U.S. patent application number 16/275081 was filed with the patent office on 2019-06-13 for multiple tube bank heat exchange unit with manifold assembly.
The applicant listed for this patent is Carrier Corporation. Invention is credited to Arindom Joardar, Bruce J. Poplawski, Tobias H. Sienel, Michael F. Taras, Mel Woldesemayat.
Application Number | 20190178580 16/275081 |
Document ID | / |
Family ID | 49780349 |
Filed Date | 2019-06-13 |
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United States Patent
Application |
20190178580 |
Kind Code |
A1 |
Taras; Michael F. ; et
al. |
June 13, 2019 |
MULTIPLE TUBE BANK HEAT EXCHANGE UNIT WITH MANIFOLD ASSEMBLY
Abstract
A multiple bank, flattened tube heat exchange unit includes a
first tube bank including a plurality of flattened tube segments
extending longitudinally in spaced parallel relationship between a
first manifold and a second manifold and a second tube bank
including a plurality of flattened tube segments extending
longitudinally in spaced parallel relationship between a first
manifold and a second manifold, the second tube bank disposed
behind the first tube bank. The second manifold of the first tube
bank and the second manifold of the second tube bank form a
manifold assembly wherein an interior volume of the second manifold
of the first tube bank and an interior volume of the second
manifold of the second tube bank of the manifold assembly are
internally connected in fluid communication.
Inventors: |
Taras; Michael F.;
(Fayetteville, NY) ; Joardar; Arindom;
(Jamesville, NY) ; Sienel; Tobias H.;
(Baldwinsville, NY) ; Woldesemayat; Mel;
(Liverpool, NY) ; Poplawski; Bruce J.; (Mattydale,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Carrier Corporation |
Palm Beach Gardens |
FL |
US |
|
|
Family ID: |
49780349 |
Appl. No.: |
16/275081 |
Filed: |
February 13, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14763557 |
Jul 27, 2015 |
10247481 |
|
|
PCT/US2013/071644 |
Nov 25, 2013 |
|
|
|
16275081 |
|
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|
|
61757273 |
Jan 28, 2013 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28D 1/0417 20130101;
B23P 15/26 20130101; F28D 1/05391 20130101; F28D 1/05358 20130101;
F28F 9/0214 20130101; F28D 1/0435 20130101 |
International
Class: |
F28D 1/04 20060101
F28D001/04; F28D 1/053 20060101 F28D001/053; F28F 9/02 20060101
F28F009/02; B23P 15/26 20060101 B23P015/26 |
Claims
1. A method of forming an integral manifold assembly for a multiple
bank heat exchanger, comprising: extruding a dual-barrel manifold
having a first tubular barrel and a second tubular barrel in spaced
parallel relationship and a central web member interconnecting the
first and second tubular barrels; forming an opening in a wall of
one of the first and second tubular barrels opposite the central
web member; inserting a drill bit through said opening and drilling
a hole transversely through the central web member to form a bore
opening in fluid communication with an interior volume of the first
tubular barrel and an interior volume of the second tubular barrel;
and plugging said opening after withdrawing the drill bit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 14/763,557 filed Jul. 27, 2015, which is a National Stage
Application of PCT/US2013/071644, filed Nov. 25, 2013, which claims
the benefit of U.S. Provisional Application No. 61/757,273 filed
Jan. 28, 2013, all of which are incorporated herein by reference in
their entirety.
BACKGROUND
[0002] This invention relates generally to heat exchangers and,
more particularly, to multiple tube bank heat exchange unit
incorporating a manifold assembly.
[0003] Heat exchangers have long been used as evaporators and
condensers in heating, ventilation, air conditioning and
refrigeration (HVACR) applications. Historically, these heat
exchangers have been round tube and plate fin (RTPF) heat
exchangers. However, all aluminum flattened tube serpentine fin
heat exchangers are finding increasingly wider use in industry,
including the HVACR industry, due to their compactness,
thermal-hydraulic performance, structural rigidity, lower weight
and reduced refrigerant charge, in comparison to conventional RTPF
heat exchangers. Flattened tubes commonly used in HVACR
applications typically have an interior subdivided into a plurality
of parallel flow channels. Such flattened tubes are commonly
referred to in the art as multi-channel tubes, mini-channel tubes
or micro-channel tubes.
[0004] A typical flattened tube serpentine fin heat exchanger
includes a first manifold, a second manifold, and a single tube
bank formed of a plurality of longitudinally extending flattened
heat exchange tubes disposed in spaced parallel relationship and
extending between the first manifold and the second manifold. The
first manifold, second manifold and tube bank assembly is commonly
referred to in the heat exchanger art as a slab. Additionally, a
plurality of fins are disposed between the neighboring pairs of
heat exchange tubes for increasing heat transfer between a fluid,
commonly air in HVACR applications, flowing over the outside
surfaces of the flattened tubes and along the fin surfaces and a
fluid, commonly refrigerant in HVACR applications, flowing inside
the flattened tubes. Such single tube bank heat exchangers, also
known as single slab heat exchangers, have a pure cross-flow
configuration.
[0005] Double bank flattened tube and serpentine fin heat
exchangers are also known in the art. Conventional double bank
flattened tube and serpentine fin heat exchangers are typically
formed of two conventional fin and tube slabs, one spaced behind
the other, with fluid communication between the manifolds
accomplished through external piping. However, to connect the two
slabs in fluid flow communication in other than a parallel
cross-flow arrangement requires complex external piping. For
example, U.S. Pat. No. 6,964,296 B2 and U.S. Patent Application
Publication 2009/0025914 A1 disclose embodiments of double bank,
multichannel flattened tube heat exchanger.
BRIEF DESCRIPTION
[0006] In an aspect, a multiple bank, flattened tube heat exchange
unit includes a first tube bank including a plurality of flattened
tube segments extending longitudinally in spaced parallel
relationship between a first manifold and a second manifold and a
second tube bank including a plurality of flattened tube segments
extending longitudinally in spaced parallel relationship between a
first manifold and a second manifold, the second tube bank disposed
behind the first tube bank. The second manifold of the first tube
bank and the second manifold of the second tube bank form a
manifold assembly wherein an interior volume of the second manifold
of the first tube bank and an interior volume of the second
manifold of the second tube bank of the manifold assembly are
connected in fluid communication internally, that is not through
external piping.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For further understanding of the disclosure, reference will
be made to the following detailed description which is to be read
in connection with the accompanying drawing, where:
[0008] FIG. 1 is a diagrammatic illustration of an embodiment of a
multiple tube bank, flattened tube finned heat exchange unit as
disclosed herein;
[0009] FIG. 2 is a side elevation view, partly in section,
illustrating an embodiment of a fin and a set of integral flattened
tube segment assemblies of the heat exchange unit of FIG. 1;
[0010] FIG. 3 is a top plan view of an embodiment single pass,
multiple pass counter crossflow embodiment of the heat exchange
unit of FIG. 1;
[0011] FIG. 4 is a top plan view of an embodiment single pass,
single pass counter crossflow embodiment of the heat exchange unit
of FIG. 1;
[0012] FIG. 5 is a sectioned plan view of an embodiment of a
manifold assembly of paired generally D-shaped tubular manifolds at
the intermediate side of the heat exchanger unit of FIG. 1
connected in fluid communication through a block insert disposed
therebetween;
[0013] FIG. 6 is a sectioned plan view of an embodiment of a
manifold assembly of paired generally cylindrical tubular manifolds
at the intermediate side of the heat exchanger unit of FIG. 1
connected in fluid communication through a block insert disposed
therebetween;
[0014] FIG. 7 is a sectioned plan view of an embodiment of a
manifold assembly of paired generally cylindrical tubular manifolds
at the intermediate side of the heat exchanger unit of FIG. 1
connected in fluid communication through a plurality of individual
tubular members extending therebetween;
[0015] FIG. 8 is a sectioned plan view of another embodiment of a
manifold assembly of paired generally tubular manifolds at the
intermediate side of the heat exchanger unit of FIG. 1 connected in
fluid communication through a plurality of individual tubular
members extending therebetween;
[0016] FIG. 9 is a sectioned plan view of another embodiment of a
manifold assembly of a full tubular manifold and a partially open
tubular manifold disposed in interfacing abutting relationship at
the intermediate side of the heat exchanger unit of FIG. 1;
[0017] FIGS. 10A and 10B are sectioned plan views of alternate
embodiments of a manifold assembly of paired partially open tubular
manifolds joined in engaging relationship at the intermediate side
of the heat exchanger unit of FIG. 1;
[0018] FIG. 11 is a sectioned plan view of another embodiment of a
manifold assembly of paired partially open tubular manifolds joined
in interfacing abutting relationship at the intermediate side of
the heat exchanger unit of FIG. 1;
[0019] FIG. 12 is a sectioned plan view of an embodiment of a
manifold assembly of paired partially open tubular manifolds
interconnected in fluid communication through a flow passage
through a single block insert disposed between the manifolds;
[0020] FIG. 13 is a sectioned plan view of an embodiment of a
manifold assembly of paired partially open tubular manifolds
interconnected in fluid communication through a flow passage formed
by two block inserts;
[0021] FIG. 14 is a sectioned plan view of an embodiment of a
manifold assembly of paired partially open tubular manifolds
interconnected in fluid communication through a flow passage
through a block insert disposed internally at the interface between
the manifolds;
[0022] FIG. 15 is a perspective view of a cladded sheet from which
an integral folded manifold assembly may be formed;
[0023] FIG. 16 is a sectioned plan view of an embodiment of a
generally tubular integral folded manifold assembly formed of a
single folded sheet;
[0024] FIG. 17 is a sectioned plan view of another embodiment of a
generally tubular integral folded manifold assembly formed of a
single folded sheet;
[0025] FIG. 18 is a sectioned plan view of another embodiment of a
generally tubular integral folded manifold assembly formed of a
single folded sheet;
[0026] FIG. 19 is a sectioned plan view of an embodiment of an
extruded dual-barrel embodiment of an integral manifold
assembly;
[0027] FIG. 20 is a sectioned plan view of an embodiment of a
fabricated flat integral manifold assembly defining a single fluid
chamber;
[0028] FIG. 21 is a sectioned plan view of an embodiment of a
fabricated flat integral manifold assembly defining a pair of fluid
chambers; and
[0029] FIGS. 22A-D are sectioned plan views of various exemplary
embodiments of a fabricated flat integral assembly formed from a
single folded sheet.
DETAILED DESCRIPTION
[0030] An exemplary embodiment of a multiple bank flattened tube
finned heat exchanger unit in accordance with the disclosure,
generally designated 10, is depicted in perspective illustration in
FIG. 1. As depicted therein, the multiple bank flattened tube
finned heat exchanger 10 includes a first tube bank 100 and a
second tube bank 200 that is disposed behind the first tube bank
100, that is downstream with respect to air flow, A, through the
heat exchanger. The first tube bank 100 may also be referred to
herein as the front heat exchanger slab 100 and the second tube
bank 200 may also be referred to herein as the rear heat exchanger
slab 200.
[0031] The first tube bank 100 includes a first manifold 102, a
second manifold 104 spaced apart from the first manifold 102, and a
plurality of heat exchange tube segments 106, including at least a
first and a second tube segment, extending longitudinally in spaced
parallel relationship between and connecting the first manifold 102
and the second manifold 104 in fluid communication. The second tube
bank 200 includes a first manifold 202, a second manifold 204
spaced apart from the first manifold 202, and a plurality of heat
exchange tube segments 206, including at least a first and a second
tube segment, extending longitudinally in spaced parallel
relationship between and connecting the first manifold 202 and the
second manifold 204 in fluid communication. As will be described in
further detail herein later, each set of manifolds 102, 202 and
104, 204 disposed at either side of the dual bank heat exchanger 10
may comprise separate paired manifolds, may comprise separate
chambers within an integral one-piece folded manifold assembly or
may comprise separate chambers within an integral fabricated (e.g.
extruded, drawn, rolled and welded) manifold assembly. Each tube
bank 100, 200 may further include "dummy" tubes (not shown)
extending between its first and second manifolds at the top of the
tube bank and at the bottom of the tube bank. These "dummy" tubes
do not convey refrigerant flow, but add structural support to the
tube bank and protect the uppermost and lowermost fins.
[0032] Referring now to FIG. 2, each of the heat exchange tube
segments 106, 206 comprises a flattened heat exchange tube having a
leading edge 108, 208, a trailing edge 110, 210, an upper surface
112, 212, and a lower surface 114, 214. The leading edge 108, 208
of each heat exchange tube segment 106, 206 is upstream of its
respective trailing edge 110, 210 with respect to airflow through
the heat exchanger 10. In the embodiment depicted in FIG. 2, the
respective leading and trailing portions of the flattened tube
segments 106, 206 are rounded thereby providing blunt leading edges
108, 208 and trailing edges 110, 210. However, it is to be
understood that the respective leading and trailing portions of the
flattened tube segments 106, 206 may be formed in other
configurations.
[0033] The interior flow passage of each of the heat exchange tube
segments 106, 206 of the first and second tube banks 100, 200,
respectively, may be divided by interior walls into a plurality of
discrete flow channels 120, 220 that extend longitudinally the
length of the tube from an inlet end of the tube to an outlet end
of the tube and establish fluid communication between the
respective headers of the first and the second tube banks 100, 200.
In the embodiment of the multi-channel heat exchange tube segments
106, 206 depicted in FIG. 2, the heat exchange tube segments 206 of
the second tube bank 200 have a greater width than the heat
exchange tube segments 106 of the first tube bank 100. Also, the
interior flow passages of the wider heat exchange tube segments 206
may be divided into a greater number of discrete flow channels 220
than the number of discrete flow channels 120 into which the
interior flow passages of the heat exchange tube segments 106 are
divided. The flow channels 120, 220 may have a circular
cross-section, a rectangular cross-section or other non-circular
cross-section.
[0034] The second tube bank 200, i.e. the rear heat exchanger slab,
is disposed behind the first tube bank 100, i.e. the front heat
exchanger slab, with respect to the airflow direction, with each
heat exchange tube segment 106 directly aligned with a respective
heat exchange tube segment 206 and with the leading edges 208 of
the heat exchange tube segments 206 of the second tube bank 200
spaced from the trailing edges 110 of the heat exchange tube
segments of the first tube bank 100 by a desired spacing, G. A
spacer or a plurality of spacers disposed at longitudinally spaced
intervals may be provided between the trailing edges 110 of the
heat exchange tube segments 106 and the leading edges 208 of the
heat exchange tube segments 206 to maintain the desired spacing, G,
during brazing of the preassembled heat exchanger unit 10 in a
brazing furnace.
[0035] In the embodiment depicted in FIG. 2, an elongated web 40 or
a plurality of spaced web members 40 span the desired spacing, G,
along at least of portion of the length of each aligned set of heat
exchange tube segments 106, 206. For a further description of a
dual bank, flattened tube finned heat exchanger unit wherein the
heat exchange tubes 106 of the first tube bank 100 and the heat
exchange tubes 206 of the second tube bank 200 are connected by an
elongated web or a plurality of web members, reference is made to
U.S. provisional application Ser. No. 61/593,979, filed Feb. 2,
2012, the entire disclosure of which is hereby incorporated herein
by reference.
[0036] Referring still to FIGS. 1 and 2, the flattened tube finned
heat exchanger 10 disclosed herein further includes a plurality of
folded fins 320. Each folded fin 320 is formed of a single
continuous strip of fin material tightly folded in a ribbon-like
serpentine fashion thereby providing a plurality of closely spaced
fins 322 that extend generally orthogonal to the flattened heat
exchange tubes 106, 206. Typically, the fin density of the closely
spaced fins 322 of each continuous folded fin 320 may be about 16
to 25 fins per inch, but higher or lower fin densities may also be
used. Heat exchange between the refrigerant flow, R, and air flow,
A, occurs through the outside surfaces 112, 114 and 212, 214,
respectively, of the heat exchange tube segments 106, 206,
collectively forming the primary heat exchange surface, and also
through the heat exchange surface of the fins 322 of the folded fin
320, which forms the secondary heat exchange surface.
[0037] In the depicted embodiment, the depth of each of the
ribbon-like folded fin 320 extends at least from the leading edge
108 of the first tube bank 100 to the trailing edge of 210 of the
second bank 200, and may overhang the leading edge 108 of the first
tube bank 100 or/and trailing edge 208 of the second tube bank 200
as desired. Thus, when a folded fin 320 is installed between a set
of adjacent multiple tube, flattened heat exchange tube assemblies
240 in the array of tube assemblies of the assembled heat exchanger
10, a first section 324 of each fin 322 is disposed within the
first tube bank 100, a second section 326 of each fin 322 spans the
spacing, G, between the trailing edge 110 of the first tube bank
100 and the leading edge 208 of the second tube bank 200, and a
third section 328 of each fin 322 is disposed within the second
tube bank 200. In an embodiment, each fin 322 of the folded fin 320
may be provided with louvers 330, 332 formed in the first and third
sections, respectively, of each fin 322.
[0038] The multiple bank, flattened tube heat exchange unit 10
disclosed herein is depicted in a cross-counterflow arrangement
wherein refrigerant (labeled "R") from a refrigerant circuit (not
shown) of a refrigerant vapor compression system (not shown) passes
through the manifolds and heat exchange tube segments of the tube
banks 100, 200, in a manner to be described in further detail
hereinafter, in heat exchange relationship with a cooling media,
most commonly ambient air, flowing through the airside of the heat
exchanger 10 in the direction indicated by the arrow labeled "A"
that passes over the outside surfaces of the heat exchange tube
segments 106, 206 and the surfaces of the folded fin strips 320.
The air flow first passes transversely across the upper and lower
horizontal surfaces 112, 114 of the heat exchange tube segments 106
of the first tube bank, and then passes transversely across the
upper and lower horizontal surfaces 212, 214 of the heat exchange
tube segments 206 of the second tube bank 200. The refrigerant
passes in cross-counterflow arrangement to the airflow, in that the
refrigerant flow passes first through the second tube bank 200 and
then through the first tube bank 100. The multiple tube bank,
flattened tube finned heat exchanger 10 having a cross-counterflow
circuit arrangement yields superior heat exchange performance, as
compared to the crossflow or cross-parallel flow circuit
arrangements, as well as allows for flexibility to manage the
refrigerant side pressure drop via implementation of tubes of
various widths within the first tube bank 100 and the second tube
bank 200.
[0039] In the embodiment depicted in FIGS. 1 and 3, the second tube
bank 200, i.e. the rear heat exchanger slab with respect to air
flow, has a single-pass refrigerant circuit configuration and the
first tube bank 100, i.e. the front heat exchanger slab with
respect to air flow, has a two pass configuration. Refrigerant flow
passes from a refrigerant circuit (not shown) into the first
manifold 202 of the second tube bank 200 through at least one
refrigerant inlet 222 (FIG. 3), passes through the heat exchange
tube segments 206 into the second manifold 204 of the second tube
bank 200, then passes into the second manifold 104 of the first
tube bank 100, thence through a lower set of the heat exchange
segments 106 into the first manifold 102 of the first tube bank
100, thence back to the second manifold 104 through an upper set of
the heat exchange tubes 106, and thence passes back to the
refrigerant circuit through at least one refrigerant outlet
122.
[0040] In the embodiment depicted in FIG. 4, the second tube bank
200, i.e., the rear heat exchanger slab with respect to air flow,
has a single-pass refrigerant circuit configuration and the first
tube bank 100, i.e. the front heat exchanger slab with respect to
air flow, also has a single pass configuration. Refrigerant flow
passes from a refrigerant circuit (not shown) into the first
manifold 202 of the second tube bank 200 through at least one
refrigerant inlet 222, passes through the heat exchange tube
segments 206 into the second manifold 204 of the second tube bank
200, then passes into the second manifold 104 of the first tube
bank 100, thence passes through the heat exchange segments 106 into
the first manifold 102 of the first tube bank 100, and thence
passes back to the refrigerant circuit through at least one
refrigerant outlet 122.
[0041] In the embodiments depicted in FIGS. 1, 3 and 4, the
neighboring second manifolds 104 and 204 are connected in fluid
flow communication such that refrigerant may flow from the interior
of the second manifold 204 of the second tube bank 200 into the
interior of the second manifold 104 of the first tube bank 100. In
an embodiment, the second manifold 104 of the first tube bank 100
has a plurality of longitudinally aligned ports, e.g., holes 244
(FIG. 5), drilled, milled or punched through the wall thereof and
disposed at longitudinally spaced intervals. Similarly, the second
manifold 204 of the second tube bank 200 has a plurality of
longitudinally aligned ports, e.g., holes 246 (FIG. 5), equal in
number to the plurality of holes 244 in the second manifold 104 of
the first tube bank 100, drilled, milled or punched through the
wall thereof and disposed at longitudinally spaced intervals. Each
port 244 forms a flow passage through the wall of the second
manifold 104 and each port 246 forms a flow passage through the
wall of the second manifold 204. When the heat exchanger unit 10 is
assembled, each flow passage, i.e. port 246, in the second manifold
204 aligns with a respective one of the flow passages, i.e. port
244, of the first manifold 104. It should be understood that the
ports 244, 246 may be holes of the same size, however certain
design configuration may benefit of the holes being of different
sizes.
[0042] In the embodiment depicted in FIG. 5, a block insert 240
having a central passage 242 extending longitudinally therethrough
is positioned between the manifolds 104 and 204 is positioned such
that the central passage 242 aligns with ports 244 and 246 formed
through the respective walls of the manifolds 104 and 204,
respectively, and spans the longitudinally expanse of the
longitudinally spaced ports 244 and 246. So assembled, a plurality
of continuous flow passages are established through which
refrigerant may pass from the interior of the second manifold 204
of the second tube bank 200 through the port 246, thence through
the central passage 242 of the block insert 240, and thence through
the port 244 into the interior of the second manifold 104 of the
first tube bank 100. In this embodiment, the block insert 240 may
comprise a longitudinally elongated block having a single
longitudinally extending slot forming a longitudinally elongated
central passage 242 that interfaces with all of the plurality of
ports 244 and 246. Alternatively, a longitudinally elongated
central passage 242 that interfaces with ports 244 and 246 may be
represented by a plurality of slots, each slot spanning only a
portion of the aligned ports 244 and 246. In the embodiment
depicted in FIG. 5, the first and second manifolds 104, 204 are
both generally D-shaped manifolds disposed in back-to-back spaced
relationship with a generally rectangular block insert 242 disposed
between the first and second manifolds 104, 204.
[0043] In the embodiment depicted in FIG. 6, the first and second
manifolds 104, 106 are both cylindrical manifolds disposed in
side-to-side spaced relationship with a contoured block insert 240.
In this embodiment, the side faces 248 of the block insert 240 are
contoured concave inwardly to match and mate with the contour of
the external surface of the respective abutting second manifolds.
In this embodiment, the block insert 240 may comprise a
longitudinally elongated block having a pair of laterally spaced,
longitudinally extending slots forming longitudinally elongated
flow passages 248 and having a plurality of longitudinally spaced
bores 245 interconnecting the laterally spaced flow passages 248 in
fluid communication. The bores 245 may be disposed in alignment
with the ports 244 and 246 in the first and second manifolds 104,
204, respectively. In either of the embodiments depicted in FIGS. 5
and 6, the block insert 240 is metallurgically bonded, for example
by brazing or welding, to each of the second manifolds 104 and 204.
It should be understood that brazing can be accomplished during
furnace brazing of the entire heat exchanger construction.
[0044] In the embodiments depicted in FIGS. 7 and 8, the second
manifolds 104 and 204 are connected in fluid communication through
a plurality of individual tubular members 250 interconnecting the
plurality of aligned pairs of ports 244 and 246 in the first and
second manifolds 104, 204, respectively. Each tubular member 250
extends through a respective one of the plurality of longitudinally
spaced sets of aligned ports 244 and 246, whereby each tubular
member forms a flow passage 252 between the interior of the second
manifold 204 of the second tube bank 200 and the interior of the
second manifold 104 of the first tube bank 100. In the embodiments
as depicted in FIGS. 7 and 8, the tubular member 250 has a tubular
first end 256 and a tubular second end 258 and a radially outwardly
directed flange 260 extending circumferentially about a mid-portion
of the tubular member 250 between the first end 256 and the second
end 258. In the embodiment as depicted in FIG. 7, the first end 256
extends through a port 244 in the manifold 104 and the second end
258 extends through a port 246 in the manifold 24 and each tubular
member 250 may be metallurgically bonded to the manifolds 104 and
204, for example by brazing during brazing of the entire heat
exchanger assembly in a brazing furnace. Additionally, the
thickness of the flange 260 may be sized to ensure a desired
spacing between the second manifolds 104 and 204.
[0045] In the embodiment depicted in FIG. 8, the first end 256 of
each tubular member 250 is threaded and is inserted into a
respective one of a plurality of threaded sockets provided in a
longitudinally extending block 254. Each socket is aligned with a
respective one of the ports 244 in the manifold 104. The second end
258 of each tubular member 250 is inserted into a respective one of
the ports 246 in the manifold 204. The block 254 and the second end
258 are metallurgically bonded to the manifold 104 and the manifold
204, respectively, for example by brazing during brazing of the
entire heat exchanger assembly in a brazing furnace. In this
embodiment, the flange 260 may be hexagonal, octagonal or otherwise
shaped to accommodate a wrench or other tool by which the tubular
member 250 may be screwed into a respective one of the threaded
holes of the longitudinally extended block 254.
[0046] In each of the embodiments depicted in FIGS. 5-8, the paired
tubular manifolds 104 and 204 in fluid communication through the
plurality of longitudinally spaced, aligned and interfacing sets of
ports 244 and 246 that are connected through a passage or passages
provided in one or more inserts 240, 260 disposed between and
brazed to the paired manifolds 104, 204, rather than being
connected via external piping. The size, number and spacing of the
ports 244, 246, as well as the thickness of the wall of the tubular
manifolds 104, 204, may be selected to satisfy structural
considerations. The cross-sectional area of the ports 244, 246 may
be sized to satisfy thermo-hydraulic considerations.
[0047] Referring now to FIG. 9, there is depicted an embodiment of
a fabricated integral manifold assembly 270 wherein one of the
second manifolds 104, 204 is a full tubular manifold and the other
of the second manifolds 104, 204 is a partially tubular manifold
being open longitudinally along its entire length over a sector of
the circumference of the manifold. The fully tubular manifold,
shown in FIG. 9 as being the second manifold 204 of the second
manifold 200, has a plurality of longitudinally aligned holes or
slots 274 drilled, milled or punched through the wall thereof and
disposed at longitudinally spaced intervals. The partially tubular
manifold, shown in FIG. 9 as being the second manifold 104 of the
first manifold 100, is disposed side-by-side along the fully
tubular manifold 204 with the longitudinally open sector straddling
the plurality of holes or slots 274 machined through the wall of
the second manifold 204 there by establishing fluid flow
communication between the respective interior chambers of the
second manifolds 104 and 204.
[0048] The partially tubular manifold and the fully tubular
manifold are metallurgically bonded, such as by brazing or welding,
along the interfaces of the partially tubular manifold with the
fully tubular manifold to form the integral manifold assembly 270.
A conventional roll and weld process may be used for both the fully
tubular manifold and the partially tubular manifold. The
longitudinal sides 276 extending along the open sector of the
partially tubular manifold may be flared outwardly and contoured to
provide a mating interface with the fully tubular manifold.
[0049] Referring now to FIGS. 10-11, there are depicted various
exemplary embodiments of a fabricated integral manifold assembly
270 wherein at least one or both of the second manifolds 104, 204
comprises a partially tubular manifold being open longitudinally
along its entire length or a portion of the entire length over a
sector of the circumference/perimeter of the manifold. The two
manifolds 104, 204, which may be formed by extrusion, are
metallurgically bonded together along a brazing joint 275 to form
the fabricated integral manifold assembly 270. In the embodiments
shown in FIGS. 10A and 10B, the manifolds 104 and 204 are extruded
with flanges 272 and 276, respectively, flanking their respective
longitudinally extending open portions. The manifolds 104 and 204
are assembled together with the flanges of one of the manifolds
104, 204 inserted within the flanges of the other of the manifolds
104, 204 to interface along a joint 275 and to form a flow passage
274 interconnecting the respective interiors of the manifolds 104,
204. The manifolds 104, 204 can be metallurgically bonded together
along the joint 275 by brazing during brazing of the entire heat
exchanger assembly in a brazing furnace. In an embodiment, both of
the manifolds 104, 204 are extruded as partially tubular manifolds
being open longitudinally along its entire length over a sector of
the circumference/perimeter of the manifold. In an embodiment, one
of the manifolds, i.e. the manifold 104 in FIG. 10A and the
manifold 204 in FIG. 10B, is extruded as a circumferentially closed
tubular member having a plurality of longitudinally spaced, aligned
holes that are disposed in fluid communication with the open sector
of the other manifold when the heat exchanger is assembled prior to
brazing the entire heat exchanger assembly.
[0050] In the embodiment of the fabricated integral manifold
assembly 270 depicted in FIG. 11, the two manifolds 104, 204 are
assembled in abutting relationship with their respective open
portions facing each other to form a flow passage 274 and with
their wall portions flanking their respective open portions
interfacing along joints 275 along which the manifolds 104, 204 are
metallurgically bonded together along the joint 275 by brazing
during brazing of the entire heat exchanger assembly in a brazing
furnace. In another embodiment of the fabricated integral manifold
assembly depicted in FIG. 11, one or both of the manifolds 104, 204
may be formed as a fully closed tubular member having a plurality
of longitudinally spaced, aligned holes instead of being a
partially open tubular manifold having a open sector extending the
length thereof.
[0051] Referring now to FIGS. 12-14, there are depicted embodiments
of a fabricated integral manifold assembly 270 wherein both of the
manifolds 104, 204 are formed as partially open tubular manifolds
being open longitudinally along its entire length over a sector of
the circumference/perimeter of the manifold. In the embodiment of
the fabricated integral manifold assembly 270 depicted in FIGS. 12
and 13, the two manifolds 104, 204 are assembled in spaced
relationship with their respective open portions facing each other.
In the embodiment depicted in FIG. 12, a longitudinally extending
block insert 278 having a plurality of bores 277 extending
transversely therethrough is disposed between the two manifolds
104, 204 to form a plurality of flow passages 274 between the
interiors of the manifolds 104, 204. The block insert 278 is brazed
to the interfacing outer wall portions of the manifolds 104, 204 to
form joints 275. In the embodiment of the fabricated integral
manifold assembly 270 depicted in FIG. 13, a pair of longitudinally
extending block inserts 279 is disposed in spaced relationship
between the spaced open manifolds 104, 204 so as to form a flow
passage 274 between the interiors of the manifolds 104, 204. The
block inserts 279 are brazed to the interfacing wall portions of
the manifolds 104, 204 to form joints 275. In the embodiment
depicted in FIG. 14, a longitudinally extending block insert 278
having a plurality of longitudinally spaced bores 277 extending
transversely therethrough is disposed internally between the
respective flanges 272, 276 of the two manifolds 104, 204 to form a
plurality of flow passages 274 between the interiors of the
manifolds 104, 204. The block insert 278 is brazed to the
interfacing inner wall portion of the flanges of the manifolds 104,
204.
[0052] The manifold assembly disclosed herein may also be formed
from a single metal sheet as an integral folded manifold assembly.
Referring to a FIG. 15, the single sheet 286 of aluminum alloy from
which the integral folded manifold assembly is formed is clad with
a layer 285 of suitable brazing alloy and provided with a plurality
of first ports 281 and a plurality of second ports 283. The ports
281 and 283 may comprise pre-drilled, pre-milled or pre-punched
round holes or pre-fabricated elliptical, racetrack, rectangular,
triangular or any other cross-section suitable for a particular
manufacturing process and heat exchanger design configuration. To
form the integral folded manifold assembly 280, the sheet 286 is
folded upon itself such as the wall portions 282, 284 interface in
side-by-side relationship such as illustrated in FIG. 10 or in FIG.
11, whereby each one of the plurality of first ports 281 registers
with a corresponding one of the plurality of second ports 283. The
interfacing surfaces of the cladded wall portions 282 and 284 are
metallurgically bonded together when the assembled heat exchanger
unit 10 is brazed in the brazing furnace, for example a controlled
atmosphere brazing furnace.
[0053] Referring now to FIGS. 16, 17 and 18, there are depicted
various exemplary embodiments of an integral folded manifold
assembly 280 formed from a single folded sheet 286. The first
manifold 104 and the second manifold 204 are formed in an integral
folded manifold assembly 280 with respective wall portions 282, 284
of the manifolds 104, 204 disposed in interfacing side-by-side
abutting relationship with a plurality of first ports 281 formed in
the wall portion 282 being in registration with a similar plurality
of second ports 283 formed in the interfacing wall portion 284. The
respective pairs of aligned ports 281 and 283 form flow passages
establishing internal fluid flow communication through which
refrigerant may pass from the second manifold 204 into the first
manifold 104. In each embodiment depicted in FIGS. 16, 17 and 18,
the integral folded manifold assembly 280 is formed by folding a
single sheet 286 of clad aluminum alloy onto itself and
metallurgically bonding the overlapping or abutting portions of the
folded sheet to each other along a brazing joint 275. This allows
for a single braze operation of the manifold and heat exchanger
core during the furnace braze process. Furthermore, one set of the
first ports 281 or second ports 283 can be slightly oversized in
comparison to the other of the first ports 281 or the second ports
283 for easier alignment during the manifold forming process.
[0054] The manifold assembly disclosed herein may also be formed as
an extruded integral dual barrel tubular manifold assembly 290, for
example as depicted in FIG. 19. The extruded manifold assembly 290
includes a first tubular barrel forming the manifold 104, a second
tubular barrel forming the manifold 204, and a central web portion
292 joining the tubular barrels along the longitudinal extent of
the assembly. A plurality of longitudinally spaced bores 295 extend
transversely through the central web portion 292 to provide a
plurality of flow passages 274 connecting the respective interiors
of the manifolds 104, 204. The bores 295 may be drilled through the
central web portion 292 of the extruded manifold assembly 290 by
first providing a series of longitudinal spaced holes 294, for
example by punching, drilling or milling, in the wall of one of the
manifolds 104, 204 opposite the central web portion 292. A drill
bit is then inserted through each hole 294 and a bore 295 is
drilled through the central web portion 292. Each of the holes 294
is then closed by inserting a plug 296 into each hole 294. The
inserted plugs 296 are metallurgically bonded to the manifold
assembly during the brazing of the heat exchanger assembly in a
brazing furnace.
[0055] The manifold assembly disclosed herein may also be
fabricated as a flat manifold rather than as paired tubular
manifolds as in the previously described embodiments. Referring to
FIGS. 20 and 21, the manifold assembly 380 depicted therein
comprises a stamped cover plate 382 metallurically bonded at brazed
joints 385 to a flat base plate 384. Flat manifolds have a reduced
interior volume as compared to comparable paired tubular manifolds.
In refrigeration applications wherein the flat manifold is
associated with a condenser heat exchanger, the reduced volume as
compared to a comparable paired tubular manifold assembly can
reduce refrigerant charge requirements up to 50%.
[0056] In the embodiment depicted in FIG. 20, the cover plate 382
is stamped to define when joined to the flat base plate 384 a
single longitudinally extending chamber into which both the
plurality of heat exchange tube segments 106 and the plurality of
heat exchange tube segments 206 open so that refrigerant may flow
from the heat exchange tube segments 106 into the heat exchange
tube segments 206. In the embodiment depicted in FIG. 21, the cover
plate 382 is stamped to define when joined to the flat base plate
384 a pair of longitudinally extending chambers 387 and 388
extending in parallel spaced relationship. In this embodiment, the
heat exchange tube segments 106 open into chamber 387 and the heat
exchange tube segments 206 open into chamber 388. Cross-over flow
passages 389 may be stamped in the cover plate 382 at one or more
locations along the length of the longitudinally extending cover
plate 382 as desired to provide flow communication between chamber
387 and chamber 388. The location of the cross-over passages 389
determines the flow circuitry of the refrigerant passing between
the chambers 387 and 388.
[0057] As depicted in FIGS. 22A-D, the flat manifold 380 may also
be formed integrally from a single metal plate 386 folded into a
desired shape with overlapping ends which are metallurgically
bonded along a brazed joint 385. Openings for receiving the heat
exchange tube segments 106 and 206 may be punched or otherwise
formed through the single plate 386 prior to or after folding the
plate 386 into the desired shape. The single metal plate 386 may
comprise an aluminum alloy plate clad with a suitable cladding
material to facilitate brazing the overlapping end portions of the
plate 386 together and also brazing the heat exchange tube segments
106 and 206 to the folded plate manifold.
[0058] Although described herein in application to the second
manifolds 104, 204, it is to be understood that in some embodiments
of the multiple bank heat exchanger 10, the first manifolds 102 and
202 may also be formed as an integral manifold having a chamber
defining the first manifold 102 and a chamber forming the first
manifold 202.
[0059] While the present invention has been particularly shown and
described with reference to the exemplary embodiments as
illustrated in the drawing, it will be recognized by those skilled
in the art that various modifications may be made without departing
from the spirit and scope of the invention. Therefore, it is
intended that the present disclosure not be limited to the
particular embodiment(s) disclosed as, but that the disclosure will
include all embodiments falling within the scope of the appended
claims.
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