[001] This present disclosure relates to refrigeration systems, and more
specifically, to header and side plates of a condenser assembly configured to be
installed in an air-conditioning system.
BACKGROUND
[002] Condenser is one of the primary components of an air-conditioning
system. Typically, the condenser includes two header plates and a plurality of
tubes for achieving condensation of a refrigerant. The opposite ends of the
plurality of tubes are inserted within a plurality of slots disposed within the
respective header plates of the condenser. Further, the header plates are
configured to include additional slots for the side plates which support the
plurality of tubes and increase the mechanical strength of the condenser.
[003] In an instance of a prior art technique, a punching tool is used to create
different types of slots along a length of the header plate. The different types of
slots include slots having cross section profile similar to the plurality of tubes and
slots having cross section profile similar to the side plates of the condenser. The
punching tool can be used for slotting the headers plates having a particular length
only. However, the length of the header plates can vary depending on the number
of tubes in the condenser. For example, a large automotive vehicle may require
condenser including greater number of tubes than a condenser which is to be used
in a low capacity air conditioning system. Further, packaging constraints
corresponding to the condenser may also dictate number of tubes required to be
installed within the condenser.
[004] The punching tool as discussed above is a non-flexible tool and cannot be
used for slotting the header plates with variable lengths. As a result, a
manufacturer is required to develop a new punching tool every time when a
header plate of different length is needed. The process of tool development is a
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time consuming and an expensive process. The cost of developing the new
punching tool is substantial which increases an overall cost for manufacturing
condensers of different specifications.
[005] Therefore, there exists a need for a cost effective method for
manufacturing the condensers with variable specifications.
SUMMARY
[006] Embodiments of the present disclosure disclose a condenser assembly
configured to be installed in an air-conditioning system. The condenser assembly
includes one or more tanks formed using a first header plate and a second header
plate. The first header plate includes at least one opening for exchanging
refrigerant with at least one component of the air-conditioning system. The
second header plate includes a first slot among a plurality of slots for receiving at
least one tube among a plurality of tubes for condensing the refrigerant and a
second slot for receiving a side plate. The first slot and the second slot have cross
section profiles substantially similar to the cross section profile of at least one tube
among the plurality of tubes and a design of the side plate is modified to conform
to the cross section profile of the at least one tube.
[007] In an embodiment, the side plate includes a projection pointing toward the
second slot and at least a portion of an end section of the projection is chamfered
so that a cross section profile of the projection is similar to the cross section
profile of the at least one tube.
[008] In another embodiment, a thickness of the side plate is different than a
thickness of the at least one tube. The side plate includes a projection pointing
toward the second slot and at least a portion of an end section of the projection is
rolled or designed in a way to match thickness of the end section with the at least
one tube.
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[009] Additional aspects, advantages, features and objects of the present
disclosure would be made apparent from the drawings and the detailed description
of the illustrative embodiments construed in conjunction with the appended claims
that follow.
[0010] It will be appreciated that features of the present disclosure are susceptible
to being combined in various combinations without departing from the scope of
the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The summary above, as well as the following detailed description of
illustrative embodiments, is better understood when read in conjunction with the
appended drawings. For the purpose of illustrating the present disclosure,
exemplary constructions of the disclosure are shown in the drawings. However,
the present disclosure is not limited to specific methods and instrumentalities
disclosed herein. Moreover, those skilled in the art will understand that the
drawings are not to scale. Wherever possible, like elements have been indicated
by identical numbers.
[0012] Embodiments of the present disclosure will now be described, by way of
example only, with reference to the following diagrams wherein:
[0013] FIG. 1 illustrates a partial perspective and exploded view of a condenser
assembly configured to be installed in an air-conditioning system in accordance
with an embodiment of the disclosure;
[0014] FIG. 2 illustrates a top view of a prior art based second header plate in
accordance with an embodiment of the disclosure;
[0015] FIG. 3 illustrates a partial perspective view of a second header plate of the
condenser in accordance with an embodiment of the disclosure;
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[0016] FIG. 4 illustrates a partial perspective view of the second header plate and
a side plate of the condenser in accordance with an embodiment of the disclosure;
[0017] FIGs. 5A and 5B illustrate a partial perspective view and a partial top view
of a design of the side plate respectively in accordance with an embodiment of the
disclosure; and
[0018] FIG. 6 illustrates different cross section profiles of slots that can be used in
the second header plate in accordance with an embodiment of the disclosure.
[0019] In the accompanying drawings, an underlined number is employed to
represent an item over which the underlined number is positioned or an item to
which the underlined number is adjacent. A non-underlined number relates to an
item identified by a line linking the non-underlined number to the item. When a
number is non-underlined and accompanied by an associated arrow, the nonunderlined
number is used to identify a general item at which the arrow is
pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0020] The following detailed description illustrates embodiments of the present
disclosure and ways in which they can be implemented. Although some modes of
carrying out the present disclosure have been disclosed, those skilled in the art
would recognize that other embodiments for carrying out or practicing the present
disclosure are also possible.
[0021] FIG. 1 illustrates a partial perspective and exploded view of a condenser
100 configured to be installed in an air-conditioning system. The condenser 100
can be configured to be used in a vehicle or home air-conditioning system. In
addition, the present invention can be used in various heat exchangers such as an
evaporator, a heater core, a radiator and the like.
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[0022] The condenser 100 includes a first header plate 102 and a second header
plate 104 which are parts of a substantially cylindrical tank 106 of the condenser
100. A front portion of the first header plate 102 forms an outer portion of the
tank 106 and a rear portion of the first header plate 102 forms a part of an inner
portion of the tank 106.
[0023] The second header plate 104 includes a plurality of slots 108 for receiving
ends of a plurality of tubes 110 which are used for condensing high pressure
refrigerant obtained in a gaseous state from a compressor of the air-conditioning
system. The opposite ends of the plurality of tubes 110 are supported by a second
tank (not shown in FIG. 1) of the condenser 100. In an embodiment, the each tube
of the plurality of tubes 110 is hollow and includes one or more channels to
maintain refrigerant communication between the two tanks. In addition, the
plurality of tubes 110 are spaced apart by vertical heat transfer surfaces such as
fins which enable effective heat transfer from the refrigerant flowing through the
plurality of tubes 110.
[0024] The condenser 100 is further configured to include first and second side
plates 112 so as to support the plurality of tubes 110. In an embodiment, slots
disposed on the opposite ends of the second header plate 104 are configured to
receive the ends of the first and second side plates 112 respectively. Further, the
opposite ends of the first and second side plates 112 are supported by another tank
of the condenser 100. In addition, the condenser 100 is configured to include end
caps 114 for sealing the opposite ends of the tank 106.
[0025] The condenser 100 is configured to include one or more coupling units
122 and brackets 142. The coupling unit 122 can be configured to connect the
condenser 100 with connecting tubes utilized for exchanging refrigerant with
respective components of the air-conditioning system. In an embodiment, the
components of the air-conditioning system can include a compressor, an
evaporator, an expansion device, and a receiver drier.
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[0026] In an embodiment, the second header plate 104 is designed in such a way
that cross sectional profiles of the slots used for the plurality of tubes 110 and the
side plates 112 is substantially similar to a cross section profile of at least one tube
among the plurality of tubes 110. Further, the present disclosure discloses novel
and inventive designs for the side plates 112 so as to conform to the cross
sectional profile of the respective slots in the second header plate 104.
[0027] FIG. 2 illustrates a top view of a prior art based second header plate 202
configured to be used as a portion of a tank 106 of the condenser 100. As
illustrated, the prior art based second header plate 202 includes different cross
section profiles for the slots 204 configured to receive the tubes and for the slots
206 configured to receive the side plates. As a result, the punching tool
configured to create slots on the second header plate 202 is required to include
punching structures as per the respective profiles of the slots at the required
positions within the prior art based second header plate 202.
[0028] The present disclosure enables the manufacturer to remain independent
from the development of the punching tool when the number of slots for the tubes
in the second header plate needs to be modified. As the punching tool creates
similar slots for the plurality of tubes 110 and the side plates 112 within the
second header plate 104, the present disclosure obviates a requirement of
developing a new punching tool when a change in a length of the second header
plate 104 is required due to change in a number of tubes of the condenser 100.
The change in the number of tubes can depend on heat transfer requirement, an
application of the condenser or heat load of the condenser. Thus the present
disclosure discloses an improved method for manufacturing the second header
plate 104 of variable length with the same punching tool.
[0029] FIG. 3 illustrates a partial perspective view of the second header plate 104
in accordance with an embodiment of the disclosure. As indicated, the cross
section profile of each of the slot on the second header plate 104 is same or
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substantially similar with respect to each other. The slot 108 (e.g., a slot 108n)
disposed near to an end section 302 of the second header plate 104 is used for
inserting the side plate 112 therein and the remaining slots are used for inserting
the plurality of tubes 110.
[0030] As shown in FIG. 3, the second header plate 104 includes a plurality of
slots such as a slot 108a, a slot 108b, a slot 108c, a slot 108d, and a slot 108n
(collectively referred herein to as the slots 108) such that each of the slot is
disposed at equal distance along the length of the second header plate 104 and
parallel to each other. Each slot among the plurality of slots 108 has same profile
as that of transverse cross section profile of the tube 110. The present disclosure
discloses a substantially same or similar end profile for the side plates 112 with
respect to an end profile of the tube 110 so that the side plates 112 can be inserted
within the slots 108 disposed in the end sections of the second header plate 104.
[0031] FIG. 4 illustrates a partial perspective view of the side plate 112 and the
second header plate 104 in accordance with an embodiment of the disclosure. An
end section 402 of the side plate 112 is modified so as to fix within the slot 108n
whose cross section profile is similar to the cross section profile of the tube 110.
[0032] FIG. 5A illustrates a partial perspective view of a design of the side plate
112 and FIG. 5B illustrates a partial top view of the design of the side plate 112.
The side plate 112 includes a planar portion 502 having a top surface and a bottom
surface. The bottom surface of the planar portion 502 faces toward the tubes 110.
The side plate 112 is configured to include a first project 504, a second projection
506 and a third projection 522. The first projection 504 and the second projection
506 extend away from the top surface of planar portion 502.
[0033] The third projection 522 extends away from the ends of the first and
second projections and points toward the slot 108 disposed at the end section 302
of the second header plate 104. An end section 510 of the third projection 522 is
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configured to be inserted within the slot 108 assigned for the side plate 112 in the
second header plate 104.
[0034] In an embodiment, the third projection 522 is configured to include
grooves 512 disposed at the respective ends of the first and second projections.
The groove 512 is provided to eliminate stress concentration due to bending. .
[0035] In an embodiment, the side plate includes a projection pointing toward the
second slot and at least a portion of an end section of the projection is chamfered
so that a cross section profile of the projection is similar to the cross section
profile of the at least one tube.
[0036] In another embodiment, a thickness of the side plate is different than a
thickness of the at least one tube. The side plate includes a projection pointing
toward the second slot and at least a portion of an end section of the projection is
rolled or designed in a way to match thickness of the end section with the at least
one tube.
[0037] FIG. 6 illustrates different cross section profiles of slots 108 that can be
used in the second header plate 104 according to an embodiment of the disclosure.
In an embodiment, the slot can be oblong and the design is preferred when the
tubes are flat. In other embodiments, the slots can be rectangular, semicircular,
elliptical, V-shape, chamfered or combination of above said profiles. The end
section (e.g., 510) of the third projection of the side plates required to be modified
in accordance with the cross section profile of the slot.
[0038] The present disclosure offers several advantages. The present disclosure
modifies the design of the side plates so that the tube slots punched on the second
header plate can be used for side plates also. The second header plate needs not to
include slots specifically for the side plates even if the length of the header plate is
modified in order to meet new specification of the condenser. As a result, the
manufacturer is no longer required to develop a new punching tool when length of
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the header plate is modified. Thus, the present disclosure enables the
manufacturer to avoid the cost of the development of the punching tool when a
new specification of the condenser is required to be manufactured and lower the
financial cost of manufacturing the condenser of variable specification.
[0039] Modifications to embodiments of the present disclosure described in the
foregoing are possible without departing from the scope of the present disclosure
as defined by the accompanying claims. Expressions such as “including”,
“comprising”, “incorporating”, “have”, “is” used to describe and claim the present
disclosure are intended to be construed in a non-exclusive manner, namely
allowing for items, components or elements not explicitly described also to be
present. Reference to the singular is also to be construed to relate to the plural.
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CLAIMS:
1. A condenser assembly configured to be installed in an air-conditioning
system, the condenser comprising:
at least one tank formed using a first header plate and a second header
plate, wherein the first header plate comprises at least one opening for exchanging
refrigerant with at least one component of the air-conditioning system and the
second header plate comprises:
a first slot among a plurality of slots for receiving at least one tube
among a plurality of tubes for condensing the refrigerant; and
a second slot among the plurality of slots for receiving a side plate;
wherein the first slot and the second slot have cross section profiles
substantially similar to a cross section profile of the at least one tube among the
plurality of tubes and a design of the side plate is modified to conform to the cross
section profile of the at least one tube.
2. The condenser assembly as claimed in claim 1, wherein thickness of the
side plate is same as the thickness of at least one tube and the side plate comprises
a projection pointing toward the second slot and at least a portion of an end
section of the projection is chamfered so that the cross section profile of the
projection is similar to the cross section profile of the at least one tube.
3. The condenser assembly as claimed in claim 1, wherein a thickness of the
side plate is different than a thickness of the at least one tube.
4. The condenser assembly as claimed in claim 3, wherein the side plate
comprises a projection pointing toward the second slot and at least a portion of an
end section of the projection is rolled or designed in a way to match thickness of
the end section with the thickness of the at least one tube.
5. The condenser assembly as claimed in claim 4, wherein edges of the slots
are processed to make the end section of the projection suitable for insertion
within the slots.
6. The condenser assembly as claimed in claim 1, wherein the first and the
second slots have same cross section profiles.
7. The condenser assembly as claimed in claim 1, wherein the first and
second slots have oblong profiles and an end of the at least one tube has
preferably a flat profile.
8. The condenser assembly as claimed in claim 1, wherein
comprises at least one of a
profile, a V-shape profile, a chamfered profile
9. The condenser assembly as claimed in claim 1, wherein each slot of the
plurality of slots is equidistant and paralle
slots.
10. The condenser assembly as claimed in claim 1, wherein the second slot is
disposed at an end of the sec
Dated this 24th July 2015
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the oblong profile
rectangular profile, a semicircular profile, an elliptical
and any combination thereof.
parallel to the other slot of the plurality of
second header plate.