III US005561987A

IIII
United States Patent (19) 11) Patent Number: 5,561,987
Hartfield et al. 45) Date of Patent: Oct. 8, 1996
54 FALLING FILMEWAPORATOR WITH 4,479,533 10/1984 Persson et al. ..... ... 165/140
WAPOR-LIQUID SEPARATOR 4,488,855 12/1984. Butterworth et al. ... 417/368
4,567,942 2/1986 Stafford et al. ..... 165/118
(75) Inventors: Jon P. Hartfield, Duane F. Sanborn, 4,622,048 11/1986 Roberts et al. ........................... 55/199
both of La Crosse, Wis. 4,730,988 3/1988 Ma .......................................... 417/313
4,768,585 9/1988 Hayes et al..... ... 165,162
(73) Assignee: American Standard Inc., Piscataway, 4,815,533 3/1989 Harada et al. .. 165/159
N.J. 4,829,786 5/1989 Sand et al. ...... ... 62A468
4,918,944 4/1990 Takahashi et al ... 62A471
4,927,339 5/1990 Riffe et al. ...... ... 418,55
21 Appl. No.: 452,605 5,004,043 4/1991 Mucic et al. .... 165/18
5,036,680 8/1991 Fujiwara et al. ... 62,509
22 Filed: May 25, 1995 5,129,798 7/1992 Crum et al. ............................... 418/55
51 Int. Cl." ............................ F25B 43/02; F28F 1/32 FOREIGN PATENT DOCUMENTS
(52) a . . . . . .. . . . . . . . . 62/471; 165/117
0140788 6/1986 Japan ..................................... 165/117
(58 Field of Search ............................... 165/117; 62/219,
62/220, 221,471 Primary Examiner-William E. Wayner
Attorney, Agent, or Firm-William J. Beres; William
(56) References Cited O'Driscoll; Peter D. Ferguson
U.S. PATENT DOCUMENTS (57) ABSTRACT
2,365,878 12/1944 Huff ........................................ 257/239 Compression refrigeration apparatus for removing heat from
2,873,140 2/1959 Merrick ..................................... 299/25 a heat load using a falling film evaporator, operated with an
2,996,286 8/1961 Trepaud ....... ... 257/.223 azeotropic refrigerant and utilizing a vapor-liquid separator,
3,213,935 10/1965 Reid, Jr. ....... ... 165/17 preferably inside the evaporator vessel. In one embodiment,
3,240,265 3/1966 Weller .................. ... 165/108 two types of heat exchange surfaces are utilized-one for
3,267,693 8/1966 Richardson et al. ...................... 62/527 maximizing the axial distribution of refrigerant film on a
3,304,741 2/1967 Weller .......... 62/47 heat exchange surface, the other for encouraging liquid
3,481,151 12/1969 Seeley ...... . 62,196
3,635,040 1/1972 Morris, Jr. ... ... 65/117 refrigerant in contact with a heat exchange surface to boil
4,158,295 6/1979 Sibley ....................................... 62A476 and evaporate. The apparatus allows for efficient recovery of
4,200,426 4/1980 Linnert ............. ... 417/312 lubricant deposited in the evaporator without redistributing
4,220,011 9/1980 Bergman et al. ......................... 62/185 the lubricant within the evaporator.
4,223,537 971980 Sanborn et al. .......................... 62A174
4,318,368 3/1982 Carson et al. ............................ 122/34 35 Claims, 8 Drawing Sheets

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U.S. Patent Oct. 8, 1996 Sheet 2 of 8 5,561,987

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U.S. Patent Oct. 8, 1996 Sheet 6 of 8 5,561,987
U.S. Patent Oct. 8, 1996 Sheet 7 of 8 5,561,987
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FIG 2
U.S. Patent Oct. 8, 1996 Sheet 8 of 8 5,561,987
 5,561987
1. 2
FALLING FILM EVAPORATOR WITH exemplary of this type of evaporator, is assigned to the
WAPOR-LIQUED SEPARATOR assignee of the present invention, and is incorporated by
reference herein.
FIELD OF THE INVENTION Another characteristic of a compression refrigerator is
that the oil for lubricating the compressor circulates with the
This invention relates generally to a falling film evapo refrigerant, and collects in the evaporator. This occurs
rator used in a refrigeration system. This invention more because the oil is less volatile than the refrigerant. Thus,
particularly relates to a falling-film evaporator for a com when the refrigerant leaves the evaporator as a vapor, the
pression refrigeration system, preferably including a vapor less-volatile oil is left behind. In a system employing a
liquid separator inside the evaporator vessel. 10 flooded evaporator, most of the lubricating oil is mixed in
with the charge of liquid refrigerant in the evaporator. This
BACKGROUND OF THE INVENTION oil is not a good refrigerant, interferes with heat transfer, and
is prevented from carrying out its primary mission: to
Compression refrigeration, chilling, heat pump, and lubricate the compressor.
related apparatus typically employing chlorofluorocarbon 15 Another known type of refrigerator is an absorption
(CFC), hydroflourocarbon (HFC), replacement or alterna refrigerator. An absorption refrigerator differs from a com
tive refrigerants are known in the art. (All kinds of such pression refrigerator in several respects. One difference is
apparatus will be referred to generally as a "refrigerator' that an absorption refrigerator employs composite or non
here, for brevity.) The primary components of a compression azeotropic refrigerant. A second difference is that an absorp
refrigerator are an expansion valve, an evaporator, a com 20 tion refrigerator includes a generator and an absorber in the
pressor and a condenser, connected in that order to form a refrigerant loop.
closed refrigerant loop. A variety of composite or non-azeotropic refrigerant
In a compression refrigerator, the refrigerant may be an systems can be used in an absorption refrigerator. Two
azeotrope. This means that the refrigerant cannot be distilled examples are an ammonia/water system and a lithium bro
into separate components having different compositions 25 mide/water system. Non-azeotropic refrigerants are inten
when it is evaporated or condensed. The composition of the tionally distilled into two components-a more-volatile and
refrigerant in its liquid or vapor forms is identical. a less-volatile component-during operation of the refrig
The evaporator of a compression refrigerator is a special erator. The two components are separated in the generator,
ized heat exchanger. In operation, a liquid refrigerant is follow different paths through the apparatus, and then are
distributed via an expansion valve into the evaporator. A 30 recombined in the absorber.
fluid to be cooled is separately introduced into the evapo Between the generator-and absorber of an absorption
rator. The fluid to be cooled carries the heat load which the refrigerator, the separated, more-volatile component of the
refrigerator is designed to cool. The evaporator transfers refrigerant is routed through a condenser and evaporator
heat from the heat load to the liquid refrigerant. which function comparably to the condenser and evaporator
For example, the fluid to be cooled in the evaporator may 35 of a compression refrigerator. Since no lubricating oil is
flow through the evaporator within the runs of a bundle of provided in an absorption refrigerator, lubricating oil does
pipe having a heat-conductive wall, and the liquid refriger not tend to collect in its evaporator.
ant entering the evaporator may be distributed on the outside In absorption apparatus, the evaporator is a falling-film
of the pipe bundle. The outside of the pipe bundle can be 40
evaporator having vertical or horizontal tubes that are
referred to as a heat exchange surface. The conditions in the sprayed from a horizontal direction. The fluid to be chilled
evaporator are arranged so heat is transferred from the fluid is typically conveyed through the interior of a bundle of
to be cooled to the refrigerant through the heat exchange pipe. In practice, the liquid refrigerant, typically water in an
surface. This heat transfer boils and/or evaporates the refrig absorption system, is sprayed horizontally by a sprayer so
erant, forming a refrigerant vapor. 45
that it contacts the outside of the pipe bundle. The bundle is
The refrigerant vapor is exhausted from the evaporator by arranged so the refrigerant will flow down along the heat
the pumping action of the compressor. The compressor also exchange surface from the top of the pipe bundle to the
compresses the refrigerant, forming a more dense vapor. The bottom. Rather than optimizing the amount of liquid refrig
compression process heats the vapor, thus preventing it from erant, copious amounts of the refrigerant are oversprayed on
condensing at this point. The compressed vapor is then 50
the vertical tubes. The tubing bundle can include vertical
transported to the condenser, which is located between the runs of pipe, horizontal runs of pipe, coils of pipe running
high-pressure side of the expansion valve and the high generally circumferentially about a vertical axis, other con
pressure side of the compressor. figurations, or combinations of these.
The condenser is another specialized heat exchanger. The U.S. Pat. No. 4,918,944 (Takahashi et al.) is an example
condenser transfers the heat resulting from compression of 55 of one type of falling film evaporator. Other patents which
the refrigerant and heat load received from the evaporator to may be pertinent are U.S. Pat. No. 3,213,935 (Reid), U.S.
a heat sink, such as ambient air, ground water, or the like. As Pat. No. 3,240,265 (Weller), U.S. Pat. No. 3,267,693 (Rich
it cools down, the compressed vapor condenses to liquid ardson et al.), and U.S. Pat. No. 5,036,680 (Fujiwara et al.).
form. Finally, the cooled, condensed refrigerant passes Compression refrigerators may also use direct expansion
through the expansion valve whereupon the refrigerant 60 (DX) evaporators where the refrigerant is within a tube and
pressure and temperature are reduced and the cycle is the fluid being cooled is external to the tube. The oil return
repeated. mechanism in a DX evaporator differs from flooded evapo
One feature of a compression refrigerator is that, typi rators and the DX evaporators are generally used where 50
cally, the bundle of pipe carrying the heat load in the tons or less of cooling is desired since dual circuitry or
evaporator is immersed in a standing body of the liquid 65 derating is required for higher tonnages.
refrigerant. This type of evaporator is called a "flooded Compression refrigerators therefore have been distin
evaporator.” U.S. Pat. No. 4,829,786 to Sand et al. is guished from absorption refrigerators by the type of refrig
 5,561987
3. 4
erant used (azeotropic versus non-azeotropic), by the transported via a pipe to the evaporation vessel and distrib
mechanism used to return the refrigerant to its initial con uted on the heat exchange surface, while the refrigerant
dition (i.e. mechanical compressor versus generator), by the vapor is separately conveyed to the headspace of the evapo
type of evaporator employed (flooded only for a compres rator.
sion system versus either type for absorption), by the ten- 5 A system having an external separator must transport the
dency only of compression refrigerators to undesirably liquid refrigerant over a distance through a pipe to carry it
collect lubricating oil in the evaporator, and in other ways. into the evaporator vessel. Because the liquid refrigerant is
Flooded evaporators have a number of disadvantages near its boiling point, it is difficult to transport evenly
distinct to their design. They use more refrigerant and more through a pipe, for two reasons. First, the pipe has a
lubricant than falling film systems, thereby increasing sys- 10 relatively high surface area in contact with ambient air. The
tem cost. Also, the liquid refrigerant at the bottom of the pipe is therefore capable of receiving ambient heat and
evaporator vessel will only boil and evaporate at a relatively evaporating the liquid refrigerant, forming bubbles or foam
high temperature because of the hydrostatic head or pressure in the liquid refrigerant which can prevent the liquid refrig
from the liquid refrigerant in the evaporator vessel. Because
the liquid refrigerant near the bottom of the evaporator 15 erant from flowing evenly within the pipe. Second, the pipe
vessel will only boil at a relatively high temperature, less from the separator to the evaporator typically has not been
evaporation occurs and less heat is removed by the refrig a straight run. Elbows, joints, and the like in the pipe form
erant. This makes the refrigerator less efficient. Further, the areas where bubbles or foam can collect and interfere with
lubricating oil trapped in the flooded evaporator of a com efficient refrigerant distribution even more.
pression refrigerator is difficult to separate because the 20 Also, the vapor-liquid separator takes up space outside of
charge of refrigerant is turbulent in the evaporator. Turbu the evaporation vessel, increasing the total system size.
lence tends to continuously mix the lubricant and refriger Finally, systems utilizing a separate vapor-liquid separator
ant, interfering with their separation. are usually more costly because the separator vessel, like the
Current falling film evaporators have their own disadvan evaporator vessel, must be built and certified to withstand
tages. Many falling film evaporators deposit an excess of 25 high pressure.
refrigerant on the top of the bundle to ensure complete
wetting of the heat exchange surface from top to bottom. The SUMMARY OF THE INVENTION
excess liquid refrigerant that inevitably reaches the bottom
of the evaporator vessel is collected in a sump, then recycled It is an object, feature and advantage of the present
from the sump to the top of the tube bundle. Such recycling, 30 invention to implement a compression refrigerator with a
falling film systems have been unsuitable for use with falling film evaporator that does not recycle lubricant within
compression refrigerators because the recycling of the the evaporator over a heat exchange surface but instead
refrigerant would leave a relatively high proportioned mix allows lubricant to be drained directly from the evaporator.
ture of entrained lubricant on the lower parts of the tube It is an object, feature and advantage of the present
bundle and in the sump. This mixture would contain a high 35 invention to provide a vapor-liquid separator in a refrigera
concentration of lubricant since most of the refrigerant in the tion system which does not require an independent pressure
evaporator vessel has already evaporated before reaching the vessel.
bottom of the evaporator if the system is working properly.
Unfortunately, recycling the lubricant-rich mixture over the It is an object, feature and advantage of the present
invention
heat exchange surface in such systems decreases system 40 liquid separator to transport liquid refrigerant from the vapor
efficiency because the lubricant distributed heavily over the to the evaporator vessel directly, instead of
heat exchange surface reduces the ability of the system to via a pipe or other transportation means.
evaporate the refrigerant. Thus, falling film evaporators, and It is an object, feature and advantage of the present
particularly recycling falling film evaporators, have not been invention to implement a refrigeration system that evapo
used in compression refrigeration systems. 45
rates arefrigerant in a falling film to remove heat from a load
Another problem is common to falling film evaporators: but also efficiently evaporates any refrigerant that may settle
the precise control of liquid refrigerant distribution. Most at the bottom of the evaporator.
falling film evaporators spray the liquid refrigerant onto the It is an object, feature and advantage of the present
heat exchange surface (typically a series of tubes carrying invention to implement a falling film evaporator which
liquid to be cooled). The sprayed liquid refrigerant tends to 50 efficiently evaporates any residual liquid refrigerant which
splash off the surface, thereby reducing the intimacy of runs off the falling film heat exchange surface and collects
contact between the refrigerant and the heat exchange sur at the bottom of the evaporator vessel.
face. Because the refrigerant is in less-intimate contact with It is an object, feature and advantage of the present
the heat exchange surface, it will have less chance to boil invention to minimize the thermodynamic quality of the
and remove heat from the liquid inside the tubes comprising 55 refrigerant provided to the distributor so as to ensure that
the heat exchange surface. Additionally, if the heat exchange liquid refrigerant is applied in a controlled fashion by the
surface is a stack of horizontally disposed tubes, it is difficult distributor.
to control the axial distribution of liquid refrigerant along One aspect of the present invention is a refrigerating
the length of the tubes. Therefore some parts of the heat system including an evaporator and a compressor. The
exchange surface may be cooled while others are not. 60 evaporator includes a pressure vessel, a refrigerant level
Finally, droplets of the sprayed refrigerant can form a mist regulator, a body of evaporator tubes, a liquid refrigerant
or aerosol in the refrigerant vapor that can be sucked into distributor, and a lubricant recovery system. The pressure
and damage the compressor of the refrigeration system. vessel has a refrigerant input and a refrigerant output. The
In most compression refrigeration systems, the pressur refrigerant level regulator maintains the top surface of a
ized liquid refrigerant leaving the expansion valve is sepa- 65 body of liquid refrigerant within the pressure vessel at a
rated into liquid and vapor phases in a vapor-liquid separator nominal elevation. The body of evaporator tubes is disposed
outside the evaporator vessel. The liquid refrigerant is then within the pressure vessel. The body of tubes includes an
 5,561987
S 6
upper heat exchange surface located above the nominal FIG. 8B is an isolated section, oriented as in FIG. 2, of a
elevation of the refrigerant in the evaporator and a lower second alternative type of evaporator tube.
heat exchange surface located below the nominal elevation FIG.9 is a diagrammatic section of an alternative embodi
of the refrigerant in the evaporator. ment of the spray tree distributor of FIG. 2.
A liquid refrigerant distributor is provided for wetting the FIG. 10 is a diagrammatic, perspective, detail view of an
upperheat exchange surface of the body of evaporator tubes alternate embodiment of the spray-tree distributor of FIG. 4.
with a refrigerant taken from the refrigerant input. The liquid FIG. 11 is an isolated cutaway diagrammatic view of an
refrigerant distributor also supplies an excess of refrigerant alternative embodiment of the mesh screen arrangement of
which collects in the lower part of the evaporator vessel, FIG. 10.
immersing the lower heat exchange surface of the body of 10
evaporator tubes. The lubricant recovery system removes a FIG. 12 is a view, similar to FIG. 11, of still another
lubricant-rich phase from a body of liquid refrigerant within embodiment of the mesh screen arrangement of FIG. 10.
the pressure vessel to a location outside the pressure vessel. FIG. 13 is a schematic side elevation of an alternative
Such a system separates the majority of a refrigerant from embodiment of FIG. 1.
15
a lubricant by evaporation at the upper heat exchange DETALED DESCRIPTION OF THE
surface, thus concentrating the lubricant at the bottom of the PREFERRED EMBODIMENTS
evaporator where it can be easily removed from the evapo
rator. The above-described system also does not recycle the While the present invention will be described in connec
lubricant over the heat exchange surface within the evapo tion with certain preferred embodiments, it will be under
20 stood that the invention is not limited to those embodiments.
rator, which would reduce the ability of the system to
evaporate the "falling film” refrigerant. Additionally, the The present invention includes all alternatives, modifica
above-described system evaporates the refrigerant from a tions and equivalents within the spirit and scope of the
falling film at the upper heat exchange surface and from a invention as defined by the appended claims.
standing pool of liquid at the lower heat exchange surface. 25
FIG. 1 shows a compression refrigerator system generally
Another aspect of the present invention is a cooling indicated at 1. In the preferred embodiment, the compression
apparatus comprising an evaporator vessel, an expansion refrigerator 1 includes a screw compressor 2, a pair of oil
valve, a liquid refrigerant sprayer and arefrigerant separator. separators 3 and 4, a condenser 5, a subcooler 6, an
The evaporator vessel has a refrigerant input, a refrigerant expansion valve 7, a falling film evaporator 8, and a lubri
vapor output, a headspace, and a body of evaporator tubes 30
cant pump 9. The outputs 10 and 11 of the screw compressor
disposed generally below the headspace. The expansion 2 are respectively connected by the vapor refrigerant lines
valve has an input and also has an output communicating 12 and 13 to the inputs 14 and 15 of the oil separators 3 and
with the refrigerant input of the evaporator vessel. The 4. The oil separators 3 and 4 have vapor outputs 16 and 17
refrigerant separator is located within the evaporator head connected via lines 18 and 19 to condenser inputs 20 and 21.
space. It has a refrigerant separator input that communicates 35 The condenser 5 has an output 22 that delivers condensed,
with the expansion valve output, a separation volume, a liquid refrigerant to the subcooler 6 via a condenser output
vapor output that communicates between the separation line 23. The subcooler 6 has the liquid refrigerant input 24
volume and the headspace, and a drain that pools liquid connected by the line 23 to a condenser output 22 and a
refrigerant and communicates between the separation vol liquid refrigerant output 31 connected by the refrigerant line
ume and the liquid refrigerant sprayer. In this way, the 40 32 to the expansion valve 7. The subcooler 6 also includes
system does not require a separate pressure vessel for the an integral oil cooler having a lubricant input 25 connected
vapor-liquid separator. Such a system is less expensive than by the line 26 to the oil separator lubricant outputs 27, 28;
systems utilizing separate vapor-liquid separators. Addition and an output 72 that is connected via the line 29 to the
ally, such systems do not need to transport a liquid refrig compressor lubricant input 30. Both the condenser 5 and the
erant which is easily subject to boiling to the evaporator. 45 subcooler 6 transfer the heat removed from either the
BRIEF DESCRIPTION OF THE DRAWINGS refrigerant or the lubricant to a heat sink33. The expansion
valve 7 is connected in the line 32 running to the falling film
FIG. 1 is a schematic side elevation of a compression evaporator 8.
refrigeration system according to the present invention. The primary components of the falling film evaporator 8
FIG. 2 is a section taken along line 2-2 of FIG. 1 of an 50 (described in more detail below in conjunction with FIG. 2)
evaporator and liquid-vapor separator assembly according to are aheadspace 34, a vapor-liquid separator 35, a refrigerant
the present invention. vapor output 36, a spray tree distribution system 37, and a
FIG. 3 is an isolated, cut-away view similar to FIG. 1 of body of evaporator tubes 38. The expansion valve 7 is in
a liquid-vapor separator. fluid communication with the vapor-liquid separator 35
FIG. 4 is a fragmentary view similar to FIG. 2 of a 55 which, in turn, is in fluid communication with the spray tree
liquid-vapor separator and spray tree distributor. distribution system 37. The falling film evaporator has a
FIG. 5 is an isolated detail view similar to FIG. 1 of a lubricant recovery output 39 connected by the line 40 to the
evaporator, and liquid-vapor separator according to the input 41 of the pump 9. A lubricant recovery line 42 is
present invention. connected to the output 43 of the pump 9 and leads to the
60 refrigerant/lubricant compressor input line (suction line) 44.
FIG. 6 is an isolated, diagrammatic top plan view of the The refrigerant/lubricant compressor input line 44 is con
spray tree distributor of FIG. 2. nected to the compressor input 45. A heat load 46, external
FIG. 7 is an enlarged, isolated section, oriented as in FIG. to the falling film evaporator 8, is in fluid communication
2, of a single spray tree distribution tube and a single with the body of evaporator tubes 38.
evaporator tube. 65 Turning to FIG. 2, one can see more details of the internal
FIG. 8A is an isolated section, oriented as in FIG. 2, of a structure of the falling film evaporator 8. The evaporator 8
first alternative type of evaporator tube. is contained in a pressure vessel 47. The pressure vessel 47
 5,561987
7 8
is constructed to withstand the pressure generated by the embodiment, the slot 61 may be replaced with a plurality of
evaporation of the refrigerant in the headspace 34 and the regularly spaced apertures (not shown) arranged along the
weight and hydrostatic pressure of the deepest possible pool bottom of the tube 55. In such case, the flange 61 may be
of liquid refrigerant that might collect at the bottom of the formed as collars (not shown).
evaporator. Positioned in the outer lumen 59 is an inner tube 62
As shown in FIGS. 2 and 3, disposed within the pressure having an inner lumen 63, a liquid input port 57 (shown in
vessel 47 is a vapor-liquid separator 35 having a refrigerant FIG. 6) in fluid communication with the manifold 54, and a
separator input 48, a separation volume 49, a refrigerant series of axially spaced orifices such as 64 providing com
vapor output 50, and a liquid refrigerant drain 51. Returning munication between the inner lumen 63 and outer lumen 59.
to FIG. 2, the expansion valve 7 communicates with the O The orifice 64 is sized to spray the liquid refrigerant supplied
refrigerant separator input 48 allowing the refrigerant to via the inner lumen 63 against the inner wall 65.
enter the separation volume 49 and separate into vapor and Multiple embodiments such as nozzles, openings, or
liquid. The vapor-liquid separator 35 preferably has a nar flanges can be used in place of the orifices 64. Similarly, a
rowing shape (in this case a "V" shape resembling an axial single slit or opening can be used in place of multiple
section of a brilliant-cut diamond). This shape provides a 15
orifices 64. Also, as many refrigerant spray orifices 64 as
relatively large volume 49 in its upper portion to contain a necessary may be used to distribute liquid refrigerant axially
large volume of vapor refrigerant without a pressure build along the interior surface 65 of the distribution tube. Simi
up. This shape also provides a relatively small pooling larly, the refrigerant spray need not be directed at the interior
volume 52 near its bottom that is deep enough that a pool surface directly above the inner tube 62. The refrigerant
containing a small quantity of liquid refrigerant will provide 20
spray can be directed at a side wall or at the axially
a sufficient hydrostatic head to spray the liquid refrigerant. extending slot 60 instead. Additionally, the spacing of the
As best seen in FIG. 5, the vapor output 50 is located spray orifices 64 can be either equidistant or irregularly
substantially horizontally distant from the refrigerant sepa spaced, depending on the refrigerant flow characteristics
rator input 48 to allow adequate space and time for vapor 25
within the inner tube 62. Under some conditions, a closer
refrigerant to separate from liquid refrigerant before entering spacing of the orifices 64 as the distance from the liquid
the headspace 34. Additionally, the vapor output 50 of the input port 57 increases may be desired. This is illustrated as
vapor-liquid separator 35 is located substantially horizon orifices 64A in FIG. 6. Under other conditions, a closer
tally distant from the refrigerant vapor output 36 of the spacing of the orifices 64 as the distance from the liquid
pressure vessel 47 and has a screen 53 interposed between 30
input port 57 decreases may be desired. This is illustrated as
the separation volume 49 and the headspace 34. The screen orifices 64B in FIG. 6.
53 captures splashes and entrained droplets of liquid refrig FIG. 2 shows that the body of evaporator tubes 38 is
erant vapor and also may be dimensioned to provide a slight arranged as a series of vertical stacks of horizontally dis
"back pressure" on the top of the liquid refrigerant pooling posed runs such as 56, 66, and 67 of tubing. Each vertical
in the bottom of the vapor-liquid separator 35. This back 35 stack has an uppermost member such as 56 which lies below
pressure, in conjunction with the hydrostatic pressure of the a distribution tube 55.
standing pool held in the pooling volume 52, forces the The body 38 of evaporator tubes is preferably homog
liquid refrigerant out the drain 51 of the vapor-liquid sepa enous but may be divided into an upper heat exchange
rator 35. The hydrostatic head also permits flow of the surface 68 and a lower heat exchange surface 69. The upper
saturated liquid out of the separator and through the dis 40 heat exchange surface 68 operates in a falling film mode
tributor tubes without flashing, thus maintaining single where each tube 56, 66, 67 is exposed to a supply of
phase flow which promotes and enhances uniform distribu refrigerant in excess of that which the particular tube can,
tion to the falling film tube bundle. boil. Thus excess refrigerant is provided to each tube in the
Returning to FIG. 2, the drain 51 of the vapor-liquid upper heat exchange surface 68, and the excess refrigerant
separator 35 is in fluid communication with and positioned 45 pools around the lower heat exchange surface 69. In con
above a spray tree distribution system 37 which, in turn, is ventional falling film evaporators, the excess refrigerant
located above a body 38 of generally horizontal evaporator pools at the bottom of the falling film evaporator where the
tubes containing liquid to be cooled. pooled refrigerant is recirculated back to the entrance of the
The spray tree distribution system 37, also shown in falling film evaporator by a pump. That recirculated refrig
isolation in FIG. 6, includes a manifold 54 and a series of 50 erant is then included in the spray on the tubes. In a
horizontal distribution tubes such as 55. Referring to FIGS. mechanical compressor having a mixture of refrigerant and
2, 6, and 7, each distribution tube such as 55 lies parallel to, lubricant, such an arrangement increases the percentage of
in close proximity to, and directly above one uppermost tube lubricant, in the falling film evaporator since the lubricant
such as 56 of the body of evaporator tubes 38. The manifold does not escape the falling film evaporator in vaporous form.
54 is in fluid communication with the horizontal distribution 55 This is overcome in the present invention by adding the
tubes 55 via a series of liquid input ports such as 57 shown lower heat exchange surface 69, which resides in the pool
in F.G. 6. 71, with sufficient capacity to boil the excess refrigerant
FIG.7 shows more details of a horizontal distribution tube supplied to the bottom row of tubes to maintain optimum
55. The tube 55 is composed of a outer tube wall 58 performance and allow concentrated lubricant to be removed
enclosing an outer lumen 59. The outer tube wall 58 has a 60 through the lubricant recovery outlet 39. Thus, the present
axially extending slot 60 through the outer tube wall 58 invention does not require a recirculating pump.
which allows fluid to drip from the outer lumen 59 onto an The upper heat exchange surface 68 is composed of the
evaporator tube 56. The slot 60 may extend substantially the outer surfaces of the tubes such as 56, 66, and 67 that are
length of the tube 55. Extending at right angles along the slot located above the nominal level 70 of the pool 71 of
60 are two downwardly extending flanges 61 for forming 65 refrigerant and lubricant at the bottom of the pressure vessel
falling liquid refrigerant so it will flow in substantially equal 47 and constitute at least 75% of the total volume or area of
amounts down both sides of the tube 56. In an alternative heat transfer surface. The tubes comprising the upper heat
 5,561987
9 10
exchange surface 68 are preferably grooved with either 3, 4, the subcooler 6, and the screw compressor 2 define the
horizontal or helical striations. These grooves help distribute primary lubrication circuit. This circuit is responsible for
falling liquid refrigerant along the horizontal axes of the ensuring the compressor works smoothly with a tight seal as
tubes, maximizing the amount of contact between the refrig it compresses vapor refrigerant.
erant and the heat exchange surface. This allows the refrig Because the oil separators 3, 4 are not one hundred
erant the maximum time to evaporate and remove heat. percent efficient, a mixture of refrigerant and carried over
Tubing such as that sold under the trade name WOLVERINE lubricant (predominantly refrigerant) successively enters the
Turbo BII is manufactured with appropriate grooves and can condenser 5, the subcooler 6, the expansion valve 7, and the
be used for the tubes that comprise the upper heat exchange evaporator 8.
surface 68. However, Turbo BII is an optimal tube for a 10 Referring now to FIG. 2, within the falling film evapo
flooded evaporator which has not been optimized for use in rator 8 the vapor and liquid refrigerant components entering
a falling film evaporator. The outer surface of the tubes of the evaporator 8 are separated in the vapor-liquid separator
the upper heat exchange surface 68 are preferably optimized
for heat exchange with a thin film of refrigerant. 35. Referring to FIG. 1, the vapor component of the entering
The lower heat exchange surface 69, in contrast to the refrigerant leaves the falling film evaporator 8 directly via
upper heat exchange surface 68, is composed of the outer 15 the refrigerant vapor output 36 and is carried to the com
surfaces of the tubes located below the nominal level 70 of pressor input 45 via the refrigerant/lubricant compressor
the pool 71 and constitutes at most 25% of the total area or input line 44.
volume of heat transfer surface. There should be enough Referring to FIGS. 2, 6, and 7, the liquid component of the
tubes in the lower heat exchange surface 69 to boil away the entering refrigerant is distributed by the spray tree distribu
20 tion system 37 onto the body 38 of evaporator tubes.
excess refrigerant from the upper heat exchange surface 68.
Preferably, there should be twice as many tubes in the lower The spray tree distribution system 37 operates as follows.
heat exchange surface 69, as there are in the bottom row of Liquid refrigerant from the pooling volume 52 exits the
the upper heat exchange surface 68. Again, because the drain 51 of the vapor liquid separator 35 and is distributed
system is not hundred percent efficient in separating refrig 25
through the horizontal distribution tubes 55 via the manifold
erant from lubricant, the pool 71 is composed of both liquid 54. As seen in FIGS. 5 and 6, the drain 51 and manifold 54
refrigerant and lubricant. Under optimal conditions, the are located at the center of the spray tree distribution system
proportion of liquid refrigerant should be small compared to 37. This ensures the most uniform distribution of liquid
the amount of lubricant in the pool 71. The outer surfaces of refrigerant through the horizontal distribution tubes 55.
the tubes comprising the lower heat exchange surface 69 can 30 Turning to FIGS. 6 and 7, the liquid refrigerant that is
be rough to encourage the liquid refrigerant that is in contact under pressure from the vapor-liquid separator 35 flows
with the lower heat exchange surface 69 to nucleate and boil. through the manifold 54 and the liquid input port 57 into the
Such boiling further concentrates the lubricant in the pool 71 inner lumen 63 and sprays onto the interior surface 65 of the
while contributing to refrigeration. Tubing such as that sold horizontal distribution tube 55. The liquid then runs down
under the trade name Wolverine Turbo BII is manufactured both sides of the interior surface 65 of the horizontal
35
with appropriate grooves and can be used for the tubes that distribution tube 55 in the form of a film 73 and out the
comprise the lower heat exchange surface 69. This tubing is axially extending slot 60 as described above. This embodi
near optimum for heat exchange with a thick film of refrig ment prevents splashing and misdirection of liquid refrig
erant such as is found in the pool 71. erant as it is distributed onto the evaporator tubes below.
Referring mostly to FIG. 1, the refrigerator of FIGS. 1-8 40 In the present invention, liquid refrigerant will form
operates as follows. The azeotropic refrigerant vapor enter droplets within the axially extending slot 60 and slowly drip
ing the input 45 of the compression refrigerator 1 is adia down the downwardly extending flanges 61 to impact upon
batically compressed by the screw compressor 2, leaving it a top-most evaporator tube 56. The use of two flanges 61
in denser vapor form and causing it to heat up. The com encourages the formation of two refrigerant droplets that
pressed, heated vapor is transported via the refrigerant vapor 45 will impact the evaporator tubes and slide down opposite
lines 12, 13 from the compressor outputs 10, 11 to the inputs sides of the tubes, covering as much of the tube surface as
14, 15 of the oil separators 3, 4. possible with a film 74. This embodiment provides an
The oil separators 3, 4 separate the lubricant from the efficient and equal distribution of liquid refrigerant within
compressed refrigerant (to a large degree). The separated the failing film evaporator 8. In a first alternative embodi
lubricant leaves the oil separators 3, 4 via the lubricant 50 ment of the present invention (shown in FIG. 8A), the
outputs 27, 28 and is transported to the subcooler 6 via the evaporator tube 75 may have a ridge shaped as a V-point 76
subcooler line 26 where it is cooled, then returned to the or a series of nodes shaped as a V-point 76 to encourage the
screw compressor 2 at the lubricant input 30. In contrast, the formation of a single droplet 77 at the center and bottom of
heated, relatively dense refrigerant vapor leaves the oil the tube. This V-point 76 may be knurled during manufac
separators 3, 4 via two outputs 17, 16 and is transported via 55 ture of the tube 56, or affixed by welding, brazing or the like.
lines 18, 19 to the condenser 5. In the condenser 5, the vapor A second alternative embodiment, (shown in FIG. 8B)
is condensed into aliquid by cooling it. The heat 53 removed contemplates a tube having a heart-shaped cross-sectional
from the refrigerant by condensing it is transferred to the shape where a V-point 76 functions as in the first alternative
heat sink 33. The cooled liquid refrigerant then exits the embodiment, and where liquid refrigerant pools in a notch
condenser 5 via the condenser output 22 and is transported 60 90 between the lobes 91 of the heart shaped tube 56. The
to the subcooler 6 via the output line 23. notch 90 may be formed by knurling the tube 56.
In the subcooler 6, the liquid refrigerant from the con As shown in FIG. 2, the liquid refrigerant that drips from
denser 5 and the lubricant from the oil separators 3, 4 each horizontal distribution tube such as 55 falls onto the
separately undergo additional cooling. The lubricant exits top-most evaporator tube 56 of a vertical column of evapo
the subcooler 6 at the subcooler output 72 and is carried to 65 rator tubes 56, 66, 67, etc. The liquid refrigerant is in the
the compressor lubricant input 30 via the subcooler line 29. form of a falling film. It first falls on the top-most evaporator
The subcooler lines 29 and 26 connecting the oil separators tube 56. Part of the refrigerant film evaporates, carrying
 5,561987
11 12
away heat from the liquid to be cooled inside the evaporator embodiment. The liquid refrigerant flows from the drain 51
tube 56. The refrigerant that does not evaporate falls onto the of the vapor-liquid separator (not shown), through a mani
next tube below, in this case, the tube 66. Again, any of the fold 54 and out a tree of horizontal distribution tubes 55. The
refrigerant that does not evaporate falls onto the next top horizontal distribution tubes 55 spray the liquid refrigerant
most tube 67, and the process continues as the ever-dimin onto a mesh screen 80 that is adapted to pass liquid and
ishing flow of liquid refrigerant flows toward the bottom of vapor refrigerant. As shown in both FIGS. 10 and 9, the
the falling film evaporator 8. mesh screen 80 is corrugated or waved, forming generally
The refrigerant that evaporates once it comes into contact parallel peaks 81 and valleys 82.
with the evaporator tubes forms a vapor which leaves the Referring particularly to FIG. 10, the mesh screen 80 is
falling film evaporator 8 via the refrigerant vapor output 36 10 positioned so that each valley 82 is generally parallel with
where it is transported to the screw compressor 2 via the and located directly above one of the uppermost evaporator
refrigerant/lubricant compressor input line 44. tubes such as 56 of the upper heat exchange surface 68 (FIG.
The refrigerant that does not evaporate as it comes into 9). The mesh screen 80 can either touch or be in close
proximity with the top-most evaporator tubes of the upper
contact with the evaporator tubes, as well as any lubricant heat exchange surface 68. In the arrangement of FIG. 10, a
carried over in the liquid refrigerant, forms a pool 71 at the 15
liquid refrigerant spray impacts the mesh screen 80 and
bottom of the pressure vessel 47. A conventional, commer pools of liquid refrigerant flow and adhere to the valleys 82
cially level sensor 78 monitors the depth of the pool 71. A of the mesh screen 80. The pools of liquid refrigerant grow
controller 79, such as that sold by the Trane division of axially along the valleys 82 until gravity overcomes the
American Standard Inc. under the trademark UCP or UCPII, surface attraction force which suspend the liquid refrigerant
is responsive to the level sensor 78 and throttles the flow of 20
on the mesh screen 80 surface. The liquid refrigerant then
two-Phase refrigerant through the expansion valve 7. If the falls as drops onto the uppermost evaporator tubes such as
level sensed by the level sensor 78 is too high, the controller 56 of the upper heat exchange surface 68 (see FIG.9). In the
79 closes the expansion valve 7 back, thereby reducing the case where the mesh screen 80 is actually touching the
rate of introduction of the two-phase refrigerant into the evaporator tubes, the pooled liquid refrigerant flows onto the
falling film evaporator 8. If the level sensed by the level 25 tube.
sensor 78 is too low, the controller 79 opens the expansion Droplets of refrigerant liquid entrained in refrigerant
valve 7, thereby increasing the rate of introduction of the vapor are captured in the mesh screen 80 and contribute to
two-phase refrigerant into the falling film evaporator 8. The the pools of liquid refrigerant that form in the valleys 82 of
controller 79 can be used to continuously adjust the amount the screen. The refrigerant vapor, however, flows upward
of the two-phase refrigerant entering the falling film evapo 30
through the open mesh without any substantial impediment
rator 8 to keep the pool 71 of refrigerant and lubricant at a to pass from the body 38 of evaporator tubes to the vapor
nominal level 70 most or all of the time.
outlet 36. The pitch or "fineness" of the mesh screen can
Unlike the body of liquid refrigerant in a typical immer range from 6 to 16 wires per inch, using 0.010-0.040 in.
sion evaporator, the pool 71 of lubricant at the bottom of the 35 diameter wire and constructed of steel, copper, aluminum or
evaporator 8 is not normally turbulent. The pool 71 is less the like.
turbulent than the pool of a flooded evaporator because most In other embodiments, illustrated in FIGS. 11 and 12,
of the refrigerant evaporates before reaching the pool 71. multiple mesh screens 83, 84, and 85 are interposed between
Comparatively less boiling occurs from the pool 71 than the horizontal distribution tubes 55 and the upper heat
occurs in a flooded evaporator. There is enough boiling to 40 exchange surface 68. The screens may be of the same or
vaporize much of the liquid refrigerant to result in a lubri varying pitch and may be arranged to support each other. If
cant-rich mixture.
the screens have varying pitch, it is desirable that the
Therefore, a pump 9 (see FIG. 1) is able to pump the uppermost screen or screens have a higher or more dense
lubricant rich mixture out of the pressure vessel 47 through pitch than the screens closest to the body of evaporator
a lubricant recovery output 39 and circulate the lubricant 45 tubes. This arrangement encourages the formation of large
back to the screw compressor 2 through the refrigerant/ droplets of liquid refrigerant and increases the amount of
lubricant compressor input 44. The lubricant rich mixture liquid refrigerant flow near the body of evaporator tubes.
leaves the falling film evaporator 8 via the lubricant recov Also, referring to FIG. 11, in the case of multiple mesh
ery output 39. The lubricant is transported via the line 40 to screens 83, 84, 85, the valleys 86 of one mesh screen should
the pump input 41. The pump 9 pumps the lubricant out its 50 be adjacent to the peaks 87 of an adjacent but lower mesh
output 43 through the lubricant recovery line 42 and into the screen in order to minimize refrigerant splashing and ease
refrigerant/lubricant compressor input line 44, thus complet the gentle flow of refrigerant through the mesh screens to the
ing the refrigeration circuit. The drained lubricant is remixed body of evaporator tubes (the topmost row of such tubes
with the refrigerant at line 44 and then fed to the compressor. shown as 88). Alternatively, the peaks and valleys of one or
Alternatively, the drained lubricant can be fed directly to the 55 more mesh screens may be skewed with respect to the peaks
compressor lubricant input 30. and valleys of adjacent mesh screens. FIG. 12 shows such an
In an alternative embodiment of the present invention, the alignment for three such mesh screens 83, 84, 85, which are
liquid refrigerant is distributed upon the body of evaporator respectively arranged orthogonally. In either embodiment,
tubes 38 in a different way. Instead of utilizing the spray tree the lower screens 85 and 84 support the screens above them,
distribution system described above, the alternative embodi 60 reducing or eliminating the need for external bracing.
ment uses a traditional spraying system, but instead of FIG. 13 is an alternative embodiment of the present
spraying liquid refrigerant directly onto the evaporator invention where the evaporator 8 includes an external vapor
tubes, the spray system sprays the liquid refrigerant onto one liquid separator 92. In describing this alternative embodi
or more mesh screens. The primary components of the ment, the reference numerals of FIG. 1 are used to describe
alternative embodiment are shown in FIGS. 9 and 10. 65 similar features. In this alternative embodiment, the expan
Many of the components in FIG. 9 are the same as those sion valve 7 connected by the line 32 to the vapor-liquid
shown in the previous figures detailing the preferred separator 92 at an inlet port 93 of the vapor-liquid separator
 5,561987
13 14
92. The vapor-liquid separator 92 is a conventional separator These patents are assigned to the assignee of the present
where a barrier 94 is used to cause separation of the liquid invention and are hereby incorporated by reference. Co
and vapor refrigerant. The liquid refrigerant pools in the rotational scroll compressors such as that shown in U.S. Pat.
lower portion of the vapor-liquid separator 92 where it is No. 5,129,798 to Crum et al. are also contemplated, this
conveyed by a line 95 from a liquid outlet 96 of the patent also being incorporated by reference.
vapor-liquid separator to the inlet 97 of the evaporator 8 and What is claimed as Letters Patent of the United States are:
thence to the spray tree distribution system 37. Refrigerant 1. An evaporator comprising:
vapor exits the vapor-liquid separator 92 by means of a a flooded evaporator portion;
vapor outlet 98 and is conveyed by a line 99 to an evaporator
vapor inlet 100 located proximate the lower heat exchange 10
a falling film evaporator portion;
surface 69 and below the nominal level 70 of the pool 71 so a housing including an upper portion defining the falling
that the vapor agitates the mixture of refrigerant and lubri film evaporator portion and allower portion defining the
cant in the pool 71. Since the agitation causes more refrig flooded evaporator portion;
erant to contact the lower heat exchange surface 69, this a first set of heat transfer tubes arranged in the upper
further enhances the concentrated lubricant by increasing the portion of the housing and having enhancements maxi
vaporization of the liquid refrigerant. As before, the con 15
centrated lubricant is removed by the lubricant recovery of mizing heat transfer with a thin film; and
outlet 39, this outlet 39 being preferably located longitudi a second set of heat transfer tubes arranged in the lower
nally distant from the inlet 100. portion of the housing and having enhancements to
FIG. 13 shows a further alternative embodiment where maximize heat transfer with a thick film.
the vapor from the vapor-separator 92 is only conveyed to 20 2. The heat exchanger of claim 1 wherein the first set of
the evaporator vapor inlet 100 when the system 1 is at part heat transfer tubes constitutes at least about 75% of an
load conditions. At full load conditions, a valve 105 diverts interior volume of the housing and the second set of heat
the vapor to the compressor input line 44 by evaporator transfer tubes constitutes at most about 25% of the interior
bypass line 106. This effectively fools the system 1 into volume of the housing.
bringing the same amount of refrigerant into the evaporator 25 3. The evaporator of claim 1 further including:
8 at both full and part load, and provides improved distri an input port in the housing accepting a vapor-liquid
bution with smaller distribution tubes in a smaller evapora mixture;
Or. a separator having an inlet, a vapor outlet and a liquid
The present invention and alternative embodiments dis 30
outlet, and adapted to receive a vapor-liquid mixture
close a compression refrigerator utilizing a falling film from the housing input port, at the separator inlet and
evaporator with a vapor-liquid separator is disposed within being operable to separate the mixture into a vapor and
the evaporator. The system operates by spraying a refriger a liquid and provide the vapor to the vapor outlet and
ant onto a surface or a mesh screen and allowing the provide the liquid to the liquid outlet.
refrigerant to drip onto a heat exchange surface. 35
4. The evaporator of claim 3 further including a distribu
The present invention maximizes the amount of contact tor operably connected to the separator liquid outlet and
between the liquid refrigerant and the heat exchange surface adapted to receive liquid therefrom and to distribute the
while minimizing refrigerant splashing and the amount of liquid to the first set of heat transfer tubes;
refrigerant sucked into the compressor. The present inven wherein the separator minimizes the thermodynamic
tion also efficiently evaporates the refrigerant that falls as a 40 quality of the refrigerant provided to the distributor so
film over the heat exchange surface, as well as the refrig as to ensure the refrigerant is applied in a controlled
erant that pools at the bottom of the evaporator. In addition, fashion by the distributor.
the present invention allows for efficient recovery of lubri 5. The evaporator of claim 4 wherein the liquid comprises
cant deposited in the evaporator without redistributing the a mixture of refrigerant and lubricant and wherein the
lubricant within the evaporator. Finally, the present inven 45 evaporator includes a pool at a lower portion operable to
tion does not require an independent pressure vessel for the accumulate the mixture; and
vapor-liquid separator but instead transports liquid refriger wherein the second set of heat transfer tubes are located
ant from the vapor-liquid separator directly to the evapora in said pool and act to increase the lubricant concen
tO. tration in the pool while decreasing the refrigerant
Although the preferred embodiment is described in terms 50 concentration so as to form a lubricant rich solution.
of a helical rotary (or 'screw) compressor such as sold by 6. The evaporator of claim 5 further including an inlet
the Trane division of American Standard Inc. under the operably connected to the liquid refrigerant pool wherein the
trademark "Series R' or shown in U.S. Pat. No. 4,622,048 separator is external of the housing and the separator vapor
to Roberts et al., the invention applies to mechanical com outlet.
pressors having refrigerant and lubricant mixtures. For 55 7. The evaporator of claim 5 further including an evapo
example, this includes any mechanical compressors such as rator outlet, and a pool inlet operably connected to the liquid
scroll compressors sold by the Trane division of American refrigerant pool, wherein the separator is external of the
Standard Inc. under the trademark "3-D' or such as shown housing and the separator vapor outlet is connected to the
in U.S. Pat. No. 4,488,855 to Butterworth et al. or U.S. Pat. evaporator outlet underfull load conditions and is connected
No. 4,927,339 to Riffe et al; centrifugal compressors such as 60 to the pool inlet under part load conditions.
sold by the Trane division of American Standard Inc. under 8. The evaporator of claim 5 wherein the separator is
the trademark "CenTraVac' or as shown in U.S. Pat. No. located within the housing and including a line operably
4,223,537 to Sanborn et al. or U.S. Pat. No. 4,220,011 to connected from the housing input port to the separator inlet.
Bergman et al; and reciprocating compressors such as sold 9. The evaporator of claim 8 further including:
by the Trane division of American Standard Inc. under the 65 a refrigerant vapor output, a headspace, and a body of the
trademark "Climatuff' or as shown in U.S. Pat. No. 4,730, first and second heat transfer tubes disposed generally
988 to Ma or U.S. Pat. No. 4,200,426 to Linnert or the like. below said headspace; and
 5,561,987
15 16
wherein the separator is disposed within said headspace 22. The evaporator of claim 21 wherein the cylindrical or
and has a separation volume: elliptical tube has a heart shaped cross-section.
wherein the vapor outlet of the separator communicates 23. The evaporator of claim 20 wherein the drip enhanc
between said separation volume and said headspace; ing formation includes a series of nodes linearly arranged
and substantially along the longitudinal downside portion of the
heat transfer tube.
wherein the separator includes a drain which pools liquid 24. The evaporator of claim 23 where the nodes are
refrigerant and communicates between said separation generally conical in shape.
volume and said distributor. 25. A falling film evaporator comprising:
10. The evaporator of claim 9 wherein the drain is located a pressure vessel;
above the distributor and fills the distributor with refrigerant 10
via gravity. a vapor-liquid separator positioned in said pressure ves
11. The evaporator of claim 9 wherein the vapor outlet of sel;
the separator has a screen disposed between the separation a liquid distributor assembly positioned in said pressure
volume and the headspace wherein the screen provides a vessel which communicates with said vapor-liquid
back pressure in the separation volume forcing refrigerant 15 separator; and
through the drain and the distributor. a plurality of generally horizontal evaporator tubes posi
12. The evaporator of claim 11 wherein the back pressure tioned in said pressure vessel and under said liquid
is such that liquid refrigerant is forced through the drain and distributor assembly such that fluid may flow from said
distributor and flashing is minimized. vapor-liquid separator, through said liquid distributor
13. The evaporator of claim 11 wherein the drain is 20 assembly and fall onto said evaporator tubes;
located substantially near a center of the distributor. wherein the vapor-liquid separator has a narrowing 'V'
14. The evaporator of claim 9 further including a drain shape resembling an axial section of a brilliant-cut
volume wherein the separation volume is significantly larger diamond.
than the drain volume.
15. The evaporator of claim 9 wherein the refrigerator 26. The falling film evaporator of claim 25 further com
separator inlet is located substantially horizontally distant 25 prising a control system for maintaining said refrigerant in
from the vapor outlet of the refrigerant separator. said pressure vessel at a nominal level.
16. The evaporator of claim 9 wherein the vapor outlet of 27. The falling film evaporator of claim 26 wherein said
the separator is located substantially horizontally distant evaporator tubes define an upper heat exchange surface and
from the refrigerant vapor output of the evaporator. a lower heat exchange surface, said upper heat exchange
17. The evaporator of claim 1 further including: 30 surface being located above said nominal level of refriger
at.
an input port in the housing accepting a vapor-liquid 28. The falling film evaporator of claim 27 wherein said
mixture; evaporator tubes defining said upper heat exchange surface
a separator having an inlet, a vapor outlet and a liquid have an outer surface which is grooved.
outlet, and adapted to receive a vapor-liquid mixture 35 29. The falling film evaporator of claim 27 further includ
from the housing input port at the separator inlet, and ing:
being operable to separate the mixture into a vapor and a headspace,
a liquid, and provide the vapor to the vapor outlet and
provide the liquid to the liquid outlet; wherein the plurality of evaporator tubes are disposed
a refrigerant vapor output; generally below said headspace;
40
a headspace; wherein the vapor-liquid separator is disposed within said
headspace and has a separation volume,
abody of the first and second heat transfer tubes disposed wherein the vapor outlet of the separator communicates
generally below said headspace; and between said separation volume and said headspace,
wherein the separator is disposed within said headspace and
and has a separation volume: 45
wherein the separator includes a drain which pools liquid
wherein the vapor outlet of the separator communicates refrigerant and communicates between said separation
between said separation volume and said headspace; volume and said distributor.
and 30. A cooling system comprising:
wherein the separator includes a drain which pools liquid 50 a compressor having an inlet and an outlet;
refrigerant and communicates between said separation a condenser having an inlet operably connected to the
volume and said distributor.
18. The evaporator of claim 18 wherein the separator has compressor outlet and an outlet;
a narrowing 'V' shape resembling an axial section of a an expansion valve having an inlet operably connected to
brilliant-cut diamond. 55
the condenser outlet and an outlet;
19. The evaporator of claim 1 wherein the first set of heat a vapor-liquid separator having an inlet operably con
transfer tubes comprises: nected to the expansion valve outlet and a liquid outlet
a cylindrical or elliptical tube having an arbitrary down and a vapor outlet; and
side; and an evaporator having a liquid inlet in a first upper portion
a drip enhancing formation integral with or affixed to the 60 of the evaporator, the liquid inlet being operably con
downside portion of the tube. nected to the liquid outlet of the separator;
20. The evaporator of claim 19 where the drip enhancing the evaporator further including
formation has a V-pointed cross-sectional shape where the V (a) a vapor outlet in a second upper portion of the
points in the downside direction. evaporator, the vapor outlet of the evaporator being
21. The evaporator of claim 20 where the drip enhancing 65 operably connected to the compressor inlet;
formation extends continuously and linearly substantially (b) a liquid pool in the lower portion of the evaporator,
the longitudinal length of the tube. and
 5,561987
17 18
(c) a vapor inlet in the lower portion where the vapor 33. The cooling system of claim 32 wherein the vapor
inlet is located below the surface of the liquid pool, liquid separator has a narrowing 'V' shape resembling an
the vapor inlet of the evaporator being operably axial section of a brilliant-cut diamond.
connected to the vapor outlet of the separator. 34. The cooling system of claim 33 wherein the evapo
31. The cooling system of claim 30 wherein the vapor rator includes a body of heat transfer tubes, the body of heat
entering the liquid pool is arranged to agitate a lubricant transfer tubes having an upper subset of tubes optimized for
refrigerant mixture comprising the liquid in the pool so as to heat transfer with a thin film, and a lower subset of tubes
enhance the vaporization of a refrigerant portion of the arranged in the pool and optimized for heat transfer with a
mixture and thereby enhance the overall concentration of a thick film.
lubricant portion of the mixture. 10 35. The cooling system of claim 30 wherein the evapo
32. The cooling system of claim 31 wherein the evapo rator includes a body of heat transfer tubes, the body of heat
rator further includes a lubricant portion drain in the lower transfer tubes having an upper subset of tubes optimized for
portion of the evaporator, the drain being operable to remove heat transfer with a thin film, and a lower subset of tubes
the highly concentrated lubricant portion, the drain being arranged in the pool and optimized for heat transfer with a
operably connected to the compressor by conduit and 15 thick film.
thereby transferring the lubricant rich mixture to the com
pressor.
 UNITED STATES PATENT AND TRADEMARK OFFICE
CERTIFICATE OF CORRECTION
PATENT NO. : 5,561,987
DATED October 8, 1996
NVENTOR(S) : Jon P. Hartfield and Duane F. Sanborn
It is certified that error appears in the above-identified patent and that said Letters Patent is hereby
corrected as shown below:

Column 2, Line 31, "generator-and" should read "generator and--.

Claim 18, Column 15, Line 55, "claim 18" should read
-- claim 17--.

Signed and Sealed this

al (a (eel
BRUCELEHMAN

Attesting Officer Commissioner of Patents and Trademarks w