Evaporator coil insert
11009271 · 2021-05-18
Assignee
Inventors
Cpc classification
F25B39/028
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2500/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2500/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B39/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F1/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2500/09
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F1/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2500/05
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
In one embodiment, an apparatus includes an insert for an evaporator coil. The insert is located within the evaporator coil. The insert for the evaporator coil reduces refrigerant charge in the evaporator coil and causes refrigerant flowing through the evaporator coil to change direction. The insert for the evaporator coil includes a solid core and a plurality of support legs.
Claims
1. An apparatus, comprising: an insert for an evaporator coil, wherein the insert comprises a solid core and a plurality of support legs, wherein the cross-sectional shape of the solid core is non-circular; wherein: the insert is located within the evaporator coil; the insert reduces refrigerant charge in the evaporator coil by reducing a volume of refrigerant within the evaporator coil; and the insert causes refrigerant flowing through the evaporator coil to change direction; the solid core comprises a first end upstream of the insert and a second end opposite to the first end downstream of the insert; a first area of the solid core at the first end is greater than a second area of the solid core at the second end.
2. The apparatus of claim 1, wherein: each support leg of the plurality of support legs is attached to a side or a corner of the solid core; each support leg of the plurality of support legs contacts an inner surface of the evaporator coil; and the solid core does not contact the inner surface of the evaporator coil.
3. The apparatus of claim 1, wherein the insert is secured to an inner surface of the evaporator coil using brazing.
4. The apparatus of claim 1, wherein the insert is secured to an inner surface of the evaporator coil using compression.
5. The apparatus of claim 1, wherein: the insert comprises a plurality of sides; a first side of the plurality of sides faces a first direction at a first end of the insert; and the first side of the plurality of sides faces a second direction at a second end of the insert.
6. The apparatus of claim 1, wherein the solid core comprises one or more of the following materials: copper, steel, and aluminum.
7. A system, comprising: an evaporator coil; and an insert for the evaporator coil, wherein the insert comprises a solid core and a plurality of support legs, wherein the cross-sectional shape of the solid core is non-circular; wherein: the insert is located within the evaporator coil; the insert reduces refrigerant charge in the evaporator coil by reducing a volume of refrigerant within the evaporator coil; and the insert causes refrigerant flowing through the evaporator coil to change direction; the solid core comprises a first end upstream of the insert and a second end opposite to the first end downstream of the insert; a first area of the solid core at the first end is greater than a second area of the solid core at the second end.
8. The system of claim 7, wherein: each support leg of the plurality of support legs is attached to a side or a corner of the solid core; each support leg of the plurality of support legs contacts an inner surface of the evaporator coil; and the solid core does not contact the inner surface of the evaporator coil.
9. The system of claim 7, wherein the insert is secured to an inner surface of the evaporator coil using brazing.
10. The system of claim 7, wherein the insert is secured to an inner surface of the evaporator coil using compression.
11. The system of claim 7, wherein: the insert comprises a plurality of sides; a first side of the plurality of sides faces a first direction at a first end of the insert; and the first side of the plurality of sides faces a second direction at a second end of the insert.
12. The system of claim 7, wherein the solid core comprises one or more of the following materials: copper, steel, and aluminum.
13. A method, comprising: locating an insert within an evaporator coil, wherein the insert comprises a solid core and a plurality of support legs, wherein the cross-sectional shape of the solid core is non-circular; wherein: the insert reduces refrigerant charge in the evaporator coil by reducing a volume of refrigerant within the evaporator coil; and the insert causes refrigerant flowing through the evaporator coil to change direction; the solid core comprises a first end upstream of the insert and a second end opposite to the first end downstream of the insert; a first area of the solid core at the first end is greater than a second area of the solid core at the second end.
14. The method of claim 13, wherein: each support leg of the plurality of support legs is attached to a side or a corner of the solid core; each support leg of the plurality of support legs contacts an inner surface of the evaporator coil; and the solid core does not contact the inner surface of the evaporator coil.
15. The method of claim 13, wherein the insert is secured to an inner surface of the evaporator coil using brazing.
16. The method of claim 13, wherein the insert is secured to an inner surface of the evaporator coil using compression.
17. The method of claim 13, wherein: the insert comprises a plurality of sides; a first side of the plurality of sides faces a first direction at a first end of the insert; and the first side of the plurality of sides faces a second direction at a second end of the insert.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) To assist in understanding the present disclosure, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:
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DETAILED DESCRIPTION
(7) Certain refrigerant systems use evaporators to convert refrigerant from its liquid form into a vapor. Legislation may require that the refrigerant system maintain a certain refrigerant charge. For example, for hydrocarbon (e.g., R290) refrigerants, legislation may limit the amount of charge to 150 grams per system. This disclosure includes an insert for an evaporator coil of a refrigerant system that reduces refrigerant charge of the system by reducing the volume in the evaporator coil.
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(10) Insert 110 of evaporator coil 105 is any physical form that can be inserted into evaporator coil 105. Insert 110 may be made of copper, steel, aluminum, a polytetrafluoroethylene (PTFE) based formula such as Teflon, rubber, any other suitable material, or a combination of the preceding. Insert 110 comprises a core 115 and support legs 120. Core 115 may be a solid or hollow core. Core 115 may be any suitable shape. For example, a cross-sectional area of core 115 may be a square, a rectangle, a circle, an oval, or a cluster of shapes (e.g., circles). In the illustrated embodiment of
(11) Insert 110 has a first end 140 and a second end 150. Core 115 is twisted along its length such that each side (e.g., side 130) of first end 140 is rotated 90 degrees from the corresponding side (e.g., side 130) of second end 150. The twisted shape of core 115 within evaporator coil 105 redirects refrigerant within evaporator coil 105, which causes the refrigerant flowing through evaporator coil 105 to change direction. This change in direction may increase the turbulence of the refrigerant in evaporator coil 105. For inserts 110 with solid cores 115, the refrigerant flows in its liquid and/or vapor form between the outer surface of solid core 115 and an inner surface of evaporator coil 105. For inserts 110 with hollow cores 115, the refrigerant flows in its liquid and/or vapor form within solid core 115 and between the outer surface of hollow core 115 and the inner surface of evaporator coil 105.
(12) Insert 110 includes four support legs 120. Each support leg 120 is attached to a side 130 of core 115 of insert 110. For example, support leg 120 may be attached to first end 140 of insert 110 at a midpoint of side 130. Each support leg 120 may contact an inner surface of evaporator coil 105. Support legs 120 of insert 110 are used to stabilize insert 110 within evaporator coil 105. Support legs 120 may secure insert 110 within evaporator coil 105. For example, an end of support leg 120 may be brazed (i.e., soldered) to an inner surface of evaporator coil 105. As another example, an end of support leg 120 may be made of a flexible material such as Teflon or rubber and secured within evaporator coil 105 using friction, compression, or a combination thereof. In some embodiments, support leg 120 may be a spring that presses against the inner surface of evaporator coil 105. Support leg 120 may be located at the end of evaporator coil 105 or inside evaporator coil 105.
(13) Insert 110 of evaporator coil 105 reduces the volume within evaporator coil 105, which reduces the refrigerant charge within evaporator coil 105. Refrigerant charge is a charge required for stable operation of a refrigerant system (e.g., an HVAC unit) under certain operating conditions. Refrigerant charge may be measured in grams per circuit. For example, a charge limit for a hydrocarbon refrigerant may be 150 grams per system.
(14) In operation, core 115 of insert 110 is twisted 90 degrees and placed within evaporator coil 105 of system 100. Support leg 120 is attached to each end of core 115 on each side of core 115. Each support leg 120 is brazed to an inner surface of evaporator coil 105 to stabilize insert 110 within evaporator coil 105. As such, insert 110 of system 100 of
(15) Although this disclosure describes and depicts the components of system 100 arranged in a particular order, this disclosure recognizes that system 100 may include (or exclude) one or more components and the components may be arranged in any suitable order. For example, insert 110 of system 100 may include more or less than four sides 130. As another example, insert 110 may be located within evaporator coil 105 without support legs 120. As still another example, insert 110 may include support legs 120 along the length of core 115, such as at a midpoint of core 115. As yet another example, insert 110 may be twisted more or less than 90 degrees (e.g., 45 degrees or 180 degrees). As still another example, evaporator coil 105 may include one or more bends or elbows. Although
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(17) At step 220 of method 200, core 115 of insert 110 is placed inside evaporator coil 105. Insert 110 may be entirely located within evaporator coil 115. Insert 110 may be the same length as evaporator coil 115. In the illustrated embodiment of
(18) At step 230 of method 200, support legs 120 are added to core 110. In the illustrated embodiment of
(19) At step 240, support legs 120 are brazed to the inner surface of evaporator coil 105. Brazing support legs 120 to the inner surface of evaporator coil 105 stabilizes insert 110 within evaporator coil 105. In some embodiments, support legs 120 may be secured to the inner surface of evaporator coil 105 using a different method than brazing. For example, support legs 120 may be glued to the inner surface of evaporator coil 105. As another example, support legs 120 may include springs that press against the inner surface of evaporator coil 105.
(20) Modifications, additions, or omissions may be made to method 200 depicted in
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(22) Insert 110 of
(23) Insert 110 of
(24) Insert 110 of
(25) Extension 310 of
(26) Insert 110 of
(27) Although
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(30) Row A shows the percentage volume drop of evaporator coil 105 after locating an insert 110 with a square shape, as shown in column 570 of row A, within evaporator coil 105. In some embodiments, the square insert 110 of row A is core 115 of
(31) Row B shows the percentage volume drop of evaporator coil 105 after locating an insert 110 with a round cluster shape, as shown in column 570 of row B, within evaporator coil 105. In some embodiments, round cluster insert 110 of row B is insert 110 of
(32) Row C shows the percentage volume drop of evaporator coil 105 after locating an insert 110 having an oval shape, as shown in column 570 of row C, within evaporator coil 105. In some embodiments, oval insert 110 of row C is insert 110 of
(33) In certain embodiments, the cross-sectional area of one or more shapes of inserts 110 shown in column 570 of rows A, B, and C of table 500 may be reduced. For example, the width and length of square insert 110 of row A at an inlet of evaporator coil 105 may be twice the width and length, respectively, of square insert 110 of row A at the outlet of evaporator coil 105. Reducing the size of insert 110 in this manner may save approximately 70 percent of refrigerant charge.
(34) Herein, “or” is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A or B” means “A, B, or both,” unless expressly indicated otherwise or indicated otherwise by context. Moreover, “and” is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A and B” means “A and B, jointly or severally,” unless expressly indicated otherwise or indicated otherwise by context.
(35) The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, feature, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Furthermore, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative. Additionally, although this disclosure describes or illustrates particular embodiments as providing particular advantages, particular embodiments may provide none, some, or all of these advantages.