U.S. patent application number 11/492243 was filed with the patent office on 2008-01-31 for heat exchanger assembly.
Invention is credited to Henry Earl Beamer, Christopher Alfred Fuller, Robert Michael Runk, Douglas Charles Wintersteen.
Application Number | 20080023183 11/492243 |
Document ID | / |
Family ID | 38984979 |
Filed Date | 2008-01-31 |
United States Patent
Application |
20080023183 |
Kind Code |
A1 |
Beamer; Henry Earl ; et
al. |
January 31, 2008 |
Heat exchanger assembly
Abstract
A heat exchanger assembly has a first manifold, a second
manifold in spaced and substantially parallel relationship with the
first manifold and a plurality of flow tubes fluidly connecting the
manifolds for passing refrigerant between the manifolds. The first
manifold includes a header and tank which are joined by their
longitudinal edges to form a cavity. The tank is extruded and has
an outer wall and an inner partition wall with a plurality of
apertures which define a distribution chamber within the cavity.
The distribution chamber is fluidly connected to the cavity. A
method of manufacturing a manifold generally includes the steps of
extruding the tank, cutting the tank to a predetermined length,
forming a plurality of apertures in the inner partition wall,
forming a plurality of openings in the header, joining the tank and
the header, and joining the end cap to the tank and header.
Inventors: |
Beamer; Henry Earl;
(Middleport, NY) ; Fuller; Christopher Alfred;
(East Aurora, NY) ; Runk; Robert Michael;
(N.Tonawanda, NY) ; Wintersteen; Douglas Charles;
(Burt, NY) |
Correspondence
Address: |
DELPHI TECHNOLOGIES, INC.
M/C 480-410-202, PO BOX 5052
TROY
MI
48007
US
|
Family ID: |
38984979 |
Appl. No.: |
11/492243 |
Filed: |
July 25, 2006 |
Current U.S.
Class: |
165/174 |
Current CPC
Class: |
F28F 2220/00 20130101;
F28F 9/0224 20130101; F25B 39/022 20130101; F28D 2021/007 20130101;
F28F 9/0273 20130101; F28F 2255/16 20130101; F28D 2021/0071
20130101 |
Class at
Publication: |
165/174 |
International
Class: |
F28F 9/02 20060101
F28F009/02 |
Claims
1. A heat exchanger assembly) comprising: a first manifold having a
tank and a header adjacent said tank and defining a hollow cavity;
a second manifold defining a hollow cavity and in spaced and
substantially parallel relationship with said first manifold; a
plurality of flow tubes extending between and fluidly connecting
said cavities of said manifolds for passing refrigerant between
said manifolds; and said tank having an outer wall defining a
channel and an inner partition wall disposed within said channel
adjacent said outer wall with said inner partition wall having a
section integrally formed with a portion of said outer wall to
define a distribution chamber disposed within said channel with
said inner partition wall having a plurality of apertures fluidly
connecting said distribution chamber with said cavity.
2. An assembly as set forth in claim 1 wherein said inner partition
wall has a generally C-shaped cross-section.
3. An assembly as set forth in claim 1 wherein said outer wall
includes a pair of opposed longitudinal edges each including a
flange integral to and extending outward from said longitudinal
edge forming a seat.
4. An assembly as set forth in claim 3 wherein said header includes
a pair of longitudinal edges.
5. An assembly as set forth in claim 4 wherein said longitudinal
edges of said header are adjacent said seats.
6. An assembly as set forth in claim 1 having at least one port in
said first manifold and fluidly connected to at least one of said
distribution chamber and said cavity.
7. An assembly as set forth in claim 6 wherein said port is
adjacent at least one of said outer wall and an end cap of said
first manifold.
8. An assembly as set forth in claim 7 wherein said at least one
port further includes a coupler adjacent at least one of said outer
wall and said end cap and fluidly connected to at least one of said
distribution chamber and said cavity.
9. An assembly as set forth in claim 1 wherein said header includes
a plurality of openings sized for accepting said plurality of flow
tubes.
10. An assembly as set forth in claim 1 wherein said flow tubes are
disposed within said cavity of said first manifold fluidly
connecting said second manifold with said cavity of said first
manifold.
11. An assembly as set forth in claim 1 wherein said inner
partition wall includes a flattened ledge running a length of said
inner partition wall adjacent said cavity with said plurality of
apertures disposed within said ledge.
12. A manifold comprising: a tank having an outer wall defining a
channel; a header mounted to said outer wall with said header and
said outer wall defining a cavity; and said tank having an inner
partition wall disposed within said channel adjacent said outer
wall with said inner partition wall having a section integrally
formed with a portion of said outer wall to define a distribution
chamber disposed within said channel with said inner partition wall
having a plurality of apertures fluidly connecting said
distribution chamber with said cavity.
13. An assembly as set forth in claim 12 wherein said inner
partition wall has a generally C-shaped cross-section.
14. An assembly as set forth in claim 13 wherein said outer wall
includes a pair of opposed flanges defining a pair of seats for
said header.
15. An assembly as set forth in claim 14 wherein said header
includes a pair of longitudinal edges abutting said seats.
16. An assembly as set forth in claim 15 having at least one port
in said tank and fluidly connected to at least one of said
distribution chamber and said cavity.
17. An assembly as set forth in claim 16 wherein said port is
adjacent at least one of said outer wall and an end cap of said
first manifold.
18. An assembly as set forth in claim 17 wherein said at least one
port further includes a coupler adjacent at least one of said outer
wall and said end cap and fluidly connected to at least one of said
distribution chamber and said cavity.
19. An assembly as set forth in claim 12 wherein said header
includes a plurality of openings.
20. An assembly as set forth in claim 12 wherein said inner
partition wall includes a flattened ledge along a length of said
inner partition wall facing said cavity with said plurality of
apertures disposed within said inner ledge.
21. A method of manufacturing a tank having an outer wall defining
a channel, and an inner partition wall with a plurality of
apertures, said method comprising the steps of: extruding the tank
having the outer wall and the inner partition wall with the inner
partition wall integrally connected to the outer wall to form a
distribution chamber; cutting the tank to a predetermined length;
and forming a plurality of apertures in the inner partition
wall.
22. A method of manufacturing a manifold having a tank with an
outer wall defining a channel and an inner partition wall with a
plurality of apertures, a header having a plurality of openings,
and at least one end cap, said method comprising the steps of:
extruding the tank having the outer wall and the inner partition
wall with the inner partition wall integrally connected to the
outer wall to form a distribution chamber; cutting the tank to a
predetermined length; forming a plurality of apertures in the inner
partition wall; forming a plurality of openings in the header;
joining the tank and the header; and joining the end cap to one end
of the tank and the header.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a heat exchanger assembly
and method of manufacturing a manifold.
[0003] 2. Description of the Prior Art
[0004] Heat exchanger assemblies are widely used in a variety of
applications, and can be either single mode or dual mode, depending
on whether functioning solely as either a condenser or an
evaporator, or if functioning as both. The heat exchanger
assemblies generally include a pair of manifolds fluidly connected
by a plurality of flow tubes. Heat conducting structures, such as
fins, are generally 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.
Refrigerant enters the heat exchanger assembly through one or more
ports which are connected to one or both manifolds. Refrigerant
passes through the heat exchanger assembly and is exited through
one or more ports connected to one or both of the manifolds.
[0005] One of the primary goals is to maximize heat exchange
efficiency by managing the velocity and distribution of the
refrigerant, as well as the temperature and pressure differences
within the manifolds and the flow tubes. A difficulty arises
because the flow characteristics of the refrigerant vary depending
on the phase, that is, whether the refrigerant is a gas, liquid, or
combination. When there is poor refrigerant distribution and
circulation, some sections of the heat exchanger assembly can be
flooded with refrigerant and some can be starved, resulting in
unequal heat transfer between portions of the heat exchanger and
can cause icing or frosting of portions of the heat exchanger,
further diminishing performance.
[0006] The largest problems exist when the heat exchanger assembly
is operating as an evaporator in order to absorb heat. The
refrigerant enters the heat exchanger assembly in two-phases,
comprising liquid and gas. As the two-phase refrigerant circulates
through the heat exchanger assembly, the refrigerant absorbs heat
from the ambient air passing over the flow tubes and other heat
conducting structures, causing the liquid 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.
[0007] Manufacturing costs, particularly assembly costs, can be
high because of the number of components, and the precision with
which they must be installed to ensure proper alignment.
Conversely, producing single integrated manifolds can present a
lack of flexibility in selecting materials and limit manufacturing
access to the interior of the manifold.
[0008] A single piece extruded tank is disclosed in PCT Application
WO 93/04334 to Creamer, et al. While this single piece extruded
tank reduces the number of components, it does not include a
structure for facilitating refrigerant distribution.
[0009] A distribution tube is disclosed within a manifold of a heat
exchanger assembly, specifically, a refrigerating coil, in U.S.
Pat. No. 1,684,083 to Bloom. The distribution tube forms a
distribution chamber and includes a plurality of apertures for
distributing refrigerant entering the manifold. The distribution
tube is a separate component joined to the manifold by welding, and
thus the problems related to assembly costs and the difficulty of
positive placement of the distribution tube are not addressed.
Further, the shape and configuration of the resulting distribution
chamber is limited.
[0010] Accordingly, there exists an opportunity to manufacture a
tank for a manifold of a heat exchanger assembly that has an
integral distribution tube that allows for robust construction and
positive placement of the distribution tube. Flexibility in options
for creation of apertures in the distribution tube would also be
beneficial.
SUMMARY OF THE INVENTION AND ADVANTAGES
[0011] The subject invention provides for a heat exchanger assembly
having a first manifold with a tank and a header adjacent the tank
defining a hollow cavity. A second manifold defines a hollow cavity
and is in spaced and substantially parallel relationship with the
first manifold. A plurality of flow tubes extend between and
fluidly connect the cavities of the manifolds for passing the
refrigerant between the manifolds. The tank has an outer wall
defining a channel and an inner partition wall disposed within the
channel adjacent the outer wall. The inner partition wall has a
section integrally formed with a portion of the outer wall to
define a distribution chamber disposed within the channel. The
inner partition wall has a plurality of apertures fluidly
connecting the distribution chamber with the cavity.
[0012] The subject invention also provides a method of
manufacturing a manifold having a tank with an outer wall defining
a channel and an inner partition wall with a plurality of
apertures, a header having a plurality of openings, and at least
one end cap. The method includes the following steps: extruding the
tank having the outer wall and the inner partition wall with the
inner partition wall integrally connected to the outer wall to form
a distribution chamber; cutting the tank to a predetermined length;
forming a plurality of apertures in the inner partition wall;
forming a plurality of openings in the header; joining the tank and
the header; and joining the end cap to at least one end of the tank
and the header.
[0013] An extruded tank which includes an integrated distribution
chamber reduces the assembly complexity. Problems associated with
mechanical assembly, location and joining of separate distribution
tubes, in particular, for longer manifolds, are completely avoided.
At the same time, because the interior of the tank is easily
accessible, tremendous flexibility is afforded in the creation of
the plurality of apertures. Further, by having a separate tank and
header, the header may be cost-effectively produced including a
braze cladding which facilitates the joining of the header and tank
as well as the header and the flow tubes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] 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.
[0015] FIG. 1 is a perspective view of a heat exchanger
assembly;
[0016] FIG. 2 is a perspective view of the first manifold of the
heat exchanger assembly, illustrating a header, a tank and an inner
partition wall;
[0017] FIG. 3 is a cross-sectional top view of one embodiment of
the manifold;
[0018] FIG. 4 is a cross-sectional top view of another embodiment
of the manifold;
[0019] FIG. 5 is a cross-sectional top view of another embodiment
of the manifold;
[0020] FIG. 6 is a cross-sectional top view of another embodiment
of the manifold;
[0021] FIG. 7 is a cross-sectional top view of another embodiment
of the manifold;
[0022] FIG. 8 is a cross-sectional top view of another embodiment
of the manifold;
[0023] FIG. 9 is a cross-sectional top view of another embodiment
of the manifold;
[0024] FIG. 10 is a cross-sectional top view of another embodiment
of the manifold;
[0025] FIG. 11 is a cross-sectional top view of another embodiment
of the manifold;
[0026] FIG. 12 is a cross-sectional side view of the manifold
including separators.
[0027] FIG. 13 is a fragmented side view of the manifold
illustrating one embodiment of a port connected to the
manifold;
[0028] FIG. 14 is a fragmented side view of the manifold
illustrating another embodiment of a port connected to the
manifold;
[0029] FIG. 15 is a fragmented side view of the manifold
illustrating another embodiment of a port connected to the
manifold;
[0030] FIG. 16 is a fragmented side view of the manifold
illustrating another embodiment of a port connected to the
manifold; and
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to the Figures, wherein like numerals indicate
corresponding parts throughout the several views, a heat exchanger
assembly is generally shown at 20 in FIG. 1. The heat exchanger
assembly 20 includes a first manifold 22, a second manifold 24, and
a plurality of flow tubes 26 fluidly connecting the manifolds 22,
24. A plurality of heat conducting structures are disposed between
the plurality of flow tubes 26, which are illustrated as fins 28.
As is known to those skilled in the art, the first manifold 22 may
be commonly referred to as an inlet manifold, therefore performing
an inlet function, and the second manifold 24 may be commonly
referred to as an outlet manifold, therefore performing an outlet
function, however, the opposite could be true. Reference to the
first and second manifolds 22, 24 is interchangeable in the
description of the subject invention.
[0032] The first manifold 22 includes a tank 30 having a length, a
first end 32 and a second end 34, and a header 36 adjacent the tank
30. The header 36 has a length substantially defined by the tank 30
and the tank 30 and the header 36 are joined to define a hollow
cavity 38. An end cap 40 is shown being attached to each end 32, 34
of the first end 32 of the tank 30 and the header 36. The end cap
40 can include a cladding material for joining to the tank 30 and
header 36 of the first manifold 22 using a variety of methods, such
as but not limited to, brazing or welding.
[0033] A second manifold 24 defines a hollow cavity 42. The second
manifold 24 has a length with a first end 44 and a second end 46
and is in spaced and substantially parallel relationship with the
first manifold 22. It can be readily appreciated that though the
second manifold 24 is shown as having the same general appearance
as that of the first manifold 22, the second manifold 24 can be
constructed differently than the first manifold 22, for example,
but not limited to, the second manifold 24 can comprise a single
extruded component. The end cap 40 is shown being attached to each
end 44, 46 of the second manifold 24. The end cap 40 can include a
cladding material, for joining the end cap 40 to the second
manifold 24 using a variety of methods, such as but not limited to,
brazing or welding. Though the heat exchanger assembly 20 is shown
throughout the drawings with the manifolds 22, 24 being vertically
oriented, it can be readily appreciated that the heat exchanger
assembly 20 can be oriented in a variety ways to accommodate
engineering requirements of a specific application, for instance,
horizontal.
[0034] At least one port may be in the first manifold 22 and
fluidly connected to at least one of the distribution chamber 66
and the cavity 38. The port may be an orifice or a tube, as is
known in the art. The port may be an inlet, an outlet, or a
combination of both. Referring to FIG. 1, one of the ports is an
inlet port 72 and is fluidly connected to the first manifold 22 for
introducing refrigerant into the heat exchanger and another of the
ports is an outlet port 74 and is fluidly connected to the second
manifold 24 for exiting refrigerant from the heat exchanger
assembly 20.
[0035] Referring to FIG. 2, the tank 30 has an outer wall 56
defining a channel 58 and an inner partition wall 60 disposed
within the channel 58 adjacent to the outer wall 56. The tank 30
may be manufactured in a single piece, such as by extrusion. The
outer wall 56 includes a pair of opposed longitudinal edges 50 each
including a flange 62 integral to and extending outward from the
longitudinal edges 50 forming a seat 52.
[0036] Referring to FIGS. 2-3, the header 36 includes a pair of
longitudinal edges 48 with a plurality of openings 54 sized for
accepting the plurality of flow tubes 26. The header 36 has a
generally arc-like cross-section. The openings 54 are typically
elongated slots. It can be appreciated that the plurality of
openings 54 can comprise different shapes including, but not being
limited to, circles and rectangles. The plurality of openings 54
can be produced by any means, including but not limited to,
drilling, lancing or punching. It can be readily appreciated that
where the plurality of openings 54 are produced by lancing, it is
possible to produce a dimpling effect adjacent the plurality of
openings 54, which can facilitate the positioning and joining of
the plurality of flow tubes 26 to the header 36. The header 36 can
be produced by a variety of processes, including but limited to,
stamping. Further, the header 36 can comprise a variety of
materials, including but not limited to, an alloy of aluminum.
[0037] The plurality of flow tubes 26 are mounted to the header 36
and are disposed within the cavity 38 of the first manifold 22
fluidly connecting the cavity 42 of the second manifold 24 with the
cavity 38 of the first manifold 22. In addition, the header 36 can
include cladding material, such as but limited to, an alloy of
silicon and aluminum. The cladding permits simple brazing of the
plurality of flow tubes 26 to the header 36. The longitudinal edges
48 of the header 36 are inserted into the flanges 62 of the tank 30
where the longitudinal edges 48 of the header 36 are positioned
adjacent the seats 52 and joined to the tank 30 by a process such
as brazing.
[0038] Referring to FIG. 2-3, the inner partition wall 60 has a
section 64 integrally formed with a portion of the outer wall 56 to
define a distribution chamber 66 disposed within the channel 58.
The distribution chamber 66 has a length generally defined by the
length of the tank 30 and is substantially parallel to the tank 30.
Referring to FIG. 3, the inner partition wall 60 has a generally
C-shaped cross-section. The distribution chamber 66 is disposed
within the cavity 38 directly opposite the plurality of openings 54
where the plurality of flow tubes 26 are inserted into the first
manifold 22 body. The plurality of apertures 68 are disposed within
the inner partition wall 60 and generally run along the length of
the distribution chamber 66. It can be readily appreciated that
because the inner partition wall 60 is easily accessible prior to
joining the tank 30 and the header 36, a number of configurations
are possible. The plurality of apertures 68 can comprise a variety
of shapes and sizes, as dictated by engineering requirements for a
specific application, including but not being limited to, circles
and polygons.
[0039] Referring to FIG. 4, a second thickness T.sub.2 of the outer
wall 56 of the tank 30 and a first thickness T.sub.1 of the inner
partition wall 60 of the tank 30 can be the same or can be
different from one another, and may be primarily dictated by burst
pressure requirements. In addition, the second thickness T.sub.2 of
the outer wall 56 can be uniform or may vary. Similarly, the first
thickness T.sub.1 of the inner partition wall 60 can be uniform or
may vary. A reduced first thickness T.sub.1 may be possible because
of the lower operating pressure between the cavity 38 and the
distribution chamber 66, and can save space, weight, and cost. It
may be advantageous to have the second thickness T.sub.2 of the
header 34 where the plurality of flow tubes 26 are joined be
thinner than other portions of the tank 28, as also shown in FIG.
4. Though the cross-section of the outer wall 56 is generally
illustrated as being circular, it can be readily appreciated that
the outer wall 56 can be a variety of shapes. Referring to FIGS.
5-7, the cross-section of the outer wall 56 can include a
protrusion, can be generally rectangular, or include additional
structural support elements. Similarly, though the header 34 is
generally illustrated as having an arc-like cross-section, it can
be appreciated that the header 36 can have a cross-section that is
more generally linear.
[0040] Referring to FIG. 6, in yet another embodiment, the flange
62 is shown having an L-shaped cross-section, forming a notched
seat 52. It can be readily appreciated that the dimensions of the
flange 62 can vary depending on the requirements of the
application.
[0041] Though the preferred embodiment describes the inner
partition wall 60 having a C-shaped cross-section, it can be
readily appreciated that other configurations are possible.
Referring to FIGS. 7-8, the inner partition wall 60 can have an
arc-like or linear cross-section, depending on the requirements of
the application. Alternatively, the formation of the plurality of
apertures 68 can be facilitated by forming a ledge 70 along the
length of the inner partition wall 60, as illustrated in FIGS.
9-10. It can further be appreciated that the distribution chamber
66 can be offset from the plurality of flow tubes 26 as illustrated
in FIG. 11. This flexibility in the positioning of the distribution
chamber 66 makes it possible to accommodate variations in plumbing,
flow and refrigerant distribution requirements.
[0042] Referring to FIG. 12, a separator 76 can be inserted within
the cavity 38 and/or distribution chamber 66 further dividing the
cavity 38 and distribution chamber 66.
[0043] Referring to FIGS. 13-16, alternative port 72, 74 placements
are illustrated. At least one port 72, 74 may be adjacent at least
one of the outer wall 56 and the end cap 40 and fluidly connected
to at least one of the distribution chamber 66 and the cavity 38,
42. The inlet port 72 may be fluidly connected to the distribution
chamber 66, through the end cap 40 or the outer wall 56 of the tank
30. Similarly, both the inlet port 72 and the outlet port 74 may be
fluidly connected to the cavity 38 of the first manifold 22 through
the outer wall 56 of the tank 30 or through the end cap 40. It can
be appreciated that the ports 72, 74 may be fluidly connected to
the cavity through the distribution chamber. It can be appreciated
that the ports 72, 74 can include a coupler 78. The coupler 78 may
be useful for connecting external plumbing to the heat exchanger
assembly 20 and may also be useful for manufacturing purposes. It
can further be appreciated that the ports 72, 74 can be fluidly
connected to the second manifold 24 as described for the first
manifold 22, depending on the requirements of a specific
application. It can further be appreciated that more than one inlet
port 72 can be used to introduce refrigerant into the heat
exchanger assembly 20 and more than one outlet port 74 can be used
to exit refrigerant from the heat exchanger assembly 20.
[0044] The present invention also provides a method of
manufacturing a tank 30 having an outer wall 56 defining a channel
58, and an inner partition wall 60 with a plurality of apertures
68. The method includes the step of extruding the tank 30 having
the outer wall 56 and the inner partition wall 60 with the inner
partition wall 60 integrally connected to the outer wall 56 to form
a distribution chamber 66. The method further includes the step of
cutting the tank 30 to a predetermined length. Cutting can be
accomplished by any means. The method further includes the step of
forming a plurality of apertures 68 in the inner partition wall 60.
The plurality of apertures 68 can be produced by any means,
including but not limited to, drilling, lancing or punching.
[0045] The present invention also provides a method of
manufacturing a manifold having a tank 30 with an outer wall 56
defining a channel 58 and an inner partition wall 60 with a
plurality of apertures 68, a header 36 having a plurality of
openings 54, and at least one end cap 40. The method includes the
step of extruding the tank 30 having the outer wall 56 and the
inner partition wall 60 with the inner partition wall 60 integrally
connected to the outer wall 56 to form a distribution chamber 66.
The method further includes the step of cutting the tank 30 to a
predetermined length. The tank 30 can be cut using any means. The
method further includes the step of forming a plurality of
apertures 68 in the inner partition wall 60. The plurality of
apertures 68 can be produced by any means, including but not
limited to, drilling, lancing or punching. The method further
includes the step of forming a plurality of openings 54 in the
header 36. This step may be accomplished by a variety of means,
including but not limited to forming the plurality of openings 54
when the header 36 is formed. The plurality of openings 54 can be
produced by any means, including but not limited to, drilling,
lancing or punching. The method further includes the step of
joining the tank 30 and the header 36. Joining can be accomplished
by a process such as welding and brazing, but is not limited to
these processes. The method further includes the step of joining
the end cap 40 to one end of the tank 30 and the header 36. Joining
the end cap 40 can be accomplished by a process such as welding and
brazing, but is not limited to these processes.
[0046] Obviously, many modifications and variations of the present
invention are possible in light of the above teachings without
departing from the essential scope thereof. Therefore, it is
intended that the invention not be limited to the particular
embodiment disclosed, but that the invention will include all
embodiments falling within the scope of the appended claims. The
reference numerals are merely for convenience and are not to be
read in any way as limiting.
* * * * *