Patent Application
20060042309
1. Field of the Invention
The present invention relates generally to air conditioning systems for motor vehicles and, more specifically, to a condenser with an integral receiver/dryer for an air conditioning system in a motor vehicle and a method of assembling the condenser.
2. Related Technology
Condenser assemblies for automotive vehicle air conditioning systems typically include a pair of headers and a core having a plurality of tubes, through which refrigerant flows, disposed horizontally between the two headers. An inlet is disposed near an upper portion of one of the headers and an outlet is disposed at the lower portion of either the same or the other header. Within the headers, partitions may be provided to divide the interior space of the headers into more than one fluidly separate spaces. As a result, the refrigerant is caused to flow in a serpentine fashion making more than one path through the tubes between the headers.
Typically attached to one of the headers and in fluid communication therewith is a receiver. Refrigerant condensed in the core flows into the receiver where it is separated into gas and liquid portions. Because the presence of water in the refrigerant will degrade the performance and structural integrity of the air conditioning system, a dryer is often associated with or located within the receiver. The dryer is located within the receiver so that the dryer is in contact with the liquid portion of the refrigerant facilitating the removal of water from the refrigerant. The dryer may itself be comprised of a bag or cartridge containing dryer granulates such as desiccant.
More recent designs of condenser assemblies have integrated the receiver/dryer with one of the headers mentioned above. One process of doing this has been to locate a plate within the header so as to divide the header into a manifold portion and a receiver/dryer portion. One drawback of this construction is that the design requires, for structural integrity of the system, a center line alignment of the core and the header containing the integrated receiver/dryer. Another drawback of this construction is that the joint between the manifold portion and the receiver/dryer portion cannot be inspected after brazing from the outside of the header.
Therefore, it may be desirable to provide a receiver/dryer structure, to provide a manifold structure, and then connect the respective structures. The manifold and the receiver/dryer are typically connected via a brazing method. More specifically, the manifold is positioned in desired location with respect to the receiver/dryer such that a portion of the manifold engages a portion of the receiver/dryer. The respective engaging portions are fixedly connected via a brazing method, such as a brazing oven. However, the manifold and the receiver/dryer may become partially or completely disengaged from each other before or during the brazing process, leading to an insufficient or an incomplete connection between the respective components.
Therefore, it is desirable to provide an assembly and a method of assembly in order to sufficiently engage the manifold and the receiver/dryer.
In one configuration of the present invention, a condenser assembly for a vehicle air conditioning system is provided, comprising: a core including first and second ends and a plurality of tubes extending therebetween, a first header located adjacent to the first end of the core, and a second header located adjacent to the second end of the core. The second header includes a receiver/dryer having a receiver/dryer chamber, a manifold cooperating with the receiver/dryer to define a manifold chamber being in fluid communication with the flow passages in the tubes, and a mounting rib unitarily formed with at least one of the receiver/dryer and the manifold. The mounting rib includes a first portion extending away from the at least one of the receiver/dryer and the manifold in a first direction and a second portion extending away from the first portion in a second direction that is substantially nonparallel with the first direction.
In another configuration, the first direction and the second direction cooperate to define an angle being greater than 45° and being less than 135°. The first direction and the second direction may be generally perpendicular with each other.
In yet another configuration, the mounting rib further includes a weakened line connecting the first portion and the second portion. The weakened line may be an arcuate groove.
In another configuration, the receiver/dryer includes a top end and a bottom end, and the mounting rib extends substantially continuously from the top end to the bottom end in a direction generally perpendicularly to the plurality of tubes.
In yet another configuration, the condenser assembly further comprises a second mounting rib unitarily formed with the at least one of the receiver/dryer and the manifold. The mounting rib and the second mounting rib and the second mounting rib are each unitarily formed with the receiver/dryer. Additionally, the manifold includes a flange and a second flange, the mounting rib engages the flange of the manifold, and the second mounting rib engages the second flange of the manifold. The mounting rib is a deformable mounting rib and the second mounting rib is a fixed mounting rib.
In another configuration, the condenser assembly further comprises a third mounting rib and a fourth mounting rib, each unitarily formed with the receiver/dryer. The third mounting rib and the fourth mounting rib engage a mounting bracket coupled to the vehicle. The third mounting rib is a deformable mounting rib and the fourth mounting rib is a fixed mounting rib.
The first header is connected to the core such that the first header is in fluid communication with the tubes in the core. Furthermore, the manifold is connected to the core such that the manifold chamber and the receiver/dryer chamber are in fluid communication with the tubes. A mounting rib is formed on at least one of the receiver/dryer and the manifold for coupling the manifold and the receiver/dryer with each other. The mounting rib may be brazed in order to further connect the manifold and the receiver/dryer with each other.
Referring now to the drawings,
The core 12 is a tube stack comprising a series of tubes 18 extending between the headers 14, 16. More specifically, a first end 15 of the core 12 extends into the first header 14 and a second end 17 of the core 12 extends into the second header 16. The tubes 18 are generally parallel to each other and are vertically stacked with respect to each other. Adjacent tubes 18 are generally evenly-spaced apart from one another such that a space 20 is located therebetween. The tubes 18 themselves may be of any appropriate construction. In one preferred embodiment, the tubes are generally flat and include portions defining one or more flow channels 21 longitudinally through the tube.
Located within the space 20 between each adjacent tube 18 is a fin 22 for increasing heat transfer between the tubes 18 and an airflow intersecting the condenser assembly 10. The fins 22 exhibit a generally corrugated shape comprising a series of convolutes as is commonly known in the industry. The fins 22 generally extend completely across the space 20 contacting both the tube located thereabove and therebelow. In the figures, the details of the shape of the fins 22 are not illustrated in significant detail since those skilled in this technology will readily appreciate such a construction. Additionally, the fins 22 are preferably provided with a series of louvers on each corrugation in order to aid in the heat transfer efficiency from the tubes, to the fins and to the air passing therethrough. The fins 22 are provided in such a manner that the overall length of the tubes 18 is greater than the overall length of the fins 22 and that the ends 24 and 26 of the tubes 18 extend beyond the end of the fins 22. These first and second ends 24, 26 of the tubes are respectively received within the first and second headers 14, 16 and, as further discussed below, are in fluid communication with the first and second headers 14, 16.
The first header 14 (hereinafter the “inlet/outlet header” or “I/O header”) is shown on the left-hand side of
The I/O header 14 includes an inlet aperture 49 that communicates with an inlet bore 50 defined in an inlet block 52. Similarly, the I/O header 14 includes an outlet aperture 54 that is in communication with an outlet bore 56 defined in an outlet block 58 mounted to the cylindrical body 28 of the I/O header 14.
During operation of the air conditioner, refrigerant enters into the condenser assembly 10 via the inlet block 52 and exits from the condenser assembly 10 via the outlet block 58. In order for the cavity 38 of the I/O header 14 to fluidly communicate with the tubes 18, the end 24 of each tube 18 is received through a tube aperture 60 defined in one side of the cylindrical body 28.
The remaining header 16 of the condenser assembly 10 is generally illustrated on the right hand side of
The receiver/dryer 62 preferably includes a cylindrical body or member 66 having top and bottom ends 67, 69 respectively closed by top and bottom caps 68, 70. Therefore, the top and bottom caps 68, 70 cooperate with the cylindrical body 66 to define a R/D chamber 72 within the R/D header 16. The cylindrical body 66 preferably exhibits a substantially constant cross-sectional profile along its length. More preferably, the cylindrical body 66 includes a generally round cross-sectional profile along its length having a longitudinal axis 71 shown in
The R/D chamber 72 is in fluid connection with the manifold chamber 74 via a first opening 75a and a second opening 75b in the receiver/dryer 62. The R/D chamber 72 preferably includes a drying element, such as a dryer 73. The dryer 73 shown in
The manifold 64 and the cylindrical body 66 cooperate to define a manifold chamber 74. The second header 16 preferably includes at least one partition and at least two caps in order to divide the manifold chamber 74 into a plurality of chambers. As shown in
In order to form a substantially fluid-tight seal between the manifold 64 and the receiver/dryer 62, the respective components 62, 64 are preferably brazed together by being exposed to relatively high temperatures as is known in the art. As discussed above, it is advantageous for respective components to be engaged with each other during the brazing process in order to form a robust connection. Therefore, it may be advantageous to provide engaging component(s) to engage the manifold 64 and the receiver/dryer 62 with each other before and during the brazing process. Similarly, the engaging components may be used as an alternative to the brazing process.
Referring now to
The mounting rib 86 preferably includes a first portion 90 extending away from the receiver/dryer 62 in a first direction 91 and a second portion 92 extending obliquely away from the first portion in a second direction 93. More specifically, the first direction 91 and the second direction 93 form an angle 94 that is preferably greater than 45° and less than 135°. More preferably, the first direction 91 and the second direction 93 are generally perpendicular to each other such that the first portion 90 and the second portion 92 each engage a respective portion of the flange 88. However, any appropriate angles may be formed by the first and second portions 90, 92.
A second mounting rib 96, similar to the first mounting rib 86, is provided in order to further engage the manifold 64 and the receiver/dryer 62 with each other. The second mounting rib 96 is unitarily formed with the receiver/dryer 62 in order to engage a second flange 98 of the manifold 64. The second flange 98 preferably extends along the receiver/dryer 62 similarly to the first flange 88. The second mounting rib 96 includes a first portion 100 extending away from the receiver/dryer 62 in a first direction 101 and a second portion 102 extending away from the first portion in a second direction 103 at an angle 104 that is preferably greater than 45° and less than 135°. More preferably, the first direction 101 and the second direction 103 are generally perpendicular to each other.
The mounting ribs 86, 96 preferably extend continuously from the top end 67 to the bottom end 69 of the receiver/dryer 62, but other configurations may be used. In particular, the mounting ribs 86, 96 may extend along a portion of the length of the receiver/dryer 62. Additionally, a plurality of first mounting ribs 86 may be longitudinally separated from each other and a plurality of second mounting ribs 96 may be similarly longitudinally separated from each other.
The first and second mounting ribs 86, 96 may be deformable mounting ribs, fixed mounting ribs, or a combination thereof. Deformable mounting ribs are defined as mounting ribs that are designed to be bent along a line in order to engage the respective manifold flanges 88, 98. In order to improve the accuracy of the line along which the deformable mounting rib(s) are bent, the first and/or second mounting ribs 86, 96 may include a weakened line extending along the length of the mounting ribs 86, 96. The weakened line is preferably located between the first portion 90, 100 and the second portion 92, 102 of the respective mounting ribs 86, 96 such that the first portion 90, 100 and the second portion 92, 102 each engage respective portions of the flanges 88, 98.
Referring now to
Also shown in
Alternatively to the first and second mounting ribs 86, 96 shown in
Referring back to
In order to engage the bracket 13 with the receiver/dryer 62, a third mounting rib 116 is provided in order to engage the bracket 13 and the receiver/dryer 62 with each other. The third mounting rib 116 in
The mounting rib 86 preferably includes a first portion 120 extending away from the receiver/dryer 62 in a first direction 121 and a second portion 122 extending away from the first portion in a second direction 123 that is nonparallel with the first direction 121. More specifically, the first direction 121 and the second direction 123 form an angle 124 that is preferably greater than 45° and less than 135°. More preferably, the first direction 121 and the second direction 123 are generally perpendicular to each other such that the first portion 120 and the second portion 122 each engage a respective portion of the flange 118. However, any appropriate angles may be formed by the first and second portions 120, 122.
A fourth mounting rib 126 is also preferably provided in order to further engage the bracket 13 and the receiver/dryer 62 with each other. The fourth mounting rib 126 is unitarily formed with the receiver/dryer 62 in order to engage the second flange 128 of the bracket 13. The second flange 128 preferably extends along the receiver/dryer 62 similarly to the first flange 118. The fourth mounting rib 126 includes a first portion 130 extending away from the receiver/dryer 62 in a first direction 131 and a second portion 132 extending away from the first portion in a second direction 133 at an angle 134 that is preferably greater than 45° and less than 135°. More preferably, the first direction 131 and the second direction 133 are generally perpendicular to each other.
The third and fourth mounting ribs 116, 126 preferably extend continuously from the top end 67 to the bottom end 69 of the receiver/dryer 62, but other configurations may be used. In particular, the third and fourth mounting ribs 116, 126 may extend along a portion of the length of the receiver/dryer 62. Additionally, a plurality of third mounting ribs 116 may be longitudinally separated from each other and a plurality of fourth mounting ribs 126 may be similarly longitudinally separated from each other.
The third and fourth mounting ribs 116, 126 may be deformable mounting ribs, fixed mounting ribs, or a combination thereof. Similarly to the first and second mounting ribs 86, 96 described above, the third and fourth mounting ribs 116, 126 may include a weakened line extending along the length of the mounting ribs 116, 126. The weakened line is preferably located between the first portion 120, 130 and the second portion 122, 132 of the respective mounting ribs 116, 126.
Referring now to
Also shown in
The third mounting rib 116 shown in
Alternatively to the third and fourth mounting ribs 116, 126 shown in
During operation of the condenser assembly 10, the refrigerant flows into the upper chamber 42 of the first header 14 via the inlet block 52 as described above. The refrigerant is typically substantially gaseous when it flows through the inlet block 52. Next, the refrigerant flows through the tubes 18, undergoing heat exchange with cross-flowing air, which promotes condensation of the refrigerant. The refrigerant then exits the tubes into the upper chamber 80 of the manifold 64. The refrigerant then flows back across the tubes 18, undergoing further heat exchange, and exits into the middle chamber 46 of the first header 14. The refrigerant makes yet another pass across the core 12 and into the middle chamber 82 of the manifold 64.
From the middle chamber 82, the refrigerant enters the R/D chamber 72 via the first opening 75a. The refrigerant is typically a 3-part fluid at this point in the system: gaseous refrigerant, liquid refrigerant, and water. The gaseous refrigerant rises to the top portion of the RID chamber 72 in order to undergo further condensation. The liquid refrigerant enters the lower chamber 84 of the manifold 64 via the second opening 75b and flows into the tubes 18, where it exits the condenser 10 via the outlet block 58 as described above. The water is preferably substantially absorbed by the dryer in order to minimize the amount of water degradating the performance of the refrigerant.
A method of assembling the manifold 64 and the receiver/dryer 62 will now be discussed. The manifold 64 is engaged with the receiver/dryer 62 such that the flanges 88, 98 engage the outer surface of the receiver/dryer 62 as shown in
Additionally, the bracket 13 is engaged with the receiver/dryer 62 such that the flanges 118, 128 engage the outer surface of the receiver/dryer 62 as shown in
Next, the second flange 128 of the bracket 13 is moved such as to engage first portion 130 of the fourth mounting rib 126 and the outer surface of the receiver/dryer 62, as shown in
After the manifold 64 and the receiver/dryer 62 have been engaged and the deformable ribs have been deformed, the respective components 62, 64 are preferably brazed together in order to form substantially fluid-tight connections. The components may be brazed using a known process, such as a brazing oven. Alternatively, the brazing process is not used, and the mounting ribs 86, 96, 116, 126 form substantially fluid-tight connections between the and the second header 16 are each preferably manifold 64 and the receiver/dryer 62.
It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.
