid conduits 22 and the face area of the fins 24.

In the embodiment shown in FIGS. 1-4, the fins 20 of the leeward condenser core 12 are separate from the fins 24 of the windward condenser core 14. The fins 20 included in the leeward condenser core 12 and the fins 24 included in the windward condenser core 14 can have the same width or different widths, and can extend beyond the edges of the fluid conduits 18, 22 to which they attach, or can be flush with the edges of the fluid conduits 18, 22.

In certain embodiments, the leeward condenser core 12 and the windward condenser core 14 share common fins 24′, as shown in FIG. 5. The common fins 24′ can have the same width of different widths, and/or the same length or different lengths. The common fins 24′ can extend beyond one or each of the condenser cores 12, 14, or they can be flush with the condenser cores 12, 14. It is understood that common fins 24′ increase heat transfer efficiency without requiring additional packaging space and allow for a simplified assembly of the heat exchanger 10 and additional coupling of the two condenser cores 12, 14.

The header 16 is connected to an end of each of the fluid conduits 18 of the leeward condenser core 12 and the fluid conduits 22 of the windward condenser core 14. The header 16 includes a header plate 25 having slots 26 that form fluid tight seals with each of the fluid conduits 18, 22 of the condenser cores 12, 14. The header plate 25 effectively secures the leeward condenser core 12 to the windward condenser core 14 to create a single unit, dual plane condenser. The ends of the fluid conduits 18, 22 that connect to the header plate 25 can be flush with the slots 26 of the header plate 25 or can extend through the slots 26 of the header plate 25. Each of the fluid conduits 18, 22 can be brazed to the header plate 25 or otherwise securely connected to form the fluid tight seal. The header plate 25 can be substantially planar (as seen in FIGS. 2, 3, 4 and 5) or any other appropriate shape. In certain embodiments, the header plate 25 has a pre-determined curved shape (e.g. two adjacent semi-cylinders). However, it is understood that the header plate 25 can have any shape (curved or planar).

In certain embodiments, the header plate 25 is connected to two semi-cylindrical caps 28, 30. A portion of the header plate 25, in combination with each of the semi-cylindrical caps 28, 30, together form a leeward core condenser tank 32 and a windward core condenser tank 34. In one embodiment, the header plate 25 can have a pre-determined curved shape to cooperate with the semi-cylindrical caps 28, 30, to form the leeward and windward core condenser tanks 32, 34, each of the leeward and windward core condenser tanks 32, 34 having a cylindrical shape. The caps 28, 30 can be any shape conducive to withstanding the pressure of the fluid that flows therein. The caps 28, 30 can be secured to the header plate 25 by brazing or other means. As shown in FIGS. 2 and 3, the caps 28, 30 can have a plurality of tabs 33 protruding from an edge thereof. Each of the tabs 33 is received in one of a plurality of cap slots 35 formed in the header plate 25 to secure the caps 28, 30 to the header plate 25. Additionally, in certain embodiments of the invention, the header plate 25 includes a plurality of header plate tabs 33′ formed along one or more peripheral edges of the header plate 25 to engage the caps 28, 30 and cooperate with the tabs 33 to secure the caps 28, 30 to the header plate 25.

A plurality of end baffles 36 is brazed or otherwise secured to the header plate 25 and the caps 28, 30 at each end, creating a pair of fluid tight chambers. Additional baffles 38 may be brazed or otherwise connected to the header plate 25 and the caps 28, 30 within the tanks 32, 34. The additional baffles 38 create divisions in the tanks 32, 34 that direct the fluid passing through certain ones of the fluid conduits 18, 22 in one direction, and in other ones of the fluid conduits 18, 22 in the opposite direction, in sequence. Such a sequence creates a pre-defined number of fluid passes through each of the condenser cores 12, 14. The header plate 25, the caps 28, 30, the end baffles 36 and the additional baffles 38 can be made from aluminum or any material capable of withstanding a pressure in both of the tanks 32, 34.

The header 16 can be positioned at both ends of the heat exchanger 10, as shown in FIG. 1, at one end of the heat exchanger 10, or at one end, which would require additional means for connecting and securing the condenser cores 12, 14 to one another. Likewise, the corresponding parts, including the header plate 25, the caps 28, 30, the end baffles 36 and the additional baffles 38 can exist at both ends, one end, or no ends. Although FIGS. 1 and 2 show a single header 16 at both ends, the heat exchanger 10 can have any number of the headers 16 at one or both ends of the condenser cores 12, 14 that are joined or separate from one another. A pair of separate split-headers (not shown) can also be disposed at each end of the condenser cores 12, 14.

An end fin 40, is typically disposed in parallel relationship with the fluid conduits 18, 22 and arranged at a “top” and/or a “bottom” of the stacked configuration of fluid conduits 18, 22. The end fin 40 can be made from aluminum or any other thermally conductive material. The end fin 40 can extend over both the fluid conduits 18 of the leeward condenser core 12 and the fluid conduits 22 of the windward condenser core 14. However, a separate end fin 40 can be disposed adjacent each of the condenser cores 12, 14.

An inlet 42 receives fluid from an incoming fluid supply at one end and is fluidly connected to the tank 32 at a first end of the heat exchanger 10 at another end. The tank 32 is in fluid communication with the fluid conduits 18 of the leeward condenser core 12. An outlet 44 is fluidly connected to the tank 34 at the first end of the heat exchanger 10 at one end, and returns the fluid to the fluid supply at the other end. The tank 34 is in fluid communication with the fluid conduits 22 of the windward condenser core 14. The inlet 42 and the outlet 44 can be formed from aluminum tubing or any other material capable of transferring fluid to and from the tanks 32, 34. The inlet 42 and the outlet 44 can be positioned anywhere on the heat exchanger 10 so as to effectively transfer fluid to and receive fluid from the heat exchanger 10. The heat exchanger 10 also includes a conduit 46 providing fluid communication between the tank 32 and the tank 34 of the second end of the heat exchanger 10. The conduit 46 can be a tube connecting the tank 32 to the tank 34, or any other means for providing direct fluid communication.

In use, the heat exchanger 10 receives fluid at the inlet 42. The fluid flows through the condenser tank 32 at the first end of the heat exchanger 10, and through the fluid conduits 18 in the leeward condenser core 12 according to the pattern created by the specific placement of each end baffle 36 and/or additional baffle 38. The fluid then flows to the tank 32 at the second end of the heat exchanger 10. The fluid then flows through the conduit 46 to the condenser tank 34 at the second end of the heat exchanger 10, where the fluid flows through the fluid conduits 22 of the windward condenser core 14 according to the pattern created by the specific placement of each end baffle 36 and/or the additional baffles 38. After passing through the leeward condenser core 12 and the windward condenser core 14, the fluid exits the heat exchanger 10 through the condenser tank 34 at the first end of the heat exchanger 10 and the outlet 44. Heat exchange occurs between the fluid and the airflow as the fluid passes through the fluid conduits 18, 22 in both the leeward and windward condenser cores 12, 14 and the airflow passes through the fins 20, 24.

As shown in FIG. 6, the end baffles 36 are placed at the ends of the headers 16 to form the tanks 32 at the first end and the second end of the heat exchanger 10. The placement of the end baffles 36 effectively creates a single compartment at each end of the leeward condenser core 12, allowing fluid to flow in a specific pattern (identified as a first flow circuit pass 50) through all fluid conduits 18 of the leeward condenser core 12 at the same time and in the same direction.

As shown in FIG. 7, the windward condenser core 14 includes two additional baffles 38 that are positioned along the length of the header plate 25, one additional baffle 38 on each end of the windward condenser core 14. The additional baffles 38 are positioned such that a specific flow pattern is created that includes three separate flow circuit passes (a second flow circuit pass 52, a third flow circuit pass 54 and a fourth flow circuit pass 56) for fluid flow through the fluid conduits 22 of the windward condenser core 14.

As a result of the positioning of the end baffles 36 and the additional baffles 38, the total face area included in the first flow circuit pass 50, divided by the sum of the combined total face area included in the first, second, third and fourth flow circuit passes 50, 52, 54, 56, is greater than 0.427. The total face area of the first flow circuit pass 50 includes the combined face area of the fluid conduits 18 and the fins 20 of the leeward condenser core 12 included in the first flow circuit pass 50. The combined total face area included in the first, second, third and fourth flow circuit passes 50, 52, 54, 56 includes the face area of the fluid conduits 18 and the fins 20 of the leeward condenser core 12 included in the first flow circuit pass 50, and the face area of the fluid conduits 22 and the fins 24 of the windward condenser core 14 included in the second, third and fourth flow circuit passes 52, 54, 56. It is understood that the placement and/or removal of the end baffles 36 and the additional baffles 38 can change the number of circuit passes and the flow pattern of fluid throughout each of the condenser cores 12, 14, if desired. Favorable results have been achieved when the leeward condenser core 12 includes one to three passes and the windward condenser core 14 includes one to four passes. However, any number of passes can be created through each of the condenser cores 12, 14.

The heat exchanger 10 shown includes a leeward condenser core 12 and a windward condenser core 14 secured together as one unit using one or more of the headers 16. The heat exchanger 10 of the present invention minimizes an amount of material required for manufacture, minimizes additional features necessary to join separate core condensers with separate headers, integrates the overall features of the dual planes, simplifies assembly, and minimizes a need to design a method for attaching one core condenser to another. Furthermore, the heat exchanger 10 optimizes the heat transfer efficiency of the heat exchanger 10 without increasing material usage and packaging space by integrating the two condenser cores 12, 14 and coordinating the structural requirements and fluid pass schemes necessary to facilitate heat transfer. Specifically, integrating the two condenser cores 12, 14 allows for use of a common fin 24′ that increases heat transfer efficiency of the heat exchanger 10. Furthermore, specific fluid pass schemes including the fluid pass scheme disclosed herein above have been shown to increase overall heat transfer efficiency of the heat exchanger 10.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.

Claims

1. A heat exchanger comprising:

a leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium;
a windward condenser core positioned adjacent and in fluid communication with the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium;
a header plate securing the windward condenser core to the leeward condenser core, the header plate forming at least a portion of a first tank in fluid communication with each of the first fluid conduits and a second tank in fluid communication with each of the second fluid conduits;
a first cap disposed on the header plate to form the first tank; and
a second cap disposed on the header plate to form the second tank.

2. The heat exchanger according to claim 1, wherein the first cap forms a fluid-tight seal with a first portion of the header plate connecting to and in fluid communication with each of the first fluid conduits, and the second cap forms a fluid-tight seal with a second portion of the header plate connecting to and in fluid communication with each of the second fluid conduits.

3. The heat exchanger according to claim 1, further comprising a plurality of fins, each of the fins interposed between adjacent ones of each of the first fluid conduits and the second fluid conduits.

4. The heat exchanger according to claim 3, wherein at least one of the fins extends between a pair of adjacent ones of the first fluid conduits and a pair of adjacent ones of the second fluid conduits.

5. The heat exchanger according to claim 1, wherein the first fluid conduits are spaced from the second fluid conduits by a gap ranging from about 0.0 to 14.0 millimeters.

6. The heat exchanger according to claim 1, wherein the first flow circuit includes at most three circuit passes through the leeward condenser.

7. The heat exchanger according to claim 1, wherein the second flow circuit is downstream of the first flow circuit.

8. A heat exchanger comprising:

a leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium, each of the first fluid conduits having a first width;
a windward condenser core positioned adjacent the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium, each of the second fluid conduits having a second width; and
a plurality of fins disposed adjacent each of the first fluid conduits and the second fluid conduits, each of the fins interposed between adjacent ones of each of the first fluid conduits and the second fluid conduits and having a fin width greater than the first width and the second width combined.

9. The heat exchanger according to claim 8, further comprising a header plate securing the windward condenser core to the leeward condenser core, the header plate at least a portion of a first tank and a second tank, a first cap disposed on the header plate to form the first tank in fluid communication with each of the first fluid conduits, and a second cap disposed on the header plate to form the second tank in fluid communication with each of the second fluid conduits.

10. The heat exchanger according to claim 9, wherein the first cap forms a fluid-tight seal with a first portion of the header plate connecting to and in fluid communication with each of the first fluid conduits, and the second cap forms a fluid-tight seal with a second portion of the header plate connecting to and in fluid communication with each of the second fluid conduits.

11. The heat exchanger according to claim 8, wherein the first fluid conduits are spaced from the second fluid conduits by a gap ranging from about 0.0 to 14.0 millimeters.

12. The heat exchanger according to claim 8, wherein the second width is greater than the first width.

13. The heat exchanger according to claim 8, wherein the second flow circuit is downstream of the first flow circuit.

14. A heat exchanger comprising:

a leeward condenser core having a first total face area, the leeward condenser core including a plurality of first fluid conduits having a first flow circuit formed therethrough to receive a heat exchanging medium, each of the first fluid conduits having a first width;
a windward condenser core having a second total face area, the windward condenser core positioned adjacent the leeward condenser core, the windward condenser core including a plurality of second fluid conduits having a second flow circuit formed therethrough to receive the heat exchanging medium, each second fluid conduit having a second width; and
at least one circuit pass extending at least partially through the first flow circuit, the at least one circuit pass including at least a portion of the first total face area, wherein the portion of the first total face area is at least 42.7 percent of the first total face area and second total face area combined.

15. The heat exchanger according to claim 14, further comprising a header plate securing the windward condenser core to the leeward condenser core, the header plate at least a portion of a first tank and a second tank, a first cap disposed on the header plate to form the first tank in fluid communication with each of the first fluid conduits, and a second cap disposed on the header plate to form the second tank in fluid communication with each of the second fluid conduits.

16. The heat exchanger according to claim 15, wherein the first cap forms a fluid-tight seal with a first portion of the header plate connecting to and in fluid communication with each of the first fluid conduits, and the second cap forms a fluid-tight seal with a second portion of the header plate connecting to and in fluid communication with each of the second fluid conduits.

17. The heat exchanger according to claim 14, further comprising a plurality of fins, each of the fins interposed between adjacent ones of each of the first fluid conduits and the second fluid conduits.

18. The heat exchanger according to claim 17, wherein at least one of the fins extends between a pair of adjacent ones of the first fluid conduits and a pair of adjacent ones of the second fluid conduits.

19. The heat exchanger according to claim 17, wherein at least one of the fins has a width that is greater than the first width and the second width combined.

20. The heat exchanger according to claim 14, wherein the first width is at least one of less than the second width and equal to the second width.

Patent History
Publication number: 20120222848
Type: Application
Filed: Mar 1, 2011
Publication Date: Sep 6, 2012
Applicant: VISTEON GLOBAL TECHNOLOGIES, INC. (Van Buren Twp., MI)
Inventors: Brennan Sicks (Farmington Hills, MI), Moiz Yusuf Nagarwala (Northville, MI)
Application Number: 13/037,920
Classifications
Current U.S. Class: With Manifold Type Header Or Header Plate (165/173)
International Classification: F28F 9/02 (20060101);