Abstract:
A condenser assembly for a vehicle air conditioning system. The condenser assembly includes a core comprised of a plurality of parallel tubes between which are located a plurality of fins. A pair of headers are located on opposite ends and in fluid communication with the tubes of the core. The headers are constructed such that their primary components exhibit constant cross sectional profiles along their lengths. This enables the volumetrics of the condenser assembly to be altered with a minimal amount of tooling change over being required.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a condenser assembly for a vehicle air conditioning system and, more specifically, to such a condenser assembly constructed so that the volumetrics of the condenser assembly may be readily varied thereby eliminating or substantially reducing the tooling cost associated with redesigning the condenser assembly for volumetric variations. 
     2. Description of Related Art 
     Condenser assemblies for automotive vehicle air conditioning systems typically include a pair of headers and a core having a plurality of tubes, through which refrigerant flows, disposed horizontally between the two headers. An inlet is disposed near an upper portion of one of the headers and an outlet is disposed at the lower portion of either the same or the other header. Within the headers, partitions may be provided to divide the interior space of the headers into more than one fluidically separate spaces. As a result, the refrigerant is caused to flow in a serpentine fashion making more than one path through the tubes between the headers. 
     Typically attached to one of the headers and in fluid communication therewith is a receiver. Refrigerant condensed in the core flows into the receiver where it is separated into gas and liquid portions. Since the presence of water in the refrigerant will degrade the performance and structural integrity of the air conditioning system, a dryer is often associated with or located within the receiver. The dryer is located within the receiver so that the dryer is in contact with the liquid portion of the refrigerant facilitating the removal of water from the refrigerant. The dryer may itself be comprised of a bag or cartridge containing a dryer granulate such as desiccant. 
     More recent designs of condenser assemblies have integrated the receiver/dryer with one of the headers mentioned above. One method of doing this has been to locate a plate within the header so as to divide the header into a manifold portion and a receiver/dryer portion. One drawback of this construction is that the design requires, for structural integrity of the system, a center line alignment of the core and the header containing the integrated receiver/dryer. Another drawback of this construction is that the joint between the manifold portion and the receiver/dryer portion cannot be inspected after brazing from the outside of the header. A further drawback is that once the tooling has been designed and constructed for such a condenser assembly, it is expensive to modify the tooling in order to provide the necessary parts with different partition locations, refrigerant communication hole locations, and volume changes of the various components of the condenser assembly, including a number of tubes in the core, as well as the lengths of the headers, the manifold portion and the receiver/dryer portion. 
     In other designs where the header is not internally divided to define a manifold portion and the receiver dryer, the problem remains whereby tooling flexibility is lacking and design changes relating to the volumetrics of the condenser assembly are expensive and time consuming to accommodate. 
     SUMMARY OF THE INVENTION 
     In view of the above it can be seen that there exists a need to provide a condenser assembly whose construction readily allows for the changing of the volumetrics in the assembly without incurring substantial costs and time involved in tooling a change over. 
     In achieving the above object, the present invention provides a condenser assembly for use in the air conditioning system of an automotive vehicle. The condenser assembly includes a core containing a plurality of tubes positioned generally horizontally and parallel to one another. The tubes accordingly define a space between adjacent ones thereof. Located within each of these spaces is a corrugated fin. The fin is in contact with both of the adjacent tubes and may be provided with louvers so as to aid in heat transfer from the refrigerant through the tubes, to the fins and, finally, to air passing through the core. On opposite sides of the core are provided a pair of headers. These headers are each in fluid communication with the tubes of the core. 
     The first header is configured such that refrigerant both enters and exits the condenser assembly through this header. Other locations for the refrigerant entrance and exit can be employed. The header is principally constructed from a cylindrical body having a constant cross sectional profile along its length. The open ends of the cylindrical body are closed by caps so as to define a cavity within the header. The cavity itself is divided by a partition into an upper and lower part. 
     The header on the opposing end of core includes two portions, a manifold portion and a receiver/dryer portion. The receiver/dryer portion is constructed of a cylindrical body having a constant cross sectional profile along its length. The ends of this cylindrical body are also closed off by caps so as to define a cavity within the receiver/dryer portion. The manifold portion is formed from another member having a constant cross sectional profile along its length. This member engages the exterior surface of the cylindrical body of the receiver/dryer portion and cooperates therewith to define a manifold chamber therein. The upper and lower most ends of the manifold chamber are closed off by partitions that extend between the manifold member and the cylindrical body of the receiver/dryer portion. Internally of the manifold chamber, an additional partition is provided to divide the manifold chamber into an upper part and a lower part. The lower part generally corresponding with the lower part of the other header. The receiver/dryer portion is further in fluid communication with the manifold portion by the formation of apertures in a generally lower end of the cylindrical body forming the receiver/dryer portion. Preferably, two apertures are provided for this communication, one being located above the partition dividing the manifold chamber into two parts and the other aperture being located below that partition. 
     Located within the receiver/dryer chamber is a dryer. The dryer includes dryer particulate or granulate located within a containment medium such as a permeable bag. When in contact with the liquid portion of the refrigerant being separated from the gaseous portion of the refrigerant, within the receiver/dryer portion, the particulate will remove any water that has become intermixed with the refrigerant fluid. 
     Prior to exiting the receiver/dryer portion, the refrigerant passes through a screen which operates to filter and remove contaminants from that fluid. This filter is incorporated into a spacer that also maintains the dryer a distance above the outlet of the receiver/dryer portion. 
     In preferred embodiments of the invention, the cross sectional profile of the cylindrical member of the receiver/dryer portion is round, as is the cross sectional profile of the cylindrical member of the inlet/outlet header. The cross sectional shape of the manifold member is preferably semicircular. This semicircular shape may be along a center portion of the cross section of the manifold with semicircular flanges extending therefrom so as to enable securement of the manifold member to the cylindrical body. 
     Other objects and advantages of the present invention will become apparent to those skilled in the technology to which the invention relates, upon a review of the detailed description, and drawings taken in conjunction with the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrate a vertical section through a condenser assembly according to the principles of the present invention; 
     FIG. 2 is an enlarged view of that portion circumscribed by circle  2 — 2  in FIG. 1; 
     FIGS. 3A and 3B are alternate cross sectional views generally taken along line  3 — 3  in FIG. 2; 
     FIG. 3C is a cross sectional view across the receiver/dryer header illustrating a partition used therewith; 
     FIG. 4 is a perspective view of the spacer utilized in the receiver/dryer portion of the present invention; and 
     FIG. 5 is perspective view of an optional filter of an optional filter that may be utilized in the outlet of a condenser assembly according to the principles of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, partially illustrated in FIG.  1  and designated at  10  is a condenser assembly embodying the principals of the present invention. The condenser assembly  10  has as its principal components a core  12  and a pair of headers  14  and  16 . The headers  14  and  16  are located at opposing ends of the core  12 , as further mentioned below. 
     The core  12  is generally seen as a tube stack comprising a series of parallel and vertically stacked tubes  18 . Adjacent tubes  18  are spaced apart from one another such that a space  20  is located therebetween. The tubes  18  themselves may be of any construction now known in the industry or developed in the future. In one preferred embodiment, the tubes are generally flat and include portions defining one or more flow channels longitudinally through the tube. 
     Located within the space  20  between each adjacent tube  18  is a fin  22 . The fins  22  exhibit a generally corrugated shape comprising a series of convolutes as is commonly known in the industry. The fins  22  generally extend completely across the space  20  contacting both the tube located thereabove and therebelow. In the figures, the details of the shape of the fins  22  are not illustrated in significant detail since those skilled in this technology will readily appreciate such a construction. Additionally, the fins  22  are preferably provided with a series of louvers on each corrugation in order to aid in the heat transfer efficiency from the tubes, to the fins and to the air passing therethrough. The fins  22  are provided in such a manner that the overall length of the tubes  18  is greater than the overall length of the fins  22  and that the ends  24  and  26  of the tubes  18  extend beyond the end of the fins  22 . These ends  24 ,  26  of the tubes are respectively received within the headers  14  and  16  and, as further discussed below, are in fluid communication with the headers  14 ,  16 . 
     The header  14  (hereinafter the “inlet/outlet header” or “I/O header” is generally seen on the left-hand side of FIG.  1 . The I/O header  14  is constructed of a cylindrical body or member  28  that has a constant cross-sectional profile, round in the preferred embodiment, over its length. The top and bottom ends  30 ,  32  of the cylindrical body  28  are respectively engaged and closed by top and bottom caps  34 ,  36 . The caps  34 ,  36  and the cylindrical body  28  therefore cooperate to define a chamber or cavity  38  within the I/O header  14 . One or more partitions  40  may be located within the cylindrical body  28  so as to divide the cavity  38  into an upper portion  42  and a lower portion  44 , the latter of which is sometimes referred to as a super cooling region. One or more additional partitions  46  may be provided in the upper portion  42  so as to further divide that portion into sections or parts not directly in fluid communication with each other. 
     Defined in the upper portion  42  of the I/O header  14  is an inlet aperture  48  that communicates with an inlet bore  50  defined in an inlet block  52 . Similarly, an outlet aperture  54  is defined in the lower portion  44  of the I/O header  14  and is in communication with an outlet bore  56  defined in an outlet block  58  mounted to the cylindrical body  28  of the I/O header  14 . Obviously, from the above description, refrigerant enters into the condenser assembly  10  via the inlet block  52  and exits from the condenser assembly  10  through the outlet block  58 . 
     Located with in the outlet bore  56  of the outlet block  58  is an additional filter means  136 . This filter  136  is seen in FIG.  6 . Generally, this filter is of a tapered or wedge shape and is inserted into the outlet block  58  such that the narrower portion of the wedge is located in the upstream position. The filter  136  includes a base ring  138  from which extends a generally U-shaped support  140 . Opposing sides of the support  140  are provided with a screen or mesh material  142 . The filter  136  may be removeably retained within the outlet block  58  by mechanical interaction between the portions of the outlet block  58  and the annular base  138  of the filter  136 . 
     In order for the cavity  38  of the I/O header  14  to fluidly communicate with the tubes  18 , the end  24  of each tube  18  is received through a tube aperture  60  defined in one side of the cylindrical body  28 . 
     The remaining header  16  of the condenser assembly  10  is generally illustrated on the right hand side of FIG.  1 . This header  16  is hereinafter referred to as the “receiver/dryer header” or “R/D header”. In certain respects, the R/D header  16  is constructed in a manner similar to the I/O header  14 . However, the R/D header  16  itself is an integrated structure made up of two portions, a manifold portion  61  and a receiver/dryer portion  62 . These portions  61 ,  62  will now be discussed. 
     The R/D header  16  is constructed with a cylindrical body or member  63  having its top and bottom ends respectively closed by top and bottom caps  68 ,  70 . As such, the top and bottom caps  68 ,  70  cooperate with the cylindrical body  63  to define a cavity  72  within the R/D header  16 . Along its length the cylindrical body  63  exhibits a constant cross-sectional profile (see FIGS.  3 A and  3 B), which, in the preferred embodiment, is round. 
     The manifold portion  61  of the R/D header  16  is defined in part by the exterior surface of the cylindrical body  63  mentioned above and in part by a manifold member  74  coupled to the cylindrical body  63 . The manifold member  74  has a cross-sectional profile which is constant along its length and is also seen in FIGS. 3A and 3B. This profile, in the preferred embodiment, includes a semicircular, central portion  76  having flanges  78  extending from the ends thereof. The flanges  78  are provided with a radius of curvature corresponding with the exterior surface of the cylindrical body  63  so as to assist in securing the manifold member  74  to the cylindrical body  63  after brazing of the assembled condenser assembly  10 . Prior brazing, the manifold member  74  may be retained to the cylindrical body  63  by tack welding or mechanically interacting structures, such as tabs extending beyond the flanges  78  and engaging dimples formed on the cylindrical body  63 . Constructed as such, the manifold member  74  cooperates with the cylindrical body  63  to define a manifold chamber  80  therebetween. The opposing ends of the manifold chamber  80  are closed off by top and bottom partitions  82 ,  84  extending between the manifold member  74  and the cylindrical body  63 . 
     Within the chamber  80 , an intermediate partition  86  is provided so as to divide the chamber  80  into an upper portion  88  and a lower portion  90 . The lower portion  90  corresponding to the lower portion  44  of the I/O header  14 . 
     Referring now to FIG. 3C, a cross-sectional view taken through the R/D header  16  immediately below the intermediate partition  86 , and looking upward, is illustrated therein. From this view, the shape of the intermediate partition  86  may be discerned. As seen therein, the intermediate partition  86  is provided with various features enabling it to interact with the manifold portion  72  and to facilitate the formation of a fluid tight seal between the partition  86 , the manifold member  74  and the cylindrical body  63  when the condenser assembly  10  is brazed. Generally, the partition  86  includes a central portion  87  having an arcuate outer surface  89  and an arcuate inner surface  91 . The radius of curvature of the outer surface  89  corresponds with the radius of curvature defined by the interior surface of the central portion  76  of the manifold member  74 . The inner surface  91  exhibits a radius at curvature corresponding with the radius of curvature defined by the exterior surface of the cylindrical body  63 . As mentioned above, the partition  86  is provided with various tabs. Two of these tabs are herein referred to lateral tabs  93 . The lateral tabs  93  are located generally on opposing ends of the partition  86  where the inner surface  91  would otherwise have intersected with the outer surface  89 , but for the presence of the lateral tabs  93 . The tabs themselves define an extension of the inner surface  91  on their inner sides and are provided with shoulders  95  on their outer sides. The shoulders  95  define a recess  97 . A slot  99  is defined in the manifold member  74  permitting the lateral tabs  93  to extend therethrough. As such, the portions defining the slot  99  are received within the recess  97  defined by the shoulders  95  of the lateral tabs  93 . The final tab  101  of the partition  86  extends outward from the outer surface  89  of the partition  86  and extends into a slot  103  defined in the manifold member  74 . It is generally centered on the outer surface  89  between the lateral tabs  93 . Provided with these features, partition  86  is readily located in the manifold member  74  and the cylindrical body  63 . When brazed therewith, a fluid tight seal is formed between these three components. 
     While the partition  86  has been described with some particularity, it should be readily understood that alternate configurations for the various tabs as well as the location of the tabs will be readily apparent based on the above. Additionally, it is noted that the top and bottom partitions  82  and  84 , and additional partition  94 , are preferably provided with the same construction as partition  86 . 
     Unlike the I/O header  14 , refrigerant enters and exits the R/D header  16  by way of the tubes  18 . The tubes  18  themselves extend into the chamber  80  passing through tube apertures  92  defined in one side of the manifold member  74 . The upper portion  88  of the chamber  80  introduces the refrigerant and may further be divided by an additional partition  94  into two parts not directly in fluid communication with one another. As a result of the various partitions  40 ,  46 ,  86 ,  94  during use, refrigerant is caused to pass multiple times through the tubes in a generally serpentine manner until exiting the condenser assembly  10 . 
     As seen in FIGS. 1 and 2, the cavity  72  and the chamber  80  of the R/D header  16  are in fluid communication with one another. To provide for this communication, an upper aperture  96  and a lower aperture  98  are respectively provided in the cylindrical body  63  at locations respectively above and below the location of the intermediate partition  86 . The upper aperture  96  operates as the inlet into the cavity  72 . The lower aperture  98  therefore operates as the outlet from the cavity  72 . 
     As indicated from the discussion above, the cavity  72  of the R/D header  16  operates as the receiver/dryer chamber for the condenser assembly  10 . To achieve this purpose, a dryer  100  is located within the-cavity  72  so as to be in contact with at least the liquid portion of the refrigerant contained therein. The dryer  100  may be one of a variety of known constructions whereby particulate or granular dryer material  102 , such as desiccant, comes in contact with the liquid refrigerant. In the illustrated embodiment of FIG. 2, the particulate  102  is contained within a bag  104  constructed of permeable material, such as fabric. The upper and lower ends  106 ,  108  of the bag  104  are closed off to contain the particulate  102  therein. 
     The bag  100  is further located within the cavity  72  so as to be vertically spaced above the lower aperture  98  in the lower most end of the R/D portion  62 . This is achieved by also providing within the cavity  72  a spacer  110 . 
     As seen in FIG. 4, the spacer  110  is generally cylindrical and includes and upper rim  112  and a lower rim  114 . A cross bar  116  extends diametrically across the upper rim  112 . The cross bar  116 , in combination with the upper rim  112 , supports the dryer  100  within the R/D portion  62 . Between the upper rim  112  and the lower rim  114  is a mesh  18 . Because of the positioning of the spacer  110  within the chamber  117 , refrigerant flowing to the lower aperture  98  passes, first, around the cross bar  116  and, then, into the central portion of the spacer  110 . Refrigerant then flows outward of the spacer  110  passing through the mesh  118 . The mesh  118  therefore operates as a filter for inappropriate materials within the refrigerant. In addition to the mesh  118 , a series of vertical posts  120 , which operate to provide additional structural integrity, extend between the upper and lower rims  112 ,  114 . 
     Within the cavity  72 , the spacer  110  is captured between a retention flange  122 , located on the interior of the cylindrical body  63  immediately above the lower aperture  98 , and the bottom cap  70 . 
     While one piece constructions may be used, the bottom cap  70  is preferably provided with a two piece construction and includes a collar  124  in contact with the bottom end  66  of the cylindrical body  63  and a plug  126 . Engagement between the plug  126  and the collar  124  is provided as a threaded engagement  128 . Accordingly, internal threads are provided on the collar  124  and matching external threads are provided on the plug  126 . In order to ensure a liquid tight seal between the collar  124  and plug  126 , a O-ring  130  may be provided within a groove  132  formed in the plug  126 . In this manner, should the dryer  100  need to be replaced during the useful life of the vehicle or should the mesh  118  at the screen  110  need to be cleaned,.the plug  126  may be disengaged from the collar  124 , the spacer  110  removed from within the cavity  72  and the dryer  100  withdrawn thereout and replaced. 
     As mentioned in the background section above, one problem with prior condenser assembly constructions is that, should the need arise to vary the volumetric requirement and therefore the size of the condenser assembly, prior constructions were expensive and required substantial retooling on the part of the condenser manufacturer. With the present invention, the expense and time required for tooling changes is minimized. This is achieved from due to the major components of the condenser assembly  10  being constructed such that the principle change required in the components (in order to achieve volumetric changes within the condenser assembly  10 ) is to vary the length of the components. These components include the cylindrical body  28  of the I/O header  14 , the cylindrical body  63  and the manifold member  74  of the R/D header  16 . The various partitions, end caps and other components would remain the same and therefore no additional tooling changes, as a result of those components, would be necessitated. The construction is further such that the location of the various partitions and apertures permitting fluid communication between the cavities and chambers defined by the principle components may be readily relocated without substantial cost. 
     Another advantage of the construction of the present invention is that while the tubes  18  may be aligned with the central axis  134  extending through the cylindrical body  63  of the R/D portion  62 , the present invention permits a canted or off-center construction as seen in FIG.  3 B. The canted construction of FIG. 3B may prove advantageous in certain situations where packaging needs to be minimized. 
     It should be apparent to those skilled in the art that the above-described embodiments are merely illustrative of but a few of the many possible specific embodiments of the present invention. Numerous and various other arrangements can be readily devised by those skilled in the art without departing from the spirit and scope of the invention as defined in the following claims.