Abstract:
a plurality of tubes defining a plurality of refrigerant flow stages between the headers. The receiver includes a housing in refrigerant flow connection with one of the condenser headers, and a receiving device removably secured in the housing. The device includes first and second members sealing against the receiver to define respective spaced first and second walls, and at least one connection line is in or on the receiving device and bridges the spacing between the first and second walls, with the connection line being adapted to guide refrigerant through the spacing from one stage to another stage. Desiccant is provided in the housing between the first and second sealing members.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S)  
       [0001]     Not applicable.  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not applicable.  
       REFERENCE TO A MICROFICHE APPENDIX  
       [0003]     Not applicable.  
       TECHNICAL FIELD  
       [0004]     The present invention relates to a receiver for a condenser, and more particularly to a receiver and insert for an air conditioner for vehicles.  
       BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART  
       [0005]     Receivers for refrigerant of vehicular condensers are shown, for example, in European patent application EP 03 004 717.9, which is conceived for use in the header of condensers in which the refrigerant flows through the condenser in several streams in the opposite direction. The streams form zones or stages that are often referred to as condensation zones- or subcooling zones, depending on the purpose. In one such known condenser, one or more condensation zones are on the top and one subcooling zone is on the bottom. The receiving device for such condensers cannot be, however, be used when the arrangement of the zones or the flow path of the condenser must be altered for specific reasons.  
         [0006]     Condensers with other, different flow paths are known, for example, from U.S. Pat. No. 5,228,315. In order to implement the flow paths shown there, the design of a header was equipped with the corresponding collector in one piece with several channels, which results in a significant (i.e., very demanding) change of the entire condenser if another flow path is desired.  
         [0007]     The condenser known from DE 198 30 329 A1 behaves similarly. The header and the collector there have a bead extending over the length of their connection, providing a connection line for the refrigerant.  
         [0008]     Kawahara U.S. Pat. No. 6,000,465 discloses a heat exchanger with a receiver structure attachable to the side thereof. The receiver is a fixed structure, whereby completely different receivers must be manufactured for use with heat exchangers having different flow requirements.  
         [0009]     Dabrowski U.S. Pat. No. 6,038,884 discloses an air conditioning condenser with an exchangeable fluid reservoir. The reservoir is secured at its bottom to a base, with flow in and out of the reservoir passing through that bottom base. Inaba et al. U.S. Pat. No. 5,709,106 discloses a condenser structure having a liquid tank which, similar to Dabrowski &#39;884, is secured alongside its bottom to a base with flow in and out of the tank passing through that bottom base.  
         [0010]     Incorvia et al. U.S. Pat. Nos. 6,468,334 B2 and 6,589,320 B2 disclose a condenser with a receiver, where liquid pools in the bottom of the receiver from which it may pass to the bottom refrigerant tubes of a supercooling core. An absorbent cartridge is located in the top of the receiver, and includes fluted channels on the outer surface of the cartridge housing, permitting refrigerant flow up and around the outside of the cartridge to the porous end member at its upper end.  
         [0011]     Balthazard et al. U.S. Pat. No. 5,896,754 discloses a condenser with reservoirs built into the manifolds, where the reservoirs include beading or partitions on their outer surface to define flow pass partitions in the manifold. Flow enters and leaves the reservoir through outlet and inlet openings near the bottom of the reservoir.  
         [0012]     The present invention is directed toward overcoming one or more of the problems set forth above.  
       SUMMARY OF THE INVENTION  
       [0013]     In one aspect of the present invention, a desiccant receiving device is provided for a vehicle air conditioner having a condenser with at least one header and a plurality of tubes defining a plurality of refrigerant flow stages. The receiving device is adapted for mounting in a receiver in refrigerant flow connection with the one condenser header, and the device includes at least one member sealing against the receiver to define a first wall between sections of the receiver and at least one connection line in or on the receiving device. The connection line is adapted to guide refrigerant therethrough from one stage to another stage.  
         [0014]     In one form of this aspect of the invention, the device is adapted for removable mounting in the receiver.  
         [0015]     In another form of this aspect of the invention, the direction of refrigerant flow in the connection line is opposite the refrigerant flow direction in the receiver outside of the connection line.  
         [0016]     In still another form of this aspect of the invention, a second sealing member defines a second wall spaced from the defined first wall, and the connection line bridges the spacing between the sealing members. In further forms, desiccant is in the receiver and between the first and second sealing members, or a perforated wall us between the first and second sealing members wherein the connection line is between the perforated wall and the desiccant, or the first and second sealing members each have an opening therethrough with the connection line being a tube extending through the sealing member openings, or one end of the connection line extends beyond one of the sealing members and the other end is sealed to the other sealing member. In another further form, the first and second sealing members each include a sealing wall having a periphery sealing around the inner wall of the receiver and, in a still further form, the wall defined by the one sealing member is generally parallel to the wall defined by the second sealing member. In yet another further form, a filter basket is secured to one of the sealing members, and the filter basket and one sealing member are releasably connected to the receiving device.  
         [0017]     In still other forms of this aspect of the invention, the connection line is a riser or a downcomer.  
         [0018]     In yet another form of this aspect of the invention, the connection line is integrated in the receiving device.  
         [0019]     In yet a further form of this aspect of the invention, the receiving device is fastened with one end to a closure cover of the receiver.  
         [0020]     In another aspect of the present invention, a receiver is provided for a vehicle air conditioner having a condenser with a pair of headers and a plurality of tubes defining a plurality of refrigerant flow stages between the headers. The receiver includes a housing in refrigerant flow connection with one of the condenser headers, and a receiving device removably secured in the housing. The device includes a first member sealing against the receiver to define a first wall between sections of the receiver, a second member sealing against the receiver to define a second wall spaced from the first wall, and at least one connection line in or on the receiving device and bridging the spacing between the first and second walls, with the connection line being adapted to guide refrigerant through the spacing from one stage to another stage. Desiccant is provided in the housing between the first and second sealing members.  
         [0021]     In one form of this aspect of the present invention, the direction of refrigerant flow in the connection line is opposite the refrigerant flow direction in the receiver outside of the connection line.  
         [0022]     In another form of this aspect of the present invention, the first and second sealing members each have an opening therethrough, and the connection line is a tube extending through the sealing member openings.  
         [0023]     In still another form of this aspect of the present invention, one end of the connection line extends beyond one of the sealing members and the other end is sealed to the other sealing member.  
         [0024]     In yet another form of this aspect of the present invention, the receiving device is fastened with one end to a closure cover of the receiver.  
         [0025]     In yet a further form of this aspect of the present invention, a filter basket is secured to one of the sealing members, with the filter basket and one sealing member being releasably connected to the receiving device.  
         [0026]     In still another aspect of the present invention, a receiver is provided for a vehicle air conditioner having a condenser with a pair of headers and a plurality of tubes defining a plurality of refrigerant flow stages between the headers. The receiver includes a housing in refrigerant flow connection with one of the condenser headers, and a receiving device removably secured in the housing. The device includes a first member sealing against the receiver to define a first wall between sections of the receiver, and at least one connection line in or on the receiving device and extending through the first wall, with the connection line being adapted to guide refrigerant through the first sealing member from one stage to another stage. Desiccant is also provided in the housing. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0027]      FIG. 1  is a top view of a receiving device embodying the present invention;  
         [0028]      FIG. 2  is one side view of the receiving device of  FIG. 1 ;  
         [0029]      FIG. 3  is another side view of the receiving device of  FIG. 1 , with the receiving device turned 90 degrees;  
         [0030]      FIG. 4  is a perspective view of the receiving device of  FIG. 1 ; and  
         [0031]      FIG. 5  is a cutout of a portion of a condenser having a receiver in which the receiving device of  FIGS. 1-4  is used. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]     The Figures show a practical example of a receiving device  10  according to the present invention, in which a collector or receiver  14  is arranged on one of the two headers  16  of the condenser  20  (see  FIG. 5 ) of the air conditioner of a vehicle. (It is well known that heat exchangers may be manufactured in a variety of ways in which the fluid flow between the multiple tubes of the heat exchanger is confined by different structures, including tanks secured to headers, and pipe structures and collector tubes mounted to the tubes. While reference is made herein to header constructions, it should be understood that the present invention may be used with not only header and tank configurations but also such other structures and that references herein to headers, including in the claims, is intended to refer to such other structures.)  
         [0033]     In the illustrated embodiment, the condenser  20  includes a plurality of tubes  24  defining suitable flow paths for fluid such as is known in the art. Suitable headers  30  are provided on opposite ends of the tubes  24  (only one header  30  is shown in  FIG. 5 ) such as is also known to provide a path for flow of fluid to and from the tubes  24 . It should be understood, however, that it is of subordinate significance in the present context whether the header  16  and collector  14  are designed in one piece or assembled from two tubes, as shown in  FIG. 5 .  
         [0034]     Also in the illustrated embodiment, the condenser outlet (not shown) is on the header (also not shown) on the other side of the condenser  20 .  
         [0035]     Suitable ribs or fins (not shown) are also provided between the tubes to facilitate cooling such as is also known in the art, for example, by the flow of cooling air over the fins and between the tubes  24 . It would be within the scope of the present invention to use any suitable fins, including serpentine or corrugated fins and plate fins.  
         [0036]     Suitable partitions  34  (two of which are shown in  FIG. 5 ) may also be provided as desired to direct fluid through separate passes or stages  40 ,  42 ,  44  of the condenser  20 . For example, as illustrated in  FIG. 5 , coolant or refrigerant will flow from the header  30  into the tubes  24   a  of the bottom pass(es)  40 , then flow from the tubes  24   a  through the other header and into the tubes  24   b  of pass  42 , then flow from the tubes  24   b  through the header  30  and (as described in greater detail hereafter) on to the overlying stage  44  which, in the illustrated embodiment, is a subcooling stage. One or more passes/stages may be provided beneath pass(es)  40  illustrated in  FIG. 5 .  
         [0037]     In accordance with the present invention, it is important that the collector  14  be in flow connection with the header  16  so that it can be traversed by the refrigerant. As illustrated in  FIG. 5 , the refrigerant exiting tubes  24   b  flows through an inflow opening  46  into the collector  14 , and refrigerant exits the collector  14  through outflow opening  48 . It should be appreciated, however, that several inflow and outflow openings  46 ,  48  can naturally be present.  
         [0038]     Flow arrows  50  show the flow directions of the refrigerant in the condenser  20  and through its collector  14 .  
         [0039]     The receiving device  10  is suitably secured in the collector  14 , for example by a threaded head  56  with a suitable seal, where the threaded head  56  forms a closure cover for the receiving device  10 . The receiving device  10  may therefore be easily removed and or replaced for maintenance and/or conversion to differently configured receiving devices  10 .  
         [0040]     The illustrated receiving device  10  includes a pair of spaced sealing walls  60 ,  62  along its length which each have an outer sealing wall  64  which essentially seals against the inner wall  64  of the collector  14  to block refrigerant flow past the sealing wall  60 ,  62 . A space  66  is therefore defined between the two sealing walls  60 ,  62  which may advantageously be at least partly filled with a suitable desiccant to remove unwanted water from the refrigerant passing therethrough.  
         [0041]     Since the path above the inflow opening  46  is blocked by the sealing wall  60 , the refrigerant from inflow opening  46  will propagate downward and then in contact with the desiccant in the space  66 . As shown in  FIGS. 2 and 4 , the wall  70  of the receiving device  10  is perforated, with several perforations  72  drawn in the wall  70  so that advantageous contact of the refrigerant with the desiccant may be achieved.  
         [0042]     Flow openings  76  through which the refrigerant can flow in and through a filter basket  78  are situated above the second sealing wall  62 , after which, cleaned of undesired components, the refrigerant is situated beneath the sealing wall  62 . In the illustrated embodiment, the filter basket  78  and sealing wall  62  form a unit releasably connected to the receiving device  10 .  
         [0043]     A connection line or tube  80  is integrated into the receiving device  10 . An opening  82  is situated in the lower sealing wall  64  through which, during assembly of the filter basket  78  with the sealing wall  62  on the receiving device  10 , the end of the connection tube  80  is pushed through. Alternatively, a connection tube  80  could also be pushed as an individual part through axially aligned openings  82  in both sealing walls  60 ,  62 .  
         [0044]     The connection line  80  may alternatively be unreleasably integrated in the receiving device  10 , for example, by manufacturing the receiving device  10  and connection line  80  uniformly from plastic. In this case, it has proven advantageous that one sealing member  62  and the filter basket  78  be designed as a common single part releasably connected to the receiving device  10 .  
         [0045]     From the filter basket  78  beneath the sealing wall  62 , the refrigerant flows upward through the connection tube  80  which extends between axially aligned holes  82  (see  FIGS. 1 and 4 ) in the sealing walls  60 ,  62 . (In the embodiment illustrated in  FIGS. 1-5 , the connection line  80  clearly extends beyond the sealing wall  60  on one end and is closed off on the other end, but it should be understood that this is due merely to the particular embodiment and it should be understood that such an extension of the connection tube  80  is not essential to the present invention.)  
         [0046]     While the connection tube  80  in the above described embodiment is a riser, with refrigerant flow occurring up through the tube  80  to the space above the upper sealing wall  60  then to the outflow opening  48  into the subcooling stage  44  of the condenser  20 , the connection tube  80  according to other practical examples can alternatively be a line which guides the refrigerant from an upper stage to an underlying or lowermost stage of the condenser. Such connection tubes  80  are then referred to as downcomers merely to clarify the difference relative to the depicted riser.  
         [0047]     In addition, the present invention envisions still other variants in which, for example, several connection lines or tubes may be provided in connection with several sealing walls in order to correspond to other desired flow paths of the condenser in a cost-effective way.  
         [0048]     It should be appreciated that the present invention facilitates the manufacture of condensers with receivers having a variety of flow paths. Different-configuration receiving devices according to the present invention may be readily provided to accommodate a wide variety of flow configurations without requiring further costly redesign and manufacture of the entire condenser/receiver structure. Moreover, receivers according to the present invention may be implemented very cost-effectively with relatively few changes to most condenser designs, with the required changes essentially being only insertion of the partitions in the condenser header and mounting of the corresponding inflow and outflow openings.  
         [0049]     It should further be appreciated that, as illustrated in the embodiment shown in the figures, the present invention may be readily used in which a subcooling stage or zone may be situated on top, notwithstanding the desire for only liquid in the subcooling stage, where liquid is, of course, typically separated out from gaseous refrigerant at the bottom.  
         [0050]     Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.