MANUFACTURING THE SAME

TECHNICAL FIELD

The present invention relates to the heat exchangers used in the refrigerating appliances. The invention relates in particular to a novel heat exchanger connected in series, which enables the heat exchangers to operate more efficiently in a smaller volume, and to a method for manufacturing the same.

DESCRIPTION OF THE STATE OF THE ART

The heat exchangers are used in the refrigerating appliances in order to enable a phase-changing heat transfer fluid to take the heat from one medium and convey it to another medium. The condensers and evaporators are employed as the heat exchanger in the refrigerating appliances. The condenser is used for the conversion of the heat transfer fluid in vapor phase to the liquid phase, whereas the evaporator is used for the conversion of the heat transfer fluid in liquid phase to the vapor phase.

Today, various forms of heat exchangers are used in line with the intended use. The most commonly used heat exchangers are of the types having the circular tubes with the use of fine wires as the heat transfer members and the types with circular copper or aluminum tubes with the use of plates or aluminum leaves as the heat transfer members.

The heat exchangers in which the plate fins are used as the heat transfer member gather dust in time. The formed dust layer should be cleaned at certain intervals, as it adversely affects the heat exchange. The tubes through which the refrigerant passes take up considerable space within the appliance. As a result, it becomes difficult to clean the formed dust. This in turn results in the inability of the refrigerating system to function efficiently. Numerous studies are under way in order to obtain high efficiency in small volume in the heat exchangers where the fine wires are used as the heat transfer members. The coils are folded in order to create maximum heat transfer area in a small volume; however, due to the positioning of the tubes one after the other in the direction of air flow, the air flow does not directly contact the tubes positioned in the back part and therefore, the reduction of efficiency is encountered.

There is a need for the manufacture of a novel heat exchanger structure, which, unlike the embodiments of the state of the art, occupies less space, is resistant to high pressure, does not gather dust and thus provides greater cooling efficiency.

The application no. TR 2013 13778 entitled "Narrow profile air processing unit having inclined rotary heat exchanger" provides a different solution. However, there is a need for developing a novel heat exchanger solution, which occupies less space, is resistant to high pressure, does not gather dust and thus provides greater cooling efficiency.

DESCRIPTION OF THE OBJECTS OF THE INVENTION

Based on the mentioned state of the art, the object of the invention is to develop a novel staggered heat exchanger connected in series, which eliminates the drawbacks in the existing embodiments and which does not gather dust.

Another object of the invention is to achieve high energy efficiency.

Another object of the invention is to increase the heat transfer, thereby enabling lower electrical energy consumption, owing to a novel staggered heat exchanger connected in series, which does not gather dust.

Another object of the invention is to enable greater heat transfer as compared to other heat exchanger groups obtained by the use of the same length of tubes. As a result, the object of the invention is to provide the possibility to use smaller quantity of tube and surface material in the same volume and to provide greater clearance between the tubes and the heat transfer members. Another object of the invention is to develop a solution that may replace the currently used heat exchanger applications with aluminum tubes and aluminum leaves owing to the efficiency achieved. Another object of the invention is thus to provide savings in the manufacturing costs as compared to such heat exchanger types, as the materials used are wires, plates and tubes.

DESCRIPTION OF THE FIGURES

Figure-1 : Drawing, in open state, of 2 coil groups, each with 3 coils, according to a preferred representative embodiment of the invention.

Figure-2: Drawing, in open state, of 1 coil group with 6 coils according to a preferred representative embodiment of the invention.

Figure-3: Drawing of the manner of folding in 3 steps according to a preferred representative embodiment of the invention.

Figure-4: Perspective drawing of the staggered heat exchanger connected in series according to a preferred representative embodiment of the invention.

Figure-5: Drawing of the front view of the staggered heat exchanger connected in series according to a preferred representative embodiment of the invention.

Figure-6: Drawing of the side view of the staggered heat exchanger connected in series according to a preferred representative embodiment of the invention.

Figure-7: Drawing of the view of the wires as the heat transfer members in a state linearly arranged according to a preferred representative embodiment of the invention.

Figure-8: Drawing of the view of the wires as the heat transfer members in a state arranged in a staggered manner according to a preferred representative embodiment of the invention.

Figure-9: Drawing of the staggered heat exchanger connected in series, fixed with a hooked fixing element according to a preferred representative embodiment of the invention.

Figure-10: Drawing of the staggered heat exchanger connected in series, fixed with a plate fixing element closed on the top according to a preferred representative embodiment of the invention.

Figure-11 : Drawing of the front view of the staggered heat exchanger connected in series with connection tubes folded on the inner side according to a preferred representative embodiment of the invention.

Figure-12: Drawing of the detailed view of the heat exchanger connected in series with connection tubes folded on the inner side according to a preferred representative embodiment of the invention. Figure-13: Drawing of the staggered heat exchanger connected in series, fixed with a plate closed on the top with air guide according to a preferred representative embodiment of the invention.

Figure-14: Drawing of the staggered heat exchanger connected in series, fixed with a plate closed on the top with fan shroud as the fixing member according to a preferred representative embodiment of the invention.

Figure-15: Drawing of the staggered heat exchanger connected in series, fixed with a plate closed on the top with fan spinning plate as the fixing member according to a preferred representative embodiment of the invention.

Figure-16: Drawing of the step of fitting the tube end into the countersunk tube in the countersink method according to a preferred representative embodiment of the invention.

Figure-17: Drawing of the staggered heat exchanger connected in series where 6 coil groups, each with 1 coil, are joined via countersink method according to a preferred representative embodiment of the invention.

Figure-18: Drawing of a detail of the staggered heat exchanger connected in series where 6 coil groups, each with 1 coil, are joined via countersink method according to a preferred representative embodiment of the invention.

REFERENCE NUMBERS

1 : Connection tube

2: Coil / tube

3: Heat transfer increasing member / fine wire

4: Countersink

5: Fixing element (hooked bracket)

6: Hook

7: Fixing element (plate closed on the top)

8: Extension folded for guiding the air

9: Mounting hole

10: Fan hole (opening for fan)

11 : Front plate

12: Fan hole wall 13: Fan mounting hole

DETAILED DESCRIPTION OF THE INVENTION

In the heat exchanger, the coil groups connected in series, which are obtained by connecting the tubes in series, are able to perform more heat transfer as compared to the heat exchanger groups obtained by the use of the same length of tubes and as a result, it becomes possible to use less tube and surface material in the same volume owing to this application.

The clearance between the tubes and the surface increasing members may be greater. Owing to the efficiency achieved with this embodiment, the heat exchanger according to the invention replaces the currently used heat exchanger embodiments having aluminum tubes and aluminum leaves, and also a lower cost is obtained as compared to said heat exchanger types, since the materials used are steel wires, plates and steel tubes.

The present invention is a heat exchanger for use in a refrigerating device, wherein said heat exchanger is connected in series and positioned as staggered one after the other, said heat exchanger comprises a coil formed by the coils/tubes (2) with circular cross-section intended to enable the flow of a heat transfer fluid through the same, and the fine wires (3), being the heat transfer surface area increasing members, are fixed by means of welding on the coils/tubes (2).

Numerous studies are under way in order to obtain high efficiency in small volume in the heat exchangers where the fine wires (3) are used as the heat transfer increasing members. The coils/tubes (2) are folded in order to create maximum heat transfer area in a small volume; however, due to the positioning of the coils/tubes (2) one after the other in the direction of air flow, the air flow does not directly contact the coils/tubes (2) positioned in the back part and therefore, the reduction of efficiency is encountered.

The staggered heat exchanger involves the positioning of the coils/tubes (2) in parallel and arrangement of the same in the form of a zigzag. According to the present invention, owing to the positioning of the coils/tubes (2) one after the other in a staggered manner, air flow is able to directly contact also the coils/tubes (2) in the back part and the inefficiency is thus eliminated.

In addition to positioning the coils/tubes (2) in a staggered manner, the fine wires (3), which are the heat transfer members, may also preferably be arranged in a staggered manner. Due to the arrangement of the fine wires (3) in an opposed manner, the fine wires (3) that are positioned in the front part with respect to the air flow prevent the direct contact with the fine wires (3) as the heat transfer increasing members where the air flow occurs in an opposite manner (Figure-7). This causes a decrease in the efficiency of heat transfer. Arrangement of the fine wires (3) in a manner staggered with respect to each other prevents such efficiency decrease (Figure-8).

The staggered heat exchanger connected in series is formed by joining one or more coil/tube (2) groups that contain one or more coil/tube (2) by way of opening a countersink (4) in one of the connection tubes (1) and passing the same through the other connection tube (1), followed by folding of the interconnected coils/tubes (2) at the connection tubes (1), thereby positioning them in a staggered manner one after the other (Figure-17, Figure-18).

While the connection tubes (1) between the coil/tube (2) groups may be joined by way of opening a countersink (4), arranging the same one within the other and employing the soldering method, the joining process may also be realized by means of the connection members such as nut, bush, etc. In this way, it is possible to obtain greater capacity by using longer tube (Figure-17, Figure-18).

The connection tubes (1) between the coils/tubes (2) may remain on the outer side of the condenser and may also be preferably positioned on the inner side of the condenser (Figure-11). Positioning of the connection tubes (1) on the inner side enables the fixing element (hooked bracket) (5) to be readily mounted to the heat exchanger without any obstacle and, since the inner position is located in the zone where the air flow is present, advantage is obtained in terms of heat transfer area. The staggered heat exchanger connected in series may comprise a coil/tube (2) group that preferably consists of one or more coil/tube (2). That the staggered heat exchanger connected in series comprises a coil/tube (2) group consisting of more than one coil/tube (2) eliminates the need for the soldering process and also prevents the risk of corrosion. As a result, a simpler and risk-free operation may be performed as the manufacturing method.

According to the current practice, the heat exchangers usually involve the welding process. The fact that the welding operation is preferably absent in the present invention provides the heat exchanger with greater pressure resistance as compared to the heat exchangers that involve the welding process and reduces the risk of leakage and the process cost.

The heat exchangers in which the plate fins are used as the heat transfer members gather dust in time. The formed dust layer should be cleaned at certain intervals, as it adversely affects the heat exchange. As a result, it becomes difficult to clean the formed dust. This in turn results in the inability of the refrigerating system to function efficiently. The use of fine wires (3) as the heat transfer increasing members prevents the problem of clogging between the fins and renders the system more efficient.

In order to mount and secure the staggered heat exchangers connected in series within any refrigerating appliance, the fixing elements are needed. The present invention includes 5 types of fixing elements, namely the fixing element (hooked bracket) (5) (Figure-9), plate fixing element closed on the top (7) (Figure-10), closed plate with air guide (Figure-13), plate closed on the top with fan shroud (Figure-14) and plate closed on the top with fan spinning plate (Figure-15).

The fixing element (hooked bracket) (5) is engaged as the fixing element under the staggered heat exchangers connected in series, and the hooks at the end portions of the folds on the sides of the bracket surround and secure the folding points of the coil/tube (2) (Figure-9).

As an alternative fixing element, the plate fixing element closed on the top (plate closed on the top) (7) is also present. The coils/tubes (2) of the staggered heat exchanger connected in series are passed through the cavities on the fixing element where said coils/tubes (2) may pass and are thus fixed (Figure-10).

Another alternative fixing element is the plate closed on the top with air guide (Figure-13). By means of the extension (8) folded for guiding the air, the sides of the top and side portions of the plate that is closed on the top are folded and the air flow is enabled to more efficiently contact the heat exchanger without being dispersed.

Another alternative fixing element is the plate fixing element closed on the top (plate closed on the top) (7) with fan shroud (Figure-14). The plate with fan shroud is formed by mounting the plate that includes the fan hole (10) for the mounting of the fan in the front part of the plate closed on the top. Owing to the condenser being closed on the top and side portions, the plate with fan shroud enables the air flow to more efficiently contact the condenser surface without being dispersed. Moreover, owing to the presence of the fan hole (10) for the fan on the front plate (11), the fan, which provides strengthening of the air flow, is enabled to be mounted to the condenser.

Another alternative fixing element is the plate closed on the top with fan spinning plate (Figure-15). Owing to the plate closed on the top with fan spinning plate, the plate with fan shroud has a fan hole wall (12) on the sides of the fan hole and the air flow is enabled to directly contact the condenser surface without being dispersed, thereby providing greater efficiency in the heat transfer. By means of the fan mounting holes (13) around the fan hole (10), the easy mounting is enabled for the fan.

Description of the Manufacturing Method According to the Invention:

In the staggered heat exchanger connected in series, the coils/tubes (2) through which the refrigerant passes are arranged in the form of one or more coil/tube (2) connected in series. The fine wires (3), which are the heat transfer surface increasing members, are secured on the coils/tubes (2) via the welding method (Figure-1 , Figure-2). The fine wires (3), which are the heat transfer surface increasing members, may be welded in an arrangement opposing one another, and they may also be welded in a staggered manner (Figure-7, Figure-8).

The coil/tube (2) groups consisting of one or more coil/tube (2) connected in series are connected together by joining the connection tubes (1) between the same.

While the connection tubes (1) between the coil/tube (2) groups may be joined by way of opening a countersink (4) on one side of the tubes (1), arranging the same one within the other and employing the soldering method, the joining process may also be realized by means of the connection members such as nut, bush, etc. (Figure-16).

The connection tubes (1) between the coils/tubes (2) may remain on the outer side of the heat exchanger and may also be preferably positioned on the inner side of the heat exchanger (Figure-11). Positioning of the connection tubes (1) on the inner side enables the fixing elements to be readily mounted to the heat exchanger without any obstacle and, since the inner position is located in the zone where the air flow is present, advantage is obtained in terms of heat transfer area.

The staggered heat exchanger connected in series may comprise a coil/tube (2) group that preferably consists of one or more coil (2). That the staggered heat exchanger connected in series comprises a coil/tube (2) group eliminates the need for the soldering process and also prevents the risk of corrosion. As a result, a simpler and risk-free operation may be performed as the manufacturing method.

In the coil group comprised by one or more coil/tube (2), the coils/tubes (2) are folded at the connection tubes (1) in between in a way to overlap (Figure-3). As a result of leaving different lengths (A - B) of connection tubes (1) (Figure-1 , Figure-2), the coils/tubes (2) are arranged in staggered manner in the direction of the air flow (Figure-5).

In order to mount the staggered heat exchanger connected in series within any refrigerating appliance, the fixing element (hooked bracket) (5) is needed. The present invention includes 5 types of fixing elements (hooked bracket), fixing element (plate closed on the top) (5, 7); namely the fixing element (hooked bracket) (5), plate closed on the top, closed plate with air guide, plate with fan shroud and plate closed on the top with fan spinning plate.

The fixing element (hooked bracket) (5) is folded on the ends of 2 sides thereof and there are present the hooks (6) on the edges of the folded ends. The fixing element (hooked bracket) (5) is positioned in a horizontal arrangement under the staggered heat exchanger connected in series and the hooks (6) on the sides of the fixing element (hooked bracket) (5) surround and secure the folding points of the staggered heat exchanger connected in series.

Referring to the plate closed on the top (Figure-10), the cavities with size allowing the entry of the coils/tubes (2) of the staggered heat exchanger connected in series are opened in the vertically positioned portions of the plate. The coils/tubes (2) of the staggered heat exchanger connected in series are passed through the cavities opened on the surface of the plate and are secured. The plate closed on the top is positioned in such a way that it covers the top of the staggered heat exchanger connected in series.

The plate closed on the top with air guide (Figure-13) involves the same manufacturing method as that for the plate closed on the top and it is formed by extending the sides on the top and side portions and by adding the method of folding the extensions inward according to a certain angle.

The plate closed on the top with fan shroud (Figure-14) is formed by mounting the plate, which comprises the fan hole (10), in the front part of the plate closed on the top. The fan hole (10) with size allowing the entry of the fan propeller is made on the front plate (11) of the plate with fan shroud. In this way, the fan propeller is mounted in the fan mounting holes (13) on the plate and provides a stable air flow.

Another alternative to the fixing element (hooked bracket) (5) is the plate closed on the top with fan spinning plate (Figure-15). The plate closed on the top with fan spinning plate involves the formation of the fan hole wall (12) by way of spinning on the sides of the fan hole (10) on the plate closed on the top with fan spinning plate. The fan mounting holes (13) are opened around the fan hole (10), thereby enabling the fan to be mounted easily.

The heat exchanger comprises the coils/tubes (2) with air flow remaining behind owing to the zigzag arrangement in parallel direction and positioning one after the other in a staggered manner and/or the fine wires (3), being the heat transfer members, arranged in a staggered and/or opposing manner with respect to one another, with the air flow remaining in the front part occurring in an opposed manner with respect to the air flow, and/or the countersink (4), which enables the coil/tube (2) groups to be positioned one after the other in a staggered manner by joining the same with one of the connection tubes (1) via the passage of the same through the other connection tube (1) followed by folding the interconnected coils/tubes (2) at the connection tubes (1).

The connection coils/tubes (1) between the coil/tube (2) groups, which may be joined by placing one within the other and by performing the soldering process and which may also be joined by means of the connection members such nut, bush, etc. in order to obtain greater capacity by the use of a longer tube, are joined by opening a countersink (4) in one of the connection coils/tubes (1).

In order to enable the heat exchangers to be mounted and secured within any refrigerating appliance, they are fixed with the elements such as the fixing element (hooked bracket) (5), plate fixing element closed on the top (plate closed on the top) (7), closed plate with air guide, plate closed on the top with fan shroud and plate closed on the top with fan spinning plate.

The coils/tubes (2) of the staggered heat exchanger connected in series comprise the fixing elements such as the plate fixing element closed on the top (plate closed on the top) (7), fixing element (hooked bracket) (5), closed plate with air guide, plate closed on the top with fan shroud and plate closed on the top with fan spinning plate wherein the coils/tubes (2) are passed through the cavities on the fixing element (hooked bracket) (5) with size allowing the passage of the same and are secured. In order to enable the fan to be easily mounted, the heat exchanger comprises the plate closed on the top with fan spinning plate, the fan hole wall (12) formed on the sides of the fan hole (10) on the plate closed on the top with fan shroud and the fan mounting holes (13) around the fan hole (10).

In order to provide the stable air flow, the heat exchanger comprises the fan hole (10) in the front portion of the plate closed on the top, the fan hole (10) where the fan propeller may enter on the front plate (11) in the plate with fan shroud formed by mounting the plate and the fan mounting holes (13) on the plate where the fan propeller is mounted.

The heat exchanger comprises the fine wires (3), being the heat transfer increasing members, in a staggered structure that ensures that the components are not positioned one after the other with respect to the air flow direction.