CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/476,484 which was filed with the United States Patent and Trademark Office on December 21, 2022, the entire contents of which is herein incorporated by reference

BACKGROUND

1. Field

[0002] Example embodiments relate heat exchanger assembly.

2. Description of the Related Art

[0003] This disclosure generally relates to a heat exchanger assembly. While heat exchangers are known in the art, they suffer from deficiencies.

[0004] Current water source heat pumps utilize coaxial refrigerant to water heat exchangers. Such configurations require an excessive length with single side heat transfer. In some applications, brazed plate heat exchangers are used to address flash freezing, such as chillers used for space or process conditioning. Coaxial configurations dominate in the geothermal heat pump market and brazed plate types are suitable in these units only if utilized for generation of hot water.

[0005] The flash freezing issue, as well as the tendency to oil slug makes these configurations unsuitable for heat absorption from ground loops due to the refrigerant boiling temperature at such low temperatures resulting in flash freezing in the small passageways provided for flow of water. The coaxial heat exchanger’s juxtaposition in the unit refrigerant circuit means that the flow station providing the circulation of water can be improperly piped, i.e., there is an in-and-out correct direction of flow. Additionally, incorrect piping can occur that will still allow the unit to function, but not according to the manufacturer’s capacity and efficiency rating.

[0006] A further problem of the coaxial heat exchanger is its linear length — though the heat exchangers are coiled to reduce the physical size — the fluid path on the water side is none the less very long. This length and the circuitous path of the water flow increases fluid head and in turn increases the pumping power consumption.

SUMMARY

[0007] Example embodiments relate to heat exchanger assembly. In at least one nonlimiting example embodiment the heat exchanger assembly includes a housing and a first end cap at a first end of the housing. The heat exchanger assembly further includes a refrigerant core subassembly configured to receive refrigerant and having at least one refrigerant tube assembly with a body through which the refrigerant traverses in a helical path. Additionally, in a least one nonlimiting example embodiment, the heat exchanger assembly includes a water jacket sub assembly having at least one jacket configured to flow water through the at least one refrigerant tube assembly and around the at least one refrigerant tube assembly to exchange heat from both inside the at least one refrigerant tube assembly and outside of the at least one refrigerant tube assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Example embodiments are described in detail below with reference to the attached drawing figures, wherein:

[0009] FIG. 1 is a cross-section view of an exemplary refrigerant tube assembly in accordance with an example of the invention;

[00010] FIG. 2 is a cross-section view of another exemplary refrigerant tube assembly in accordance with an example of the invention;

[00011] FIG. 3 is a cross-section view of an exemplary refrigerant tube assembly in a housing in accordance with an example of the invention;

[00012] FIG. 4 is a view of another exemplary refrigerant tube assembly in accordance with an example of the invention;

[00013] FIG. 5 is a view of an outside tube of an exemplary refrigerant tube assembly in accordance with an example of the invention;

[00014] FIG. 6 is a view of an inside tube of an exemplary refrigerant tube assembly in accordance with an example of the invention;

[00015] FIG. 7 is a view of an annular seal;

[00016] FIG. 8 is a view of an exemplary turbulator in accordance with an example of the invention;

[00017] FIG. 9 is a perspective view of a heat exchanger in accordance with an example of the invention;

[00018] FIG. 10 is an exploded view of the heat exchanger in accordance with an example of the invention; [00019] FIG. 1 1 is a first perspective view of a refrigerant core subassembly in accordance with an example of the invention;

[00020] FIG. 12 is a second perspective view of a refrigerant core subassembly in accordance with an example of the invention;

[00021] FIG. 13 is an exploded view of the refrigerant core subassembly in accordance with an example of the invention;

[00022] FIG. 14 is a perspective view of a water jacket sub assembly in accordance with an example of the invention;

[00023] FIG. 15 is an exploded view of a water jacket sub assembly in accordance with an example of the invention;

[00024] FIG. 16 is a view of the refrigerant core sub assembly partially enclosed by the water jacket sub assembly in accordance with an example of the invention;

[00025] FIG. 17 is a view of an exemplary refrigerant tube assembly having a turbulator on the outside in accordance with an example of the invention;

[00026] FIG. 18 is a view of the exemplary refrigerant tube assembly having the turbulator on the outside and partially enclosed by a water jacket in accordance with an example of the invention; and

[00027] FIG. 19 is a cross section view of the exemplary refrigerant tube assembly having the turbulator on the outside and partially enclosed by the water jacket in accordance with an example of the invention DETAILED DESCRIPTION

[00028] Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are not intended to limit the disclosure since the disclosure may be embodied in different forms. Rather, example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. In the drawings, the sizes of components may be exaggerated for clarity.

[00029] In this application, when a first element is described as being “on” or “connected to” a second element, the first element may be directly on or directly connected to the second element or may be on or connected to an intervening element that may be present between the first element and the second element. When a first element is described as being “directly on” or “directly connected to” a second element, there are no intervening elements. In this application, the term “and/or” includes any and all combinations of one or more of the associated listed items.

[00030] In this application, spatially relative terms merely describe one element’s relationship to another. The spatially relative terms are intended to encompass different orientations of the structure. For example, if a first element of a structure is described as being “above” a second element, the term “above” is not meant to limit the disclosure since, if the structure is turned over, the first element would be “beneath” the second element. As such, use of the term “above” is intended to encompass the terms “above” and “below”. The structure may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. [00031] Example embodiments are illustrated by way of ideal schematic views. However, example embodiments are not intended to be limited by the ideal schematic views since example embodiments may be modified in accordance with manufacturing technologies and/or tolerances.

[00032] The subject matter of example embodiments, as disclosed herein, is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different features or combinations of features similar to the ones described in this document, in conjunction with other technologies. Example embodiments relate to a heat exchanger assembly.

[00033] FIG. 1 is a cross-section view of an exemplary refrigerant tube assembly 10 in accordance with an example of the invention. In FIG. 1 the exemplary refrigerant tube assembly 10 may include a main body 20 which may resemble a hollow tube formed from an outside tube 30 and an inside tube 40. In operation, water may flow through the inside tube 40 and exchange heat with refrigerant which may be flowing through the main body 20 (e.g. between the outside tube 30 and the inside tube 40). In addition, the refrigerant tube assembly 10 may include an inlet tube 50 through which refrigerant may flow into the main body 20 between the outside tube 30 and the inside tube 40 and an outlet tube 60 through which the refrigerant may exit the main body 20.

[00034] As shown in FIG. 1, the outside tube 30 may have an inner surface 32 with one or more structures 34 which substantially form a helix or spiral along the inner surface 32. A portion of the inside tube 40 may be formed as a helix 44 that extends along the inside tube 40. The one or more structures 34 of the outside tube 30 may cooperate with helical portion 44 formed in the in the inside tube 40 to form a helical space/path through which refrigerant provided from the inlet tube 50 enters. This space/path forces the refrigerant to flow around the main body 20 in a helical manner. In other words, the structures 34 and 44 form a helical type barrier/path forcing the refrigerant to flow in a helical path between the outside tube 30 and the inside tube 40 as it traverses a length of the main body 20. The helical path may create a greater surface area to facilitate heat exchange between the refrigerant tube assembly 10 and any water which may flow through the inside tube 40. Additionally, forcing the refrigerant to flow around the main body 20 may slow the flow of the refrigerant and may also enhance heat exchange between the main body 20 of the refrigerant tube assembly 10 and any water flowing through the inside tube 40.

[00035] FIG. 2 is a cross-section view of another exemplary refrigerant tube assembly 100 in accordance with an example of the invention. In FIG. 2 the exemplary refrigerant tube assembly 100 may include a main body 120 which may resemble a hollow tube formed from an outside tube 130 (which may also be considered a refrigerant outer core jacket) and an inside tube 140 (which may also be considered a refrigerant tube). In addition, the refrigerant tube assembly 100 may include an inlet tube 150 through which refrigerant may flow into the main body 120 between the outside tube 130 and the inside tube 140 and an outlet tube 160 through which the refrigerant may exit the main body 120.

[00036] FIG. 2 also shows that the exemplary refrigerant tube assembly 100 includes a second main body 170 which may resemble a hollow tube formed from an outside tube 180 (which may also be considered a refrigerant inner core jacket) and an inside tube 185 (which may also be considered a refrigerant flow inner core). In addition, the refrigerant tube assembly 100 may include a second inlet tube 190 through which refrigerant may flow into the second main body 170 between the outside tube 180 and the inside tube 185 and a second outlet tube 195 through which the refrigerant may exit the second main body 170.

[00037] As shown in FIG. 2, the outside tube 130 may have an inner surface 132 having at least one structure 134 which forms a helix along the inner surface 132. The at least one structure 134 cooperates with a section 144 which forms a helical path along the inside tube 140. This space, between the at least one structure 134 and section 144 forms a helical space/path through which refrigerant provided from the inlet tube 150 enters to flow around the main body 120 in a helical manner. In other words, the at least one structure 134 and section 144 form a helical type barrier forcing the refrigerant to flow in a helical path between the outside tube 130 and the inside tube 140 as it traverses a length of the main body 120. The helical path may create a greater surface area to facilitate heat exchange between the refrigerant tube assembly 100 and any water which may flow through the inside tube 140. Additionally, forcing the refrigerant to flow helically around the main body 120 may slow the flow of the refrigerant and may also enhance heat exchange between the main body 120 of the refrigerant tube assembly 100 and any water flowing through the inside tube 140.

[00038] As shown in FIG. 2, the outside tube 180 may have an inner surface 182 having at least one structure 184 which extends to an outside surface 186 of the inside tube 185. These structures 184 fomi a helical type path allowing any refrigerant flowing through the second body 170 to helically flow through and around the second body 170. Additionally, in at least one example embodiment, an outside diameter of the outside tube 180 may extend to the structures 144 formed in inside tube 140. In this manner, the structures 144 may force any water flowing between the outside tube 180 and the inside tube 140 to flow in a helical patten around the second body 170.

[00039] In operation, refrigerant may enter the first main body 120 via the inlet tube 150 where the refrigerant flows through the first main body 120 in a helical path until it exits the first main body 120 via the outlet tube 160. Further, refrigerant may enter the second main body 170 via the second inlet tube 190 and may flow through the second main body 170 in a helical path until it exits the second main body 170 via the second outlet tube 195. Water flowing between the inside tube 140 and the outside tube 180 may be directed in a helical path via the structures 144. Water flowing through the inside tube 185 may flow relatively unobstructed or, in the alternative, a turbulator 800 (see FIG. 8) may be placed in the inside of the inside tube 185 to force water to traverse the inside tube 185 in a helical manner. A turbulator, in this example, may take the form of a helical member having an outside diameter about the same as the inside diameter of the inside tube 185. It can be formed, for example, by twisting a strip of metal into a helical shape having a length which may be, but is not required to be, the same as the length of the inside tube 185.

[00040] FIG. 3 is a cross section/schematic view of the refrigerant tube assembly

100 enclosed by a water jacket sleeve 300. In this example embodiment, the water jacket sleeve 300 may resemble a hollow cylinder which may, at least, partially enclose the refrigerant tube assembly 100. As one skilled in the art would readily appreciate, water may flow between an outer wall of the outer tube 130 and an inner wall of the water jacket sleeve 300. Water may also flow between the inner tube 140 and the outer tube 130, and water may also flow through the inner tube 184 of the second main body 170. As previously explained, water traversing between the inner tube 140 of the main body 120 and the outer tube 182 of the second main body 170 travels in a helical manner. Similarly, water flowing through the inside tube 185 of second main body 170 may travel in a helical manner if a turbulator is placed therein. As was also previously explained, refrigerant passing through the first and second main bodies 120 and 170 may also travel in a helical manner.

[00041] FIG. 4 is yet another example an exemplary refrigerant tube assembly 400 in accordance with an example of the invention. In FIG. 4 the exemplary refrigerant tube assembly 400 may include a main body 420 which may resemble a hollow tube formed from an outside tube 430 and an inside tube 440. The outside tube 430 may resemble a cylindrical tube have an outer diameter of DOo and an inner diameter of DOi (see FIG. 5). The inside tube 440 may have an outer diameter of Dio and an inner diameter of Dli (see FIG. 6). In this nonlimiting example embodiment the inside tube 440 includes a helical fin 445 on an outside surface of the inside tube 440. In this nonlimiting example embodiment, the helical fin 445 has a diameter DF (see FIG. 6) which is about the same size as, or slightly smaller than, the inside diameter DOi of the outside tube 430. This allows the inside tube 440 with the fin 445 to slide into the outside tube 430. Ends of the main body 420 may be sealed with an annular seal 450 which may have an inner diameter of about Dli and an outer diameter of about DOo. Refrigerant may enter the main body 420 via an inlet tube 460 and may exit the main body 420 via an exit tube 465. As one skilled in the art will readily appreciate, as refrigerant enters the main body 420 and into a space between the outside tube 430 and the inside tube 440 the refrigerant is helically guided in the space by the fin 445. As before, the fin 445 causes the refrigerant to travel in a helical path as the refrigerant flows along a length of the main body 420. This helical path may create a greater surface area to facilitate heat exchange between the refrigerant tube assembly 400 and any water which may flow through the inside tube 440. Additionally, forcing the refrigerant to helically flow around the main body 420 may slow the flow of the refrigerant and may also enhance heat exchange between the main body 420 of the refrigerant tube assembly 400 and any water flowing through the inside tube 440 or may be flowing on the outside of the outside tube 430.

[00042] In example embodiments water may flow unobstructed through the inside tube 440. However, the inventor has found that placing a turbulator 800 inside of the inside tube 440 causes the water to helically flow along the inside of the inside tube 440 which slows the water and increases heat transfer between the inside tube 440 and the water. An example of a turbulator is illustrate in FIG. 8 which, in this nonlimiting example embodiment, resembles a twisted metal plate.

[00043] In operation, water may flow through the inside tube 440 and exchange heat with refrigerant which may be helically flowing through the main body 420 (e.g. between the outside tube 430 and the inside tube 440). In addition, the refrigerant tube assembly 400 may include an inlet tube 460 through which refrigerant may flow into the main body 420 between the outside tube 430 and the inside tube 440 and an outlet tube 465 through which the refrigerant may exit the main body 420. [00044] It is understood the inventive concepts are not limited by the instant examples. For example, rather than using a fin 445 as a means to direct refrigerant in a helical manner a user could substitute a coil or tube for the fin 445 by helically wrapping the coil or tube around the inside tube 440 to form the helical flow path for the refrigerant. As yet another example, the fin could be formed on the inside surface of the outside tube 430 rather than being on the inside tube.

[00045] FIG. 9 is a perspective view of a heat exchanger assembly 1000 in accordance with example embodiments. FIG. 10 is an exploded view of the heat exchanger assembly 1000. As shown in at least FIGS. 9 and 10 the heat exchanger assembly 1000 includes, amongst other things, a housing 1100, a first end cap 1200 at a first end of the housing 1000, a second end cap 1300 at a second end of the housing 1100, a refrigerant core subassembly 1400, and a water jacket sub assembly 1500. These elements are described below.

[00046] FIG. 11 is a first perspective view of the refrigerant core subassembly 1400, FIG. 12 is a second perspective view of the refrigerant core subassembly 1400, and FIG.13 is an exploded view of the refrigerant core subassembly 1400. As shown in FIGS. 11-13, the exemplary refrigerant core subassembly 1400 may be comprised of a plurality of refrigerant tube assemblies which may resemble the previously described refrigerant tube assembly 400. In this example, the refrigerant core subassembly 1400 is comprised of seven refrigerant tube assemblies 400-1 , 400-2, 400-3, 400-4, 400-5, 400-6, and 400-7 interconnected by a plurality of refrigerant interconnect tubes 470. Refrigerant may be introduced to the plurality of refrigerant tube assemblies 400-1, 400-2, 400-3, 400-4, 400- 5, 400-6, and 400-7 by a T 480. Refrigerant may flow along the seven refrigerant tube assemblies 400-1 , 400-2, 400-3, 400-4, 400-5, 400-6, and 400-7 and exit the assembly via a refrigerant return tube 485. In this nonlimiting example embodiment refrigerant may flow from T 480 to refrigerant tube assemblies 400-1 and 400-2. The refrigerant flowing into refrigerant tube assembly 400-1 may flow to refrigerant tube assembly 400-3 via a refrigerant interconnect tube 470. This refrigerant may then flow along refrigerant tube assembly 400-3 and into refrigerant tube assembly 400-4 via another interconnect tube 470. This refrigerant may then flow along refrigerant tube assembly 400-4 an into refrigerant tube assembly 400-7 via another interconnect tube 470. The refrigerant flowing into refrigerant tube assembly 400-2 from the T 480 may flow to refrigerant tube assembly 400-5 via a refrigerant interconnect tube 470. This refrigerant may then flow along refrigerant tube assembly 400-5 and into refrigerant tube assembly 400-6 via another interconnect tube 470. This refrigerant may then flow along refrigerant tube assembly 400-6 and into refrigerant tube assembly 400-7 via another interconnect tube 470. The refrigerant entering refrigerant tube assembly 400-7 from refrigerant tube assembly 400-6 may exit the system through the refrigerant return tube 485.

[00047] FIG. 14 is a perspective view of the water jacket sub assembly 1500 whereas FIG. 15 is an exploded view of the exemplary water jacket sub assembly 1500. As shown in FIGS. 14 and 15 the water jacket sub assembly 1500 includes a plurality of water jacket tubes, namely, water jackets 500-1, 500-2, 500-3, 500-4, 500-5, 500-6, and 500-7. The water jackets 500-1 , 500-2, 500-3, 500-4, 500-5, 500-6, and 500-7 generally enclose and provide water to the refrigerant tube assemblies 400-1, 400-2, 400-3, 400-4, 400-5, 400-6, and 400-7, for heat exchange. For example, water jacket 500-1 generally encloses refrigerant tube assembly 400-1, water jacket 500-2 encloses refrigerant tube assembly 400-2 and so on. In general, the water jackets 500-1 , 500-2, 500-3, 500-4, 500- 5, 500-6, and 500-7are supported at both ends by a disc 510 having apertures to receive the water jackets 500-1, 500-2, 500-3, 500-4, 500-5, 500-6, and 500-7. Water may flow into the water jacket sub assembly 1500 via the end cap 540. This water initially flows through water jacket 500-7 which encloses refrigerant tube assembly 400-7 and exchanges heat therewith. The water proceeds through water jacket 500-7 until it comes into contact with end cap 530 which splits the flow of water into two flows of water: 1) flow through water jacket 500-4; and 2) flow through water jacket 500-6. The flow of water through water jacket 500-4 causes the water to exchange heat with refrigerant tube assembly 400-4. This flow of water then flows down water jacket 500-4 until it strikes end cap 520-3 which redirects the water flow to water jacket 500-3 causing the water flow to come into contact with refrigerant tube assembly 400-3. This flow of water continues until it strikes end cap 520-1 which redirects the flow to water jacket 500-1 which causes the water to exchange heat with refrigerant tube assembly 400- 1. The flow of water through water jacket 500-6 continues until it comes into contact with end cap 520 -4 which redirects the water to water jacket 500-5 causing the water to exchange heat with refrigerant tube assembly 400-5. This flow of water continues until the flow of water comes into contact with end cap 520-2 which redirects the flow of water to water jacket 500-2 which causes the water to exchange heat with refrigerant tube assembly 400- 2. Water may leave the water jacket sub assembly 1500 via water jackets 500-1 and 500- 2 which may be known in this application as “errupters.”

[00048] In example embodiments there is generally space between an inside surface of a water jacket and an outside surface of a refrigerant tube assembly. Although the inventive concepts may be allow the water flowing through the water jackets to be substantially free flowing, the inventive concepts herein cover placing a turbulator 490 on the outside of the refrigerant tube assembly 400 as shown in FIGS. 17 and 18. The turbulator 490 causes the flow around the refrigerant tube assembly 400 to flow in a helical pattern. In this example, the turbulator 490 may be a fin that protrudes from the out surfaces of the refrigerant tube assembly 400 or some equivalent structure, for example, a wire or tube helically wrapped around the refrigerant tube assembly 400. With this in mind FIG. 19 illustrates a cross section which includes a water jacket 500, a refrigerant tube assembly 400, a turbulator 800 in the refrigerant tub assembly 400, and a turbulator 490 on the refrigerant tube assembly 400 to control a flow of water around the refrigerant tube assembly 400. As shown in FIG. 19, the turbulator 490 may extend to (or nearly to) the inside surface of the jacket 500 which causes water flowing between the jacket 500 and the refrigerant tube assembly 400 to move in a helical path as it moves along the outside surface of the refrigerant tube assembly 400. As one skilled in the art will truly appreciate, because water is flowing between the refrigerant tube assembly 400 and the water jacket 500 and because water also moves through the refrigerant tube assembly 400 heat exchange from the refrigerant occurs both inside and outside the refrigerant tube assembly 400 thus improving heat transfer within the heat exchanger assembly 1000.

[00049] In the above described heat exchanger assembly 1000 water may enter the heat exchanger assembly 1000 via a port 1310 in the second end cap 1300. This port connects to water jacket 500-7 which distributes water through the water jacket sub assembly 1500 as described above. Refrigerant may be introduced into the heat exchanger assembly 1000 through T 480 which may be exposed by the second end cap 1300 and may also exit the heat exchanger assembly 1000 via the refrigerant return tube 485 which is also exposed by the second end cap 1300. Refrigerant may flow through the refrigerant core subassembly 1400 as also previously described. Water exiting the errupters may flow into the housing 1100 and exit the housing through a hole which may be present in the housing 1100 which is aligned with a hole present in the first end cap 1200.

[00050] Example embodiments of the disclosure have been described in an illustrative manner. It is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of example embodiments are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present disclosure may be practiced otherwise than as specifically described.