Coil assembly plate with compensator accommodation
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Solution Overview
Problem
HVAC systems face inefficiencies due to refrigerant imbalances and stacking during heating mode operation, particularly in microchannel heat exchangers, which affect refrigerant flow and heat exchange efficiency.
Innovation Solution
Incorporation of a refrigerant charge compensator within the refrigerant circuit, utilizing a conduit surrounded by a chamber, to store excess refrigerant during heating mode and return it during cooling mode, integrated with a receptacle in the coil assembly plate to conserve space and maintain airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a refrigerant charge compensator is added to manage refrigerant flow during heating mode, then system efficiency is improved, but device complexity increases
Solution Approach 1:
The refrigerant charge compensator is nested within the coil assembly plate structure. The compensator housing is formed as an integrated part of the coil assembly plate, with the compensator chamber and conduit system embedded within the plate's thickness. This nesting approach allows the compensator functionality to be added without requiring separate external components or increasing overall device complexity.
Solution Approach 2:
The compensator is merged with the coil assembly plate by forming the compensator housing as a single integrated component. The plate includes both the coil mounting functions and the compensator chamber in one unified structure, eliminating the need for separate compensator housings and reducing the number of discrete parts in the system.
2Loss of energy
If a compensator chamber is added to store excess refrigerant, then refrigerant flow management is improved, but volume of the heat exchanger increases
Solution Approach 1:
The compensator chamber is formed by utilizing the thickness dimension of the coil assembly plate. Rather than adding volume in the planar dimensions where coils are mounted, the chamber is created by forming a recess or cavity within the plate's thickness, effectively using the z-dimension to accommodate the compensator without increasing the heat exchanger's footprint.
Solution Approach 2:
The compensator chamber is nested within the existing coil assembly plate volume. The plate structure is designed to contain the compensator chamber internally, with the chamber walls formed by the plate material itself. This nesting allows the compensator to be accommodated within the existing envelope of the heat exchanger assembly.
3Ease of manufacture
If a receptacle is formed in the coil assembly plate to house the compensator, then ease of manufacture is improved, but the structural integrity of the plate may be compromised
Solution Approach 1:
The receptacle is designed with localized reinforcement at critical stress points. The plate material is thickened or reinforced in specific areas around the receptacle opening and along the chamber walls to maintain structural integrity. This local quality enhancement ensures that the receptacle does not compromise the overall strength of the coil assembly plate while still providing adequate accommodation for the compensator.
Data Source
AI summary
A heating, ventilation, and/or air conditioning (HVAC) system includes a refrigerant circuit configured to circulate refrigerant. The circuit includes a compressor, an indoor heat exchanger, an outdoor heat exchanger, and a reversing valve that transitions between a first configuration to direct the refrigerant from the compressor toward the outdoor heat exchanger and a second configuration to direct the refrigerant from the compressor toward the indoor heat exchanger. The system includes a compensator with a conduit that is part of the refrigerant circuit and configured to pass the refrigerant therethrough and a chamber disposed about the conduit. The chamber is also communicatively coupled to the refrigerant circuit, and configured to retain a portion of the refrigerant in the chamber. A coil assembly plate of the indoor heat exchanger or the outdoor heat exchanger includes a receptacle configured to receive the refrigerant charge compensator.