Heat exchanger having an inlet distributor and outlet collector

Abstract

An improved heat exchanger assembly having an inlet header in hydraulic communication with an outlet header via a plurality of multi-channel flat refrigerant tubes, in which the multi-channel flat refrigerant tubes are substantially perpendicular to the headers. Interconnecting the refrigerant tubes are corrugated fins. The plurality of refrigerant tubes together with the fins defines the core of the heat exchanger assembly. The heat exchanger assembly also includes a distributor tube disposed in the inlet header cavity and a collector tube disposed in the outlet header cavity. The distributor tube and collector tube have cooperating features for archiving uniform refrigerant distribution through the refrigerant tubes.

1 . A heat exchanger assembly comprising:
 an inlet header defining an inlet header cavity extending along an axis A 1 ;   an outlet header defining an outlet header cavity extending along an axis A 2  spaced apart from and substantially parallel to said axis A 1 ;   said inlet header includes a plurality of header slots and said outlet header includes a plurality header slots corresponding to header slots of inlet header;   a plurality of multi-channel flat refrigerant tubes defining fluid passages and extending through said header slots, thereby providing hydraulic communication between said headers for refrigerant flow, wherein said plurality of multi-channel flat refrigerant tubes are substantially perpendicular to said axis A 1  and axis A 2 ;   a distributor tube disposed in said inlet header cavity; and   a collector tube disposed in said outlet header cavity.   
     
     
         2 . The heat exchanger assembly of  claim 1 , wherein:
 said collector tube includes an inwardly curved surface defining a plurality of orifices, wherein said inwardly curved surface is oriented towards said plurality of straight multi-channel flat refrigerant tubes.   
     
     
         3 . The heat exchanger assembly of  claim 2 , wherein:
 said outlet header includes an interior surface defining a first shape; and   said collector tube includes an exterior surface opposite that of said inwardly curved surface, wherein said exterior surface of collector tube is complementary to that of said interior surface of said outlet header, such that said exterior surface of collector tube abuts said interior surface of outlet header thereby forming a refrigerant vapor tight fit.   
     
     
         4 . The heat exchanger assembly of  claim 3 , wherein:
 said plurality of orifices of collector tube is substantially evenly spaced along said collector tube.   
     
     
         5 . The heater exchanger assembly of  claim 4 , wherein:
 said heater exchanger assembly includes an upstream air side; and   said distributor tube defines a plurality of orifices, wherein said orifices are oriented between 45° to 135° degrees toward said upstream air side of heat exchanger assembly with respect to 0° being aligned in a direction opposite that of gravity.   
     
     
         6 . The heat exchanger of assembly of  claim 5 , wherein:
 wherein said orifices of said distributor tube are oriented 90° degrees toward said upstream air side of heat exchanger assembly with respect to 0° being aligned in a direction opposite that of gravity.   
     
     
         7 . The heater exchanger assembly of  claim 4 , wherein:
 said heater exchanger assembly includes a downstream air side; and   said distributor tube defines a plurality of orifices, wherein said orifices are oriented between 225° to 315° degrees toward said downstream air side of heat exchanger assembly with respect to 0° being aligned in a direction opposite that of gravity.   
     
     
         8 . The heat exchanger assembly of  claim 7 , wherein:
 said orifices of said distributor tube are 270° degrees toward said downstream air side of heat exchanger assembly with respect to 0° being aligned in a direction opposite that of gravity.   
     
     
         9 . The heat exchanger assembly of  claim 2 , wherein said distributor tube have an outside diameter of ¼″ to ⅜″ and defines a plurality of orifices having a diameter of 0.7 mm to 1.5 mm arranged substantially linearly along said distributor tube 
     
     
         10 . The heat exchanger assembly of  claim 9 , wherein said plurality of orifices are spaced 20 mm to 90 mm apart. 
     
     
         11 . The heat exchanger assembly of  claim 10 ,
 wherein said outlet header have a length up to 57″; and   wherein said collector tube defines a plurality of orifices having a diameter of ⅛″ to ¼″ arranged substantially linearly along said collector tube on said inwardly curved surface.   
     
     
         12 . The heat exchanger assembly of  claim 11 , wherein said plurality of orifices are spaced approximately 27 mm apart. 
     
     
         13 . The heat exchanger assembly of  claim 10 ,
 wherein said outlet header have a length between 57″ and 96″; and   wherein said collector tube defines a plurality of orifices having a diameter of ⅛″ arranged substantially linearly along said distributor tube.   
     
     
         14 . The heat exchanger assembly of  claim 13 , wherein said plurality of orifices are spaced 60 mm apart.