US20230392870A1 - Heat exchanger for a heating, ventilation, and air-conditioning system - Google Patents
Heat exchanger for a heating, ventilation, and air-conditioning system Download PDFInfo
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- US20230392870A1 US20230392870A1 US18/450,455 US202318450455A US2023392870A1 US 20230392870 A1 US20230392870 A1 US 20230392870A1 US 202318450455 A US202318450455 A US 202318450455A US 2023392870 A1 US2023392870 A1 US 2023392870A1
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- 238000010438 heat treatment Methods 0.000 title claims description 25
- 238000004378 air conditioning Methods 0.000 title claims description 5
- 238000009423 ventilation Methods 0.000 title claims description 5
- 239000003507 refrigerant Substances 0.000 claims abstract description 133
- 238000000926 separation method Methods 0.000 claims description 24
- 238000000034 method Methods 0.000 claims description 7
- 239000012811 non-conductive material Substances 0.000 claims description 7
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- 239000007789 gas Substances 0.000 description 18
- 238000001816 cooling Methods 0.000 description 16
- 239000003570 air Substances 0.000 description 12
- 238000010586 diagram Methods 0.000 description 9
- 239000007788 liquid Substances 0.000 description 7
- 230000007704 transition Effects 0.000 description 4
- 239000012080 ambient air Substances 0.000 description 3
- 230000006870 function Effects 0.000 description 3
- 238000005219 brazing Methods 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000005086 pumping Methods 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
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- 239000003345 natural gas Substances 0.000 description 1
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- 230000009467 reduction Effects 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
- F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
- F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
- F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
- F28D1/0535—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
- F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
- F28D1/05391—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits combined with a particular flow pattern, e.g. multi-row multi-stage radiators
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B39/00—Evaporators; Condensers
- F25B39/02—Evaporators
- F25B39/028—Evaporators having distributing means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B39/00—Evaporators; Condensers
- F25B39/04—Condensers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
- F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
- F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
- F28D1/0408—Multi-circuit heat exchangers, e.g. integrating different heat exchange sections in the same unit or heat exchangers for more than two fluids
- F28D1/0426—Multi-circuit heat exchangers, e.g. integrating different heat exchange sections in the same unit or heat exchangers for more than two fluids with units having particular arrangement relative to the large body of fluid, e.g. with interleaved units or with adjacent heat exchange units in common air flow or with units extending at an angle to each other or with units arranged around a central element
- F28D1/0452—Combination of units extending one behind the other with units extending one beside or one above the other
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0202—Header boxes having their inner space divided by partitions
- F28F9/0204—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0202—Header boxes having their inner space divided by partitions
- F28F9/0204—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions
- F28F9/0209—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions having only transversal partitions
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2400/00—General features or devices for refrigeration machines, plants or systems, combined heating and refrigeration systems or heat-pump systems, i.e. not limited to a particular subgroup of F25B
- F25B2400/06—Several compression cycles arranged in parallel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B39/00—Evaporators; Condensers
- F25B39/02—Evaporators
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0068—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for refrigerant cycles
- F28D2021/0071—Evaporators
Definitions
- HVAC heating, ventilation, and air-conditioning
- low-temperature (for cooling) or high-temperature (for heating) sources thereby adjusting an 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.
- a fluid refrigerant circulates through a closed loop of tubing that uses a compressor and flow-control devices to manipulate the refrigerant's flow and pressure, causing the refrigerant to cycle between the liquid and gas phases.
- these phase transitions occur within the HVAC system heat exchangers, which are part of the closed loop and designed to transfer heat between the circulating refrigerant and flowing ambient air.
- 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.”
- Those in the HVAC industry describe this cycle of absorbing and releasing heat as “pumping.”
- 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.
- FIG. 1 is a block diagram of an HVAC system, according to one or more embodiments
- FIG. 2 is a block diagram of an HVAC system 200 , according to one or more embodiments.
- FIG. 3 is a block diagram of a heat exchanger, according to one or more embodiments.
- FIG. 4 is a block diagram of a heat exchanger, according to one or more embodiments.
- FIG. 5 is a block diagram of a heat exchanger, according to one or more embodiments.
- FIG. 6 A is a front view of a microchannel heat exchanger, according to one or more embodiments.
- FIG. 6 B is a back view of the microchannel heat exchanger of FIG. 6 A ;
- FIG. 6 C is a side view of the microchannel heat exchanger of FIG. 6 A ;
- FIG. 7 A is a front view of a heat exchanger, according to one or more embodiments.
- FIG. 7 B is a back view of the heat exchanger of FIG. 7 A ;
- FIG. 7 C is a side view of the heat exchanger of FIG. 7 A .
- the present disclosure describes heat exchangers for use with an HVAC system.
- the heat exchangers may be round tube and plate fin (“RTPF”) heat exchangers that include a plurality of tubes that pass from one side of the head exchanger to the other through a slab made of fins.
- the tubes in turn may be connected to a plurality of circuits providing parallel paths for the fluid flowing within.
- the heat exchangers may also be microchannel heat exchangers that include a plurality of tubes that each include a number of microchannels for flowing refrigerant from one side of the heat exchanger to the other, or one “pass” across the heat exchanger.
- the fluid may make two or more passes across the heat exchanger, with each successive pass being a different stage.
- One or more tubes that flow fluid in a given direction across the heat exchanger at the same stage in the flow circuit are grouped together into a section and multiple sections are fluidly connected via the headers or manifolds.
- the tubes may also be bonded to the fins therebetween.
- the adjacent sections of tubes are separated, as discussed in more detail below.
- the separation between the adjacent sections of tubes is sufficient enough to reduce the cross transfer of heat between the sections, improving the performance of the microchannel heat exchanger and reducing the size of the microchannel heat exchanger when compared to a heat exchanger without a separation.
- the separation also reduces the thermal stress on the joints between the tubes and the header since there is a smaller temperature differential between the tube and the header.
- the heat exchanger may include multiple refrigeration circuits passing therethrough.
- the circuits may be arranged such that each circuit utilizes the entire face area of the heat exchanger, the overall system efficiency is increased while operating at a part load condition. Further, this arrangement may allow for a reduction in the overall size of the heat exchanger since, under a part load condition, the operational circuit can utilize the entire face area of the heat exchanger.
- FIG. 1 shows an HVAC system 100 in accordance with one embodiment.
- the HVAC system 100 provides heating and cooling for a residential structure 102 .
- the concepts disclosed herein are applicable to numerous of heating and cooling situations, which include residential, industrial, and commercial settings.
- the described HVAC system 100 is divided into two primary portions: (1) the outdoor unit 104 , which mainly comprises components for transferring heat with the environment outside the structure 102 ; and (2) the indoor unit 106 , which mainly comprises components for transferring heat with the air inside the structure 102 .
- the indoor unit 106 draws ambient indoor air via return ducts 110 , 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 112 through the supply ducts or ductworks 114 —which are relatively large conduits that may be rigid or flexible.
- a blower 116 provides the motivational force to circulate the ambient air through the return ducts 110 and the supply ducts 114 . Additionally, although a split system is shown in FIG. 1 , the disclosed embodiments can be equally applied to the packaged or other types of the HVAC system configurations.
- the HVAC system 100 is a “dual-fuel” system that has multiple heating elements, such as an electric heating element or a gas furnace 118 .
- the gas furnace 118 located downstream (in relation to airflow) of the blower 116 combusts natural gas to produce heat in furnace tubes (not shown) that coil through the gas furnace 118 .
- furnace tubes act as a heating element for the ambient indoor air being pushed out of the blower 116 , over the furnace tubes, and into the supply ducts 114 .
- the gas furnace 118 is generally operated when robust heating is desired.
- air from the blower 116 is routed over an indoor heat exchanger 120 and into the supply ducts 114 .
- the blower 116 , the gas furnace 118 , and the indoor heat exchanger 120 may be packaged as an integrated air handler unit, or those components may be modular. In other embodiments, the positions of the gas furnace 118 , the indoor heat exchanger 120 , and the blower 116 can be reversed or rearranged.
- the indoor heat exchanger 120 acts as a heating or cooling means that adds or removes heat from the structure, respectively, by manipulating the pressure and flow of refrigerant circulating within and between the indoor and outdoor units via refrigerant lines 122 .
- the refrigerant could be circulated to only cool (i.e., extract heat from) the structure, with heating provided independently by another source, such as, but not limited to, the gas furnace 118 . There may also be no heating of any kind.
- HVAC systems 100 that use refrigerant to both heat and cool the structure 102 are often described as heat pumps, while HVAC systems 100 that use refrigerant only for cooling are commonly described as air conditioners.
- the outdoor heat exchanger 124 is in the opposite state. More specifically, if heating is desired, the illustrated indoor heat exchanger 120 acts as a condenser, aiding transition of the refrigerant from a high-pressure gas to a high-pressure liquid and releasing heat in the process.
- the outdoor heat exchanger 124 acts as an evaporator, aiding transition of the refrigerant from a low-pressure liquid to a low-pressure gas, thereby absorbing heat from the outdoor environment.
- the outdoor unit 104 has flow control devices 126 that reverse the flow of the refrigerant, allowing the outdoor heat exchanger 124 to act as a condenser and allowing the indoor heat exchanger 120 to act as an evaporator.
- the flow control devices 126 may also act as an expander to reduce the pressure of the refrigerant flowing therethrough.
- the expander may be a separate device located in either the outdoor unit 104 or the indoor unit 106 .
- the respective heat exchangers 120 , 124 have tubing that winds or coils through heat-exchange surfaces, to increase the surface area of contact between the tubing and the surrounding air or environment.
- the illustrated outdoor unit 104 may also include an accumulator 128 that helps prevent liquid refrigerant from reaching the inlet of a compressor 130 .
- the outdoor unit 104 may include a receiver 132 that helps to maintain sufficient refrigerant charge distribution in the HVAC system 100 .
- the size of these components is often defined by the amount of refrigerant employed by the HVAC system 100 .
- the compressor 130 receives low-pressure gas refrigerant from either the indoor heat exchanger 120 if cooling is desired or from the outdoor heat exchanger 124 if heating is desired.
- the compressor 130 then compresses the gas refrigerant to a higher pressure based on a compressor volume ratio, namely the ratio of a discharge volume, the volume of gas outputted from the compressor 130 once compressed, to a suction volume, the volume of gas inputted into the compressor 130 before compression.
- the compressor is a multi-stage compressor 130 that can transition between at least two volume ratios depending on whether heating or cooling is desired.
- the HVAC system 100 may be configured to only cool or only heat, and the compressor 130 may be a single-stage compressor having only a single volume ratio.
- the compressor 130 receives electrical power from a control system 134 that may include an inverter system, as described in more detail below with reference to FIG. 2 , which converts the AC power received by the HVAC system 100 to DC power for use by the compressor 130 .
- the control system 134 controls the speed of the compressor 130 , as well as the switching between compressor stages for multi-stage compressors, based on the required heating or cooling that must be provided by the HVAC system, i.e., the load on the HVAC system 100 .
- the control system may also control the speed of a fan 136 that blows air across the heat exchanger 124 .
- FIG. 2 shows a block diagram of an HVAC system 200 .
- the HVAC system 200 includes a first heat exchanger 202 , an expansion device 204 , a second heat exchanger 206 , and a compressor 208 .
- the heat exchangers 202 , 206 may be either indoor or outdoor heat exchangers, depending on the configuration of the HVAC system 200 .
- the HVAC system 200 may also include the equipment shown in FIG. 1 and function as discussed above with reference to FIG. 1 . Accordingly, the function of first heat exchanger 202 , the expansion device 204 , the second heat exchanger 206 , and the compressor 208 will not be discussed in detail except as necessary for the understanding of the HVAC system 200 shown in FIG. 2 .
- high-pressure refrigerant flows from the compressor 208 to the first heat exchanger 202 , where it is condensed.
- the high-pressure liquid refrigerant then flows to the expansion device 204 , where it is expanded to low-pressure refrigerant.
- the low-pressure refrigerant is then evaporated in the second heat exchanger 206 and the low-pressure vapor flows into the compressor 208 as a vapor, to begin the cycle again.
- FIG. 3 is a block diagram of a front view of a two-pass microchannel heat exchanger 300 that can be used in an HVAC system, as described above.
- a refrigerant pass is one passage of refrigerant from one header 302 , 304 at one end of the heat exchanger 300 to the opposing header 304 , 306 at the opposing end of the heat exchanger 300 .
- refrigerant flows through a section 308 , 310 of a plurality of tubes that carry the refrigerant from one end of the heat exchanger 300 to an opposing end of the heat exchanger 300 for a given stage of the flow through the heat exchanger 300 .
- FIG. 4 is an expanded block diagram of a cross sectional view of heat exchanger section 308 shown in FIG. 3
- Heat exchanger section 308 includes a plurality of tubes 400 .
- Tubes 400 may be tubes known as flat tubes that are wider than high.
- Each tube 400 includes a plurality of microchannels 402 for carrying refrigerant.
- Tubes 400 are stacked, thus defining a size or volume of heat exchanger section 308 along the refrigerant flow direction.
- a heat exchanger may include tubes that are “vertically” stacked.
- a plurality of fins 404 are arranged between tubes 400 to aid in heat transfer from the microchannels.
- Heat exchanger section 308 in operation receives airflow AF across the fins between the tubes and exchanges heat between the airflow and the refrigerant flow.
- Heat exchanger section 310 is composed likewise of tubes and fins (not shown).
- headers 302 and 304 are in fluid communication with section 308 .
- Header 302 includes an inlet 312 for receiving refrigerant to the heat exchanger 300 .
- Header 306 includes an outlet 314 for delivering refrigerant from the heat exchanger 300 .
- section 308 receives refrigerant flow from header 302 and flows the refrigerant into header 304 .
- the refrigerant then flows from header 304 , through section 310 , and into header 306 .
- the heat exchanger 300 acts as either a condenser or an evaporator to condense or vaporize the refrigerant, respectively.
- the temperature differential can lead to a heat transfer between adjacent sections of tubes, resulting in a loss of efficiency and increased thermal stress on the joints between the tubes and the header.
- the above-mentioned temperature differential is much larger in the case of a condenser or gas cooler than in the case of an evaporator.
- header 302 and header 306 and section 308 and section 310 to remove any direct contact between header 306 and header 306 and to remove any direct contact between section 308 and section 310 .
- the separations are large enough to reduce, or even minimize, the cross heat transfer between adjacent sections because the heat transfer from each section is with the surrounding environment rather than between the adjacent sections of tubes.
- the separations may be a gap 316 between section 308 and section 310 , and a gap 318 between header 302 and header 306 .
- there may be a gap 318 between section 308 and 310 and the headers 302 , 306 may be connected, but spaced apart such that the portions of the headers 302 , 306 that contain refrigerant are not in direct contact.
- one or more of the gaps 316 , 318 may be filled with a non-conductive material, such as a plastic, to provide structural support to the heat exchanger 300 or comprise the fins attached to one of the microchannel tubes either belonging to the section 308 or section 310 , but not to the other.
- the non-conductive material can be used to prevent such bonding by brazing or mechanical interference contact.
- the clad material could be stripped from the referred tube surface (one side only) to prevent brazing. Other techniques may also be used.
- FIG. 5 is a block diagram of a front view of a two-pass microchannel heat exchanger 500 that can be used in an HVAC system, as described above. Similar to the heat exchanger 300 described above with reference to FIG. 3 , the heat exchanger 500 includes headers 502 and 504 that are in fluid communication via section 508 . The heat exchanger further includes header 506 that is in fluid communication with header 504 via section 510 .
- the heat exchanger 500 further includes a section 520 of one or more “dead” microchannel tubes; i.e., a section of microchannel tubes that have no refrigerant passing therethrough.
- Header 502 separates section 508 from section 510 to reduce heat transfer while the HVAC system is in operation.
- the fins extending between section 520 and sections 508 and 510 may also be cut longitudinally to further reduce heat transfer between section 508 and 510 via conduction across section 520 .
- header 502 and header 506 are separated by two separator plates 522 , which form a chamber 524 between header 502 and header 506 .
- the chamber separates the fluid flowing at different stages within the headers 502 , 506 and also acts as an insulator, reducing heat transfer between the headers 502 , 506 . Further, the use of two separator plates reduces the possibility of leakage between the headers 502 , 506 , as both plates must develop a leak to have fluid transfer between the headers 502 , 506 .
- headers 502 , 506 may be separated by a gap, such as the gap 318 depicted in FIG. 3 . In the latter case, the “dead” microchannel tube(s), if used, may be closed via crimping and/or brazed shut.
- FIGS. 3 and 5 are two-pass microchannel heat exchangers, the invention is not thereby limited.
- the separation methods described above can be applied to heat exchangers having any number passes and sections.
- a single heat exchanger may utilize gaps between sections, sections of one or more dead microchannel tubes between sections, or both gaps and sections of dead microchannel tubes.
- a single heat exchanger may include gaps between headers, separation plates forming chambers between headers, or both gaps and chambers.
- the term gap refers to a physical gap or a gap preventing the cross-conduction path between the heat exchanger sections.
- FIGS. 6 A- 6 C depict front, back, and side views of a microchannel heat exchanger 600 , according to one or more embodiments.
- FIGS. 6 A- 6 C include features that are similar to those described in relation to FIGS. 3 - 5 . Accordingly, similar elements will not be described again in detail, except as necessary to describe the features of the heat exchanger 600 .
- the heat exchanger 600 is arranged to be used with an HVAC system that has two refrigerant circuits that are each similar to the refrigerant circuit described above with reference to FIG. 2 .
- the heat exchanger 600 is made up of four heat exchanger sections 602 , 604 , 606 , 608 .
- the first upper heat exchanger section 602 and the first lower heat exchanger section 604 both include an inlet 610 that receives a first refrigerant and a second refrigerant, respectively. The refrigerants then flow through the respective heat exchanger sections 602 , 604 , 606 , 608 and through the outlets 612 .
- the refrigerant passing through the first upper heat exchanger 602 then flows through a fluid coupling 614 and into the second lower heat exchanger.
- the refrigerant passing through the first lower heat exchanger then flows through a fluid coupling 614 and into the second upper heat exchanger.
- the refrigerants then flow through the outlets 612 of the second upper heat exchanger and the second lower heat exchanger and continue through their respective circuits.
- This configuration of heat exchanger sections 602 , 604 , 606 , 608 allows both the first refrigerant and the second refrigerant to flow through the majority of the face area or the entire face area of the heat exchangers, i.e., the surface area of the heat exchanger indicated by box 616 , while remaining separate into two different circuits.
- the heat exchanger sections 602 , 604 , 606 , 608 may be individual heat exchanger cells that are spaced apart, e.g., physically separated, from each other to decrease or minimize heat transfer between the cells. Additionally, the second upper heat exchanger section and the second lower heat exchanger may implement any of the spacing mechanisms described above with reference to FIGS. 3 - 5 to reduce heat transfer between passes. In other embodiments, the heat exchanger sections 602 , 604 , 606 , 608 may be formed by installing internal baffles, similar to the baffles described above with reference to FIG. 5 , within the headers of a single microchannel heat exchanger.
- FIGS. 6 A- 6 C depict a heat exchanger that is operable with two refrigerant circuits
- the invention is not thereby limited.
- a heat exchanger may be expanded as necessary based on the principles herein to accommodate three, four, or more refrigerant circuits.
- heat exchanger cells do not need to be a uniform size or arranged parallel to each other, FIGS. 6 A- 6 C .
- the heat exchanger cells may form an “X” pattern or a “V” pattern and/or one or more of the heat exchanger cells may be a different size than the other heat exchanger cells.
- the fin density and or the microchannel tube dimensions may also be varied between each cell based on the cooling and/or heating requirements of a particular HVAC system.
- the two or more refrigerant circuits may use the same type of refrigerant (e.g., both refrigerants are R-32, R410A, R454B, or R-134a) or different types of refrigerants.
- FIGS. 7 A- 7 C are front, back, and side views of a heat exchanger 700 , according to one or more embodiments.
- the heat exchanger 700 depicted in FIGS. 7 A- 7 C is a round tube, plate, and fin (“RTPF”) heat exchanger. Similar to the heat exchanger described above with reference to FIGS. 6 A- 6 C , the heat exchanger 700 is arranged to be used with an HVAC system that has two refrigerant circuits that are each similar the refrigerant circuits described above with reference to FIG. 2 and can be viewed as a first upper section 702 , a first lower section 704 , a second upper section 706 , and a second lower section 708 .
- RTPF round tube, plate, and fin
- the first upper heat exchanger section 702 and the first lower heat exchanger section 704 both include an inlet 710 that receives a first refrigerant and a second refrigerant, respectively.
- the refrigerants are distributed between multiple tubes 714 that extend through the first upper section 702 and the second lower section 708 , and the first lower section 704 and the second upper section 706 , respectively, and are then consolidated to flow through the outlets 712 .
- This configuration of heat exchanger sections 702 , 704 , 706 , 708 allows both the first refrigerant and the second refrigerant to flow through a majority of the face area 716 or the entire face area 716 of the heat exchangers while remaining separate into two different circuits.
- the heat exchanger 700 depicted in FIGS. 7 A and 7 B includes a uniform number of tubes 714 on each circuit that extend through uniform sections 702 , 704 , 706 , 708 of the heat exchanger 700 , the invention is not thereby limited.
- the number and position of tubes 714 for each circuit may be varied as necessary to meet the heating and/or cooling requirements of the HVAC system.
- the heat exchanger may enlarged and the spacing between tubes may be changed as necessary based on the principles herein to accommodate three, four, or more refrigerant circuits.
- the tubes of one or more of the circuits may extend between more than two sections of the heat exchanger 700 (e.g., a tube may extend between the first upper section and second upper section before returning to the first upper section and then extending to the second lower section).
- a tube may extend between the first upper section and second upper section before returning to the first upper section and then extending to the second lower section.
- the heat exchanger 700 may also be formed from separate slabs or the heat exchanger 700 may be a slit fin heat exchanger formed from a single slab.
- Example 1 is an HVAC system for use with a first refrigerant and a second refrigerant.
- the HVAC system includes a first refrigerant circuit for use with the first refrigerant, a second refrigerant circuit for use with the second refrigerant, and a heat exchanger operable as at least one of a condenser or a gas cooler.
- the first refrigerant circuit includes may include a first compressor, a first expansion device, and a first evaporator.
- the second refrigerant circuit includes a second compressor, a second expansion device, and a second evaporator.
- the compressor includes a first upper section, a first lower section, a second upper section in fluid communication with the first lower section, and a second lower section in fluid communication with the first upper section.
- the first upper section includes a first inlet to receive a first refrigerant from the first refrigerant circuit and the first lower section includes a second inlet to receive a second refrigerant from the second refrigerant circuit.
- the first upper section, the first lower section, the second upper section, and the second lower section are arranged such that the first refrigerant and the second refrigerant both flow through a majority of a face area of the heat exchanger while remaining in two different circuits.
- Example 2 is the HVAC system of example 1 or any other appropriate example, wherein the heat exchanger is a microchannel heat exchanger.
- Example 3 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are heat exchanger cells.
- Example 4 is the HVAC system of example 3 or any other appropriate example, wherein at least one of the first upper section, the first lower section, the second upper section, and the second lower section include a first header including an inlet for receiving refrigerant, a first section of microchannel tubes fluidly coupled to the first header for flowing the refrigerant through a first pass through the heat exchanger cell, a second header fluidly coupled to the first section, and a second section of microchannel tubes for flowing refrigerant through a second pass through the heat exchanger cell.
- the second section of microchannel tubes is fluidly coupled to the second header and separated from the first section of microchannel tubes enough to reduce heat transfer between the refrigerant flowing through the first pass and the refrigerant flowing through the second pass.
- Example 5 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section and the second upper section are spaced apart and the first lower section and the second lower section are spaced apart.
- Example 6 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section and the first lower section are spaced apart and the second upper section and the second lower section are spaced apart.
- Example 7 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are separated from each other via baffles positioned within headers of the heat exchanger.
- Example 8 is the HVAC system of example 1 or any other appropriate example, wherein the heat exchanger is a RTPF heat exchanger.
- Example 9 is the HVAC system of example 8 or any other appropriate example, wherein the heat exchanger further includes a first set of tubes fluidly coupled to the first inlet and extending though the first upper section and the second lower section and a second set of tubes fluidly coupled to the second inlet and extending though the first lower section and the second upper section.
- Example 10 is the HVAC system of example 1 or any other appropriate example, wherein the first refrigerant and the second refrigerant are different types of refrigerant.
- Example 11 is a heat exchanger for use with an HVAC system having a first refrigerant circuit and a second refrigerant circuit.
- the heat exchanger includes a first upper section, a first lower section, a second upper section in fluid communication with the first lower section, and a second lower section in fluid communication with the first upper section.
- the first upper section includes a first inlet to receive a first refrigerant from the first refrigerant circuit and the first lower section includes a second inlet to receive a second refrigerant from the second refrigerant circuit.
- the first upper section, the first lower section, the second upper section, and the second lower section are arranged such that the first refrigerant and the second refrigerant both flow through a majority of a face area of the heat exchanger while remaining in two different circuits.
- Example 12 is the heat exchanger of example 11 or any other appropriate example, wherein the heat exchanger is a microchannel heat exchanger.
- Example 13 is the heat exchanger of example 12 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are heat exchanger cells.
- Example 14 is the heat exchanger of example 13 or any other appropriate example, wherein at least one of the first upper section, the first lower section, the second upper section, and the second lower section include a first header including an inlet for receiving refrigerant, a first section of microchannel tubes fluidly coupled to the first header for flowing the refrigerant through a first pass through the heat exchanger cell, a second header fluidly coupled to the first section, and a second section of microchannel tubes for flowing refrigerant through a second pass through the heat exchanger cell.
- the second section of microchannel tubes is fluidly coupled to the second header and separated from the first section of microchannel tubes enough to reduce heat transfer between the refrigerant flowing through the first pass and the refrigerant flowing through the second pass.
- Example 15 is the heat exchanger of example 12 or any other appropriate example, wherein at least two sections of the first upper section, the first lower section, second upper section, or the second lower section are spaced apart.
- Example 16 is the heat exchanger of example 15 or any other appropriate example, wherein the at least two sections are spaced apart via a non-conductive material.
- Example 17 is the heat exchanger of example 15 or any other appropriate example, wherein the at least two sections are spaced apart via dead microchannel tubes.
- Example 18 is the heat exchanger of example 12 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are separated from each other via baffles positioned within headers of the heat exchanger.
- Example 19 is the heat exchanger of example 11 or any other appropriate example, wherein the heat exchanger is a RTPF heat exchanger.
- Example 20 is the heat exchanger of example 19 or any other appropriate example, further including a first set of tubes fluidly coupled to the first inlet and extending though the first upper section and the second lower section and a second set of tubes fluidly coupled to the second inlet and extending though the first lower section and the second upper section.
- Example 21 is the heat exchanger of example 19 or any other appropriate example, wherein the RTPF heat exchanger is a slit fin heat exchanger.
- Example 22 is the heat exchanger of example 11 or any other appropriate example, wherein at least two of the first upper section, the first lower section, the second upper section and the second lower section are different sizes.
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Abstract
An HVAC system for use with a first refrigerant and a second refrigerant. The HVAC system may include a first refrigerant circuit for use with the first refrigerant, a second refrigerant circuit for use with the second refrigerant, and a heat exchanger. The first refrigerant circuit and the second refrigerant circuit may each include may include a compressor, an expansion device, and an evaporator. The compressor may include a first upper section, a first lower section, a second upper section in fluid communication with the first lower section, and a second lower section in fluid communication with the first upper section. The first upper section, the first lower section, the second upper section, and the second lower section may be arranged such that the first refrigerant and the second refrigerant both flow through a majority of a face area of condenser while remaining in two different circuits.
Description
- This section is intended to provide relevant background information to facilitate a better understanding of the various aspects of the described embodiments. Accordingly, these statements are to be read in this light and not as admissions of prior art.
- 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 an 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 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 system heat exchangers, which are part of the closed loop and designed to transfer heat between the circulating refrigerant and flowing ambient air. As would be expected, 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.
- Embodiments of the HVAC system are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components. The features depicted in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness.
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FIG. 1 is a block diagram of an HVAC system, according to one or more embodiments; -
FIG. 2 is a block diagram of anHVAC system 200, according to one or more embodiments; and -
FIG. 3 is a block diagram of a heat exchanger, according to one or more embodiments; -
FIG. 4 is a block diagram of a heat exchanger, according to one or more embodiments; and -
FIG. 5 is a block diagram of a heat exchanger, according to one or more embodiments; -
FIG. 6A is a front view of a microchannel heat exchanger, according to one or more embodiments; -
FIG. 6B is a back view of the microchannel heat exchanger ofFIG. 6A ; -
FIG. 6C is a side view of the microchannel heat exchanger ofFIG. 6A ; -
FIG. 7A is a front view of a heat exchanger, according to one or more embodiments; -
FIG. 7B is a back view of the heat exchanger ofFIG. 7A ; and -
FIG. 7C is a side view of the heat exchanger ofFIG. 7A . - The present disclosure describes heat exchangers for use with an HVAC system. The heat exchangers may be round tube and plate fin (“RTPF”) heat exchangers that include a plurality of tubes that pass from one side of the head exchanger to the other through a slab made of fins. The tubes in turn may be connected to a plurality of circuits providing parallel paths for the fluid flowing within. The heat exchangers may also be microchannel heat exchangers that include a plurality of tubes that each include a number of microchannels for flowing refrigerant from one side of the heat exchanger to the other, or one “pass” across the heat exchanger. The fluid may make two or more passes across the heat exchanger, with each successive pass being a different stage. One or more tubes that flow fluid in a given direction across the heat exchanger at the same stage in the flow circuit are grouped together into a section and multiple sections are fluidly connected via the headers or manifolds. The tubes may also be bonded to the fins therebetween.
- Further, in the microchannel heat exchanger, the adjacent sections of tubes are separated, as discussed in more detail below. The separation between the adjacent sections of tubes is sufficient enough to reduce the cross transfer of heat between the sections, improving the performance of the microchannel heat exchanger and reducing the size of the microchannel heat exchanger when compared to a heat exchanger without a separation. The separation also reduces the thermal stress on the joints between the tubes and the header since there is a smaller temperature differential between the tube and the header.
- In either case, the heat exchanger may include multiple refrigeration circuits passing therethrough. As will be explained in further detail below, by arranging the circuits such that each circuit utilizes the entire face area of the heat exchanger, the overall system efficiency is increased while operating at a part load condition. Further, this arrangement may allow for a reduction in the overall size of the heat exchanger since, under a part load condition, the operational circuit can utilize the entire face area of the heat exchanger.
- Turning now to the figures,
FIG. 1 shows anHVAC system 100 in accordance with one embodiment. As depicted, theHVAC system 100 provides heating and cooling for aresidential structure 102. However, the concepts disclosed herein are applicable to numerous of heating and cooling situations, which include residential, industrial, and commercial settings. - The described
HVAC system 100 is divided into two primary portions: (1) theoutdoor unit 104, which mainly comprises components for transferring heat with the environment outside thestructure 102; and (2) theindoor unit 106, which mainly comprises components for transferring heat with the air inside thestructure 102. To heat or cool the illustratedstructure 102, theindoor unit 106 draws ambient indoor air viareturn ducts 110, 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-controlledspaces 112 through the supply ducts orductworks 114—which are relatively large conduits that may be rigid or flexible. Ablower 116 provides the motivational force to circulate the ambient air through thereturn ducts 110 and thesupply ducts 114. Additionally, although a split system is shown inFIG. 1 , the disclosed embodiments can be equally applied to the packaged or other types of the HVAC system configurations. - As shown, the
HVAC system 100 is a “dual-fuel” system that has multiple heating elements, such as an electric heating element or agas furnace 118. Thegas furnace 118 located downstream (in relation to airflow) of theblower 116 combusts natural gas to produce heat in furnace tubes (not shown) that coil through thegas furnace 118. These furnace tubes act as a heating element for the ambient indoor air being pushed out of theblower 116, over the furnace tubes, and into thesupply ducts 114. However, thegas furnace 118 is generally operated when robust heating is desired. During conventional heating and cooling operations, air from theblower 116 is routed over anindoor heat exchanger 120 and into thesupply ducts 114. Theblower 116, thegas furnace 118, and theindoor heat exchanger 120 may be packaged as an integrated air handler unit, or those components may be modular. In other embodiments, the positions of thegas furnace 118, theindoor heat exchanger 120, and theblower 116 can be reversed or rearranged. - The
indoor heat exchanger 120 acts as a heating or cooling means that adds or removes heat from the structure, respectively, by manipulating the pressure and flow of refrigerant circulating within and between the indoor and outdoor units viarefrigerant lines 122. Alternatively, the refrigerant could be circulated to only cool (i.e., extract heat from) the structure, with heating provided independently by another source, such as, but not limited to, thegas furnace 118. There may also be no heating of any kind.HVAC systems 100 that use refrigerant to both heat and cool thestructure 102 are often described as heat pumps, whileHVAC systems 100 that use refrigerant only for cooling are commonly described as air conditioners. - Whatever the state of the indoor heat exchanger 120 (i.e., absorbing or releasing heat), the
outdoor heat exchanger 124 is in the opposite state. More specifically, if heating is desired, the illustratedindoor heat exchanger 120 acts as a condenser, aiding transition of the refrigerant from a high-pressure gas to a high-pressure liquid and releasing heat in the process. Theoutdoor heat exchanger 124 acts as an evaporator, aiding transition of the refrigerant from a low-pressure liquid to a low-pressure gas, thereby absorbing heat from the outdoor environment. If cooling is desired, theoutdoor unit 104 hasflow control devices 126 that reverse the flow of the refrigerant, allowing theoutdoor heat exchanger 124 to act as a condenser and allowing theindoor heat exchanger 120 to act as an evaporator. Theflow control devices 126 may also act as an expander to reduce the pressure of the refrigerant flowing therethrough. In other embodiments, the expander may be a separate device located in either theoutdoor unit 104 or theindoor unit 106. To facilitate the exchange of heat between the ambient indoor air and the outdoor environment in the describedHVAC system 100, therespective heat exchangers - The illustrated
outdoor unit 104 may also include anaccumulator 128 that helps prevent liquid refrigerant from reaching the inlet of acompressor 130. Theoutdoor unit 104 may include areceiver 132 that helps to maintain sufficient refrigerant charge distribution in theHVAC system 100. The size of these components is often defined by the amount of refrigerant employed by theHVAC system 100. - The
compressor 130 receives low-pressure gas refrigerant from either theindoor heat exchanger 120 if cooling is desired or from theoutdoor heat exchanger 124 if heating is desired. Thecompressor 130 then compresses the gas refrigerant to a higher pressure based on a compressor volume ratio, namely the ratio of a discharge volume, the volume of gas outputted from thecompressor 130 once compressed, to a suction volume, the volume of gas inputted into thecompressor 130 before compression. In the illustrated embodiment, the compressor is amulti-stage compressor 130 that can transition between at least two volume ratios depending on whether heating or cooling is desired. In other embodiments, theHVAC system 100 may be configured to only cool or only heat, and thecompressor 130 may be a single-stage compressor having only a single volume ratio. - The
compressor 130 receives electrical power from acontrol system 134 that may include an inverter system, as described in more detail below with reference toFIG. 2 , which converts the AC power received by theHVAC system 100 to DC power for use by thecompressor 130. Thecontrol system 134 controls the speed of thecompressor 130, as well as the switching between compressor stages for multi-stage compressors, based on the required heating or cooling that must be provided by the HVAC system, i.e., the load on theHVAC system 100. In some embodiments, the control system may also control the speed of afan 136 that blows air across theheat exchanger 124. - Referring now to
FIG. 2 ,FIG. 2 shows a block diagram of anHVAC system 200. TheHVAC system 200 includes afirst heat exchanger 202, anexpansion device 204, asecond heat exchanger 206, and acompressor 208. Additionally, theheat exchangers HVAC system 200. TheHVAC system 200 may also include the equipment shown inFIG. 1 and function as discussed above with reference toFIG. 1 . Accordingly, the function offirst heat exchanger 202, theexpansion device 204, thesecond heat exchanger 206, and thecompressor 208 will not be discussed in detail except as necessary for the understanding of theHVAC system 200 shown inFIG. 2 . - As shown in
FIG. 2 , high-pressure refrigerant flows from thecompressor 208 to thefirst heat exchanger 202, where it is condensed. The high-pressure liquid refrigerant then flows to theexpansion device 204, where it is expanded to low-pressure refrigerant. The low-pressure refrigerant is then evaporated in thesecond heat exchanger 206 and the low-pressure vapor flows into thecompressor 208 as a vapor, to begin the cycle again. - Referring now to
FIG. 3 ,FIG. 3 is a block diagram of a front view of a two-passmicrochannel heat exchanger 300 that can be used in an HVAC system, as described above. As explained above, a refrigerant pass is one passage of refrigerant from oneheader heat exchanger 300 to the opposingheader heat exchanger 300. For each pass, refrigerant flows through asection heat exchanger 300 to an opposing end of theheat exchanger 300 for a given stage of the flow through theheat exchanger 300. - Referring now to
FIGS. 3 and 4 ,FIG. 4 is an expanded block diagram of a cross sectional view ofheat exchanger section 308 shown inFIG. 3 Heat exchanger section 308 includes a plurality oftubes 400.Tubes 400 may be tubes known as flat tubes that are wider than high. Eachtube 400 includes a plurality ofmicrochannels 402 for carrying refrigerant.Tubes 400 are stacked, thus defining a size or volume ofheat exchanger section 308 along the refrigerant flow direction. It will be understood that while tubes are shown “horizontally” stacked inFIG. 4 , a heat exchanger may include tubes that are “vertically” stacked. A plurality offins 404 are arranged betweentubes 400 to aid in heat transfer from the microchannels.Heat exchanger section 308 in operation receives airflow AF across the fins between the tubes and exchanges heat between the airflow and the refrigerant flow.Heat exchanger section 310 is composed likewise of tubes and fins (not shown). - Referring back to
FIG. 3 ,headers section 308.Header 302 includes aninlet 312 for receiving refrigerant to theheat exchanger 300.Header 306 includes anoutlet 314 for delivering refrigerant from theheat exchanger 300. When the HVAC system is in operation,section 308 receives refrigerant flow fromheader 302 and flows the refrigerant intoheader 304. The refrigerant then flows fromheader 304, throughsection 310, and intoheader 306. - As described above, the
heat exchanger 300 acts as either a condenser or an evaporator to condense or vaporize the refrigerant, respectively. In either scenario, there is a large temperature differential between the refrigerant passing throughheader 302 andsection 308 and the refrigerant passing throughsection 310 andheader 306. The temperature differential can lead to a heat transfer between adjacent sections of tubes, resulting in a loss of efficiency and increased thermal stress on the joints between the tubes and the header. The above-mentioned temperature differential is much larger in the case of a condenser or gas cooler than in the case of an evaporator. In order to reduce this cross heat transfer, separations have been introduced betweenheader 302 andheader 306, andsection 308 andsection 310 to remove any direct contact betweenheader 306 andheader 306 and to remove any direct contact betweensection 308 andsection 310. The separations are large enough to reduce, or even minimize, the cross heat transfer between adjacent sections because the heat transfer from each section is with the surrounding environment rather than between the adjacent sections of tubes. - As shown in
FIG. 3 , the separations may be agap 316 betweensection 308 andsection 310, and agap 318 betweenheader 302 andheader 306. In other embodiments, there may be agap 318 betweensection headers headers gaps heat exchanger 300 or comprise the fins attached to one of the microchannel tubes either belonging to thesection 308 orsection 310, but not to the other. In the latter case, for instance, the non-conductive material can be used to prevent such bonding by brazing or mechanical interference contact. Alternatively, the clad material could be stripped from the referred tube surface (one side only) to prevent brazing. Other techniques may also be used. - Referring now to
FIG. 5 ,FIG. 5 is a block diagram of a front view of a two-passmicrochannel heat exchanger 500 that can be used in an HVAC system, as described above. Similar to theheat exchanger 300 described above with reference toFIG. 3 , theheat exchanger 500 includesheaders section 508. The heat exchanger further includesheader 506 that is in fluid communication withheader 504 viasection 510. - The
heat exchanger 500 further includes asection 520 of one or more “dead” microchannel tubes; i.e., a section of microchannel tubes that have no refrigerant passing therethrough.Header 502 separatessection 508 fromsection 510 to reduce heat transfer while the HVAC system is in operation. In some embodiments, the fins extending betweensection 520 andsections section section 520. As shown inFIG. 5 ,header 502 andheader 506 are separated by twoseparator plates 522, which form achamber 524 betweenheader 502 andheader 506. The chamber separates the fluid flowing at different stages within theheaders headers headers headers headers gap 318 depicted inFIG. 3 . In the latter case, the “dead” microchannel tube(s), if used, may be closed via crimping and/or brazed shut. - Although the embodiments illustrated in
FIGS. 3 and 5 are two-pass microchannel heat exchangers, the invention is not thereby limited. The separation methods described above can be applied to heat exchangers having any number passes and sections. Further, a single heat exchanger may utilize gaps between sections, sections of one or more dead microchannel tubes between sections, or both gaps and sections of dead microchannel tubes. Similarly, a single heat exchanger may include gaps between headers, separation plates forming chambers between headers, or both gaps and chambers. As described above, the term gap refers to a physical gap or a gap preventing the cross-conduction path between the heat exchanger sections. - Turning now to
FIGS. 6A-6C ,FIG. 6A-6C depict front, back, and side views of amicrochannel heat exchanger 600, according to one or more embodiments.FIGS. 6A-6C include features that are similar to those described in relation toFIGS. 3-5 . Accordingly, similar elements will not be described again in detail, except as necessary to describe the features of theheat exchanger 600. Theheat exchanger 600 is arranged to be used with an HVAC system that has two refrigerant circuits that are each similar to the refrigerant circuit described above with reference toFIG. 2 . - As shown most clearly in
FIG. 6C , theheat exchanger 600 is made up of fourheat exchanger sections heat exchanger section 602 and the first lowerheat exchanger section 604 both include aninlet 610 that receives a first refrigerant and a second refrigerant, respectively. The refrigerants then flow through the respectiveheat exchanger sections outlets 612. - The refrigerant passing through the first
upper heat exchanger 602 then flows through afluid coupling 614 and into the second lower heat exchanger. Similarly, the refrigerant passing through the first lower heat exchanger then flows through afluid coupling 614 and into the second upper heat exchanger. The refrigerants then flow through theoutlets 612 of the second upper heat exchanger and the second lower heat exchanger and continue through their respective circuits. This configuration ofheat exchanger sections box 616, while remaining separate into two different circuits. This increases the efficiency of theheat exchanger 600 when the HVAC system is operating in a part load condition; i.e. only one of the refrigerant circuits is required to provide heating or cooling to the conditioned space, since the operational circuit can utilize a majority of theface area 616 or theentire face area 616 of theheat exchanger 600. This allows the operational circuit to transfer additional heat away from the refrigerant when compared to only utilizing a half or less offace area 616 theheat exchanger 600. Additionally, the crossing orientation of the circuits that is depicted inFIG. 6C increases efficiency of theheat exchanger 600 when both circuits are active. - As shown in
FIG. 6C , theheat exchanger sections FIGS. 3-5 to reduce heat transfer between passes. In other embodiments, theheat exchanger sections FIG. 5 , within the headers of a single microchannel heat exchanger. - Although
FIGS. 6A-6C depict a heat exchanger that is operable with two refrigerant circuits, the invention is not thereby limited. A heat exchanger may be expanded as necessary based on the principles herein to accommodate three, four, or more refrigerant circuits. Further, heat exchanger cells do not need to be a uniform size or arranged parallel to each other,FIGS. 6A-6C . In other embodiments, the heat exchanger cells may form an “X” pattern or a “V” pattern and/or one or more of the heat exchanger cells may be a different size than the other heat exchanger cells. The fin density and or the microchannel tube dimensions may also be varied between each cell based on the cooling and/or heating requirements of a particular HVAC system. Further, the two or more refrigerant circuits may use the same type of refrigerant (e.g., both refrigerants are R-32, R410A, R454B, or R-134a) or different types of refrigerants. - Turning now to
FIGS. 7A-7C ,FIGS. 7A and 7B are front, back, and side views of aheat exchanger 700, according to one or more embodiments. Theheat exchanger 700 depicted inFIGS. 7A-7C is a round tube, plate, and fin (“RTPF”) heat exchanger. Similar to the heat exchanger described above with reference toFIGS. 6A-6C , theheat exchanger 700 is arranged to be used with an HVAC system that has two refrigerant circuits that are each similar the refrigerant circuits described above with reference toFIG. 2 and can be viewed as a firstupper section 702, a firstlower section 704, a secondupper section 706, and a secondlower section 708. - The first upper
heat exchanger section 702 and the first lowerheat exchanger section 704 both include aninlet 710 that receives a first refrigerant and a second refrigerant, respectively. The refrigerants are distributed betweenmultiple tubes 714 that extend through the firstupper section 702 and the secondlower section 708, and the firstlower section 704 and the secondupper section 706, respectively, and are then consolidated to flow through theoutlets 712. This configuration ofheat exchanger sections face area 716 or theentire face area 716 of the heat exchangers while remaining separate into two different circuits. This increases the efficiency of theheat exchanger 600 when the HVAC system is operating in a part load condition; i.e. only one of the refrigerant circuits is operational, since the operational circuit can utilize majority of theface area 716 or theentire face area 716 of theheat exchanger 700 and transfer additional heat away from the refrigerant when compared to only utilizing a portion of face area theheat exchanger 700. - Although the
heat exchanger 700 depicted inFIGS. 7A and 7B includes a uniform number oftubes 714 on each circuit that extend throughuniform sections heat exchanger 700, the invention is not thereby limited. The number and position oftubes 714 for each circuit may be varied as necessary to meet the heating and/or cooling requirements of the HVAC system. Further, the heat exchanger may enlarged and the spacing between tubes may be changed as necessary based on the principles herein to accommodate three, four, or more refrigerant circuits. Additionally, the tubes of one or more of the circuits may extend between more than two sections of the heat exchanger 700 (e.g., a tube may extend between the first upper section and second upper section before returning to the first upper section and then extending to the second lower section). Many of the variations discussed above with reference toFIGS. 6A-6C may also be implemented, as well as varying the tube dimensions, tube pattern, fin design, section size, and circuit length. Theheat exchanger 700 may also be formed from separate slabs or theheat exchanger 700 may be a slit fin heat exchanger formed from a single slab. - Further examples include:
- Example 1 is an HVAC system for use with a first refrigerant and a second refrigerant. The HVAC system includes a first refrigerant circuit for use with the first refrigerant, a second refrigerant circuit for use with the second refrigerant, and a heat exchanger operable as at least one of a condenser or a gas cooler. The first refrigerant circuit includes may include a first compressor, a first expansion device, and a first evaporator. The second refrigerant circuit includes a second compressor, a second expansion device, and a second evaporator. The compressor includes a first upper section, a first lower section, a second upper section in fluid communication with the first lower section, and a second lower section in fluid communication with the first upper section. The first upper section includes a first inlet to receive a first refrigerant from the first refrigerant circuit and the first lower section includes a second inlet to receive a second refrigerant from the second refrigerant circuit. The first upper section, the first lower section, the second upper section, and the second lower section are arranged such that the first refrigerant and the second refrigerant both flow through a majority of a face area of the heat exchanger while remaining in two different circuits.
- Example 2 is the HVAC system of example 1 or any other appropriate example, wherein the heat exchanger is a microchannel heat exchanger.
- Example 3 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are heat exchanger cells.
- Example 4 is the HVAC system of example 3 or any other appropriate example, wherein at least one of the first upper section, the first lower section, the second upper section, and the second lower section include a first header including an inlet for receiving refrigerant, a first section of microchannel tubes fluidly coupled to the first header for flowing the refrigerant through a first pass through the heat exchanger cell, a second header fluidly coupled to the first section, and a second section of microchannel tubes for flowing refrigerant through a second pass through the heat exchanger cell. The second section of microchannel tubes is fluidly coupled to the second header and separated from the first section of microchannel tubes enough to reduce heat transfer between the refrigerant flowing through the first pass and the refrigerant flowing through the second pass.
- Example 5 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section and the second upper section are spaced apart and the first lower section and the second lower section are spaced apart.
- Example 6 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section and the first lower section are spaced apart and the second upper section and the second lower section are spaced apart.
- Example 7 is the HVAC system of example 2 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are separated from each other via baffles positioned within headers of the heat exchanger.
- Example 8 is the HVAC system of example 1 or any other appropriate example, wherein the heat exchanger is a RTPF heat exchanger.
- Example 9 is the HVAC system of example 8 or any other appropriate example, wherein the heat exchanger further includes a first set of tubes fluidly coupled to the first inlet and extending though the first upper section and the second lower section and a second set of tubes fluidly coupled to the second inlet and extending though the first lower section and the second upper section.
- Example 10 is the HVAC system of example 1 or any other appropriate example, wherein the first refrigerant and the second refrigerant are different types of refrigerant.
- Example 11 is a heat exchanger for use with an HVAC system having a first refrigerant circuit and a second refrigerant circuit. The heat exchanger includes a first upper section, a first lower section, a second upper section in fluid communication with the first lower section, and a second lower section in fluid communication with the first upper section. The first upper section includes a first inlet to receive a first refrigerant from the first refrigerant circuit and the first lower section includes a second inlet to receive a second refrigerant from the second refrigerant circuit. The first upper section, the first lower section, the second upper section, and the second lower section are arranged such that the first refrigerant and the second refrigerant both flow through a majority of a face area of the heat exchanger while remaining in two different circuits.
- Example 12 is the heat exchanger of example 11 or any other appropriate example, wherein the heat exchanger is a microchannel heat exchanger.
- Example 13 is the heat exchanger of example 12 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are heat exchanger cells.
- Example 14 is the heat exchanger of example 13 or any other appropriate example, wherein at least one of the first upper section, the first lower section, the second upper section, and the second lower section include a first header including an inlet for receiving refrigerant, a first section of microchannel tubes fluidly coupled to the first header for flowing the refrigerant through a first pass through the heat exchanger cell, a second header fluidly coupled to the first section, and a second section of microchannel tubes for flowing refrigerant through a second pass through the heat exchanger cell. The second section of microchannel tubes is fluidly coupled to the second header and separated from the first section of microchannel tubes enough to reduce heat transfer between the refrigerant flowing through the first pass and the refrigerant flowing through the second pass.
- Example 15 is the heat exchanger of example 12 or any other appropriate example, wherein at least two sections of the first upper section, the first lower section, second upper section, or the second lower section are spaced apart.
- Example 16 is the heat exchanger of example 15 or any other appropriate example, wherein the at least two sections are spaced apart via a non-conductive material.
- Example 17 is the heat exchanger of example 15 or any other appropriate example, wherein the at least two sections are spaced apart via dead microchannel tubes.
- Example 18 is the heat exchanger of example 12 or any other appropriate example, wherein the first upper section, the first lower section, the second upper section, and the second lower section are separated from each other via baffles positioned within headers of the heat exchanger.
- Example 19 is the heat exchanger of example 11 or any other appropriate example, wherein the heat exchanger is a RTPF heat exchanger.
- Example 20 is the heat exchanger of example 19 or any other appropriate example, further including a first set of tubes fluidly coupled to the first inlet and extending though the first upper section and the second lower section and a second set of tubes fluidly coupled to the second inlet and extending though the first lower section and the second upper section.
- Example 21 is the heat exchanger of example 19 or any other appropriate example, wherein the RTPF heat exchanger is a slit fin heat exchanger.
- Example 22 is the heat exchanger of example 11 or any other appropriate example, wherein at least two of the first upper section, the first lower section, the second upper section and the second lower section are different sizes.
- Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. Further, terms such as upper, lower, front, and/or back are only used as general references within the individual components. The terms are not intended to imply any directionality within the overall HVAC system.
- Reference throughout this specification to “one embodiment,” “an embodiment,” “embodiments,” “some embodiments,” “certain embodiments,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present disclosure. Thus, these phrases or similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Reference to “includes” means, “includes, but is not limited to.”
- The embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
Claims (20)
1. A heating, ventilation, and air-conditioning (“HVAC”) system for use with a refrigerant, the HVAC system comprising a multi-pass microchannel heat exchanger operable as at least one of condenser or an evaporator, the heat exchanger comprising:
a first header at an end of the heat exchanger;
a second header at an opposite end of the heat exchanger;
a third header at the same end as the first header;
a first section of microchannel tubes fluidly connecting the first and second headers in a first pass for flowing the refrigerant from the first header to the second header; and
a second section of microchannel tubes fluidly connecting the second and third headers in a second pass for flowing the refrigerant from the second header to the third header,
wherein the first and third headers are arranged with a header separation between the first and third headers such that portions of the first and third headers that contain the refrigerant are not in direct contact.
2. The HVAC system of claim 1 , wherein the header separation comprises a gap such that the first and third headers are not directly physically connected.
3. The HVAC system of claim 2 , further comprising a non-conductive material located in the gap.
4. The HVAC system of claim 1 , wherein the header separation comprises a chamber formed between connected first and third headers.
5. The HVAC system of claim 1 , wherein the first section and the second section are spaced apart by a section separation.
6. The HVAC system of claim 5 , wherein the section separation comprises a gap.
7. The HVAC system of claim 6 , further comprising a non-conductive material located in the gap.
8. The HVAC system of claim 5 , wherein the section separation comprises one or more sections of one or more dead microchannel tubes.
9. A multi-pass microchannel heat exchanger for a heating, ventilation, and air-conditioning (“HVAC”) system for use with a refrigerant and operable as at least one of a condenser or an evaporator, the heat exchanger comprising:
a first header at an end of the heat exchanger;
a second header at an opposite end of the heat exchanger;
a third header at the same end as the first header;
a first section of microchannel tubes fluidly connecting the first and second headers in a first pass for flowing the refrigerant from the first header to the second header; and
a second section of microchannel tubes fluidly connecting the second and third headers in a second pass for flowing the refrigerant from the second header to the third header,
wherein the first and third headers are arranged with a first separation between the first and third headers such that portions of the first and third headers that contain the refrigerant are not in direct contact.
10. The heat exchanger of claim 9 , wherein the header separation comprises a gap such that the first and third headers are not directly physically connected.
11. The HVAC system of claim 10 , further comprising a non-conductive material located in the gap.
12. The HVAC system of claim 9 , wherein the header separation comprises a chamber formed between connected first and third headers.
13. The HVAC system of claim 9 , wherein the first section and the second section are spaced apart by a section separation.
14. The HVAC system of claim 13 , wherein the section separation comprises a gap.
15. The HVAC system of claim 14 , further comprising a non-conductive material located in the gap.
16. The HVAC system of claim 13 , wherein the section separation comprises one or more sections of one or more dead microchannel tubes.
17. A method of operating a heating, ventilation, and air-conditioning (“HVAC”) system, comprising:
flowing a refrigerant through a multi-pass microchannel heat exchanger to either condense or expand the refrigerant,
wherein flowing the refrigerant through the heat exchanger comprises:
flowing the refrigerant to a first header at an end of the heat exchanger;
flowing the refrigerant from the first header to a second header at an opposite end of the heat exchanger through a first section of microchannel tubes in a first pass;
flowing the refrigerant from the second header to a third header at the same end as the first header through a second section of microchannel tubes in a second pass; and
reducing heat transfer between the refrigerant in the first header and the refrigerant in the third header by arranging a header separation between the first and third headers such that portions of the first and third headers that contain the refrigerant are not in direct contact.
18. The method of claim 17 , wherein the header separation comprises at least one of a gap such that the first and third headers are not directly physically connected or a chamber formed between connected first and third headers.
19. The method of claim 17 , further comprising reducing heat transfer between the refrigerant in the first section and the refrigerant in the second section by arranging a section separation between the first and second sections.
20. The method of claim 19 , wherein the section separation comprises at least one of a gap or one or more sections of one or more dead microchannel tubes.
Priority Applications (1)
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US18/450,455 US20230392870A1 (en) | 2020-12-29 | 2023-08-16 | Heat exchanger for a heating, ventilation, and air-conditioning system |
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US17/136,889 US11774178B2 (en) | 2020-12-29 | 2020-12-29 | Heat exchanger for a heating, ventilation, and air-conditioning system |
US18/450,455 US20230392870A1 (en) | 2020-12-29 | 2023-08-16 | Heat exchanger for a heating, ventilation, and air-conditioning system |
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US17/136,889 Continuation US11774178B2 (en) | 2020-12-29 | 2020-12-29 | Heat exchanger for a heating, ventilation, and air-conditioning system |
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