U.S. patent application number 16/508122 was filed with the patent office on 2020-11-26 for heat exchanger assembly for an hvac system.
The applicant listed for this patent is Johnson Controls Technology Company. Invention is credited to Manian A K S, Kirankumar A. Muley, Sumedh J. Suryawanshi.
Application Number | 20200370841 16/508122 |
Document ID | / |
Family ID | 1000004202154 |
Filed Date | 2020-11-26 |
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United States Patent
Application |
20200370841 |
Kind Code |
A1 |
Muley; Kirankumar A. ; et
al. |
November 26, 2020 |
HEAT EXCHANGER ASSEMBLY FOR AN HVAC SYSTEM
Abstract
A heat exchanger includes a tube configured to direct a working
fluid therethrough. The heat exchanger also includes a fin disposed
about the tube and having a louver, where the tube and the fin are
made of a polymeric material.
Inventors: |
Muley; Kirankumar A.; (Pune,
IN) ; Suryawanshi; Sumedh J.; (Pune, IN) ; A K
S; Manian; (Chennai, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson Controls Technology Company |
Auburn Hills |
MI |
US |
|
|
Family ID: |
1000004202154 |
Appl. No.: |
16/508122 |
Filed: |
July 10, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62852856 |
May 24, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28F 1/26 20130101; F28F
21/06 20130101; F28F 1/24 20130101 |
International
Class: |
F28F 1/26 20060101
F28F001/26; F28F 1/24 20060101 F28F001/24; F28F 21/06 20060101
F28F021/06 |
Claims
1. A heat exchanger, comprising: a tube configured to direct a
working fluid therethrough; and a fin disposed about the tube and
having a louver, wherein the tube and the fin are made of a
polymeric material.
2. The heat exchanger of claim 1, wherein the tube and the fin are
integrally formed as a single piece component.
3. The heat exchanger of claim 1, wherein the polymeric material is
a high density polyethylene.
4. The heat exchanger of claim 1, wherein the polymeric material
has a thermal conductivity value of at least 10 Watts per
meter-Kelvin.
5. The heat exchanger of claim 1, wherein the tube has an oblong
cross-sectional profile.
6. The heat exchanger of claim 1, wherein the fin includes an
opening, and the tube is disposed within the opening and is secured
within the opening via an interference fit.
7. The heat exchanger of claim 6, wherein the fin includes a flange
extending about a perimeter of the opening, and the flange is
engaged with the tube via the interference fit.
8. The heat exchanger of claim 1, wherein the louver is a first
louver, and the fin includes a second louver, wherein the first
louver extends from a first side of the fin, and the second louver
extends from a second side of the fin opposite to the first
side.
9. A heat exchanger, comprising: a fin having an opening and a
louver formed therein; and a tube positioned within the opening and
configured to receive a flow of working fluid, wherein the tube and
the fin are made of a polymeric material.
10. The heat exchanger of claim 9, wherein the opening has an
oblong cross-sectional profile that is configured to engage with
the tube via an interference fit.
11. The heat exchanger of claim 9, wherein an adhesive is
configured to couple the tube to a perimeter of the opening.
12. The heat exchanger of claim 9, wherein the fin is a first fin,
and the heat exchanger includes a second fin positioned adjacent to
the first fin and having an additional opening, wherein the tube is
positioned within the additional opening.
13. The heat exchanger of claim 12, comprising a first flange
extending about a perimeter of the opening and a second flange
extending about a perimeter of the additional opening, wherein the
first flange is configured to abut the second flange to form a
tunnel extending through the first fin and the second fin in an
assembled configuration of the heat exchanger.
14. The heat exchanger of claim 13, wherein the tunnel includes an
interior surface, and an exterior surface of the tube is configured
to abut the interior surface.
15. The heat exchanger of claim 9, wherein the louver forms a fluid
flow path that extends from a first surface of the fin to a second
surface of the fin disposed opposite to the first surface.
16. The heat exchanger of claim 9, wherein the louver is one of a
plurality of louvers arrayed in a louver group, wherein each louver
in the louver group forms a respective fluid flow path through the
fin from a first surface of the fin to a second surface of the fin,
opposite to the first surface, wherein the fluid flow paths include
louver openings defined between respective ones of the louvers and
the first surface, and wherein each of the louver openings is
oriented toward a perimeter of the opening.
17. The heat exchanger of claim 9, wherein the tube is configured
to contain and facilitate flow of water as the working fluid.
18. The heat exchanger of claim 9, wherein the polymeric material
is a high density polyethylene having a thermal conductivity value
of at least 10 Watts per meter-Kelvin.
19. A heat exchanger for a heating, ventilation, and/or air
conditioning (HVAC) system, comprising: a fin made of a first
polymeric material and having a louver formed therein; and a tube
made of a second polymeric material and coupled to the fin, wherein
the tube is configured to receive a flow of working fluid.
20. The heat exchanger of claim 19, wherein the first polymeric
material is different from the second polymeric material.
21. The heat exchanger of claim 19, wherein the first polymeric
material and the second polymeric material are a high density
polyethylene.
22. The heat exchanger of claim 19, wherein the louver is formed
integrally with the fin via an injection molding process or an
additive manufacturing process.
23. The heat exchanger of claim 19, wherein the fin includes an
opening, and the tube extends through the opening.
24. The heat exchanger of claim 23, wherein the fin includes a
flange that extends about a perimeter of the opening and that
extends bi-directionally from the fin in directions generally
orthogonal to the fin.
25. The heat exchanger of claim 24, wherein the tube is coupled to
an interior surface of the flange via an interference fit, via an
adhesive, or both.
26. The heat exchanger of claim 19, wherein the tube and the fin
are integrally formed as a one piece structure.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from and the benefit of
U.S. Provisional Application Ser. No. 62/852,856, entitled "HEAT
EXCHANGER ASSEMBLY FOR AN HVAC SYSTEM," filed May 24, 2019, which
is herein incorporated by reference in its entirety for all
purposes.
BACKGROUND
[0002] This section is intended to introduce the reader to various
aspects of art that may be related to various aspects of the
present techniques, which are described and/or claimed below. This
discussion is believed to be helpful in providing the reader with
background information to facilitate a better understanding of the
various aspects of the present disclosure. Accordingly, it should
be understood that these statements are to be read in this light
and not as an admission of any kind.
[0003] A heating, ventilation, and/or air conditioning (HVAC)
system may be used to thermally regulate an environment, such as a
space within a building, home, or other structure. The HVAC system
may include heat exchangers, such as a condenser, an evaporator,
and/or a hydronic coil, which may be utilized to transfer thermal
energy between the HVAC system and the environment. The heat
exchangers generally include an arrangement of heat transfer tubes
that are configured to receive a flow of working fluid. A fan may
be used to direct an air flow across the heat transfer tubes to
facilitate heat exchange between the working fluid circulating
through the heat transfer tubes and the air flow. In some cases, an
array of fins may be coupled to the heat transfer tubes to enhance
a heat exchange rate between the working fluid and the air flow.
Unfortunately, conventional heat exchangers may incur wear over
time, which may result in performance degradation of the heat
exchangers. Additionally, conventional heat exchangers may be heavy
and cumbersome to move.
SUMMARY
[0004] The present disclosure relates to a heat exchanger that
includes a tube configured to direct a working fluid therethrough.
The heat exchanger also includes a fin disposed about the tube and
having a louver, where the tube and the fin are made of a polymeric
material.
[0005] The present disclosure also relates to a heat exchanger that
includes a fin having an opening and a louver formed therein. The
heat exchanger includes a tube positioned within the opening and
configured to receive a flow of working fluid. The tube and the fin
of the heat exchanger are made of a polymeric material.
[0006] The present disclosure also relates to a heat exchanger for
a heating, ventilation, and/or air conditioning (HVAC) system. The
heat exchanger includes a fin made of a first polymeric material,
where the fin includes a louver formed therein. The heat exchanger
also includes a tube made of a second polymeric material. The tube
is coupled to the fin and is configured to receive a flow of
working fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various aspects of this disclosure may be better understood
upon reading the following detailed description and upon reference
to the drawings in which:
[0008] FIG. 1 is a perspective view of an embodiment of a building
that may utilize a heating, ventilation, and/or air conditioning
(HVAC) system in a commercial setting, in accordance with an aspect
of the present disclosure;
[0009] FIG. 2 is a perspective view of an embodiment of a packaged
HVAC unit, in accordance with an aspect of the present
disclosure;
[0010] FIG. 3 is a perspective view of an embodiment of a split,
residential HVAC system, in accordance with an aspect of the
present disclosure;
[0011] FIG. 4 is a schematic diagram of an embodiment of a vapor
compression system that may be used in an HVAC system, in
accordance with an aspect of the present disclosure;
[0012] FIG. 5 is a perspective view of an embodiment of a polymeric
heat exchanger for an HVAC system, in accordance with an aspect of
the present disclosure;
[0013] FIG. 6 is a front perspective view of an embodiment of a
heat transfer fin for a polymeric heat exchanger, in accordance
with an aspect of the present disclosure;
[0014] FIG. 7 is a rear perspective view of an embodiment of a heat
transfer fin for a polymeric heat exchanger, in accordance with an
aspect of the present disclosure;
[0015] FIG. 8 is an axial view of an embodiment of a fin block
having heat transfer fins, in accordance with an aspect of the
present disclosure; and
[0016] FIG. 9 is a heat distribution diagram of a heat transfer fin
for a polymeric heat exchanger, in accordance with an embodiment of
the present disclosure.
DETAILED DESCRIPTION
[0017] One or more specific embodiments of the present disclosure
will be described below. These described embodiments are only
examples of the presently disclosed techniques. Additionally, in an
effort to provide a concise description of these embodiments, all
features of an actual implementation may not be described in the
specification. It should be appreciated that in the development of
any such actual implementation, as in any engineering or design
project, numerous implementation-specific decisions must be made to
achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which may vary
from one implementation to another. Moreover, it should be
appreciated that such a development effort might be complex and
time consuming, but would nevertheless be a routine undertaking of
design, fabrication, and manufacture for those of ordinary skill
having the benefit of this disclosure.
[0018] When introducing elements of various embodiments of the
present disclosure, the articles "a," "an," and "the" are intended
to mean that there are one or more of the elements. The terms
"comprising," "including," and "having" are intended to be
inclusive and mean that there may be additional elements other than
the listed elements. Additionally, it should be understood that
references to "one embodiment" or "an embodiment" of the present
disclosure are not intended to be interpreted as excluding the
existence of additional embodiments that also incorporate the
recited features.
[0019] As briefly discussed above, a heating, ventilation, and/or
air conditioning (HVAC) system may include various heat exchangers,
such as a condenser, an evaporator, and/or a hydronic coil, which
may be utilized to facilitate heating or cooling of a space within
a building, home, or other suitable structure. The heat exchangers
are typically constructed from metallic materials including, for
example, copper, aluminum, and/or brass. Unfortunately, such
metallic heat exchangers may incur wear over time, which may result
in performance degradation of the heat exchangers. Additionally,
metallic heat exchangers may be heavy and cumbersome to move,
thereby complicating installation and/or transportation of the heat
exchangers.
[0020] It is now recognized that constructing heat exchangers from
polymeric materials may mitigate or substantially eliminate
performance degradation of the heat exchangers due to wear or other
physical degradation. Accordingly, polymeric heat exchangers may
have an increased operational life, as compared to an operational
life of metallic heat exchangers. Therefore, polymeric heat
exchangers may reduce overall maintenance costs and/or operating
costs associated with the HVAC system. Moreover, it is now
recognized that constructing heat exchangers from polymeric
materials may reduce a weight of the heat exchangers, thus
facilitating improved installation and/or transportation of the
heat exchangers.
[0021] Accordingly, embodiments of the present disclosure are
directed toward a polymeric heat exchanger that is formed from one
or more polymeric materials. As an example, such polymeric
materials may include plastic, high-density polyethylene,
low-density polyethylene, poly vinyl chloride, high conductivity
polymers, polypropylene, or various other polymeric materials. The
polymeric heat exchanger includes one or more heat transfer tubes
that are configured to receive a working fluid, such water, oil,
refrigerant, or another suitable working fluid. The heat transfer
tubes are placed in thermal communication with one or more heat
transfer fins that are configured to facilitate heat transfer
between the working fluid an ambient environment, such as the
atmosphere. As discussed herein, in some embodiments, the heat
transfer tubes and the heat transfer fins may be separate
components that may be coupled to one another via a suitable
adhesive, such as bonding glue, and/or via an interference fit.
Particularly, the heat transfer tubes may extend through respective
apertures or openings formed within the heat transfer fins, such
that the heat transfer tubes may be coupled to the heat transfer
fins along a perimeter of the apertures. Accordingly, the heat
transfer tubes and the heat transfer fins may collectively form a
heat exchanger assembly that defines a heat exchange area of the
polymeric heat exchanger. In other embodiments, the heat transfer
fins may be integrally formed with the heat transfer tubes. For
example, the heat transfer fins and the heat transfer tubes may be
formed as a single piece component via a suitable injection molding
process or an additive manufacturing process. Accordingly, in such
embodiments, the heat exchanger may be a single piece component
that includes the heat transfer tubes and the heat transfer fins,
amongst other components of the polymeric heat exchanger. These and
other features will be described below with reference to the
drawings.
[0022] Turning now to the drawings, FIG. 1 illustrates an
embodiment of a heating, ventilation, and/or air conditioning
(HVAC) system for environmental management that may employ one or
more HVAC units. As used herein, an HVAC system includes any number
of components configured to enable regulation of parameters related
to climate characteristics, such as temperature, humidity, air
flow, pressure, air quality, and so forth. For example, an "HVAC
system" as used herein is defined as conventionally understood and
as further described herein. Components or parts of an "HVAC
system" may include, but are not limited to, all, some of, or
individual parts such as a heat exchanger, a heater, an air flow
control device, such as a fan, a sensor configured to detect a
climate characteristic or operating parameter, a filter, a control
device configured to regulate operation of an HVAC system
component, a component configured to enable regulation of climate
characteristics, or a combination thereof. An "HVAC system" is a
system configured to provide such functions as heating, cooling,
ventilation, dehumidification, pressurization, refrigeration,
filtration, or any combination thereof. The embodiments described
herein may be utilized in a variety of applications to control
climate characteristics, such as residential, commercial,
industrial, transportation, or other applications where climate
control is desired.
[0023] In the illustrated embodiment, a building 10 is air
conditioned by a system that includes an HVAC unit 12. The building
10 may be a commercial structure or a residential structure. As
shown, the HVAC unit 12 is disposed on the roof of the building 10;
however, the HVAC unit 12 may be located in other equipment rooms
or areas adjacent the building 10. The HVAC unit 12 may be a single
package unit containing other equipment, such as a blower,
integrated air handler, and/or auxiliary heating unit. In other
embodiments, the HVAC unit 12 may be part of a split HVAC system,
such as the system shown in FIG. 3, which includes an outdoor HVAC
unit 58 and an indoor HVAC unit 56.
[0024] The HVAC unit 12 is an air cooled device that implements a
refrigeration cycle to provide conditioned air to the building 10.
Specifically, the HVAC unit 12 may include one or more heat
exchangers across which an air flow is passed to condition the air
flow before the air flow is supplied to the building. In the
illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU)
that conditions a supply air stream, such as environmental air
and/or a return air flow from the building 10. After the HVAC unit
12 conditions the air, the air is supplied to the building 10 via
ductwork 14 extending throughout the building 10 from the HVAC unit
12. For example, the ductwork 14 may extend to various individual
floors or other sections of the building 10. In certain
embodiments, the HVAC unit 12 may be a heat pump that provides both
heating and cooling to the building with one refrigeration circuit
configured to operate in different modes. In other embodiments, the
HVAC unit 12 may include one or more refrigeration circuits for
cooling an air stream and a furnace for heating the air stream.
[0025] A control device 16, one type of which may be a thermostat,
may be used to designate the temperature of the conditioned air.
The control device 16 also may be used to control the flow of air
through the ductwork 14. For example, the control device 16 may be
used to regulate operation of one or more components of the HVAC
unit 12 or other components, such as dampers and fans, within the
building 10 that may control flow of air through and/or from the
ductwork 14. In some embodiments, other devices may be included in
the system, such as pressure and/or temperature transducers or
switches that sense the temperatures and pressures of the supply
air, return air, and so forth. Moreover, the control device 16 may
include computer systems that are integrated with or separate from
other building control or monitoring systems, and even systems that
are remote from the building 10.
[0026] FIG. 2 is a perspective view of an embodiment of the HVAC
unit 12. In the illustrated embodiment, the HVAC unit 12 is a
single package unit that may include one or more independent
refrigeration circuits and components that are tested, charged,
wired, piped, and ready for installation. The HVAC unit 12 may
provide a variety of heating and/or cooling functions, such as
cooling only, heating only, cooling with electric heat, cooling
with dehumidification, cooling with gas heat, or cooling with a
heat pump. As described above, the HVAC unit 12 may directly cool
and/or heat an air stream provided to the building 10 to condition
a space in the building 10.
[0027] As shown in the illustrated embodiment of FIG. 2, a cabinet
24 encloses the HVAC unit 12 and provides structural support and
protection to the internal components from environmental and other
contaminants. In some embodiments, the cabinet 24 may be
constructed of galvanized steel and insulated with aluminum foil
faced insulation. Rails 26 may be joined to the bottom perimeter of
the cabinet 24 and provide a foundation for the HVAC unit 12. In
certain embodiments, the rails 26 may provide access for a forklift
and/or overhead rigging to facilitate installation and/or removal
of the HVAC unit 12. In some embodiments, the rails 26 may fit into
"curbs" on the roof to enable the HVAC unit 12 to provide air to
the ductwork 14 from the bottom of the HVAC unit 12 while blocking
elements such as rain from leaking into the building 10.
[0028] The HVAC unit 12 includes heat exchangers 28 and 30 in fluid
communication with one or more refrigeration circuits. Tubes within
the heat exchangers 28 and 30 may circulate refrigerant, such as
R-410A, through the heat exchangers 28 and 30. The tubes may be of
various types, such as multichannel tubes, conventional copper or
aluminum tubing, and so forth. Together, the heat exchangers 28 and
30 may implement a thermal cycle in which the refrigerant undergoes
phase changes and/or temperature changes as it flows through the
heat exchangers 28 and 30 to produce heated and/or cooled air. For
example, the heat exchanger 28 may function as a condenser where
heat is released from the refrigerant to ambient air, and the heat
exchanger 30 may function as an evaporator where the refrigerant
absorbs heat to cool an air stream. In other embodiments, the HVAC
unit 12 may operate in a heat pump mode where the roles of the heat
exchangers 28 and 30 may be reversed. That is, the heat exchanger
28 may function as an evaporator and the heat exchanger 30 may
function as a condenser. In further embodiments, the HVAC unit 12
may include a furnace for heating the air stream that is supplied
to the building 10. While the illustrated embodiment of FIG. 2
shows the HVAC unit 12 having two of the heat exchangers 28 and 30,
in other embodiments, the HVAC unit 12 may include one heat
exchanger or more than two heat exchangers.
[0029] The heat exchanger 30 is located within a compartment 31
that separates the heat exchanger 30 from the heat exchanger 28.
Fans 32 draw air from the environment through the heat exchanger
28. Air may be heated and/or cooled as the air flows through the
heat exchanger 28 before being released back to the environment
surrounding the HVAC unit 12. A blower assembly 34, powered by a
motor 36, draws air through the heat exchanger 30 to heat or cool
the air. The heated or cooled air may be directed to the building
10 by the ductwork 14, which may be connected to the HVAC unit 12.
Before flowing through the heat exchanger 30, the conditioned air
flows through one or more filters 38 that may remove particulates
and contaminants from the air. In certain embodiments, the filters
38 may be disposed on the air intake side of the heat exchanger 30
to prevent contaminants from contacting the heat exchanger 30.
[0030] The HVAC unit 12 also may include other equipment for
implementing the thermal cycle. Compressors 42 increase the
pressure and temperature of the refrigerant before the refrigerant
enters the heat exchanger 28. The compressors 42 may be any
suitable type of compressors, such as scroll compressors, rotary
compressors, screw compressors, or reciprocating compressors. In
some embodiments, the compressors 42 may include a pair of hermetic
direct drive compressors arranged in a dual stage configuration 44.
However, in other embodiments, any number of the compressors 42 may
be provided to achieve various stages of heating and/or cooling. As
may be appreciated, additional equipment and devices may be
included in the HVAC unit 12, such as a solid-core filter drier, a
drain pan, a disconnect switch, an economizer, pressure switches,
phase monitors, and humidity sensors, among other things.
[0031] The HVAC unit 12 may receive power through a terminal block
46. For example, a high voltage power source may be connected to
the terminal block 46 to power the equipment. The operation of the
HVAC unit 12 may be governed or regulated by a control board 48.
The control board 48 may include control circuitry connected to a
thermostat, sensors, and alarms. One or more of these components
may be referred to herein separately or collectively as the control
device 16. The control circuitry may be configured to control
operation of the equipment, provide alarms, and monitor safety
switches. Wiring 49 may connect the control board 48 and the
terminal block 46 to the equipment of the HVAC unit 12.
[0032] FIG. 3 illustrates a residential heating and cooling system
50, also in accordance with present techniques. The residential
heating and cooling system 50 may provide heated and cooled air to
a residential structure, as well as provide outside air for
ventilation and provide improved indoor air quality (IAQ) through
devices such as ultraviolet lights and air filters. In the
illustrated embodiment, the residential heating and cooling system
50 is a split HVAC system. In general, a residence 52 conditioned
by a split HVAC system may include refrigerant conduits 54 that
operatively couple the indoor unit 56 to the outdoor unit 58. The
indoor unit 56 may be positioned in a utility room, an attic, a
basement, and so forth. The outdoor unit 58 is typically situated
adjacent to a side of residence 52 and is covered by a shroud to
protect the system components and to prevent leaves and other
debris or contaminants from entering the unit. The refrigerant
conduits 54 transfer refrigerant between the indoor unit 56 and the
outdoor unit 58, typically transferring primarily liquid
refrigerant in one direction and primarily vaporized refrigerant in
an opposite direction.
[0033] When the system shown in FIG. 3 is operating as an air
conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a
condenser for re-condensing vaporized refrigerant flowing from the
indoor unit 56 to the outdoor unit 58 via one of the refrigerant
conduits 54. In these applications, a heat exchanger 62 of the
indoor unit 56 functions as an evaporator. Specifically, the heat
exchanger 62 receives liquid refrigerant, which may be expanded by
an expansion device, and evaporates the refrigerant before
returning it to the outdoor unit 58.
[0034] The outdoor unit 58 draws environmental air through the heat
exchanger 60 using a fan 64 and expels the air above the outdoor
unit 58. When operating as an air conditioner, the air is heated by
the heat exchanger 60 within the outdoor unit 58 and exits the unit
at a temperature higher than it entered. The indoor unit 56
includes a blower or fan 66 that directs air through or across the
indoor heat exchanger 62, where the air is cooled when the system
is operating in air conditioning mode. Thereafter, the air is
passed through ductwork 68 that directs the air to the residence
52. The overall system operates to maintain a desired temperature
as set by a system controller. When the temperature sensed inside
the residence 52 is higher than the set point on the thermostat, or
a set point plus a small amount, the residential heating and
cooling system 50 may become operative to refrigerate additional
air for circulation through the residence 52. When the temperature
reaches the set point, or a set point minus a small amount, the
residential heating and cooling system 50 may stop the
refrigeration cycle temporarily.
[0035] The residential heating and cooling system 50 may also
operate as a heat pump. When operating as a heat pump, the roles of
heat exchangers 60 and 62 are reversed. That is, the heat exchanger
60 of the outdoor unit 58 will serve as an evaporator to evaporate
refrigerant and thereby cool air entering the outdoor unit 58 as
the air passes over outdoor the heat exchanger 60. The indoor heat
exchanger 62 will receive a stream of air blown over it and will
heat the air by condensing the refrigerant.
[0036] In some embodiments, the indoor unit 56 may include a
furnace system 70. For example, the indoor unit 56 may include the
furnace system 70 when the residential heating and cooling system
50 is not configured to operate as a heat pump. The furnace system
70 may include a burner assembly and heat exchanger, among other
components, inside the indoor unit 56. Fuel is provided to the
burner assembly of the furnace system 70 where it is mixed with air
and combusted to form combustion products. The combustion products
may pass through tubes or piping in a heat exchanger, separate from
heat exchanger 62, such that air directed by the blower 66 passes
over the tubes or pipes and extracts heat from the combustion
products. The heated air may then be routed from the furnace system
70 to the ductwork 68 for heating the residence 52.
[0037] FIG. 4 is an embodiment of a vapor compression system 72
that can be used in any of the systems described above. The vapor
compression system 72 may circulate a refrigerant through a circuit
starting with a compressor 74. The circuit may also include a
condenser 76, an expansion valve(s) or device(s) 78, and an
evaporator 80. The vapor compression system 72 may further include
a control panel 82 that has an analog to digital (A/D) converter
84, a microprocessor 86, a non-volatile memory 88, and/or an
interface board 90. The control panel 82 and its components may
function to regulate operation of the vapor compression system 72
based on feedback from an operator, from sensors of the vapor
compression system 72 that detect operating conditions, and so
forth.
[0038] In some embodiments, the vapor compression system 72 may use
one or more of a variable speed drive (VSDs) 92, a motor 94, the
compressor 74, the condenser 76, the expansion valve or device 78,
and/or the evaporator 80. The motor 94 may drive the compressor 74
and may be powered by the variable speed drive (VSD) 92. The VSD 92
receives alternating current (AC) power having a particular fixed
line voltage and fixed line frequency from an AC power source, and
provides power having a variable voltage and frequency to the motor
94. In other embodiments, the motor 94 may be powered directly from
an AC or direct current (DC) power source. The motor 94 may include
any type of electric motor that can be powered by a VSD or directly
from an AC or DC power source, such as a switched reluctance motor,
an induction motor, an electronically commutated permanent magnet
motor, or another suitable motor.
[0039] The compressor 74 compresses a refrigerant vapor and
delivers the vapor to the condenser 76 through a discharge passage.
In some embodiments, the compressor 74 may be a centrifugal
compressor. The refrigerant vapor delivered by the compressor 74 to
the condenser 76 may transfer heat to a fluid passing across the
condenser 76, such as ambient or environmental air 96. The
refrigerant vapor may condense to a refrigerant liquid in the
condenser 76 as a result of thermal heat transfer with the
environmental air 96. The liquid refrigerant from the condenser 76
may flow through the expansion device 78 to the evaporator 80.
[0040] The liquid refrigerant delivered to the evaporator 80 may
absorb heat from another air stream, such as a supply air stream 98
provided to the building 10 or the residence 52. For example, the
supply air stream 98 may include ambient or environmental air,
return air from a building, or a combination of the two. The liquid
refrigerant in the evaporator 80 may undergo a phase change from
the liquid refrigerant to a refrigerant vapor. In this manner, the
evaporator 80 may reduce the temperature of the supply air stream
98 via thermal heat transfer with the refrigerant. Thereafter, the
vapor refrigerant exits the evaporator 80 and returns to the
compressor 74 by a suction line to complete the cycle.
[0041] In some embodiments, the vapor compression system 72 may
further include a reheat coil in addition to the evaporator 80. For
example, the reheat coil may be positioned downstream of the
evaporator relative to the supply air stream 98 and may reheat the
supply air stream 98 when the supply air stream 98 is overcooled to
remove humidity from the supply air stream 98 before the supply air
stream 98 is directed to the building 10 or the residence 52.
[0042] It should be appreciated that any of the features described
herein may be incorporated with the HVAC unit 12, the residential
heating and cooling system 50, or other HVAC systems. Additionally,
while the features disclosed herein are described in the context of
embodiments that directly heat and cool a supply air stream
provided to a building or other load, embodiments of the present
disclosure may be applicable to other HVAC systems as well. For
example, the features described herein may be applied to mechanical
cooling systems, free cooling systems, chiller systems, or other
heat pump or refrigeration applications.
[0043] FIG. 5 is a perspective view of an embodiment of a polymeric
heat exchanger 100 that may be included in the HVAC unit 12, the
residential heating and cooling system 50, a rooftop unit, a
terminal unit, or any other HVAC system that utilizes heat
exchangers. It should be appreciated that, in certain embodiments,
the polymeric heat exchanger 100 may be included in other heat
transfer applications such as, for example, automotive heating and
cooling systems or heating and cooling systems for electronic
devices. In any case, as shown in the illustrated embodiment, the
polymeric heat exchanger 100 includes a plurality of heat transfer
fins 102 that are positioned adjacent to one another to define a
fin block 104 of the polymeric heat exchanger 100. The polymeric
heat exchanger 100 may include a plurality of heat transfer tubes
106 that are configured to extend through respective apertures 110,
as shown in FIG. 6, formed within each of the heat transfer fins
102. The heat transfer tubes 106 may be fluidly coupled to one
another via a plurality of elbows 114 to form a serpentine fluid
flow path 116 that extends between an inlet 118 and an outlet 120
of the polymeric heat exchanger 100. Accordingly, the heat transfer
fins 102, the heat transfer tubes 106, and the elbows 114 may
collectively define a heat exchanger assembly 122 of the polymeric
heat exchanger 100.
[0044] The fluid flow path 116 may be configured to receive a flow
of working fluid from a suitable fluid source to place the working
fluid in thermal communication with the heat exchanger assembly
122. For example, in some embodiments, the fluid flow path 116 may
be configured to receive a heated working fluid from a boiler or to
receive a chilled working fluid from a chiller. In such
embodiments, the working fluid may include water, oil, or another
suitable working fluid. In other embodiments, the working fluid may
include a flow of refrigerant provided via a vapor compression
system, such as the vapor compression system 72. In any case, the
polymeric heat exchanger 100 may facilitate heat transfer between
the working fluid circulating through the fluid flow path 116 and
an air flow 126 that may be directed across heat transfer tubes 106
and the heat transfer fins 102. For example, a fan or other
suitable flow generating device may be configured to generate the
air flow 126 and to force the air flow 126 in a downstream
direction 128 across the heat transfer tubes 106 and the heat
transfer fins 102 from an upstream end portion 130 of the heat
transfer fins 102 to a downstream end portion 132 of the heat
transfer fins 102. However, it should be understood that, in other
embodiments, another suitable heat transfer fluid may be directed
across the heat transfer tubes 106 and the heat transfer fins 102
in addition to, or in lieu of, the air flow 126. Indeed, in some
embodiments, polymeric heat exchanger 100 may be utilized in a
variety of heat transfer applications to facilitate heat transfer
from one fluid to another fluid.
[0045] In some embodiments, the heat transfer fins 102, the heat
transfer tubes 106, the elbows 114, or any combination thereof, may
be formed from one or more polymeric materials. As discussed above,
such polymeric materials may include, but are not limited to,
plastic, high-density polyethylene, low-density polyethylene, poly
vinyl chloride, high conductivity polymers, polypropylene, or
various other polymeric materials. Accordingly, the heat transfer
fins 102, the heat transfer tubes 106, and/or the elbows 114 may be
substantially inhibited from or resistant to corrosion, which may
increase an operational life of the polymeric heat exchanger 100.
As such, the polymeric heat exchanger 100 may reduce overall
maintenance costs associated with an HVAC system having the
polymeric heat exchanger 100, as compared to an HVAC system having
conventional metallic heat exchangers. Moreover, constructing the
polymeric heat exchanger 100 from polymeric materials may reduce an
overall assembly cost of the polymeric heat exchanger 100. Indeed,
as discussed in detail herein, the heat transfer fins 102, the heat
transfer tubes 106, and/or the elbows 114 may be produced
relatively inexpensively via, for example, an injection molding
process, an extrusion process, or an additive manufacturing
process. It should be appreciated that, in some embodiments, the
heat transfer tubes 106 and the elbows 114 may be formed from a
first polymeric material, while the heat transfer fins 102 are
formed from a second polymeric material that is different from the
first polymeric material. In other embodiments, the heat transfer
tubes 106, the elbows 114, and the heat transfer fins 102 may each
be formed from different polymeric materials or from the same
polymeric material.
[0046] FIG. 6 is a front perspective view of an embodiment of a
portion of a heat transfer fin 136, such as one of the heat
transfer fins 102 of the polymeric heat exchanger 100. FIG. 7 is a
rear perspective view of an embodiment of the portion of the heat
transfer fin 136. FIGS. 6 and 7 will be discussed concurrently
below. The heat transfer fin 136 includes a body panel 138 having
the apertures 110, also referred to herein as openings, formed
therein. The apertures 110 may include a cross-sectional profile
that is substantially similar to a cross-sectional profile of the
heat transfer tubes 106. As an example, in some embodiments, the
apertures 110 and the heat transfer tubes 106 may each include a
generally oval or oblong cross-sectional profile. In some
embodiments, respective surface areas of the heat transfer tubes
106 may be increased by forming the heat transfer tubes 106 to
include oblong cross-sectional profiles. Such a tube configuration
of the heat transfer tubes 106 may therefore increase interaction
between the air flow 126 and the heat transfer tubes 106, and thus,
may enhance a heat transfer rate between the air flow 126 and the
working fluid circulating through the fluid flow path 116.
Moreover, in some embodiments, forming the heat transfer tubes 106
to include a generally oblong cross-sectional profile may reduce
fluidic restriction across the polymeric heat exchanger 100, as
compared to heat transfer tubes including, for example, a circular
cross-sectional profile. Accordingly, the heat transfer tubes 106
discussed herein may increase an operational efficiency of a fan
configured to direct the air flow 126 across the polymeric heat
exchanger 100 from the upstream end portion 130 to the downstream
end portion 132 of the polymeric heat exchanger 100. However, it
should be appreciate that, in other embodiments, the apertures 110
and the heat transfer tubes 106 may include any other suitable
cross-sectional profiles that are complementary to one another.
[0047] In some embodiments, each of the heat transfer tubes 106 may
be configured to extend through a respective one of the apertures
110. Multiple heat transfer fins 102 may be engaged with the heat
transfer tubes 106 in a stacked manner to form the fin block 104.
In some embodiments, the heat transfer tubes 106 may include
exterior dimensions that are marginally greater than interior
dimensions of the corresponding apertures 110. Accordingly, an
interference fit may be generated between the heat transfer tubes
106 extending through the apertures 110 that may facilitate
coupling the heat transfer fins 102 to the heat transfer tubes 106.
That is, in such embodiments, interior surfaces of the apertures
110 may be configured to apply and maintain a compressive force on
the exterior surfaces of the heat transfer tubes 106. In certain
embodiments, an adhesive, such as bonding glue, may be used to
couple the heat transfer fins 102 to the heat transfer tubes 106 in
addition to, or in lieu of such an interference fit.
[0048] In some embodiments, the heat transfer fin 136 may include
respective flanges 140 that extend about a perimeter of one or more
of the apertures 110. The flanges 140 may extend generally
orthogonal to the body panel 138 from a first surface 144 or a
first side of the body panel 138, from a second surface 146 or a
second side of the body panel 138, or both. Indeed, in some
embodiments, the flanges 140 may extend bi-directionally from the
body panel 138 in directions that extend generally orthogonal or
cross-wise to the body panel 138. The heat transfer tubes 106 may
be configured to engage with the flanges 140 in a similar manner as
the engagement between the heat transfer tubes 106 and the inner
perimeter of the apertures 110 discussed above. That is, the heat
transfer tubes 106 may be coupled to an inner perimeter of the
flanges 140 via an interference fit or via a suitable adhesive.
[0049] In some embodiments, when the heat transfer fins 102 are
stacked in the fin block 104, the flanges 140 of neighboring heat
transfer fins 102 may be configured to engage with one another.
Accordingly, the flanges 140 may form continuous tunnels that
extend along a length 150, as shown in FIG. 5, of the fin block 104
through a corresponding set of the apertures 110. To better
illustrate and to facilitate the following discussion, FIG. 8 is an
axial view of an embodiment of the fin block 104. As shown in the
illustrated embodiment, when arranged in the fin block 104, the
flanges 140 of adjacent heat transfer fins 102 may engage with one
another to define a plurality of tunnels 152 that extend along the
length 150 of the fin block 104. The heat transfer tubes 106 may
each be configured to extend through a corresponding one of the
tunnels 152. In some embodiments, each of the tunnels 152 may form
a substantially fluid tight flow path that is defined by respective
interior surfaces of the flanges 140 and that extends between a
first lateral end 156 and a second lateral end 158 of the fin block
104. As noted above, exterior surfaces of the heat transfer tubes
106 may be configured to abut the interior surfaces of the flanges
140. Accordingly, when the heat transfer fins 102 are positioned to
form the tunnels 152, the flanges 140 may cover substantially all
of the exterior surfaces of the heat transfer tubes 106 positioned
between the first and second lateral ends 156, 158 of the fin block
104. In some embodiments, this configuration may provide additional
structural rigidity to the heat transfer tubes 106 and the entire
polymeric heat exchanger 100. In particular, the flanges 140 may
reduce or substantially mitigate expansion or swelling of the heat
transfer tubes 106 when a pressure within the fluid flow path 116
is elevated. It should be understood that, in certain embodiments,
a gap may remain between adjacent flanges 140 when the heat
transfer fins 102 are arrayed in the fin block 104.
[0050] The subsequent discussion continues with reference to FIGS.
6 and 7. In some embodiments, the body panel 138 may include a
plurality of louvers 160 that extend outwardly from the first
surface 144 of the body panel 138, that extend outwardly from the
second surface 146 of the body panel 138, or both. For example, the
louvers 160 may include a set of first louvers 162 that extend
outwardly from the first surface 144 of the body panel 138.
Accordingly, first louvers 162 may form respective first fluid
passages 164 that extend from the first surface 144 to the second
surface 146 of the heat transfer fin 136. The first fluid passages
164 may initiate at respective louver openings that are formed
between the first surface 144 and corresponding ones of the first
louvers 162.
[0051] The louvers 160 may include a set of second louvers 168 that
extend outwardly from the second surface 146 of the body panel 138.
Similar to the first louvers 162, the second louvers 168 may form
respective second fluid passages 170 that extend from the second
surface 146 to the first surface 144 of the body panel 138. The
second fluid passages 170 may initiate at respective louver
openings that are formed between the second surface 146 and
corresponding ones of the second louvers 168. As one of skill in
the art will appreciate, the first and second louvers 162, 168 may
facilitate fluid flow between the first and second surfaces 144,
146 of the body panel 138 which, in some embodiments, may
facilitate and/or improve heat transfer between the air flow 126
and the heat transfer fin 136.
[0052] In some embodiments, the louvers 160 may be configured to
generate fluidic turbulences within the air flow 126 as the air
flow 126 is directed across the heat transfer fins 102 in the
downstream direction 128. As such, the louvers 160 may reduce or
substantially eliminate the generation of relatively large wake
regions that may be formed downstream of each of the heat transfer
tubes 106. Indeed, such wake regions may typically be formed during
laminar air flow conditions across the heat transfer tubes 106.
Accordingly, by reducing or mitigating such wake regions, the
louvers 160 may increase an effective surface area of the heat
transfer tubes 106 with which the air flow 126 interacts. As such,
the louvers 160 may facilitate heat transfer between the air flow
126 and the working fluid circulating through the fluid flow path
116.
[0053] In some embodiments, the louvers 160 may be arranged in
various louver groups 180 along the heat transfer fin 136. In
certain embodiments, certain of the louver groups 180 may be
oriented toward particular apertures 110, while other louver groups
180 are oriented away from particular apertures 110. For example,
as shown in the illustrated embodiment of FIG. 6, the louver groups
180 may include a first louver group 182 that includes four of the
first louvers 162. Each of the first louvers 162 within the first
louver group 182 may be oriented such that the respective louver
openings of the first fluid passages 164 of these first louvers 162
are positioned adjacent to a perimeter of one of the apertures 110,
referred to herein as a pilot aperture 184. As shown in the
illustrated embodiment of FIG. 7, the louver groups 180 may also
include a second louver group 190 that includes four of the second
louvers 168. Each of the second louvers 168 within the second
louver group 190 may be oriented such that respective louver
openings of the second fluid passages 170 of these second louvers
168 are positioned distal to the perimeter of the pilot aperture
184.
[0054] As noted above, in some embodiments, the heat transfer fins
102, the heat transfer tubes 106, and/or the elbows 114 may be
formed as individual components from various polymeric materials
via, for example, an injection molding process, an extrusion
process, or an additive manufacturing process, also referred to as
a three dimensional (3D) printing process. Accordingly, the heat
transfer fins 102, the heat transfer tubes 106, and the elbows 114
may be assembled to collectively form the heat exchanger assembly
122. In other embodiments, the heat transfer fins 102, the heat
transfer tubes 106, the elbows 114, or any combination thereof, may
be integrally formed as a single piece component. That is, in some
embodiments, the heat exchanger assembly 122 may be manufactured as
a single piece component using, for example, an additive
manufacturing process.
[0055] In some embodiments, the polymeric material used to the
construct the polymeric heat exchanger 100 may be selected to
enhance a heat transfer ability of the polymeric heat exchanger
100. In other words, the polymeric material may be tailored to
facilitate heat transfer between the air flow 126 and a working
fluid circulating through the fluid flow path 116. As a
non-limiting example, such a polymeric material may include high
density polyethylene having a thermal conductivity value of at
least 10 Watts per meter-Kelvin. However, in other embodiments, the
polymeric material used to construct the polymeric heat exchanger
100 may include any other suitable polymeric material having a
thermal conductivity value that is less than or greater than 10
Watts per meter-Kelvin. FIG. 9 is an embodiment of a heat
distribution diagram 200 illustrating a heat distribution across
the heat transfer fin 136 for a particular polymeric material.
[0056] As set forth above, embodiments of the present disclosure
may provide one or more technical effects useful for substantially
eliminating performance degradation of heat exchangers due to
corrosion or other wear. Indeed, the polymeric heat exchanger 100
of the present disclosure may be constructed of one or more
polymeric materials that are substantially resistant to corrosion,
such that the polymeric heat exchanger 100 may have an increased
operational life, as compared to an operational life of metallic
heat exchangers. Therefore, polymeric heat exchanger 100 may reduce
overall maintenance costs and/or operating costs associated with an
HVAC system. Moreover, constructing the polymeric heat exchanger
100 from polymeric materials may reduce a weight of the polymeric
heat exchanger 100, as compared to a weight of metallic heat
exchangers, thus facilitating installation and/or transportation of
the heat exchangers. The technical effects and technical problems
in the specification are examples and are not limiting. It should
be noted that the embodiments described in the specification may
have other technical effects and can solve other technical
problems.
[0057] While only certain features and embodiments of the present
disclosure have been illustrated and described, many modifications
and changes may occur to those skilled in the art, such as
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, such as temperatures
and pressures, mounting arrangements, use of materials, colors,
orientations, and so forth, without materially departing from the
novel teachings and advantages of the subject matter recited in the
claims. The order or sequence of any process or method steps may be
varied or re-sequenced according to alternative embodiments. It is,
therefore, to be understood that the appended claims are intended
to cover all such modifications and changes as fall within the true
spirit of the present disclosure. Furthermore, in an effort to
provide a concise description of the exemplary embodiments, all
features of an actual implementation may not have been described,
such as those unrelated to the presently contemplated best mode of
carrying out the present disclosure, or those unrelated to enabling
the claimed embodiments. It should be appreciated that in the
development of any such actual implementation, as in any
engineering or design project, numerous implementation specific
decisions may be made. Such a development effort might be complex
and time consuming, but would nevertheless be a routine undertaking
of design, fabrication, and manufacture for those of ordinary skill
having the benefit of this disclosure, without undue
experimentation.
* * * * *