Patent Application
20230204297
This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the presently described embodiments. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present embodiments. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
Modern residential and industrial customers expect indoor spaces to be climate controlled. In general, heating, ventilation, and air conditioning (“HVAC”) systems circulate an indoor space's air over low-temperature (for cooling) or high-temperature (for heating) sources, thereby adjusting the indoor space's ambient air temperature. HVAC systems generate these low- and high-temperature sources by, among other techniques, taking advantage of a well-known physical principle: a fluid transitioning from gas to liquid releases heat, while a fluid transitioning from liquid to gas absorbs heat. Within a typical HVAC system, a fluid refrigerant circulates through a closed loop of tubing that uses a compressor and other flow-control devices to manipulate the refrigerant's flow and pressure, causing the refrigerant to cycle between the liquid and gas phases. Generally, these phase transitions occur within the HVAC's heat exchangers, which are part of the closed loop and designed to transfer heat between the circulating refrigerant and flowing ambient air.
In some instances, a HVAC system is a split system having indoor and outdoor units, each having a heat exchanger, connected in fluid communication. As would be expected in such cases, the heat exchanger providing heating or cooling to the climate-controlled space or structure is described adjectivally as being “indoors,” and the heat exchanger transferring heat with the surrounding outdoor environment is described as being “outdoors.” The refrigerant circulating between the indoor and outdoor heat exchangers—transitioning between phases along the way—absorbs heat from one location and releases it to the other. Those in the HVAC industry describe this cycle of absorbing and releasing heat as “pumping.” To cool the climate-controlled indoor space, heat is “pumped” from the indoor side to the outdoor side. And the indoor space is heated by doing the opposite, pumping heat from the outdoors to the indoors.
In some other instances, a packaged HVAC system is a self-contained unit including two heat exchangers (e.g., an evaporator coil and a condenser coil), a blower, a compressor, and a refrigerant circuit installed in a shared cabinet. A packaged HVAC system can be installed at any suitable location but is often installed outside, such as on the ground or on the roof of a building. Heated or cooled air is provided from the packaged HVAC system to the indoor space of a building, such as through a supply duct, and air is drawn from the indoor space to the packaged HVAC system, such as through a return duct.
Certain aspects of some embodiments disclosed herein are set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of certain forms the invention might take and that these aspects are not intended to limit the scope of the invention. Indeed, the invention may encompass a variety of aspects that may not be set forth below.
Certain embodiments of the present disclosure generally relate to heat exchangers for HVAC systems. More specifically, some embodiments relate to a microchannel heat exchanger having an array of tubes arranged between a first manifold and a second manifold. Refrigerant may be routed between the first and second manifolds via tubes of the array. But in at least some instances, the array of tubes includes at least one “dead” tube that is not in fluid communication with the first and second manifold and does not convey the refrigerant between these manifolds. In the case of a multi-pass heat exchanger, so-called dead tubes may be provided in the array to reduce thermal cross-conduction between tubes of two different passes. Dead tubes may also or instead be provided in the array to reduce corrosion and increase reliability of the heat exchanger. Still further, dead tubes may also or instead be provided in the array to reduce thermal stress in the heat exchanger. If the dead tubes are positioned at the microchannel heat exchanger ends, they provide mechanical protection to the live tubes caring refrigerant. Therefore, the dead tubes are strategically positioned within the microchannel heat exchanger array. The heat exchangers may be installed in a packaged system, a split system, or any other suitable HVAC system.
Various refinements of the features noted above may exist in relation to various aspects of the present embodiments. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. Again, the brief summary presented above is intended only to familiarize the reader with certain aspects and contexts of some embodiments without limitation to the claimed subject matter.
These and other features, aspects, and advantages of certain embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Specific embodiments of the present disclosure are described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that 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.
When introducing elements of various embodiments, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As noted above, some embodiments of the present disclosure relate to heat exchangers with an array of tubes in which some of the tubes convey refrigerant but one or more of the tubes are dead tubes that do not convey refrigerant. In some instances, such a heat exchanger is a microchannel heat exchanger having microchannels in the tubes for conveying refrigerant. The heat exchanger can be installed in a split system, a packaged system, or some other HVAC system.
By way of example, and turning now the figures,
Many North American residences employ “ducted” systems, in which a structure's ambient air is circulated over a central indoor heat exchanger and then routed back through relatively large ducts (or ductwork) to multiple climate-controlled indoor spaces. However, the use of a central heat exchanger can limit the ducted system's ability to vary the temperature of the multiple indoor spaces to meet different occupants' needs. This is often resolved by increasing the number of separate systems within the structure—with each system having its own outdoor unit that takes up space on the structure's property, which may not be available or at a premium.
Residences outside of North America often employ “duchess” systems, in which refrigerant is circulated between an outdoor unit and one or more indoor units to heat and cool specific indoor spaces. Unlike ducted systems, duchess systems route conditioned air to the indoor space directly from the indoor unit—without ductwork. Typically, duchess systems are suited for moderate climates, and are not optimal for climates where robust heating of the indoor space may be desired.
The described HVAC system 10 of
Focusing on the ducted indoor unit 16, it has an air-handler unit (or AHU) 24 that provides airflow circulation, which in the illustrated embodiment draws ambient indoor air via a return vent 26, passes that air over one or more heating/cooling elements (i.e., sources of heating or cooling), and then routes that conditioned air, whether heated or cooled, back to the various climate-controlled spaces 20 through supply vents 28. As depicted in
As shown, the ducted indoor unit 16 is a “dual-fuel” system that has multiple heating elements. A gas furnace 34, which may be located downstream (in terms of airflow) of the blower 32, combusts natural gas to produce heat in furnace tubes (not shown) that coil through the furnace. These furnace tubes act as a heating element for the ambient indoor air being pushed out of the blower 32, over the furnace tubes, and into supply ducts 30 to supply vents 28. In other instances, the furnace 34 is an electric furnace, with one or more heat strips or other electric heating elements for heating air passing through the AHU 24, rather than a gas furnace. Whether gas or electric, the furnace 34 is generally operated when robust heating is desired. During conventional heating and cooling operations, air from the blower 32 is routed over an indoor heat exchanger 36 and into the supply ducts 30.
The blower 32, furnace 34, and indoor heat exchanger 36 may be packaged as an integrated AHU, or those components may be modular. Moreover, it is envisaged that the positions of the furnace, indoor heat exchanger, and blower can be reversed or rearranged. Internal components of the blower 32, the furnace 34, and the indoor heat exchanger 36 can be positioned within one or more casings, cabinets, or other housings (integrated or modular).
The indoor heat exchanger 36—which in this embodiment for the ducted indoor unit 16 is an A-coil 38 (
In the illustrated embodiment of
The outdoor unit 14 is a side-flow unit that houses, within a plastic or metal casing or housing 50, the various components that manage the refrigerant's flow and pressure. This outdoor unit 14 is described as a side-flow unit because the airflow across the outdoor heat exchanger 42 is motivated by a fan that rotates about an axis that is non-perpendicular with respect to the ground. In contrast, “up-flow” devices generate airflow by rotating a fan about an axis generally perpendicular to the ground. (As illustrated, the Y-axis is perpendicular to the ground.) In one embodiment, the side-flow outdoor unit 14 may have a fan 52 that rotates about an axis that is generally parallel to the ground. (As illustrated, the X- and Z-axes are parallel to the ground.) It is envisaged that either up-flow or side-flow units could be employed. Advantageously, the side-flow outdoor unit 14 provides a smaller footprint than traditional up-flow units, which are more cubic in nature.
In addition to the ducted indoor unit 16, the illustrated HVAC system has ductless indoor units 18 that also circulate refrigerant, via the refrigerant lines 40, between the outdoor heat exchanger 42 and the ductless indoor unit's heat exchanger. The ductless indoor units 18 may work in conjunction with or independent of the ducted indoor unit 16 to heat or cool the given indoor space 20. That is, the given indoor space 20 may be heated or cooled with the structure's air that has been conditioned by the ductless indoor unit 18 and by the air routed through the ductwork 30 after being conditioned by the A-coil 38, or it may be entirely conditioned by the ductless indoor unit or the ducted indoor unit working independent of one another. As another embodiment, the A-coil refrigerant loop may be operated to provide cooling or heating only—and the ductless indoor units may also be designed to provide cooling or heating only.
As is well known, the HVAC system may be in communication with a thermostat 54 that senses the indoor space's temperature and allows the structure occupants to “set” the desired temperature for that sensed indoor space. The thermostat may operate using a simple on/off protocol that sends 24V signals, for example, to the HVAC system to either activate or deactivate various components; or it may be a more complex thermostat that uses a “communicating protocol,” such as ClimateTalk or P1/P2, that sends and receives data signals and can provide more complex operating instructions to the HVAC system.
To cool the structure, the high-pressure gas is routed to the outdoor heat exchangers 42, where airflow generated by the fans 52 aids the transfer of heat from the refrigerant to the environment—causing the refrigerant to condense into a liquid that is at high-pressure. As shown, the outdoor unit 14 has multiple heat exchangers 42 and fans 52 connected in parallel, to aid the HVAC system's operation.
The refrigerant leaving the heat exchangers 42 is or is almost entirely in the liquid state and flows through or bypasses a metering device 74. From there, the high-pressure liquid refrigerant flows into a series of receiver check valves 76 that manage the flow of refrigerant into the receiver 78. The receiver 78 stores refrigerant for use by the system and provides a location where residual high-pressure gaseous refrigerant can transition into liquid form. The receiver may be located within the casing 50 of the outdoor unit or may be external to the casing 50 of the outdoor unit (or the system may have no receiver at all). From the receiver 78, the high-pressure liquid refrigerant flows to the indoor units 16, 18, specifically to metering devices 80 that restrict the flow of refrigerant into each heat exchanger of the indoor units 16, 18, to reduce the refrigerant's pressure. The refrigerant leaves the indoor metering devices 80 as a low-pressure liquid (or mostly liquid). In the described embodiment, the metering device 80 is an electronic expansion valve, but other types of metering devices—like capillaries, thermal expansion valves, reduced orifice tubing—are also envisaged. Electronic expansion valves provide precise control of refrigerant flow into the heat exchangers of the indoor units, thus allowing the indoor units—in conjunction with the compressor—to provide individualized cooling for the given indoor space 20 the unit is assigned to.
Low-pressure liquid refrigerant is then routed to the indoor heat exchangers 36. As illustrated, the indoor heat exchanger 36 for the ducted indoor unit 16 is an “A-coil” style heat exchanger 38. But the heat exchanger 38 can be an “N-coil” (or “Z-coil”) style heat exchanger or a slab coil or can take any other suitable form. Airflow generated by the blower 32 aids in the absorption of heat from the flowing air by the refrigerant, causing the refrigerant to transition from a low-pressure liquid to a low-pressure gas as it progresses through the indoor heat exchanger 36. And the airflow generated by the blower 32 drives the now cooled air into the ductwork 30 (specifically the supply ducts), cooling the indoor spaces 20. In a similar fashion, the low-pressure liquid refrigerant is routed to the indoor heat exchangers 36 of the ductless indoor units 18, where it is evaporated, causing the refrigerant to absorb heat from the environment. However, unlike the ducted indoor unit, the ductless indoor units circulate air without ductwork, using a local fan 52, for example.
The refrigerant leaving the indoor heat exchangers 36, which is now entirely or mostly a low-pressure gas, is routed to the reversing valve 64 that directs refrigerant to the accumulator 82. Any remaining liquid in the refrigerant is separated in the accumulator, ensuring that the refrigerant reaching the compressor inlet 70 is almost entirely in a gaseous state. The compressor 46 then repeats the cycle, by compressing the refrigerant and expelling it as a high-pressure gas.
For heating the structure 12, the process is reversed. High-pressure gas is still expelled from the compressor outlet 60 and through the oil separator 66 and flow meter 62. However, for heating, the reversing valve 64 directs the high-pressure gas to the indoor heat exchangers 36. There, the refrigerant—aided by airflow from the blower 32 or the fans 52—transitions from a high-pressure gas to a high-pressure liquid, rejecting heat. And that heat is driven by the airflow from the blower 32 into the ductwork 30 or by the fans 52 in the ductless indoor units 18, heating the indoor spaces 20. If more robust heating is desired, the gas furnace 34 may be ignited, either supplementing or replacing the heat from the heat exchanger. That generated heat is driven into the indoor spaces by the airflow produced by the blower 32. In other instances, electric heating elements (e.g., of an electric furnace 34 of the indoor units 16 or 18) may also or instead be used to provide heat to the indoor spaces 20.
The high-pressure liquid refrigerant leaving each indoor heat exchanger 36 is routed through or past the given metering valve 80, which is, in this embodiment, an electronic expansion valve. But for other embodiments, the valve may be any other type of suitable expansion valve, like a thermal expansion valve or capillary tubes, for example. Using the refrigerant lines 40, the high-pressure liquid refrigerant is routed to the receiver check valves 76 and into the receiver 78. As described above, the receiver 78 stores liquid refrigerant and allows any refrigerant that may remain in gaseous form to condense. From the receiver, the high-pressure liquid refrigerant is routed to an outdoor metering device 74, which lowers the pressure of the liquid. Just like the indoor metering device 80, the illustrated outdoor metering device 74 is an electrical expansion valve. But it is envisaged that the outdoor metering device could be any number of devices, including capillaries, thermal expansion valves, reduced orifice tubing, for example.
The lower-pressure liquid refrigerant is then routed to the outdoor heat exchangers 42, which are acting as evaporators. That is, the airflow generated by the fans 52 aids the transition of low-pressure liquid refrigerant to a low-pressure gaseous refrigerant, absorbing heat from the outdoor environment in the process. The low-pressure gaseous refrigerant exits the outdoor heat exchanger 42 and is routed to the reversing valve 64, which directs the refrigerant to the accumulator 82. The compressor 46 then draws in gaseous refrigerant from accumulator 82, compresses it, and then expels it via the outlet 60 as high-pressure gas, for the cycle to be repeated.
As illustrated in
In many instances, the structure 12 may have had a previous HVAC system with pre-existing refrigerant piping at least partially built into the structure's interior walls. For example, the pre-existing system may be a traditional HVAC unit that uses circulating refrigerant for cooling only and a gas furnace for heating, with all of the conditioned air delivered to the interior spaces via the ductwork. And the pre-existing refrigerant lines—which are built into the walls of the structure—may have a gas line with a 6/8-inch, ⅞-inch, or 9/8-inch outer diameter gas line. However, in certain embodiments, the outdoor unit 14 may have more modern refrigerant piping, which tends to be smaller in outer diameter. For example, the outdoor unit 14 may be 2-, 3-, or 4-Ton unit that has a gas line diameter of ⅝ inch. It would be laborious and cost ineffective to replace the pre-existing gas line in the structure with ⅝-inch diameter tubing. Accordingly, the illustrated HVAC system includes a coupler 88 that helps couple the varying diameter gas lines to one another. For example, the coupler 88 may facilitate coupling of the outdoor unit's ⅝-inch diameter gas line to the structure's pre-existing 6/8-inch, ⅞-inch, or 9/8-inch diameter gas line. In another embodiment, the outdoor unit 14 may be a 5-Ton unit with a gas line having a diameter of 6/8 inch. The coupler could facilitate coupling of this outdoor unit with a pre-existing gas line of ⅞-inch or 9/8-inch diameter.
In another embodiment depicted in
The heat exchangers 36, 42, 108, and 110 can be provided in any suitable form. In certain embodiments, for instance, some or all of the heat exchangers 36, 42, 108 and 110 are microchannel heat exchangers. An example of a microchannel heat exchanger 120 is generally provided in
In the embodiment depicted in
The microchannel heat exchanger 120 can have any suitable number of passes in which refrigerant flows from one of the manifolds 124 or 126 to the other. For instance, the microchannel heat exchanger 120 can be a two-pass heat exchanger in which the refrigerant received in the manifold 124 via the inlet flows in one direction (a first pass) from the manifold 124 to the manifold 126 through some of the tubes of the array 122 and then flows in an opposite direction (a second pass) from the manifold 126 to the manifold 124 through other tubes of the array 122 before exiting the heat exchanger 120 through the outlet. In other embodiments, the heat exchanger 120 with the inlet and outlet provided on the manifold 124 could have four, six, eight, ten, or even more passes. In still other instances, the inlet and outlet could be provided on opposite sides (e.g., the inlet on the manifold 124 and the outlet on the manifold 126) and the heat exchanger 120 may have an odd number of passes, such as one pass, three passes, five passes, seven passes, nine passes, and so forth.
Additional details of the microchannel heat exchanger 120 are depicted in
Each tube 134 is shown in
Ambient air is treated by flowing the ambient air through the array 122, between the tubes 134 and past the fins 136, and transferring heat between the refrigerant circulated through the tubes 134 and the ambient air. Although the heat exchanger 120 is depicted in
The heat exchanger 120 can be made of any suitable material. In some embodiments, the heat exchanger 120 is an aluminum heat exchanger having each of the manifolds 124 and 126, the tubes 134, and the fins 136 made of aluminum or an aluminum alloy. Each of the components could be made of the same aluminum alloy, for instance, or multiple aluminum materials (pure aluminum or aluminum alloys) could be used for the different components. Other materials, such as stainless steel, copper, or polymer, may also or instead be used.
By way of further example, the heat exchanger 120 is shown as a six-pass microchannel heat exchanger in
Refrigerant may be received through the connection 128 into a bore 148 of the manifold 124. A baffle 150 (e.g., a separator plate) within the bore 148 blocks flow of the refrigerant down the bore 148 and causes the refrigerant received through the connection 128 to flow from the manifold 124 through a first subset 152 of tubes 134 (which includes the outer flat tube 144) into a bore 154 of the manifold 126. This transit of refrigerant from the manifold 124 to the manifold 126 through the first subset 152 of tubes 134 is the first pass in the heat exchanger 120. A baffle 156 in the bore 154 causes the refrigerant received from the first subset 152 of tubes 134 to then flow through a second subset 158 of tubes 134 from the manifold 126 to the manifold 124 (i.e., the second pass). In similar fashion, a baffle 160 causes this refrigerant to flow back to the manifold 126 through a third subset 162 of the tubes 134 (i.e., the third pass), and a baffle 164 then causes the refrigerant to flow from the manifold 126 back to the manifold 124 though a fourth subset 166 of tubes 134 (i.e., the fourth pass). Another baffle 168 causes refrigerant received in the manifold 124 from the fourth subset 166 of tubes 134 to flow to the manifold 126 through a fifth subset 170 of tubes 134 (i.e., the fifth pass), and the refrigerant flows back to the manifold 124 from the manifold 126 through a sixth subset 172 of tubes 134 (i.e., the sixth pass) and exits the heat exchanger 120 through the connection 130.
Because they control flow through the manifolds and direct refrigerant into tubes 134, the baffles 150, 156, 160, 164, and 168 may be said to divide the passes through the heat exchanger 120. That is, the baffle 150 divides the first pass from the second pass, the baffle 156 divides the second pass from the third pass, the baffle 160 divides the third pass from the fourth pass, the baffle 164 divides the fourth pass from the fifth pass, and the baffle 168 divides the fifth pass from the sixth pass.
Each pass can use any suitable number of tubes 134. The number of passes and the number of tubes used in each pass may be selected to optimize heat transfer and pressure drop through the heat exchanger 120. In at least some instances, the first pass uses more tubes 134 than the last pass. As depicted in
While the tubes 134 of the array 122 collectively enable refrigerant to flow between the manifolds 124 and 126, one or more of the tubes 134 can be provided as dead tubes that do not convey refrigerant between the manifolds 124 and 126. In some embodiments, the array 122 includes dead tubes to reduce thermal cross-conduction between tubes of two different passes. As depicted in
In some instances, dead tubes may also or instead be provided in the array 122 to reduce thermal stress along a manifold 124 or 126 of the heat exchanger. In
As shown in
Although two dead tubes are depicted in
In some embodiments, the microchannel heat exchanger 120 has at least one dead tube between each pair of adjacent passes. For instance, as depicted in
Although dead tubes can be provided in the array 122 to reduce thermal stress near a baffle, as discussed above, dead tubes may also or instead be provided in the array 122 to reduce thermal stress at other locations. In
Still further, dead tubes may also or instead be provided in the array 122 of the heat exchanger 120 to reduce corrosion and increase reliability. Heat exchangers, such as microchannel heat exchangers, may be used in indoor or outdoor environments as evaporator or condenser coils. The heat exchangers may be subject to corrosion (e.g., galvanic or general corrosion) in the presence of standing water or debris accumulated in a base pan of an HVAC system or of drain pan water, water bridging, or splashing near the bottom of the heat exchanger. Corrosion of the heat exchanger can cause refrigerant leaks and negatively impact operating life. Sacrificial materials may be provided to protect the heat exchanger, such as zinc coating on the tubes or other components. In some instances, a heat exchanger is raised above a base pan or drip pan with stand-offs (e.g., rubber stand-offs) or a sheet metal emboss. But in some embodiments, dead tubes of the array 122 may be used as sacrificial tubes to increase the distance between a lowermost live tube of the array 122 and the pan below and reduce the incidence of corrosion of the refrigerant-carrying components of the heat exchanger.
In
In still other embodiments, plates are used to protect ends of the array 122. In an embodiment depicted in
Finally, the heat exchanger 120 can be constructed through any suitable manufacturing techniques. In some instances, this includes assembling the flat tubes 134 in the array 122 with the fins 136 and the manifolds 124 and 126 and then brazing the array 122 to the manifolds 124 and 126 and to the fins 136. Other components, such as protective plates 210 and 212, may also be brazed to the assembly. The brazing can be done with a non-corrosive flux in a vacuum furnace or other brazing oven, for example. In some embodiments, such as those with dead tubes having bent ends that do not contact the manifolds 124 and 126, brazing the array 122 to the manifolds 124 and 126 may include brazing live tubes of the array 122 to the manifolds 124 and 126 but not brazing dead tubes of the array 122 to the manifolds 124 and 126. The dead tubes may be brazed to the fins 136 or other components to mechanically secure the dead tubes in place within the array 122. In other instances, however, the dead tubes may also or instead be brazed to the manifolds 124 and 126 but prevented from conveying refrigerant between these manifolds in some other manner.
While the aspects of the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. But it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.
