Multistage, Microchannel Condensers with Displaced Manifolds for Use in HVAC Systems

Abstract

In one instance, a multistage microchannel condenser is provided for use as an aspect of a heating, ventilating, and air conditioning (HVAC) system. The multistage microchannel condenser includes at least two pluralities of flat tubes having microchannels, each associated with a different refrigeration circuit, that are interspersed so that when only one refrigeration circuit is operational, the multistage microchannel condenser still does not have any substantial thermal dead spots. Manifolds are used on each end of the multistage microchannel condenser to fluidly couple members of the at least two pluralities of flat tubes such that the refrigerant in each refrigeration circuit remains separated while still using a majority of the area of the face of the multistage microchannel condenser. Other aspects are presented.

What is claimed is: 
     
         1 . A heating, ventilating, and air conditioning (HVAC) system comprising:
 a first closed refrigeration circuit comprising:   a first compressor,   a condenser fluidly coupled to the first compressor,   a first expansion device fluidly coupled to the condenser,   a first evaporator fluidly coupled to the expansion device and to a suction side of the first compressor, and   a first refrigerant;   a second closed refrigeration circuit comprising:   a second compressor,   the condenser fluidly coupled to the second compressor,   a second expansion device fluidly coupled to the condenser,   a second evaporator fluidly coupled to the second expansion device and to a suction side of the second compressor, and   a second refrigerant, wherein the first refrigerant and second refrigerant remain separated;   wherein the condenser comprises a multistage microchannel condenser having an exchange profile, wherein the exchange profile comprises an exchange area;   a condenser blower for producing a condenser airflow across the multistage microchannel condenser; and   wherein the multistage microchannel condenser comprises:   a first plurality of flat tubes having a first end and a second end, the first plurality of flat tubes for receiving and transporting the first refrigerant, each flat tube of the first plurality of flat tubes having a plurality of microchannels and in fluid communication with the first closed refrigeration circuit, the first plurality of flat tubes extending in a first, longitudinal direction,   a second plurality of flat tubes having a first end and a second end, the second plurality of flat tubes for receiving and transporting the second refrigerant, each flat tube of the second plurality of flat tubes having a plurality of microchannels and in fluid communication with the second closed refrigeration circuit, the second plurality of flat tubes extending in the first, longitudinal direction,   wherein at least a portion of the first plurality of flat tubes is interspersed with at least a portion of the second plurality of flat tubes throughout at least a majority of the exchange area,   a first manifold fluidly coupled to the first plurality of flat tubes at the first end of the first plurality of flat tubes, and the first manifold extending in a second, vertical direction that is substantially orthogonal to the first, longitudinal direction,   a second manifold fluidly coupled to the first plurality of flat tubes at the second end of the first plurality of flat tubes and extending in the second, vertical direction,   a third manifold fluidly coupled to the second plurality of flat tubes at the first end of the second plurality of flat tubes and the third manifold extending in the second, vertical direction,   a fourth manifold fluidly coupled to the second plurality of flat tubes at the second end of the second plurality of flat tubes and the fourth manifold extending in the second, vertical direction, and   wherein the first manifold and third manifold are parallel to one another and displaced from one another along a third, lateral direction substantially orthogonal to the first direction and second direction.   
     
     
         2 . The system of  claim 1 , wherein the first manifold has a baffling member therein that forms a first chamber and a second chamber. 
     
     
         3 . The system of  claim 1 , wherein the third manifold has a baffling member therein that forms a third chamber and a fourth chamber. 
     
     
         4 . The system of  claim 1 , wherein each of the first plurality of flat tubes has a manifold extension portion formed at the first end and second end that extends in the third, lateral direction a portion of a width of the flat tube of the first plurality of flat tubes. 
     
     
         5 . The system of  claim 1 , wherein each of the first plurality of flat tubes has a manifold extension portion formed at the first end and second end that each extends in the third, lateral direction a portion of a width of the flat tube and wherein each of the second plurality of flat tubes has a manifold extension portion formed at the first end and second end that each extends in the third, lateral direction a portion of a width of the flat tube of the second plurality of flat tubes. 
     
     
         6 . The system of  claim 1 , wherein each of first plurality of flat tubes has a manifold extension portion formed at the first end and second end that extends in the third direction less than half a width of the flat tube and extends away from a first longitudinal edge of the flat tube, and wherein each of the second plurality of flat tubes has a manifold extension portion formed at the first end and second end that extends in the third, lateral direction less than half a width of the flat tube and extends away from a second longitudinal edge of the flat tube. 
     
     
         7 . The system of  claim 1 , wherein each of first plurality of flat tubes has a first manifold extension portion formed at the first end and second end that extends in the third, lateral direction a portion of the flat tube and extends away from a first longitudinal edge of the flat tube to form a stepped portion to provide a space for another laterally adjacent manifold to be placed, and wherein each of the second plurality of flat tubes has a second manifold extension portion formed at the first end and second end that extends in the third, lateral direction a portion of the flat tube and extends away from a second longitudinal edge of the flat tube to form a second stepped portion to provide a space for another laterally adjacent manifold to be placed. 
     
     
         8 . The system of  claim 1 , where the first plurality of flat tubes has a longitudinal dimension that is equal to a longitudinal dimension of the second plurality of flat tubes. 
     
     
         9 . The system of  claim 1 , where the first plurality of flat tubes has a longitudinal dimension that is not equal to a longitudinal dimension of the second plurality of flat tubes. 
     
     
         10 . The system of  claim 1 , further comprising a plurality of fins coupled to a top portion of the first plurality of flat tubes. 
     
     
         11 . A heating, ventilating, and air conditioning (HVAC) system comprising:
 at least two closed refrigerant circuits;   a multistage microchannel condenser having an exchange area and having at least two pluralities of flat tubes interspersed in the exchange area, wherein the at least two closed refrigerant circuits are fluidly coupled to the multistage microchannel condenser;   at least two manifolds at a first longitudinal end of the at least two pluralities of flat tubes and on a first end of the multistage microchannel condenser, wherein the at least two manifolds at the first longitudinal end are laterally displaced from one another in a direction orthogonal to a length of the two pluralities of flat tubes;   at least two manifolds at a second longitudinal end of the at least two pluralities of flat tubes and on a second end of the multistage microchannel condenser, wherein the at least two manifolds at the second longitudinal end are laterally displaced from one another in a direction orthogonal to the length of the two pluralities of flat tubes.   
     
     
         12 . A heating, ventilating, and air conditioning (HVAC) system comprising:
 a first closed refrigeration circuit comprising:   a first compressor,   a condenser fluidly coupled to the first compressor,   a first expansion device fluidly coupled to the condenser,   a first evaporator fluidly coupled to the expansion device and to a suction side of the first compressor, and   a first refrigerant;   a second closed refrigeration circuit comprising:   a second compressor,   the condenser fluidly coupled to the compressor,   a second expansion device fluidly coupled to the condenser,   a second evaporator fluidly coupled to the second expansion device and to a suction side of the second compressor, and   a second refrigerant, wherein the first refrigerant and second refrigerant remain separated;   wherein the condenser comprise a multistage microchannel condenser having an exchange profile, wherein the exchange profile comprises an exchange area;   a condenser blower for producing a condenser airflow across the multistage microchannel condenser; and   wherein the multistage microchannel condenser comprises:   a first plurality of flat tubes having a first end and a second end, the first plurality of flat tubes for receiving and transporting the first refrigerant, each flat tube of the first plurality of flat tubes having a plurality of microchannels, and in fluid communication with the first closed refrigeration circuit, the first plurality of flat tubes extending in a first direction,   a second plurality of flat tubes having a first end and a second end, the second plurality of flat tubes for receiving and transporting the second refrigerant, each flat tube of the second plurality of flat tubes having a plurality of microchannels and in fluid communication with the second closed refrigeration circuit, the second plurality of flat tubes extending in the first direction,   wherein at least a portion of the first plurality of flat tubes is interspersed with at least a portion of the second plurality of flat tubes throughout at least a majority of the exchange area,   a first manifold fluidly coupled to the first plurality of flat tubes at the first end of the first plurality of flat tubes and extending with respect to its long dimension in a second direction that is substantially orthogonal to the first direction,   a second manifold fluidly coupled to the first plurality of flat tubes at the second end of the first plurality of flat tubes and extending with respect to its long dimension in the second direction,   a third manifold fluidly coupled to the second plurality of flat tubes at the first end of the second plurality of flat tubes and extending with respect to its long dimension in a second direction that is substantially orthogonal to the first direction,   a fourth manifold fluidly coupled to the second plurality of flat tubes at the second end of the second plurality of flat tubes and the fourth manifold extending with respect to its long dimension in the second direction,   wherein the first manifold and third manifold are parallel to one another and displaced from one another with respect to the first direction, and   wherein at least a portion of the first plurality of flat tubes extends through the third manifold.   
     
     
         13 . The heating, ventilating, and air conditioning (HVAC) system of  claim 12 , wherein the first manifold comprises a first chamber in a vertical member and the third manifold comprises a second chamber in the vertical member that is parallel to the first chamber in the vertical member. 
     
     
         14 . The heating, ventilating, and air conditioning (HVAC) system of  claim 12 , wherein the first end of the first plurality of flat tubes is disposed within the first manifold and the second end of the first plurality of flat tubes is disposed within the second manifold. 
     
     
         15 . The heating, ventilating, and air conditioning (HVAC) system of  claim 12 , wherein the first end of the first plurality of flat tubes is disposed within the first manifold and the second end of the first plurality of flat tubes is disposed within the second manifold, and wherein the first end of the second plurality of flat tubes is disposed within the third manifold and the second end of the second plurality of flat tubes is disposed within the fourth manifold. 
     
     
         16 . The heating, ventilating, and air conditioning (HVAC) system of  claim 12 , wherein the first direction is orthogonal to a gravitational field and the second direction parallel to the gravitational field. 
     
     
         17 . A multistage microchannel condenser for use in a heating, ventilating, and air conditioning (HVAC) system, the multistage microchannel condenser comprising:
 a first plurality of flat tubes having a first end and a second end, the first plurality of flat tubes for receiving and transporting a first refrigerant, each flat tube of the first plurality of flat tubes having a plurality of microchannels, the first plurality of flat tubes extending, with respect to its long dimension, in a first direction;   a second plurality of flat tubes having a first end and a second end, the second plurality of flat tubes for receiving and transporting a second refrigerant, each flat tube of the second plurality of flat tubes having a plurality of microchannels, the second plurality of flat tubes extending in the first direction;   wherein at least a portion of the first plurality of flat tubes is interspersed with at least a portion of the second plurality of flat tubes throughout at least a majority of an exchange area of a front face of the multistage microchannel condenser;   a first manifold fluidly coupled to the first plurality of flat tubes at the first end of the first plurality of flat tubes and the first manifold extending, with respect to its long dimension, in a second direction that is substantially orthogonal to the first direction;   a second manifold fluidly coupled to the first plurality of flat tubes at the second end of the first plurality of flat tubes and the second manifold extending, with respect to its long dimension, in the second direction;   a third manifold fluidly coupled to the second plurality of flat tubes at the first end of the second plurality of flat tubes and the third manifold extending, with respect to its long dimension, in the second direction that is substantially orthogonal to the first direction;   a fourth manifold fluidly coupled to the second plurality of flat tubes at the second end of the second plurality of flat tubes and the fourth manifold extending, with respect to its long dimension, in the second direction;   wherein the first manifold and third manifold are parallel to one another, with respect to their long dimensions, and are displaced from one another with respect to the first direction; and   wherein at least a portion of the first plurality of flat tubes extends through the third manifold.   
     
     
         18 . An heating, ventilating, and air conditioning (HVAC) system comprising:
 at least two closed refrigerant circuits;   a multistage microchannel condenser having an exchange area and having at least two pluralities of flat tubes interspersed in the exchange area, wherein the at least two closed refrigerant circuits are fluidly coupled to the multistage microchannel condenser;   a first first-end manifold having long dimension at a right angle to a long dimension of the at least two pluralities of flat tubes and wherein the first first-end manifold is disposed proximate a first end of the multistage microchannel condenser;   a second first-end manifold having long dimension at a right angle to a long dimension of the at least two pluralities of flat tubes and wherein the second first-end manifold is disposed proximate the first end of the multistage microchannel condenser;   a first second-end manifold having long dimension at a right angle to the long dimension of the at least two pluralities of flat tubes and wherein the first second-end manifold is disposed proximate a second end of the multistage microchannel condenser;   a second second-end manifold having long dimension at a right angle to the long dimension of the at least two pluralities of flat tubes and wherein the second second-end manifold is disposed proximate a second end of the multistage microchannel condenser;   wherein the first end of the first plurality of flat tubes is fluidly coupled to the first first-end manifold and the second end of the first plurality of flat tubes is fluidly coupled to the first second-end manifold; and   wherein the first end of the second plurality of flat tubes is fluidly coupled to the second first-end manifold and the second end of the second plurality of flat tubes is fluidly coupled to the second second-end manifold.   
     
     
         19 . The heating, ventilating, and air conditioning (HVAC) system of  claim 18 , wherein the first first-end manifold and the second first-end manifold are longitudinally displaced from one another in a direction parallel to the long dimension of the two pluralities of flat tubes. 
     
     
         20 . The heating, ventilating, and air conditioning (HVAC) system of  claim 18 , wherein the first first-end manifold and the second first-end manifold are laterally displaced from one another in a direction orthogonal to the long dimension of the two pluralities of flat tubes and substantially adjacent to one another with respect to the direction of the long dimension of the two pluralities of flat tubes. 
     
     
         21 . The heating, ventilating, and air conditioning (HVAC) system of  claim 18 , wherein the first first-end manifold comprises a first baffling within the first first-end manifold to form two chambers therein; and wherein the second first-end manifold comprises a second baffling within the second first-end manifold to form two chambers therein.