Laminated header for a microchannel heat exchanger

Abstract

A laminated header (100) for a microchannel heat exchanger comprises a first plate (102) comprising a first bore-hole (102-1), a second plate (104) comprising a first cut-out section (104-1), wherein a volume of the first cut-out section (104-1) along the length decreases in a direction away from the first bore-hole (102-1), a third plate (106) comprising a plurality of second bore-holes (106-1), a fourth plate (108) comprising a plurality of second cut-out sections (108-1), and a fifth plate (110) comprising a plurality of slots (S). The second plate (104) is parallel and between the first plate (102) and the third plate (106), and the fourth plate (108) is parallel and between the third plate (106) and the fifth plate (110). The first cut-out section (104-1) fluidically connects the first bore-hole (102-1) to each of the second bore-holes (106-1) and the second cut-out sections (108-1) fluidically connects the second bore-holes (106-1) to the second slots (S). The stacked header (100) is configured to fluidically connect the first bore-hole (102) to microchannel tubes (112).

Description

BACKGROUND

[0001] The invention relates to the field of heat exchangers, and more particularly, laminated header for a microchannel heat exchanger.

[0002] US 2016 / 169595 A1 discloses a stacking-type header for a heat exchanger, including: a first plate-shaped unit and a second plate-shaped unit stacked on one another.SUMMARY

[0003] According to a first aspect of the invention there is provided a laminated header for a microchannel heat exchanger. The laminated header comprises a first plate comprising a first bore-hole formed therein, a second plate comprising a first cut-out section of a first shape extending along a length of the second plate, wherein a volume of the first cut-out section along the length decreases in a direction away from the first bore-hole, a third plate comprising a plurality of second bore-holes formed therein and separated by a distance therebetween, a fourth plate comprising a plurality of second cut-out sections of a second shape, and a fifth plate comprising a plurality of slots, wherein the second plate is parallelly stacked between the first plate and the third plate, and the fourth plate is parallelly stacked between the third plate and the fifth plate in same orientation to form the laminated header, wherein the first cut-out section fluidically connects the first bore-hole to each of the second bore-holes and the plurality of second cut-out sections fluidically connects the plurality of second bore-holes to the plurality of slots, and wherein the laminated header is configured to receive and secure, within the plurality of slots, an end of a plurality of microchannel tubes associated with the microchannel heat exchanger, thereby fluidically connecting the first bore-hole to the plurality of microchannel tubes.

[0004] Optionally, the first plate, the second plate, the third plate, the fourth plate, and the fifth plate are parallelly stacked and brazed together to form the laminated header, and wherein the end of the plurality of microchannel tubes associated with the microchannel heat exchanger is inserted within the plurality of slots of the laminated header and further brazed to the laminated header to create a leak-proof connection between the laminated header and the plurality of microchannel tubes.

[0005] Optionally, the laminated header forms a fluidic passage that extends from the first bore-hole towards the plurality of slots while extending in a first direction along the length, between a top end and a bottom end, of the second plate and further extending from the first cut-out section into each of the second cut-out sections and the plurality of slots, via the plurality of second bore-holes, in a second direction perpendicular to the first direction and extending towards the plurality of slots or the microchannel tubes.

[0006] Optionally, the first bore-hole is at a bottom end of the first plate, and wherein the area or volume of the first cut-out section decreases from a bottom end towards a top end of the second plate.

[0007] Optionally, the first cut-out section has a trapezoidal shape with the volume decreasing from a bottom end towards a top end of the second plate.

[0008] Optionally, the first bore-hole is at a middle portion of the first plate, and wherein the volume of the first cut-out section decreases from the middle portion towards a bottom end and a top end of the second plate.

[0009] Optionally, the first bore-hole is at a top end of the first plate, and wherein the volume of the first cut-out section decreases from a top end towards a bottom end of the second plate.

[0010] Optionally, size or radii of the plurality of second bore-holes associated with the third plate increases in the direction away from the first bore-hole.

[0011] Optionally, the first bore-hole is at a bottom end of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from a bottom end towards a top end of the third plate.

[0012] Optionally, the first bore-hole is at a middle portion of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from the middle portion towards a bottom end and a top end of the third plate.

[0013] Optionally, the first bore-hole is at a top end of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from a top end towards a bottom end of the third plate.

[0014] Optionally, a constriction is defined on the first cut-out section of the second plate, between the first bore hole and the plurality of second bore-holes adjacent to the first bore hole.

[0015] Optionally, the plurality of second cut-out sections associated with the fourth plate has a rectangular or square profile.

[0016] Optionally, size or length of the plurality of second cut-out sections increases in the direction away from the first bore-hole.

[0017] Optionally, the second plate has a thickness that is greater than a thickness of each of the first plate and the third plate.

[0018] Optionally, the laminated header is configured to receive a fluid via the first bore-hole of the first plate and further allow the flow of the received fluid within the first cut-out section of the second plate in a first direction along a length, between a top end and a bottom end, of the second plate.

[0019] Optionally, the laminated header is further configured to allow uniform flow of the fluid from the first cut-out section into each of the second cut-out sections of the fourth plate, via the plurality of second bore-holes of the third plate, in a second direction perpendicular to the first direction and extending towards the plurality of microchannel tubes, and wherein the laminated header further allows uniform flow of the fluid from the plurality of second cut-out sections into one or more ports associated with each of the microchannel tubes via the slots of the fifth plate.

[0020] Optionally, the adjacent second cut-out sections associated with the fourth plate are separated by a baffle extending in a direction, orthogonal to the first direction and the second direction, along a width of the fourth plate.

[0021] Optionally, the first bore-hole is formed at a center of a width of the first plate; the plurality of second bore-holes is formed at a center of a width of the third plate; and the plurality of slots is formed at a center of a width of the fifth plate.

[0022] According to a second aspect of the invention there is provided a heat exchanger comprises the one or more laminated headers; wherein the one or more headers are coaxially and sequentially stacked in a longitudinal direction to form a vertical header having one or more compartments, wherein the plurality of microchannel tubes associated with the heat exchanger is fluidically connected to the plurality of slots associated with the one or more laminated headers.

[0023] In one or more embodiments, the heat exchanger further comprises an external distributor comprising: an inlet configured to be fluidically connected to a supply tube; and one or more outlets, each configured to be fluidically connected to the first bore-hole associated with one of the laminated headers via feeder tubes or tube stubs.

[0024] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, features, and techniques of the invention will become more apparent from the following description taken in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings are included to provide a further understanding of the invention. The drawings illustrate exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention by way of example only.

[0026] In the drawings, similar components and / or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label. FIG. 1A illustrates an exemplary side cross-sectional side view of a laminated vertical header. FIG. 1B illustrates exemplary front views of the plates associated with the header of FIG. 1A. FIG. 2A illustrates an exemplary side cross-sectional side view of another laminated vertical header. FIG. 2B illustrates exemplary front views of the plates associated with the header of FIG. 2A. FIG. 3 illustrates an exemplary side cross-sectional side view depicting multiple laminated vertical headers stacked together and connected to form a single external fluid distributor. FIG. 4A illustrates exemplary front views of the first and second plates associated with the header of FIGs. 1A and 2A where the first bore-hole is at middle portion of the first plate. FIG. 4B illustrates exemplary front views of the first and second plates associated with the header of FIGs. 1A and 2A where the first bore-hole is at top end of the first plate. FIG. 5 illustrates exemplary front views of the plates associated with yet another laminated vertical header where a portion of the first cut-out section, between the first bore-hole and the second bore-hole adjacent to the first bore-hole, of the second plate has a substantially narrow passage or area. FIG. 6 illustrates exemplary front views of the plates associated with another vertical header where the first bore-hole is at middle portion of the first plate and a portion of the first cut-out section, between the first bore-hole and the second bore-hole adjacent to the first bore-hole, has a substantially narrow passage or area. DETAILED DESCRIPTION

[0027] The following is a detailed description of embodiments of the invention depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

[0028] Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0029] In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the invention, the components described herein may be positioned in any desired orientation. Thus, the use of terms such as "above," "below," "upper," "lower," "first", "second" or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, described herein may be oriented in any desired direction.

[0030] Microchannel heat exchangers (MCHX) are widely employed in heating, ventilation, and air conditioning (HVAC) systems for their compact size, high heat transfer efficiency, and improved energy efficiency. However, the effectiveness of heat transfer in the MCHX may impact the overall efficiency of the HVAC system. One of the challenges faced in MCHX is maldistribution of two-phase flow at the inlet of heat exchange tubes associated with the MCHX. Maldistribution occurs when there is an uneven distribution of refrigerant between the tubes, leading to variations in local heat transfer rates. In particular, maldistribution within a vertical header of the MCHX poses a substantial hurdle, as the force of gravity acts against maintaining a consistent mixing of liquid and vapor along the header's height. There is, therefore, a need to provide an improved vertical header for MCHX which enables uniform supply of fluid (refrigerant) into the ports of the heat exchange tubes connected to the vertical header while restricting separation of liquid-phase within the header under gravity.

[0031] Referring to FIGs. 1A to 2B, a laminated header 100 (referred to as header 100, hereinafter) for a heat exchanger is disclosed. The header 100 may include a first plate 102 (also referred to as an inlet plate 102, herein), that further includes a first bore-hole 102-1 formed therein. Further, the header 100 may include a second plate 104 (also referred to as an interlayer plate, herein) that includes a first cut-out section 104-1 of a first shape extending along a length of the second plate 104. The header 100 may further include a third plate 106 (also referred to as a hole plate, herein) that includes a plurality of second bore-holes 106-1 formed therein and separated by a distance therebetween. In addition, the header 100 may include a fourth plate 108 (also referred to as a section plate, herein) including a plurality of second cut-out sections 108-1 of a second shape. Further, the header 100 may include a fifth plate 110 (also referred to as a tube plate, herein) that includes a plurality of slots S. The detailed shape and construction of these plates have been explained in conjunction with FIGs. 1B and 2B.

[0032] In one or more embodiments, the second plate 104 may be parallelly stacked between the first plate 102 and the third plate 106, and the fourth plate 108 may be parallelly stacked between the third plate 106 and the fifth plate 110 in same orientation to form the (stacked) header 100, such that the first cut-out section 104-1 fluidically connects the first bore-hole 102-1 to each of the second bore-holes 106-1 and the second cut-out sections 108-1 fluidically connects the second bore-holes 106-1 to the slots S. Further, the (stacked) header 100 may be configured to receive and secure, within the plurality of slots S, an end of a plurality of microchannel tubes 112 associated with the heat exchanger, thereby fluidically connecting the first bore-hole 102-1 to the microchannel tubes 112. The size of slots S may be based on size of individual microchannel tubes 112, such that the ends of the microchannel tubes 112 can be securely fitted in the corresponding slots S.

[0033] In one or more embodiments, the first plate 102, the second plate 104, the third plate 106, the fourth plate 108, and the fifth plate 110 may be parallelly stacked and brazed together to form the laminated header 100. Further, the end of the microchannel tubes 112 may be inserted within the slots S of the laminated header 100 and further brazed to the laminated header 100 to create a leak-proof connection between the laminated header 100 and the microchannel tubes 112. Accordingly, the (stacked) header 100 forms a fluidic passage that extends from the first bore-hole 102-1 of the first plate 102 towards the plurality of slots S of the third plate 106 while extending in a first direction (A) along a length, between a top end and a bottom end, of the second plate 104 and further extending from the first cut-out section 104-1 into each of the second cut-out sections 108-1 and the plurality of slots S or the microchannel tubes 112, via the plurality of second bore-holes 106-1, in a second direction (B) substantially perpendicular to the first direction (A). Further, the first-bore hole of the first plate 102 may be fluidically connected to a supply tube 114 associated with the heat exchanger that may be configured to supply two-phase refrigerant (fluid) into the header 100.

[0034] In one or more embodiments, as illustrated in FIG. 1B and 2B, the first bore-hole 102-1 may be formed at a center of a width of the first plate 102. The second bore-holes 106-1 may be formed at a center of a width of the third plate 106 with a space therebetween. Further, the slots S may be formed at a center of a width of the fifth plate 110, each of the slots S being separated by a partition wall. Furthermore, in one or more embodiments, the second plate 104 may have the same or different thickness compared to the first plate 102 and the third plate 106 to facilitate flow of the fluid with minimal back pressure. However, in some embodiments, the first, second, and third plate 106s may also have same thickness without any limitations.

[0035] In one or more embodiments, a volume of (or area defined by) the first cut-out section 104-1 may decrease along its length in a direction away from the first bore-hole 102-1. This configuration can keep the same mass flow rate at the inlet of all second bore-holes 106-1 of the third plate 106 and further into the ports of the of microchannel tubes 112.

[0036] Referring to FIG. 1B, in one or more embodiments, the first bore-hole 102-1 of the first plate 102 may be at a bottom end of the first plate 102. Accordingly, the area or volume of the first cut-out section 104-1 may decrease along a bottom end towards a top end of the second plate 104. As illustrated, the first cut-out section 104-1 may have a trapezoidal shape / contour with the volume / width decreasing from the bottom end towards the top end of the second plate 104. The decreasing volume may help ensuring equal fluid flow velocity in the flow channel as the part of the two-phase mixture is fed through holes 106-1.

[0037] Referring to FIG. 4A, in one or more embodiments, the first bore-hole 102-1 of the first plate 102 may be at a substantially middle portion of the first plate 102. Accordingly, the area or volume of the first cut-out section 104-1 may decrease from the middle portion towards a bottom end and / or a top end of the second plate 104. In such embodiments, the first cut-out section 104-1 may have a shape / contour similar to that of a stretched hexagon or a diamond.

[0038] Referring to FIG. 4B, in one or more embodiments, the first bore-hole 102-1 of the first plate 102 may be at a top end of the first plate 102. Accordingly, the area or volume of the first cut-out section 104-1 may decrease from a top end towards a bottom end of the second plate 104.

[0039] In one or more embodiments, size or radii of the second bore-holes 106-1 associated with the third plate 106 may increase in the direction away from the first bore-hole 102-1. In such embodiments, the volume of the first cut-out section 104-1 may be equal or uniform along its length. The first cut-out section 104-1 may have a substantially rectangular or square profile. This configuration may keep the same or uniform mass flow rate at the outlet of all second bore-holes 106-1 of the third plate 106 and further into the ports of the of microchannel tubes 112.

[0040] Referring to FIG. 2B, in one or more embodiments, the first bore-hole 102-1 may be at a bottom end of the first plate 102. Accordingly, the size or radii of each of the second bore-holes 106-1 may increase from a bottom end towards a top end of the third plate 106. For example, the second bore-hole 106-1 at or proximate to the bottom end of the third plate 106 may have a smaller size / diameter in comparison to the second bore-hole 106-1 at or proximate to the top end of the third plate 106. The second bore-holes 106- may be arranged in increasing order of sizes / diameters from the bottom end to the top end of the third plate 106.

[0041] Further, in one or more embodiments (as shown in FIG. 4A), the first bore-hole 102-1 may be at a substantially middle portion of the first plate 102. Accordingly, the size or radii of the plurality of second bore-holes 106-1 may increase from the middle portion towards a bottom end and a top end of the third plate 106. In such embodiment, the second bore-holes 106-1 at or in proximity to the center of the third plate 106 may have the smallest radii or size of all the second bore-holes 106-1, and each successive second bore-hole 106-1 defined from the center / middle to the top end and / or the bottom end of the third plate 106 may have a larger size or radii than the preceding second-bore hole.

[0042] Furthermore, in one or more embodiments (as shown in FIG. 4B), the first bore-hole 102-1 may be at a top end of the first plate 102. Accordingly, the size or radii of the plurality of second bore-holes 106-1 may increase from a top end towards a bottom end of the third plate 106.

[0043] Referring back to FIGs. 1B and 2B, in one or more embodiments, the plurality of second cut-out sections 108-1 associated with the fourth plate 108 may have a substantially rectangular or square profile. Further, in one or more embodiments (not shown), the size or length of the plurality of second cut-out sections 108-1 may increase in the direction away from the first bore-hole 102-1. For example, the second cut-out sections 108-1 may be arranged in increasing order of sizes from the top end to the bottom end of the fourth plate 108 (when the first bore-hole 102-1 is defined on the bottom end of the first plate 102), or from the bottom end to the top end of the fourth plate 108 (when the first bore-hole 102-1 defined on the top end of the first plate 102). However, in some embodiments, the size or length of each of the second cut-out sections 108-1 may be equal and uniform.

[0044] In one or more embodiments, the adjacent second cut-out sections 108-1 associated with the fourth plate 108 may be separated by a baffle 108-2 (shown in FIGs. 1B and 2B) extending in a direction (C), orthogonal to the first direction (A) and the second direction (B), along a width of the fourth plate 108.

[0045] Accordingly, referring to FIG. 1A and 2A, the (stacked) header 100 may be configured to receive a fluid via the first bore-hole 102-1 of the first plate 102 and further allow the flow of the received fluid within the first cut-out section 104-1 of the second plate 104 in a first direction (A) along a length, between a top end and a bottom end, of the second plate 104. The header 100 may be further configured to allow uniform flow of the fluid from the first cut-out section 104-1 into each of the second cut-out sections 108-1 of the fourth plate 108, via the second bore-holes 106-1 of the third plate 106, in a second direction (B) perpendicular to the first direction (A) and extending towards the plurality of microchannel tubes 112. Furthermore, the header 100 may allow uniform flow of the fluid from the plurality of second cut-out sections 108-1 into one or more ports associated with each of the microchannel tubes 112 via the slots S of the fifth plate 110.

[0046] Referring to FIGs. 5 and 6, in one or more embodiments, a constriction or a narrow passage / area is defined between the first bore-hole 102-1 and the second bore-hole 106-1 adjacent to the first bore-hole 102-1, on the first cut-out section 104-1 of the second plate 104 (also referred to as a constriction, herein). As illustrated in FIG. 5, in one or more embodiments, when the first bore-hole 102-1 is at a bottom end of the first plate 102, a portion P at a bottom end of the first cut-out section 104-1, between the first bore-hole 102-1 and the bottom-most second bore-hole 106-1 (adjacent to the first bore-hole 102-1) may define the constriction, i.e., a substantially narrow passage or area (C). Further, as illustrated in FIG. 6, in one or more embodiments, when the first bore-hole 102-1 is in a middle of the first plate 102, the portions P1, P2 of the first cut-out section 104-1, between the first bore-hole 102-1 and the second bore-holes 106-1 (above and below the first bore-hole 102-1) may define the constriction, i.e., a substantially narrow passage or area (C). In such embodiments, the first cut-out section 104-1 may have two narrowed portions P1, P2 adjacent to the opposite ends of the first bore-hole 102-1.

[0047] Referring to FIG. 3, in one or more embodiments, a heat exchanger comprising one or more laminated headers 100 of FIGs. 1A and / or FIG. 2A is disclosed. As illustrated, the headers 100-1 to 100-N may be coaxially and sequentially stacked in a longitudinal direction to form a single vertical header 300 having one or more compartments (headers 100-1 to 100-N). Further, the plurality of microchannel tubes 112 associated with the heat exchanger may be fluidically connected to the plurality of slots S associated with the headers 100-1 to 100-N.

[0048] In addition, in one or more embodiments, the heat exchanger may include an external distributor 302 having an inlet, and one or more outlet connected to the inlet via fluidic passages. The inlet of the distributor 302 may be configured to be fluidically connected to a supply tube 114. Further, each of the outlets of the distributor 302 may be configured to be fluidically connected to the first bore-hole 102-1 associated with one of the headers 100-1 to 100-N via feeder tubes 304 or tube stubs to provide two-phase flow with equal volumes at the inlet of each compartment formed in the corresponding header 100. Accordingly, the distributor 302 may supply equal volume of fluid into each of the header 100-1 to 100-N (or compartments of the vertical header 300). Further, each of the header 100-1 to 100-N (compartments) may be configured to uniformly supply an equal volume of the received fluid into ports of each of the microchannel tubes 112 of the heat exchanger.

[0049] It is to be appreciated that the decrease in the flow area of the first cut-out section 104-1 in the second plate 104 in a direction away from the first bore-hole 102-1 may allow the same mass flow rate of the fluid at the inlet of all holes of the third plate 106 and further into the ports of the of microchannel tubes 112. Moreover, when the flow area of the first cut-out section 104-1 is uniform along its length in the second plate 104, the increase in size or radii of the second-bore holes of the third plate 106 (while moving) in a direction away from the first bore-hole 102-1 may allow the same mass flow rate of the fluid at the outlet of all holes of the third plate 106 and further into the ports of the of microchannel tubes 112. Hence, the volume of the fluid may be uniformly distributed out of the third plate 106 and eventually to the microchannel tubes 112, thereby preventing the problems associated with maldistribution of two-phase flow to the microchannel tubes 112 associated with the heat exchanger, such as variations in local heat transfer rates and maintaining of a consistent mixing of liquid and vapour along the header's height.

[0050] Thus, the invention overcomes the challenges associated with existing heat exchangers, by providing an improved laminated vertical header for the heat exchanger. The header uniformly supplies the fluid (refrigerant) into the ports of each of the tubes while maintaining a lower pressure drop and and restricting separation of liquid-phase within the header under gravity, thereby improving the performance and efficiency of the overall heat exchanger. In addition, the simple design of the header makes it easier to manufacture as well as cost-effective, and further allows these headers to be stacked coaxially to increase the overall height of the header while restricting separation of liquid-phase within the header under gravity.

[0051] In interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Examples

Embodiment Construction

[0027]The following is a detailed description of embodiments of the invention depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

[0028]Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0029]In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those...

BACKGROUND

[0001] The invention relates to the field of heat exchangers, and more particularly, laminated header for a microchannel heat exchanger.

[0002] US 2016 / 169595 A1 discloses a stacking-type header for a heat exchanger, including: a first plate-shaped unit and a second plate-shaped unit stacked on one another.SUMMARY

[0003] According to a first aspect of the invention there is provided a laminated header for a microchannel heat exchanger. The laminated header comprises a first plate comprising a first bore-hole formed therein, a second plate comprising a first cut-out section of a first shape extending along a length of the second plate, wherein a volume of the first cut-out section along the length decreases in a direction away from the first bore-hole, a third plate comprising a plurality of second bore-holes formed therein and separated by a distance therebetween, a fourth plate comprising a plurality of second cut-out sections of a second shape, and a fifth plate comprising a plurality of slots, wherein the second plate is parallelly stacked between the first plate and the third plate, and the fourth plate is parallelly stacked between the third plate and the fifth plate in same orientation to form the laminated header, wherein the first cut-out section fluidically connects the first bore-hole to each of the second bore-holes and the plurality of second cut-out sections fluidically connects the plurality of second bore-holes to the plurality of slots, and wherein the laminated header is configured to receive and secure, within the plurality of slots, an end of a plurality of microchannel tubes associated with the microchannel heat exchanger, thereby fluidically connecting the first bore-hole to the plurality of microchannel tubes.

[0004] Optionally, the first plate, the second plate, the third plate, the fourth plate, and the fifth plate are parallelly stacked and brazed together to form the laminated header, and wherein the end of the plurality of microchannel tubes associated with the microchannel heat exchanger is inserted within the plurality of slots of the laminated header and further brazed to the laminated header to create a leak-proof connection between the laminated header and the plurality of microchannel tubes.

[0005] Optionally, the laminated header forms a fluidic passage that extends from the first bore-hole towards the plurality of slots while extending in a first direction along the length, between a top end and a bottom end, of the second plate and further extending from the first cut-out section into each of the second cut-out sections and the plurality of slots, via the plurality of second bore-holes, in a second direction perpendicular to the first direction and extending towards the plurality of slots or the microchannel tubes.

[0006] Optionally, the first bore-hole is at a bottom end of the first plate, and wherein the area or volume of the first cut-out section decreases from a bottom end towards a top end of the second plate.

[0007] Optionally, the first cut-out section has a trapezoidal shape with the volume decreasing from a bottom end towards a top end of the second plate.

[0008] Optionally, the first bore-hole is at a middle portion of the first plate, and wherein the volume of the first cut-out section decreases from the middle portion towards a bottom end and a top end of the second plate.

[0009] Optionally, the first bore-hole is at a top end of the first plate, and wherein the volume of the first cut-out section decreases from a top end towards a bottom end of the second plate.

[0010] Optionally, size or radii of the plurality of second bore-holes associated with the third plate increases in the direction away from the first bore-hole.

[0011] Optionally, the first bore-hole is at a bottom end of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from a bottom end towards a top end of the third plate.

[0012] Optionally, the first bore-hole is at a middle portion of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from the middle portion towards a bottom end and a top end of the third plate.

[0013] Optionally, the first bore-hole is at a top end of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from a top end towards a bottom end of the third plate.

[0014] Optionally, a constriction is defined on the first cut-out section of the second plate, between the first bore hole and the plurality of second bore-holes adjacent to the first bore hole.

[0015] Optionally, the plurality of second cut-out sections associated with the fourth plate has a rectangular or square profile.

[0016] Optionally, size or length of the plurality of second cut-out sections increases in the direction away from the first bore-hole.

[0017] Optionally, the second plate has a thickness that is greater than a thickness of each of the first plate and the third plate.

[0018] Optionally, the laminated header is configured to receive a fluid via the first bore-hole of the first plate and further allow the flow of the received fluid within the first cut-out section of the second plate in a first direction along a length, between a top end and a bottom end, of the second plate.

[0019] Optionally, the laminated header is further configured to allow uniform flow of the fluid from the first cut-out section into each of the second cut-out sections of the fourth plate, via the plurality of second bore-holes of the third plate, in a second direction perpendicular to the first direction and extending towards the plurality of microchannel tubes, and wherein the laminated header further allows uniform flow of the fluid from the plurality of second cut-out sections into one or more ports associated with each of the microchannel tubes via the slots of the fifth plate.

[0020] Optionally, the adjacent second cut-out sections associated with the fourth plate are separated by a baffle extending in a direction, orthogonal to the first direction and the second direction, along a width of the fourth plate.

[0021] Optionally, the first bore-hole is formed at a center of a width of the first plate; the plurality of second bore-holes is formed at a center of a width of the third plate; and the plurality of slots is formed at a center of a width of the fifth plate.

[0022] According to a second aspect of the invention there is provided a heat exchanger comprises the one or more laminated headers; wherein the one or more headers are coaxially and sequentially stacked in a longitudinal direction to form a vertical header having one or more compartments, wherein the plurality of microchannel tubes associated with the heat exchanger is fluidically connected to the plurality of slots associated with the one or more laminated headers.

[0023] In one or more embodiments, the heat exchanger further comprises an external distributor comprising: an inlet configured to be fluidically connected to a supply tube; and one or more outlets, each configured to be fluidically connected to the first bore-hole associated with one of the laminated headers via feeder tubes or tube stubs.

[0024] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, features, and techniques of the invention will become more apparent from the following description taken in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings are included to provide a further understanding of the invention. The drawings illustrate exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention by way of example only.

[0026] In the drawings, similar components and / or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label. FIG. 1A illustrates an exemplary side cross-sectional side view of a laminated vertical header. FIG. 1B illustrates exemplary front views of the plates associated with the header of FIG. 1A. FIG. 2A illustrates an exemplary side cross-sectional side view of another laminated vertical header. FIG. 2B illustrates exemplary front views of the plates associated with the header of FIG. 2A. FIG. 3 illustrates an exemplary side cross-sectional side view depicting multiple laminated vertical headers stacked together and connected to form a single external fluid distributor. FIG. 4A illustrates exemplary front views of the first and second plates associated with the header of FIGs. 1A and 2A where the first bore-hole is at middle portion of the first plate. FIG. 4B illustrates exemplary front views of the first and second plates associated with the header of FIGs. 1A and 2A where the first bore-hole is at top end of the first plate. FIG. 5 illustrates exemplary front views of the plates associated with yet another laminated vertical header where a portion of the first cut-out section, between the first bore-hole and the second bore-hole adjacent to the first bore-hole, of the second plate has a substantially narrow passage or area. FIG. 6 illustrates exemplary front views of the plates associated with another vertical header where the first bore-hole is at middle portion of the first plate and a portion of the first cut-out section, between the first bore-hole and the second bore-hole adjacent to the first bore-hole, has a substantially narrow passage or area. DETAILED DESCRIPTION

[0027] The following is a detailed description of embodiments of the invention depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

[0028] Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0029] In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the invention, the components described herein may be positioned in any desired orientation. Thus, the use of terms such as "above," "below," "upper," "lower," "first", "second" or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, described herein may be oriented in any desired direction.

[0030] Microchannel heat exchangers (MCHX) are widely employed in heating, ventilation, and air conditioning (HVAC) systems for their compact size, high heat transfer efficiency, and improved energy efficiency. However, the effectiveness of heat transfer in the MCHX may impact the overall efficiency of the HVAC system. One of the challenges faced in MCHX is maldistribution of two-phase flow at the inlet of heat exchange tubes associated with the MCHX. Maldistribution occurs when there is an uneven distribution of refrigerant between the tubes, leading to variations in local heat transfer rates. In particular, maldistribution within a vertical header of the MCHX poses a substantial hurdle, as the force of gravity acts against maintaining a consistent mixing of liquid and vapor along the header's height. There is, therefore, a need to provide an improved vertical header for MCHX which enables uniform supply of fluid (refrigerant) into the ports of the heat exchange tubes connected to the vertical header while restricting separation of liquid-phase within the header under gravity.

[0031] Referring to FIGs. 1A to 2B, a laminated header 100 (referred to as header 100, hereinafter) for a heat exchanger is disclosed. The header 100 may include a first plate 102 (also referred to as an inlet plate 102, herein), that further includes a first bore-hole 102-1 formed therein. Further, the header 100 may include a second plate 104 (also referred to as an interlayer plate, herein) that includes a first cut-out section 104-1 of a first shape extending along a length of the second plate 104. The header 100 may further include a third plate 106 (also referred to as a hole plate, herein) that includes a plurality of second bore-holes 106-1 formed therein and separated by a distance therebetween. In addition, the header 100 may include a fourth plate 108 (also referred to as a section plate, herein) including a plurality of second cut-out sections 108-1 of a second shape. Further, the header 100 may include a fifth plate 110 (also referred to as a tube plate, herein) that includes a plurality of slots S. The detailed shape and construction of these plates have been explained in conjunction with FIGs. 1B and 2B.

[0032] In one or more embodiments, the second plate 104 may be parallelly stacked between the first plate 102 and the third plate 106, and the fourth plate 108 may be parallelly stacked between the third plate 106 and the fifth plate 110 in same orientation to form the (stacked) header 100, such that the first cut-out section 104-1 fluidically connects the first bore-hole 102-1 to each of the second bore-holes 106-1 and the second cut-out sections 108-1 fluidically connects the second bore-holes 106-1 to the slots S. Further, the (stacked) header 100 may be configured to receive and secure, within the plurality of slots S, an end of a plurality of microchannel tubes 112 associated with the heat exchanger, thereby fluidically connecting the first bore-hole 102-1 to the microchannel tubes 112. The size of slots S may be based on size of individual microchannel tubes 112, such that the ends of the microchannel tubes 112 can be securely fitted in the corresponding slots S.

[0033] In one or more embodiments, the first plate 102, the second plate 104, the third plate 106, the fourth plate 108, and the fifth plate 110 may be parallelly stacked and brazed together to form the laminated header 100. Further, the end of the microchannel tubes 112 may be inserted within the slots S of the laminated header 100 and further brazed to the laminated header 100 to create a leak-proof connection between the laminated header 100 and the microchannel tubes 112. Accordingly, the (stacked) header 100 forms a fluidic passage that extends from the first bore-hole 102-1 of the first plate 102 towards the plurality of slots S of the third plate 106 while extending in a first direction (A) along a length, between a top end and a bottom end, of the second plate 104 and further extending from the first cut-out section 104-1 into each of the second cut-out sections 108-1 and the plurality of slots S or the microchannel tubes 112, via the plurality of second bore-holes 106-1, in a second direction (B) substantially perpendicular to the first direction (A). Further, the first-bore hole of the first plate 102 may be fluidically connected to a supply tube 114 associated with the heat exchanger that may be configured to supply two-phase refrigerant (fluid) into the header 100.

[0034] In one or more embodiments, as illustrated in FIG. 1B and 2B, the first bore-hole 102-1 may be formed at a center of a width of the first plate 102. The second bore-holes 106-1 may be formed at a center of a width of the third plate 106 with a space therebetween. Further, the slots S may be formed at a center of a width of the fifth plate 110, each of the slots S being separated by a partition wall. Furthermore, in one or more embodiments, the second plate 104 may have the same or different thickness compared to the first plate 102 and the third plate 106 to facilitate flow of the fluid with minimal back pressure. However, in some embodiments, the first, second, and third plate 106s may also have same thickness without any limitations.

[0035] In one or more embodiments, a volume of (or area defined by) the first cut-out section 104-1 may decrease along its length in a direction away from the first bore-hole 102-1. This configuration can keep the same mass flow rate at the inlet of all second bore-holes 106-1 of the third plate 106 and further into the ports of the of microchannel tubes 112.

[0036] Referring to FIG. 1B, in one or more embodiments, the first bore-hole 102-1 of the first plate 102 may be at a bottom end of the first plate 102. Accordingly, the area or volume of the first cut-out section 104-1 may decrease along a bottom end towards a top end of the second plate 104. As illustrated, the first cut-out section 104-1 may have a trapezoidal shape / contour with the volume / width decreasing from the bottom end towards the top end of the second plate 104. The decreasing volume may help ensuring equal fluid flow velocity in the flow channel as the part of the two-phase mixture is fed through holes 106-1.

[0037] Referring to FIG. 4A, in one or more embodiments, the first bore-hole 102-1 of the first plate 102 may be at a substantially middle portion of the first plate 102. Accordingly, the area or volume of the first cut-out section 104-1 may decrease from the middle portion towards a bottom end and / or a top end of the second plate 104. In such embodiments, the first cut-out section 104-1 may have a shape / contour similar to that of a stretched hexagon or a diamond.

[0038] Referring to FIG. 4B, in one or more embodiments, the first bore-hole 102-1 of the first plate 102 may be at a top end of the first plate 102. Accordingly, the area or volume of the first cut-out section 104-1 may decrease from a top end towards a bottom end of the second plate 104.

[0039] In one or more embodiments, size or radii of the second bore-holes 106-1 associated with the third plate 106 may increase in the direction away from the first bore-hole 102-1. In such embodiments, the volume of the first cut-out section 104-1 may be equal or uniform along its length. The first cut-out section 104-1 may have a substantially rectangular or square profile. This configuration may keep the same or uniform mass flow rate at the outlet of all second bore-holes 106-1 of the third plate 106 and further into the ports of the of microchannel tubes 112.

[0040] Referring to FIG. 2B, in one or more embodiments, the first bore-hole 102-1 may be at a bottom end of the first plate 102. Accordingly, the size or radii of each of the second bore-holes 106-1 may increase from a bottom end towards a top end of the third plate 106. For example, the second bore-hole 106-1 at or proximate to the bottom end of the third plate 106 may have a smaller size / diameter in comparison to the second bore-hole 106-1 at or proximate to the top end of the third plate 106. The second bore-holes 106- may be arranged in increasing order of sizes / diameters from the bottom end to the top end of the third plate 106.

[0041] Further, in one or more embodiments (as shown in FIG. 4A), the first bore-hole 102-1 may be at a substantially middle portion of the first plate 102. Accordingly, the size or radii of the plurality of second bore-holes 106-1 may increase from the middle portion towards a bottom end and a top end of the third plate 106. In such embodiment, the second bore-holes 106-1 at or in proximity to the center of the third plate 106 may have the smallest radii or size of all the second bore-holes 106-1, and each successive second bore-hole 106-1 defined from the center / middle to the top end and / or the bottom end of the third plate 106 may have a larger size or radii than the preceding second-bore hole.

[0042] Furthermore, in one or more embodiments (as shown in FIG. 4B), the first bore-hole 102-1 may be at a top end of the first plate 102. Accordingly, the size or radii of the plurality of second bore-holes 106-1 may increase from a top end towards a bottom end of the third plate 106.

[0043] Referring back to FIGs. 1B and 2B, in one or more embodiments, the plurality of second cut-out sections 108-1 associated with the fourth plate 108 may have a substantially rectangular or square profile. Further, in one or more embodiments (not shown), the size or length of the plurality of second cut-out sections 108-1 may increase in the direction away from the first bore-hole 102-1. For example, the second cut-out sections 108-1 may be arranged in increasing order of sizes from the top end to the bottom end of the fourth plate 108 (when the first bore-hole 102-1 is defined on the bottom end of the first plate 102), or from the bottom end to the top end of the fourth plate 108 (when the first bore-hole 102-1 defined on the top end of the first plate 102). However, in some embodiments, the size or length of each of the second cut-out sections 108-1 may be equal and uniform.

[0044] In one or more embodiments, the adjacent second cut-out sections 108-1 associated with the fourth plate 108 may be separated by a baffle 108-2 (shown in FIGs. 1B and 2B) extending in a direction (C), orthogonal to the first direction (A) and the second direction (B), along a width of the fourth plate 108.

[0045] Accordingly, referring to FIG. 1A and 2A, the (stacked) header 100 may be configured to receive a fluid via the first bore-hole 102-1 of the first plate 102 and further allow the flow of the received fluid within the first cut-out section 104-1 of the second plate 104 in a first direction (A) along a length, between a top end and a bottom end, of the second plate 104. The header 100 may be further configured to allow uniform flow of the fluid from the first cut-out section 104-1 into each of the second cut-out sections 108-1 of the fourth plate 108, via the second bore-holes 106-1 of the third plate 106, in a second direction (B) perpendicular to the first direction (A) and extending towards the plurality of microchannel tubes 112. Furthermore, the header 100 may allow uniform flow of the fluid from the plurality of second cut-out sections 108-1 into one or more ports associated with each of the microchannel tubes 112 via the slots S of the fifth plate 110.

[0046] Referring to FIGs. 5 and 6, in one or more embodiments, a constriction or a narrow passage / area is defined between the first bore-hole 102-1 and the second bore-hole 106-1 adjacent to the first bore-hole 102-1, on the first cut-out section 104-1 of the second plate 104 (also referred to as a constriction, herein). As illustrated in FIG. 5, in one or more embodiments, when the first bore-hole 102-1 is at a bottom end of the first plate 102, a portion P at a bottom end of the first cut-out section 104-1, between the first bore-hole 102-1 and the bottom-most second bore-hole 106-1 (adjacent to the first bore-hole 102-1) may define the constriction, i.e., a substantially narrow passage or area (C). Further, as illustrated in FIG. 6, in one or more embodiments, when the first bore-hole 102-1 is in a middle of the first plate 102, the portions P1, P2 of the first cut-out section 104-1, between the first bore-hole 102-1 and the second bore-holes 106-1 (above and below the first bore-hole 102-1) may define the constriction, i.e., a substantially narrow passage or area (C). In such embodiments, the first cut-out section 104-1 may have two narrowed portions P1, P2 adjacent to the opposite ends of the first bore-hole 102-1.

[0047] Referring to FIG. 3, in one or more embodiments, a heat exchanger comprising one or more laminated headers 100 of FIGs. 1A and / or FIG. 2A is disclosed. As illustrated, the headers 100-1 to 100-N may be coaxially and sequentially stacked in a longitudinal direction to form a single vertical header 300 having one or more compartments (headers 100-1 to 100-N). Further, the plurality of microchannel tubes 112 associated with the heat exchanger may be fluidically connected to the plurality of slots S associated with the headers 100-1 to 100-N.

[0048] In addition, in one or more embodiments, the heat exchanger may include an external distributor 302 having an inlet, and one or more outlet connected to the inlet via fluidic passages. The inlet of the distributor 302 may be configured to be fluidically connected to a supply tube 114. Further, each of the outlets of the distributor 302 may be configured to be fluidically connected to the first bore-hole 102-1 associated with one of the headers 100-1 to 100-N via feeder tubes 304 or tube stubs to provide two-phase flow with equal volumes at the inlet of each compartment formed in the corresponding header 100. Accordingly, the distributor 302 may supply equal volume of fluid into each of the header 100-1 to 100-N (or compartments of the vertical header 300). Further, each of the header 100-1 to 100-N (compartments) may be configured to uniformly supply an equal volume of the received fluid into ports of each of the microchannel tubes 112 of the heat exchanger.

[0049] It is to be appreciated that the decrease in the flow area of the first cut-out section 104-1 in the second plate 104 in a direction away from the first bore-hole 102-1 may allow the same mass flow rate of the fluid at the inlet of all holes of the third plate 106 and further into the ports of the of microchannel tubes 112. Moreover, when the flow area of the first cut-out section 104-1 is uniform along its length in the second plate 104, the increase in size or radii of the second-bore holes of the third plate 106 (while moving) in a direction away from the first bore-hole 102-1 may allow the same mass flow rate of the fluid at the outlet of all holes of the third plate 106 and further into the ports of the of microchannel tubes 112. Hence, the volume of the fluid may be uniformly distributed out of the third plate 106 and eventually to the microchannel tubes 112, thereby preventing the problems associated with maldistribution of two-phase flow to the microchannel tubes 112 associated with the heat exchanger, such as variations in local heat transfer rates and maintaining of a consistent mixing of liquid and vapour along the header's height.

[0050] Thus, the invention overcomes the challenges associated with existing heat exchangers, by providing an improved laminated vertical header for the heat exchanger. The header uniformly supplies the fluid (refrigerant) into the ports of each of the tubes while maintaining a lower pressure drop and and restricting separation of liquid-phase within the header under gravity, thereby improving the performance and efficiency of the overall heat exchanger. In addition, the simple design of the header makes it easier to manufacture as well as cost-effective, and further allows these headers to be stacked coaxially to increase the overall height of the header while restricting separation of liquid-phase within the header under gravity.

[0051] In interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Examples

Embodiment Construction

[0027]The following is a detailed description of embodiments of the invention depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

[0028]Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0029]In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those...

Claims

1. A laminated header (100) for a microchannel heat exchanger, the laminated header comprising: a first plate (102) comprising a first bore-hole (102-1) formed therein; a second plate (104) comprising a first cut-out section (104-1) of a first shape extending along a length of the second plate, wherein a volume of the first cut-out section along the length decreases in a direction away from the first bore-hole; a third plate (106) comprising a plurality of second bore-holes (106-1) formed therein and separated by a distance therebetween; a fourth plate (108) comprising a plurality of second cut-out sections (108-1) of a second shape; and a fifth plate (110) comprising a plurality of slots (S), wherein the second plate is parallelly stacked between the first plate and the third plate, and the fourth plate is parallelly stacked between the third plate and the fifth plate in same orientation to form the laminated header, wherein the first cut-out section fluidically connects the first bore-hole to each of the second bore-holes and the plurality of second cut-out sections fluidically connects the plurality of second bore-holes to the plurality of slots, and wherein the laminated header is configured to receive and secure, within the plurality of slots, an end of a plurality of microchannel tubes (112) associated with the microchannel heat exchanger, thereby fluidically connecting the first bore-hole to the plurality of microchannel tubes.

2. The laminated header (100) of claim 1, wherein the first plate (102), the second plate (104), the third plate (106), the fourth plate (108), and the fifth plate (110) are parallelly stacked and brazed together to form the laminated header, and wherein the end of the plurality of microchannel tubes (112) associated with the microchannel heat exchanger is inserted within the plurality of slots (S) of the laminated header and further brazed to the laminated header to create a leak-proof connection between the laminated header and the plurality of microchannel tubes.

3. The laminated header (100) of claim 1 or 2, wherein the laminated header forms a fluidic passage that extends from the first bore-hole (102-1) towards the plurality of slots (S) while extending in a first direction (A) along the length, between a top end and a bottom end of the second plate (104) and further extending from the first cut-out section (104-1) into each of the second cut-out sections (108-1) and the plurality of slots, via the plurality of second bore-holes (106-1), in a second direction (B) perpendicular to the first direction and extending towards the plurality of slots or the microchannel tubes (112).

4. The laminated header (100) of any preceding claim, wherein the first bore-hole (102-1) is at a bottom end of the first plate (102), and wherein the area or volume of the first cut-out section (104-1) decreases from a bottom end towards a top end of the second plate (104), and / or, wherein the first cut-out section has a trapezoidal shape with the volume decreasing from a bottom end towards a top end of the second plate.

5. The laminated header (100) of any of claims 1 to 3, wherein the first bore-hole (102-1) is at a middle portion of the first plate (102), and wherein the volume of the first cut-out section (104-1) decreases from the middle portion towards a bottom end and a top end of the second plate (104), or, wherein the first bore-hole is at a top end of the first plate, and wherein the volume of the first cut-out section decreases from a top end towards a bottom end of the second plate.

6. The laminated header (100) of any preceding claim, wherein size or radii of the plurality of second bore-holes (106-1) associated with the third plate (106) increases in the direction away from the first bore-hole (102-1).

7. The laminated header (100) of claim 6, wherein the first bore-hole (102-1) is at a bottom end of the first plate (102), and wherein the size or radii of the plurality of second bore-holes (106-1) increases from a bottom end towards a top end of the third plate (106).

8. The laminated header (100) of claim 6, wherein the first bore-hole (102-1) is at a middle portion of the first plate (102), and wherein the size or radii of the plurality of second bore-holes (106-1) increases from the middle portion towards a bottom end and a top end of the third plate (106), or, wherein the first bore-hole is at a top end of the first plate, and wherein the size or radii of the plurality of second bore-holes increases from a top end towards a bottom end of the third plate.

9. The laminated header (100) of any preceding claim, wherein a constriction is defined on the first cut-out section (104-1) of the second plate (104), between the first bore-hole (102-1) and the plurality of second bore-holes (106-1) adjacent to the first bore-hole.

10. The laminated header (100) of any preceding claim, wherein the plurality of second cut-out sections (108-1) associated with the fourth plate (108) has a rectangular or square profile, and / or, wherein size or length of the plurality of second cut-out sections increases in the direction away from the first bore-hole (102-1).

11. The laminated header (100) of any preceding claim, wherein the second plate (104) has a thickness that is greater than a thickness of each of the first plate (102) and the third plate (106).

12. The laminated header (100) of any preceding claim, wherein the laminated header is configured to receive a fluid via the first bore-hole (102-1) of the first plate (102) and further allow the flow of the received fluid within the first cut-out section (104-1) of the second plate (104) in a first direction (A) along a length, between a top end and a bottom end, of the second plate.

13. The laminated header (100) of claim 12, wherein the laminated header is further configured to allow uniform flow of the fluid from the first cut-out section (104-1) into each of the second cut-out sections (108-1) of the fourth plate (108), via the plurality of second bore-holes (106-1) of the third plate (106), in a second direction (B) perpendicular to the first direction and extending towards the plurality of microchannel tubes (112), and wherein the laminated header further allows uniform flow of the fluid from the plurality of second cut-out sections into one or more ports associated with each of the microchannel tubes via the plurality of slots (S) of the fifth plate (110), optionally, wherein adjacent second cut-out sections associated with the fourth plate are separated by a baffle (108-2) extending in a direction, orthogonal to the first direction and the second direction, along a width of the fourth plate.

14. The laminated header of any preceding claim, wherein the first bore-hole (102-1) is formed at a center of a width of the first plate; the plurality of second bore-holes (106-1) is formed at a center of a width of the third plate; and the plurality of slots (S) is formed at a center of a width of the fifth plate (110).

15. A heat exchanger, comprising: one or more laminated headers (100-1 to 100-N) according to any preceding claim, wherein the one or more laminated headers are coaxially and sequentially stacked in a longitudinal direction to form a vertical header (300) having one or more compartments, wherein the plurality of microchannel tubes (112) associated with the heat exchanger is fluidically connected to the plurality of slots (S) associated with the one or more laminated headers, and wherein the heat exchanger further comprises an external distributor (302) comprising: an inlet configured to be fluidically connected to a supply tube (114); and one or more outlets, each configured to be fluidically connected to the first bore-hole (102-1) associated with one of the laminated headers via feeder tubes (304) or tube stubs.

Images