Abstract:
An evaporator for conducting a heat exchanger between a refrigerant and ambient air including a plurality of refrigerant tubes, at least two header tanks in fluid communication with the plurality of refrigerant tubes and at least one of the heater tanks having a plurality of serrations through which refrigerant flows into each of the plurality of refrigerant tubes and a plurality of fins dispersed between each of the plurality of refrigerant tubes.

Description:
TECHNICAL FIELD  
         [0001]    The present invention relates to heat exchangers for use in automobile air conditioning circuits and to configurations for improving refrigerant distribution through the heat exchanger.  
         BACKGROUND  
         [0002]    Automotive heat exchangers or evaporators include a plurality of refrigerant tubes connected typically to two headers or tanks. One header has an inlet for receiving refrigerant while the other header has an outlet for evacuating refrigerant from the evaporator. Heat dissipation fins are disposed between the refrigerant tubes to facilitate heat exchange between the evaporator and the ambient air.  
           [0003]    In operation, refrigerant flows into the inlet through the refrigerant tubes where heat contained within the ambient air is exchanged with the refrigerant, thereafter the refrigerant leaves the evaporator through the outlet. Inertial and gravitational forces in the headers of the evaporator separate the liquid from the vapor phase of the refrigerant causing a mal-distribution of the liquid phase throughout the heat exchanger tubes. Consequently, a number of the refrigerant tubes will dry out prematurely and then superheat. The superheated refrigerant reduces heat transfer from the ambient air to the refrigerant. Furthermore, the refrigerant tubes containing single phase vapor have a heat transfer coefficient that can be three times lower than the corresponding two-phase (i.e. liquid/vapor) flow conditions. Uniform two-phase flow distribution can improve heat transfer rates up to thirty percent as compared to a completely separated single phase flow and in turn improve performance of the evaporator reducing the overall power consumption of the compressor. The improved efficiency of the refrigerant system not only reduces energy consumption but can lead to a reduced evaporator size while still providing the same performance both in terms of capacity and coefficient of performance. A smaller evaporator is advantageous as space is a premium within the vehicle and specifically underneath the instrument panel.  
           [0004]    In order to address the mal-distribution problem described above, prior art evaporators have utilized a four pass refrigerant flow configuration. While the four pass configuration minimizes the mal-distribution of the refrigerant in the evaporator, this four pass configuration increases the pressure drop across the evaporator core due to the increased velocity of the refrigerant and superheated refrigerant expanding towards the latter part of the evaporator. Furthermore, one half of the core is in parallel flow and the other half is in counter-flow with respect to the ambient air flow direction through the heat exchanger. A counter-flow circuit has a better heat transfer rate than a parallel flow circuit.  
           [0005]    Therefore, what is needed is a new and improved evaporator design which corrects the mal-distribution problem described above while providing a low pressure drop across the evaporator core and a counter-flow circuitry.  
         SUMMARY  
         [0006]    In an aspect of the present invention, an evaporator for exchanging heat between a refrigerant and ambient air is provided. The evaporator includes a plurality of refrigerant tubes at least two header tanks in fluid communication with the plurality of refrigerant tubes.  
           [0007]    In another aspect of the present invention at least one of the heater tanks has a plurality of serrations through which refrigerant flows into each of the plurality of refrigerant tubes and a plurality of fins dispersed between each of the plurality of refrigerant tubes.  
           [0008]    In yet another aspect of the present invention each of the plurality of refrigerant tubes are formed in a U-shape and includes at least one of the header tanks having an inlet for receiving refrigerant into the evaporator and at least one of the header tanks having an outlet for expelling refrigerant from the evaporator.  
           [0009]    In yet another aspect of the present invention the serrations in the distribution tube has slots/serrations and the slots/serrations in the distribution tube that is disposed in the header tank have varying depth.  
           [0010]    In still another aspect of the present invention the slot in a center of the header tank has the largest depth and the depth of the slots progressively decreases moving from the center toward the end of the header tank.  
           [0011]    In yet another aspect of the present invention the slot/serration has depth arrangement in accordance with that shown in FIG. 6.  
           [0012]    In yet another aspect of the present invention the distribution tube can be rotated between −35 degrees and +35 degrees from a vertical position without degrading the evaporator&#39;s performance.  
           [0013]    In yet another aspect of the present invention a plurality of internal turbulators are formed from a piercing operation. The turbulators turbulate (produce turbulent flow) the two phase flow and directs the flow through the slots/serrations located in the beginning and middle of the distribution tube. Without these turbulators, two phase refrigerant will flow to the bottom of the tube first and then to the rest of the serrations causing mal-distribution.  
           [0014]    These and other aspects and advantages of the present invention will become apparent upon reading the following detailed description of THE invention in combination with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0015]    [0015]FIG. 1 is a perspective view of a four pass evaporator;  
         [0016]    [0016]FIG. 2 is a schematic diagram illustrating the flow path of the four pass evaporator of FIG. 1;  
         [0017]    [0017]FIG. 3 is a perspective view of a two pass evaporator having a side inlet and side outlet, in accordance with the present invention;  
         [0018]    [0018]FIG. 4 is a schematic diagram of the refrigerant flow path of the evaporator of FIG. 3;  
         [0019]    [0019]FIGS. 5 a ,  5   b  and  5   c  are top, cross-sectional and perspective views of a flow distributor, in accordance with the present invention;  
         [0020]    [0020]FIG. 6 is a chart illustrating a serration depth versus serration location along the tube, in accordance with the present invention; and  
         [0021]    [0021]FIGS. 7 a ,  7   b , and  7   c  are an end views of the distributor tube angular insertion into the inlet of the evaporator, in accordance with the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0022]    Referring now to FIG. 1, a conventional evaporator  10  is illustrated. Evaporator  10  includes two header tanks  12  and  14 , a plurality of refrigerant tubes  16 , a plurality of fins  18 , and side plates  19  and  20 . Typically, these components are affixed using conventional brazing techniques. Generally, the fins are disposed between the refrigerant tubes to facilitate heat dissipation. Each of the refrigerant tubes define a U-shaped flow path for the refrigerant. The two ends of the U-shaped path are connected to header tanks  12  and  14 . Tank  14  is divided into two subtanks  22  and  24  by a partition (not shown). An inlet pipe  26  communicates with subtank  22  and an outlet pipe  28  communicates with the subtank  24 .  
         [0023]    Referring now to FIG. 2, a schematic diagram illustrating a flow path of the refrigerant in evaporator  10 , in accordance with the prior art. The mode of refrigerant flow in FIG. 2 is referred to in the art as four path flow. As shown, refrigerant enters at one end of the evaporator and flows in a U-shape until it reaches the other header tank where the refrigerant flows again in a U-shaped flow pattern until it exits through the outlet. This prior art flow configuration has an improved refrigerant distribution characteristic over other designs. However, the four path flow evaporator has a higher refrigerant pressure drop across the evaporation core due to the higher refrigerant velocity. Conventional two path evaporators, experience uneven temperature distribution over the surface of the refrigerant tubes when the refrigerant circuit is operating due to the mal-distribution of the two phase refrigerant. Mal-distribution of the refrigerant occurs in a two path flow evaporator without a distributor tube because each refrigerant tube sees a varying pressure differential depending on its location from the inlet and outlet tubes. For example, refrigerant tubes closest to inlet/outlet tubes will have the highest pressure differential and therefore see most of the refrigerant flow while the refrigerant tubes farthest from inlet/outlet tubes will have the lowest refrigerant flow. The temperature difference between refrigerant tubes may be several degrees.  
         [0024]    Referring now to FIG. 3, a two path flow evaporator  50  is illustrated, in accordance with the present invention. Evaporator  50  has two header tanks  52  and  54 . Header tank  52  is in communication with an inlet  56  and with refrigerant tubes  58 . Header tank  54  is in communication with an outlet  60  and the refrigerant tubes  58 . More specifically, refrigerant tubes  58  are substantially U-shaped and are connected at one end to header tank  52  and at the other end to header tank  54 . As illustrated, the inlet  56  and outlet  60  are disposed at an end  62  of evaporation  50 . In operation, refrigerant is received in inlet  56  into header tank  52  and then through predominantly U-shaped refrigerant tubes  58  to header tank  54 . Header tank  54  empties through refrigerant through outlet  60 . Additionally, a plurality of heat dissipation fins  64  are disposed between the U-shaped refrigerant tubes  58  to facilitate heat exchange between the refrigerant and the ambient air.  
         [0025]    Referring now to FIG. 4, a schematic diagram illustrating the flow path of refrigerant through evaporator  50 , in accordance with the present invention. Refrigerant enters evaporator  50  at inlet  56  and flows within header tank  52  along a flow path indicated by arrow  70  where it is distributed to each of the refrigerant tubes, as indicated by arrows  72 . The refrigerant then enters header tank  54  as indicated by arrows  74  and flows through header tank  54  to outlet  60 , as indicated by arrow  76 . The refrigerant exists in two phases, a liquid and a vapor phase. The flow velocities of the refrigerant in each of the refrigerant tubes are about equal. The result is that an imbalance in the mass flow rate in the refrigerant tubes corresponding to the distance from the inlet pipe causes reduced refrigerant in several of the refrigerant tubes. The refrigerant tubes having the highest mass flow rate have a higher refrigerant coefficient as compared to the refrigerant tubes having a lower mass flow rate. This phenomenon is well known in the field of heat exchangers.  
         [0026]    Referring now to FIG. 5 a , a plan view illustration of a flow distributor  80 , in accordance with the present invention. Flow distributor  80  has a generally elongated tubular body  82  having a diameter “D” that is sized for receipt into inlet  56  of evaporator  50 . A flange  84  is affixed to end  86  of the tubular body  82 . Flange  84 , as will become clear, acts to regulate the insertion depth of tubular body  82  through inlet  56  into header tank  52 .  
         [0027]    A plurality of spaced serrations or slots  88  are disposed along tubular body  82 . A spacing of dimension “S” from the first slot  90  is defined such that slot  90  aligns with the first refrigerant tube  58 . The spacing of each of the other serrations from slot  90  is such that each serration aligns with each of the refrigerant tubes  58  of evaporator  50 . The sizing of each of the serrations  88  along tubular body  82  are configured such that a uniform distribution of the liquid and vapor phases of the refrigerant is achieved through evaporator  50 . For example, the depth (which controls the overall opening) of the serrations  88  are varied such that the serrations at a center portion  92  of tubular body  82  are larger than at the ends of the tubular body  82 . In other words, the depth of each of the serrations are largest at the center of the tubular body  82  and progressively decrease towards the ends of tubular body  82 .  
         [0028]    As illustrated in FIG. 5 b  in a cross-sectional view through tubular body  82 , at a point indicated in FIG. 5 a , serration  88  may be achieved using a cutting tool  94  having a tapered blade  96 . The depth of the serration would be controlled by the distance cutting tool  94  travels into tubular body  82 . A pair of internal turbulators  98  are formed at each serration  88  each time cutting tool  94  pierces tubular body  82 . The turbulators  98  turbulate (produce turbulent flow) the two phase flow and directs the flow through the slots/serrations located in the beginning and middle of distribution tube  80 . Without these turbulators  98 , two phase refrigerant will flow to the bottom of the tube first and then to the rest of the serrations causing mal-distribution.  
         [0029]    Referring now to FIG. 5 c , a perspective view of flow distributor  80  is further illustrated, in accordance with the present invention. Flow distributor  80  achieves a uniform two-phase refrigerant distribution through the refrigerant tubes of evaporator  50  by providing a plurality of slots or serrations along tubular body  82  having varied depths or sizes. Further, the spacing between the serrations or slot is such that each slot  88  is aligned with each refrigerant tube  58  within evaporator  50 .  
         [0030]    In an alternative embodiment, the depth of each of the serrations vary in accordance with a relationship  100  shown chart  102  of FIG. 6. As chart  102  illustrates, the depth (or size) of the serrations vary from one end of tubular body  82  to the other end according to relationship  100 . Relationship  100  varies as a function of serration position along the tubular body.  
         [0031]    Referring now to FIGS. 7 a ,  7   b , and  7   c  end views of flow distributor tube  80  are illustrated. Distributor tube  80  may be inserted into inlet  56  of evaporator  50  (shown in FIG. 3) at an angle between minus 35 degrees and plus 35 degrees with respect to a vertical line “v”. FIG. 7 a  illustrates distributor tube  80  rotated by zero degrees with respect to vertical line “v”. FIG. 7 b  illustrates distributor tube  80  rotated by minus 35 degrees with respect to vertical line “v”. FIG. 7 c  illustrates distributor tube  80  rotated by plus 35 degrees with respect to vertical line “v”. Thus, any rotation between the angles specified above is preferable and will produce a desired refrigerant flow distribution through the evaporator.  
         [0032]    In an alternate embodiment of an integrated flow distributor is provided. In other words, the present invention contemplates integrating the slots or serrations into header tank  52  as an alternative to flow distributor  80 . Accordingly, the serrations would be spaced and sized to achieve uniform refrigerant distribution through the refrigerant tubes as previously described.  
         [0033]    As any person skilled in the art of heat exchanger design will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the preferred embodiments of the invention without departing from the scope of this invention defined in the following claims.