Abstract:
A condenser for an air conditioning system includes a receiver integrally formed with a second, or return, header which is in fluid communication with a second, or sub-cooling, group of tubes. A conduit extends between entry and discharge ends both of which are completely enclosed within the interior of the receiver. The conduit transports a refrigerant fluid in an upflow direction within the interior of the receiver and through a second fluid port located adjacent the discharge end of the conduit for directing the fluid into and through the return header to the sub-cooling group of tubes.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates to air conditioning systems. More specifically, the invention relates to an integral receiver assembly for a sub-cooled condenser.  
         [0003]     2. Description of the Related Art  
         [0004]     Condensers designed for upflow operation and which utilize integral receivers are well known in the art. Such condensers often utilize receivers which are connected to, or otherwise integrally formed with, the return header of the condenser. An example of such a condenser is disclosed in U.S. Pat. No. 6,3,97,627 (“Aki et al.”). The Aki et al. condenser includes a plurality of tubes through which a refrigerant fluid flows between initial and return header tanks. The tubes are divided into an upstream group within which the fluid is condensed from a gas to a liquid, and a downstream, or “sub-cooling” group within which the condensed fluid is further cooled prior to exiting the condenser. The sub-cooling group is disposed above the upstream group within the core. The refrigerant fluid flows from the initial header through the uptream group of tubes into the return header and then flows through the sub-cooling tubes prior to exiting the condenser.  
         [0005]     The receiver utilized in the Aki et al. condenser is integrally formed with the return header. Designed to separate any gaseous components remaining in the refrigerant from the liquid components thereof before the remaining fluid flows back into the return header and then into the sub-cooling group of tubes, the Aki et al. receiver extends from a closed base positioned adjacent to the downstream group of tubes to a closed cover located adjacent the sub-cooling group. An elongate communications pipe interconnects the cover of the receiver with the return header. The pipe extends from a lower portion to an upper portion. The lower portion is disposed completely within the interior of the receiver and has an open end which is positioned adjacent to the base. The upper portion extends from the interior of the receiver through the cover to the exterior, and is connected directly to the return tank. Condensed fluid flows from the downstream group of tubes into the return tank, and passes into the receiver through a single communications hole located in the wall between the return header and the receiver.  
         [0006]     The communication hole within the Aki et al. receiver is disposed higher than the open end of the pipe, which prevents the gaseous components in the condensed refrigerant from entering the open end. Once inside the receiver, the gaseous components are effectively isolated within the interior. The liquid components are directed to flow through the open end upwardly through the pipe and into the return tank before being introduced to the sub-cooling group of tubes.  
         [0007]     The Aki et al. receiver effectively separates gaseous components from a condensed fluid and successfully transports the remaining liquid components in an “upflow” direction through the receiver to the sub-cooling area of a condenser. However, extending the communications pipe through the receiver cover and attaching the upper portion directly to the return tank increases the number of exterior joints through which the condensed fluid may leak. This compromises the structural integrity of the receiver and reduces the thermal efficiency of the condenser.  
       BRIEF SUMMARY OF THE INVENTION AND ADVANTAGES  
       [0008]     The subject invention provides a condenser for an air conditioning system. The condenser includes first and second headers, with a receiver that extends parallel to the second header. A first group of tubes extends between the first and second headers and is in fluid communication therewith for permitting a fluid to flow between the headers through the first group of tubes. A second group of tubes also extends between the first and second headers. The second group is likewise in fluid communication with the headers, which permits the fluid to flow between the headers through the second group. A header separator is in each of the headers and divides the header into a first header chamber in fluid communication with the first group and a second header chamber in fluid communication with the second group.  
         [0009]     A first fluid port is between the first header chamber of the second header and the receiver for directing the fluid to flow from the first tube group and the first header chamber to the receiver. A conduit extends within the receiver between an entry end and a discharge end. The discharge end is disposed within the receiver. A receiver separator extends between the conduit and the receiver to establish a receiver chamber, which surrounds the discharge end of the conduit for directing the fluid to flow through the conduit from the entry end to the discharge end and into the chamber. A second fluid port is located between the receiver and the second header chamber of the second header. The second fluid port is disposed adjacent the discharge end for directing the fluid through the receiver chamber to the second header chamber and the second group of tubes.  
         [0010]     The subject invention overcomes the limitations of the art by providing a condenser with an integrally formed receiver that utilizes a conduit which is completely enclosed within the interior of the receiver. Disposing the entire conduit inside the receiver prevents additional external leak paths from being created by avoiding the introduction of additional welded or brazed external parts to the condenser. This reduces manufacturing costs, promotes ease of assembly, and reduces operating costs to the end user. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0011]     Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
         [0012]      FIG. 1  is a cross-sectional view of a condenser according to one embodiment of the present invention;  
         [0013]      FIG. 2  is a top planar view of the condenser according to  FIG. 1 ;  
         [0014]      FIG. 3  is a schematic view of the condenser according to  FIG. 1 ;  
         [0015]      FIG. 4  is a cross-sectional view of a condenser according to an alternative embodiment of the invention;  
         [0016]      FIG. 5  is a fragmentary view of the condenser shown in  FIG. 1 ;  
         [0017]      FIG. 6  is another fragmentary view of the condenser shown in  FIG. 1 ;  
         [0018]      FIG. 7  is a fragmentary perspective view of the conduit and receiver separator of the condenser shown in  FIG. 1 ;  
         [0019]      FIG. 8  is a fragmentary perspective view of the support member and desiccant of the condenser shown in  FIG. 1 ;  
         [0020]      FIG. 9  is a cross-sectional view of a condenser according to another alternative embodiment of the invention;  
         [0021]      FIG. 10  is a fragmentary view illustrating the receiver of the condenser shown in  FIG. 9 ;  
         [0022]      FIG. 11  is a fragmentary view of the receiver shown in  FIG. 10 ;  
         [0023]      FIG. 12  is a fragmentary perspective view of the receiver separator of the condenser shown in  FIG. 10 ;  
         [0024]      FIG. 13  is a perspective view of the conduit of the condenser shown in  FIG. 9 ;  
         [0025]      FIG. 14  is a perspective view of the support member of the condenser shown in  FIG. 9 ;  
         [0026]      FIG. 15  is a perspective view of the conduit and desiccant assembled with the support member shown in  FIG. 14 ; and  
         [0027]      FIG. 16  is a fragmentary cross-sectional view of the conduit, desiccant and support member assembled within the condenser shown in  FIG. 9 .  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]     Referring now to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a condenser for an air conditioning system is generally shown at  20  in  FIGS. 1 through 3 . The condenser  20  includes a first header  22 , a second header  24 , and a receiver  26 . The receiver  26  extends parallel to the second header  24 .  
         [0029]     As is best shown in  FIG. 3 , a first group  28  of tubes  30  extends between the first and second headers  22 ,  24 . The tubes  30  in the first group  28  are in fluid communication with the headers  22 ,  24 , which permits a fluid  32  to flow between the headers  22 ,  24  and through the first group  28 . A second group  34  of tubes  30  also extends between the first and second headers  22 ,  24 . Like the tubes  30  in the first group  28 , the tubes  30  in the second group  34  are in fluid communication with the headers  22 ,  24 , which similarly permits the fluid  32  to flow between the headers  22 ,  24  through the second group  34 . As is shown in  FIG. 1 , a plurality of corrugated fins  36  are interposed between the tubes  30 .  
         [0030]     The first header  22  also includes an inlet  38  and an outlet  40 . Referring again to  FIG. 3 , the fluid  32  enters the first header  22 , passes through the first group  28  of tubes  30  into the second header  24 , and flows through the receiver  26  back into the second header  24 . The fluid  32  then passes from the second header  24  through the second group  34  of tubes  30 , and exits the condenser  20  through the outlet  40 .  
         [0031]     A header separator  42  is disposed in each of the headers  22 ,  24 . Each separator  42  divides a selected one of the headers  22 ,  24  into first and second header chambers  44 ,  46 . The first header chamber  44  is in fluid communication with the first group  28  of tubes  30 , and the second header chamber  46  is in fluid communication with the second group  34 . A first fluid port  48  is located between the receiver  26  and the first header chamber  44  of the second header  24 , which directs the fluid  32  to flow from the first group  28  of tubes  30  and the first header chamber  44  to the receiver  26 .  
         [0032]     A conduit  50  extends within the receiver  26 . The conduit  50  has an entry end  52 , and extends to a discharge end  54  which is disposed within the receiver  26 . A receiver separator  56  extends between the conduit  44  and the receiver  26 . As is best shown in  FIG. 5 , the receiver separator  56  establishes a receiver chamber  58  that surrounds the discharge end  54 , whereby the fluid  32  is directed to flow through the conduit  50  from the entry end  52  to the discharge end  54  and into the receiver chamber  58 .  
         [0033]     Referring again to  FIG. 1 , a second fluid port  60  is located between the receiver  26  and the second header chamber  46  of the second header  24 . Positioned adjacent the discharge end  54  of the conduit  50 , the second fluid port  60  directs the fluid  32  through the receiver chamber  58  to the second header chamber  46 , where the fluid  32  then flows to the second group  34  of tubes  30 .  
         [0034]     As is shown in  FIG. 1 , the first fluid port  48  is disposed adjacent the receiver separator  56 . However, as is the case in the alternative embodiment of the condenser  120  shown in  FIG. 4 , the first fluid port  148  may alternatively be disposed adjacent the entry end  152  of the conduit  150 . With the exception of the location of first fluid port  148 , the condenser  120  shown in  FIG. 4  is fabricated from the same materials and utilizes the same components as the condenser  20 . With respect to both embodiments of the condenser  20 ,  120 , regardless of the proximity of the first fluid port  48 ,  148  to the receiver separator  56 ,  156 , the entry end  52 ,  152  of the conduit  50 ,  150  extends below the first fluid port  48 ,  148 . This ensures that any gaseous components remaining in the fluid  32 ,  132  remain within the receiver  26 ,  126  below the receiver separator  56 ,  156  rather than flowing with the liquid components of the condensed fluid  32 ,  132  into the entry end  46 ,  146  and through the conduit  50 ,  150 .  
         [0035]     Referring again to  FIG. 1  and using the condenser  20  as a representative example, the receiver  26  extends between first and second closed ends  62 ,  64 , with the conduit  50  disposed totally within the receiver  26 . Although the ends  62 ,  64  may be closed by brazing or by utilizing any other suitable processes or components, a first end cap  66  covers the first closed end  62 . This encloses the discharge end  54  of the conduit  50  within the receiver  26 . A second end cap  68  similarly covers the second closed end  64  to enclose the entry end  52  of the conduit  50  within the receiver  26 .  
         [0036]     Referring now to  FIG. 5 , the receiver separator  56  includes a disc  70  which extends radially from the conduit  50  to an outer peripheral edge  72 . The outer peripheral edge  72  is disposed against the interior of the receiver  26 . In addition, an annular lip  74  extends axially from the outer peripheral edge  72 . The lip  74  is in sealing engagement with the receiver  26 , which prevents any gaseous components of the fluid  32  from entering the receiver chamber  58 . The disc  70  also features a neck  76  with a cylindrical sidewall  78  that engages the conduit  50  to support the conduit  50  within the receiver  26 .  
         [0037]     Referring now to  FIG. 6 , the condenser  20  also includes a support member  80  that extends radially between the conduit  50  and the receiver  26 . Like the receiver separator  56 , the support member  80  supports the conduit  50  within the receiver  26 . A desiccant  82  is also supported by the support member  80 . The desiccant  82  dehydrates the fluid  32 . As is shown in  FIG. 1 , the desiccant  82  is disposed about the conduit  50  and extends from an upper portion  84  adjacent the receiver separator  56  to a lower portion  86 . As is best shown in  FIG. 6 , the lower portion  86  abuts the support member  80 , which prevents the desiccant  82  from settling against the first closed end  62  of the receiver  26  and blocking the first fluid port  48 . Although any suitable type of desiccant may be used, the desiccant  82  is a conventional, annular desiccant cartridge.  
         [0038]     Referring now to  FIG. 8 , the components of the support member  80  are specifically designed not only to maintain the desiccant  82  in a stationary position above the first fluid port  48 , but also to provide stabilizing support to the conduit  50  while simultaneously permitting the fluid  32  to flow freely from the first fluid port  48  into the entry end  52 . The support member  80  has a tubular base  88  that extends from an upper edge  90  to a lower edge  92 . The base  88  defines a bore  94  which is disposed about the entry end  52  of the conduit  50 . A flange  96  extends radially outwardly from the upper edge  90  and includes spaced openings  98 . The fluid  32  is exposed to the desiccant  82  by flowing around the flange  96  and through the openings  98 .  
         [0039]     The support member  80  also includes a plurality of spaced projections  100  that extend from the lower edge  92  of the tubular base  88 . Referring again to  FIG. 5 , the projections  100  are disposed against the first closed end  62  of the receiver  26  to define a space  102  between the entry end  52  of the conduit  50  and the first closed end  62 , which in turn permits the fluid  32  to flow freely through the receiver  26  from the first fluid port  48  into the entry end  52 .  
         [0040]     Referring now to  FIGS. 9 through 16 , a condenser  220  according to an alternative embodiment of the invention is shown. With the exception of the components disposed within the receiver  226 , the condenser  220  is fabricated out of the same materials and utilizes the same components as the condenser  20 .  
         [0041]     The receiver separator  256  of the condenser  220  differs from the receiver separator  56  of the condenser  20  in that the cylindrical sidewall  278  of the receiver separator  256  extends to an upper end  FIG. 12 . A cap  312  covers the upper end  310 , which causes the discharge end  254  of the conduit  250  to be disposed completely within the neck  276 . In addition, the cylindrical sidewall  278  includes at least one, or as is disclosed in  FIG. 12 , two openings  314 . Each opening  314  is positioned intermediate the cap  312  and the discharge end  254  of the conduit  250 . The fluid is directed from the discharge end  254  through the openings  314  and into the receiver chamber  258 .  
         [0042]     The receiver separator  256  also includes a cylindrical outer wall  316  that extends from the outer peripheral edge  272  of the disc  270 . As is shown in  FIGS. 10 and 11 , the cylindrical outer wall  316  is disposed against the interior of the receiver  226 , and includes an annular groove  318  into which an O-ring  320  is received for creating a fluid seal against the interior of the receiver  226 . An identically-shaped annular groove  318  is spaced parallel to the annular groove  318 . Another O-ring  320  is received within the identically-shaped groove  318 , which enhances the fluid seal.  
         [0043]     Referring now to  FIG. 13 , the sealing capability of the receiver separator  256  is further enhanced by modifications to the conduit  250 . Specifically, the conduit  250  has an exterior surface  322  from which an annular rib  324  extends adjacent the discharge end  254 . As is shown in  FIG. 11 , the rib  324  is positioned in abutting engagement with the disc  270 , which in turn orients the discharge end  254  within the receiver chamber  256 . In addition, the exterior surface  322  has at least one, or as disclosed two, second annular grooves  326  into which second O-rings  328  are received. The second grooves  326  and second O-rings  328  create a fluid seal against the interior of the cylindrical sidewall  278  of the neck  276 .  
         [0044]     Referring now to  FIGS. 14 through 16 , the support member  280  differs from the support member  80  of the condenser  20  in that the tubular base  288  includes an interior sidewall  330  defining a shoulder  332 . The shoulder  332  extends radially inwardly into the bore  294  and engages the conduit  250 .  
         [0045]     The conduit  250  also includes a second annular rib  334  that extends from the exterior surface  322  adjacent the entry end  252 . The second annular rib  334  is in abutting engagement with the shoulder  332 , which orients the entry end  252  within the interior of the receiver  226 .  
         [0046]     The support member  280  also differs from the support member  80  by having a detent  336  that extends resiliently from the tubular base  288  to a distal end  338 . The distal end  338  engages the second annular rib  334  to maintain the second annular rib  324  disposed against the shoulder  332 . As is shown in  FIGS. 15 and 16 , the entry end  252  of the conduit  250  extends through the bore  298  to a beveled edge  340  which is disposed adjacent the second closed end  264  of the second header  224 . This defines a space  342  between the beveled edge  340  and the second closed end  264  for permitting the fluid to flow into the entry end  252 .  
         [0047]     While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.