Patent Grant
10520255
The present disclosure relates generally to heating, ventilating, and air conditioning systems (HVAC) and, more particularly, to finned coil portions of the HVAC systems.
A wide range of applications exists for HVAC systems. For example, residential, light commercial, commercial, and industrial systems are used to control temperatures and air quality in indoor environments and buildings. Generally, HVAC systems may circulate a fluid, such as a refrigerant, through a closed loop between an evaporator where the fluid absorbs heat and a condenser where the fluid releases heat. The fluid flowing within the closed loop is generally formulated to undergo phase changes within the normal operating temperatures and pressures of the system so that quantities of heat can be exchanged by virtue of the latent heat of vaporization of the fluid.
HVAC units, such as heat exchangers, air handlers, heat pumps, and air conditioning units, are used to provide conditioned air to conditioned environments. Depending on specifications and requirements of the conditioned environment, the HVAC units may require larger equipment or more energy to condition the air for the conditioned environment. However, the increased equipment size or increased energy use may correspond to increased capital and/or operating costs of the HVAC units. Accordingly, it may be desirable to increase the efficiency of certain processes of the HVAC units.
In one embodiment of the present disclosure, a heat exchanger includes a frame and a plurality of coil passes disposed within the frame. The plurality of coil passes is configured to direct a flow of a refrigerant therethrough to transfer heat with an air flow passing over the heat exchanger. The plurality of coil passes includes a U-bend disposed between first and second linear portions of the plurality of coil passes to redirect the refrigerant from a first longitudinal end of the heat exchanger to a second longitudinal end of the heat exchanger. Additionally, a first plurality of fins is disposed on an outer surface the U-bend.
In another embodiment of the present disclosure, a heat exchanger includes a frame and a plurality of coil passes disposed within the frame. The plurality of coil passes is configured to direct a flow of a refrigerant therethrough to transfer heat with an air flow passing over the heat exchanger. The heat exchanger also includes a distributor fluidly coupled to the plurality of coil passes and configured to supply the flow of the refrigerant to the plurality of coil passes. Additionally, a first plurality of fins is disposed on an outer surface of the distributor.
In a further embodiment of the present disclosure, a heat exchanger includes a frame and a plurality of coil passes disposed within the frame. The plurality of coil passes is configured to direct a flow of a refrigerant therethrough to transfer heat with an air flow passing over the heat exchanger. Additionally, the heat exchanger includes a header manifold configured to receive the flow of the refrigerant from the plurality of coil passes. Moreover, a first plurality of fins is disposed on the header manifold.
Other features and advantages of the present application will be apparent from the following, more detailed description of the embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the application.
The present disclosure is directed to heating, ventilating, and air conditioning (HVAC) systems and components of HVAC systems that include fins (e.g., heat transfer fins) that may increase a heat transfer surface area for an evaporator coil or other heat exchanger of the HVAC systems. In general, HVAC systems may include an indoor heat exchanger to transfer heat from outdoor air and/or return air to a coolant or refrigerant when the HVAC systems are operating in a cooling mode. In general, the coolant may flow through multiple coil passes within the indoor heat exchanger, while the air flows over an outer surface of the multiple coil passes. In this manner, thermal energy leaves the air to warm the coolant. To increase the heat transfer surface area of the multiple coil passes, coil portions such as U-bends, distributor tubes, and header manifolds of the multiple coil passes may include fins or other comparable surface features. The fins may be disposed within a flow path of the air such that more thermal energy may be removed from the air for a given size of the indoor heat exchanger. Thus, smaller, less expensive equipment may be employed for conditioning an indoor environment compared to indoor heat exchangers without finned U-bends, distributor tubes, and header manifolds. Additionally, by increasing the heat transfer surface area of the indoor heat exchanger and thus an efficiency of the HVAC system, less electrical energy may be utilized by the HVAC system.
Turning now to the drawings,
The HVAC unit 12 is an air cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air stream, such as environmental air and/or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building with one refrigeration circuit configured to operate in different modes. In other embodiments, the HVAC unit 12 may include one or more refrigeration circuits for cooling an air stream and a furnace for heating the air stream.
A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and/or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.
As shown in the illustrated embodiment of
The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more refrigeration circuits. Tubes within the heat exchangers 28 and 30 may circulate refrigerant (for example, R-410A, steam, or water) through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the refrigerant undergoes phase changes and/or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and/or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the refrigerant to ambient air, and the heat exchanger 30 may function as an evaporator where the refrigerant absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may function as an evaporator and the heat exchanger 30 may function as a condenser. In further embodiments, the HVAC unit 12 may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of
The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and/or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the rooftop unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.
The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the refrigerant before the refrigerant enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and/or cooling. As may be appreciated, additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other things.
The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms (one or more being referred to herein separately or collectively as the control device 16). The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.
When the system shown in
The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat (plus a small amount), the residential heating and cooling system 50 may become operative to refrigerate additional air for circulation through the residence 52. When the temperature reaches the set point (minus a small amount), the residential heating and cooling system 50 may stop the refrigeration cycle temporarily.
The residential heating and cooling system 50 may also operate as a heat pump. When operating as a heat pump, the roles of heat exchangers 60 and 62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58 will serve as an evaporator to evaporate refrigerant and thereby cool air entering the outdoor unit 58 as the air passes over outdoor the heat exchanger 60. The indoor heat exchanger 62 will receive a stream of air blown over it and will heat the air by condensing the refrigerant.
In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace 70 where it is mixed with air and combusted to form combustion products. The combustion products may pass through tubes or piping in a heat exchanger (that is, separate from heat exchanger 62), such that air directed by the blower 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.
In some embodiments, the vapor compression system 72 may use one or more of a variable speed drive (VSDs) 92, a motor 94, the compressor 74, the condenser 76, the expansion valve or device 78, and/or the evaporator 80. The motor 94 may drive the compressor 74 and may be powered by the variable speed drive (VSD) 92. The VSD 92 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 94. In other embodiments, the motor 94 may be powered directly from an AC or direct current (DC) power source. The motor 94 may include any type of electric motor that can be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.
The compressor 74 compresses a refrigerant vapor and delivers the vapor to the condenser 76 through a discharge passage. In some embodiments, the compressor 74 may be a centrifugal compressor. The refrigerant vapor delivered by the compressor 74 to the condenser 76 may transfer heat to a fluid passing across the condenser 76, such as ambient or environmental air 96. The refrigerant vapor may condense to a refrigerant liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid refrigerant from the condenser 76 may flow through the expansion device 78 to the evaporator 80.
The liquid refrigerant delivered to the evaporator 80 may absorb heat from another air stream, such as a supply air stream 98 provided to the building 10 or the residence 52. For example, the supply air stream 98 may include ambient or environmental air, return air from a building, or a combination of the two. The liquid refrigerant in the evaporator 80 may undergo a phase change from the liquid refrigerant to a refrigerant vapor. In this manner, the evaporator 38 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the refrigerant. Thereafter, the vapor refrigerant exits the evaporator 80 and returns to the compressor 74 by a suction line to complete the cycle.
In some embodiments, the vapor compression system 72 may further include a reheat coil in addition to the evaporator 80. For example, the reheat coil may be positioned downstream of the evaporator relative to the supply air stream 98 and may reheat the supply air stream 98 when the supply air stream 98 is overcooled to remove humidity from the supply air stream 98 before the supply air stream 98 is directed to the building 10 or the residence 52.
It should be appreciated that any of the features described herein may be incorporated with the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems. Additionally, while the features disclosed herein are described in the context of embodiments that directly heat and cool a supply air stream provided to a building or other load, embodiments of the present disclosure may be applicable to other HVAC systems as well. For example, the features described herein may be applied to mechanical cooling systems, free cooling systems, chiller systems, or other heat pump or refrigeration applications.
As discussed in more detail below, certain coil portions of the HVAC unit 12, the residential heating and cooling system 50, or other HVAC systems may include fins (e.g., heat transfer fins) to increase a surface area for heat transfer. For example, the heat exchanger 62 may include fins on U-bends, distributor tubes, and/or header manifolds of to increase a heat transfer surface area of the heat exchanger 62 and thus increase an efficiency of the residential heating and cooling system 50. Moreover, it is to be understood that these techniques may be applied to other elements of any suitable HVAC and/or refrigeration system.
The heat exchanger 340 may include multiple parallel circuits. For example, the heat exchanger 340 includes two parallel circuits on each frame portion 440, 460. That is, a first parallel circuit 540 may be defined in an outer surface of the first frame portion 440, a second parallel circuit 560 may be defined in an inner surface of the first frame portion 440, a third parallel circuit 580 may be defined in an inner surface of the second frame portion 460, and a fourth parallel circuit 600 may be defined in an outer surface of the second frame portion 460. Each parallel circuit 540, 560, 580, 600 may wind back and forth within the heat exchanger 340. For example, the parallel circuits 540, 560, 580, 600 may include the multiple coil passes 400 that extend from a first longitudinal end 620 of the heat exchanger 340 to a second longitudinal end 640 of the heat exchanger 340 and from an upper end 660 of the heat exchanger 340 to a lower end 680 of the heat exchanger 340. By winding through an entire length 700 and height 720 of the heat exchanger 340, the parallel circuits 540, 560, 580, 600 provide heat transfer surface area for cooling or heating of the air flow 480 across the heat exchanger 340.
To provide refrigerant 780 to the multiple coil passes 400, the heat exchanger 340 includes a distributor 800. The distributor 800 may supply the refrigerant 780 from a main distributor tube 820 to distributor tubes 840 individually connected to each parallel circuit 540, 560, 580, 600 of the heat exchanger 340. Thus, the refrigerant 780 flows through each parallel circuit 540, 560, 580, 600. When the heating and cooling system 230 is operating as an air conditioner, the refrigerant 780 is supplied at a low temperature, such that thermal energy from the air flow 480 may transfer to the refrigerant 780. The refrigerant 780 may also be supplied at sufficient pressure to ensure a flow of the refrigerant 780 through the multiple coil passes 400 travels completely therethrough. Additionally, as discussed below with reference to
To return the refrigerant 780 from the first longitudinal end 620 to the second longitudinal end 640 of the multiple coil passes 400 and back again, each parallel circuit 540, 560, 580, 600 may include multiple U-bends 860. The U-bends 860 may be disposed between linear portions 880 of the multiple coil passes 400. Refrigerant 780 may therefore flow from the distributor 800, through one linear portion 880 of the multiple coil passes 400, through one U-bend 860, and through another linear portion 880 of the multiple coil passes 400. Therefore, the refrigerant 780 is continuously provided through the heat exchanger 340 for transferring heat with the air flow 480. Additionally, as discussed below with reference to
After the refrigerant 780 has traveled through the multiple coil passes 400, spent refrigerant 900 is continuously removed from the multiple coil passes 400 via a header manifold 920. The spent refrigerant 900 from each parallel circuit 540, 560, 580, 600 may flow into a respective header manifold tube 940 and to a main header manifold tube 960 of the header manifold 920. Each header manifold tube 940 is fluidly connected to the main header manifold tube 960, which receives the spent refrigerant 900 and directs the spent refrigerant 900 to the next portion of the refrigeration cycle, where the spent refrigerant 900 is recharged. Moreover, as discussed below with reference to
As shown, the distributor 800 includes fins 1100 coupled to an outer surface 1120 of the distributor 800. The fins 1100 may be coupled to the main distributor tube 820 and each distributor tube 840. In certain embodiments, the fins 1100 may only be coupled to a portion of the main distributor tube 820 and a portion of each distributor tube 840. In some embodiments, a longitudinal axis of the fins 1100 may be generally perpendicular to the outer surface 1120 of the distributor 800. Additionally, to provide fins 1100 in junctions between each distributor tube 840 and the main distributor tube 820, the longitudinal axis of the fins 1100 may be disposed at 45 degrees or another suitable angle less than 90 degrees from the outer surface 1120 of the distributor 800. Additionally, the fins 1100 on the main distributor tube 820 and the distributor tubes 840 may have different lengths or heights, such that more fins 1100 may be supplied on the outer surface 1120 of the distributor 800. The fins 1100 may be slit-type fins, spiny-type fins, ribbon-type fins, or another suitable type of fin, as discussed below with reference to
As shown, the U-bend 860 includes fins 1300 coupled to an outer surface 1320 of the U-bend 860. The fins 1300 may be coupled to the U-bend 860, the first linear portion 1200, and the second linear portion 1220. In certain embodiments, the fins 1300 may only be coupled to a portion of the U-bend 860 and/or a portion of the first linear portion 1200 and/or a portion of the second linear portion 1220. In some embodiments, a longitudinal axis of the fins 1300 may be generally perpendicular to the outer surface 1320 of the U-bend 860. Additionally, to provide the fins 1300 along the curved outer surface 1320, the longitudinal axis of the fins 1300 may be disposed at 45 degrees or another suitable angle less than 90 degrees from the outer surface 1320 of the U-bend 86. In some embodiments, a width between the first linear portion 1200 and the second linear portion 1220 is at least twice as wide as a height of the fins 1300, so that the fins 1300 may be disposed on the first and second linear portions 1200, 1220 without overlapping. The fins 1300 may be slit-type fins, spiny-type fins, or another suitable type of fin, as discussed below with reference to
As shown, the header manifold 920 includes fins 1400 coupled to an outer surface 1420 of the header manifold 920. The fins 1400 may be coupled to each header manifold tube 940 and the main header manifold tube 960. In certain embodiments, the fins 1400 may only be coupled to a portion of each header manifold tube 940 and/or a portion of the main header manifold tube 960. In some embodiments, a longitudinal axis of the fins 1400 may be generally perpendicular to the outer surface 1420 of the header manifold 920. Additionally, to provide the fins 1400 in junctions between each header manifold tube 940 and the main header manifold tube 960, the longitudinal axis of the fins 1400 may be disposed at 45 degrees or another suitable angle less than 90 degrees from the outer surface 1420 of the header manifold 920. Additionally, the fins 1400 on each header manifold tube 940 and the main header manifold tube 960 may have different lengths or heights, such that more fins 1400 may be supplied on the outer surface 1420 of the header manifold 920. The fins 1400 may be slit-type fins, spiny-type fins, ribbon-type fins, or another suitable type of fin, as discussed below with reference to
To provide the slit fins 1600 around the tubular surface 1620, the slit fins 1600 may be spaced closer together on the inner portion 1660 of the tubular surface 1620 than on the outer portion 1700 of the tubular surface 1620. That is, a longitudinal axis 1720 through each slit fin 1600 on the U-bend 860 may extend approximately through the central intersection point 1740. It is to be understood that approximately extending through the central intersection point 1740 means the longitudinal axis 1720 extends through the central intersection point 1740 within 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 percent of the distance between a respective slit fin 1600 and the central intersection point 1740. Additionally, the slit fins 1600 may be welded on the tubular surface 1620, injection molded on the tubular surface 1620, or integrally formed with the tubular surface 1620. The slit fins 1600 may be provided on linear portions of the multiple coil passes 400, the distributor 800, and/or the header manifold 920 as desired. Thus, the heat transfer surface area of the heat exchanger 340 is greater than that of a heat exchanger without finned coil portions.
To provide the spiny fins 1800 around the tubular surface 1820, the spiny fins 1800 may be welded on the tubular surface 1820 or integrally formed with the tubular surface 1820. The spiny fins 1800 may be provided on linear portions and/or curved portions of the multiple coil passes 400, the distributor 800, and/or the header manifold 920 as desired. Thus, the heat transfer surface area of the heat exchanger 340 is greater than that of a heat exchanger without finned coil portions.
Accordingly, the present disclosure is directed to providing heat transfer fins on coil portions of a heat exchanger 340 and disposing the finned portions within the air flow 480 passing across the heat exchanger 340 to increase the surface area for heat transfer. The additional heat transfer surface area provides for conditioned air more efficiently than heat exchangers without finned coil portions. Thus, capital and maintenance costs for providing the desired conditioned air to the indoor space are reduced.
While only certain features and embodiments of the present disclosure have been illustrated and described, many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure. Furthermore, in an effort to provide a concise description of the embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the disclosure, or those unrelated to enabling the claimed features). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.
This application claims priority from and the benefit of U.S. Provisional Patent Application No. 62/421,047, entitled FINNED HEAT EXCHANGER U-BENDS, MANIFOLDS, DISTRIBUTOR TUBES, filed Nov. 11, 2016, which is hereby incorporated by reference.
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