Patent Application
20100147501
1. Field of the Invention
The invention relates to manifolds having multiple passages. More specifically, the invention relates to multi-pass manifolds.
2. Description of the Prior Art
Air-cooling (or heating) cross-counter flow heat exchangers are often used in applications where space limitations restrict the surface are of the heat exchanger. Cross-counter flow heat exchangers typically include a plurality of stacked, assembled modules, with each module including a pair of spaced manifolds interconnected by a plurality of spaced and parallel tubes. The modules are stacked such that air flows in a direction perpendicular to the face of the heat exchanger, and air fins are disposed between adjacent pairs of tubes for transferring heat from the tubes to the passing air. U.S. Pat. No. 6,581,679 granted to Fisher discloses a heat exchanger having an upper manifold defining an interior and having an upper top portion and an upper lower portion. U.S. Pat. No. 5,582,239 granted to Tsunoda discloses an upper manifold having a partition.
There is a need for more efficient heat exchangers and methods of manufacturing the same.
In summary, the invention provides a manifold for use in a heat exchanger assembly and a method of forming the manifold. The method starts with the step of forming an upper manifold defining an interior and having an upper top potion defining an upper opening in the center of the upper top portion and an upper bottom portion defining a plurality of spaced upper tube slots. The method is finalized by the step of dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold and joining the partition and the upper manifold through a snap fit.
The apparatus includes a partition disposed in the upper manifold to define a plurality of chambers in the interior of the upper manifold. The partition has a plurality of spaced projections and a plurality of spaced upper recesses that extend longitudinally straight along a central axis for accepting the projections.
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:
Referring to the Figures, like numerals indicate corresponding parts throughout the several views. Referring to
A plurality of tubes 34, each having flat sides 36 and round ends 68, extend between upper and lower tube ends 38, 40 in the upper and lower tube slots 30, 32. Each of the tubes 34 extend parallel and spaced from one another and define a plurality of air or refrigerant passages 42 there between. The tube slots 30, 32 include a plurality of rows of tube slots 30, 32 one on each side of said central axis A and the tubes 34 include a plurality of rows of tubes 34 one on each side of said central axis A and are disposed in the tube slots 30, 32.
Referring to
A partition 48 is disposed in the upper manifold 20 and defines a plurality of chambers 50 in the interior of the upper manifold 20. The partition 48 has a plurality of spaced projections 58. The upper bottom portion 24 has a plurality of spaced upper recesses 64 extending longitudinally straight for accepting the projections 58. The partition 48 defines a plurality of holes 56 for conveying refrigerant through the manifold. The holes 56 may be gradient as shown in
In a second embodiment and as shown in
When applied to an Inlet/Outlet manifold, the partition 48 prevents the refrigerant from flowing from one chamber 50 to another. When applied to a return manifold, the partition 48 includes holes 56 that allow the refrigerant to flow from one chamber 50 to the other. The partition 48 also acts as a stiffener and provides additional strength.
Referring to
The invention also includes a method of forming a manifold for use in a heat exchanger assembly. The method starts with the step of forming an upper manifold 20 defining an interior and having an upper top portion 22 defining an upper opening 26 in the center of the upper top portion 22 and an upper bottom portion 24 defining a plurality of spaced upper tube slots 30. The method continues with the step of dividing the upper manifold 20 to define a plurality of chambers 50 in the interior of the upper manifold 20. The method proceeds with the step of joining the partition 48 and the upper manifold 20. The joining step includes inserting projections 58 from the partition 48 into spaced recesses 64 defined by the bottom portion of the manifold. The joining step also includes projecting a dimple 54 from the partition 48 and providing an opening 26 in the upper top portion 22 and elastically forming the opening 26 of the upper top portion 22 and sliding the dimple 54 through the opening 26, creating a snap fit.
The method continues with the step of permanently fixing the partition 48 to the upper manifold 20. The method proceeds with the step of permanently fixing at least one locking tab 52 disposed on the partition 48 to the exterior of the upper top portion 22 of the upper manifold 20 wherein the permanent fixing is further defined as brazing. The method proceeds with the step of forming a plurality of tubes 34 extending between upper and lower tube ends 38, 40 and defining a plurality of air or refrigerant passages 42. The method continues with inserting the upper tube ends 38 of each tube 34 into one of the upper tube slots 30 of the upper manifold 20 to establish fluid communication between the passages 42 of the tubes 34 and the chambers 50 of the upper manifold 20.
The method continues with the step of forming a lower manifold 28 defining an interior and having an lower top portion 60 defining and a lower bottom portion 62 defining a plurality of spaced upper tube slots 30 aligning with the upper tube slots 30. The method further continues with the step of inserting the lower tube end 40 of each of the tubes 34 into the corresponding lower tube slot 32 of the lower manifold 28 to establish fluid communication between the passages 42 of each tube 34 and the lower manifold 28.
The method proceeds with the step of forming an air fin 46 between adjacent tubes 34 to dissipate heat from the tube 34. The method is completed with the step of inserting a separator 70 into the top portions 22, 60 for dividing the interior of the manifolds 20, 28 into more than two chambers 50.
It is to be understood that “upper” and “lower” as used in the present application are arbitrary, inasmuch as a heat exchanger in accordance with the present invention can be oriented in different directions. Therefore, “upper” and “lower” should be understood to be used with reference to the orientation of the manifolds 20, 28 and tubes 34 as shown in the drawings herein, and is not limiting the orientation of the manifolds 20, 28 or tubes 34 in actual use.
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teaching of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
