EP4589238A1

EP4589238A1 - A fluid distributor for a heat exchanger

Info

Publication number: EP4589238A1
Application number: EP25152122.5A
Authority: EP
Inventors: Tobias Sienel
Original assignee: Carrier Corp
Current assignee: Carrier Corp
Priority date: 2024-01-17
Filing date: 2025-01-15
Publication date: 2025-07-23
Also published as: US20250230995A1; CN120333198A

Abstract

A fluid distributor (108) for a heat exchanger (100) comprises a first tube (112) having an open first end (112-1) and a closed second end (112-2), wherein a plurality of first channels (HC) extends in a helical configuration along a length in an interior of the first tube (112) and one or more outlet ports (202) are configured along a surface of the first tube (112), wherein the fluid distributor (108) is configured with the heat exchanger (100) such that the one or more outlet ports (202) fluidically connect the plurality of first channels (HC) to a plurality of tubes (106) associated with a heat exchange section of the heat exchanger (100) or an interior volume of an inlet header (102) associated with the heat exchanger (100).

Description

BACKGROUND

This invention relates to the field of heat exchangers, and more particularly, to a fluid distributor with an optional separator for a heat exchanger.

SUMMARY

Described herein is a fluid distributor for a heat exchanger. The fluid distributor comprises a first tube having an open first end and a closed second end, wherein a plurality of first channels extends in a helical configuration along a length in an interior of the first tube and one or more outlet ports are configured along a surface of the first tube, wherein the distributor is configured with the heat exchanger such that the one or more outlet ports fluidically connect the plurality of first channels to a plurality of tubes associated with a heat exchange section of the heat exchanger or an interior volume of an inlet header associated with the heat exchanger.
The distributor is optionally configured to receive a two-phase fluid within the plurality of first channels via the open first end of the first tube, causing the two-phase fluid to flow in helical motion, wherein the helical motion of the two-phase fluid causes the two-phase fluid to radially flow out of the distributor into the plurality of tubes of the heat exchange section or the internal volume of the inlet header via the one or more outlet ports.
The distributor optionally comprises a second tube having a closed first end and an open second end, the second tube concentrically disposed within and extending longitudinally through the first tube with a predefined gap therebetween to define a shape of the distributor, wherein the second tube forms a second central channel within the first tube and the plurality of first channels extend in the helical configuration around the second central channel, along the length of the first tube, within the gap between the first tube and second tube. The distributor further comprises one or more inlet ports configured along a surface of the second tube, wherein the one or more inlet ports fluidically connect the plurality of first channels to the second central channel.
The distributor is optionally configured to receive a two-phase fluid within the plurality of first channels via the open first end of the first tube, causing the two-phase fluid to flow in helical motion, wherein the helical motion of the two-phase fluid causes a liquid phase associated with the two-phase fluid to radially flow out of the distributor into the tubes of the heat exchange section or the internal volume of the inlet header via the one or more outlet ports and a vapor phase associated with the two-phase fluid to flow into the second central channel via the one or more inlet ports.
The distributor is optionally configured to be longitudinally disposed in the inlet header such that the distributor extends at least partially through the inlet header.
The inlet header optionally comprises one or more first compartments separated by one or more first walls, wherein the one or more outlet ports are configured at first predefined positions on the first tube, such that at least one of the one or more outlet ports remains in each of the first compartments.
The distributor is optionally configured external to the inlet header with the one or more outlet ports fluidically connecting the plurality of first channels of the distributor to the plurality of tubes of the heat exchange section or the interior volume of the inlet header.
The inlet header optionally comprises one or more first compartments separated by one or more first walls, wherein the one or more outlet ports are configured at first predefined positions on the first tube, such that at least one of the one or more outlet ports remains fluidically connected to at least one of the first compartments via one or more tube stubs.
The inlet header optionally comprises a plurality of first compartments separated by one or more first walls, the plurality of first compartments comprising at least one fluid inlet compartment and at least one fluid outlet compartment, wherein the plurality of tubes of the heat exchange section has a predefined number of turns and passes such that the tube associated with each of the passes extends between one of the fluid inlet compartments and one of the fluid outlet compartments among the one or more first compartments.
The one or more outlet ports of the distributor are optionally configured at first predefined positions on the first tube, such that at least one of the one or more outlet ports remains fluidically connected to at least one of the fluid inlet compartments via one or more tube stubs, and wherein each of the fluid outlet compartments comprises an opening to discharge a substantially vapor phase, created within the corresponding tubes, out of the inlet header.
The one or more inlet ports are optionally configured at second predefined positions on the second tube, such that the one or more inlet ports fluidically connect each of the first channels to the second central channel.
The second central channel optionally comprises a plurality of second channels extending longitudinally through the second tube, wherein the one or more inlet ports are configured at second predefined positions on the second tube, such that the one or more inlet ports fluidically connects each of the first channels to the at least one of the second channel.
The distributor is optionally disposed in the inlet header such that the distributor extends through each of the first compartments of the inlet header, wherein the second tube is concentrically disposed in the first tube such that the open second end of the second tube extends at least partially out of the closed second end of first tube and the inlet header to transfer the vapor phase out of the inlet header.
The distributor is optionally longitudinally disposed in the inlet header such that the open second end of the second tube extends at least partially out of the closed second end of the first tube into one of the first compartments of the inlet header to transfer the vapor phase into the corresponding first compartment.
The open second end of the second tube optionally extends at least partially out of the closed second end of the first tube to transfer the vapor phase out of the inlet header.
The open second end of the second tube optionally extends at least partially out of the closed second end of the first tube into an external compartment to transfer the vapor phase into the corresponding external compartment, wherein the external compartment comprises at least one of the outlet ports fluidically connected to at least one of the first compartments of the inlet header.
The open second end of the second tube optionally extends at least partially out of the closed second end of the first tube to transfer the vapor phase, separated within the distributor, out of the inlet header.
The open second end of the second tube optionally comprises a check valve to restrict back flow of the vapor phase into the second tube or the second central channel, wherein the first end of the second tube is closed by a flow restrictor, and the open first end of the first tube or the distributor is configured to be fluidically connected to a supply tube associated with the heat exchanger.
The heat exchanger optionally comprises a plurality of heat-dissipating fins in thermal contact with the plurality of tubes in the heat exchange section of the heat exchanger, wherein the plurality of heat-dissipating fins is any of corrugated-fin type or inserted-fin type.
The heat exchanger is optionally in a horizontal configuration or a vertical configuration.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, features, and techniques of the present invention will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain exemplary embodiments will now be described in greater detail by way of example only and with reference to the accompanying drawings. The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description, serve to explain the principles of the present invention.
In the drawings, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

FIG. 1A illustrates an exemplary view of a heat exchanger having a fluid distributor configured inside the inlet header of the heat exchanger, where the second tube of the fluid distributor opens out of the first tube and the inlet header.
FIG. 1B illustrates an exemplary view of another heat exchanger having the fluid distributor configured inside the inlet header, where a check valve is provided at one end of the second tube which opens in one of the compartments of the inlet header.
FIG. 1C illustrates an exemplary view of the heat exchanger of FIG. 1B where the second tube is without the check valve.
FIG. 1D illustrates an exemplary view of a heat exchanger having the fluid distributor outside of the inlet header, where the second tube opens out of the first tube.
FIG. 1E illustrates an exemplary view of a heat exchanger having a multi-pass heat exchange section where the fluid distributor is configured outside of the inlet header and a set of compartments of the inlet header includes an opening for outflow of vapor-phase formed in the heat exchange section.
FIG. 1F illustrates an exemplary view of another heat exchanger having the fluid distributor configured outside of the inlet header, where the vapor-phase separated within the distributor is supplied to one of the compartments of the inlet header.
FIG. 1G illustrates an exemplary view of yet another heat exchanger having the fluid distributor comprising the first tube as well as the second tube, where the outlet ports of the distributor are directly connected to the tubes associated with the heat exchange section and the second tube opens out of the first tube. This embodiment illustratively shows a serpentine arrangement of the heat exchanger tubes with inserted fins.
FIG. 1H illustrates an exemplary view of another heat exchanger having the fluid distributor without the central channel or second tube, where the outlet ports of the distributor are directly connected to the tubes associated with the heat exchange section of the heat exchanger. This illustratively shows a serpentine arrangement of the heat exchanger tubes with inserted fins.
FIGs. 2A and 2B illustrate exemplary views of the fluid distributor.
FIGs. 3A-3C illustrates exemplary cross-sectional views of extrusion profiles of the fluid distributor having different numbers of helical channels.
FIG. 4 illustrates an exemplary view of the fluid distributor with a flow restrictor.

DETAILED DESCRIPTION

The following is a detailed description of embodiments depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims.
Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present disclosure, the components of this invention described herein may be positioned in any desired orientation. Thus, the use of terms such as "above," "below," "upper," "lower," "first", "second" or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the header, distribution tube, refrigerant distributor, multichannel tubes, heat exchanger, supply tube, and corresponding components, described herein may be oriented in any desired direction.
Microchannel heat exchangers (MCHX) employing microchannel tubes are important components in heat pump systems, facilitating efficient heat transfer between different fluid streams. These heat exchangers are employed in a wide range of applications, including residential and commercial heating, ventilation, and air conditioning (HVAC) systems. An important challenge in the design and operation of MCHX is the effective distribution of the working fluid (refrigerant) across the microchannel tubes to ensure optimal heat transfer performance and capacity. The working fluid may be in two phases, vapor and liquid. When two phases are present, the two phases must be mixed to facilitate effective distribution.
Mal-distribution of the working fluid within MCHX can lead to significant imbalances in thermal characteristics and a reduction in overall heat transfer efficiency. One of the primary concerns associated with mal-distribution is the varying heat transfer coefficient between the vapor and liquid phases. Due to the lower heat transfer coefficient of the vapor phase, an uneven distribution can result in localized areas of reduced heat transfer, leading to decreased capacity and overall performance of the heat pump system.
There is a need for a solution to address the challenges posed by mal-distribution in heat exchangers, by providing an improved and effective fluid distribution system that helps the heat exchanger achieve a more uniform distribution of the working fluid phases across all the heat exchange tubes, thereby enhancing the overall thermal performance of the heat exchanger.
Referring to FIGs. 1A to 1F, in one or more embodiments, a heat exchanger 100 configured with a fluid distributor 108 is disclosed. The heat exchanger 100 can include an inlet header 102 which may or may not comprise one or more first compartments 104-1 to 104-N (collectively designated as first compartments 104) separated by one or more partition walls. Further, the heat exchanger 100 can include an outlet header (not illustrated here) which may or may not comprise one or more second compartments. The heat exchanger 100 can include a heat exchange section comprising a plurality of microchannel tubes 106 extending between the inlet header 102 and the outlet header and can be fluidically connected to the inlet header 102 and the outlet header. The heat exchanger 100 may be in a horizontal configuration or a vertical configuration but is not limited to the like. Further, the heat exchanger 100 can include a plurality of heat-dissipating fins 110 in thermal contact with the plurality of microchannel tubes 106 in a heat exchange section of the heat exchanger 100. In one or more embodiments, the heat-dissipating fins 110 may be any of a corrugated-fin type as shown in FIGs. 1A to 1F, however, the heat-dissipating fins 110 may also be inserted-fin type as shown in FIGs. 1G and 1H.
Referring to FIGs. 1G and 1H, in one or more embodiments, the heat exchanger 100 may not include the inlet header. Further, the heat exchange section can include a plurality of tubes 106 (which may or may not be microchannel tubes) having a predefined number and passes which may directly receive refrigerant through a supply tube 120 and a distributor 108. As illustrated, the tubes 106 may be in a serpentine configuration, but is not limited to the like, and the fins 110 may be of inserted-fin type.
Referring to FIGs. 1A to 1C, in one or more embodiments, the heat exchanger 100 can further include a fluid distributor cum separator 108 (also referred to as distributor 108, herein) that can be longitudinally disposed in the inlet header 102 such that the distributor 108 can extend at least partially through the inlet header 102. Further, referring to FIGs. 1D to 1F, in one or more embodiments, the heat exchanger 100 can include the fluid distributor 108 configured external to or extending outside of the inlet header 102 and fluidically connected to the interior volume of the inlet header 102.
In one or more embodiments, the distributor 108 of FIGs. 1A to 1F can include a first tube 112 having an open first end 112-1 and a closed second end 112-2, and a second tube 114 having a closed first end 114-1 and an open second end 114-2. The second tube 114 can be concentrically disposed within and extending longitudinally through the first tube 112 with a predefined gap therebetween to define the shape of the distributor 108. However, in some embodiments, the distributor 108 may not include the second tube 114 and can only include the first tube 112 having the open first end 112-1 and the closed second end 112-2.
Further, in one or more embodiments, the second tube 114 can form a second central channel (CC) within the first tube 112 and a plurality of first channels (HC) can extend in a helical configuration around the second central channel CC, along a length of the first tube 112, within the gap between the first tube 112 and second tube 114 as shown in FIG. 2A to 3C. However, in other embodiments (not illustrated here), the second tube 114 can include a plurality of second channels CC extending longitudinally therethrough, with the plurality of first channels HC extending in a helical configuration around the plurality of second channels CC.
In one or more embodiments, the gap between the first tube 112 and the second tube 114 can include a plurality of partitions having a helical profile extending along the length of the first tube 112 to form the plurality of first channels HC having the helical configuration.
In addition, one or more outlet ports 202 (collectively referred to as outlet ports 202, herein) can be configured along a surface of the first tube 112, such that the outlet ports 202 can fluidically connect the plurality of first channels HC to the tubes 106 of the heat exchange section or an interior volume of the inlet header 102. Referring to FIGs. 1A to 1C, as the distributor 108 is configured within the inlet header 102, the outlet ports 202 can open in the interior volume of the inlet header 102. Further, referring to FIGs. 1D to 1F, as the distributor 108 is configured outside of the inlet header 102, the outlet ports 202 can be fluidically connected to the interior volume or compartments of the inlet header 102 via one or more tube stubs. Furthermore, referring to FIGs. 1G and 1H, as the distributor 108 is directly connected to the tubes 106 of the heat exchange section of the heat exchanger 100, the outlet ports 202 can be fluidically connected to the tubes 106.
This fluidic connection of the outlet ports 202 with the interior volume of the inlet header 102 or to the tubes 106, allows the outlet ports 202 to be arranged at the same radial location around the distributor 108, which is not possible with existing axial extrusion distributors. It is to be appreciated that when the outlet ports 202 are arranged at the same radial location around the distributor 108, there may not be a need for the central channel or the second tube 114 in the distributor 108 and all such embodiments are well within the scope of this invention.
Furthermore, in one or more embodiments, one or more inlet ports 204 (collectively referred to as inlet ports 204, herein) can be configured along a surface of the second tube 114, such that the inlet ports 204 can fluidically connect the plurality of second channels to the second central channel CC.
Accordingly, the distributor 108 can receive a two-phase working fluid (refrigerant) within the plurality of first channels HC via the open first end 112-1 of the first tube 112 as shown in FIG. 4, causing the two-phase fluid to flow in a helical motion. This helical motion of the two-phase fluid can cause a liquid phase (being heavier compared to the vapor phase) associated with the two-phase fluid to radially flow out of the distributor 108 into the inlet header 102 via the outlet ports 202 under centrifugal force and a vapor phase (being lighter) associated with the two-phase fluid to flow into the second central channel CC via the inlet ports 204 as shown in FIG. 3C, thereby separating the vapor phase from the liquid phase and supplying only the liquid phase into the inlet header 102 and further into the microchannel tubes 106. Thus, the distributor 108 helps achieve a more uniform distribution of the liquid phase of the refrigerant across all the microchannel tubes 106, thereby enhancing the overall thermal performance of the heat exchanger 100.
In one or more embodiments, referring to FIGs. 1A to 1C, when the inlet header 102 includes one or more first compartments 104 and the distributor 108 is configured within the inlet header 102, the outlet ports (202 shown in FIGs. 2A, 2B and 3C) can be configured at first predefined positions on the first tube 112 such that at least one of the outlet ports 202 remains in each of the first compartments 104, thereby fluidically connecting each of the first helical channels HC to at least one of the first compartments 104 of the inlet header 102. Further, the inlet ports (204 shown in FIG. 3C) can be configured at second predefined positions on the second tube 114 such that the inlet ports 204 fluidically connect each of the first channels HC to the second central channel CC.
In one or more embodiments, referring to FIGs. 1D to 1F, when the inlet header 102 includes the first compartments 104 and the distributor 108 is configured outside of the inlet header 102, the outlet ports 202 can be configured at first predefined positions on the first tube 112 such that at least one of the outlet ports 202 remains fluidically connected to each of the first compartments 104 via one of the tube stubs, thereby fluidically connecting each of the first helical channels HC to at least one of the first compartments 104 of the inlet header 102. Further, the inlet ports 204 can be configured at second predefined positions on the second tube 114 such that the inlet ports 204 fluidically connect each of the first channels HC to the second central channel CC.
In one or more embodiments (not illustrated here), when the second tube 114 comprises a plurality of second channels extending longitudinally therethrough, the inlet ports 204 can be configured at the second predefined positions on the second tube 114 such that the inlet ports 204 fluidically connect each of the first channels HC to the at least one of the second channel CC.
Referring to FIG. 1A, in one or more embodiments, the distributor 108 can be disposed in the inlet header 102 such that the distributor 108 extends through each of the first compartments 104-1 to 104-N of the inlet header 102, with the second tube 114 concentrically disposed in the first tube 112 such that the open second end 114-2 of the second tube 114 extends at least partially out of the closed second end 112-2 of the first tube 112 and further out of second end 102-2 of the inlet header 102 to transfer the substantially vapor phase out of the inlet header 102. Accordingly, the substantially vapor phase flowing into the second tube 114 or the second central channel via the inlet ports 204 can be collected or transferred out of the distributor 108 and inlet header 102 via the open second end 114-2 of the second tube 114.
Referring to FIGs. 1B and 1C, in one or more embodiments, the distributor 108 can be longitudinally disposed in the inlet header 102 such that the open second end 114-2 of the second tube 114 extends at least partially out of the closed second end 112-2 of the first tube 112 into one of the first compartments 104 of the inlet header 102 to transfer the vapor phase into the corresponding first compartment. For instance, the first tube 112 can extend through the compartments 104-1 to 114-4, and the second tube 114 can extend at least partially into the compartment 114-N such that the open second end 114-2 of the second tube 114 extends at least partially out of the closed second end 112-2 of the first tube 112 into the compartment 104-N, thereby transferring the substantially vapor phase into the corresponding compartment 104-N.
In one or more embodiments, a set of tubes (designated as A in FIGs. 1B and 1C) among the plurality of microchannel tubes 106, connected to one of the first compartments 104-N that is receiving the vapor phase from the distributor 108, can have a size greater than the size of remaining tubes (designated as B in FIGs. 1B and 1C) among the plurality of microchannel tubes 106. For instance, the tubes A can have a size greater than the size of the remaining tubes B among the plurality of microchannel tubes 106 as shown in FIGs. 1B and 1C. This may allow the tubes A to mostly carry the vapor with a much lower density than the substantially liquid phase fluid carried in the tubes B of the heat exchanger.
Referring to FIG. 1D, in one or more embodiments, the distributor 108 can be configured external to or outside of the inlet header 102 such that the distributor 108 extends substantially parallel to the inlet header 102, however, the distributor 108 may also be configured non-parallel to the inlet header 102. Further, the second tube 114 of the distributor 102 can be concentrically disposed in the first tube 112 such that the open second end 114-2 of the second tube 114 extends at least partially out of the closed second end 112-2 of the first tube 112 to transfer the vapor phase out of the first tube 112. Accordingly, the distributor 108 can receive the two-phase working fluid (refrigerant) within the plurality of first channels HC via the open first end 112-1 of the first tube 112 and cause the two-phase fluid to flow in a helical motion. This can cause the liquid phase (being denser) associated with the two-phase fluid to radially flow out of the distributor 108 into the inlet header 102 via the outlet ports 202 and the tube stubs under the centrifugal force and the vapor phase (being less dense) associated with the two-phase fluid to flow into the second central channel CC or second tube 114 via the inlet ports 204. Further, the vapor phase flowing through the second tube 114 can be collected or transferred out of the distributor 108 via the open second end 114-2 of the second tube 114.
Referring to FIG. 1E, the heat exchanger 100 can include a single header 102 having a plurality of (first) compartments 104-1 to 104-N separated by partition walls. The compartments can include at least one fluid inlet compartment 104-1, 104-3, and 104-N, and at least one fluid outlet compartment 104-2 and 104-4. In addition, the plurality of tubes 106 of the heat exchange section can have a predefined number of turns and passes such that the tubes 106 associated with each of the passes can fluidically connect and extend between one of the fluid inlet compartments 104-1, 104-3, and 104-N and one of the fluid outlet compartments 104-2 and 104-4 among compartments. Further, the heat exchanger 100 can include the distributor 108 configured outside and fluidically connected to the header 102. In such embodiments, the outlet ports 202 of the distributor 108 can be provided at first predefined positions on the first tube 112, such that at least one of the outlet ports 202 remains fluidically connected to at least one of the fluid inlet compartments 104-1, 104-3, and 104-N via one of the tube stubs to allow flow of liquid phase, separated within the distributor 108, out of the distributor 108 into the fluid inlet compartments 104-1, 104-3, and 104-N and further evenly distributing into the corresponding tubes 106. Further, each of the fluid outlet compartments 104-2 and 104-4 can include an opening 122 to discharge a substantially vapor phase created, within the corresponding tubes 106, out of the header 102.
Further, in one or more embodiments, the second tube 114 of the distributor 102 of FIG. 1E can be concentrically disposed in the first tube 112 such that the open second end 114-2 of the second tube 114 extends at least partially out of the closed second end 112-2 of the first tube 112 to transfer the vapor phase, separated within the distributor 108, out of the inlet header 102.
Referring to FIG. 1F, in one or more embodiments, the distributor 108 can be configured external to or outside of the inlet header 102 such that the distributor 108 extends substantially parallel to the inlet header 102, however, the distributor 108 may also be configured non-parallel to the inlet header 102. Further, at least one of the outlet ports 202 associated with the distributor 108 can be fluidically connected to each of the first compartments 104-1 to 104-4 of the inlet header 102 via a tube stub. Furthermore, the open second end 114-2 of the second tube 114 of the distributor 108 can extend at least partially out of the closed second end 112-2 of the first tube 112 into an external compartment 124. The external compartment 124 may be further fluidically connected to one of the first compartments 104-N of the inlet header 102.
Accordingly, the distributor 108 can receive the two-phase working fluid (refrigerant) within the plurality of first channels HC via the open first end 112-1 of the first tube 112 and cause the two-phase fluid to flow in a helical motion, which can cause the liquid phase (being heavier) associated with the two-phase fluid to radially flow out of the distributor 108 into the compartments 104-1 to 104-4 of the inlet header 102 via the outlet ports 202 and the tube stubs under the centrifugal force and the vapor phase (being lighter) associated with the two-phase fluid to flow into the second central channel CC or second tube 114 via the inlet ports 204. Further, the vapor phase flowing through the second tube 114 can be collected or transferred to the external compartment 124 and further into the compartment 104-N of the inlet header 102 via another tube stub.
In one or more embodiments, a set of tubes (designated as A in FIG. 1F) among the plurality of microchannel tubes 106, connected to one of the first compartments 104-N that is receiving the vapor phase from the external compartment 124 of the distributor 108, can have a size greater than the size of remaining tubes (designated as B in FIGs. 1B and 1C) among the plurality of microchannel tubes 106. For instance, the tubes A can have a size greater than the size of the remaining tubes B among the plurality of microchannel tubes 106 as shown in FIGs. 1B and 1C.
Referring to FIGs. 1G and 1H, in one or more embodiments, the heat exchanger 100 may not include the inlet header, where the heat exchange section can include a plurality of tubes 106 having a predefined number and passes. As illustrated, the tubes 106 may be in a serpentine configuration, but is not limited to the like, and the fins 110 may be of inserted-fin type. Further, the distributor 108 can be fluidically connected to the inlets of the tubes 106, where the outlet ports 202 of the distributor can be directly fluidically connected to the inlets of the tubes 106.
In one or more embodiments, referring to FIG. 1G, the open second end 114-2 of the second tube 114 of the distributor 108 can extend at least partially out of the closed second end 112-2 of the first tube 112. Accordingly, the distributor 108 can be configured to receive a two-phase fluid within the plurality of first channels HC via the open first end 112-1 of the first tube 112, causing the two-phase fluid to flow in a helical motion. This helical motion of the two-phase fluid can cause a liquid phase associated with the two-phase fluid to radially flow out of the distributor 108 into the plurality of tubes 106 of the heat exchange section via the outlet ports 202 (not shown). Further, the vapor phase flowing through the second tube 114 can be collected or transferred out of the distributor 108 via the open second end 114-2 of the second tube 114.
In one or more embodiments, referring to FIG. 1H, when the distributor 108 is without the second tube, the distributor 108 can be configured to receive a two-phase fluid within the plurality of first channels HC via the open first end 112-1 of the first tube 112, causing the two-phase fluid to flow in helical motion, and allows the fluid to flow out of the distributor 108 into the plurality of tubes 106 of the heat exchange section via the outlet ports 202 (not illustrated here).
Referring back to FIGs. 1A, 1B and 1D to 1F, the open second end 114-2 of the second tube 114 can include a check valve 116. The check valve can be employed during heat pump applications where the flow through the heat exchanger may reverse. However, the open second end 114-2 of the second tube 114 may not include the check valve 116 as shown in FIG. 1C. Further, referring to FIGs. 1A to 1H, the closed first end 114-1 of the second tube 114 can be closed by an optional flow restrictor 118, and the open first end 112-1 of the first tube 112 or the distributor 108 can be configured to be fluidically connected to a supply tube 120 associated with the heat exchanger 100.
In one or more embodiments, the first tube 112 and second tube 114 of the distributor 108 can have a cylindrical profile with an inner circular cross-section, however, in other embodiments, the first tube 112 and second tube 114 can also have a non-cylindrical or polyhedral profile with an inner circular cross-section or a polygonal cross-section, without any limitations.
In one or more embodiments, for the heat exchanger 100 of FIG. 1A, an opening can be provided at a first end (supply tube end) 102-1 as well as a second end 102-2 (opposite to the first end) of the inlet header 102, and a hole can be provided on each of the partition walls of the inlet header 102 such that the opening of the inlet header 102 and the holes of the partition walls of the compartments 104 remain in line. Further, the distributor 108 can be extended longitudinally into the inlet header 102 through the opening and holes of the walls such that the open second end 114-2 of the second tube 114 extends out of the inlet header 102 via the last compartment 104-N at the second end 102-2 of the inlet header 102. Finally, the overall distributor 108 and inlet header 102 can be brazed to secure the distributor 108 to the inlet header 102 body and make a leakproof structure.
In one or more embodiments, for the heat exchanger 100 of FIG. 1B and 1C, an opening can be provided at the first end (supply tube end) of the inlet header 102, and a hole can be provided on each of the partition walls of the inlet header 102 such that the opening of the inlet header 102 and the holes of the partition walls of the compartments 104 remain in line. Further, the distributor 108 can be extended longitudinally into the inlet header 102 through the opening and holes of the walls such that the open second end 114-2 of the second tube 114 opens in the last compartment 104-N at the second end 102-2 of the inlet header 102. Finally, the overall distributor 108 and inlet header 102 can be brazed to secure the distributor 108 to the inlet header 102 body and make a leakproof structure.
Thus, this invention addresses the challenges posed by existing heat exchangers, by providing an improved and effective fluid distributor that helps the heat exchanger achieve a more uniform distribution of the working fluid phases (liquid phase of refrigerant) across all the heat exchange tubes, thereby enhancing the overall thermal performance of the heat exchanger. Moreover, the fluid distributor also reduces or restricts the flow of the vapor phase of refrigerant into the heat exchange tubes. In addition, the distributor allows the outlet ports to be arranged at the same radial location around the distributor which is not possible with existing axial extrusion distributors.
While the present invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention as defined by the appended claims. Modifications may be made to adopt a particular situation or material to the teachings of the present invention without departing from the scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed, but that the present invention includes all embodiments falling within the scope of the present invention as defined by the appended claims.
In interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
The following clauses set out features of the invention which may not presently be claimed in this application, but which may form the basis for future amendment or a divisional application.

1. A fluid distributor for a heat exchanger, the fluid distributor comprising:
- a first tube having an open first end and a closed second end, wherein a plurality of first channels extends in a helical configuration along a length in an interior of the first tube, and one or more outlet ports are configured along a surface of the first tube,
- wherein the distributor is configured with the heat exchanger such that the one or more outlet ports fluidically connect the plurality of first channels to a plurality of tubes associated with a heat exchange section of the heat exchanger or an interior volume of an inlet header associated with the heat exchanger.
2. The fluid distributor of clause 1, wherein the distributor is configured to receive a two-phase fluid within the plurality of first channels via the first open end of the first tube, causing the two-phase fluid to flow in helical motion, wherein the helical motion of the two-phase fluid causes the fluid to radially flow out of the distributor into the plurality of tubes of the heat exchange section or the internal volume of the inlet header via the one or more outlet ports.
3. The distributor of clause 1, wherein the distributor comprises:
- a second tube having a closed first end and an open second end, the second tube concentrically disposed within and extending longitudinally through the first tube with a predefined gap therebetween to define a shape of the distributor;
- wherein the second tube forms a second central channel within the first tube and the plurality of first channels extend in the helical configuration around the second central channel, along the length of the first tube, within the gap between the first tube and second tube; and
- one or more inlet ports configured along a surface of the second tube, wherein the one or more inlet ports fluidically connect the plurality of first channels to the second central channel.
4. The fluid distributor of any one of clauses 1 and 3, wherein the distributor is configured to receive a two-phase fluid within the plurality of first channels via the first open end of the first tube, causing the two-phase fluid to flow in helical motion, wherein the helical motion of the two-phase fluid causes a liquid phase associated with the two-phase fluid to radially flow out of the distributor into the tubes of the heat exchange section or the internal volume of the inlet header via the one or more outlet ports and a vapor phase associated with the two-phase fluid to flow into the second central channel via the one or more inlet ports.
5. The distributor of any one of clauses 1 to 4, wherein the distributor is configured to be longitudinally disposed in the inlet header such that the distributor extends at least partially through the inlet header.
6. The fluid distributor of clause 5, wherein the inlet header comprises one or more first compartments separated by one or more first walls, wherein the one or more outlet ports are configured at first predefined positions on the first tube, such that at least one of the one or more outlet ports remains in each of the first compartments.
7. The distributor of any one of clauses 1 to 4, wherein the distributor is configured external to the inlet header with the one or more outlet ports fluidically connecting the plurality of first channels of the distributor to the plurality of tubes of the heat exchange section or the interior volume of the inlet header.
8. The fluid distributor of clause 7, wherein the inlet header comprises one or more first compartments separated by one or more first walls, wherein the one or more outlet ports are configured at first predefined positions on the first tube, such that at least one of the one or more outlet ports remains fluidically connected to at least one of the first compartments via one or more tube stubs.
9. The fluid distributor of clause 7, wherein the inlet header comprises a plurality of first compartments separated by one or more first walls, the plurality of first compartments comprising at least one fluid inlet compartment and at least one fluid outlet compartment, wherein the plurality of tubes of the heat exchange section has a predefined number of turns and passes such that the tube associated with each of the passes extends between one of the fluid inlet compartments and one of the fluid outlet compartments among the one or more first compartments.
10. The fluid distributor of clause 9, wherein the one or more outlet ports of the distributor are configured at first predefined positions on the first tube, such that at least one of the one or more outlet ports remains fluidically connected to at least one of the fluid inlet compartments via one or more tube stubs, and wherein each of the fluid outlet compartments comprises an opening to discharge a substantially vapor phase, created within the corresponding tubes, out of the inlet header.
11. The fluid distributor of any one of clauses 1 to 10, wherein the one or more inlet ports are configured at second predefined positions on the second tube, such that the one or more inlet ports fluidically connect each of the first channels to the second central channel.
12. The fluid distributor of any one of clauses 1 to 11, wherein the second central channel comprises a plurality of second channels extending longitudinally through the second tube, wherein the one or more inlet ports are configured at second predefined positions on the second tube, such that the one or more inlet ports fluidically connects each of the first channels to the at least one of the second channel.
13. The fluid distributor of clause 6, wherein the distributor is disposed in the inlet header such that the distributor extends through each of the first compartments of the inlet header, wherein the second tube is concentrically disposed in the first tube such that the second open end of the second tube extends at least partially out of the second closed end of the first tube and the inlet header to transfer the vapor phase out of the inlet header.
14. The fluid distributor of clause 6, wherein the distributor is longitudinally disposed in the inlet header such that the second open end of the second tube extends at least partially out of the second closed end of the first tube into one of the first compartments of the inlet header to transfer the vapor phase into the corresponding first compartment.
15. The fluid distributor of clause 8, wherein the second open end of the second tube extends at least partially out of the second closed end of the first tube to transfer the vapor phase out of the inlet header.
16. The fluid distributor of clause 8, wherein the second open end of the second tube extends at least partially out of the second closed end of the first tube into an external compartment to transfer the vapor phase into the corresponding external compartment, wherein the external compartment comprises at least one of the outlet ports fluidically connected to at least one of the first compartments of the inlet header.
17. The fluid distributor of clause 9, wherein the second open end of the second tube extends at least partially out of the second closed end of the first tube to transfer the vapor phase, separated within the distributor, out of the inlet header.
18. The fluid distributor of any one of clauses 1 to 17, wherein the second open end of the second tube comprises a check valve to restrict back flow of the vapor phase into the second tube or the second central channel, and wherein the first end of the second tube is closed by a flow restrictor, and the first open end of the first tube or the distributor is configured to be fluidically connected to a supply tube associated with the heat exchanger.
19. The fluid distributor of any one of clauses 1 to 18, wherein the heat exchanger comprises a plurality of heat-dissipating fins in thermal contact with the plurality of tubes in the heat exchange section of the heat exchanger, wherein the plurality of heat-dissipating fins is any of corrugated-fin type or inserted-fin type.
20. The fluid distributor of any one of clauses 1 to 19, wherein the heat exchanger is in a horizontal configuration or a vertical configuration.

Claims

A fluid distributor (108) for a heat exchanger (100), the fluid distributor comprising:
a first tube (112) having an open first end (112-1) and a closed second end (112-2), wherein a plurality of first channels (HC) extends in a helical configuration along a length in an interior of the first tube (112), and one or more outlet ports (202) are configured along a surface of the first tube (112),

wherein the fluid distributor (108) is configured with the heat exchanger (100) such that the one or more outlet ports (202) fluidically connect the plurality of first channels (HC) to a plurality of tubes (106) associated with a heat exchange section of the heat exchanger (100) or an interior volume of an inlet header (102) associated with the heat exchanger.
The fluid distributor of claim 1, wherein the fluid distributor (108) is configured to receive a two-phase fluid within the plurality of first channels (HC) via the open first end (112-1) of the first tube (112), causing the two-phase fluid to flow in helical motion, wherein the helical motion of the two-phase fluid causes the fluid to radially flow out of the fluid distributor (108) into the plurality of tubes (106) of the heat exchange section or the internal volume of the inlet header (102) via the one or more outlet ports (202).
The fluid distributor of claim 1, wherein the fluid distributor (108) comprises:
a second tube (114) having a closed first end (114-1) and an open second end (114-2), the second tube (114) concentrically disposed within and extending longitudinally through the first tube (112) with a predefined gap therebetween to define a shape of the fluid distributor (108);

wherein the second tube (114) forms a second central channel (CC) within the first tube (112) and the plurality of first channels (HC) extend in the helical configuration around the second central channel (CC), along the length of the first tube (112), within the gap between the first tube (112) and second tube (114); and

one or more inlet ports (204) configured along a surface of the second tube (114), wherein the one or more inlet ports (204) fluidically connect the plurality of first channels (HC) to the second central channel (CC).
The fluid distributor of claim 3, wherein the fluid distributor (108) is configured to receive a two-phase fluid within the plurality of first channels (HC) via the open first end (112-1) of the first tube (112), causing the two-phase fluid to flow in helical motion, wherein the helical motion of the two-phase fluid causes a liquid phase associated with the two-phase fluid to radially flow out of the fluid distributor (108) into the tubes (106) of the heat exchange section or the internal volume of the inlet header (102) via the one or more outlet ports (202) and a vapor phase associated with the two-phase fluid to flow into the second central channel (CC) via the one or more inlet ports (204).
The fluid distributor of any preceding claim, wherein the fluid distributor (108) is configured to be longitudinally disposed in the inlet header (102) such that the fluid distributor (108) extends at least partially through the inlet header (102).
The fluid distributor of claim 5, wherein the inlet header (102) comprises one or more first compartments (104) separated by one or more first walls, wherein the one or more outlet ports (202) are configured at first predefined positions on the first tube (112), such that at least one of the one or more outlet ports (202) remains in each of the first compartments (104).
The fluid distributor of any of claims 1 to 4, wherein the fluid distributor (108) is configured external to the inlet header (102) with the one or more outlet ports (202) fluidically connecting the plurality of first channels (HC) of the fluid distributor (108) to the plurality of tubes (106) of the heat exchange section or the interior volume of the inlet header (102).
The fluid distributor of claim 7, wherein the inlet header (102) comprises one or more first compartments (104) separated by one or more first walls, wherein the one or more outlet ports (202) are configured at first predefined positions on the first tube (112), such that at least one of the one or more outlet ports (202) remains fluidically connected to at least one of the first compartments (104) via one or more tube stubs.
The fluid distributor of claim 7, wherein the inlet header (102) comprises a plurality of first compartments (104) separated by one or more first walls, the plurality of first compartments (104) comprising at least one fluid inlet compartment (104-1, 104-3) and at least one fluid outlet compartment (104-2, 104-4), wherein the plurality of tubes (106) of the heat exchange section has a predefined number of turns and passes such that the tube associated with each of the passes extends between one of the fluid inlet compartments (104-1, 104-3) and one of the fluid outlet compartments (104-2, 104-4) among the one or more first compartments,
optionally, wherein the one or more outlet ports (202) of the fluid distributor are configured at first predefined positions on the first tube (112), such that at least one of the one or more outlet ports (202) remains fluidically connected to at least one of the fluid inlet compartments (104-1, 104-3) via one or more tube stubs, and wherein each of the fluid outlet compartments (104-2, 104-4) comprises an opening (122) to discharge a substantially vapor phase, created within the corresponding tubes, out of the inlet header (102).
The fluid distributor of any of claim 3 or any of claims 4 to 9 when dependent from claim 3, wherein the one or more inlet ports (204) are configured at second predefined positions on the second tube (114), such that the one or more inlet ports (204) fluidically connect each of the first channels (HC) to the second central channel (CC),
and/or, wherein the second central channel (CC) comprises a plurality of second channels extending longitudinally through the second tube (114), wherein the one or more inlet ports (204) are configured at second predefined positions on the second tube (114), such that the one or more inlet ports (204) fluidically connects each of the first channels (HC) to the at least one of the second channel (CC).
The fluid distributor of claim 6 when dependent from claim 3, wherein the fluid distributor (108) is disposed in the inlet header (102) such that the fluid distributor extends through each of the first compartments (104) of the inlet header (102), wherein the second tube (114) is concentrically disposed in the first tube (112) such that the open second end (114-2) of the second tube (114) extends at least partially out of the closed second end (112-2) of the first tube (112) and the inlet header (102) to transfer the vapor phase out of the inlet header,
or, wherein the fluid distributor (108) is longitudinally disposed in the inlet header (102) such that the open second end (114-2) of the second tube (114) extends at least partially out of the closed second end (112-2) of the first tube (112) into one of the first compartments (104) of the inlet header (102) to transfer the vapor phase into the corresponding first compartment (104).
The fluid distributor of claim 8 when dependent from claim 3, wherein the open second end (114-2) of the second tube (114) extends at least partially out of the closed second end (112-2) of the first tube (112) to transfer the vapor phase out of the inlet header (102),
or, wherein the open second end (114-2) of the second tube (114) extends at least partially out of the closed second end (112-2) of the first tube (112) into an external compartment (124) to transfer the vapor phase into the corresponding external compartment, wherein the external compartment (124) comprises at least one of the outlet ports (202) fluidically connected to at least one of the first compartments (104) of the inlet header (102).
The fluid distributor of claim 9 when dependent from claim 3, wherein the open second end (114-2) of the second tube (114) extends at least partially out of the closed second end (112-2) of the first tube (112) to transfer the vapor phase, separated within the fluid distributor (108), out of the inlet header (102).
The fluid distributor of any of claim 3 or any of claims 4 to 13 when dependent from claim 3, wherein the open second end (114-2) of the second tube (114) comprises a check valve (116) to restrict back flow of the vapor phase into the second tube (114) or the second central channel (CC), and wherein the closed first end (114-1) of the second tube (114) is closed by a flow restrictor (118), and the open first end (112-1) of the first tube (112) or the fluid distributor (108) is configured to be fluidically connected to a supply tube (120) associated with the heat exchanger (100).
The fluid distributor of any preceding claim, wherein the heat exchanger (100) comprises a plurality of heat-dissipating fins (110) in thermal contact with the plurality of tubes (106) in the heat exchange section of the heat exchanger, wherein the plurality of heat-dissipating fins (110) is any of corrugated-fin type or inserted-fin type,
and/or wherein the heat exchanger (100) is in a horizontal configuration or a vertical configuration.