HEAT EXCHANGER WITH SPRING TUBE COIL

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. 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 disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

A heating, ventilation, and/or air conditioning (HVAC) system provides ventilation, maintains air quality and desired temperature in a conditioned space (e.g., a confined space), for example, in a commercial or residential building. The HVAC system may circulate a refrigerant through a closed loop comprising a compressor, a condenser, an expansion device, and an evaporator, which change pressure and/or temperature conditions of the refrigerant at various locations of the closed loop. The refrigerant in the evaporator, for example, is utilized to extract heat from (e.g., cool) an airflow via thermal exchange (heat exchange), where the airflow is routed to the conditioned space to facilitated desired environmental conditions within the conditioned space.

Certain HVAC systems, depending on specifications and requirements of the conditioned space and/or refrigerants, may require different sized heat exchangers or different levels of energy to condition the conditioned space. However, adjusted equipment size (e.g., larger equipment) or energy consumption adjustment (e.g., increased energy consumption) may correspond to cost of manufacturing, installation costs, and/or operating costs of HVAC systems. Indeed, functional efficiency and cost efficiency of HVAC systems may be impacted by numerous variables. Accordingly, it is now recognized that improved HVAC systems, HVAC components, and methods of operating and assembling HVAC systems are desired.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be noted that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In an embodiment, a heating, ventilation, and/or air condition (HVAC) system includes a heat exchanger with at least one spring tube wound in a geometric configuration formed around a geometric axis. A passage through the spring tube is configured to transport a working fluid therethrough to facilitate heat exchange between the working fluid and air directed over an exterior of the at least one spring tube.

In an embodiment, a heat exchanger for a heating ventilation and/or air condition (HVAC) system includes a plurality of spring tubes configured to transport working fluid therethrough to facilitate heat exchange between the working fluid and conditioning fluid passing over the plurality of spring tubes. The one or more spring tubes of the plurality of spring tubes are wound in a geometric configuration around a geometric axis.

In an embodiment, a heating, ventilation, and air conditioning (HVAC) system, includes a heat exchanger configured to facilitate heat exchange between a working fluid and a conditioning fluid. The heat exchanger includes at least one spring tube wound in a geometric configuration formed around a geometric axis. The heat exchanger also includes a passage through the at least one spring tube, wherein the passage is configured to transport the working fluid to facilitate the heat exchange of the working fluid with the conditioning fluid passing over an exterior of the at least one spring tube.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a perspective view of a building housing an embodiment of a heating, ventilation, and/or air conditioning (HVAC) system that may employee one or more HVAC units, in accordance with aspects of the present disclosure;

FIG. 2A is a perspective view of an embodiment of an HVAC unit of the HVAC system of FIG. 1, in accordance with aspects of the present disclosure;

FIG. 2B is a perspective view of an embodiment of a residential split heating and cooling system, in accordance with aspects of the present disclosure;

FIG. 3 is a schematic view of an embodiment of a vapor compression system that may be used in an HVAC system, in accordance with aspects of the present disclosure;

FIG. 4 is a front view of an embodiment of a spring tube of a heat exchanger of an HVAC unit, in accordance with aspects of the present disclosure;

FIG. 5 is a front view of an embodiment of a heat exchanger including the spring tube of FIG. 4, in accordance with aspects of the present disclosure;

FIG. 6 is a front view of an embodiment of a heat exchanger having a support member to support the spring tube of FIG. 4, in accordance with aspects of the present disclosure;

FIG. 7 is a front view of an embodiment of a heat exchanger including the spring tube of FIG. 4, and having a cylindrical helix geometric configuration, in accordance with aspects of the present disclosure;

FIG. 8 is a perspective view of an embodiment of a heat exchanger including a plurality of spring tubes wound in a conical helix geometric configuration, in accordance with aspects of the present disclosure;

FIG. 9 is a perspective view of an embodiment of a heat exchanger including a plurality of spring tubes wound in a cylindrical helix geometric configuration, in accordance with aspects of the present disclosure; and

FIG. 10 is a perspective view of an embodiment of a heat exchanger including a plurality of spring tubes having inlets at different positions of the geometric configuration, in accordance with aspects of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. 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 of the present disclosure, the articles “a,” “an,” and “the” 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. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

As used herein, the terms “approximately,” “generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,” “slope,” “perpendicular,” “parallel,” and so forth are intended to encompass features of surfaces or elements as understood by one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.

The present disclosure is directed to heating, ventilation, and/or air conditioning (HVAC) systems. More particularly, the present disclosure is related to a heat exchanger (e.g., one or more heat exchangers) with a spring tube coil for transmitting working fluid and facilitating heat exchange with a conditioning fluid. Relative to traditional heat exchangers of traditional HVAC systems, the spring tube coil provides for increased heat transfer/exchange area at a lower refrigerant charge.

A heating, ventilation, and/or air conditioning (HVAC) system provides ventilation, maintains air quality, and controls temperature in a conditioned space, for example, in a commercial or residential building. The HVAC system may circulate a refrigerant through a closed loop comprising a compressor, a condenser, an expansion device, and an evaporator, which change pressure and/or temperature conditions of the refrigerant at various locations of the closed loop. The refrigerant in the evaporator, for example, is utilized to extract heat from (e.g., cool) a conditioning fluid (e.g., an airflow) via thermal exchange (heat exchange), where the conditioning fluid is routed to the confined space to condition the confined space. Thermal exchange in an HVAC system in accordance with present embodiments may be facilitated by one or more heat exchangers that employ one or more spring tube coils to improve efficiency, including spatial efficiency, operational efficiency, and/or cost efficiency.

In accordance with the present disclosure, tubing of the heat exchanger is formed using one or more spring tubes. Spring tubes are tubes formed in a “helical” or “spiral” shape. As used herein, the terms “helical”, “spiral”, and “helix” may include, but are not limited, to a three dimensional-curve that turns around an axis (spring tube axis) while extending generally parallel to the axis. The spring tubes have a spring tube axis about which a helical shape of the spring tube itself is formed. That is, a spring tube is a coil or spiraling sequence of tubing around a void that the spring tube axis extends along. More specifically, a spring tube includes a tube (e.g., a mini tube with a diameter of between 1 and 3 millimeters) formed or coiled into the helical or spiral shape. Thus, the spring tube shape has a tube diameter (e.g., the diameter of the mini tubing) and a spring tube diameter, which may be referenced to as a “coil diameter.” The term “coil diameter” may refer to the diameter of a single turn or revolution of the spring tube at any given point across the length of the spring tube.

The coil does not necessarily maintain a consistent geometry. For example, the spring tube diameter may vary along the length of the spring tube or may remain consistent. That is, the coil of tubing forming a spring tube may create varying cross sections along the spring tube axis and through the void formed by the spiraling. In other words, in accordance with present embodiments, the helical or spiral shape of the spring tube is not necessarily consistent. For example, a cross section of the void formed by the spiraling tubing of the spring tube may vary between different spring tubes and/or along the length of a single spring tube. However, in some embodiments, the cross section of the void is substantially consistent, (e.g., consistently round or circular). In some embodiment, the spiral or coil of a spring tube maintains a substantially consistent radius about the spring tube axis, as generally illustrated in FIGS. 4-10.

The spring tube (the overall spring tube, as opposed to the tube forming the spring tube) may also be wound in a geometric shape configuration formed around a geometric axis, which is non-coaxial to the spring tube axis. Examples of this are shown in FIGS. 5-10. The geometric shape may vary in cross-section (e.g., a conical shape) or maintain a certain consistency of the cross-section (e.g., a cylindrical shape). In order to allow for greater heat transfer area as compared to a standard A-shaped coil used in conventional heat exchangers, the geometric configuration of the wound spring tubes can be a helix shape or a cylindrical shape. For example, the geometric configuration of the wound spring tubes can be a cylinder, an upright cone, an inverted cone, among other configurations. The orientation of the geometric configuration may be dependent on a direction of desired flow of conditioning fluid (e.g., airflow). Thus, in some embodiments, the heat exchanger may be configured in a geometric configuration to promote upward flow, downward flow, or sideways flow. In some embodiments, one or more spring tubes are formed into a geometric configuration (e.g., via winding about a corresponding geometric shape that is removed). In some embodiments one or more spring tubes are disposed about a support structure (e.g., via winding about a corresponding geometrically shaped structure that is left in place).

The spring tubes in accordance with the present disclosure include more surface area than the tubing in traditional coils, which enables more efficient heat transfer via the spring tubes than can typically be achieved by traditional coils. Accordingly, in an embodiment of the present disclosure, spring tubes do not include heat transfer fins, which are commonly used in traditional coils to increase heat transfer surface area. For example, for the same length, a finless spring tube can have a higher heat transfer/exchange area as compared to a finless traditional tube. By excluding such fins, present embodiments may eliminate costs associated with manufacturing and assembling heat transfer fins. Additionally, spring tubes may consume less space than traditional tubes while achieving the same or better heat exchange rate.

Embodiments of the present disclosure also provide efficiency related to refrigerant charge. Refrigerant charge may refer to an amount of refrigerant contained within a refrigeration circuit. Heat exchanger tubes having a lesser total internal volume reduce the refrigerant charge in the heat exchanger. A section of spring tubing has a lower internal volume than a section of straight tubing of the same size. For example, a spring tube with a spring tube diameter or coil diameter of ⅜ inches has a total internal volume that is less than that of a ⅜-inch diameter straight tube. Thus, the use of spring tubes as tubing in a heat exchanger may provide more heat transfer per area/volume at a lower refrigerant charge as compared to straight tubes. Further, the heat transfer/exchange area of spring tube can be easily altered by varying coil diameter, coil pitch, and length of the spring tube. Thus, present embodiments reduce refrigerant usage relative to traditional systems and saves associated costs.

In some embodiments, the heat exchanger may include a plurality of spring tubes. For example, the heat exchanger may include two spring tubes wound in a conical or cylindrical shape to form two stacked parallel circuits for heat exchange. In certain embodiments, where multiple spring circuits are included in a heat exchanger, direction of refrigerant flow in different spring tubes can be the same or different. For example, one of the spring tubes can have up-flow of refrigerant and the other spring tube can have downflow of refrigerant. Additionally or alternatively, two spring tubes may be connected end to end (e.g., via a header) such that the outlet of one spring tube is connected to the inlet of the other spring tube.

In some embodiments of the present disclosure, a heat exchanger may include a support member, which may provide structural support to the spring tubes. For example, the heat exchanger with spring tubes wound in a conical geometric configuration may include a conical support frame. Such support members aid in retaining the spring tubes in the desired geometric configuration and/or in a desired orientation (e.g., relative to condition fluid flow). For example, a support member may keep a spring tube in a desired geometric configuration and relative location when subjected to a conditioning fluid flow (e.g., air flow).

In general, presently disclosed embodiments may improve HVAC heat exchanger operation by increasing the efficiency of the heat transfer/exchange area of heat exchangers, and reducing the refrigerant charge necessary for heat transfer. Further, present embodiments may improve cost efficiency by reducing the use of refrigerant, conserving space within an HVAC unit and/or heat exchanger, and eliminating expensive aspects of manufacturing (e.g., assembly of fins) typically required in traditional systems.

Turning now to the drawings, FIG. 1 illustrates an HVAC system for building environmental management that may employ one or more HVAC units. The HVAC system 11 of FIG. 1 may also employ present embodiments to more efficiently transfer/exchange heat. In the illustrated embodiment, a building 10 is air conditioned by an HVAC system 11 that includes an HVAC unit 12. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit, such as the system shown in FIG. 2A. The HVAC unit 12 may contain other equipment, such as a blower, integrated air handler, and/or auxiliary heating unit. In other embodiments, the HVAC unit 12 may be part of a split HVAC system 11, such as the system shown in FIG. 2B, which includes an outdoor HVAC unit 12C and an indoor HVAC unit 12B.

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 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 heat exchanger of the HVAC unit 12, such as one in a refrigeration circuit, may circulate a refrigerant to efficiently transfer/exchange heat in accordance with embodiments of the presently disclosed invention.

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 HVAC system 11, 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.

FIG. 2A is a perspective view of an embodiment of the HVAC unit 12A. In the illustrated embodiment, the HVAC unit 12A is a single package unit that may include one or more independent refrigeration circuits and components that are tested, charged, wired, piped, and ready for installation. The HVAC unit 12A may provide a variety of heating and/or cooling functions, such as cooling only, heating only, cooling with electric heat, cooling with dehumidification, cooling with gas heat, or cooling with a heat pump. As described above, the HVAC unit 12A may directly cool and/or heat an air stream provided to the building 10 to condition a space in the building 10.

As shown in the illustrated embodiment of FIG. 2A, a cabinet 24 encloses the HVAC unit 12A and provides structural support and protection to the internal components from environmental and other contaminants. In some embodiments, the cabinet 24 may be constructed of galvanized steel and insulated with aluminum foil faced insulation. Rails 26 may be joined to the bottom perimeter of the cabinet 24 and provide a foundation for the HVAC unit 12A. In certain embodiments, the rails 26 may provide access for a forklift and/or overhead rigging to facilitate installation and/or removal of the HVAC unit 12A. In some embodiments, the rails 26 may fit into “curbs” on the roof to enable the HVAC unit 12A to provide air to the ductwork 14 from the bottom of the HVAC unit 12A while blocking elements such as rain from leaking into the building 10.

The HVAC unit 12A includes heat exchangers 28 and 30 in fluid communication with one or more refrigeration circuits. Tubes, such as those in embodiments of the presently disclosed invention, within the heat exchangers 28 and 30 may circulate a working fluid, such as R-410A, through the heat exchangers 28 and 30. In accordance with embodiments of the presently disclosed invention, the heat exchanger tubes may be spring tubes that facilitate more efficient heat transfer/exchange. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the working fluid 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 working fluid to ambient air, and the heat exchanger 30 may function as an evaporator where the working fluid absorbs heat to cool an air stream. In other embodiments, the HVAC unit 12A 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 12A may include a furnace for heating the air stream that is supplied to the building 10. While the illustrated embodiment of FIG. 2A shows the HVAC unit 12A as having two of the heat exchangers 28 and 30, in other embodiments, the HVAC unit 12A may include one heat exchanger or more than two heat exchangers.

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 12A. 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 12A also may include other equipment for implementing the thermal cycle. Compressors 40 and 42 increase the pressure and temperature of the working fluid before the working fluid enters the heat exchanger 28. The compressors 40 and 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 40 and 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 40 and 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 12A, 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 12A 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 12A 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 of these components may be 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 12A.

FIG. 2B illustrates a residential heating and cooling system 50, also in accordance with present techniques. The residential heating and cooling system 50 may provide heated and cooled air to a residential structure, as well as provide outside air for ventilation and provide improved indoor air quality (IAQ) through devices such as ultraviolet lights and air filters. In the illustrated embodiment, the residential heating and cooling system 50 is a split HVAC system. In general, a residence 52 conditioned by a split HVAC system may include working fluid conduits 54 that operatively couple the indoor unit 12B to the outdoor unit 12C. The indoor unit 12B may be positioned in a utility room, an attic, a basement, and so forth. The outdoor unit 12C is typically situated adjacent to a side of residence 52 and is covered by a shroud to protect the system components and to prevent leaves and other debris or contaminants from entering the unit. The working fluid conduits 54 transfer working fluid between the indoor unit 56 and the outdoor unit 58, typically transferring primarily liquid working fluid in one direction and primarily vaporized working fluid in an opposite direction.

When the system shown in FIG. 2B is operating as an air conditioner, a heat exchanger 60 in the outdoor unit 12C serves as a condenser for re-condensing vaporized working fluid flowing from the indoor unit 12B to the outdoor unit 12C via one of the working fluid conduits 54. In accordance with an embodiment of the present disclosure, the heat exchanger 60 includes spring tubing as heat exchanger tubing. Further, in these applications, a heat exchanger 62 of the indoor unit 12B functions as an evaporator. Specifically, the heat exchanger 62 receives liquid working fluid, which may be expanded by an expansion device, and evaporates the working fluid before returning it to the outdoor unit 12C. In accordance with an embodiment of the present disclosure, the heat exchanger 62 includes spring tubing as heat exchanger tubing.

The outdoor unit 12C draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 12C. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 12C and exits the unit at a temperature higher than it entered. The indoor unit 12B 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, or the set point 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, or 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 12C will serve as an evaporator to evaporate working fluid and thereby cool air entering the outdoor unit 12C 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 working fluid.

In some embodiments, the indoor unit 12B may include a furnace system 70. For example, the indoor unit 12B 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 12B. 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, 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.

FIG. 3 is an embodiment of a vapor compression system 72 that can be used in any of the systems described above and incorporates one or more heat exchangers with one or more spring tubes in accordance with present embodiments. The vapor compression system 72 may circulate a working fluid through a circuit starting with a compressor 74. The circuit may also include a condenser 76, an expansion valve(s) or device(s) 78, and an evaporator 80. The vapor compression system 72 may further include a control panel 82 that has an analog to digital (A/D) converter 84, a microprocessor 86, a non-volatile memory 88, and/or an interface board 90. The control panel 82 and its components may function to regulate operation of the vapor compression system 72 based on feedback from an operator, from sensors of the vapor compression system 72 that detect operating conditions, and so forth.

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 working fluid 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 working fluid 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 working fluid vapor may condense to a working fluid liquid in the condenser 76 as a result of thermal heat transfer with the environmental air 96. The liquid working fluid from the condenser 76 may flow through the expansion device 78 to the evaporator 80.

The liquid working fluid 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 working fluid in the evaporator 80 may undergo a phase change from the liquid working fluid to a working fluid vapor. In this manner, the evaporator 80 may reduce the temperature of the supply air stream 98 via thermal heat transfer with the working fluid. Thereafter, the vapor working fluid 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 below, the system(s) and/or unit(s) described with respect to FIGS. 1-4 above may employ one or more heat exchangers having one or more spring tubes, wherein the spring tube has a spring tube axis and is wound in a geometric configuration formed around a geometric axis. The heat exchanger tubes may be configured to increase heat transfer/exchange area at a lower refrigerant charge and thus, improve the heat transfer/exchange area of heat exchangers, refrigerant charge necessary for heat transfer of heat exchangers, and manufacturing, assembly and/or operating costs of HVAC systems as a whole. These and other aspects of the present disclosure are described in detail below.

FIG. 4 is a front view of an embodiment of a spring tube 400 for a heat exchanger of an HVAC unit, in accordance with an embodiment of the present disclosure. In the illustrated embodiment, the spring tube 400 is depicted with a substantially consistent spiral about a spring tube axis 402, which forms a cylindrical shape about a round void having a spring tube length 408 along the spring tube axis 402. The spring tube 400 includes a first opening 404 and second opening 406. Refrigerant or another fluid may be transported or passed through the interior volume of the spring tube 400 between the first and second openings 404, 406. In the illustrated embodiment, the coils of the spring tube 400 are slightly separated, which allows fluid flow into and out of the interior void formed by the spiral of the spring tube 400. In accordance with present embodiments, smaller or larger gaps between adjacent coils may be provided to achieve desired characteristics (e.g., increased or decreased airflow between coils).

The spring tube 400 is a heat exchanger tube formed in a “helical” or “spiral” shape. The spring tube 400 has the spring tube axis 402 around which the helical or spiral shape is formed. In the illustrated embodiment, the spring tube axis 402 defines a centerline of the spring tube 400. As used herein, the terms “helical”, “spiral”, and “helix” may include, but are not limited, to a three-dimensional curve that turns around an axis (e.g., the spring tube axis 402) while moving generally parallel to the axis. In accordance with present embodiments, the spring tube 400 is not limited to a consistent cross-section (e.g., the radius extending between the spring tube axis 402 and the coils of the spring tube 400 can vary). The axis may turn (e.g., to form an overall shape of the spring tube 400). For example, the spring tube 400 may form a cone or cylinder. The spring tube 400 may be made of copper tubing, aluminum tubing, or any suitable material.

The spring tube 400 has a passage (interior volume) defined between the first opening 404 and the second opening 406 through which a working fluid (e.g., a refrigerant) can pass. For example, this passage may be defined by a mini tube that is coiled to form the spring tube 400. This allows for a heat exchange relationship between the working fluid and conditioning fluid passing over the spring tube 400. For example, heat can exchange (via the spring coil) between the refrigerant in the passage (inside tubing forming the spring coil) and air passing over (contacting the exterior) of the spring coil. In one embodiment, the diameter (e.g., cross-sectional diameter) of the passage of the spring tube 400 may be less than ⅜ inches. For example, in some embodiments, the passage is defined by a mini tube and the diameter of the passage of the spring tube 400 may be in a range of 1 millimeter to 3 millimeters. In other embodiments, the diameter of the passage may vary along the length of the spring tube 400.

In some embodiments, adjacent coils of the spring tube 400 may be in contact with each other. The term “coil” may refer to a single turn or revolution of the spring tube 400 that forms the helical or spiral shape. In other embodiments, adjacent coils of the spring tube 400 may be spaced apart from each other. The distance between adjacent coils of the spring tube 400 can be uniform or variable across a length of the spring tube 400. The length of the spring tube 400 may be defined as the length running parallel to the spring tube axis 402. In FIG. 4, the length of the spring tube 400 is represented by arrow 408. The spring tube 400 can have uniform or variable coil pitch (e.g., distance between adjacent coils) depending on heat exchange or thermodynamic requirements of the heat exchanger, without deviating from the scope of the disclosure. For example, the distance between the first and second coils of the spring tube 400 may be the same or different from the distance between the second and third coils of the spring tube 400.

In some embodiments, the spring tube 400 may have uniform coil diameter 409 throughout the length of the spring tube 400. The term “coil diameter” may refer to the diameter of a single turn or revolution of the spring tube at any given point across the length of the spring tube 400. The spring tube 400 in FIG. 4 is shown to have uniform coil diameter 409. However, in other embodiments, a coil diameter may vary across the length of the spring tube 400. For example, a coil diameter of a first coil in the spring tube 400 may be different from a second coil in the spring tube 400. In other words, the spring tube 400 can have uniform or variable coil diameter depending upon heat exchange or thermodynamic requirements of the heat exchanger, without deviating from the scope of the disclosure.

While fins may be employed in accordance with present embodiments, in some embodiments, the spring tube 400 is finless. For the same length, the finless spring tube 400 can have higher heat transfer/exchange area as compared to a finless straight tube, thereby saving on fin manufacturing costs. Additionally, heat transfer/exchange area of the spring tube 400 can be easily altered by varying the coil diameter, coil pitch, and the length of the spring tube 400. Further, in one embodiment, as the diameter of the internal passage of tubing (e.g., mini tubing) coiled to form the spring tube 400 is less than ⅜ inches, the total internal volume of the spring tube 400 is less than the total internal volume of a ⅜-inch diameter straight tube. Lesser total internal volume also reduces refrigerant charge in the heat exchanger as required in various applications. Refrigerant charge may refer to an amount of refrigerant contained within a refrigeration circuit. Maintaining correct refrigerant charge is part of efficient heat exchanger operation. In other words, the use of spring tube 400 as tubing in a heat exchanger may provide more heat transfer per area/volume at a lower refrigerant charge as compared to straight tubes. However, in other embodiments, the heat transfer/exchange area can be further enhanced by providing one or more fins on the spring tube 400.

FIG. 5 is a front view of an embodiment of a heat exchanger 500 including the spring tube 400, in accordance with aspects of the present disclosure. Heat exchangers 28, 30, 60, 62 as described above with respect to FIGS. 2A and 2B may be implemented using the heat exchanger 500. The heat exchanger 500 is a part of an HVAC system, which may be any of the systems discussed above, for example, the HVAC system 11 shown in FIG. 1.

A coil portion 501 is realized using the spring tube 400 as described above with respect to FIG. 4. The complete structure of the spring tube 400 is not depicted as coiled or helical in FIG. 5. However, in an actual implementation, the entire structure of the spring tube 400 between the first opening 404 and the second opening 406 may be coiled or helical. In some embodiments, the coil portion 501 may be disposed within a housing.

The spring tube 400 may be used in the heat exchanger 500 to provide more heat transfer per area/volume at a lesser refrigerant charge as compared to straight tubes. To form the coil portion 501, the spring tube 400 may be wound in a conical helix geometric configuration 502 formed around a geometric axis 504. The spring tube axis 402 and the geometric axis 504 are not tangible physical components and are shown merely to represent reference central lines around which the spring tube 400 and the conical helix geometric configuration 502 are formed. The spring tube axis 402 is in a non-coaxial arrangement with the geometric axis 504.

In some embodiments, adjacent coils of the conical helix geometric configuration 502 may be in contact with each other. In other embodiments, adjacent coils of the conical helix geometric configuration 502 may be spaced apart from each other. The distance between adjacent coils of the conical helix geometric configuration 502 may be uniform or vary. For example, the distance between the first and second coils of the conical helix geometric configuration 502 may be different from the distance between the second and third coils of the conical helix geometric configuration 502. In other words, the conical helix geometric configuration 502 can have uniform or variable coil pitch (e.g., distance between adjacent coils) depending on heat exchange or thermodynamic requirements of the heat exchanger 500, without deviating from the scope of the disclosure.

In some embodiments, the first opening 404 may serve as an inlet for introducing refrigerant 506 into the heat exchanger 500 and the second opening 406 may serve as an outlet for discharging the refrigerant 506 out of the heat exchanger 500. To provide the refrigerant 506 to a plurality of coils of the conical helix geometric configuration 502, the heat exchanger 500 may include a distributor 508 fluidly coupled to the inlet (e.g., the first opening 404) of the heat exchanger 500. The distributor 508 may supply the refrigerant 506 to the inlet and thus, the refrigerant 506 may flow through the spring tube 400, and in turn through the plurality of coils of the conical helix geometric configuration 502. The refrigerant 506 may also be supplied at sufficient pressure to ensure that the refrigerant 506 flows through the plurality of coils of the conical helix geometric configuration 502 completely. In other words, the refrigerant 506 is continuously provided through the heat exchanger 500 for exchanging heat with a conditioning fluid (e.g., air flow). In some embodiments, the air flow may be in an upward direction as indicated by arrow 509. It should be noted that the distributor 508 may supply multiple spring tubes 400 (and corresponding first openings 404), which may cooperate to reduce pressure drop across the heat exchanger 500.

After the refrigerant 506 has traveled through the plurality of coils of the heat exchanger 500 (or the conical helix geometric configuration 502), the refrigerant 506 is continuously removed from the heat exchanger 500 via a manifold 510. The manifold 510 may be fluidly coupled to the outlet (e.g., the second opening 406) of the heat exchanger 500. The manifold 510 may receive the refrigerant 506 after heat exchange and direct the refrigerant 506 to a next portion of the refrigeration cycle, where the refrigerant 506 is recharged for heat exchange. It should be noted that the manifold 510 may receive the refrigerant from multiple spring tubes 400 (and corresponding second openings 406), which may cooperate to reduce pressure drop across the heat exchanger 500.

In some embodiments, the heat exchanger 500 may be used to provide cooling to a building, such as building 10. In such an embodiment, the refrigerant 506 may be supplied to the heat exchanger 500 at a lower temperature, such that thermal energy from the conditioning fluid (e.g., air flow) may transfer to the refrigerant 506, thereby cooling the conditioning fluid.

In some embodiments, the second opening 406 may serve as the inlet of the heat exchanger 500 and the first opening 404 may serve as the outlet of the heat exchanger 500. In such an embodiment, the second opening 406 may be fluidly coupled with the distributor 508 and the second opening 406 may be fluidly coupled with the manifold 510. While the illustrated embodiment of FIG. 5 illustrates the first opening 404 and the second opening 406 to be on opposite sides of the conical helix geometric configuration 502, the scope of the disclosure is not limited to this illustrated embodiment. In some embodiments, the spring tube 400 may be wound in the conical helix geometric configuration 502 such that the first opening 404 and the second opening 406 are on the same sides of the conical helix geometric configuration 502.

While the illustrated embodiment of FIG. 5 shows the conical helix geometric configuration 502 as an upright conical helix, the scope of the disclosure is not limited to this illustrated embodiment. In other embodiments, the conical helix geometric configuration 502 may be an inverted conical helix that is to be used with downward flow of air (e.g., in a direction opposite to arrow 509), without deviating from the scope of the disclosure. The orientation of the conical helix geometric configuration 502 may be dependent on a desired air flow direction. Thus, in other embodiments, the heat exchanger 500 may be oriented in another direction (e.g., the geometric axis 504 may be inverted, diagonal, or horizontal), such that downward flow or non-vertical flow configurations, instead of the depicted upward flow configuration, are achieved as desired. In different embodiments, direction of refrigerant flow may be the same, opposite, orthogonal, or angled to the direction of air flow.

While the illustrated embodiment of FIG. 5 shows the coil portion 501 including a single refrigeration circuit of the spring tube 400, the scope of the disclosure is not limited to this illustrated embodiment. In other embodiments, the coil portion 501 may include a plurality of spring tubes 400 forming a plurality of parallel refrigeration circuits, a plurality of stacked refrigeration circuits, or a combination thereof for heat exchange. One such embodiment, where two spring tubes are used in a heat exchanger is described later in conjunction with FIGS. 8, 9, and 10.

In some embodiments, during manufacturing of the heat exchanger 500 or the coil portion 501, a conical support member may be used to wind the spring tube 400 in the conical helix geometric configuration 502. Once the spring tube 400 is successfully wound in the conical helix geometric configuration 502, the conical support member may be removed and the spring tube 400 may remain in the conical helix geometric configuration 502 without the conical support member. For example, the spring tube 400 may be flexible enough to bend when forced but rigid enough to maintain its shape when force is removed. In some embodiments, the heat exchanger 500 may include one or more support members or elements coupled to the spring tube 400 to support the spring tube 400 in the conical helix geometric configuration 502 after the removal of the support member. Such support members aid in retaining the spring tube 400 in the conical helix geometric configuration 502. For example, the support member may assist in retaining the geometric configuration 502 or relative positioning of the spring tube 400 when subjected to conditioning fluid flow (e.g., airflow). However, in other embodiments, the conical support member may not be removed, without deviating from the scope of the disclosure.

FIG. 6 is a front view of an embodiment of a heat exchanger 600 which includes a support member 602 to support the spring tube 400, in accordance with aspects of the present disclosure. The heat exchanger 600 is a part of an HVAC system, which may be any of the systems discussed above, for example, the HVAC system 11 shown in FIG. 1. For the sake of brevity, the complete structure of the spring tube 400 is not depicted as coiled or helical in FIG. 6. However, in an actual implementation, the entire structure of the spring tube 400 between the first opening 404 and the second opening 406 may be coiled or helical.

The heat exchanger 600 is similar to the heat exchanger 500 described above with respect to FIG. 5 except that the heat exchanger 600 includes the support member 602 that supports the spring tube 400 wound in the conical helix geometric configuration 502. The support member 602 may have a conical shape with its axis as the geometric axis 504. The spring tube 400 may be wound around the support member 602 in the conical helix geometric configuration 502. In some embodiments, the support member 602 may be constructed as a frame including interconnected members or elements so as to allow unobstructed flow of the conditioning fluid (e.g., air flow) for heat exchange with the refrigerant 506. In another embodiment, the support member 602 may be made of perforated material, a mesh, wiring, and/or a grid.

FIG. 7 is a front view of an embodiment of a heat exchanger 700 including the spring tube 400, in accordance with aspects of the present disclosure. The heat exchanger 700 is a part of an HVAC system, which may be any of the systems discussed above, for example, the HVAC system 11 shown in FIG. 1. For the sake of brevity, the complete structure of the spring tube 400 is not depicted as coiled or helical in FIG. 7. However, in an actual implementation, the entire structure of the spring tube 400 between the first opening 404 and the second opening 406 may be coiled or helical.

The heat exchanger 700 is similar to the heat exchanger 500 described above with respect to FIG. 5 except that in the heat exchanger 700, the spring tube 400 is wound in a cylindrical helix geometric configuration 702 around a geometric axis 704 instead of the conical helix geometric configuration 502 as shown in FIGS. 5 and 6.

In some embodiments, adjacent coils of the cylindrical helix geometric configuration 702 may be in contact with each other. In other embodiments, adjacent coils of the cylindrical helix geometric configuration 702 may be spaced apart from each other. In some embodiments, the distance between adjacent coils of the cylindrical helix geometric configuration 702 may be uniform. In other embodiments, the distance between adjacent coils of the cylindrical helix geometric configuration 702 may vary. In other words, the cylindrical helix geometric configuration 702 can have uniform or variable coil pitch (e.g., distance between adjacent coils) depending on heat exchange or thermodynamic requirements of the heat exchanger 700, without deviating from the scope of the disclosure.

While the illustrated embodiment in FIG. 7 shows the cylindrical helix geometric configuration 702 as having a uniform coil diameter, the scope of the disclosure is not limited to the illustrated embodiment. In other embodiments, coil diameter of the cylindrical helix geometric configuration 702 may vary non-uniformly in a direction from the first opening 404 to the second opening 406 depending upon heat exchange or thermodynamic requirements of the heat exchanger, without deviating from the scope of the disclosure.

Additionally or alternatively, the heat exchanger 700 may further include a cylindrical support member to support the spring tube 400 in the cylindrical helix geometric configuration 702.

The orientation of the cylindrical helix geometric configuration 702 may be dependent on a desired air flow direction. Thus, in some embodiments, the heat exchanger 700 may be oriented in another direction (e.g., the geometric axis 704 may be diagonal or horizontal), such that non-vertical flow configuration, instead of upward or downward flow configuration, is achieved as desired.

FIG. 8 is a perspective view of an embodiment of a heat exchanger 800 which includes spring tubes 802A and 802B, in accordance with aspects of the present disclosure. The heat exchanger 800 is a part of an HVAC system, which may be any of the systems discussed above, for example, the HVAC system 11 shown in FIG. 1. The spring tubes 802A and 802B are essentially the same as the spring tube 400. For the sake of brevity, the complete structure of the spring tubes 802A and 802B is not depicted as coiled or helical in FIG. 8. However, in an actual implementation, the entire structure of the spring tubes 802A and 802B may be coiled or helical.

In the heat exchanger 800, spring tubes 802A and 802B are used to form two stacked refrigeration circuits for heat exchange. The spring tubes 802A and 802B are stacked together and wound in the conical helix geometric configuration 502 formed around the geometric axis 504. Inlet 804A and 804B of each spring tube 802A and 802B may be fluidly coupled to the distributor 508 (shown in FIGS. 5 and 6) to introduce the refrigerant 506 into the heat exchanger 800 and outlet 806A and 806B of each spring tube 802A and 802B may be fluidly coupled to the manifold 510 to discharge the refrigerant 506 from the heat exchanger 800. Each refrigeration circuit operates in a similar manner as described above with respect to the illustrated embodiment of FIG. 5.

In some embodiments, the spring tubes 802A and 802B can be wound in the conical helix geometric configuration 502 to form multiple parallel refrigeration circuits. For example, a heat exchanger may include two parallel refrigeration circuits formed using the spring tubes 802A and 802B. While present embodiments include any of numerous arrangements, in one embodiment, the spring tube 802B may be wound around the spring tube 802A, which is already wound to form the conical helix shape. Thus, a first parallel refrigeration circuit may be defined in an outer surface of the conical helix shape by the spring tube 802B, and a second parallel refrigeration circuit may be defined in an inner surface of the conical helix shape by the spring tube 802A. Additionally or alternatively, the heat exchanger 800 may further include a conical support member to support the spring tubes 802A and 802B in the conical helix geometric configuration 502.

In some embodiments, additional spring tubes may be used to form a plurality of parallel stacked refrigeration circuits. For example, a third and fourth spring tube may be wound around the stacked spring tubes 802A and 802B, which are already wound to form the conical helix shape shown in FIG. 8. Thus, a first parallel stacked refrigeration circuit may be defined in an outer surface of the conical helix shape by the third and fourth spring tubes and a second parallel stacked refrigeration circuit may be defined in an inner surface of the conical helix shape by the spring tubes 802A and 802B.

While the illustrated embodiment of FIG. 8 shows adjacent spring tubes 802A and 802B as having no space between them, the scope of the disclosure is not limited to the illustrated embodiment. In some embodiments, the spring tubes 802A and 802B may be spaced apart from each other and the heat exchanger 800 may include one or more spacers to maintain a distance between adjacent spring tubes 802A and 802B. Similarly, spacers may also be used to maintain a distance between spring tubes in adjacent parallel refrigeration circuits.

In some embodiments, the inlets 804A and 804B of the spring tubes 802A and 802B may be located at same positions of the conical helix geometric configuration 502. Similarly, the outlets 806A and 806B of the spring tubes 802A and 802B may also be located at same positions of the conical helix geometric configuration 502. For example, as shown in FIG. 8, the inlets 804A and 804B of the spring tubes 802A and 802B are located at the lower end of the conical helix geometric configuration 502 and the outlets 806A and 806B are located at the upper end of the conical helix geometric configuration 502.

FIG. 9 is a perspective view of an embodiment of a heat exchanger 900 which includes spring tubes 902A and 902B, in accordance with aspects of the present disclosure. The heat exchanger 900 is a part of an HVAC system, which may be any of the systems discussed above, for example, the HVAC system 11 shown in FIG. 1. The spring tubes 902A and 902B are same as the spring tube 400. For the sake of brevity, the complete structure of the spring tubes 902A and 902B is not depicted as coiled or helical in FIG. 9. However, in an actual implementation, the entire structure of the spring tubes 902A and 902B between may be coiled or helical.

In the heat exchanger 900, the spring tubes 902A and 902B are used to form two stacked refrigeration circuits for heat exchange. The spring tubes 902A and 902B are stacked together and wound in the cylindrical helix geometric configuration 702 formed around the geometric axis 704. Inlet 904A and 904B of each spring tube 902A and 902B may be fluidly coupled to the distributor 508 (shown in FIG. 7) to introduce the refrigerant 506 into the heat exchanger 900 and outlet 906A and 906B of each spring tube 902A and 902B may be fluidly coupled to the manifold 510 (shown in FIG. 7) to discharge the refrigerant 506 from the heat exchanger 900. Each refrigeration circuit operates in a similar manner as described above with respect to FIGS. 5 and 7. Additionally or alternatively, the heat exchanger 900 may further include a cylindrical support member to support the spring tubes 902A and 902B in the cylindrical helix geometric configuration 702.

In some embodiments, the spring tubes 902A and 902B can be wound in the cylindrical helix geometric configuration 702 to form parallel refrigeration circuits. For example, a heat exchanger may include two parallel refrigeration circuits formed using the spring tubes 902A and 902B. The spring tube 902B may be wound around the spring tube 902A, which is already wound to form the cylindrical helix geometric configuration 702. Thus, a first parallel refrigeration circuit may be defined in an outer surface of the cylindrical helix shape by the spring tube 902B, and a second parallel circuit may be defined in an inner surface of the cylindrical helix shape by the spring tube 902A.

In some embodiments, additional spring tubes 400 may be used to form a plurality of parallel stacked refrigeration circuits. For example, a third and fourth spring tube may be wound around the stacked spring tubes 902A and 902B, which are already wound to form the cylindrical helix shape shown in FIG. 9. Thus, a first parallel stacked refrigeration circuit may be defined in an outer surface of the cylindrical helix shape by the third and fourth spring tubes and a second parallel stacked refrigeration circuit may be defined in an inner surface of the cylindrical helix shape by the spring tubes 902A and 902B.

In some embodiments, the spring tubes 902A and 902B may be spaced apart from each other and the heat exchanger 900 may include one or more spacers to maintain a distance between adjacent spring tubes 902A and 902B. Similarly, spacers may also be used to maintain a distance between spring tubes in adjacent parallel refrigeration circuits.

In some embodiments, the inlets 904A and 904B of the spring tubes 902A and 902B may be located at same positions of the cylindrical helix geometric configuration 702. Similarly, the outlets 906A and 906B of the spring tubes 902A and 902B may also be located at same positions of the cylindrical helix geometric configuration 702. For example, as shown in FIG. 9, the inlets 904A and 904B of the spring tubes 902A and 902B are located at a lower end of the cylindrical helix geometric configuration 702 and the outlets 906A and 906B are located at the upper end of the cylindrical helix geometric configuration 702.

FIG. 10 is a perspective view of an embodiment of a heat exchanger 1000 which includes the spring tubes 802A and 802B having inlets at different positions of the conical helix geometric configuration 502, in accordance with aspects of the present disclosure. The heat exchanger 1000 is a part of an HVAC system, which may be any of the systems discussed above, for example, the HVAC system 11 shown in FIG. 1. The spring tubes 802A and 802B are essentially the same as the spring tube 400. The complete structure of the spring tubes 802A and 802B is not depicted as coiled or helical in FIG. 8. However, in an actual implementation, the entire structure of the spring tubes 802A and 802B may be coiled or helical.

The heat exchanger 1000 is similar to the heat exchanger 800 except that in the heat exchanger 1000, the inlets 804A and 804B of spring tubes 802A and 802B are located at different positions of the conical helix geometric configuration 502. For example, the inlet 804A of the spring tube 802A is located at the lower end of the conical helix geometric configuration 502 and the inlet 804B of the spring tube 802B is located near the middle of the conical helix geometric configuration 502. Similarly, the outlets 806A and 806B can also be located at different positions of the conical helix geometric configuration 502 without deviating from the scope of the disclosure.

In some embodiments, where a plurality of refrigeration circuits is included in a heat exchanger (e.g., the heat exchanger 800, 900, 1000), direction of refrigerant flow in different spring tubes can be the same or different, without deviating from the scope of the disclosure. For example, one of the spring tubes 804A can have upward flow of refrigerant 506 and the other spring tube 804B can have downward flow of refrigerant. In another example, two spring tubes may be connected end to end such that outlet of one spring tube is connected to inlet of the other spring tube. This may be done indirectly (e.g., via a header) or directly.

While the illustrated embodiments of FIGS. 8-10 show the use of two spring tubes, the scope of the disclosure includes any number of spring tubes. A heat exchanger according to the present disclosure can include one, two, or more than two spring tubes 400 depending on heat exchange or thermodynamic requirements of the heat exchanger. Likewise, a heat exchanger according to the present disclosure can include more than two parallel or stacked refrigeration circuits.

Embodiments of the present disclosure may provide one or more technical effects or benefits useful in the operation of an HVAC system. In particular, presently disclosed embodiments enable improved heat transfer/exchange area of heat exchangers, refrigerant charge necessary for heat transfer of heat exchangers, and manufacturing, assembly and/or operating costs of the HVAC systems as a whole (e.g., relative to traditional configurations).

While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, such as temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth, 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 exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. 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.

The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

HEAT EXCHANGER WITH SPRING TUBE COIL

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)