Systems and Methods for Vapor Compression Systems with a Multi-Circuit Heat Exchanger and a Low Cost Distributor
20260002706 ยท 2026-01-01
Inventors
Cpc classification
F25B41/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/37
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F25B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/37
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Systems and methods for vapor compression systems having at least one multi-circuit heat exchanger and a distributor designed to receive multi-phase refrigerant from an expansion valve and evenly distribute the multi-phase refrigerant using the distributor have been developed for improved efficiency and reduced cost. The distributor may be positioned in close proximity to the expansion valve and may be oriented with respect to an output of the expansion valve to cause the refrigerant flow to impact the distributor and enhance turbulent flow to facilitate mixing of the liquid and vapor refrigerant. Channels extending from the distributor may be positioned with respect to the output of the expansion valve to facilitate even distribution of the multi-phase refrigerant flow. With each circuit of the multi-circuit heat exchanger supplied with evenly distributed multi-phase refrigerant, efficiency will be improved.
Claims
1. A system comprising: a compressor configured to compress a refrigerant; a first heat exchanger in fluid communication with the compressor and configured to exchange thermal energy with the refrigerant; an expansion valve in fluid communication with the first heat exchanger and configured to reduce a pressure of and accelerate the refrigerant, the refrigerant forming a multi-phase fluid at an exit of the expansion valve; a distributor in fluid communication with the expansion valve and comprising a junction oriented with respect to expansion valve such that the junction is positioned in a flow path of the multi-phase fluid upon exiting the expansion valve and directs the refrigerant into a first channel and a second channel; and a second heat exchanger comprising a first circuit in fluid communication with the first channel and a second circuit in fluid communication with the second channel, the second heat exchanger configured to exchange thermal energy with the refrigerant and guide the refrigerant to the compressor.
2. The system of claim 1, wherein the refrigerant is turbulent upon collision with the junction in the flow path of the multi-phase fluid.
3. The system of claim 1, wherein the refrigerant is evenly distributed between the first channel and the second channel.
4. The system of claim 1, further comprising a flow divider configured to extend from the distributor toward the expansion valve to facilitate even distribution of the refrigerant into the first channel and the second channel.
5. The system of claim 1, further comprising a third channel between the distributor and the first channel and the second channel, the third channel configured to guide the refrigerant from the expansion valve to the distributor and wherein the first channel and second channel each have an orthogonal orientation with respect the third channel.
6. The system of claim 1, wherein the first channel and the second channel each have a radius of curvature and are each configured to direct the refrigerant in a direction opposite of the flow path.
7. The system of claim 1, further comprising a third channel between the distributor and the first channel and the second channel configured to guide the refrigerant from the expansion valve to the distributor and wherein the first channel and second channel each form an angle with the third channel of between 50 degrees and 90 degrees.
8. The system of claim 1, wherein the distributor is positioned no more than three inches from the expansion valve.
9. The system of claim 1, wherein the first heat exchanger is a condenser and the second heat exchanger is an evaporator.
10. The system of claim 1, wherein the refrigerant in the first channel and the second channel comprises both liquid refrigerant and vapor refrigerant.
11. A system comprising: a compressor configured to compress a refrigerant; a first heat exchanger in fluid communication with the compressor and comprising at least one circuit configured to exchange thermal energy with the refrigerant; an expansion valve in fluid communication with the first heat exchanger and configured to accelerate the refrigerant; a capillary tube in fluid communication with the expansion valve and configured to accelerate the refrigerant upon exiting the expansion valve; a distributor in fluid communication with the capillary tube and comprising a junction oriented with respect to the capillary tube such that the junction is positioned in a flow path of the of the refrigerant upon exiting the capillary tube, the junction configured to direct the refrigerant into a first channel and a second channel; and a second heat exchanger comprising a first circuit in fluid communication with the first channel and a second circuit in fluid communication with the second channel, the second heat exchanger configured to exchange thermal energy with the refrigerant and guide the refrigerant to the compressor.
12. The system of claim 11, wherein the refrigerant is evenly distributed between the first channel and the second channel.
13. The system of claim 11, wherein the refrigerant is turbulent upon exiting the capillary tube and colliding with the junction to form a multi-phase fluid flow.
14. The system of claim 13, further comprising a flow divider configured to extend from the distributor toward the capillary tube to facilitate even distribution of the multi-phase fluid flow into the first channel and the second channel.
15. The system of claim 11, wherein the flow path has an orthogonal orientation with respect the first channel and the second channel.
16. The system of claim 11, wherein the first channel and the second channel each have a radius of curvature and are each configured to direct the refrigerant in a direction opposite of the flow path.
17. The system of claim 11, wherein an exit of the capillary tube has a first orientation and the first channel and the second channel each form an angle with the exit of the capillary tube at the first orientation of between 50 degrees and 90 degrees.
18. The system of claim 11, where the first heat exchanger is a condenser and the second heat exchanger is an evaporator.
19. The system of claim 11, wherein the refrigerant in the first channel and the second channel comprises both liquid refrigerant and vapor refrigerant.
20. The system of claim 11, wherein the expansion valve induces a first pressure reduction in the refrigerant and the capillary tube induces a second pressure reduction in the refrigerant, the second pressure reduction less than the first pressure reduction.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0014] Vapor compression systems having at least one multi-circuit heat exchanger and a distributor designed to receive multi-phase refrigerant from an expansion valve and evenly distribute the multi-phase refrigerant using a distributor to the multi-circuit heat exchanger for improved efficiency and reduced cost are provided. The vapor compression system may be a heat pump, air conditioner, water-to-water heat pump, heat pump water heater or any vapor compression system with multiple circuits, or the like. The distributor may be positioned in close proximity to the expansion valve and may be oriented with respect to an output of the expansion valve to cause the refrigerant flow to impact the distributor and enhance turbulent flow to facilitate mixing of the liquid and vapor refrigerant. Channels extending from the distributor may be positioned with respect to the output of the expansion valve to facilitate even distribution of the multi-phase refrigerant flow. With each circuit of the multi-circuit heat exchanger supplied with evenly distributed multi-phase refrigerant, efficiency will be improved as compared to circuits supplied with an uneven distribution of liquid refrigerant and vapor refrigerant.
[0015] A vapor compression system may broadly encompass any system that is configured to heat and/or cool a conditioned space, heat and/or cool a fluid that is provided to a load, and/or perform any other actions associated with a vapor compression cycle. Non-limiting examples of types of vapor compression systems can include air conditioners (e.g., no reversing valve, only provides cooling mode), heat pumps (e.g., air source or geothermal; has a reversing valve and operates in both heating and cooling modes), heat pump water heaters, integrated heat pump water heaters, split system heat pump water heaters, heat pump water heaters with a circulation pump and a brazed plate heat exchanger, split systems, packaged systems, mini-splits, PTACs, window units, vertical packaged systems, VRF systems, etc.
[0016] For example, a vapor compression system may generally include components that combine to form a refrigerant loop that is used to produce conditioned air that is circulated throughout the conditioned space by the vapor compression system. For example, the refrigerant loop may include an indoor heat exchanger coil, an outdoor heat exchanger coil, a compressor, and an expansion valve (however, these components may vary, depending on the specific vapor compression system).
[0017] Continuing this example, during the operation of this exemplary vapor compression system in a cooling mode, warm indoor air is pulled (or pushed) over the indoor heat exchanger coil (which may be the evaporator coil of the vapor compression system) by a fan of the vapor compression system. As the liquid refrigerant inside the indoor heat exchanger coil converts to gas, heat is absorbed from the indoor air into the refrigerant, thus cooling the air that is pulled over the indoor heat exchanger coil. The fan is then operated to pull the cooled air into a conditioned space (such as a residential home or commercial establishment) that is being cooled by the air conditioning system. In some instances, this cooled air may be distributed throughout the conditioned space using ductwork installed within the conditioned space. The refrigerant gas then passes into the compressor. The compressor pressurizes the refrigerant gas and sends the refrigerant into the outdoor heat exchanger coil, which may operate as a condenser coil. A fan pulls outdoor air through the outdoor heat exchanger coil, allowing the air to absorb heating energy from the home and release it outside. During this process, the refrigerant is converted back to a liquid. The refrigerant then travels back to the indoor heat exchanger coil. The refrigerant passes through an expansion valve, which regulates the flow of refrigerant into the indoor heat exchanger coil. The cold refrigerant then absorbs more heat from the indoor air and the cycle repeats.
[0018] Likewise, in a standard heating mode, a reversing valve may be transitioned to direct refrigerant from the compressor to the indoor heat exchanger coil as opposed to directing it to the outdoor heat exchanger coil, as is done in the cooling mode. In a heating mode, the refrigerant absorbs heat from the outdoor air through the outdoor heat exchanger coil. The refrigerant then passes through the compressor, which compresses (and thus warms) the refrigerant. The heated refrigerant is transferred to the indoor heat exchanger coil. One or more fans push or pull air over the indoor heat exchanger coil, thereby transferring heat from the indoor heat exchanger coil to the conditioned space. Ductwork then directs the conditioned air throughout the conditioned space to heat the conditioned space. One or more supplemental heating sources, such as an electric heating kit, and/or a gas furnace with a heat exchanger in the indoor coil portion, may additionally be used. This description is merely exemplary and the specific operation of the vapor compression system may vary depending on the specific vapor compression system.
[0019] The disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology can, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology.
[0020] In the following description, numerous specific details are set forth. But it is to be understood that examples of the disclosed technology can be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to one embodiment, an embodiment, example embodiment, some embodiments, certain embodiments, various embodiments, one example, an example, some examples, certain examples, various examples, etc., indicate that the embodiment(s) and/or example(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase in one embodiment or the like does not necessarily refer to the same embodiment, example, or implementation, although it may.
[0021] Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term or is intended to mean an inclusive or. Further, the terms a, an, and the are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.
[0022] Unless otherwise specified, the use of the ordinal adjectives first, second, third, etc., to describe a common object, merely indicate that different instances of like objects are being referenced and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.
[0023] Throughout this disclosure, reference is made to the accompanying drawings in which like numerals represent like elements. Certain groups of elements and/or components are referenced generally using a common numeral, while specific instances of the element and/or component are referenced using the numeral followed by a corresponding alphanumeric reference.
[0024] Unless otherwise specified, all ranges disclosed herein are inclusive of stated end points, as well as all intermediate values. By way of example, a range described as being between approximately 0.5 and approximately 4 inches includes the values 0.5 and 4 inches and all intermediate values within the range. Likewise, the expression that a property may be in a range from approximately 0.5 to approximately 4 inches (or may be in a range from 0.5 to 4 inches) means that the property can be approximately 0.5 inches, can be approximately 4 inches, or can be any value therebetween.
[0025] Referring now to
[0026] As shown in
[0027] Vapor compression system 200 may include compressor 210, which may pressurize and/or compress refrigerant (e.g., R-410A, R-454B) in vapor compression system 200. Compressor 210 may direct the refrigerant to heat exchanger 202 (e.g., via piping 205). Heat exchanger 202 may be a conventional heat exchanger, a multi-circuit heat exchanger, or any other suitable heat exchanger. Blower 220 may be directed across heat exchanger 220 to facilitate thermal energy exchange between heat expends 202 and the refrigerant. In one example, heat exchanger 202 may be a condenser that expels the thermal energy to heat a fluid surrounding heat exchanger 220.
[0028] Refrigerant may then be directed from heat exchanger 202 to expansion valve 206. Expansion valve 206 may be any suitable expansion valve for reducing the pressure of the refrigerant and accelerating the refrigerant such that at the output of the expansion valve, the refrigerant is ejected as multi-phase refrigerant with both liquid refrigerant and gas refrigerant. At the output of expansion valve 206, the multi-phase refrigerant is accelerated such that the velocity of the refrigerant at the output is larger than the velocity of the refrigerant at the input of the expansion valve.
[0029] Distributor 208 may be positioned in close proximity to expansion valve 206 such that the accelerated refrigerant exits expansion valve 206 and collides with distributor 208. It may be desirable for the distributor to maximize the collision of the multi-phase refrigerant flow and the distributor to enhance turbulent flow for improved distribution of the liquid refrigerant and the vapor refrigerant. In one example, distributor 208 may be positioned between approximately 0.5 and approximately 4 inches from expansion valve 206. In another example, distributor 208 may be positioned less than 6 inches from expansion valve 206. More generally, the distributor 208 may be positioned within a range of where refrigerant is accelerated by the expansion valve 206 (e.g., refrigerant has not resumed laminar flow). Alternatively, any other distance between the distributor and output 514 may be used. A channel (e.g., piping) may separate output 214 from distributor 208. Given the simplicity of the design and components, it will be understood by one skilled in the art that such a distributor may be produced and/or manufactured for a relatively low cost.
[0030] Distributor 208 may connect to multiple channels extending from distributor 208 to heat exchanger 204 for even distribution of the multi-phase refrigerant to heat exchanger 204. For example, channels 214 and 216 may each direct the multi-phase refrigerant to respective circuits of heat exchanger 204. Channels 214 and 216 may be separate channels which may each be the same as or similar to piping 205.
[0031] The heat exchanger 204 may direct refrigerant through each circuit and out of heat exchanger 204. Refrigerant from each circuit may then be rejoined via a connector 217, which may join refrigerant flows from the separate circuits. Connector 217 may be a standalone component from heat exchanger 204 or may be integrated into heat exchanger 204 (e.g., in a heater or manifold). The refrigerant may then be directed to compressor 210 for again compressing the refrigerant.
[0032] In the example illustrated in
[0033] Referring now to
[0034] Distributor 304 may include channel 306 and channel 308, which may evenly distribute refrigerant flow 320 ejected from output 314. As shown in
[0035] Distributor 304 is positioned to evenly distribute refrigerant flow 320 into channels 306 and 308 such that about 50% of refrigerant is directed into channel 306 and about 50% of refrigerant is directed into channel 308. As shown in
[0036] Referring now to
[0037] As shown in
[0038] Refrigerant flow 420 may be oriented in the direction of gravity (e.g., downward) and channels may redirect the refrigerant flow to an upward orientation, opposite the direction of gravity. Orienting channels 406 and 408 upward opposite of gravity facilitates even distribution of refrigerant liquid and gas. As refrigerant liquid is heavier than gas, if channels 406 and 408 were oriented downward, it is possible that one channel 406 or 408 would receive a greater amount of liquid than gas. However, with channels 406 and 408 oriented upward, the heavier refrigerant liquid is less likely to favor one channel over the other.
[0039] As shown in
[0040] Referring now to
[0041] Distributor 504 may include channels 506 and 508, which may evenly distribute refrigerant flow 520 ejected from output 514. As shown in
[0042] Distributor 504 may include impact area 510, which may be positioned to obstruct refrigerant flow 520 such that refrigerant flow 520 collides with impact area 510, resulting in enhanced turbulent flow. As refrigerant flow 520 is a multi-phase refrigerant flow with liquid refrigerant and vapor refrigerant, turbulence facilitates mixing and/or evenly distributing the liquid and the vapor into channels 506 and 508.
[0043] Distributor 504 is positioned to evenly distribute refrigerant flow 520 into channels 506 and 508 such that about 50% of the refrigerant is directed into channel 506 and 50% of the refrigerant is directed into channel 508. As shown in
[0044] Referring now to
[0045] Capillary tube 625 may be designed to accelerate the refrigerant ejected from output 614 and/or reduce the pressure of the refrigerant. In one example, expansion valve 602 may be designed to reduce the pressure of the refrigerant traversing the expansion valve and capillary tube 625 may be designed to further reduce the pressure of the refrigerant traversing the capillary tube. For example, the pressure decrease resulting from capillary tube 625 may be less than the pressure decrease resulting from expansion valve 602. In this manner, capillary tube 625 may further accelerate the refrigerant and reduce the refrigerant pressure to facilitate even distribution of liquid and vapor refrigerant and/or even distribution between the multiple channels of the distributor. Capillary tube 625 may be used as an alternative to an additional expansion valve, for example.
[0046] The refrigerant may be ejected from the capillary tube 625 as refrigerant flow 620, which may be a multi-phase refrigerant flow. Distributor 604 with channels may be connected to and/or positioned in close proximity to (e.g., the same distance between the expansion valves and distributors described above with respect to
[0047] Referring now to
[0048] Distributor 704 may be similar to distributor 304 of
[0049] Although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, can, could, might, or may, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.