[0001] The present invention relates to a heat exchanger using micro-channel tubes, and
more particularly to a structure of a heat exchanger using micro-channel tubes, which
is applied to an evaporator of a household air conditioner.
[0002] Generally, a heat exchanger using micro channel tubes is a heat exchanger, in which
refrigerant flows along a plurality of tubes having a diameter of less than several
mm. Such a heat exchanger is widely used by a condenser of a vehicle air conditioner.
[0003] Korean Patent Publication No. 1996-0009342 discloses a structure of a heat exchanger
using micro-channel tubes. Hereinafter, with reference to FIG. 1, the heat exchanger
using micro-channel tubes will be described.
[0004] The heat exchanger using the micro-channel tubes comprises a plurality of tubes 1
laid in a horizontal direction. The tubes 1 are vertically arranged, and corrugated
pins 2 are interposed between the tubes 1. Headers 3 and 4 for distributing refrigerant
into the tubes 1 or for collecting the refrigerant from the tubes 1 are placed at
both ends of the tubes 1. The headers 3 and 4 are made of an aluminum rod member having
a circular cross-section, and placed perpendicularly at both ends of the tubes 1.
The tubes 1 communicate with the headers 3 and 4, and separators 10 and 11 for dividing
the tubes 1 into several channel groups A, B, and C are installed in the headers 3
and 4.
[0005] The plural tubes 1 are divided into an inlet-side channel group A, through which
the refrigerant enters to the evaporator, an outlet-side channel group C, through
which the refrigerant is discharged from the evaporator, and an intermediate channel
group B.
[0006] With reference to FIG. 2, the overall flow of the refrigerant in the heat exchanger
is described. The refrigerant flows along all of the tubes 1 of each of the channel
groups A, B, and C in one direction, and then flows along the tubes 1 of the next
groups B and C. That is, the refrigerant, having entered into the tubes 1 through
a refrigerant inlet 6, is uniformly distributed into all of the tubes 1 of the inlet-side
channel group A, and flows toward the upper portion of the right header 4 above the
separator 11. In the upper portion of the right header 4 above the separator 11, the
inlet-side channel group A and the intermediate channel group B communicate with each
other, the entered refrigerant flows toward the intermediate channel group B and is
transmitted to the lower portion of the left header 3 below the separator 10. Then,
the refrigerant, having been transmitted to the left header 3 through the intermediate
channel group B, enters into the lower portion of the right header 4 below the separator
11 through the outlet-side channel group C, and is discharged to the outside through
a refrigerant outlet 8.
[0007] Here, non-described reference numerals 7 and 9 represent caps for closing the ends
of the headers 3 and 4, and non-described reference numerals 13 and 14 represent side
plates placed on the outer surfaces of the outermost corrugated pins 2.
[0008] In the above-described heat exchanger using micro-channel tubes, the refrigerant
in a gaseous state, having entered into the heat exchanger through the refrigerant
inlet 6, flows in each of the tubes 1 from the inlet-side channel group A to the outlet-side
channel group C, exchanges heat with air in the tubes 1 to be condensed to a liquid
state, and the refrigerant in the liquid state is discharged to the outside through
the refrigerant outlet 8.
[0009] The heat exchanger using micro-channel tubes is called various names, i.e., an aluminum
heat exchanger due to the material thereof, a flat tube-type heat exchanger due to
the shape of the tubes thereof, and a PFC (parallel flow condenser) due to the flow
of the refrigerant.
[0010] The heat exchanger using micro-channel tubes is advantageous in that it has heat
transfer efficiency higher than that of a pin tube-type heat exchanger, and is miniaturized.
However, the heat exchanger using micro-channel tubes cannot be used as an evaporator
of a household air conditioner due to several problems, as follows.
[0011] Since the evaporator exchanges heat with air of a high temperature rather than air
of the temperature thereof, moisture in air is condensed and condensation of water
occurs on the surface of the evaporator. In the conventional heat exchanger using
micro-channel tubes, which comprises the tubes laid in the horizontal direction, the
condensed water formed on the surface of the heat exchanger is gathered in hollow
portions of the corrugated pins between the tubes, thus decreasing heat exchanging
efficiency.
[0012] While the flow rate of air around the vehicle condenser is comparatively rapid, such
as 3~4 m/s, the flow rate of air around the evaporator of the household air conditioner
is comparatively slow, such as 0.5~1.5 m/s, thus reducing a heat transfer rate per
unit hour. Accordingly, the conventional heat exchanger using micro-channel tubes
requires a large heat transfer area.
[0013] While the flow of the refrigerant, flowing in the heat exchanger, from the entrance
of the refrigerant into the upper portion of one header to the discharge of the refrigerant
from the lower portion of the other header, has an S shape, the refrigerant, flowing
in the condenser, is condensed from a gaseous state to a liquid state, thus naturally
having an S-shaped flow. As shown in FIG. 2, the number of the tubes 1 of the outlet-side
channel group C is smaller than the number of the tubes of the inlet-side channel
group A due to the phase change of the refrigerant, thus minimizing pressure loss
in the heat exchanger. However, since the refrigerant flowing in the evaporator is
vaporized from the liquid state to the gaseous state, it is difficult to apply the
channel structure of the condenser to the evaporator.
[0014] In spite of the above problems, several methods have been proposed for applying the
heat exchanger using micro-channel tubes to an evaporator of a household air conditioner.
[0015] Korean Patent Laid-open No. 2003-0063980 discloses a heat exchanger, in which headers
are erected horizontally and micro-channel tubes are laid perpendicularly between
the headers. Drain holes and line grooves for facilitating the discharge of condensed
water are formed in the heat exchanger. Korean Patent Laid-open Nos. 2004-0017447,
2004-0017449, 2004-0017920, and 2004-0019628 disclose structures of heat exchangers
for facilitating the discharge of condensed water under the condition that headers
and micro-channel tubes are disposed in the same manner as that of the preceding Patent.
[0016] As disclosed by the above Patents, an evaporator, in which the headers are erected
horizontally and the micro-channel tubes are laid perpendicularly between the headers,
may discharge a sufficient quantity of the condensed water, but has disadvantages,
such as a small heat transfer area and a difficulty in achieving uniform flow of the
refrigerant.
[0017] Since the refrigerant at an inlet of the evaporator is in a two-phase state, the
refrigerant, which enters into the header of the evaporator, cannot be uniformly distributed
to the respective tubes due to the difference of speeds of flow between the gaseous
phase and the liquid phase. Particularly, the transmission of the refrigerant from
one channel group to another channel group is performed in one header, thus accelerating
the above problems.
[0018] The present invention provides an evaporator of a household air conditioner using
compact micro-channel tubes having a high heat transfer efficiency.
[0019] The present invention provides an evaporator of a household air conditioner uses
micro-channel tubes, from which condensed water is easily discharged, and into which
refrigerant is uniformly distributed.
[0020] In one aspect of the present invention, an evaporator uses micro-channel tubes and
comprises a plurality of heat exchanging units, each heat exchanging unit including
a plurality of the micro-channel tubes installed between a pair of non-integral headers,
and an integral header for transmitting refrigerant between the neighboring heat exchanging
units.
[0021] The headers of each of the heat exchanging units may be laid horizontally, and the
micro-channel tubes may be erected vertically.
[0022] The integral header may be divided into a header unit for one heat exchanging unit
and a header unit for the other heat exchanging unit, and may include a partition
having openings for communicating the refrigerant between the two header units.
[0023] Each of the headers may be divided by a plurality of separators so that the micro-channel
tubes of each of the heat exchanging units form a plurality of channel groups.
[0024] The channel groups of one heat exchanging unit may be connected to the channel groups
of the neighboring heat exchanging unit; and a plurality of refrigerant circuits may
be formed by the connection between the channel groups of the heat exchanging units.
[0025] The cross-sectional areas of flow channels of a downstream channel group may be greater
than or equal to those of flow channels of an upstream channel group.
[0026] The flow directions of the neighboring refrigerant circuits may be opposite to each
other.
[0027] In another aspect of the present invention, an evaporator uses micro-channel tubes
and comprises a first heat exchanging unit including a plurality of the micro-channel
tubes installed between a pair of upper and lower headers laid horizontally, and a
second heat exchanging unit, installed adjacent to the first heat exchanging unit,
including a plurality of the micro-channel tubes installed between a pair of upper
and lower headers laid horizontally, wherein the upper header of the first heat exchanging
unit and the upper header of the second heat exchanging unit are formed integrally
with each other, thus producing one integral upper header, and wherein the lower header
of the first heat exchanging unit and the lower header of the second heat exchanging
unit are non-integral headers.
[0028] The integral upper header may include a base, to which the micro-channel tubes of
the first and second heat exchanging units are bonded, a cover forming a closed space
together with the base, and a partition, to divide the closed space, formed by the
base and the cover, into a first upper header unit for the first heat exchanging unit
and a second upper header unit for the second heat exchanging unit, and including
openings for communicating refrigerant between the first and second upper header units.
[0029] Each of the integral upper header and the lower headers of the first and second heat
exchanging units may be divided by a plurality of separators so that the micro-channel
tubes of each of the first and second heat exchanging units form a plurality of channel
groups.
[0030] One channel group of one heat exchanging unit may be connected to the one channel
group of the neighboring heat exchanging unit; and a plurality of refrigerant circuits
may be formed by the connection between the channel groups of the heat exchanging
units.
[0031] The cross-sectional areas of flow channels of a channel group located at an inlet
of each of the refrigerant circuits, through which the refrigerant enters into the
evaporator, may be smaller than or equal to the cross-sectional areas of flow channels
of a channel group located at an outlet of the refrigerant circuit, through which
the refrigerant is discharged to the outside.
[0032] Additional aspects and/or advantages of the invention will be set forth in part in
the description which follows and, in part, will be obvious from the description,
or may be learned by practice of the invention.
[0033] These and/or other aspects and advantages of the invention will become apparent and
more readily appreciated from the following description of the embodiments, taken
in conjunction with the accompanying drawings of which:
FIG. 1 is a front view of a conventional heat exchanger using micro-channel tubes;
FIG. 2 is a schematic view illustrating the flow of refrigerant in the heat exchanger
of FIG. 1;
FIG. 3 is an exploded perspective view of an evaporator using micro-channel tubes
in accordance with a preferred embodiment of the present invention;
FIG. 4 is an exploded perspective view of an upper header of the evaporator of FIG.
3;
FIG. 5 is a perspective view of a lower header of the evaporator of FIG. 3;
FIG. 6 is a plan view illustrating the flow of refrigerant in the upper header of
the evaporator of FIG. 3;
FIG. 7 is a top view of the evaporator of FIG. 3;
FIG. 8 is a schematic view illustrating the flow of refrigerant in the evaporator
of FIG. 3;
FIGS. 9a and 9b are plan views illustrating the flow of refrigerant in upper headers
of evaporators in accordance with other embodiments of the present invention; and
FIGS. 10a, 10b, and 10c are front views illustrating structures of a partition of
the upper header of the evaporator using micro-channel tubes in accordance with a
preferred embodiment of the present invention.
[0034] Reference will now be made in detail to the embodiments of the present invention,
examples of which are illustrated in the accompanying drawings, wherein like reference
numerals refer to the like elements throughout. The embodiments are described below
to explain the present invention by referring to the figures.
[0035] As shown in FIG. 3, an evaporator using micro-channel tubes in accordance with a
preferred embodiment of the present invention comprises two heat exchanging units
20 and 30, each of which includes a plurality of micro-channel tubes 43 vertically
erected between a pair of headers laid horizontally. Hereinafter, the heat exchanging
unit, which is placed at the front position, is referred to as a first heat exchanging
unit 20, and the heat exchanging unit, which is placed at the rear position, is referred
to as a second heat exchanging unit 30.
[0036] An integral upper header 50 is placed on the upper surfaces of the first heat exchanging
unit 20 and the second heat exchanging unit 30, thus transmitting refrigerant between
the first and second heat exchanging units 20 and 30.
[0037] As shown in FIG. 4, the upper header 50 includes base 53 provided with a plurality
of longitudinal holes 58 formed therethrough perpendicularly to the longitudinal direction
of the base 53, a cover 54 having an arc-shaped cross section placed above the upper
surface of the base 53 for forming a closed space together with the base 53, a partition
55 for dividing the space formed by the base 53 and the cover 54, in the longitudinal
direction of the base 53, into a first upper header unit 51 forming a part of the
first heat exchanging unit 20 and a second upper header unit 52 forming a part of
the second heat exchanging unit 30, and separators 57 for dividing each of the first
upper header unit 51 and the second upper header unit 52 into plural portions. Openings
56 for transmitting refrigerant between the first and second heat exchanging units
20 and 30 therethrough are formed through the partition 55.
[0038] A plurality of micro-channel tubes (hereinafter, abbreviated to 'tubes') 43, which
are erected vertically, are connected to the lower part of the upper header 50. Upper
ends of the tubes 43 are bonded to the upper header 50 under the condition that designated
lengths of the upper ends of the tubes 43 are inserted into the longitudinal holes
58. The insides of the tubes 43 are divided into plural portions so as to form fine
channels. Since the cross-sections of the tubes 43 are similar to the structure of
a harmonica, the tubes 43 are referred to as harmonica tubes.
[0039] Corrugated pins 44 are intercalated between the micro-channel tubes 43. Preferably,
louvers 44a are formed on the corrugated pins 44 for facilitating heat transfer.
[0040] Generally, when the evaporator is installed, the surface of the evaporator is perpendicular
to the flow direction of air. As shown in FIG. 4, water condensed on the surface of
the evaporator flows down along the surfaces of the tubes 43, which are erected vertically,
by its own weight. Water condensed on the corrugated pins 44 flows down by the gradient
of the corrugated pins 44, and then flows down along the surfaces of the tubes 43
or flows down again along the corrugated pins 44 at contacts between the corrugated
pins 44 and the tubes 43.
[0041] A first lower header 22 is placed below the tubes 43 of the first heat exchanging
unit 20, and a second lower header 32 is placed below the tubes 43 of the second heat
exchanging unit 30.
[0042] As shown in FIG. 5, the first lower header 22 is made of an aluminum pipe having
a circular cross-section. Since the inside of the first lower header 22 is divided
into plural portions by a plurality of separators 23, it is possible to cut off the
flow of the refrigerant between the neighboring portions of the inside of the first
lower header 22. A plurality of longitudinal holes 24 are formed through the upper
surface of the first lower header 22 such that the longitudinal holes 24 are perpendicular
to the longitudinal direction of the first lower header 22, and the lower ends of
the tubes 43 are bonded to the first lower header 22 under the condition that designated
lengths of the lower ends of the tubes 43 are inserted into the longitudinal holes
43. The second lower header 32 has the same structure as that of the first lower header
22.
[0043] Inlet pipes 45, for inhaling the refrigerant, having passed through an expansion
valve (not shown) of the conventional refrigerating cycle, into the evaporator, and
outlet pipes 46, for discharging the refrigerant, having vaporized by the evaporator,
to the outside of the evaporator, are connected to the lower parts of the first lower
header 22 and the second lower header 32. The refrigerants discharged from the outlet
pipes 46 are gathered in a collecting manifold 47 connected to the lower ends of the
outlet pipes 46, and transmitted to a compressor (not shown) (with reference to FIG.
7).
[0044] Hereinafter, with reference to FIG. 8, the flow of the refrigerant in the evaporator
using the micro-channel tubes with reference to the above embodiment of the present
invention will be described.
[0045] An upper portion of FIG. 8 illustrates the flow of the refrigerant in the second
heat exchanging unit 30, a lower portion of FIG. 8 illustrates the flow of the refrigerant
in the first heat exchanging unit 20, and a middle portion of FIG. 8 illustrates the
flow of the refrigerant in the upper header 50.
[0046] As described above, the inside of each of the upper header 50 and the first and second
lower headers 22 and 32 is divided into several portions by a plurality of the corresponding
separators 57, 23, or 33. In the evaporator in this embodiment, the inside of each
of the upper header 50 and the first and second lower headers 22 and 32 is divided
into four portions, and the four portions have different sizes so as to form the flow
of the refrigerant as shown in FIG. 8.
[0047] In FIG. 8, a left portion 32a of the second lower header 32 and a left portion 52a
of the second upper header unit 52 have the same size, and the tubes 43, which are
installed between the left portion 32a of the second lower header 32 and the left
portion 52a of the second upper header unit 52, form one channel group G1. The remaining
portions 32b, 32c, and 32d of the second lower header 32 and the corresponding remaining
portions of 52b, 52c, and 52d of the second upper header unit 52 respectively have
the same sizes, so as to form channel groups G2, G3, and G4. In the same manner as
the second lower header 32 and the second upper header unit 52, the first upper header
unit 51 is divided into four portions 51a, 51b, 51c, and 51d, and the first lower
header 22 is divided into four portions 22a, 22b, 22c, and 22d, so as to form channel
groups G5, G6, G7, and G8 in order.
[0048] The number of the tubes 43 of any one of the channel groups G1, G3, G6, and G8 is
smaller than that of the tubes 43 of any one of the channel groups G2, G4, G5, and
G7. The above difference of numbers of the tubes 43 among the channel groups G1, G2,
G3, G4, G5, G6, G7, and G8 reduces the decrease in the pressure of the refrigerant
in the evaporator in consideration of the expanded volume of the refrigerant when
the refrigerant is vaporized in the evaporator.
[0049] The inlet pipe 45 is connected to the portion 32a of the second lower header 32 connected
to the channel group G1. The refrigerant, having entered into the second lower header
32 through the inlet pipe 45, is distributed at the portion 32a into the tubes 43
of the channel group G1. The divided parts of the refrigerant flowing along the tubes
43 of the channel group G1 are collected at the portion 52a of the second upper header
unit 52, and the collected refrigerant is transmitted to the portion 51a of the first
upper header unit 51 through the opening 56 of the partition 51. The refrigerant is
divided again into the tubes 43 of the channel group G5 and transmitted to the portion
22a of the first lower header 22. The refrigerant at the portion 22a of the first
lower header 22 is discharged to the outside through the outlet pipe 46 connected
to the portion 22a.
[0050] When the refrigerant passes through the channel groups G1 and G5, the refrigerant
is vaporized by exchanging heat with peripheral air. The channel group G1, through
which the refrigerant enters to the evaporator, is an inlet-side channel group, and
the channel group G5, through which the refrigerant is discharged from the evaporator,
is an outlet-side channel group. The route of the refrigerant from one inlet pipe
45 to the opposite outlet pipe 46 is referred to as a refrigerant circuit. In the
same manner as the channel groups G1 and G5, the channel groups G3, G6, and G8 are
inlet-side channel groups, and the channel groups G2, G4, and G7 are outlet-side channel
groups, thus forming three refrigerant circuits. Accordingly, a total of four refrigerant
circuits is formed in the evaporator, and the flow directions of the refrigerant of
the neighboring refrigerant circuits are opposite to each other. The flow directions
are designed in consideration of the difference of the numbers of the tubes 43 among
the channel groups G1, G2, G3, G4, G5, G6, G7, and G8.
[0051] As described above, the number of the tubes 43 of any one of the channel groups G1,
G3, G6, and G8 is smaller than that of the tubes 43 of any one of the channel groups
G2, G4, G5, and G7. The above difference of numbers of the tubes 43 among the channel
groups G1, G2, G3, G4, G5, G6, G7, and G8 denotes that the cross sectional areas of
flow channels of the outlet-side channel groups G2, G4, G5, and G7 are greater than
those of the flow channels of the inlet-side channel groups G1, G3, G6, and G8. Since
the evaporator receives the refrigerant in a liquid state and discharges the refrigerant
in a gaseous state, the evaporator generally has the above-described structure to
reduce the decrease of the pressure in the evaporator.
[0052] When the refrigerant is transmitted from one channel group to the next channel group
in a conventional evaporator, since the refrigerant flows in the header and is distributed
into the tubes 43, it is difficult to uniformly distribute the refrigerant. In the
evaporator in accordance with this embodiment, since the refrigerant is transmitted
through the opening 56 formed through the partition 55 of the upper header 50, the
refrigerant may be uniformly distributed (with reference to FIG. 6).
[0053] FIGs. 9a and 9b illustrate internal structures of integral upper headers of evaporators
in accordance with other embodiments of the present invention. In the same manner
as the evaporator in accordance with the preceding embodiment, each of the evaporators
in accordance with other embodiments comprises two heat exchanging units. However,
each of the evaporators has a refrigerant channel structure differing from that of
the evaporator of the preceding embodiment. The evaporator of the embodiment shown
in FIG. 9a has a total of three refrigerant circuits. Each of a first upper header
unit 61 and a second upper header unit 62 of an upper header 60 is divided into three
portions by two separators 63. In the same manner as that of the evaporator of the
preceding embodiment, the cross sectional areas of the flow channels of outlet-side
channel groups are greater than the cross sectional areas of the flow channels of
the inlet-side channel groups. The transmission of the refrigerant between the heat
exchanging units is achieved through openings of a partition 64 of the upper header
60, and the flow directions of the refrigerant of the neighboring refrigerant circuits
are opposite to each other, as shown by the arrows. The evaporator of the embodiment
shown in FIG. 9b has a total of two refrigerant circuits. Each of a first upper header
unit 71 and a second upper header unit 72 of an upper header 70 is divided into two
portions by one separator 73, the cross sectional areas of the flow channels of outlet-side
channel groups are greater than those of the flow channels of inlet-side channel groups,
and the flow directions of the refrigerant of the neighboring refrigerant circuits
are opposite to each other, as shown by the arrows.
[0054] FIGS. 10a, 10b, and 10c illustrate various modifications of shapes, sizes, and positions
of openings formed through the partition of the upper header. A partition 81 as shown
in FIG. 10a includes circular-shaped openings 82, a partition 83 as shown in FIG.
10b includes an opening 84 formed through the upper part thereof, and a partition
85 as shown in FIG. 10c includes an opening 86 formed through the whole part thereof.
[0055] The headers, the tubes, and the corrugated pins of the above evaporator using micro-channel
tubes are made of aluminum material, and manufactured by a furnace brazing process.
[0056] As apparent from the above description, the present invention provides an evaporator
using micro-channel tubes, which has a small size and a high efficiency, thus being
capable of miniaturizing a household air conditioner.
[0057] The evaporator of the present invention comprises a plurality of heat exchanging
units, thus having a sufficient heat transfer area.
[0058] The evaporator of the present invention uniformly distributes refrigerant in the
installed direction thereof and the upper header to transmit the refrigerant between
the heat exchanging units.
[0059] The evaporator of the present invention easily discharges condensed water by the
installed direction thereof.
[0060] Although a few preferred embodiments have been shown and described, it will be appreciated
by those skilled in the art that various changes and modifications might be made without
departing from the scope of the invention, as defined in the appended claims.
[0061] Attention is directed to all papers and documents which are filed concurrently with
or previous to this specification in connection with this application and which are
open to public inspection with this specification, and the contents of all such papers
and documents are incorporated herein by reference.
[0062] All of the features disclosed in this specification (including any accompanying claims,
abstract and drawings), and/or all of the steps of any method or process so disclosed,
may be combined in any combination, except combinations where at least some of such
features and/or steps are mutually exclusive.
[0063] Each feature disclosed in this specification (including any accompanying claims,
abstract and drawings) may be replaced by alternative features serving the same, equivalent
or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated
otherwise, each feature disclosed is one example only of a generic series of equivalent
or similar features.
[0064] The invention is not restricted to the details of the foregoing embodiment(s). The
invention extends to any novel one, or any novel combination, of the features disclosed
in this specification (including any accompanying claims, abstract and drawings),
or to any novel one, or any novel combination, of the steps of any method or process
so disclosed.