This invention relates generally to heat exchangers, and more particularly to evaporators.
In conventional practice, supermarkets and convenience stores are equipped with refrigerated merchandisers, reach-in coolers, and/or unit coolers for presenting food and/or beverage products to customers while maintaining the food and/or beverage products in a refrigerated environment. Typically, cold, moisture-bearing air is provided to a product display area of the merchandiser, reach-in cooler, and/or unit cooler by passing an airflow over the heat exchange surface of an evaporator coil, or evaporator. A suitable refrigerant is passed through the evaporator to act as a heat exchange medium. The refrigerant absorbs heat from the airflow through the evaporator, and as the heat exchange takes place, the refrigerant evaporates while passing through the evaporator. As a result, the temperature of the airflow through the evaporator is lowered for introduction into the product display area of the merchandiser, reach-in cooler, and/or unit cooler.
The present invention provides, in one aspect, a flat-tube evaporator with a micro-distributor. The micro-distributor includes a tube having an inlet and an outlet comprised of a plurality of orifices in the tube. The tube is at least partially positioned in an inlet manifold of the flat-tube evaporator to enhance distribution of refrigerant from the tube to the inlet manifold of the flat-tube evaporator.
The present invention provides, in another aspect, a refrigeration system including one or more flat-tube evaporators connected in parallel, each having a micro-distributor. The refrigeration system may also include a distributor in a fluid series connection with the micro-distributors of the flat-tube evaporators.
Some embodiments of the present invention provide a flat-tube evaporator that can include an inlet manifold, an outlet manifold separated a distance from the inlet manifold, a distributor tube positioned within the inlet manifold and fluidly connected to a source of refrigerant, and a plurality of flat tubes fluidly connecting the inlet manifold and the outlet manifold. The distributor tube can include a plurality of orifices arranged in a substantially linear configuration along the length of the distributor tube, each of the plurality of orifices directing refrigerant into the inlet manifold in a first direction. Each of the plurality of flat tubes can define a second direction of fluid flow from the inlet manifold to the outlet manifold, the second direction being substantially opposite to the first direction.
In some embodiments, a flat-tube evaporator is provided. The flat-tube evaporator an include an inlet manifold, an outlet manifold separated a distance from the inlet manifold, a distributor tube positioned within the inlet manifold and in fluid communication with a refrigerant source, and a plurality of flat tubes positioned to fluidly connect the inlet manifold and the outlet manifold. The distributor tube can include a plurality of orifices through which refrigerant is directed into the inlet manifold. The plurality of orifices can be arranged to direct refrigerant into the inlet manifold in a first direction, wherein refrigerant is substantially only directed from the distributor tube into the inlet manifold in the first direction. The plurality of flat tubes can be positioned to direct the refrigerant from the inlet manifold to the outlet manifold in a second direction, the second direction being substantially opposite the first direction.
Some embodiments of the present invention provide a refrigeration system that can include a common distributor fluidly connected to a refrigerant source, and a plurality of flat-tube evaporators. Each of the plurality of flat-tube evaporators can include an inlet manifold, an outlet manifold separated a distance from the inlet manifold, a distributor tube positioned within the inlet manifold and fluidly connected to the common distributor, and a plurality of flat tubes positioned to fluidly connect the inlet manifold and the outlet manifold. The distributor tube can include a plurality of orifices positioned along the length of the distributor tube, each of the plurality of orifices positioned to direct the refrigerant into the inlet manifold in a first direction. Each of the plurality of flat tubes can be positioned to direct the refrigerant from the inlet manifold to the outlet manifold in a second direction, the second direction being substantially opposite the first direction.
Other features and aspects of the present invention will become apparent to those skilled in the art upon review of the following detailed description and drawings.
In the drawings, wherein like reference numerals indicate like parts:
Before any features of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The use of letters to identify elements of a method or process is simply for identification and is not meant to indicate that the elements should be performed in a particular order.
Typically, refrigerated merchandisers, reach-in coolers, and/or unit coolers utilize long spans (upwards of 12′) of round-tube plate-fin evaporators (not shown) to span the length of the refrigerated space of the refrigerated merchandisers, reach-in coolers, and/or unit coolers. The long spans of round-tube plate-fin evaporators may be replaced with one or more flat-tube evaporators 10 in an effort to improve upon the performance and/or efficiency of the refrigeration system of the refrigerated merchandisers, reach-in coolers, and/or unit coolers.
Generally, flat-tube evaporators 10 offer better performance than conventional round-tube plate-fin evaporators. For example, flat-tube evaporators 10 may achieve a refrigerant-side pressure drop as low as about 0.67 psi, compared to the 2 psi refrigerant-side pressure drop of conventional round-tube plate-fin evaporators. A lower refrigerant-side pressure drop allows the refrigerant to more easily move throughout the evaporator 10. Also, flat-tube evaporators 10 may achieve an air-side pressure drop as low as about 0.03 inwg (inches of water column gauge), compared to the 0.07 inwg pressure drop of conventional round-tube plate-fin evaporators. This may be accomplished by utilizing a flat-tube evaporator 10 having a relatively large face area. A lower air-side pressure drop allows the fan power to be reduced. Further, flat-tube evaporators 10 may allow for an approach temperature as low as about 1° F. The approach temperature is defined as the difference between the temperature of the discharged airflow and the saturation temperature of the refrigerant passing through the evaporator 10. Conventional round-tube plate-fin evaporators are less efficient than the flat-tube evaporator. As a result, the costs associated with operating a merchandiser 100 utilizing the flat-tube evaporator 10 may be substantially lower than the costs associated with operating a merchandiser utilizing a conventional round-tube plate-fin evaporator.
However, maldistribution of two-phase refrigerant in flat-tube evaporators 10 is an inherent problem. In other words, the refrigerant entering the flat-tube evaporator 10 via an inlet manifold 14 may be concentrated toward one end of the inlet manifold 14. As a result, the entire heat exchange surface of the flat-tube evaporator 10 may not be effectively utilized.
Refrigerant may enter the tube 22 via the inlet 26, while an end 28 of the tube 22 opposite the inlet 26 may be blocked or closed to force discharge of the refrigerant through the orifices 30. The orifices 30 are sized appropriately to cause a pressure increase or build-up in the tube 22. The build-up of pressure in the tube 22 causes the refrigerant to substantially equally distribute along the length of the tube 22. The tube 22 and orifices 30 are also sized appropriately to reduce the amount of separation of vapor refrigerant and liquid refrigerant in the two-phase flow.
In the illustrated construction, the orifices 30 are aligned in the tube 22 in a substantially linear configuration. However, alternate constructions of the micro-distributor 18 may include orifices 30 in the tube 22 in a curvlinear configuration, or orifices 30 substantially arranged about the circumference of the tube 22 in any of a number of different patterns or random configurations. Also, in the illustrated construction, the orifices 30 are substantially equally-spaced from one another. However, alternate constructions of the micro-distributor 18 may include orifices 30 having different concentrations or spacing along the length of the tube 22.
In the illustrated construction, the tube 22 utilizes a relatively small diameter (i.e., an internal diameter) of about 3/16″ to ¼″. However, in another construction of the micro-distributor 18, the tube 22 may have a diameter of at least about ¼″. In yet another construction of the micro-distributor 18, the tube 22 may have a diameter of at least about ⅛″. Further, in another construction of the micro-distributor 18, the tube 22 may have a diameter less than about ½″. In yet another construction of the micro-distributor 18, the tube 22 may have a diameter less than about ¼″. Alternate constructions of the micro-distributor 18 may also include a tube 22 having a non-circular cross-sectional shape of nominal size corresponding to the circular cross-sectional tube 22.
Also, in the illustrated construction, the micro-distributor 18 includes orifices 30 having a diameter of about 0.032″. However, in another construction of the micro-distributor 18, the orifices 30 may have a diameter of at least about 0.020″. In yet another construction of the micro-distributor 18, the orifices 30 may have a diameter of at least about 0.050″. Further, in another construction of the micro-distributor 18, the orifices 30 may have a diameter less than about 0.150″. In yet another construction of the micro-distributor 18, the orifices 30 in the tube 22 may have a diameter less than about 0.050″. Alternate constructions of the micro-distributor 18 may also include orifices 30 having a non-circular shape of nominal size corresponding to the circular orifices 30.
The inlet manifold 14 is substantially sealed such that refrigerant is fed to the micro-distributor 18, and discharged from the micro-distributor 18 via the orifices 30 into the inlet manifold 14. The flat-tube evaporator 10 also includes an outlet manifold 34 fluidly connected to the inlet manifold 14 by a plurality of flat tubes 38. The flat-tubes 38 may be formed to include a plurality of internal passageways, or microchannels 40 (as shown in
The microchannels 40 allow for more efficient heat transfer between the airflow passing over the flat-tubes 38 and the refrigerant carried within the microchannels 40, compared to the airflow passing over the coil of the round-tube plate-fin evaporator. The microchannels 40 may be configured with rectangular cross-sections (as shown in
The flat tubes 38 may be separated into about 12 to 15 microchannels 40, with each microchannel 40 being about 1.5 mm in height and about 1.5 mm in width, compared to a diameter of about 9.5 mm (⅜″) to 12.7 mm (½″) for the internal passageway of a coil in a round-tube plate-fin evaporator. However, in other constructions of the flat tubes 38, the microchannels 40 may be as small as 0.5 mm by 0.5 mm, and as large as 4 mm by 4 mm. In the illustrated construction, the flat-tubes 38 may be about 22 mm wide. However, in other constructions, the flat tubes 38 may be as wide as 127 mm, or as narrow as 18 mm. Further, the spacing between adjacent flat tubes 38 may be about 9.5 mm. However, in other constructions, the spacing between adjacent flat tubes 38 may be as much as 16 mm, or as little as 3 mm.
The tube 22, the orifices 30, and/or the microchannels 40 in the flat-tubes 38 may be appropriately sized to provide a desired flow rate of refrigerant in the refrigeration system. As such, certain relationships and/or ratios between the tube 22 and orifices 30, the orifices 30 and microchannels 40, and the tube 22 and microchannels 40, among others, may be desirable over others to achieve a desired flow rate of refrigerant in the refrigeration system. For example, a preferred range of ratios between the diameter of the tube 22 and the diameter of the orifices 30 may be between about 3:1 to about 10:1.
As shown in
Generally, the fins 42 aid in the heat transfer between the airflow passing through the flat-tube evaporator 10 and the refrigerant carried by the flat tubes 38. The increased efficiency of the flat-tube evaporator 10 is due in part to such a high fin density, compared to the fin density of 2 to 4 fins per inch of the round-tube plate-fin evaporator. The increased efficiency of the flat-tube evaporator 10 is also due in part to the louvers, which provide a plurality of leading edges to redirect the airflow through and around the fins 42. As a result, heat transfer between the fins 42 and the airflow is increased. Further, the high air-side heat transfer of the louver fins 42 and the high refrigerant-side heat transfer of the flat tubes 38, along with minimal contact resistance of the brazed aluminum construction, yields the highly efficient, and high-performance flat-tube evaporator 10.
As shown in
Specifically, angle α in
In some embodiments, the direction 27 is oriented directly opposite (i.e., the angle α is about 180 degrees, as shown in
In some embodiments, as described above, the orifices 30 are not aligned in the tube 22 in a substantially linear configuration, but are arranged in a different configuration about the circumference of the tube 22. In such embodiments, each orifice 30 directs the refrigerant into the inlet manifold 14 at an angle α, and one or more of the orifices 30 directs the refrigerant at a different angle α. For example, in some embodiments, angle α increases for each orifice 30 from one end of the tube 22 to another. In some embodiments, each orifice 30 directs the refrigerant into the inlet manifold 14 at an angle α, and the plurality of orifices 30 directs the refrigerant at substantially the same angle α.
From the inlet manifold 14, refrigerant passes through the flat tubes 38 and is discharged into the outlet manifold 34 in substantially gaseous form. From the outlet manifold 34, the refrigerant may be discharged from the evaporator 10 via an outlet 46 in the outlet manifold 34, and drawn into the suction side of a compressor (not shown) in the refrigeration system for re-processing.
As shown in
Refrigerant may exit the flat-tube evaporators 10 via the respective outlets 46 to a common outlet header 62, which may be fluidly connected to the suction side of the compressor. In the illustrated construction, the expansion valve 56 can modulate the refrigerant flow with superheat feedback 66 from the outlet header 62. Alternatively, the superheat feedback 66 may be taken at a location between the outlets 46 of the respective flat-tube evaporators 10 and the common outlet header 62.
Although the illustrated flat-tube evaporators 10 are shown in a fluid parallel assembly 50, the flat-tube evaporators 10 with respective micro-distributors 18 may be arranged in any of a number of different module configurations, which, in turn, may be arranged in either a fluid parallel assembly 50 or a fluid series assembly.
Various features and aspects are set forth in the following claims.
Priority benefit is claimed to U.S. Provisional Patent Application Ser. No. 60/531,818, filed Dec. 22, 2003.
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