Microchannel heat exchanger for an appliance condenser

Abstract

A heat exchanger includes: a microchannel tube having a plurality of straight sections interconnected by a plurality of curved sections; a plurality of accordion-shaped fins located between adjacent straight sections of the microchannel tube; and a plurality of supports having a plurality of slots therein, each slot configured to receive a corresponding straight section of the microchannel tube, wherein the plurality of supports are configured to compress the accordion-shaped fins to directly engage with adjacent straight sections of the microchannel tube, and wherein at least one of the accordion-shaped fins and the microchannel tube includes a mating feature that prevents lateral movement of the accordion-shaped fins relative to adjacent straight sections of the microchannel tube.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 163,117, filed March 19, 2021, and priority to U.S. Patent Application No. 17 / 697,988, filed March 18, 2022. The entire disclosure of the above applications is incorporated herein by reference. Technical Field

[0003] This disclosure relates to a microchannel heat exchanger for an appliance condenser. Background Technology

[0004] This section provides background information relating to this disclosure, which is not necessarily prior art.

[0005] Heating, ventilation, air conditioning, and refrigeration (HVAC&R) systems include heat exchangers to dissipate or receive heat between a refrigerant circulating within the system and its surrounding environment. One type of heat exchanger that has become increasingly popular due to its compactness, structural rigidity, and superior performance is the microchannel heat exchanger. A microchannel heat exchanger comprises a tube through which a cooling or heating fluid (e.g., refrigerant) circulates. The tube typically has a flat cross-section and multiple parallel flow channels formed therein. Fins are typically arranged to extend between sections of the tube to facilitate heat transfer between the heating / cooling fluid and the surrounding environment. The fins may have a corrugated pattern, combined with louvers to promote heat transfer, and are typically brazed to the tube.

[0006] Brazing fins and microchannel tubes together minimizes the contact resistance between them. Brazing material can be applied to the fins or coated onto the tubes. However, brazing is an expensive process, and the material cost of applying brazing material to the fins or coating the tubes is significantly higher than that associated with non-brazed heat exchangers. Brazing is also not necessarily environmentally friendly, as it uses chemical fluxes and has high energy requirements. Therefore, there is a need for a microchannel heat exchanger that does not require brazing and exhibits similar performance in HVAC&R applications. Summary of the Invention

[0007] This section provides a general overview of this disclosure rather than a full disclosure of its entire scope or all its features.

[0008] According to a first aspect, this disclosure provides a heat exchanger comprising: a microchannel tube having a plurality of straight sections interconnected by a plurality of curved sections; a plurality of accordion-style fins located between adjacent straight sections of the microchannel tube; and a plurality of supports having a plurality of slots formed therein, each slot configured to receive a corresponding straight section of the microchannel tube, wherein the plurality of supports are configured to orient adjacent straight sections of the microchannel tube such that the plurality of accordion-style fins located between adjacent straight sections of the microchannel tube are compressed by the adjacent straight sections of the microchannel tube.

[0009] According to the first aspect, these accordion-shaped fins are compressed by the adjacent straight section of the microchannel tube by a distance ranging from 0.003 inches to 0.015 inches.

[0010] According to the first aspect, at least one of the accordion-shaped fins and the microchannel tube includes a mating feature that prevents lateral movement of the accordion-shaped fins relative to adjacent straight sections of the microchannel tube.

[0011] According to the first aspect, these accordion-shaped fins were not brazed to the adjacent straight section of the microchannel tube.

[0012] According to a first aspect, the microchannel tube may include an upper planar main surface and a lower planar main surface, and the mating feature includes at least one protrusion extending longitudinally along each of the upper planar main surface and the lower planar main surface, and the accordion-shaped fin located between adjacent straight sections of the microchannel tube may include a pair of recesses configured to mate with corresponding protrusions formed on adjacent straight sections of the microchannel tube.

[0013] According to the first aspect, a plurality of laterally spaced protrusions may be formed on each of the main surface above the plane and the main surface below the plane, and the accordion-shaped fins located between adjacent straight sections of the microchannel tube may include a plurality of recesses configured to engage with corresponding protrusions formed on adjacent straight sections of the microchannel tube.

[0014] According to a first aspect, the microchannel tube may include an upper main surface and a lower main surface, and a pair of side surfaces connecting the upper main surface and the lower main surface, wherein the mating feature may include a spherical portion formed at each side surface, the spherical portion defining an adjacent surface extending outward from at least one of the upper main surface and the lower main surface and contacting the accordion fin, and the spherical portion restricting lateral movement of the accordion fin located between adjacent straight segments of the microchannel tube.

[0015] According to the first aspect, the mating feature may be a recessed section formed in the accordion fin at the curved portion of the accordion fin, wherein the recessed section is configured to receive the straight section of the microchannel tube, thereby restricting the lateral movement of the microchannel tube relative to the accordion fin.

[0016] According to the first aspect, the recessed section may have a depth that allows the curved portion of the accordion-like fin to extend outward from the microchannel tube.

[0017] According to the first aspect, the accordion-shaped fin may include a pair of tabs located at the recessed section, the pair of tabs being curved away from the curved portion, and the microchannel tube being located on the pair of tabs.

[0018] According to the first aspect, the plurality of slots of the stent can be separated by fingers having tapered distal ends.

[0019] According to the first aspect, the plurality of slots can be formed as a plurality of holes, the plurality of holes being configured to receive the microchannel tube in the plurality of holes.

[0020] According to the first aspect, the heat exchanger may further include a pair of planar support members that clamp the heat exchanger in the middle and cooperate with the plurality of supports.

[0021] According to a second aspect of this disclosure, a heat exchanger is provided, comprising: a microchannel tube having a plurality of straight sections interconnected by a plurality of curved sections; a plurality of accordion-shaped fins located between adjacent straight sections of the microchannel tube; and a plurality of supports having a plurality of slots formed therein, each slot configured to receive a corresponding straight section of the microchannel tube, wherein the microchannel tube includes an upper main surface and a lower main surface, each of the upper and lower main surfaces including a plurality of protrusions extending longitudinally at least along each of the plurality of straight sections; and the accordion-shaped fins located between adjacent straight sections of the microchannel tube including a plurality of recesses configured to engage with the plurality of protrusions such that, when the recesses engage with the protrusions, lateral movement of the accordion-shaped fins relative to adjacent straight sections of the microchannel tube is restricted.

[0022] According to the second aspect, each accordion fin includes a plurality of planar portions connected by curved portions, wherein the curved portions are configured to contact the upper and lower main surfaces of the microchannel tube when the accordion fin is located between adjacent straight sections of the microchannel tube, and the recesses are formed at these curved portions.

[0023] According to the second aspect, these curved portions were not brazed to the upper and lower main surfaces of the adjacent straight sections of the microchannel tube.

[0024] According to the second aspect, the plurality of supports are configured to orient adjacent straight sections of the microchannel tube such that a plurality of accordion-like fins located between adjacent straight sections of the microchannel tube are compressed by the adjacent straight sections of the microchannel tube.

[0025] According to the second aspect, the plurality of slots of the support are separated by fingers having tapered distal ends.

[0026] According to the second aspect, the heat exchanger may also include a pair of structural members attached to the support, the pair of structural members sandwiching the heat exchanger in the middle.

[0027] According to the second aspect, the engagement between the plurality of protrusions and the plurality of recesses does not restrict the longitudinal movement of the accordion-shaped fin relative to the adjacent straight section.

[0028] Other areas of application will become apparent from the description provided herein. The description and specific embodiments in this invention are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0029] The accompanying drawings described herein are for illustrative purposes only, representing selected embodiments and not all possible implementations, and are not intended to limit the scope of this disclosure.

[0030] Figure 1 This is a schematic diagram of an HVAC&R system based on the principles of this disclosure;

[0031] Figure 2 This is a perspective view of a heat exchanger based on the principles of the present invention;

[0032] Figure 3 yes Figure 2 The diagram shows a perspective view of the heat exchanger fins, which are located at... Figure 2 The microchannel tubes of the heat exchanger shown are located between adjacent sections;

[0033] Figure 4 yes Figure 2 A three-dimensional view of the tubes used in the heat exchanger shown;

[0034] Figure 5 It is a cross-sectional view of fins positioned between a pair of adjacent tubes that cooperate with each other, in accordance with the principles of this disclosure;

[0035] Figure 6 and Figure 7 This is a perspective view of an exemplary support that can be used to compress fins in a heat exchanger located between adjacent sections of the heat exchanger's tubes;

[0036] Figure 8 It is a cross-sectional view of a microchannel tube with multiple mating features that can be used to fix the fins of a heat exchanger to it;

[0037] Figure 9 It is a cross-sectional view of fins positioned between a pair of adjacent tubes that cooperate with each other, according to another principle of this disclosure;

[0038] Figure 10 It is a cross-sectional view of fins positioned between a pair of adjacent tubes that cooperate with each other, according to another principle of this disclosure;

[0039] Figure 11 It is a perspective view of fins positioned between a pair of adjacent tubes that cooperate with each other, according to another principle of this disclosure; and

[0040] Figure 12 This is a perspective view of another heat exchanger based on the principles of this disclosure.

[0041] Throughout the accompanying drawings, the corresponding reference numerals refer to the corresponding components. Detailed Implementation

[0042] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

[0043] Exemplary embodiments are provided to make this disclosure thorough and to fully convey the scope to those skilled in the art. Numerous specific details (such as examples of specific components, devices, and methods) are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that exemplary embodiments may be implemented in many different forms, and none should be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known device structures, and well-known technologies have not been described in detail.

[0044] Figure 1 A refrigeration system 2 is shown, which typically includes a compressor 3, a condenser 4, and an evaporator 5 connected by connecting lines 6. The condenser 4 and evaporator 5 are referred to as heat exchangers. The refrigeration system 2 can be integrated into an appliance (e.g., a refrigerator or freezer) and can be used in residential or commercial environments to cool and / or heat structures. An expansion device 7, such as a valve or capillary tube, can be disposed between the condenser 4 and the evaporator 5. The compressor 3 receives low-pressure refrigerant from the evaporator 5 through one connecting line 6 on the suction side and distributes high-pressure refrigerant from the discharge side to the condenser 4 through another connecting line 6.

[0045] During refrigeration, refrigeration system 2 utilizes the cooling effect of refrigerant evaporation to lower the ambient temperature near one heat exchanger (i.e., evaporator 5) and the heating effect of the high-pressure, high-temperature gas to raise the ambient temperature near another heat exchanger (i.e., condenser 4). This is typically achieved by releasing refrigerant under pressure (usually in liquid phase) into a low-pressure region, causing the refrigerant to expand into a low-temperature mixture of liquid and vapor. This low-pressure region typically includes a coil forming part of evaporator 5. Once inside the evaporator coil, the refrigerant mixture exchanges heat with the coil's piping, which in turn exchanges heat with the high-temperature ambient air in the area requiring cooling. The refrigerant absorbs heat from the surrounding air as it evaporates from liquid to gas, thus cooling the air.

[0046] Figure 2 An exemplary heat exchanger 10 according to the principles of this disclosure is shown. The heat exchanger 10 can be used as a condenser 4 or an evaporator 5, or each of the condenser 4 and the evaporator 5 can have... Figure 2 The heat exchanger 10 shown is constructed as follows. In any case, the heat exchanger 10 includes a tube 12, a plurality of supports 18 and a plurality of fins 20, the tube having an inlet 14 and an outlet 16 connected to the tube.

[0047] like Figure 3 As best shown, the fin 20 is an accordion-type fin having a plurality of planar portions 22 connected by bends 24, wherein the bends 24 serve as contact points 26 between adjacent sections of the fin 20 and the tube 12, allowing heat exchange between the tube 12 and the fin 20. The fin 20 can be formed of any material known to those skilled in the art, provided that the material is sufficient to facilitate heat exchange between the tube 12 and the fin 20. For example, the fin 20 can be formed of a metallic material, such as aluminum, copper, or an alloy (e.g., a steel alloy or an aluminum alloy). Preferably, for cost reasons, the fin 20 is formed of aluminum or an aluminum alloy. Although the bends 24 are shown as triangular, it should be understood that the bends 24 can be rectangular, rounded, or some other shape without departing from the scope of this disclosure.

[0048] like Figure 4 and Figure 5 As best shown, tube 12 is a microchannel tube having a plurality of channels 28 formed therein for conveying refrigerant. Tube 12 includes a first or upper main surface 30, a second or lower main surface 32, and a pair of side surfaces 34 connecting the upper main surface 30 to the lower main surface 32. A plurality of walls 36 extend longitudinally along the length of tube 12 and between the upper main surface 30 and the lower main surface 32 to define the channels 28, which also extend longitudinally along the length of tube 12. While most of the channels 28 are in… Figure 5The channel 28 is shown as a square or rectangle, but it should be understood that the channel 28 can have any desired cross-sectional shape. Similar to the fin 20, the tube 12 can be formed of a metallic material, such as aluminum, copper, or an alloy (e.g., a steel alloy or an aluminum alloy). Preferably, for cost and heat exchange purposes, the tube 12 is formed of aluminum or an aluminum alloy.

[0049] In the illustrated embodiment, tube 12 may be a single tube bent at different locations 38 to meander back and forth through heat exchanger 10 (i.e., having a serpentine configuration). However, it should be understood that tube 12 may be formed from multiple straight sections 40, each straight section being connected by a separate bent section 42, the bent section 42 being subsequently joined to the straight section 40. The bent section 42 may be mechanically joined to the straight section 40, brazed to the straight section 40, or attached to the straight section 40 in any manner known to those skilled in the art, such manner being satisfied with withstanding the operating pressure of heat exchanger 10 and providing a leak-free seal between the bent section 42 and the straight section 40. Another alternative includes attaching the straight sections 40 of tube 12 to a manifold (not shown) at the opposite end of the straight sections 40.

[0050] Figure 6 and Figure 7 Exemplary supports 18 are shown, which are configured to support and orient the tube 12 as it meanders back and forth through the heat exchanger 10, or to support the straight sections 40 of the tube 12 if the tube 12 is not a single tube but a plurality of straight sections 40 interconnected by curved sections 42. Figure 6 The support 18 is a planar body 44 in which a plurality of slots 46 are formed. The slots 46 have a width configured to receive the tube 12. More specifically, slot 46a is configured to receive one passage of the tube 12, while slot 46b is configured to receive another passage of the tube 12. The number of slots 46 is variable and depends on the size of the heat exchanger 10 (i.e., a larger heat exchanger may have a tube 12 whose length requires passing through the support 18 multiple times).

[0051] Each slot 46 is separated by fingers 48, which may have a tapered end 50 that facilitates the placement of the support 18 within the corresponding section of the receiving tube 12. Alternatively, as Figure 7 As best shown, each support 18 may include an elongated aperture 52 configured for receiving a corresponding straight section 40 of the tube 12 or through it. Another alternative includes using one or more [unclear - possibly referring to a specific type of support] at the center of the heat exchanger 10. Figure 6 The brackets 18 shown are used at opposite ends of the heat exchanger 10. Figure 7The bracket 18 is shown. In any of these cases, the bracket 18 may be formed of a metallic material, such as aluminum, copper, or an alloy (e.g., a steel alloy or an aluminum alloy), to facilitate heat transfer between the tube 12 and the bracket 18. Alternatively, a polymeric material that is not necessarily thermally conductive may also be used.

[0052] Although Figure 2 Three supports 18 are shown, but it should be understood that more or fewer supports 18 may be used. For example, if the tube 12 is connected to a manifold (not shown), only a single support 18 may be needed. Furthermore, regardless of which support 18 is chosen for the heat exchanger 10, it should be understood that the slots 46 and holes 52 are spaced apart from each other such that when the tube 12 is mounted to the support 18, the support 18 is configured to compress the tube 12 and the fins 20 into close (i.e., direct) contact (i.e., in the z-direction), which increases heat transfer between the tube 12 and the fins 20 to present a connection similar to a brazing connection.

[0053] More specifically, it should be understood that, according to this disclosure, when assembling the heat exchanger 10, the connection between the support 18, the tube 12, and the fins 20 does not require brazing. Although brazing is not required to connect the support 18, the tube 12, and the fins 20, the heat exchanger 10 exhibits similar heat exchange capacity compared to a heat exchanger where the fins 20 are brazed to the tube 12. Furthermore, the cost of manufacturing the heat exchanger 10, which does not involve brazing connections between the support 18, the tube 12, and the fins 20, is significantly lower than that of a brazed heat exchanger.

[0054] In this respect, when manufacturing the heat exchanger 10, the tube 12 is bent into a serpentine shape, such as... Figure 2 As shown. Then, accordion-style fins 20 are loosely arranged between the straight sections 40 of the tube 12. After the fins 20 are loosely arranged between the straight sections 40 of the tube 12, a support 18 is attached to the tube 12 such that each passage of the tube 12 is held in the groove 46 of the support 18. When the support 18 is attached to the straight sections 40 of the tube 12, each fin 20 located between adjacent straight sections 40 of the tube 12 is compressed (in... Figure 3The bends 24 are positioned such that the lower main surface 32 of a straight section 40 of the tube 12 is tightly engaged (i.e., directly engaged) with the upper main surface 30 of an adjacent straight section 40 of the tube 12, improving the contact between the tube 12 and the fins 20. The slots 46 and holes are spaced apart such that the fins 20 are compressed between the straight sections 40 to achieve a tight engagement, but not to the point that the fins 20 buckle due to the compressive force applied by the support 18. That is, the support 18 orients the straight sections 40 relative to the tube 12 such that the fins 20 are compressed a distance in the range of 0.003 inches to 0.015 inches, with approximately 0.005 inches being preferred. Due to the use of the support 18, each fin 20 in the heat exchanger 10 can be compressed to substantially the same degree.

[0055] In addition, refer to again Figure 3 It should be understood that when opposite ends of fin 20 are contacted by supports 18 at opposite ends, fin 20 can be compressed in the direction toward the center of fin 20 (i.e., by...). Figure 3 The fins 20 are compressed from each side in the x direction. By compressing the fins in the x direction, the spacing between the contact points 26 (bent portions 24) narrows, which forces the contact points 26 to engage more tightly with the adjacent segments 40 of the tube 12 in the upward and downward directions (i.e., in the z direction).

[0056] Importantly, when manufacturing the heat exchanger 10, the fins 20 are correctly positioned between adjacent straight sections 40 of the tube 12 to ensure proper performance of the heat exchanger 10. In this respect, because the fins 20 are not brazed to the tube 12, if the fins 20 loosen during use of the heat exchanger 10, they may block the fan (not shown) used to draw or push air through the heat exchanger 10, or have other detrimental effects that could reduce the heat transfer capacity of the heat exchanger 10.

[0057] Figure 2 and Figure 5 A first example connection between tube 12 and fin 20 is shown to ensure proper positioning of fin 20 relative to tube 12 during assembly of heat exchanger 10. In the example shown, each of the upper main surface 30 and lower main surface 32 includes an elongated protrusion 54. In the illustrated embodiment, the protrusion 54 extends along the entire length of tube 12. However, it should be understood that if tube 12 is formed of straight sections 40 interconnected by curved sections 42, only the straight sections 40 may include the elongated protrusion 54 along their length. The protrusion 54 is configured to mate with a recess 56 formed at least at the curved portion 24 of fin 20. During assembly, the protrusion 54 mates with the recess 56 to prevent the fin 20 from being laterally displaced relative to tube 12 (i.e., at...). Figure 3The fin 20 is allowed to move longitudinally (i.e., in the x direction) while the support 18 moves in the y direction, while allowing the fin 20 to move longitudinally (i.e., in the x direction). Furthermore, after the support 18 engages with the tube 12 to compress the fin 20 in the longitudinal direction (x direction) to force the contact point 26 to engage tightly with the tube 12, disengagement of the fin 20 from the tube 12 is prevented. Although the tube 12 is shown as having a single protrusion 54 on each of the upper main surface 30 and the lower main surface 32, it should be understood that the tube 12 may have multiple protrusions 54 formed on each of the upper main surface 30 and the lower main surface 32. Figure 8 If this configuration is used, it should be understood that the fin 20 will have a corresponding number of recesses 56. Furthermore, although the protrusions 54 and the corresponding recesses 56 are shown as rounded, it should be understood that the protrusions 54 and the recesses 56 may have any other corresponding shapes (e.g., squares, rectangles, or triangles) without departing from the scope of the invention.

[0058] Now refer to Figure 9 This illustrates a second example connection between tube 12 and fin 20. In the example shown, fin 20 is a standard accordion fin, meaning that fin 20 does not have the recess 56 formed therein. Although the recess 56 is missing for properly orienting fin 20 relative to tube 12 and ensuring a good heat exchange connection between fin 20 and tube 12, it can be seen that tube 12 has been modified to include spherical portions 58 at side surfaces 34 to ensure that fin 20 remains properly positioned between adjacent segments 40 of tube 12. The spherical portions 58 act as barriers on opposite sides of fin 20, preventing fin 20 from being laterally displaced relative to segments 40 of tube 12 (i.e., in...). Figure 3 The fins move in the y-direction. Specifically, the spherical portion 58 defines abutment surfaces 59 that extend outward from the upper surface 30 and lower surface 32 of the tube 12 and are configured to restrict lateral movement of the fins 20 therebetween. Furthermore, after the support 18 engages with the tube 12 to compress the fins 20, the contact between the abutment surfaces 59 and the fins 20 prevents the fins 20 from disengaging from the tube 12.

[0059] Figure 10A third example connection between tube 12 and fin 20 is shown. In the example shown, tube 12 is a standard microchannel tube, meaning that tube 12 does not have the protrusion 54 or spherical portion 58 as described above. However, to ensure that fin 20 remains correctly positioned between adjacent segments 40 of tube 12, it can be seen that fin 20 has been modified to include at least at the curved portion 24 of fin 20 a scalloped or recessed segment 60 extending along the width of fin 20. The scalloped segment 60 is shaped to receive tube 12 therein, such that fin 20 cannot move laterally relative to tube 12. Therefore, the scalloped segment 60 can have any shape corresponding to the shape of microchannel tube 12, thereby preventing fin 20 from moving laterally relative to tube 12. Furthermore, although it is preferred to form the fan-shaped section 60 to correspond to the shape of the microchannel tube 12, it should be understood that the fan-shaped section 60 does not necessarily have to be formed to correspond to the microchannel tube 12, but only needs to be formed to suppress the lateral movement of the fins 20 relative to the tube 12.

[0060] The fan-shaped segment 60 can be formed by punching multiple holes in a flat sheet used to form the fin 20. This flat sheet can then be bent into an accordion-like structure, in which the holes formed at the bent portions 24 of the fin 20 will form the fan-shaped segment 60. Furthermore, after the support 18 and the tube 12 cooperate to compress the fin 20, it prevents the fin 20 from disengaging from the tube 12.

[0061] Figure 11 A fourth example connection between tube 12 and fin 20 is shown, which is Figure 10 Further modifications to the example embodiment shown. In the example shown, tube 12 is a standard microchannel tube, meaning that tube 12 does not have the protrusion 54 or spherical portion 58 as described above. However, to ensure that the fins 20 remain correctly positioned between adjacent segments 40 of tube 12, it can be seen that the fins 20 have been further modified such that the fan-shaped segments or recessed segments 60 are aligned with... Figure 10 The image shown is deeper than the one depicted.

[0062] Specifically, the fan-shaped segment 60 has a depth such that the curved portion 24 extends away from the upper main surface 30 and lower main surface 32 of the tube 12, such that the tube 12 is located within the fan-shaped segment 60, and the curved portion 24 does not engage with the tube 12. Although the tube 12 does not contact the curved portion 24 of the fin 20, it should be understood that the fin 20 maintains close contact with the tube 12. In this respect, when forming the fan-shaped segment 60, the material of the fin 20 forming the fan-shaped segment 60 can be cut into a pair of tabs 62, each tab having a free distal end 64 and a proximal end 66 that remains attached to the fin 20. Each tab 62 can be bent in a direction away from the curved portion 24 and in a direction opposite to each other, such that each free distal end 64 is substantially aligned with each other. The tube 12 can then be located within the fan-shaped segment 60, where the proximal end 66 is connected to the fin 20. Thus, the fin 20 remains in contact with the tube 12, and lateral movement of the fin 20 relative to the tube 12 is prevented. Furthermore, after the support 18 and tube 12 are engaged to compress the fins 20, it prevents the fins 20 from disengaging from the tube 12.

[0063] Figure 12 A pair of structural members 68 are shown in configuration that mate with a support 18 at the top and bottom of a heat exchanger 10. In addition to helping to compress the tubes 12 and fins 20 throughout the heat exchanger 10, it should be understood that the structural members 68 can provide protection for the tubes 12 at the top and bottom of the heat exchanger 10 against puncture. The structural member 68 is typically a planar member with at least one side edge 70 bent to extend away from the planar surface 72 of the structural member 68, thereby forming a flange 74 (e.g., the structural member 68 may be U-shaped, or the structural member 68 may be L-shaped). The support 18 may include a groove shaped to receive the structural member 68 passing through it. For example, see again... Figure 6 As can be seen, grooves 47 with notches 49 configured to mate with flange 74 can be located at opposite ends of support 18 for receiving L-shaped structural members 68. Alternatively, structural members 68 can be sandwiched between tube 12 and grooves 46 of support 18. In other words, tube 12 and structural members 68 mate with support 18 at the same grooves 46. Although structural members 68 are described above as U-shaped, it should be understood that one or both structural members 68 can have shapes such as I-beams, rods, or planar strips. An important function of structural members 68 is that they help compress tube 12 and fins 20 and / or provide protection for tube 12.

[0064] In each of the exemplary configurations described above, the tube 12 is not brazed to the fins 20, which reduces the manufacturing cost of the heat exchanger 10. In fact, after a preliminary evaluation of the heat exchanger 10, it was determined that the cost of producing the heat exchanger 10 could be reduced by more than 25% compared to a brazed heat exchanger. Furthermore, although the tube 12 is not brazed to the fins 20, it has been determined that the heat transfer exhibited by the heat exchanger 10 is within approximately 3% of that exhibited by a brazed heat exchanger. Therefore, this disclosure provides a heat exchanger 10 that exhibits satisfactory heat exchange capacity while significantly reducing cost. It should also be understood that the heat exchanger 10 is significantly more environmentally friendly because it does not require the use of chemicals in the manufacture of conventional brazed heat exchangers.

[0065] For purposes of illustration and description, the foregoing description of embodiments has been provided. This disclosure is not intended to be exhaustive or limiting. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and may be used in chosen embodiments even if not specifically shown or described. Variations are also possible in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A heat exchanger, the heat exchanger comprising: A microchannel tube having multiple straight segments interconnected by multiple curved segments; Multiple accordion-shaped fins are located between adjacent straight sections of the microchannel tube; as well as Multiple supports, each having multiple slots formed therein, each slot being configured to receive a corresponding straight segment of the microchannel tube. The plurality of supports are configured to orient adjacent straight sections of the microchannel tube such that the plurality of accordion-shaped fins located between adjacent straight sections of the microchannel tube are compressed by the adjacent straight sections of the microchannel tube. In this embodiment, the accordion-shaped fins are compressed by the adjacent straight section of the microchannel tube by a distance ranging from 0.003 inches to 0.015 inches.

2. The heat exchanger according to claim 1, wherein, At least one of the accordion-shaped fin and the microchannel tube includes a mating feature that prevents lateral movement of the accordion-shaped fin relative to an adjacent straight section of the microchannel tube.

3. The heat exchanger according to claim 1, wherein, The accordion-shaped fins were not brazed to the adjacent straight section of the microchannel tube.

4. The heat exchanger according to claim 2, wherein, The microchannel tube includes an upper planar main surface and a lower planar main surface, and the mating feature includes at least one protrusion extending longitudinally along each of the upper planar main surface and the lower planar main surface. The accordion-shaped fin located between adjacent straight sections of the microchannel tube includes a pair of recesses configured to engage with corresponding protrusions formed on adjacent straight sections of the microchannel tube.

5. The heat exchanger according to claim 4, wherein, A plurality of laterally spaced protrusions are formed on each of the upper main surface and the lower main surface of the plane, and the accordion-shaped fin located between adjacent straight sections of the microchannel tube includes a plurality of recesses configured to mate with corresponding protrusions formed on adjacent straight sections of the microchannel tube.

6. The heat exchanger according to claim 2, wherein, The microchannel tube includes an upper main surface and a lower main surface, and a pair of side surfaces connecting the upper main surface and the lower main surface, wherein the mating feature includes a spherical portion formed at each side surface, the spherical portion defining an adjacent surface that extends outward from at least one of the upper main surface and the lower main surface and contacts the accordion fin, and the spherical portion restricts lateral movement of the accordion fin located between adjacent straight segments of the microchannel tube.

7. The heat exchanger according to claim 2, wherein, The fitting feature is that a recessed section is formed in the accordion-shaped fin at the curved portion of the accordion-shaped fin, the recessed section being configured to receive the straight section of the microchannel tube, thereby restricting the lateral movement of the microchannel tube relative to the accordion-shaped fin.

8. The heat exchanger according to claim 7, wherein, The recessed section has a depth that allows the curved portion of the accordion-shaped fin to extend outward from the microchannel tube.

9. The heat exchanger according to claim 8, wherein, The accordion-shaped fin includes a pair of tabs located at the recessed section, the pair of tabs being curved away from the curved portion, and the microchannel tube being located on the pair of tabs.

10. The heat exchanger according to claim 1, wherein, The plurality of slots of the support are separated by fingers having tapered distal ends.

11. The heat exchanger according to claim 1, wherein, The plurality of slots are formed into a plurality of holes, and the plurality of holes are configured to receive the microchannel tube in the plurality of holes.

12. The heat exchanger of claim 1, further comprising a pair of planar support members that clamp the heat exchanger in the middle and cooperate with the plurality of supports.

13. A heat exchanger, the heat exchanger comprising: A microchannel tube having multiple straight segments interconnected by multiple curved segments; Multiple accordion-shaped fins are located between adjacent straight sections of the microchannel tube; as well as Multiple supports, each having multiple slots formed therein, each slot being configured to receive a corresponding straight segment of the microchannel tube. The microchannel tube includes an upper main surface and a lower main surface, each of which includes a plurality of protrusions, and the plurality of protrusions extend longitudinally along at least each of the plurality of straight segments; The accordion-shaped fins located between adjacent straight sections of the microchannel tube include a plurality of recesses configured to engage with a plurality of protrusions, such that when the recesses engage with the protrusions, lateral movement of the accordion-shaped fins relative to adjacent straight sections of the microchannel tube is restricted; and In this embodiment, the accordion-shaped fins are compressed by the adjacent straight section of the microchannel tube by a distance ranging from 0.003 inches to 0.015 inches.

14. The heat exchanger according to claim 13, wherein, Each accordion fin includes a plurality of planar portions connected by curved portions, the curved portions being configured to contact the upper main surface and the lower main surface of the microchannel tube when the accordion fin is located between adjacent straight sections of the microchannel tube, and the recesses are formed at the curved portions.

15. The heat exchanger according to claim 14, wherein, The curved portion was not brazed to the upper and lower main surfaces of the adjacent straight section of the microchannel tube.

16. The heat exchanger according to claim 13, wherein, The plurality of supports are configured to orient adjacent straight sections of the microchannel tube such that the plurality of accordion-shaped fins located between adjacent straight sections of the microchannel tube are compressed by the adjacent straight sections of the microchannel tube.

17. The heat exchanger according to claim 13, wherein, The plurality of slots of the support are separated by fingers having tapered distal ends.

18. The heat exchanger of claim 13, further comprising a pair of structural members attached to the support, the pair of structural members sandwiching the heat exchanger in between.

19. The heat exchanger according to claim 13, wherein, The engagement between the plurality of protrusions and the plurality of recesses does not restrict the longitudinal movement of the accordion-shaped fins relative to the adjacent straight sections.

20. A heat exchanger, the heat exchanger comprising: A microchannel tube having multiple straight segments interconnected by multiple curved segments; Multiple accordion-shaped fins are located between adjacent straight sections of the microchannel tube; as well as Multiple supports, each having multiple slots formed therein, each slot being configured to receive a corresponding straight segment of the microchannel tube. The plurality of supports are configured to orient adjacent straight sections of the microchannel tube such that the plurality of accordion-shaped fins located between adjacent straight sections of the microchannel tube are compressed by the adjacent straight sections of the microchannel tube. The plurality of slots in the bracket are separated by fingers, the fingers having tapered distal ends.

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