US20120047940A1 - Low charge heat exchanger in a sealed refrigeration system - Google Patents
Low charge heat exchanger in a sealed refrigeration system Download PDFInfo
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- US20120047940A1 US20120047940A1 US13/099,575 US201113099575A US2012047940A1 US 20120047940 A1 US20120047940 A1 US 20120047940A1 US 201113099575 A US201113099575 A US 201113099575A US 2012047940 A1 US2012047940 A1 US 2012047940A1
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- refrigerant
- evaporator
- condenser
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- 239000003507 refrigerant Substances 0.000 claims abstract description 106
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- 239000012080 ambient air Substances 0.000 description 2
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- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
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- 238000004378 air conditioning Methods 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
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Images
Classifications
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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
-
- 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
- F25B39/04—Condensers
-
- 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
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D11/00—Self-contained movable devices, e.g. domestic refrigerators
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F1/00—Tubular elements; Assemblies of tubular elements
- F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
- F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
- F28F1/34—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending obliquely
- F28F1/36—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element and extending obliquely the means being helically wound fins or wire spirals
-
- 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
- F25B2400/00—General features or devices for refrigeration machines, plants or systems, combined heating and refrigeration systems or heat-pump systems, i.e. not limited to a particular subgroup of F25B
- F25B2400/12—Inflammable refrigerants
-
- 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
- F25B2500/00—Problems to be solved
- F25B2500/01—Geometry problems, e.g. for reducing size
-
- 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
Definitions
- the present subject matter relates generally to refrigeration systems, and more particularly to heat exchangers used in sealed refrigeration systems.
- Consumer refrigerators generally utilize a relatively simple vapor compression refrigeration cycle that includes a compressor, a condenser, an expansion device, and an evaporator connected in series.
- the system is charged with a refrigerant such as R-134a.
- the type and amount of refrigerant are important considerations in the cost, efficiency, and safety aspects of the refrigerators.
- R-600a is a known refrigerant that has a dramatically lower Greenhouse Warming Potential (GWP) than R-134a, and has replaced R-134a in much of the world outside of the U.S.
- GWP Greenhouse Warming Potential
- R-600a also tends to reduce the energy use of conventional refrigerators by as much as four percent (4%).
- the refrigerants with the least environment impact also tend to be the most flammable or toxic.
- R-600a, R-600, R-152a, and HFO-1234ze are alternative refrigerants, but are also flammable.
- Ammonia has excellent refrigerant characteristics, but is toxic in large charge amounts. Thus, it is desired to minimize the charge requirements of these refrigerants.
- the present invention provides heat exchangers, such as evaporators and condensers, for a sealed refrigeration system, wherein the heat exchangers have a unique combination of refrigerant side (inner) diameter, tube length, and refrigerant charge mass that provides balanced efficiency between cooling capacity of the system and reduced refrigerant charge.
- an exemplary embodiment of a consumer refrigeration appliance for example a refrigerator, includes at least one compartment configured for storage of items to be refrigerated, such as a fresh food or freezer compartment.
- a sealed refrigeration system within the appliance is charged with a refrigerant and further includes a compressor, a condenser, an expansion device, and an evaporator.
- the condenser and evaporator may be configured in accordance with aspects of the invention.
- the evaporator is a spine fin heat exchanger having a defined length (L 1 ) of tube with a spine fin material configured around at least a portion of the tube.
- the tube may have a refrigerant side diameter (D 1 ) of less than 0.3 inch and a refrigerant side area (A 1 ) determined by (L 1 ) and (D 1 ).
- the refrigeration system has a refrigerant charge mass such that a ratio (R 1 ) of the charge mass to refrigerant side area (A 1 ) is less than 0.10 and a refrigerant pressure drop across the evaporator is less than 0.7 psi.
- the refrigerant may be R-134a and (L 1 ) is from 20 to 40 ft. In other embodiments, the refrigerant may be R-600a with the same (L 1 ).
- the refrigeration appliance may also include a spine fin condenser in alone or in combination with the spine fin evaporator discussed above.
- a spine fin condenser may be provided with a defined length (L 2 ) of tube and a spine fine material configured around at least a portion of the tube.
- the condenser tube may have a refrigerant side diameter (D 2 ) of less than 0.2 inch and a refrigerant side area (A 2 ) determined by (L 2 ) and (D 2 ).
- the refrigeration system may have a refrigerant charge mass such that a ratio (R 2 ) of the charge mass to refrigerant side area (A 2 ) is less than 0.23.
- the invention also encompasses a consumer refrigeration appliance wherein the condenser is configured in accordance with aspects described herein regardless of the evaporator configuration.
- FIG. 1 is a perspective view of a consumer refrigeration appliance, in particular a refrigerator, that may incorporate aspects of the present invention
- FIG. 2 is schematic view of a refrigeration system within a refrigeration appliance
- FIG. 3 is a cross-sectional view of a tube component of a spine fin heat exchanger in accordance with aspects of the invention.
- FIG. 4 is a perspective and partial cut-away view of a length of tube from a spine fin heat exchanger in accordance with aspects of the invention.
- FIG. 1 depicts a consumer refrigeration appliance 10 in the form of a refrigerator that may incorporate a sealed refrigeration system in accordance with aspects of the invention.
- the term “consumer refrigeration appliance” is used in a generic sense herein to encompass any manner of refrigeration appliance, such as a freezer, refrigerator/freezer combination, and any style or model of conventional refrigerator.
- the refrigerator 10 is depicted as an upright refrigerator having a cabinet or casing 12 that defines a number of internal storage compartments.
- the refrigerator 10 includes upper fresh-food compartments 14 having doors 16 and lower freezer compartment 18 having upper drawer 20 and lower drawer 22 .
- the drawers 20 , 22 are “pull-out” drawers in that they can be manually moved into and out of the freezer compartment 18 on suitable slide mechanisms.
- FIG. 2 is a schematic view of refrigerator 10 including an exemplary sealed refrigeration system 60 .
- a machinery compartment 62 contains components for executing a known vapor compression cycle for cooling air.
- the components include a compressor 64 , a first heat exchanger or condenser 66 , an expansion valve 68 , and an evaporator 70 connected in series and charged with a refrigerant.
- Evaporator 70 is also a type of heat exchanger which transfers heat from air passing over the evaporator to a refrigerant flowing through evaporator 70 thereby causing the refrigerant to vaporize. As such, cooled air is produced and configured to refrigerate compartments 14 , 18 of refrigerator 10 .
- vaporized refrigerant flows to compressor 64 , which operates to increase the pressure of the refrigerant.
- This compression of the refrigerant raises its temperature, which is lowered by passing the gaseous refrigerant through condenser 66 where heat exchange with ambient air takes place so as to cool the refrigerant.
- a fan 72 is used to pull air across condenser 66 , as illustrated by arrows A, so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant and the ambient air.
- An expansion device e.g., a valve, capillary tube, or other restriction device 68 further reduces the pressure of refrigerant leaving condenser 66 before being fed as a liquid to evaporator 70 .
- a valve, capillary tube, or other restriction device e.g., a valve, capillary tube, or other restriction device 68 further reduces the pressure of refrigerant leaving condenser 66 before being fed as a liquid to evaporator 70 .
- a sealed refrigeration system operable to force cold air through refrigeration compartments 12 , 14 .
- the refrigeration system 60 depicted in FIG. 2 is provided by way of example only. It is within the scope of the present invention for other configurations of the refrigeration system to be used as well.
- the sealed refrigeration system 60 includes heat exchangers in the form of the evaporator 70 and the condenser 66 . Either or both of these heat exchangers may be constructed in accordance with aspects of the invention.
- one or both of the evaporator 70 and condenser 66 is a spine fin heat exchanger.
- a spine fin heat exchanger includes a tube or conduit 74 having a defined length 76 that will vary depending on a number of factors, such as system capacity (size), whether the heat exchanger is a condenser or evaporator, and so forth.
- the tube 74 has a refrigerant (inside) side diameter 78 and an outside diameter 79 .
- the outer surface of the tube 74 is covered with a spine fin material 80 that has multiple, pin-like elements or fins 84 that project from a base 82 that wraps around the tube 74 such that the fins 84 project radially from the tube 74 .
- These radial spine fins 84 increase the area available for heat transfer with the surrounding air.
- the spine fin material 80 is typically in the form of a ribbon that is readily wrapped around the tube 74 .
- the spacing (“pitch”) between adjacent wraps of the ribbon base 82 may be varied to change the heat transfer characteristics of the heat exchanger for particular applications within the refrigeration system 60 .
- the spine fins 84 enhance the ability of the evaporator to absorb and transfer heat from the refrigerator compartments 14 , 18 to the refrigerant.
- the spine fins 84 enhance the ability of the condenser 66 to transfer heat from the refrigerant to air drawn across the condenser tubes.
- the tubing 74 and radial spine fins 84 are constructed from a thermally-conductive material, such as one or more metals.
- Spine fin evaporators 70 are widely used in the refrigeration and air conditioning arts, and a detailed explanation of the operation and construction of these heat exchangers is not necessary for those skilled in the art. Reference is made to the following U.S. patents for a description of spine fin evaporators used in commercial refrigerators: U.S. Pat. No. 5,067,322; U.S. Pat. No. 5,214,938; U.S. Pat. No. 5,241,840; U.S. Pat. No. 5,255,535; and U.S. Pat. No. 5,720,186. Spine fin condensers 66 have not been widely used in residential refrigeration systems.
- the heat exchangers of the present refrigeration system 60 are preferably spine fin heat exchangers that have a modified tube diameter and length to reduce the internal capacity of the sealed system 60 while balancing efficiency losses associated with higher pressure drops.
- Conventional wisdom has been that an increased internal tube area is necessary for efficient heat transfer, which resulted in greater refrigerant charge mass. For example, work has been done in the art to increase internal tube area with internal partitions or other structure, as discussed in U.S. Pat. No. 5,967,228.
- a reduced tube area is advantageous when combined with a carefully selected tube diameter, tube length, and type of refrigerant, resulting in a decreased refrigerant charge and corresponding increase in heat transfer coefficient.
- a decreased refrigerant charge typically requires higher refrigerant velocity through the circuit, which increases concerns of detrimental pressure drop. It has, however, now been found by computer modeling and actual device testing that a reduction in tube diameter with associated reduction in refrigerant charge can achieve significant benefits with only a moderate pressure drop across the heat exchangers. In the case of an evaporator 70 , this pressure drop can be maintained at less than about 0.7 psi. Pressure drop across the condenser 66 is less of a concern and a much larger pressure drop (i.e., up to about 3.0 psi) can be tolerated in a spine fin condenser 66 with modified diameter without a noticeable change in energy usage
- a reduced refrigerant charge also reduces energy use by limiting transient losses.
- the refrigeration system 60 When the refrigeration system 60 is shut off, a portion of the warm refrigerant migrates from the condenser to the evaporator and carries heat into the cabinet 12 . This occurs for approximately three minutes in most residential-sized refrigerators.
- the refrigerant is not optimally distributed through the circuit.
- Tables 1 and 2 below relate to various evaporator embodiments in accordance with aspects of the invention:
- Table 1 Various evaporator tube combinations are presented in Table 1, with the first two columns (“Comp”) corresponding to known conventional evaporator configurations and provided for comparison purposes.
- Table 1 provides outside diameter (OD) values and refrigerant side (inside) diameters (D 1 ) for thin and thick wall variations of the same (OD) tube diameters.
- the First Component of Table 2 provides the refrigerant side areas (in square inches) for the tubes of Table 1 over three lengths of tube (20 ft., 34.25 ft., and 40 ft.).
- the evaporator tube 74 would likely fall within the range of 20 to 40 ft. (All ranges expressed herein are inclusive of the end values and include all intermediate values and ranges. For example, the range of 20 ft. to 40 ft. includes the range of 25 ft. to 35 ft.).
- the Second Component of Table 2 provides a calculated R-134a refrigerant charge for evaporators having the tube dimensions and lengths set forth in the First Component.
- the Third Component of Table 2 provides a calculated R-600a refrigerant charge for evaporators having the tube dimensions and lengths set forth in the First Component.
- an evaporator placed within a system 60 in accordance with aspects of the invention may have a refrigerant side diameter (D 1 ) of less than 0.30 inch and a refrigerant side area (A 1 ) determined by (L 1 ) and (D 1 ).
- the system 60 may have the corresponding charge masses provided in the Second Component such that a ratio (R 1 ) of the charge mass to refrigerant side area (A 1 ) is less than 0.10 for the various combinations set forth in Table 2.
- the evaporator tube has an outside diameter (OD) of 5/16 inch (or 0.3125 inch), with (D 1 ) from 0.2525 to 0.2725 inch.
- the refrigerant charge masses with R-134a refrigerant provide a ratio (R 1 ) in this embodiment may be from 0.086 to 0.094.
- the evaporator tube has an outside diameter (OD) of 1 ⁇ 4 inch (or 0.25 inch), with (D 1 ) from 0.19 to 0.21 inch.
- the refrigerant charge masses with R-134a refrigerant provide a ratio (R 1 ) in this embodiment may from 0.063 to 0.070.
- the evaporator tube has an outside diameter (OD) of 3/16 inch, with (D 1 ) from 0.1275 to 0.1475 inch.
- the refrigerant charge masses with R-134a refrigerant provide a ratio (R 1 ) in this embodiment from 0.041 to 0.048.
- the evaporator tube may have an outside diameter (OD) of 5/16 inch, with (D 1 ) from 0.2525 to 0.2725 inch.
- the refrigerant charge provide a ratio (R 1 ) in this embodiment from 0.031 to 0.034.
- the evaporator tube has an outside diameter (OD) of 1 ⁇ 4 inch, with (D 1 ) from 0.19 to 0.21 inch.
- the ratio (R 1 ) is from 0.022 to 0.026.
- the evaporator tube has an outside diameter (OD) of 3/16 inch, with (D 1 ) from 0.1275 to 0.1475 inch.
- the ratio (R 1 ) is from 0.015 to 0.017.
- a refrigeration system 60 incorporating any of the evaporator configurations discussed above may also include a spine fin condenser in accordance with the principles discussed herein.
- Tables 3 and 4 relate to various condenser embodiments in accordance with aspects of the invention:
- Table 3 is similar to Table 1 discussed above and provides various condenser tube configurations.
- the First Component of Table 4 provides the refrigerant side areas (in square inches) for the tubes of Table 3 over three lengths of tube (30 ft., 66 ft., and 80 ft.).
- the condenser tube 74 would likely fall within the range of 30 to 80 ft. (all ranges expressed herein are inclusive of the end values and include all intermediate values and ranges).
- the Second Component of Table 4 provides a calculated R-134a refrigerant charge for condensers having the tube dimensions and lengths set forth in the First Component.
- the Third Component of Table 4 provides a calculated R-600a refrigerant charge for condensers having the tube dimensions and lengths set forth in the First Component.
- a spine fin condenser placed within a system 60 in accordance with aspects of the invention may have a defined length (L 2 ) of tube with a spine fine material configured around at least a portion of said tube, with the tube having a refrigerant side diameter (D 2 ) of less than 0.2 inch and a refrigerant side area (A 2 ) (square inches) defined by (L 2 ) and (D 2 ).
- the refrigeration system may have a refrigerant charge mass (grams) such that a ratio (R 2 ) of the charge mass to refrigerant side area (A 2 ) is less than 0.23.
- the condenser may have a length (L 2 ) from 30 to 80 ft.
- the condenser tube may have an outside diameter (OD) of 1 ⁇ 4 inch, with (D 2 ) from 0.17 to 0.19 inch.
- the ratio (R 2 ) in this embodiment may be from 0.198 to 0.220.
- the condenser tube has an outside diameter (OD) of 3/16 inch, with (D 2 ) from 0.1315 to 0.1475 inch.
- the ratio (R 2 ) is from 0.153 to 0.172.
- the condenser tube may have an outside diameter (OD) of 1 ⁇ 4 inch, with (D 2 ) from 0.17 to 0.19 inch.
- OD outside diameter
- the ratio (R 2 ) in this embodiment may be from 0.071 to 0.079.
- the condenser tube has an outside diameter (OD) of 3/16 inch, with (D 2 ) from 0.1315 to 0.1475 inch.
- the ratio (R 2 ) is from 0.055 to 0.062.
- a refrigeration system 60 in accordance with the present invention may utilize a condenser as described herein regardless of the evaporator configuration.
Abstract
A consumer refrigeration appliance, such as a refrigerator, includes a refrigeration system charged with a refrigerant and further having a compressor, a condenser, an expansion device, and an evaporator. At least one of the evaporator or condenser is a spine fin heat exchanger having a defined length of tube with a spine fine material configured around at least a portion of tube. The tube has a reduced refrigerant side diameter that provides a reduced refrigerant side area defined by the tube length and refrigerant side diameter. The refrigeration system has a reduced refrigerant charge mass.
Description
- The present subject matter relates generally to refrigeration systems, and more particularly to heat exchangers used in sealed refrigeration systems.
- Consumer refrigerators generally utilize a relatively simple vapor compression refrigeration cycle that includes a compressor, a condenser, an expansion device, and an evaporator connected in series. The system is charged with a refrigerant such as R-134a. The type and amount of refrigerant are important considerations in the cost, efficiency, and safety aspects of the refrigerators.
- Essentially all available refrigerants have environmental and safety concerns. For example, it has been found that CFC and HCFC refrigerants are a significant contributor to depletion of the stratospheric ozone layer. As a result, the use of CFC refrigerants was discontinued in most countries by 1996, and the use of HCFC refrigerants is being curtailed.
- In addition to the environmental concerns, when a refrigerant containing chlorine or fluorine is burned, poisonous gases are generated and released.
- R-600a is a known refrigerant that has a dramatically lower Greenhouse Warming Potential (GWP) than R-134a, and has replaced R-134a in much of the world outside of the U.S. R-600a also tends to reduce the energy use of conventional refrigerators by as much as four percent (4%). Unfortunately, the refrigerants with the least environment impact (such as R-600a) also tend to be the most flammable or toxic. Besides R-600a, R-600, R-152a, and HFO-1234ze are alternative refrigerants, but are also flammable. Ammonia has excellent refrigerant characteristics, but is toxic in large charge amounts. Thus, it is desired to minimize the charge requirements of these refrigerants.
- Accordingly, it would be desirable to provide a sealed refrigeration system particularly suited for residential consumer refrigerators that reduces the refrigerant charge without a significant impact on cooling capacity or efficiency.
- Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
- The present invention provides heat exchangers, such as evaporators and condensers, for a sealed refrigeration system, wherein the heat exchangers have a unique combination of refrigerant side (inner) diameter, tube length, and refrigerant charge mass that provides balanced efficiency between cooling capacity of the system and reduced refrigerant charge.
- In this regard, an exemplary embodiment of a consumer refrigeration appliance, for example a refrigerator, includes at least one compartment configured for storage of items to be refrigerated, such as a fresh food or freezer compartment. A sealed refrigeration system within the appliance is charged with a refrigerant and further includes a compressor, a condenser, an expansion device, and an evaporator. Either or both of the condenser and evaporator may be configured in accordance with aspects of the invention. For example, in a particular embodiment, the evaporator is a spine fin heat exchanger having a defined length (L1) of tube with a spine fin material configured around at least a portion of the tube. The tube may have a refrigerant side diameter (D1) of less than 0.3 inch and a refrigerant side area (A1) determined by (L1) and (D1). The refrigeration system has a refrigerant charge mass such that a ratio (R1) of the charge mass to refrigerant side area (A1) is less than 0.10 and a refrigerant pressure drop across the evaporator is less than 0.7 psi.
- In certain evaporator embodiments, the refrigerant may be R-134a and (L1) is from 20 to 40 ft. In other embodiments, the refrigerant may be R-600a with the same (L1).
- Different combinations of evaporator tube dimensions and refrigerant charge masses can provide the benefits of the present invention, and certain non-limiting embodiments are descried in greater detail below.
- The refrigeration appliance may also include a spine fin condenser in alone or in combination with the spine fin evaporator discussed above. For example, in particular embodiments, a spine fin condenser may be provided with a defined length (L2) of tube and a spine fine material configured around at least a portion of the tube. The condenser tube may have a refrigerant side diameter (D2) of less than 0.2 inch and a refrigerant side area (A2) determined by (L2) and (D2). The refrigeration system may have a refrigerant charge mass such that a ratio (R2) of the charge mass to refrigerant side area (A2) is less than 0.23.
- As with the evaporator, different combinations of condenser tube dimensions and refrigerant charge masses can provide the benefits of the present invention, and certain non-limiting embodiments of the condenser are also descried in greater detail below.
- The invention also encompasses a consumer refrigeration appliance wherein the condenser is configured in accordance with aspects described herein regardless of the evaporator configuration.
- These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
- A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
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FIG. 1 is a perspective view of a consumer refrigeration appliance, in particular a refrigerator, that may incorporate aspects of the present invention; -
FIG. 2 is schematic view of a refrigeration system within a refrigeration appliance; -
FIG. 3 is a cross-sectional view of a tube component of a spine fin heat exchanger in accordance with aspects of the invention; and -
FIG. 4 is a perspective and partial cut-away view of a length of tube from a spine fin heat exchanger in accordance with aspects of the invention. - Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
-
FIG. 1 depicts aconsumer refrigeration appliance 10 in the form of a refrigerator that may incorporate a sealed refrigeration system in accordance with aspects of the invention. It should be appreciated that the term “consumer refrigeration appliance” is used in a generic sense herein to encompass any manner of refrigeration appliance, such as a freezer, refrigerator/freezer combination, and any style or model of conventional refrigerator. In the illustrated embodiment, therefrigerator 10 is depicted as an upright refrigerator having a cabinet orcasing 12 that defines a number of internal storage compartments. In particular, therefrigerator 10 includes upper fresh-food compartments 14 havingdoors 16 and lower freezer compartment 18 havingupper drawer 20 andlower drawer 22. Thedrawers -
FIG. 2 is a schematic view ofrefrigerator 10 including an exemplary sealedrefrigeration system 60. Amachinery compartment 62 contains components for executing a known vapor compression cycle for cooling air. The components include acompressor 64, a first heat exchanger orcondenser 66, anexpansion valve 68, and anevaporator 70 connected in series and charged with a refrigerant.Evaporator 70 is also a type of heat exchanger which transfers heat from air passing over the evaporator to a refrigerant flowing throughevaporator 70 thereby causing the refrigerant to vaporize. As such, cooled air is produced and configured to refrigeratecompartments 14, 18 ofrefrigerator 10. - From
evaporator 70, vaporized refrigerant flows tocompressor 64, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the gaseous refrigerant throughcondenser 66 where heat exchange with ambient air takes place so as to cool the refrigerant. Afan 72 is used to pull air acrosscondenser 66, as illustrated by arrows A, so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant and the ambient air. - An expansion device (e.g., a valve, capillary tube, or other restriction device) 68 further reduces the pressure of
refrigerant leaving condenser 66 before being fed as a liquid toevaporator 70. Collectively, the vapor compression cycle components in a refrigeration circuit, associated fans, and associated compartments are sometimes referred to as a sealed refrigeration system operable to force cold air throughrefrigeration compartments refrigeration system 60 depicted inFIG. 2 is provided by way of example only. It is within the scope of the present invention for other configurations of the refrigeration system to be used as well. - The sealed
refrigeration system 60 includes heat exchangers in the form of theevaporator 70 and thecondenser 66. Either or both of these heat exchangers may be constructed in accordance with aspects of the invention. In particular embodiments, one or both of theevaporator 70 andcondenser 66 is a spine fin heat exchanger. Referring toFIGS. 3 and 4 , a spine fin heat exchanger includes a tube orconduit 74 having a definedlength 76 that will vary depending on a number of factors, such as system capacity (size), whether the heat exchanger is a condenser or evaporator, and so forth. Thetube 74 has a refrigerant (inside)side diameter 78 and anoutside diameter 79. The outer surface of thetube 74 is covered with aspine fin material 80 that has multiple, pin-like elements orfins 84 that project from a base 82 that wraps around thetube 74 such that thefins 84 project radially from thetube 74. Theseradial spine fins 84 increase the area available for heat transfer with the surrounding air. Thespine fin material 80 is typically in the form of a ribbon that is readily wrapped around thetube 74. The spacing (“pitch”) between adjacent wraps of theribbon base 82 may be varied to change the heat transfer characteristics of the heat exchanger for particular applications within therefrigeration system 60. - In the case of an
evaporator 70, thespine fins 84 enhance the ability of the evaporator to absorb and transfer heat from the refrigerator compartments 14, 18 to the refrigerant. In the case of acondenser 66, thespine fins 84 enhance the ability of thecondenser 66 to transfer heat from the refrigerant to air drawn across the condenser tubes. Preferably, thetubing 74 andradial spine fins 84 are constructed from a thermally-conductive material, such as one or more metals. -
Spine fin evaporators 70 are widely used in the refrigeration and air conditioning arts, and a detailed explanation of the operation and construction of these heat exchangers is not necessary for those skilled in the art. Reference is made to the following U.S. patents for a description of spine fin evaporators used in commercial refrigerators: U.S. Pat. No. 5,067,322; U.S. Pat. No. 5,214,938; U.S. Pat. No. 5,241,840; U.S. Pat. No. 5,255,535; and U.S. Pat. No. 5,720,186.Spine fin condensers 66 have not been widely used in residential refrigeration systems. - Spine fin heat exchangers are advantageous in that they possess a large ratio of secondary (fin) area to primary (tube) area. The heat exchangers of the
present refrigeration system 60 are preferably spine fin heat exchangers that have a modified tube diameter and length to reduce the internal capacity of the sealedsystem 60 while balancing efficiency losses associated with higher pressure drops. Conventional wisdom has been that an increased internal tube area is necessary for efficient heat transfer, which resulted in greater refrigerant charge mass. For example, work has been done in the art to increase internal tube area with internal partitions or other structure, as discussed in U.S. Pat. No. 5,967,228. In accordance with certain aspects of the present invention, it has been found that a reduced tube area is advantageous when combined with a carefully selected tube diameter, tube length, and type of refrigerant, resulting in a decreased refrigerant charge and corresponding increase in heat transfer coefficient. - A decreased refrigerant charge typically requires higher refrigerant velocity through the circuit, which increases concerns of detrimental pressure drop. It has, however, now been found by computer modeling and actual device testing that a reduction in tube diameter with associated reduction in refrigerant charge can achieve significant benefits with only a moderate pressure drop across the heat exchangers. In the case of an
evaporator 70, this pressure drop can be maintained at less than about 0.7 psi. Pressure drop across thecondenser 66 is less of a concern and a much larger pressure drop (i.e., up to about 3.0 psi) can be tolerated in aspine fin condenser 66 with modified diameter without a noticeable change in energy usage - Besides the environmental and economic benefit, a reduced refrigerant charge also reduces energy use by limiting transient losses. When the
refrigeration system 60 is shut off, a portion of the warm refrigerant migrates from the condenser to the evaporator and carries heat into thecabinet 12. This occurs for approximately three minutes in most residential-sized refrigerators. In addition, at the beginning of a subsequent compressor on cycle, there is a period of time when the system is less efficient because the refrigerant is not optimally distributed through the circuit. When a smaller refrigerant charge is used, these losses are minimized. - Tables 1 and 2 below relate to various evaporator embodiments in accordance with aspects of the invention:
-
TABLE 1 Evaporator Tube Dimensions Comp Comp “1” “2” “3” “4” “5” “6” Outside Tube 0.375 ⅜ 0.3125 5/16 0.25 ¼ 0.1875 3/16 diameter (inches) Wall thickness 0.03 0.02 0.03 0.02 0.03 0.02 0.03 0.02 (inches) Inside diameter 0.315 0.335 0.2525 0.2725 0.19 0.21 0.1275 0.1475 (inches) (D1) -
TABLE 2 Length ft. (L1) First Component: Evaporator Refrigerant side area (A1) in square inches 20 237.5 252.6 190.4 205.5 143.3 158.3 96.1 111.2 34.25 406.7 432.6 326.0 351.9 245.3 271.2 164.6 190.5 40 475.0 505.2 380.8 410.9 286.5 316.7 192.3 222.4 Second Component: Evaporator Estimated charge R-134a (grams) 20 26.3 30.4 16.4 19.3 9.1 11.1 4.0 5.4 34.25 45 52 28 33 15.5 19 6.8 9.2 40 52.6 60.7 32.7 38.5 18.1 22.2 7.9 10.7 Ratio (R1) 0.111 0.120 0.086 0.094 0.063 0.070 0.041 0.048 Third Component: Evaporator Estimated charge R-600a (grams) 20 9.3 10.8 5.8 7.0 3.2 4.1 1.5 1.9 34.25 16 18.5 10 12 5.5 7 2.5 3.3 40 18.7 21.6 11.7 14.0 6.4 8.2 2.9 3.9 Ratio (R1) 0.046 0.043 0.031 0.034 0.022 0.026 0.015 0.017 - Various evaporator tube combinations are presented in Table 1, with the first two columns (“Comp”) corresponding to known conventional evaporator configurations and provided for comparison purposes. Table 1 provides outside diameter (OD) values and refrigerant side (inside) diameters (D1) for thin and thick wall variations of the same (OD) tube diameters.
- The First Component of Table 2 provides the refrigerant side areas (in square inches) for the tubes of Table 1 over three lengths of tube (20 ft., 34.25 ft., and 40 ft.). For purposes of a range of residential refrigerator spine fin evaporators, the
evaporator tube 74 would likely fall within the range of 20 to 40 ft. (All ranges expressed herein are inclusive of the end values and include all intermediate values and ranges. For example, the range of 20 ft. to 40 ft. includes the range of 25 ft. to 35 ft.). - The Second Component of Table 2 provides a calculated R-134a refrigerant charge for evaporators having the tube dimensions and lengths set forth in the First Component. Likewise, the Third Component of Table 2 provides a calculated R-600a refrigerant charge for evaporators having the tube dimensions and lengths set forth in the First Component.
- It can be appreciated from Tables 1 and 2 that an evaporator placed within a
system 60 in accordance with aspects of the invention may have a refrigerant side diameter (D1) of less than 0.30 inch and a refrigerant side area (A1) determined by (L1) and (D1). Thesystem 60 may have the corresponding charge masses provided in the Second Component such that a ratio (R1) of the charge mass to refrigerant side area (A1) is less than 0.10 for the various combinations set forth in Table 2. With these evaporators and charge masses, the refrigerant pressure drop across the evaporator can be maintained at 0.7 psi. or less. - In a particular embodiment supported in Table 2, the evaporator tube has an outside diameter (OD) of 5/16 inch (or 0.3125 inch), with (D1) from 0.2525 to 0.2725 inch. The refrigerant charge masses with R-134a refrigerant provide a ratio (R1) in this embodiment may be from 0.086 to 0.094.
- In another embodiment, the evaporator tube has an outside diameter (OD) of ¼ inch (or 0.25 inch), with (D1) from 0.19 to 0.21 inch. The refrigerant charge masses with R-134a refrigerant provide a ratio (R1) in this embodiment may from 0.063 to 0.070.
- In still another embodiment, the evaporator tube has an outside diameter (OD) of 3/16 inch, with (D1) from 0.1275 to 0.1475 inch. The refrigerant charge masses with R-134a refrigerant provide a ratio (R1) in this embodiment from 0.041 to 0.048.
- In an embodiment supported in Table 2 wherein the refrigerant is R-600a and the evaporator tube length (L1) is from 20 to 40 ft., the evaporator tube may have an outside diameter (OD) of 5/16 inch, with (D1) from 0.2525 to 0.2725 inch. The refrigerant charge provide a ratio (R1) in this embodiment from 0.031 to 0.034.
- In another embodiment wherein the refrigerant is R-600a, the evaporator tube has an outside diameter (OD) of ¼ inch, with (D1) from 0.19 to 0.21 inch. The ratio (R1) is from 0.022 to 0.026.
- In still a further embodiment with R-600a refrigerant, the evaporator tube has an outside diameter (OD) of 3/16 inch, with (D1) from 0.1275 to 0.1475 inch. The ratio (R1) is from 0.015 to 0.017.
- It should be appreciated that a
refrigeration system 60 incorporating any of the evaporator configurations discussed above may also include a spine fin condenser in accordance with the principles discussed herein. - Tables 3 and 4 relate to various condenser embodiments in accordance with aspects of the invention:
-
TABLE 3 Condenser Tube Dimensions Outside Tube 0.25 ¼ 0.1875 3/16 diameter (inches) Wall thickness 0.03 0.04 0.028 0.02 (inches) Inside diameter 0.19 0.17 0.1315 0.1475 (inches) (D2) -
TABLE 4 Length ft. (L2) First Component: Condenser Refrigerant side area in square inches 30 214.9 192.3 148.7 166.8 66 472.7 423.0 327.2 367.0 80 573.0 512.7 396.6 444.8 Second Component: Condenser Estimated charge R-134a (grams) 30 47.3 38.0 22.7 28.6 66 104 83.7 50 63 80 126.1 101.5 60.6 76.4 Ratio (R2) 0.220 0.198 0.153 0.172 Third Component: Condenser Estimated charge R-600a (grams) 30 17.0 13.6 8.2 10.3 66 37.5 30 18 22.6 80 45.5 36.4 21.8 27.4 Ratio (R2) 0.079 0.071 0.055 0.062 - Table 3 is similar to Table 1 discussed above and provides various condenser tube configurations. The First Component of Table 4 provides the refrigerant side areas (in square inches) for the tubes of Table 3 over three lengths of tube (30 ft., 66 ft., and 80 ft.). For purposes of a range of residential refrigerator spine fin condensers, the
condenser tube 74 would likely fall within the range of 30 to 80 ft. (all ranges expressed herein are inclusive of the end values and include all intermediate values and ranges). - The Second Component of Table 4 provides a calculated R-134a refrigerant charge for condensers having the tube dimensions and lengths set forth in the First Component. Likewise, the Third Component of Table 4 provides a calculated R-600a refrigerant charge for condensers having the tube dimensions and lengths set forth in the First Component.
- It can be appreciated from Tables 3 and 4 that a spine fin condenser placed within a
system 60 in accordance with aspects of the invention may have a defined length (L2) of tube with a spine fine material configured around at least a portion of said tube, with the tube having a refrigerant side diameter (D2) of less than 0.2 inch and a refrigerant side area (A2) (square inches) defined by (L2) and (D2). The refrigeration system may have a refrigerant charge mass (grams) such that a ratio (R2) of the charge mass to refrigerant side area (A2) is less than 0.23. - In a particular embodiment wherein the refrigerant is R-134a, the condenser may have a length (L2) from 30 to 80 ft. The condenser tube may have an outside diameter (OD) of ¼ inch, with (D2) from 0.17 to 0.19 inch. The ratio (R2) in this embodiment may be from 0.198 to 0.220.
- In a different condenser embodiment with R-134a refrigerant, the condenser tube has an outside diameter (OD) of 3/16 inch, with (D2) from 0.1315 to 0.1475 inch. The ratio (R2) is from 0.153 to 0.172.
- In a particular embodiment wherein the refrigerant is R-600a and the condenser has a length (L2) from 30 to 80 ft., the condenser tube may have an outside diameter (OD) of ¼ inch, with (D2) from 0.17 to 0.19 inch. The ratio (R2) in this embodiment may be from 0.071 to 0.079.
- In a different condenser embodiment with R-600a refrigerant, the condenser tube has an outside diameter (OD) of 3/16 inch, with (D2) from 0.1315 to 0.1475 inch. The ratio (R2) is from 0.055 to 0.062.
- It should be appreciated that a
refrigeration system 60 in accordance with the present invention may utilize a condenser as described herein regardless of the evaporator configuration. - This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (20)
1. A consumer refrigeration appliance, comprising:
at least one compartment configured for storage of items to be refrigerated;
a refrigeration system, said refrigeration system charged with a refrigerant and further comprising:
a compressor;
a condenser;
an expansion device; and
an evaporator
said evaporator comprising a spine fin heat exchanger having a defined length (L1) of tube with a spine fine material configured around at least a portion of said tube;
said tube having a refrigerant side diameter (D1) of less than 0.3 inch and a refrigerant side area (A1) (square inches) defined by (L1) and (D1);
said refrigeration system having a refrigerant charge mass (grams) such that a ratio (R1) of said charge mass to (A1) is less than 0.10 and a refrigerant pressure drop across said evaporator is less than 0.7 psi.
2. The consumer refrigeration appliance as in claim 1 , wherein said refrigerant is R-134a and said (L1) is from 20 to 40 ft.
3. The consumer refrigeration appliance as in claim 2 , wherein said evaporator tube has an outside diameter (OD) of 5/16 inch, said (D1) is from 0.2525 to 0.2725 inch, and said (R1) is from 0.085 to 0.095.
4. The consumer refrigeration appliance as in claim 2 , wherein said evaporator tube has an outside diameter (OD) of ¼ inch, said (D1) is from 0.19 to 0.21 inch, and said (R1) is from 0.062 to 0.071.
5. The consumer refrigeration appliance as in claim 2 , wherein said evaporator tube has an outside diameter (OD) of 3/16 inch, said (D1) is from 0.1275 to 0.1475 inch, and said (R1) is from 0.040 to 0.049.
6. The consumer refrigeration appliance as in claim 1 , wherein said refrigerant is R-600a and said (L1) is from 20 to 40 ft.
7. The consumer refrigeration appliance as in claim 6 , wherein said evaporator tube has an outside diameter (OD) of 5/16 inch, said (D1) is from 0.2525 to 0.2725 inch, and said (R1) is from 0.030 to 0.035.
8. The consumer refrigeration appliance as in claim 6 , wherein said evaporator tube has an outside diameter (OD) of ¼ inch, said (D1) is from 0.19 to 0.21 inch, and said (R1) is from 0.021 to 0.027.
9. The consumer refrigeration appliance as in claim 6 , wherein said evaporator tube has an outside diameter (OD) of 3/16 inch, said (D1) is from 0.1275 to 0.1475 inch, and said (R1) is from 0.014 to 0.018.
10. The consumer refrigeration appliance as in claim 1 , wherein said condenser also comprises a spine fin heat exchanger having a defined length (L2) of tube with a spine fine material configured around at least a portion of said tube;
said tube having a refrigerant side diameter (D2) of less than 0.2 inch and a refrigerant side area (A2) (square inches) defined by (L2) and (D2);
said refrigeration system having a refrigerant charge mass (grams) such that a ratio (R2) of said charge mass to (A2) is less than 0.23.
11. The consumer refrigeration appliance as in claim 10 , wherein said refrigerant is R-134a and said (L2) is from 30 to 80 ft.
12. The consumer refrigeration appliance as in claim 11 , wherein said condenser tube has an outside diameter (OD) of ¼ inch, said (D2) is from 0.17 to 0.19 inch, and said (R2) is from 0.197 to 0.221.
13. The consumer refrigeration appliance as in claim 11 , wherein said condenser tube has an outside diameter (OD) of 3/16 inch, said (D2) is from 0.1315 to 0.1475 inch, and said (R2) is from 0.152 to 0.173.
14. The consumer refrigeration appliance as in claim 10 , wherein said refrigerant is R-600a and said (L2) is from 30 to 80 ft.
15. The consumer refrigeration appliance as in claim 14 , wherein said condenser tube has an outside diameter (OD) of ¼ inch, said (D2) is from 0.17 to 0.19 inch, and said (R2) is from 0.070 to 0.080.
16. The consumer refrigeration appliance as in claim 14 wherein said condenser tube has an outside diameter (OD) of 3/16 inch, said (D2) is from 0.1315 to 0.1475 inch, and said (R2) is from 0.054 to 0.063.
17. A consumer refrigeration appliance, comprising:
at least one compartment configured for storage of items to be refrigerated;
a refrigeration system, said refrigeration system charged with a refrigerant and further comprising:
a compressor;
a condenser;
an expansion device; and
an evaporator
wherein said condenser comprises a spine fin heat exchanger having a defined length (L2) of tube with a spine fine material configured around at least a portion of said tube;
said tube having a refrigerant side diameter (D2) of less than 0.2 inch and a refrigerant side area (A2) (square inches) defined by (L2) and (D2);
said refrigeration system having a refrigerant charge mass (grams) such that a ratio (R2) of said charge mass to (A2) is less than 0.23.
18. The consumer refrigeration appliance as in claim 17 , wherein said refrigerant is R-600a and said (L2) is from 30 to 80 ft.
19. The consumer refrigeration appliance as in claim 18 , wherein said condenser tube has an outside diameter (OD) of ¼ inch, said (D2) is from 0.17 to 0.19 inch, and said (R2) is from 0.070 to 0.080.
20. The consumer refrigeration appliance as in claim 18 , wherein said condenser tube has an outside diameter (OD) of 3/16 inch, said (D2) is from 0.1315 to 0.1475 inch, and said (R2) is from 0.054 to 0.063.
Priority Applications (2)
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US13/099,575 US20120047940A1 (en) | 2011-05-03 | 2011-05-03 | Low charge heat exchanger in a sealed refrigeration system |
CA2775428A CA2775428A1 (en) | 2011-05-03 | 2012-04-19 | Low charge heat exchanger in a sealed refrigeration system |
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US13/099,575 US20120047940A1 (en) | 2011-05-03 | 2011-05-03 | Low charge heat exchanger in a sealed refrigeration system |
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US13/099,575 Abandoned US20120047940A1 (en) | 2011-05-03 | 2011-05-03 | Low charge heat exchanger in a sealed refrigeration system |
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US20180045445A1 (en) * | 2013-03-15 | 2018-02-15 | Emerson Climate Technologies, Inc. | System For Refrigerant Charge Verification |
US10558229B2 (en) | 2004-08-11 | 2020-02-11 | Emerson Climate Technologies Inc. | Method and apparatus for monitoring refrigeration-cycle systems |
US10884403B2 (en) | 2011-02-28 | 2021-01-05 | Emerson Electric Co. | Remote HVAC monitoring and diagnosis |
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US10558229B2 (en) | 2004-08-11 | 2020-02-11 | Emerson Climate Technologies Inc. | Method and apparatus for monitoring refrigeration-cycle systems |
US10884403B2 (en) | 2011-02-28 | 2021-01-05 | Emerson Electric Co. | Remote HVAC monitoring and diagnosis |
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US10775084B2 (en) * | 2013-03-15 | 2020-09-15 | Emerson Climate Technologies, Inc. | System for refrigerant charge verification |
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