US20080023184A1 - Heat exchanger assembly - Google Patents
Heat exchanger assembly Download PDFInfo
- Publication number
- US20080023184A1 US20080023184A1 US11/492,244 US49224406A US2008023184A1 US 20080023184 A1 US20080023184 A1 US 20080023184A1 US 49224406 A US49224406 A US 49224406A US 2008023184 A1 US2008023184 A1 US 2008023184A1
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- Prior art keywords
- manifold
- wall
- assembly
- cavity
- inner partition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
- F28F9/0224—Header boxes formed by sealing end plates into covers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/026—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits
- F28F9/027—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits in the form of distribution pipes
- F28F9/0273—Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits in the form of distribution pipes with multiple holes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B39/00—Evaporators; Condensers
- F25B39/02—Evaporators
- F25B39/022—Evaporators with plate-like or laminated elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
- F28D2021/007—Condensers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
- F28D2021/0071—Evaporators
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2220/00—Closure means, e.g. end caps on header boxes or plugs on conduits
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/16—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes extruded
Definitions
- the present invention relates to a heat exchanger assembly and method of manufacturing a manifold.
- Heat exchanger assemblies are widely used in a variety of applications, and can be either single mode or dual mode, depending on whether functioning solely as either a condenser or an evaporator, or if functioning as both.
- the heat exchanger assemblies generally include a pair of manifolds fluidly connected by a plurality of flow tubes. Heat dissipating structures, such as fins, are generally disposed between the flow tubes to add surface area to the heat exchanger assembly for further aiding in heat transfer to or from ambient air passing over the flow tubes.
- Refrigerant enters the heat exchanger assembly through one or more ports which are connected to one or both manifolds. Refrigerant passes through the heat exchanger assembly and is exited through one or more ports connected to one or both of the manifolds.
- One of the primary goals is to maximize heat exchange efficiency by managing the velocity and distribution of the refrigerant, as well as the temperature and pressure differences within the manifolds and the flow tubes.
- a difficulty arises because the flow characteristics of the refrigerant vary depending on the phase, that is, whether the refrigerant is a gas, liquid, or a combination.
- some sections of the heat exchanger assembly can be flooded with refrigerant and some can be starved, resulting in unequal heat transfer between portions of the heat exchanger and can cause icing or frosting of portions of the heat exchanger, further diminishing performance.
- the refrigerant enters the heat exchanger assembly in two-phases, comprising liquid and gas.
- the refrigerant absorbs heat from the ambient air passing over the flow tubes and other heat conducting structures, causing the liquid to further evaporate and the gas phase to further expand.
- Momentum effects due to large mass differences between the liquid and gas phases causes separation of the two-phase refrigerant. Separation of the phases adds to the already present distribution problem within the passes, which further decreases overall heat exchange performance of the evaporator.
- Manufacturing costs can be high because of the number of components, and the precision with which they must be installed to insure proper alignment. Further, manifolds constructed of multiple parts, include joints which can be prone to failure.
- the Nagasaka '407 patent Application discloses manifolds divided into chambers for maximizing heat exchanger assembly efficiency whether a refrigerant is circulated at a high or low flow rate.
- the refrigerant enters the inlet port of the manifold and the chambers direct the refrigerant circulation throughout the heat exchanger assembly.
- the chambers do not solve the problem related to refrigerant distribution within individual flow tubes.
- the Gowan '303 patent Application discloses an extruded manifold for a heat exchanger assembly used as either condensers or evaporators.
- the manifold body includes longitudinal partitions forming a plurality of longitudinal passages to direct refrigerant within the manifold. Again, the number of components is reduced, but a structure to aid in the distribution of the refrigerant is not included.
- the Bloom '083 patent Application discloses a distribution tube disposed within a manifold of a heat exchanger assembly, specifically, a refrigerating coil.
- the distributor tube forms a distribution chamber and includes a plurality of apertures for distributing refrigerant entering the manifold.
- the distribution tube is a separate component joined to the manifold by welding, and thus the problems related to assembly costs and the difficulty of positive placement of the distribution tube are not addressed. Further, the shape and configuration of the resulting distribution chamber is limited.
- the subject invention provides a heat exchanger assembly with a first manifold having a first manifold body defining a hollow cavity.
- a second manifold having a second manifold body defining a hollow cavity is in spaced and substantially parallel relationship with the first manifold.
- a plurality of flow tubes extend between and fluidly connect the cavities of the manifolds for passing refrigerant between the manifolds.
- the first manifold body has an outer wall defining the cavity and an inner partition wall disposed within the cavity adjacent the outer wall with the inner partition wall having a section integrally formed with a portion of the outer wall to define a distribution chamber disposed within the cavity with the inner partition wall having a plurality of apertures fluidly connecting the distribution chamber with the cavity.
- the subject invention also provides a method of manufacturing a manifold having a manifold body with an outer wall defining a hollow cavity, an inner partition wall with a plurality of apertures and at least one end cap, including the following steps: extruding the manifold body having the outer and inner partition walls with the inner partition wall integrally connected to the outer wall to form a distribution chamber within the cavity; cutting the manifold body to a pre-determined length; forming a plurality of openings in the outer wall; forming a plurality of apertures in the inner partition wall aligned with the openings in the outer wall; and mounting the end cap to at least one end of the manifold body.
- FIG. 1 is a perspective view of a heat exchanger assembly
- FIG. 2 is a fragmented perspective view of a first manifold of the heat exchanger assembly, illustrating an inner partition wall;
- FIG. 3 is a cross-sectional top view of one embodiment of the manifold
- FIG. 4 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 5 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 6 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 7 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 8 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 9 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 10 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 11 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 12 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 13 is a cross-sectional top view of another embodiment of the manifold.
- FIG. 14 is a fragmented side view of the manifold illustrating one embodiment of a port connected to the manifold;
- FIG. 15 is a fragmented side view of the manifold illustrating another embodiment of a port connected to the manifold;
- FIG. 16 is a fragmented side view of the manifold illustrating another embodiment of a port connected to the manifold;
- FIG. 17 is a fragmented side view of the manifold illustrating another embodiment of a port connected to the manifold;
- FIG. 18 is a cross-sectional side view of the manifold including separators.
- the heat exchanger assembly 20 includes a first manifold 22 , a second manifold 52 , a plurality of flow tubes 42 fluidly connecting the manifolds 22 , 52 , and a plurality of heat conducting structures, here illustrated as fins 44 .
- the first manifold 22 includes a first manifold body 24 having a length with a first end 58 and a second end 60 .
- An end cap 26 is shown being attached to each end 58 , 60 of the first manifold body 24 .
- the end cap 26 can include a cladding material, and can be joined to the first manifold body 24 using a variety of methods, such as but not limited to, brazing or welding. It can be readily appreciated that the first manifold body 24 can include an end produced as part of an extrusion process.
- the first manifold 22 may be commonly referred to as an inlet manifold, therefore performing an inlet function
- the second manifold 52 may be commonly referred to as an outlet manifold, therefore performing an outlet function, however, the opposite could be true.
- Reference to the first and second manifolds 22 , 52 is interchangeable in the description of the subject invention.
- the second manifold 52 includes a second manifold body 54 and defines a hollow cavity 31 .
- the second manifold 52 has a length with a first end 62 and a second end 64 and is in spaced and substantially parallel relationship with the first manifold 22 . It can be readily appreciated that though the second manifold 52 is shown as having the same general appearance as that of the first manifold 22 , the second manifold 52 can be constructed differently than the first manifold 22 , for example, but not limited to, the second manifold 52 can comprise multiple joined pieces. End caps 26 are shown being attached to each end 62 , 64 of the second manifold body 54 .
- the end cap 26 can include a cladding material, and can be joined to the second manifold body 54 using a variety of methods, such as but not limited to, brazing or welding. It can be readily appreciated that the second manifold body 54 can include an end produced as part of an extrusion process.
- the heat exchanger assembly 20 is shown throughout the drawings with the manifolds 22 , 52 being vertically oriented, it can be readily appreciated that the heat exchanger assembly 20 can be oriented in a variety ways to accommodate engineering requirements of a specific application, for instance, horizontal.
- a plurality of flow tubes 42 extend between and fluidly connect the cavities 30 , 31 of the manifolds 22 , 52 for passing refrigerant between the manifolds 22 , 52 .
- the outer wall 28 includes a plurality of openings 40 sized for accepting the plurality of flow tubes 42 .
- the openings 40 are typically elongated slots, however different shapes can be used, such as but not limited to, circles and squares.
- the flow tubes are disposed within the cavity 30 of the first manifold 22 fluidly connecting the cavity 31 of the second manifold 52 to the cavity 30 of the first manifold 22 .
- the first manifold body 24 has an outer wall 28 defining a cavity 30 and an inner partition wall 32 disposed within the cavity 30 adjacent to the outer wall 28 .
- the inner partition wall 32 has a section 34 integrally formed with a portion of the outer wall 28 to define a distribution chamber 36 disposed within the cavity 30 .
- the inner partition wall 32 has a plurality of apertures 38 fluidly connecting the distribution chamber 36 with the cavity 30 .
- the first manifold body 24 is shown being generally cylindrical, however many shapes are possible. Referring to FIG. 9 , a first thickness T 1 of the inner partition wall 32 and second thickness T 2 of the outer wall 28 can be the same or can be different from one another. In addition, the second thickness T 2 of the outer wall 28 can be uniform or may vary.
- first thickness T 1 of the inner partition wall 32 can be uniform or may vary. It can be readily appreciated that it may be advantageous to have different wall thicknesses T 1 , T 2 in different locations of the first manifold body 24 . A reduced first thickness T 1 may be possible because of the lower operating pressure between the cavity 30 and the distribution chamber 36 , and can save space and weight.
- the second thickness T 2 may be generally dictated by burst strength requirements. Reduced thickness T 1 , T 2 in the inner partition wall 32 and the outer wall 28 could be used to facilitate formation of the plurality of openings 40 and the plurality of apertures 38 , and thicker regions can be used elsewhere to provide structural support, as shown in FIG. 9 .
- the outer wall 28 can be a variety of shapes, for instance and referring to FIG. 12 , the outer wall 28 can include a protrusion resulting in the outer wall 28 itself defining a majority of the distribution chamber 36 .
- the distribution chamber 36 has a length generally defined by the length of the first manifold body 24 . Modifications can be made to the length of the distribution chamber 36 , for instance, by inserting a separator 48 into the distribution chamber 36 , which closes off a portion of the chamber 36 . Alternatively, the effective length of the distribution chamber 36 can be shortened by selectively eliminating some of the plurality of apertures 38 in an unnecessary area.
- the distribution chamber 36 is substantially parallel to the first manifold body 24 . Referring to FIG. 3 , the inner partition wall 32 has a generally C-shaped cross-section. Referring to FIGS.
- the cross-section of the inner partition wall 32 may have many shapes, including but not limited to, arc-like, linear, D-shaped, and a pyramid.
- the distribution chamber 36 can be disposed within the cavity 30 directly opposite the plurality of openings 40 where the plurality of flow tubes 42 are inserted into the first manifold body 24 . Referring to FIGS. 7-8 , it can be appreciated that the distribution chamber 36 can also be located in different positions within the cavity 30 to accommodate variations in plumbing, flow and refrigerant distribution requirements.
- the plurality of apertures 38 are disposed within the inner partition wall 32 generally run along the length of the distribution chamber 36 and are generally aligned with the plurality of openings 40 in the outer wall 28 , but can vary depending on performance requirements.
- the plurality of apertures 38 can comprise a variety of shapes and sizes, including but not limited to, circles and polygons.
- a flat ledge 50 can be included along the length of the inner partition wall 32 disposed within the cavity 30 , for locating and forming the plurality of apertures 38 .
- At least one port may be in the first manifold 22 and fluidly connected to at least one of the distribution chamber 36 and the cavity 30 .
- the port may be an orifice or a tube, as is known in the art.
- the port may be an inlet, an outlet, or a combination of both. Referring to FIG. 1 , one of the ports is an inlet port 56 and is fluidly connected to the first manifold 22 for introducing refrigerant into the heat exchanger and another one of the ports is an outlet port 57 and is fluidly connected to the second manifold 52 for exiting refrigerant from the heat exchanger assembly 20 . Referring to FIGS.
- the preferred embodiment includes the port 56 , 57 fluidly connected to the distribution chamber 36 , either through the end cap 26 or the outer wall 28 .
- the port 56 , 57 can be fluidly connected to the cavity 30 of the first manifold 22 through the outer wall 28 or through the end cap 26 .
- the ports 56 , 57 can include a coupler 66 .
- the coupler 66 may be useful for connecting external plumbing to the heat exchanger assembly 20 and may also be useful for manufacturing purposes.
- the ports 56 , 57 can be fluidly connected to the second manifold 52 as described for the first manifold 22 , depending on the engineering requirements of a specific application.
- a separator 48 can be inserted within the cavity 30 , 31 and/or distribution chamber 36 , further dividing the cavity 30 , 31 and distribution chamber 36 .
- the present invention also provides a method of manufacturing a manifold having a first manifold body 24 with an outer wall 28 defining a hollow cavity 30 , an inner partition wall 32 with a plurality of apertures 38 and at least one end cap 26 .
- the method includes the step of extruding the first manifold body 24 which has an outer wall 28 and an inner partition wall 32 with the inner partition wall 32 integrally connected to the outer wall 28 to form a distribution chamber 36 within the cavity 30 .
- the method further includes the step of cutting the first manifold body 24 to a predetermined length. Cutting can be accomplished by any means.
- the method further includes forming a plurality of openings 40 in the outer wall 28 .
- the openings 40 can be formed by a variety of means, including, but not limited to, drilling, lancing or punching.
- the method further includes forming a plurality of apertures 38 in the inner partition wall 32 aligned with the openings 40 in the outer wall 28 .
- the method further includes inserting a separator 48 into the manifold body 24 . It can be appreciated that the separator 48 can be slid into the distribution chamber 36 or the cavity 30 or alternatively that the separator 48 can be inserted through a slot 49 formed in the outer wall 28 . It can further be appreciated that more than one separator 48 can be inserted, and the separator 48 can span the distribution chamber 36 , the cavity 30 or both 30 , 36 .
- the method further includes mounting the end cap 26 to one end of the first manifold body 24 .
Abstract
A heat exchanger assembly includes a first manifold having a first manifold body with an outer wall defining a cavity and an inner partition wall integrally formed with the outer wall to define a distribution chamber disposed within the cavity. A second manifold defines a hollow cavity and is in spaced and substantially parallel relationship with the first manifold. A plurality of flow tubes extend between and fluidly connect the cavities of the manifolds. The inner partition wall has a plurality of apertures fluidly connecting the distribution chamber with the cavity. A method of manufacturing the first manifold includes the steps of extruding the manifold body, forming a plurality of openings in the outer wall, forming a plurality of apertures in the inner partition wall, inserting a separator in the manifold body, and mounting the end cap to one end of the first manifold body.
Description
- 1. Field of the Invention
- The present invention relates to a heat exchanger assembly and method of manufacturing a manifold.
- 2. Description of the Prior Art
- Heat exchanger assemblies are widely used in a variety of applications, and can be either single mode or dual mode, depending on whether functioning solely as either a condenser or an evaporator, or if functioning as both. The heat exchanger assemblies generally include a pair of manifolds fluidly connected by a plurality of flow tubes. Heat dissipating structures, such as fins, are generally disposed between the flow tubes to add surface area to the heat exchanger assembly for further aiding in heat transfer to or from ambient air passing over the flow tubes. Refrigerant enters the heat exchanger assembly through one or more ports which are connected to one or both manifolds. Refrigerant passes through the heat exchanger assembly and is exited through one or more ports connected to one or both of the manifolds.
- One of the primary goals is to maximize heat exchange efficiency by managing the velocity and distribution of the refrigerant, as well as the temperature and pressure differences within the manifolds and the flow tubes. A difficulty arises because the flow characteristics of the refrigerant vary depending on the phase, that is, whether the refrigerant is a gas, liquid, or a combination. When there is poor refrigerant distribution and circulation, some sections of the heat exchanger assembly can be flooded with refrigerant and some can be starved, resulting in unequal heat transfer between portions of the heat exchanger and can cause icing or frosting of portions of the heat exchanger, further diminishing performance.
- The largest problems exist when the heat exchanger assembly is operating as an evaporator. The refrigerant enters the heat exchanger assembly in two-phases, comprising liquid and gas. As the two-phase refrigerant circulates through the heat exchanger, the refrigerant absorbs heat from the ambient air passing over the flow tubes and other heat conducting structures, causing the liquid to further evaporate and the gas phase to further expand. Momentum effects due to large mass differences between the liquid and gas phases causes separation of the two-phase refrigerant. Separation of the phases adds to the already present distribution problem within the passes, which further decreases overall heat exchange performance of the evaporator.
- Manufacturing costs, particularly assembly costs, can be high because of the number of components, and the precision with which they must be installed to insure proper alignment. Further, manifolds constructed of multiple parts, include joints which can be prone to failure.
- Several approaches have been employed to address the problem of refrigerant distribution in heat exchanger assemblies operating as evaporators, as well as the problem of assembly cost. Examples of these heat exchanger assemblies are disclosed in U.S. Pat. No. 5,203,407 to Nagasaka, U.S. Patent Publication 2004/0194312 A1 to Gowan et al., U.S. Pat. No. 6,830,100 B2 to Gowan et al., U.S. Pat. No. 5,941,303 to Gowan, et al., and U.S. Pat. No. 1,684,083 to Bloom.
- The Nagasaka '407 patent Application discloses manifolds divided into chambers for maximizing heat exchanger assembly efficiency whether a refrigerant is circulated at a high or low flow rate. The refrigerant enters the inlet port of the manifold and the chambers direct the refrigerant circulation throughout the heat exchanger assembly. The chambers do not solve the problem related to refrigerant distribution within individual flow tubes.
- The Gowan '312 patent Application and '100 patent Publication disclose an extruded manifold which reduces the number of components, however they fail to include any structure to aid in the distribution of the refrigerant.
- The Gowan '303 patent Application discloses an extruded manifold for a heat exchanger assembly used as either condensers or evaporators. The manifold body includes longitudinal partitions forming a plurality of longitudinal passages to direct refrigerant within the manifold. Again, the number of components is reduced, but a structure to aid in the distribution of the refrigerant is not included.
- The Bloom '083 patent Application, discloses a distribution tube disposed within a manifold of a heat exchanger assembly, specifically, a refrigerating coil. The distributor tube forms a distribution chamber and includes a plurality of apertures for distributing refrigerant entering the manifold. The distribution tube is a separate component joined to the manifold by welding, and thus the problems related to assembly costs and the difficulty of positive placement of the distribution tube are not addressed. Further, the shape and configuration of the resulting distribution chamber is limited.
- Accordingly, an opportunity exists to produce a manifold for a heat exchanger assembly which incorporates structures that aid in the distribution of refrigerant when operating as an evaporator. In addition, it would be advantageous for the manifold to minimize components required in order to reduce assembly costs.
- The subject invention provides a heat exchanger assembly with a first manifold having a first manifold body defining a hollow cavity. A second manifold having a second manifold body defining a hollow cavity is in spaced and substantially parallel relationship with the first manifold. A plurality of flow tubes extend between and fluidly connect the cavities of the manifolds for passing refrigerant between the manifolds. The first manifold body has an outer wall defining the cavity and an inner partition wall disposed within the cavity adjacent the outer wall with the inner partition wall having a section integrally formed with a portion of the outer wall to define a distribution chamber disposed within the cavity with the inner partition wall having a plurality of apertures fluidly connecting the distribution chamber with the cavity.
- The subject invention also provides a method of manufacturing a manifold having a manifold body with an outer wall defining a hollow cavity, an inner partition wall with a plurality of apertures and at least one end cap, including the following steps: extruding the manifold body having the outer and inner partition walls with the inner partition wall integrally connected to the outer wall to form a distribution chamber within the cavity; cutting the manifold body to a pre-determined length; forming a plurality of openings in the outer wall; forming a plurality of apertures in the inner partition wall aligned with the openings in the outer wall; and mounting the end cap to at least one end of the manifold body.
- The production of an extruded single-piece manifold body which includes an integral distribution chamber, allows for the positive location of the distribution chamber, and more robust construction than designs using multiple pieces by including a distribution chamber as an integral part of the manifold body. Incorporation of the distribution chamber in the single piece construction, also results in the reduction of manufacturing costs by reducing the number of parts required, and avoids problems associated with mechanical assembly, location and joining of separate distribution tubes, in particular, for longer manifolds.
- Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
-
FIG. 1 is a perspective view of a heat exchanger assembly; -
FIG. 2 is a fragmented perspective view of a first manifold of the heat exchanger assembly, illustrating an inner partition wall; -
FIG. 3 is a cross-sectional top view of one embodiment of the manifold; -
FIG. 4 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 5 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 6 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 7 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 8 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 9 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 10 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 11 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 12 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 13 is a cross-sectional top view of another embodiment of the manifold; -
FIG. 14 is a fragmented side view of the manifold illustrating one embodiment of a port connected to the manifold; -
FIG. 15 is a fragmented side view of the manifold illustrating another embodiment of a port connected to the manifold; -
FIG. 16 is a fragmented side view of the manifold illustrating another embodiment of a port connected to the manifold; -
FIG. 17 is a fragmented side view of the manifold illustrating another embodiment of a port connected to the manifold; -
FIG. 18 is a cross-sectional side view of the manifold including separators. - Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a heat exchanger assembly is generally shown at 20 in
FIG. 1 . Theheat exchanger assembly 20 includes afirst manifold 22, asecond manifold 52, a plurality offlow tubes 42 fluidly connecting themanifolds fins 44. Thefirst manifold 22 includes a firstmanifold body 24 having a length with afirst end 58 and asecond end 60. Anend cap 26 is shown being attached to eachend manifold body 24. Theend cap 26 can include a cladding material, and can be joined to the firstmanifold body 24 using a variety of methods, such as but not limited to, brazing or welding. It can be readily appreciated that the firstmanifold body 24 can include an end produced as part of an extrusion process. As is known to those skilled in the art, thefirst manifold 22 may be commonly referred to as an inlet manifold, therefore performing an inlet function, and thesecond manifold 52 may be commonly referred to as an outlet manifold, therefore performing an outlet function, however, the opposite could be true. Reference to the first andsecond manifolds - The
second manifold 52 includes a secondmanifold body 54 and defines ahollow cavity 31. Thesecond manifold 52 has a length with afirst end 62 and asecond end 64 and is in spaced and substantially parallel relationship with thefirst manifold 22. It can be readily appreciated that though thesecond manifold 52 is shown as having the same general appearance as that of thefirst manifold 22, thesecond manifold 52 can be constructed differently than thefirst manifold 22, for example, but not limited to, thesecond manifold 52 can comprise multiple joined pieces. End caps 26 are shown being attached to eachend manifold body 54. Theend cap 26 can include a cladding material, and can be joined to the secondmanifold body 54 using a variety of methods, such as but not limited to, brazing or welding. It can be readily appreciated that the secondmanifold body 54 can include an end produced as part of an extrusion process. Though theheat exchanger assembly 20 is shown throughout the drawings with themanifolds heat exchanger assembly 20 can be oriented in a variety ways to accommodate engineering requirements of a specific application, for instance, horizontal. - A plurality of
flow tubes 42 extend between and fluidly connect thecavities manifolds manifolds FIG. 2 , theouter wall 28 includes a plurality ofopenings 40 sized for accepting the plurality offlow tubes 42. Theopenings 40 are typically elongated slots, however different shapes can be used, such as but not limited to, circles and squares. The flow tubes are disposed within thecavity 30 of thefirst manifold 22 fluidly connecting thecavity 31 of thesecond manifold 52 to thecavity 30 of thefirst manifold 22. - Referring to
FIG. 2 , the firstmanifold body 24 has anouter wall 28 defining acavity 30 and aninner partition wall 32 disposed within thecavity 30 adjacent to theouter wall 28. Theinner partition wall 32 has asection 34 integrally formed with a portion of theouter wall 28 to define adistribution chamber 36 disposed within thecavity 30. Theinner partition wall 32 has a plurality ofapertures 38 fluidly connecting thedistribution chamber 36 with thecavity 30. The firstmanifold body 24 is shown being generally cylindrical, however many shapes are possible. Referring toFIG. 9 , a first thickness T1 of theinner partition wall 32 and second thickness T2 of theouter wall 28 can be the same or can be different from one another. In addition, the second thickness T2 of theouter wall 28 can be uniform or may vary. Similarly, the first thickness T1 of theinner partition wall 32 can be uniform or may vary. It can be readily appreciated that it may be advantageous to have different wall thicknesses T1, T2 in different locations of the firstmanifold body 24. A reduced first thickness T1 may be possible because of the lower operating pressure between thecavity 30 and thedistribution chamber 36, and can save space and weight. The second thickness T2 may be generally dictated by burst strength requirements. Reduced thickness T1, T2 in theinner partition wall 32 and theouter wall 28 could be used to facilitate formation of the plurality ofopenings 40 and the plurality ofapertures 38, and thicker regions can be used elsewhere to provide structural support, as shown inFIG. 9 . Though the cross-section of theouter wall 28 is generally illustrated as being circular, it can be readily appreciated that theouter wall 28 can be a variety of shapes, for instance and referring toFIG. 12 , theouter wall 28 can include a protrusion resulting in theouter wall 28 itself defining a majority of thedistribution chamber 36. - The
distribution chamber 36 has a length generally defined by the length of the firstmanifold body 24. Modifications can be made to the length of thedistribution chamber 36, for instance, by inserting aseparator 48 into thedistribution chamber 36, which closes off a portion of thechamber 36. Alternatively, the effective length of thedistribution chamber 36 can be shortened by selectively eliminating some of the plurality ofapertures 38 in an unnecessary area. Thedistribution chamber 36 is substantially parallel to the firstmanifold body 24. Referring toFIG. 3 , theinner partition wall 32 has a generally C-shaped cross-section. Referring toFIGS. 4-13 , it can be readily appreciated that the cross-section of theinner partition wall 32 may have many shapes, including but not limited to, arc-like, linear, D-shaped, and a pyramid. Thedistribution chamber 36 can be disposed within thecavity 30 directly opposite the plurality ofopenings 40 where the plurality offlow tubes 42 are inserted into the firstmanifold body 24. Referring toFIGS. 7-8 , it can be appreciated that thedistribution chamber 36 can also be located in different positions within thecavity 30 to accommodate variations in plumbing, flow and refrigerant distribution requirements. The plurality ofapertures 38 are disposed within theinner partition wall 32 generally run along the length of thedistribution chamber 36 and are generally aligned with the plurality ofopenings 40 in theouter wall 28, but can vary depending on performance requirements. The plurality ofapertures 38 can comprise a variety of shapes and sizes, including but not limited to, circles and polygons. Aflat ledge 50 can be included along the length of theinner partition wall 32 disposed within thecavity 30, for locating and forming the plurality ofapertures 38. - At least one port may be in the
first manifold 22 and fluidly connected to at least one of thedistribution chamber 36 and thecavity 30. The port may be an orifice or a tube, as is known in the art. The port may be an inlet, an outlet, or a combination of both. Referring toFIG. 1 , one of the ports is aninlet port 56 and is fluidly connected to thefirst manifold 22 for introducing refrigerant into the heat exchanger and another one of the ports is anoutlet port 57 and is fluidly connected to thesecond manifold 52 for exiting refrigerant from theheat exchanger assembly 20. Referring toFIGS. 14 and 16 , the preferred embodiment includes theport distribution chamber 36, either through theend cap 26 or theouter wall 28. Referring toFIGS. 15 and 17 , in another embodiment, theport cavity 30 of thefirst manifold 22 through theouter wall 28 or through theend cap 26. It can be appreciated that theports coupler 66. Thecoupler 66 may be useful for connecting external plumbing to theheat exchanger assembly 20 and may also be useful for manufacturing purposes. It can further be appreciated that theports second manifold 52 as described for thefirst manifold 22, depending on the engineering requirements of a specific application. It can further be appreciated that more than oneinlet port 56 can be connected to theheat exchanger assembly 20 to introduce refrigerant into theheat exchanger assembly 20 and more than oneoutlet port 57 can be used to exit refrigerant from theheat exchanger assembly 20. Referring toFIG. 18 , aseparator 48 can be inserted within thecavity distribution chamber 36, further dividing thecavity distribution chamber 36. - The present invention also provides a method of manufacturing a manifold having a first
manifold body 24 with anouter wall 28 defining ahollow cavity 30, aninner partition wall 32 with a plurality ofapertures 38 and at least oneend cap 26. The method includes the step of extruding the firstmanifold body 24 which has anouter wall 28 and aninner partition wall 32 with theinner partition wall 32 integrally connected to theouter wall 28 to form adistribution chamber 36 within thecavity 30. The method further includes the step of cutting the firstmanifold body 24 to a predetermined length. Cutting can be accomplished by any means. The method further includes forming a plurality ofopenings 40 in theouter wall 28. Theopenings 40 can be formed by a variety of means, including, but not limited to, drilling, lancing or punching. The method further includes forming a plurality ofapertures 38 in theinner partition wall 32 aligned with theopenings 40 in theouter wall 28. The method further includes inserting aseparator 48 into themanifold body 24. It can be appreciated that theseparator 48 can be slid into thedistribution chamber 36 or thecavity 30 or alternatively that theseparator 48 can be inserted through aslot 49 formed in theouter wall 28. It can further be appreciated that more than oneseparator 48 can be inserted, and theseparator 48 can span thedistribution chamber 36, thecavity 30 or both 30, 36. The method further includes mounting theend cap 26 to one end of the firstmanifold body 24. - Obviously, many modifications and variations of the present invention are possible in light of the above teachings without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. The reference numerals are merely for convenience and are not to be read in any way as limiting.
Claims (22)
1. A heat exchanger assembly comprising:
a first manifold having a first manifold body defining a hollow cavity;
a second manifold having a second manifold body defining a hollow cavity and in spaced and substantially parallel relationship with said first manifold;
a plurality of flow tubes extending between and fluidly connecting said cavities of said manifolds for passing refrigerant between said manifolds; and
said first manifold body having an outer wall defining said cavity and an inner partition wall disposed within said cavity adjacent said outer wall with said inner partition wall having a section integrally formed with a portion of said outer wall to define a distribution chamber disposed within said cavity with said inner partition wall having a plurality of apertures fluidly connecting said distribution chamber with said cavity.
2. An assembly as set forth in claim 1 wherein said inner partition wall has a generally C-shaped cross-section.
3. An assembly as set forth in claim 1 wherein a length of said distribution chamber is defined by a length of said first manifold body.
4. An assembly as set forth in claim 3 wherein said distribution chamber is substantially parallel to said first manifold body.
5. An assembly as set forth in claim 1 having at least one port in said first manifold and fluidly connected to at least one of said distribution chamber and said cavity.
6. An assembly as set forth in claim 5 wherein said port is adjacent at least one of said outer wall and an end cap of said first manifold.
7. An assembly as set forth in claim 6 wherein said at least one port further includes a coupler adjacent at least one of said outer wall and said end cap and fluidly connected to at least one of said distribution chamber and said cavity.
8. An assembly as set forth in claim 1 wherein said outer wall includes a plurality of openings sized for accepting said plurality of flow tubes.
9. An assembly as set forth in claim 8 wherein said apertures in said inner partition wall are aligned with said openings in said outer wall.
10. An assembly as set forth in claim 8 wherein said flow tubes are mounted in said openings and disposed within said cavity of said first manifold fluidly connecting said second manifold to said cavity of said first manifold.
11. An assembly as set forth in claim 1 wherein said inner partition wall has a first thickness different than a second thickness of said outer wall.
12. A manifold assembly comprising:
an outer wall defining a hollow cavity; and
an inner partition wall disposed within said cavity adjacent said outer wall with said inner partition wall having a section integrally formed with a portion of said outer wall to define a distribution chamber disposed within said cavity with said inner partition wall having a plurality of apertures fluidly connecting said distribution chamber with said cavity.
13. An assembly as set forth in claim 12 wherein said inner partition wall has a generally C-shaped cross-section.
14. An assembly as set forth in claim 12 wherein a length of said distribution chamber is defined by a length of said outer wall.
15. An assembly as set forth in claim 14 wherein said distribution chamber is substantially parallel to said outer wall.
16. An assembly as set forth in claim 12 having at least one port in said first manifold and fluidly connected to at least one of said distribution chamber and said cavity.
17. An assembly as set forth in claim 16 wherein said port is adjacent at least one of said outer wall and an end cap of said first manifold.
18. An assembly as set forth in claim 17 wherein said inlet port further includes a coupler adjacent at least one of said outer wall and said end cap and fluidly connected to at least one of said distribution chamber and said cavity for introducing refrigerant into said first manifold.
19. An assembly as set forth in claim 12 wherein said outer wall includes a plurality of openings sized for accepting a plurality of flow tubes.
20. An assembly as set forth in claim 19 wherein said apertures in said inner partition wall are aligned with said openings in said outer wall.
21. An assembly as set forth in claim 12 wherein said inner partition wall has a first thickness different than a second thickness of said outer wall.
22. A method of manufacturing a manifold having a manifold body with an outer wall defining a hollow cavity, an inner partition wall with a plurality of apertures and at least one end cap, said method comprising the steps of:
extruding the manifold body having the outer wall and inner partition wall with the inner partition wall integrally connected to the outer wall to form a distribution chamber within the cavity;
cutting the manifold body to a pre-determined length;
forming a plurality of openings in the outer wall;
forming a plurality of apertures in the inner partition wall aligned with the openings in the outer wall;
inserting a separator into the manifold body; and
mounting the end cap to one end of the manifold body.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/492,244 US20080023184A1 (en) | 2006-07-25 | 2006-07-25 | Heat exchanger assembly |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/492,244 US20080023184A1 (en) | 2006-07-25 | 2006-07-25 | Heat exchanger assembly |
Publications (1)
Publication Number | Publication Date |
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US20080023184A1 true US20080023184A1 (en) | 2008-01-31 |
Family
ID=38984980
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/492,244 Abandoned US20080023184A1 (en) | 2006-07-25 | 2006-07-25 | Heat exchanger assembly |
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US (1) | US20080023184A1 (en) |
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US20100089095A1 (en) * | 2006-10-13 | 2010-04-15 | Carrier Corporation | Multi-pass heat exchangers having return manifolds with distributing inserts |
US20110056654A1 (en) * | 2009-09-04 | 2011-03-10 | Vaughn James J | Heat exchanger having flow diverter and method of operating the same |
US20110088883A1 (en) * | 2009-10-16 | 2011-04-21 | Johnson Controls Technology Company | Multichannel heat exchanger with improved flow distribution |
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US9267737B2 (en) | 2010-06-29 | 2016-02-23 | Johnson Controls Technology Company | Multichannel heat exchangers employing flow distribution manifolds |
US9151540B2 (en) | 2010-06-29 | 2015-10-06 | Johnson Controls Technology Company | Multichannel heat exchanger tubes with flow path inlet sections |
US10371451B2 (en) | 2010-06-29 | 2019-08-06 | Johnson Control Technology Company | Multichannel heat exchanger tubes with flow path inlet sections |
US20130284415A1 (en) * | 2010-12-28 | 2013-10-31 | Denso Corporation | Refrigerant radiator |
US20160116230A1 (en) * | 2013-05-15 | 2016-04-28 | Carrier Corporation | Method for manufacturing a multiple manifold assembly having internal communication ports |
US10830542B2 (en) * | 2013-05-15 | 2020-11-10 | Carrier Corporation | Method for manufacturing a multiple manifold assembly having internal communication ports |
EP3021064B1 (en) * | 2013-07-08 | 2019-05-01 | Mitsubishi Electric Corporation | Heat pump device |
US20160161190A1 (en) * | 2013-07-25 | 2016-06-09 | Jaeggi Hybridtechnologie Ag | Collector pipe for a heat exchanger device, a heat exchanger device and a method for emptying a heat exchanger device |
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