US20250283673A1

US20250283673A1 - Laminated header for a microchannel heat exchanger

Info

Publication number: US20250283673A1
Application number: US19/071,163
Authority: US
Inventors: Arindom Joardar; Fatemeh Hejripour Rafsanjani; Christopher Keinath; Thomas Visalli; Lokanath Mohanta; Tobias Sienel
Original assignee: Carrier Corp
Current assignee: Carrier Corp
Priority date: 2024-03-11
Filing date: 2025-03-05
Publication date: 2025-09-11
Also published as: CN120627787A; EP4617604A1

Abstract

A laminated header for a microchannel heat exchanger comprises a distribution plate comprising a first cut-out section of a first shape extending along a longitudinal axis of the distribution plate, wherein a width of the first cut-out section at least partially decreases along the longitudinal axis a hole plate comprising a plurality of bore-holes formed therein and separated by a distance therebetween, a section plate comprising a plurality of second cut-out sections of a second shape different from the first shape, and wherein the hole plate is parallelly stacked between the distribution plate and the section plate. The first cut-out section fluidically connects with each of the bore-holes and the second cut-out sections fluidically connects the bore-holes to a plurality of microchannel tubes of the heat exchanger.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of U.S. Provisional Patent Application No. 63/563,529, filed on Mar. 11, 2024, which is incorporated by reference herein in its entirety.

BACKGROUND

The subject disclosure relates to the field of heat exchangers, and more particularly, to a laminated header for a microchannel heat exchanger.

SUMMARY

Described herein is a laminated header for a microchannel heat exchanger. The header comprises, a distribution plate comprising a first cut-out section of a first shape extending along a longitudinal axis of the distribution plate, where a width of the first cut-out section at least partially along the longitudinal axis, a hole plate comprising a plurality of bore-holes formed therein and separated by a distance therebetween, and a section plate comprising a plurality of second cut-out sections of a second shape different from the first shape. The hole plate is parallelly stacked between the distribution plate and the section plate.
In one or more embodiments, the laminated header further comprises an inlet plate having an inlet bore-hole is defined at a bottom end of the inlet plate, and wherein the width of the first cut-out section decreases from a bottom end towards a top end of the distribution plate.
In one or more embodiments, the first cut-out section has a trapezoidal shape with the width decreasing from the bottom end towards the top end of the distribution plate.
In one or more embodiments, the laminated header further comprises an inlet plate having an inlet bore-hole defined at a middle portion of the inlet, and wherein the width of the first cut-out section decreases from the middle portion towards a bottom end and a top end of the distribution plate.
In one or more embodiments, the laminated header further comprises a tube plate comprising a plurality of slots, wherein the laminated header is configured to receive and secure, within the plurality of slots, an end of a plurality of microchannel tubes of the microchannel heat exchanger.
In one or more embodiments, the distribution plate, the hole plate, and the section plate, are parallelly stacked between an inlet plate and a tube plate, and brazed together to form the laminated header, and wherein an end of the plurality of microchannel tubes of the heat exchanger is inserted within a plurality of slots of the tube plate and brazed to the laminated header to create a leak-proof connection between the laminated header and the microchannel tubes.
In one or more embodiments, the laminated header forms a fluidic passage that extends from the inlet bore-hole towards the plurality of slots while extending in a first direction along the longitudinal axis, between a top end and a bottom end, of the distribution 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 bore-holes, in a second direction substantially perpendicular to the first direction and extending towards the plurality of slots or the microchannel tubes.
In one or more embodiments, the laminated header further comprising an inlet plate having an inlet bore-hole defined at a top end of the inlet plate, and wherein the width of the first cut-out section decreases from a top end towards a bottom end of the distribution plate.
In one or more embodiments, size or radii of the plurality of bore-holes associated with the hole plate increases in the direction away from the inlet bore-hole.
In one or more embodiments, the inlet bore-hole is at a bottom end of the inlet plate, and wherein the size or radii of the plurality of bore-holes increases from a bottom end towards a top end of the hole plate.
In one or more embodiments, the inlet bore-hole is at a substantially middle portion of the inlet plate, and wherein the size or radii of the plurality of bore-holes increases from the middle portion towards a bottom end and a top end of the hole plate.
In one or more embodiments, the inlet bore-hole is at a top end of the inlet plate, and wherein the size or radii of the plurality of bore-holes increases from a top end towards a bottom end of the hole plate.
In one or more embodiments, the plurality of second cut-out sections associated with the section plate has a substantially rectangular or square profile.
In one or more embodiments, size of the plurality of second cut-out sections increases in at least one direction along the longitudinal axis.
In one or more embodiments, the distribution plate has a thickness that is greater than a thickness of the inlet plate and the hole plate.
In one or more embodiments, the laminated header is configured to allow a fluid from an inlet bore-hole defined on an inlet plate to flow within the first cut-out section of the distribution plate in along the longitudinal axis, between a top end and a bottom end, of the distribution plate.
In one or more embodiments, the 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 section plate, via the plurality of bore-holes of the hole plate, in a second direction perpendicular to the first direction and extending towards the plurality of microchannel tubes, and wherein the 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 tube plate.
In one or more embodiments, the adjacent second cut-out sections among the plurality of second cut-out sections of the section plate are separated by a baffle extending in a direction, orthogonal to the first direction and the second direction, along a width of the section plate.
In one or more embodiments, the distribution plate, the hole plate, and the section plate are parallelly stacked between an inlet plate and a tube plate, and wherein, an inlet bore-hole of the inlet plate is formed at a corresponding widthwise center of the inlet plate, the plurality of bore-holes are formed at a corresponding widthwise center of the hole plate, and a plurality of slots of the tube plate are formed at a corresponding width-wise center of a width of a tube plate.
Also described herein is 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 headers.
In one or more embodiments, the heat exchanger 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 one of the laminated headers via feeder tubes or tube stubs.
A further aspect of the subject disclosure relates to a laminated header for a microchannel heat exchanger. The laminated header comprises, a distribution plate comprising a first cut-out section of a first shape, a hole plate comprising a plurality of bore-holes formed therein and separated by a distance therebetween, a diameter of each of the plurality of bore-holes varies along a longitudinal axis of the hole plate, and a section plate comprising a plurality of second cut-out sections of a second shape different from the first shape, wherein the hole plate is parallelly stacked between the distribution plate and the section plate.
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 subject disclosure will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the subject disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the subject disclosure and, together with the description, serve to explain the principles of the subject disclosure.

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 exemplary side cross-sectional side view of an embodiment of the laminated vertical header, in accordance with one or more embodiments of the subject disclosure.

FIG. 1B illustrates an exemplary front view of an inlet plate associated with the header of FIG. 1A, in accordance with one or more embodiments of the subject disclosure.

FIG. 1C illustrates an exemplary front view of a distribution plate associated with the header of FIG. 1A, in accordance with one or more embodiments of the subject disclosure.

FIG. 1D illustrates an exemplary front view of a hole plate associated with the header of FIG. 1A, in accordance with one or more embodiments of the subject disclosure.

FIG. 1E illustrates an exemplary front view of a section plate associated with the header of FIG. 1A, in accordance with one or more embodiments of the subject disclosure.

FIG. 1F illustrates an exemplary front view of a tube plate associated with the header of FIG. 1A, in accordance with one or more embodiments of the subject disclosure.

FIG. 2A illustrate exemplary side cross-sectional side view of another embodiment of the laminated vertical header, in accordance with one or more embodiments of the subject disclosure.

FIG. 2B illustrates an exemplary front view of the inlet plate associated with the header of FIG. 2A, in accordance with one or more embodiments of the subject disclosure.

FIG. 2C illustrates an exemplary front view of a distribution plate associated with the header of FIG. 2A, in accordance with one or more embodiments of the subject disclosure.

FIG. 2D illustrates an exemplary front view of a hole plate associated with the header of FIG. 2A, in accordance with one or more embodiments of the subject disclosure.

FIG. 2E illustrates an exemplary front view of a section plate associated with the header of FIG. 2A, in accordance with one or more embodiments of the subject disclosure.

FIG. 2F illustrates an exemplary front view of a tube plate associated with the header of FIG. 2A, in accordance with one or more embodiments of the subject disclosure.

FIG. 3 illustrates exemplary side cross-sectional side view depicting multiple laminated vertical headers stacked together and connected to form a single external fluid distributor, in accordance with one or more embodiments of the subject disclosure.

FIG. 4A illustrates an exemplary front view of the distribution plate associated with the header of FIGS. 1A and 2A where the inlet bore-hole is at middle portion of the first plate, in accordance with one or more embodiments of the subject disclosure.

FIG. 4B illustrates an exemplary front view of the inlet plate associated with the header of FIGS. 1A and 2A where the inlet bore-hole is at middle portion of the first plate, in accordance with one or more embodiments of the subject disclosure.

FIG. 4C illustrates an exemplary front view of the distribution plate associated with the header of FIGS. 1A and 2A where the inlet bore-hole is at top end of the first plate, in accordance with one or more embodiments of the subject disclosure.

FIG. 4D illustrates an exemplary front view of the inlet plate associated with the header of FIGS. 1A and 2A where the inlet bore-hole is at top end of the first plate, in accordance with one or more embodiments of the subject disclosure.

FIG. 5A illustrates an exemplary front view of a first plate associated with yet another embodiment of the laminated vertical header where a portion of the first cut-out section, between the inlet bore-hole and the bore-hole adjacent to the inlet bore-hole, of an distribution plate has a substantially narrow passage or area, in accordance with one or more embodiments of the subject disclosure.

FIG. 5B illustrates an exemplary front view of the distribution plate associated with the header of FIG. 5A, in accordance with one or more embodiments of the subject disclosure.

FIG. 5C illustrates an exemplary front view of a hole plate associated with the header of FIG. 5A, in accordance with one or more embodiments of the subject disclosure.

FIG. 5D illustrates an exemplary front view of a section plate associated with the header of FIG. 5A, in accordance with one or more embodiments of the subject disclosure.

FIG. 5E illustrates an exemplary front view of a tube plate associated with the header of FIG. 5A, in accordance with one or more embodiments of the subject disclosure.

FIG. 6A illustrates an exemplary front view of a first plate associated with another embodiment of the laminated vertical header where the inlet bore-hole is at middle portion of the first plate and a portion of the first cut-out section, between the inlet bore-hole and the bore-hole adjacent to the inlet bore-hole, has a substantially narrow passage or area, in accordance with one or more embodiments of the subject disclosure.

FIG. 6B illustrates an exemplary front view of the distribution plate associated with the header of FIG. 6A, in accordance with one or more embodiments of the subject disclosure.

FIG. 6C illustrates an exemplary front view of a hole plate associated with the header of FIG. 6A, in accordance with one or more embodiments of the subject disclosure.

FIG. 6D illustrates an exemplary front view of a section plate associated with the header of FIG. 6A, in accordance with one or more embodiments of the subject disclosure.

FIG. 6E illustrates an exemplary front view of a tube plate associated with the header of FIG. 5A, in accordance with one or more embodiments of the subject disclosure.

DETAILED DESCRIPTION

The following is a detailed description of embodiments of the subject disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the subject disclosure. 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 spirit and scope of the subject disclosure as defined by the appended claims.
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.
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 subject disclosure, 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.
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.
Referring to FIGS. 1A to 2F, 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/inlet bore-hole 102-1 formed therein. Further, the header 100 may include a second plate 104 (also referred to as an distribution plate 104, herein) that includes a first cut-out section 104-1 of a first shape extending along a longitudinal axis 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 to 1F and 2B to 2F.
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 inlet bore-hole 102-1 to each of the bore-holes 106-1 and the second cut-out sections 108-1 fluidically connects the 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 inlet 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.
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 inlet 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/longitudinal axis, 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 bore-holes 106-1, in a second direction (B) substantially perpendicular to the first direction (A). In some embodiments, the longitudinal axis corresponds to the axis along the longest dimension of the (second) plates. In some embodiments, the longitudinal direction may correspond to a length or dimension from the bottom end to the top end of the second plate 104, as shown in FIGS. 1A to 2F. In some embodiments, the longitudinal axis may be dimensions along which the microchannel tubes 112 are arranged, or direction/axis along which the bore-holes are 106-1 are arranged aligned. 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.
In one or more embodiments, the second plate 104, the third plate 106, and the further plate 108 may be stacked parallelly and brazed together. In such embodiments, the first cut-out section 104-1 of the second plate 104, the bore-holes 106-1 of the hole plate 106, and the second cut-out sections 108-1 of the section plate 108 may form a fluidical passage therebetween. In some embodiments, a fluid may be received from an inlet bore-hole, such as inlet bore-hole 102-1 on the inlet plate 102, or any other inlet bore-hole defined on a cover that encapsulates the first cut-out section 104-1 of the second plate 104. In some embodiments, the cover may be hermetically attached to the second plate 104. The fluid may pass through the first cut-out section 104-1, the bore-holes 106-1, and the second cut-out sections 108-1, as described subsequently in the subject disclosure. Further, the fluid flow into the microchannel tubes 112, which may be fluidically connected to the second cut-out sections 108-1 through slots, such as slots S on the fifth plate 110, or slots defined on a slotted plate. The slotted plate may be attached to the fourth plate 108.
In one or more embodiments, as illustrated in FIGS. 1B to 1F and 2B to 2F, the inlet bore-hole 102-1 may be formed at a width-wise center (i.e., center with respect to the width) the first plate 102. The bore-holes 106-1 may be formed at a width-wise center of the third plate 106 with a space therebetween. Further, the slots S may be formed at a width-wise center 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 106 s may also have same thickness without any limitations.
In one or more embodiments, a width (i.e., a dimension perpendicular to the longitudinal axis, and/or direction of flow of a fluid through the laminated header 100), and correspondingly volume of (or area defined by), the first cut-out section 104-1 may decrease along its length/longitudinal axis in at least one direction (i.e., in a direction away from) the inlet bore-hole 102-1. This configuration can keep the same mass flow rate at the inlet of all bore-holes 106-1 of the third plate 106 and further into the ports of the of microchannel tubes 112.
Referring to FIGS. 1B to 1C, in one or more embodiments, the inlet bore-hole 102-1 of the first plate 102 may be at a bottom end of the first plate 102. Accordingly, the width (and correspondingly 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/width may help ensure equal fluid flow velocity in the flow channel as the part of the two-phase mixture is fed through holes 106-1.
Referring to FIGS. 4A and 4B, in one or more embodiments, the inlet bore-hole 102-1 of the first plate 102 may be at a substantially middle portion of the first plate 102. Accordingly, the width (and correspondingly 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.
Referring to FIGS. 4C and 4D, in one or more embodiments, the inlet bore-hole 102-1 of the first plate 102 may be at a top end of the first plate 102. Accordingly, the width (and correspondingly 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.
In one or more embodiments, size or radii of the bore-holes 106-1 associated with the third plate 106 may increase in at least one direction along the longitudinal axis (such as along the direction away from the inlet bore-hole 102-1). In such embodiments, the width/volume of the first cut-out section 104-1 may be equal or uniform along its length/longitudinal axis. 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 bore-holes 106-1 of the third plate 106 and further into the ports of the of microchannel tubes 112.
Referring to FIGS. 2B to 2D, in one or more embodiments, the inlet bore-hole 102-1 may be at a bottom end of the first plate 102. Accordingly, the size or radii of each of the bore-holes 106-1 may increase from a bottom end towards a top end of the third plate 106. For example, the 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 bore-hole 106-1 at or proximate to the top end of the third plate 106. The bore-holes 106-1 may be arranged in increasing order of sizes/diameters from the bottom end to the top end of the third plate 106.
Further, in one or more embodiments (as shown in FIGS. 4A and 4B), the inlet 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 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 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 bore-holes 106-1, and each successive 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.
Furthermore, in one or more embodiments (as shown in FIGS. 4C and 4D), the inlet bore-hole 102-1 may be at a top end of the first plate 102. Accordingly, the size or radii of the plurality of bore-holes 106-1 may increase from a top end towards a bottom end of the third plate 106.
Referring back to FIGS. 1B to 1F and 2B to 2F, 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 of the plurality of second cut-out sections 108-1 may increase along the longitudinal axis, i.e., in the direction away from the inlet 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 inlet 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 inlet bore-hole 102-1 defined on the top end of the first plate 102). However, in some embodiments, the size of each of the second cut-out sections 108-1 may be equal and uniform along the longitudinal axis.
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 to 1F and 2B to 2F) extending in a direction (C), orthogonal to the first direction (A) and the second direction (B), along a width of the fourth plate 108.
Accordingly, referring to FIGS. 1A and 2A, the (stacked) header 100 may be configured to receive a fluid via the inlet 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/longitudinal axis, 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 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.
Referring to FIGS. 5A to 5E, and 6A to 6E, in one or more embodiments, a constriction or a narrow passage/area is defined between the inlet bore-hole 102-1 and the bore-hole 106-1 adjacent to the inlet 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 FIGS. 5A to 5E, in one or more embodiments, when the inlet 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 inlet bore-hole 102-1 and the bottom-most bore-hole 106-1 (adjacent to the inlet bore-hole 102-1) may define the constriction, i.e., a substantially narrow passage or area (C). Further, as illustrated in FIGS. 6A to 6E, in one or more embodiments, when the inlet 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 inlet bore-hole 102-1 and the bore-holes 106-1 (above and below the inlet 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 inlet bore-hole 102-1.
Referring to FIG. 3 , in one or more embodiments, a heat exchanger comprising one or more laminated headers 100 of FIGS. 1A and/or 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.
In addition, in one or more embodiments, the heat exchanger may include an external distributor 302 having an inlet, and one or more outlets 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 inlet 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.
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 inlet 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/longitudinal axis in the second plate 104, the increase in size or radii of the second-bore holes of the third plate 106 (while moving) along the longitudinal direction, such as in a direction away from the inlet 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.
Thus, the subject disclosure 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.
While the subject disclosure has been described with reference to exemplary embodiments, various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the subject disclosure as defined by the appended claims. Modifications may be made to adopt a particular situation or material to the teachings of the subject disclosure without departing from the scope thereof. Therefore, it is intended that the subject disclosure not be limited to the particular embodiment disclosed, but that the subject disclosure includes all embodiments falling within the scope of the subject disclosure as defined by the appended claims.
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.

Claims

1. A laminated header for a microchannel heat exchanger, the laminated header comprising:

a distribution plate comprising a first cut-out section of a first shape extending along a longitudinal axis of the distribution plate, wherein a width of the first cut-out section at least partially decreases along the longitudinal axis;

a hole plate comprising a plurality of bore-holes formed therein and separated by a distance therebetween;

a section plate comprising a plurality of second cut-out sections of a second shape different from the first shape; and

wherein the hole plate is parallelly stacked between the distribution plate and the section plate.

2. The laminated header of claim 1, further comprising an inlet plate having an inlet bore-hole defined at one end of the inlet plate, and wherein the width of the first cut-out section decreases from a bottom end towards a top end of the distribution plate.

3. The laminated header of claim 1, further comprising an inlet plate having an inlet bore-hole defined at a middle portion of the inlet plate, and wherein the width of the first cut-out section decreases from the middle portion towards a bottom end and a top end of the distribution plate.

4. The laminated header of claim 1, further comprising an inlet plate having an inlet bore-hole defined at a top end of the inlet plate, and wherein the width of the first cut-out section decreases from a top end towards a bottom end of the distribution plate.

5. The laminated header of claim 1, further comprising a tube plate comprising a plurality of slots, wherein the laminated header is configured to receive and secure, within the plurality of slots, an end of a plurality of microchannel tubes of the microchannel heat exchanger.

6. The laminated header of claim 1, wherein the distribution plate, the hole plate, and the section plate are parallelly stacked between an inlet plate and a tube plate, and are brazed together to form the laminated header, and wherein an end of a plurality of microchannel tubes of the microchannel heat exchanger is inserted within a plurality of slots of the tube plate and brazed to create a leak-proof connection between the laminated header and the plurality of microchannel tubes.

7. The laminated header of claim 6, wherein the laminated header forms a fluidic passage extends from an inlet bore-hole towards the plurality of slots while extending in a first direction along the longitudinal axis, 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 bore-holes, in a second direction perpendicular to the first direction and extending towards the plurality of slots or the microchannel tubes.

8. The laminated header of claim 1, wherein the first cut-out section has a trapezoidal shape with the width decreasing from a bottom end towards a top end of the distribution plate.

9. The laminated header of claim 1, wherein size or radii of the plurality of bore-holes of the hole plate increases in the direction away from an inlet bore-hole defined on an inlet plate, along the longitudinal axis.

10. The laminated header of claim 1, wherein a constriction is defined on the first cut-out section of the distribution plate.

11. The laminated header of claim 1, wherein the plurality of second cut-out sections associated with the section plate has a rectangular or square profile.

12. The laminated header of claim 1, wherein size of the plurality of second cut-out sections increases in at least one direction along the longitudinal axis.

13. The laminated header of claim 1, further comprising an inlet plate having an inlet bore-hole, and wherein the distribution plate has a thickness that is greater than a thickness of each of the inlet plate defining the inlet bore-hole and the hole plate.

14. The laminated header of claim 1, wherein the laminated header is configured to allow a fluid from an inlet bore-hole defined on an inlet plate to flow within the first cut-out section of the distribution plate in along the longitudinal axis, between a top end and a bottom end, of the distribution plate.

15. The laminated header of claim 14, wherein 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 section plate, via the plurality of bore-holes of the hole 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 a plurality of slots of a tube plate.

16. The laminated header of claim 1, wherein adjacent second cut-out sections among the plurality of second cut-out sections of the section plate are separated by a baffle extending in a direction, orthogonal to the first direction and the second direction, along a width of the section plate.

17. The laminated header of claim 1, wherein the distribution plate, the hole plate, and the section plate are parallelly stacked between an inlet plate and a tube plate, and wherein,

an inlet bore-hole of the inlet plate is formed at a corresponding widthwise center of the inlet plate;

the plurality of bore-holes are formed at a corresponding widthwise center of the hole plate; and

a plurality of slots of the tube plate are formed at a corresponding width-wise center of a width of a tube plate.

18. A heat exchanger, comprising:

one or more laminated headers according to claim 1,

wherein the one or more laminated 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 microchannel heat exchanger is fluidically connected to the plurality of slots associated with the one or more laminated headers, and

wherein 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 one of the laminated headers via feeder tubes or tube stubs.

19. A laminated header for a microchannel heat exchanger, the laminated header comprising:

a distribution plate comprising a first cut-out section of a first shape;

a hole plate comprising a plurality of bore-holes formed therein and separated by a distance therebetween, a diameter of each of the plurality of bore-holes varies along a longitudinal axis of the hole plate;