System and method for heat exchanger of an HVAC and R system
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Solution Overview
Problem
Typical condensers in HVAC systems are unable to completely condense refrigerant, resulting in a two-phase mixture being recirculated, which decreases the system's efficiency in transferring thermal energy and cooling fluids.
Innovation Solution
A multi-pass heat exchanger design with multiple slabs of micro-channel tubes allows the refrigerant to complete multiple passes, enabling efficient thermal energy removal through a first pass in one slab and subsequent passes in additional slabs, where it can fully condense and sub-cool, improving the HVAC system's efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a typical condenser is used, then the device complexity is low, but the refrigerant cannot be completely condensed and the system efficiency decreases
Solution Approach 1:
The heat exchanger is divided into multiple slabs (first slab, second slab, third slab) with multiple tubes in each slab, creating a segmented structure that enables multi-pass refrigerant flow. This segmentation allows the refrigerant to undergo complete condensation across different segments, resolving the contradiction between maintaining simple structure and achieving complete condensation for high efficiency.
Solution Approach 2:
The patent introduces a multi-dimensional approach by arranging tubes in three separate slabs positioned at different locations, creating a three-dimensional heat exchanger configuration. This dimensional expansion enables the refrigerant to traverse multiple passes through different spatial zones, achieving complete condensation while managing system complexity through structured spatial arrangement.
2Productivity
If the refrigerant flow path is extended to enable complete condensation, then the thermal energy transfer efficiency improves, but the heat exchanger volume increases
Solution Approach 1:
By transitioning from a single-plane to a three-dimensional arrangement with multiple slabs positioned at different locations, the patent extends the refrigerant flow path without proportionally increasing volume. The multi-slab configuration allows the refrigerant to traverse an extended path through vertical and horizontal dimensions, achieving complete condensation while optimizing space utilization.
Solution Approach 2:
The multiple tubes within each slab and the nested arrangement of slabs create a compact configuration where the refrigerant flow path is extended within a constrained volume. The nested structure of tubes within slabs and slabs within the overall heat exchanger assembly enables efficient thermal energy transfer without excessive volume increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multi-pass heat exchanger design enhances the efficiency of thermal energy transfer within the HVAC system by ensuring the refrigerant completes multiple phases of condensation and sub-cooling, thereby improving the overall performance of the HVAC system.
Implementation Method 1
the refrigerant flowing through the evaporator may absorb thermal energy from the flow of fluid to be cooled
Implementation Method 2
The thermal energy absorbed by the refrigerant may heat the refrigerant to a hot, gaseous phase
Implementation Method 3
The gaseous refrigerant may be directed through a condenser, which may remove the absorbed thermal energy the refrigerant and transfer the thermal energy to a cooling fluid
Implementation Method 4
typical condensers are unable to remove a sufficient amount of thermal energy from the refrigerant that enables the refrigerant to completely change phase within the condenser
Data Source
AI summary
The present disclosure relates to a heat exchanger for a heating, ventilating, and air conditioning (HVAC) system that includes a first slab having a first plurality of tubes extending between a first manifold and a second manifold and a second slab having a second plurality of tubes and a third plurality of tubes. The second plurality of tubes extends between a third manifold and a fourth manifold and the third plurality of tubes extends between the fourth manifold and a fifth manifold, such that the heat exchanger defines a refrigerant path sequentially through the first plurality of tubes, the second plurality of tubes, and the third plurality of tubes.