Integrated condenser/receiver and insert for use therein

Abstract

An integrated condenser/receiver unit including a filter insert. The filter insert extends just beyond a refrigerant inlet of the receiver and is formed from a unitary plastic body having a flow-deflection portion and a filter portion. The flow-deflection portion is located opposite the refrigerant inlet of the receiver housing to prevent the refrigerant flow from the inlet from directly impinging a desiccant charge contained within the receiver housing. A method is provided for forming the condenser/receiver wherein a desiccant and filter are inserted into the receiver housing after the remainder of the condenser/receiver has been brazed together as a unit, and after insertion of the desiccant and filter, an end cap is metallurgically bonded to the receiver housing to close the same.

1 . In an integrated condenser/receiver for use in a vehicular air conditioning system, the condenser/receiver comprising: a heat exchanger core, at least one header connected to said core to receive refrigerant therefrom, and a receiver housing connected to said header, said receiver housing having an inlet opening for directing a refrigerant flow from said header into said receiver housing, and a refrigerant outlet for directing refrigerant from said receiver housing, and a desiccant charge contained within said receiver housing, the improvement comprising: 
 a filter insert contained with said receiver housing, said filter insert comprising a unitary body having an end terminating adjacent said refrigerant inlet, said unitary body including a flow-deflection portion and a filter portion, said flow-deflection portion extending from said end to past said refrigerant inlet to prevent said refrigerant flow from directly impinging said desiccant charge.    
   
   
       2 . The improvement of  claim 1  wherein the flow-deflection portion comprises a cylindrical wall.  
   
   
       3 . The improvement of  claim 2  wherein said inlet and said outlet are spaced by a linear distance, and the unitary body has a total length that corresponds approximately to said distance.  
   
   
       4 . The improvement of  claim 1  wherein said filter portion comprises a cylindrical shaped filter basket.  
   
   
       5 . The improvement of  claim 1  wherein said unitary body comprises a seal that engages an inner wall of said receiver housing.  
   
   
       6 . The improvement of  claim 1  wherein said unitary body comprises another seal that engages the inner wall of said receiver housing.  
   
   
       7 . The improvement of  claim 1  wherein said receiver housing comprises a cylindrical wall and a pair of end caps, one of the caps closing a first open end of said cylindrical wall and the other of the caps closing a second open end of said cylindrical wall, with at least one of said caps inseparably connected to the cylindrical wall.  
   
   
       8 . A filter insert for use in a refrigerant receiver of a vehicular air conditioning system, the receiver having a housing containing a desiccant charge, the housing connected to a header of a condenser via a refrigerant inlet and further including a refrigerant outlet, said filter insert comprising: 
 a unitary body having an end terminating adjacent said refrigerant inlet with the insert received in said housing, said unitary body including a flow-deflection portion and a filter portion, said flow-deflection portion extending from said end to past said refrigerant inlet to prevent said refrigerant flow from directly impinging said desiccant charge with the insert received in the housing.    
   
   
       9 . The filter insert of  claim 1  wherein the flow-deflection portion comprises a cylindrical wall.  
   
   
       10 . The filter insert of  claim 9  wherein said inlet and said outlet are spaced by a linear distance, and the unitary body has a total length that corresponds approximately to said distance.  
   
   
       11 . The filter insert of  claim 8  wherein said filter portion comprises a cylindrical shaped filter basket.  
   
   
       12 . The filter insert of  claim 8  wherein said unitary body comprises a seal that engages an inner wall of said receiver housing.  
   
   
       13 . The filter insert of  claim 8  wherein said unitary body comprises another seal that engages the inner wall of said receiver housing.  
   
   
       14 . A method of manufacturing an integrated condenser/receiver for use in a vehicular air conditioning system, the condenser/receiver comprising a core, a header connected to said core to receive refrigerant therefrom, and a receiver housing connected to said header, the method comprising the steps of: 
 brazing the heat exchanger core, the header, and the receiver housing together in an oven;    after the brazing step, inserting a desiccant charge and a filter into the receiver housing through an opening in the receiver housing; and    after the inserting step, closing said opening by metallurgically bonding a cap to the receiver housing.    
   
   
       15 . The method of  claim 1  wherein said inserting step comprises inserting the filter in the form of a unitary plastic body.  
   
   
       16 . The method of  claim 1  wherein said inserting step comprises inserting the desiccant charge in the form of a plastic container through which refrigerant can flow and within which the desiccant is contained, the plastic container having a shape that conforms to an interior shape of said housing.  
   
   
       17 . The method of  claim 1  wherein said metallurgical bonding comprising a welding method that involves a small input of heat, and further comprises cooling a region of the housing containing said filter as needed to prevent heat damage to said filter.