TRAY AND ASSEMBLY FOR DIRECTING AND DETECTING LEAKED REFRIGERANT

Abstract

An assembly for directing and detecting leaked refrigerant in a heat exchanger is disclosed. The assembly comprises one or more tray configured at one or more leak-prone locations in the heat exchanger. A first tray is configured at bottom of one or more manifold associated with the heat exchanger, which extends along a length of the corresponding manifold. A second tray is configured on top of the manifold(s), which extends along a length of the corresponding manifold and covers the top of the corresponding manifold. The first and second trays are adapted to block and collect leaked refrigerant from any of the one or more leak-prone locations and direct the collected leaked refrigerant toward a predetermined location or a refrigerant sensor.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of U.S. Provisional Patent Application No. 63/477,639, filed on Dec. 29, 2022, which is incorporated by reference herein in its entirety.

BACKGROUND

This invention relates to the field of heat exchangers, and more particularly, a tray and an assembly for directing and detecting leaked refrigerant in a heat exchanger.

Heat exchangers may have refrigerant leakage at leak-prone locations, which is to be detected to mitigate safety and economic concerns. However, there may be some critical leak locations where refrigerant leak detection may not be possible without leak trays.

SUMMARY

Described herein is an assembly for directing and detecting leaked refrigerant in a heat exchanger. The assembly comprises one or more trays configured at one or more leak-prone location in the heat exchanger, wherein the one or more trays are adapted to block and collect leaked refrigerant from any of the one or more leak-prone locations and direct the collected leaked refrigerant towards a predetermined location.

In one or more embodiments, the one or more trays comprises a first tray configured at the bottom of one or more manifolds associated with the heat exchanger such that there is at least one first tray below each of the one or more manifolds, wherein the first tray extends along a length of the corresponding manifold.

In one or more embodiments, the one or more trays comprises a second tray configured on top of one or more manifolds associated with the heat exchanger such that there is at least one second tray on top of each of the one or more manifolds, wherein the second tray extends along the length of the corresponding manifold and covers the top of corresponding manifold.

In one or more embodiments, the predetermined location is at a bottom end of coils of the heat exchanger.

In one or more embodiments, the assembly comprises a refrigerant sensor at the predetermined location, wherein the refrigerant sensor is associated with a refrigerant leakage detection and mitigation system implemented in the heat exchanger.

In one or more embodiments, the assembly comprises a reservoir at the predetermined location to store the collected leaked refrigerant.

In one or more embodiments, the leaked refrigerant is directed from the one or more tray towards the predetermined location at the bottom end of the coils or towards the refrigerant sensor through outer surface of the coils of the heat exchanger.

In one or more embodiments, the one or more tray is fluidically connected to the predetermined location or the refrigerant sensor using one or more conduits, and a channel.

In one or more embodiments, the refrigerant is an A2L refrigerant. In one or more embodiments, the heat exchanger is a microchannel heat exchanger having a V-coil arrangement.

Also described herein is a tray for directing and detecting leaked refrigerant in a heat exchanger. The tray comprises a first member, and a second member extending upward at a predetermined acute angle from a bottom end of the first member, wherein the tray is configured to be positioned below one or more manifolds of the heat exchanger, such that the tray extends along a length of the one or more manifolds, and wherein the tray is adapted to block and collect leaked refrigerant from one or more leak-prone locations of the one or more manifolds and direct the collected leaked refrigerant towards a predetermined location.

In one or more embodiments, wherein the tray is configured with the one or more manifolds such that: the first member remains parallel to a vertical plane of the corresponding manifold, with the bottom end of the first member below a bottom end of the corresponding manifold; and the second member extends from the bottom end of the first member towards the bottom end of the corresponding manifold at the predetermined acute angle.

In one or more embodiments, the first member comprises an engaging section configured to facilitate attachment of the tray to an inner vertical wall of a housing of the heat exchanger such that the first member remains parallel to the inner vertical wall of the housing, with the bottom end of the first member being below a bottom end of the corresponding manifold.

In one or more embodiments, the tray comprises a support section of a predetermined profile between the first member and the second member, wherein the support section is adapted to accommodate and support the one or more manifolds thereover, upon attachment of the first member of the tray to the vertical inner wall of the housing.

In one or more embodiments, the predetermined profile of the support section is selected based on a profile of the one or more manifolds or a profile of a manifold support frame associated with the one or more manifold.

Further described herein is a tray for directing and detecting leaked refrigerant in a heat exchanger. The tray comprises a first member, a second member attached laterally to and inclined at a predetermined angle from the first member, and third members, each attached to the first and second members at two opposite ends of the tray, wherein the tray is configured to be positioned on top of one or more manifolds of the heat exchanger, such that the tray extends along a length of the corresponding manifold and covers the top of the corresponding manifold, and wherein the tray is adapted to block and collect leaked refrigerant from one or more leak-prone locations of the one or more manifolds and direct the collected leaked refrigerant towards a predetermined location.

In one or more embodiments, the tray is configured to be positioned on top of the one or more manifolds, such that the first member extends along the length on top of the corresponding manifold, the second member extends along the length on a coil side of the corresponding manifold, and the third member remains parallel to two opposite ends of the corresponding manifold.

In one or more embodiments, the second member comprises one or more notches formed therein to facilitate attachment of the tray on the top of the one or more manifolds within the heat exchanger.

In one or more embodiments, the first member, the second member, and third member have a flat profile.

In one or more embodiments, the first member is substantially perpendicular to the second member.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, features, and techniques of the invention will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the subject disclosure of this invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the subject disclosure and, together with the description, explain the principles of the subject disclosure.

In the drawings, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

FIGS. 1A to 1D illustrate exemplary views of an assembly configured with a heat exchanger for directing and detecting leaked refrigerants in accordance with one or more embodiments of the disclosure.

FIGS. 2A to 2B illustrate exemplary views of a first embodiment of a tray that is configurable with manifolds of a heat exchanger for directing and detecting leaked refrigerants in accordance with one or more embodiments of the disclosure.

FIGS. 3A to 3C illustrate exemplary views of a second embodiment of a tray that is configurable with manifolds of a heat exchanger for directing and detecting leaked refrigerants in accordance with one or more embodiments of the disclosure.

DETAILED DESCRIPTION

The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject disclosure as defined by the appended claims.

Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the subject disclosure, the components of the invention described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” “first”, “second” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the heat exchanger, trays, coils, refrigerant sensor, and corresponding components, described herein may be oriented in any desired direction.

Heat exchangers generally have refrigerant leakage at leak-prone locations including but not limited to brazed joints, bends, the connection point between two components made of dissimilar materials, and corrosion-prone areas. It is critical to rapidly detect refrigerant leakage in order to mitigate safety and economic concerns. Heat exchangers may involve a refrigerant detection system (RDS) comprising a refrigerant sensor positioned at the bottom end of coils of the heat exchanger to detect refrigerant leakage. However, there may be various critical leak locations such as the manifolds of the heat exchanger where it may not be easily and efficiently possible for the refrigerant sensor to detect the refrigerant leak. This may cause safety concerns and may also lead to significant refrigerant losses if it remains undetected. There is therefore a need to provide a compact, efficient, and cost-effective solution for detecting, capturing and collecting leaked refrigerant within a heat exchanger, which also directs the collected refrigerant toward the refrigerant sensor and/or a collection reservoir.

This invention provides a compact, cost-effective, reliable, and efficient refrigerant collection tray and assembly for a heat exchanger, which blocks, captures, and collects leaked refrigerant within a heat exchanger. This invention also diverts the collected leaked refrigerant towards a refrigerant detection system for mitigating any safety and economic concerns. This invention also supports and keeps the coils and manifolds of the heat exchanger in place.

Referring to FIGS. 1A to 1D, an assembly for directing and detecting leaked refrigerant in a heat exchanger 100. The assembly may include one or more trays 112, 114 (collectively referred to as trays and individually referred to as a tray, herein) configured at one or more leak-prone locations in the heat exchanger 100. In one or more embodiments, the leak-prone location may be the manifolds 102, 104 of the heat exchanger 100. The refrigerant associated with the heat exchanger 100 may generally leak from the top of the manifold 102, 104, bottom of the manifold 102, 104, or through the brazed joints between the coils 106 and manifold 102, 104 of the heat exchanger 100. The trays 112, 114 are adapted to block and collect leaked refrigerant from any leak-prone locations including, but not limited to, the manifold locations noted above, and direct the collected leaked refrigerant toward a predetermined location 108 within or outside the heat exchanger 100.

In one or more embodiments, a first tray 112 among the one or more trays may be configured at bottom of each manifold 102, 104. The first tray 112 may extend along the length of the corresponding manifold 102, 104 and may cover the bottom of the corresponding manifold 102, 104. The first tray 112 may capture any leaked refrigerant from the bottom of the manifold 102, 104, thereby blocking the leakage of the refrigerant from the bottom of the manifold 102, 104 and also helping to direct the collected leaked refrigerant towards the predetermined location 108 within or outside the heat exchanger 100. A support section of the tray may have a profile based on a profile of the manifold 102, 104 or a profile of a manifold support frame 110 associated with the manifold 102, 104 such that the support section of the first tray 112 may accommodate and support the manifold 102, 104 above it. The detailed operation of the first tray 112 is described further in conjunction with FIGS. 2A to 2B.

In one or more embodiments, a second tray 114 may be configured on top of each manifold 102, 104. The second tray 114 may extend along the length of the corresponding manifold 102, 104 and may cover the top of the corresponding manifold 102, 104. The first tray 112 may capture any leaked refrigerant from the top of the manifold 102, 104, thereby blocking the leakage of the refrigerant from the top of the manifold 102, 104 and helping to direct the collected leaked refrigerant towards the predetermined location 108 within or outside the heat exchanger 100. The detailed operation of the second tray 114 is described further in conjunction with FIGS. 3A to 3C.

In one or more embodiments, the predetermined location 108 where the collected leaked refrigerant is to be diverted may be at the bottom end of the coils 106 of the heat exchanger 100, such that the collected leaked refrigerant may move toward the predetermined location (bottom end) 108 under the effect of gravity. Further, a refrigerant sensor 116 may be installed at the bottom end of the coils 106 (predetermined location 108). The refrigerant sensor 116 may be associated with a refrigerant leakage detection and mitigation system (not shown) implemented in the heat exchanger 100, which may detect the leaked refrigerant, and the refrigerant leakage detection and mitigation system may notify users or technicians to further mitigate the refrigerant leakage.

In one or more embodiments, the collected leaked refrigerant may be directed from the first tray 112 and/or the second tray 114 toward the bottom end of the coils 106 or toward the refrigerant sensor 116 through the outer surface of the coils 106 of the heat exchanger 100 under the effect of gravity. For example, in a V-coil arrangement heat exchanger 100 is shown in FIG. 1A to 1D, the refrigerant sensor may be positioned at condensate pan below a bottom trough (bottom bent) of the V-coils 106. However, the trays 112, 114 and assembly of this invention may be implemented in heat exchangers 100 having other types of coil arrangements as well, without any limitation, and all such embodiments are well within the scope of this invention. In other embodiments, the first tray 112 and second tray 114 may be fluidically connected to the predetermined location 108 or the refrigerant sensor 116 or the reservoir using one or more conduits, channels, and the like. In one or more embodiments, the first tray 112 and second tray 114 may be made of plastic.

Referring to FIGS. 2A to 2B, the first tray 112 for directing and detecting leaked refrigerant in the heat exchanger 100 is disclosed. The first tray 112 may include a first member 202, and a second member 204 extending upward at a predetermined acute angle from the bottom end of the first member 202. The first tray 112 may be configured to be positioned below each manifold 102, 104 of the heat exchanger 100, such that the first tray 112 extends along a length of the corresponding manifold 102, 104. The first tray 112 may be adapted to block and collect leaked refrigerant from the bottom of the manifold 102, 104 and further direct the collected leaked refrigerant toward the predetermined location 108 within or outside the heat exchanger 100.

The first tray 112 is configured to be positioned at bottom of each of the manifolds 102, 104 such that the first member 202 remains parallel to a vertical plane of the corresponding manifold 102, 104, with the bottom end of the first member 202 below the bottom end of the corresponding manifold 102, 104. Further, the second member 204 extends from the bottom end of the first member 202 toward the bottom end of the corresponding manifold 102, 104 at the predetermined acute angle.

In one or more embodiments, the first member 202 of the first tray 112 may further comprise an engaging section 206 to facilitate attachment of the tray to an inner vertical wall 118-1, 118-2 of a housing 118 of the heat exchanger 100 such that the first member 202 remains parallel to the inner vertical wall 118-1, 118-2 of the housing 118, with the bottom end of the first member 202 being below a bottom end of the corresponding manifold 102, 104. Further, the first tray 112 may comprise a support section 208 of a predetermined profile between the first member 202 and the second member 204. The predetermined profile of the support section 208 may be selected based on a profile of the manifold 102, 104 or a profile of a manifold support frame 110 associated with the manifold 102, 104 such that the support section 208 of the first tray 112 may accommodate and support the manifold 102, 104 above it, upon attachment of the first member 202 of the first tray 112 to the vertical inner wall 118-1, 118-2 of the housing 118, thereby keeping the coils 106 and manifolds 102, 104 in place within the heat exchanger 100.

Referring to FIGS. 3A to 3C, the second tray 114 for directing and detecting leaked refrigerant in the heat exchanger 100 is disclosed. The second tray 114 may include a first member 302, a second member 304 attached laterally to and inclined at a predetermined angle from the first member 302, and third members 306 attached to the first and second members 302, 304 at two opposite ends of the tray 114. The second tray 114 is configured to be positioned on top of each of the manifolds 102, 104 of the heat exchanger 100, such that the second tray 114 extends along a length of the corresponding manifold 102, 104 and covers the top of the corresponding manifold 102, 104. The second tray 114 is adapted to block and direct leaked refrigerant from the top of the manifold 102, 104 and further direct the collected leaked refrigerant toward the predetermined location 108.

The second tray 114 is configured to be positioned on top of the manifold 102, 104, such that the first member 302 extends along the length on top of the corresponding manifold 102, 104, the second member 304 extends along the length on a coil side of the corresponding manifold 102, 104, and the third members 306 remain parallel to two opposite ends of the corresponding manifold 102, 104. In one or more embodiments, the second tray 114 may be made of a single sheet of material that may be machined to bend and form the portions of the first member 302 and second member 304, such that the first and second members 302, 304 remain inclined at the predetermined angle. The first and second members 302, 304 of the second tray 114 may be substantially perpendicular (predetermined angle). Further, the third members 306 may then be separately attached to the first and second members 302, 304 at opposite ends of the second tray 114. In other embodiments, the first member 302 and second member 304 of the second tray 114 may be separate elongated members that may be laterally joined together at the predetermined angle using known techniques, followed by attaching the third member 306 to the first and second members 302, 304 at opposite ends of the second tray 114. In one or more embodiments, the second member of the second tray 114 may comprise one or more notches 308 formed therein to facilitate attachment of the second tray 114 on top of the manifolds 102, 104 within the heat exchanger 100.

Those skilled in the art would appreciate that the trays 112, 114 of this invention may be easily installed/mounted on the top and bottom end along the length of the manifolds 102, 104. Thus, the assembly and trays 112, 114 of this invention facilitate blocking and directing the leaked refrigerant from the leak-prone location of the manifolds 102, 104 and further help direct the collected leaked refrigerant toward the refrigerant sensor 116 at the bottom of the heat exchanger 100 under the effect of gravity for refrigerant leakage detection and mitigation. Moreover, the trays 112, 114 of this invention also support and keep the coils 106 and manifolds 102, 104 in place within the housing 118 of the heat exchanger 100.

Various embodiments, figures, and examples of this invention have been described for the first tray and the second tray having a specific design or profile. However, the teachings of this invention are equally applicable for the trays having other designs as well, where the trays extend along the length of the manifolds, and block and capture leaked refrigerant from the manifolds All such embodiments are well within the scope of this invention.

Thus, this invention overcomes the drawbacks, limitations, and shortcomings associated with existing technologies by providing a compact, cost-effective, reliable, and efficient refrigerant collection tray and assembly for a heat exchanger, which blocks, directs, and collects leaked refrigerant within a heat exchanger. In addition, this invention also diverts the collected leaked refrigerant towards a refrigerant detection system for mitigating any safety and economic concerns. Moreover, this invention also supports and keeps the coils and manifolds in place within the heat exchanger.

While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined by the appended claims. Modifications may be made to adopt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention includes all embodiments falling within the scope of the invention as defined by the appended claims.

In interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

1. An assembly for directing and detecting leaked refrigerant in a heat exchanger, the assembly comprising:

one or more trays configured at one or more leak-prone locations in the heat exchanger,

wherein the one or more trays are adapted to block and collect leaked refrigerant from any of the one or more leak-prone locations and direct the collected leaked refrigerant towards a predetermined location.

2. The assembly of claim 1, wherein the one or more trays comprises a first tray configured at the bottom of one or more manifolds associated with the heat exchanger such that there is at least one first tray below each of the one or more manifolds, wherein the first tray extends along a length of the corresponding manifold.

3. The assembly of claim 1, wherein the one or more trays comprises a second tray configured on top of one or more manifolds associated with the heat exchanger such that there is at least one second tray on top of each of the one or more manifolds, wherein the second tray extends along a length of the corresponding manifold and covers the top of corresponding manifold.

4. The assembly of claim 1, wherein the predetermined location is at a bottom end of coils of the heat exchanger.

5. The assembly of claim 1, wherein the assembly comprises a refrigerant sensor at the predetermined location, wherein the refrigerant sensor is associated with a refrigerant leakage detection and mitigation system implemented in the heat exchanger.

6. The assembly of claim 1, wherein the leaked refrigerant is directed from the one or more trays towards the predetermined location at the bottom end of the coils or towards the refrigerant sensor through outer surface of the coils of the heat exchanger.

7. The assembly of claim 1, wherein the one or more trays is fluidically connected to the predetermined location or the refrigerant sensor using one or more of conduits, and a channel.

8. The assembly of claim 1, wherein the refrigerant is an A2L refrigerant.

9. The assembly of claim 1, wherein the heat exchanger is a microchannel heat exchanger having a V-coil arrangement.

10. A tray for directing and detecting leaked refrigerant in a heat exchanger, the tray comprising:

a first member; and

a second member extending upward at a predetermined acute angle from a bottom end of the first member;

wherein the tray is configured to be positioned below one or more manifolds of the heat exchanger, such that the tray extends along a length of the one or more manifolds, and

wherein the tray is adapted to block and collect leaked refrigerant from one or more leak-prone location of the one or more manifolds and direct the collected leaked refrigerant towards a predetermined location.

11. The tray of claim 10, wherein the tray is configured with the one or more manifolds such that:

the first member remains parallel to a vertical plane of the corresponding manifold, with the bottom end of the first member below a bottom end of the corresponding manifold; and

the second member extends from the bottom end of the first member towards the bottom end of the corresponding manifold at the predetermined acute angle.

12. The tray of claim 10, wherein the first member comprises an engaging section configured to facilitate attachment of the tray to an inner vertical wall of a housing of the heat exchanger such that the first member remains parallel to the inner vertical wall of the housing, with the bottom end of the first member being below a bottom end of the corresponding manifold.

13. The tray claim 10, wherein the tray comprises a support section of a predetermined profile between the first member and the second member, wherein the support section is adapted to accommodate and support the one or more manifolds thereover, upon attachment of the first member of the tray to the vertical inner wall of the housing.

14. The tray claim 10, wherein the predetermined profile of the support section is selected based on a profile of the one or more manifolds or a profile of a manifold support frame associated with the one or more manifold.

15. A tray for directing and detecting leaked refrigerant in a heat exchanger, the tray comprising:

a first member;

a second member attached laterally to and inclined at a predetermined angle from the first member; and

third members, each attached to the first and second members at two opposite ends of the tray;

wherein the tray is configured to be positioned on top of one or more manifolds of the heat exchanger, such that the tray extends along a length of the corresponding manifold and covers the top of the corresponding manifold, and

wherein the tray is adapted to block and collect leaked refrigerant from one or more leak-prone locations of the one or more manifolds and direct the collected leaked refrigerant towards a predetermined location.

16. The tray of claim 15, wherein the tray is configured to be positioned on top of the one or more manifolds, such that the first member extends along the length on top of the corresponding manifold, the second member extends along the length on a coil side of the corresponding manifold, and the third members remain parallel to two opposite ends of the corresponding manifold.

17. The tray of claim 15, wherein the second member comprises one or more notches formed therein to facilitate attachment of the tray on the top of the one or more manifolds within the heat exchanger.

18. The tray of claim 15, wherein the first member, the second member, and third member have a flat profile.

19. The tray of claim 15, wherein the first member is substantially perpendicular to the second member.