The present invention relates to a heat exchanger, and more particularly, to a heat exchanger including fins and one or more microchannel coils.
Refrigeration systems are well known and widely used in supermarkets and warehouses to refrigerate food product displayed in a product display area of a refrigerated merchandiser or display case. Conventional refrigeration systems often include an evaporator, a compressor, and a condenser connected in series. The evaporator provides heat transfer between a refrigerant and a fluid passing over the evaporator coil. The evaporator transfers heat from the fluid to the refrigerant so that the fluid cools the product display area. The refrigerant absorbs heat from the fluid in a refrigeration mode, and the compressor mechanically compresses the evaporated refrigerant from the evaporator and feeds the superheated refrigerant to the condenser, which cools the refrigerant via heat transfer between the condenser coil and a fluid (typically ambient air) flowing through the condenser. From the condenser, the cooled refrigerant is fed through one or more expansion valves to reduce the temperature and pressure of the refrigerant, and then the refrigerant is directed through the evaporator.
Commercial refrigerators use heat exchangers for the purpose of absorbing heat from the air stream to reduce the temperature of the air and use that air mass to cool product. In most below-freezing applications this is done with a traditional fin and tube design. On the condensing side of the system, microchannel coils are becoming increasingly more common, but due to fin density and design the microchannel coils ice over rapidly in below-freezing applications.
In one construction, the invention embodies a heat exchanger including a coil that has bends and tube passes that are disposed between the bends. The coil further has an inlet end and an outlet end and is continuous between the inlet end and the outlet end. The coil is defined by parallel microchannel passageways extending from the inlet end to the outlet end. The heat exchanger also includes a plurality of elongated fins spaced apart from each other between a first end of the heat exchanger and a second end of the heat exchanger. Each of the fins defines two or more apertures, and two or more of the tube passes extend through the same fin of the plurality of fins.
In another construction, the invention embodies a heat exchanger including a serpentine coil that has an inlet end and an outlet end and that is continuous between the inlet end and the outlet end. The serpentine coil is defined by parallel fluid passageways extending from the inlet end to the outlet end. The heat exchanger also includes one or more fins disposed between a first end of the heat exchanger and a second end of the heat exchanger, and each of the one or more fins is coupled to different portions of the serpentine coil.
In yet another construction, the invention embodies a heat exchanger including a coil that has bends and tube passes disposed between the bends. The coil further has an inlet end and an outlet end and being continuous between the inlet end and the outlet end. The coil is defined by parallel microchannel passageways extending from the inlet end to the outlet end. The heat exchanger also includes a plurality of fins spaced apart from each other between a first end of the heat exchanger and a second end of the heat exchanger, and each of the plurality of fins is coupled to and surrounds multiple tube passes of the coil.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
The refrigerated merchandiser 10 includes a case 100 that has a base 104, a rear wall 108, and a canopy or case top 112. The area that is partially enclosed by the base 104, the rear wall 108, and the canopy 112 defines a product display area 116. As illustrated, the product display area 116 is accessible by customers through an opening 120 adjacent the front of the case 100. Shelves 124 are coupled to the rear wall 108 and extend forward toward the opening 120 adjacent the front of the merchandiser to support food product that is accessible by a consumer through the opening 120.
The base 104 defines a lower portion of the product display area 116 and can support food product. The base 104 further defines a lower flue 134 and includes an inlet 138 located adjacent a lower area of the opening 120. As illustrated, the lower flue 134 is in fluid communication with the inlet 138 and directs an airflow 144, which is generated by a fan 146 that is coupled to the case 100, substantially horizontally through the base 104 from the inlet 138. The inlet 138 is positioned to receive surrounding air in a substantially vertical direction and directs the air into the lower flue 134.
With continued reference to
The canopy 112 defines an upper flue 156. The upper flue 156 is in fluid communication with the rear flue 148 and directs the airflow 144 substantially horizontally through the canopy 112 toward an outlet 160. The lower flue 134, the rear flue 148, and the upper flue 156 are fluidly coupled to each other to define an air passageway that directs the airflow 144 from the inlet 138 to the outlet 160.
The airflow that is discharged from the outlet 160 forms an air curtain 174 that is directed generally downward across the opening 120 to cool the food product within a desired or standard temperature range (e.g., 32 to 41 degrees Fahrenheit). Generally, the inlet 138 receives at least some air from the air curtain 174. Although not shown, the case 100 can define a secondary air passageway that directs a secondary air curtain (e.g., refrigerated or non-refrigerated) from the canopy 112 generally downward across the opening 120 to buffer the air curtain 174 to minimize infiltration of ambient air into the product display area 116.
As illustrated in
Referring to
Each coil circuit 210A-F includes a plurality of tube passes 225 (e.g., twelve tube passes 225 in each coil circuit 210A-F as illustrated in
In some constructions, one or more tube passes 225 can be oriented parallel to the vertical plane 240 or the horizontal plane 245 with one or more other tube passes 225 oriented at the non-zero angle 235. When the tube plane 230 is vertical compared to being horizontal, heat transfer between the airflow and the heat exchanger 190 increases, but the velocity of the airflow traveling through the heat exchanger 190 decreases (e.g., the static pressure of the airflow increases). In contrast, when the tube plane 230 is horizontal compared to being vertical, heat transfer between the airflow and the heat exchanger 190 decreases, but the velocity of the airflow traveling through the heat exchanger 190 increases (e.g., the static pressure of the airflow decreases). Therefore, when the tube plane 230 is disposed at an angle 235 between the horizontal and vertical, an inverse relationship is observed between the amount of heat transfer and the velocity of the airflow traveling through the heat exchanger 190.
As best seen in
With reference to
With reference to
As illustrated, each coil circuit 210A-F is formed from a continuous microchannel tube that is bent into a serpentine shape (e.g., the third coil circuit 210C is illustrated in
As shown in
The heat exchanger 190 is assembled by inserting each tube pass 225 within a corresponding series of apertures 270 of the fins 214. In an exemplary embodiment, the heat exchanger 190 can be assembled in the same or a similar manner as described and illustrated in U.S. patent application Ser. No. 13/768,238, filed Feb. 15, 2013, (entitled “Multi-Zone Circuiting for a Plate-Fin and Continuous Tube Heat Exchanger”), the entire contents of which are incorporated herein by reference. For example, the tube passes 225 extend through each fin 214 so that the return bend portions 255 are coupled to two tube passes 225 adjacent the last fin 214 at the second end 200, and the crossover bend portions 250a, 250b are coupled to two tube passes 225 adjacent the fin 214 at the first end 194 to construct each coil circuit 210A-210F. In particular and with reference to
As illustrated, the first circuit 210A passes from the first zone 1 to the second zone 2, from the second zone 2 to the third zone 3, from the third zone 3 to the first zone 1, from the first zone 1 to the second zone 2, and from the second zone 2 to the third zone 3. The second circuit 210B passes from the second zone 2 to the third zone 3, from the third zone 3 to the first zone 1, from the first zone 1 to the second zone 2, from the second zone 2 to the third zone 3, and from the third zone 3 to the first zone 1. The third circuit 210C passes from the third zone 3 to the first zone 1, from the first zone 1 to the second zone 2, from the second zone 2 to the third zone 3, from the third zone 3 to the first zone 1, and from the first zone 1 to the second zone 2. The four circuit 210D passes from the fourth zone 4 to the fifth zone 5, from the fifth zone 5 to the sixth zone 6, from the sixth zone 6 to the fourth zone 4, from the fourth zone 4 to the fifth zone 5, and from the fifth zone 5 to the sixth zone 6. The fifth circuit 210E passes from the fifth zone 5 to the sixth zone 6, from the sixth zone 6 to the fourth zone 4, from the fourth zone 4 to the fifth zone 5, from the fifth zone 5 to the sixth zone 6, and from the sixth zone 6 to the fourth zone 4. The sixth circuit 210F passes from the sixth zone 6 to the fourth zone 4, from the fourth zone 4 to the fifth zone 5, from the fifth zone 5 to the sixth zone 6, from the sixth zone 6 to the fourth zone 4, and from the fourth zone 4 to the fifth zone 5. In the illustrated construction, the connections between the tube passes 225 and the bend portions 250, 250a, 250b and the connections between the coil circuits 210A-F and the manifolds 204, 245 are provided by a brazing operation.
Although the heat exchanger 190 includes six zones 1-6 and six coil circuits 210A-F, heat exchangers with fewer or more than six zones and six coil circuits are possible and considered herein. Also, the horizontal and/or vertical spacing between the tubes of each coil circuit or between the coil circuits can be modified as desired. Other tube patterns also can be incorporated into the heat exchanger (e.g., inline, staggered, angled, etc.).
In operation, refrigerant from the refrigerant system (not shown) is directed from the inlet manifold 204 and is dispersed through the coil circuits 210A-F such that refrigerant passes within zones 1-6 toward the return bend portions 255 at the second end 200. The return bend portions 255 route the refrigerant back through the heat exchanger 190 toward the first end 194 so that refrigerant is again routed back through the heat exchanger 190 within different zones 1-6 toward the second end 200 via the crossover bends 270. The back and forth movement of the refrigerant between the first and second ends 194, 200, as well as the refrigerant passing through different zones 1-6 repeats until the refrigerant reaches the outlet manifold 220. As the refrigerant travels through the heat exchanger 190, heat is absorbed in the coil circuits 210A-F via the airflow 144, and the vaporized refrigerant is collected from each coil circuit 210A-F at the outlet manifold 220 and thereafter dispersed back to the remainder of the refrigerant system. The amount of time the refrigerant in the circuits 210A-F spends in each zone (refrigerant passage time) directly correlates with the amount of thermal balancing between the circuits 210A-210F. Shifting individual coil circuits between zones 1-6 balances the refrigerant superheat levels within each circuit, maximizing the heat transfer rate from the air to the refrigerant and more uniformly cooling the air across the entire width of the heat exchanger 190. The microchannel design of the coil circuits 210A-F also provides an increased cooling capacity of the heat exchanger 190 compared to conventional heat exchangers 190. Due to the larger spacing between the microchannel circuits 210A-F achieved by the hybrid heat exchanger 190 when compared to conventional microchannel heat exchangers, the heat exchanger 190 is less susceptible to ice formation in below freezing applications.
Various features and advantages of the invention are set forth in the following claims.