Abstrict In accordance with one preferred embodiment, a desiccant cartridge
(30) for insertion into an integrated condenser/receiver (10) comprises
a rigid stand-off member (72) and a porous desiccant bag (34). The
preferred rigid stand-off member comprises spaced inner and outer
pad portions and an elongated stand-off portion terminating in the
inner pad portion. The inner pad may include a tab portion. The
porous desiccant bag is positioned between the inner and outer pad
portions and affixed to one or both of the inner and outer pad portions.
A rigid cap with a plurality of holes may be provided to which a
second end of the porous desiccant bag may be attached. The porous
desiccant bag includes first and second flat end seals, one of which
is secured to attachment tab portions.
Claims What is claimed is:
1. A desiccant cartridge for insertion into a receiver of an integrated
condenser/receiver, said desiccant cartridge comprising: a porous
desiccant bag defining sealed first and second end portions, said
second end portion having a flat seal; and a rigid member having
a web portion and a skirt portion closed at one end by said web
portion to form a cavity, and a tab portion extending transversely
from said web portion, said flat seal being secured to said tab
portion.
2. The desiccant cartridge as recited in claim 1 wherein the skirt
portion defines an exterior surface, and said skirt portion has
at least one hole extending from said exterior surface to said cavity.
3. The desiccant cartridge as recited in claim 1 wherein: said
rigid member includes a relatively thin, elongated stand-off portion
extending from said web portion.
4. The desiccant cartridge as recited in claim 1 wherein: said
rigid member includes a relatively thin, elongated stand-off portion
extending from said web portion, said stand-off portion defining
a free end spaced from said web portion; and a flange portion positioned
along said stand-off portion intermediate said web portion and said
free end; and said web portion and said flange portion are of substantially
the same size and shape.
5. The desiccant cartridge as recited in claim 1 wherein: said
rigid member includes a relatively thin, elongated stand-off portion
extending from said web portion, said stand-off portion having a
boss and an eye through said boss.
6. The desiccant cartridge as recited in claim 1 wherein: said
porous desiccant bag is secured to said tab portion by means selected
from the group consisting of ultrasonic welding, thermal welding
and vibration welding.
7. The desiccant cartridge as recited in claim 1 wherein said porous
desiccant bag contains a fluorescent dye wafer.
8. The desiccant cartridge as recited in claim 1 wherein the integral
condenser/receiver includes a rigid end closure, said rigid end
closure including a plug portion for closing an open end of said
reservoir and an elongated stand-off portion extending from said
plug portion for abutment against said web portion of said rigid
member to position said desiccant cartridge in said reservoir, said
plug portion and said open end of said reservoir present complementary
threads for securing said plug portion in said open end.
9. A desiccant cartridge for insertion into a reservoir of an integrated
condenser/receiver, said desiccant cartridge comprising: a porous
desiccant bag defining sealed first and second end portions, said
second end portion having a flat seal; and a rigid dongle having
a skirt portion defining an exterior surface, a web portion closing
said skirt portion to define a cavity and a tab portion extending
transversely from said web portion, said flat seal being secured
to said tab portion, said skirt portion has at least one hole extending
from said exterior surface to said cavity.
10. The desiccant cartridge as recited in claim 19 wherein: said
rigid dongle is an integral plastic casting; and said porous desiccant
bag is secured to said tab portion by means selected from the group
consisting of ultrasonic welding, thermal welding and vibration
welding.
11. The desiccant cartridge as recited in claim 9 wherein: said
rigid dongle is an integral plastic casting; and said porous desiccant
bag is secured to said tab portion by ultrasonic welding.
12. A method for charging a desiccant material into a receiver
of an integrated receiver/condenser comprising the steps of: a)
casting a rigid plastic member having a web portion and a tab portion
extending transversely from said web portion; b) affixing a flat
end seal of a porous desiccant bag to said tab portion to form a
desiccant cartridge by means selected from the group consisting
of ultrasonic welding, thermal welding and vibration welding; and
c) inserting said desiccant cartridge through an open end of said
receiver into a reservoir of said receiver.
13. The method as recited in claim 12 wherein: said step a) includes
casting said rigid plastic member such that said rigid plastic member
is an elongated stand-off member extending from the web portion,
the stand-off member including a skirt portion closed at one end
by said web portion to form a cavity.
14. The method as recited in claim 12 wherein: said step a) includes
casting said rigid plastic member such that said rigid plastic member
includes a skirt portion defining an exterior surface, said skirt
portion being closed at one end by said web portion to form a cavity;
and said skirt portion has at least one hole extending from said
exterior surface to said cavity.
15. The method as recited in claim 12 including the additional
step of: d) engaging a rigid end closure in said open end of said
receiver, said rigid end closure including a plug portion for closing
said open end and an elongated stand-off portion extending from
said plug portion for abutment against said web portion of said
rigid member to position said desiccant cartridge in said reservoir.
16. The method as recited in claim 12 wherein: said step a) includes
casting said rigid plastic member such that said rigid plastic member
includes a relatively thin, elongated stand-off portion extending
from said web portion, said stand-off portion defining a free end
spaced from said web portion; and a flange portion positioned along
said stand-off portion intermediate said web portion and said free
end, said web portion and said flange portion are of substantially
the same size and shape as a cross-section of said reservoir so
as to promote positioning, and inhibit lateral movement, of said
desiccant cartridge in said reservoir.
17. The method as recited in claim 12 wherein: said step a) includes
casting said rigid plastic member such that said rigid plastic member
includes a relatively thin, elongated stand-off portion extending
from said web portion, said stand-off portion having a boss and
an eye through said boss.
18. A desiccant cartridge for installation in a receiver of an
integrated condenser/receiver, said desiccant cartridge comprising:
a rigid stand-off member having an inner pad portion, an elongated
stand-off portion terminating in said inner pad portion, and an
outer pad portion spaced from said inner pad portion; and a porous
desiccant bag positioned between said inner and outer pad portions,
said porous desiccant bag being affixed to at least one of said
inner and outer pad portions.
19. The desiccant cartridge as recited in claim 18 including an
eccentric spacing rib portion spacing said inner and outer pads.
20. The desiccant cartridge as recited in claim 18 wherein: said
rigid stand-off member includes an eccentric spacing rib portion
and a clamp portion supported by said spacing rib portion between
said inner pad portion and said outer pad portion; and said porous
desiccant bag being secured by said clamp portion in a position
between said inner and outer pad portions.
21. The desiccant cartridge as recited in claim 18 wherein: said
rigid stand-off member includes an eccentric spacing rib portion
and a clamp portion supported by said spacing rib portion between
said inner pad portion and said outer pad portion; said clamp portion
including a first clamping jaw supported by said spacing rib portion
and a second clamping jaw supported by said first clamping jaw through
a living hinge; said first and second clamping jaws defining complementary
detents for engagement to secure said clamp in embracing relationship
with said porous desiccant bag; and said porous desiccant bag being
secured by said clamp portion.
22. The desiccant cartridge as recited in claim 18 wherein: said
rigid stand-off member includes an eccentric spacing rib portion
and a clamp portion supported by said spacing rib portion between
said inner pad portion and said outer pad portion; said clamp portion
including a first clamping jaw supported by said spacing rib portion
and a second clamping jaw supported by said first clamping jaw through
a living hinge; said first and second clamping jaws defining complementary
detents for engagement to secure said clamp in embracing relationship
with said porous desiccant bag and an outer annular channel for
receiving an annular seal; and said porous desiccant bag being secured
by said clamp portion.
23. The desiccant cartridge as recited in claim 18 wherein: said
rigid stand-off member includes a cylindrical cage portion spacing
said inner and outer portions; and said porous desiccant bag being
secured by said cage portion in a position between said inner and
outer pad portions.
24. The desiccant cartridge as recited in claim 18 wherein: said
rigid stand-off member includes a cylindrical cage portion spacing
said inner and outer portions; said cage portion comprising a first
cage element coupled to said inner and outer pad portions and a
second cage element supported by said first cage element through
a living hinge; said first and second cage elements defining complementary
detents for engagement to secure said cage portion in embracing
relationship with said porous desiccant bag; and said porous desiccant
bag being secured by said cage portion in a position between said
inner and outer pad portions.
25. The desiccant cartridge as recited in claim 18 wherein: said
rigid stand-off portion includes a flange portion; and said inner
pad portion, said outer pad portion and said flange portion are
of substantially the same size and shape.
26. The desiccant cartridge as recited in claim 18 wherein said
porous desiccant bag contains a fluorescent dye wafer.
27. The desiccant cartridge of claim 26 wherein the inner pad
further comprises a tab portion to which the desiccant bag is affixed
to.
28. The desiccant cartridge as recited in claim 27 further comprising
a rigid cap defining a cavity, a plurality of holes communicating
between said cavity and an exterior of said cap, and a spacer portion
extending away from said cavity, said second end portion of said
porous desiccant bag being received in said cavity.
29. The desiccant cartridge as recited in claim 28 wherein: said
rigid cap includes a sleeve portion and a web portion closing one
end of said sleeve portion to define said cavity; said plurality
of holes extends through said web portion; and said spacer portion
extends from said web portion.
30. The desiccant cartridge of claim 29 wherein said rigid cap
defines a cavity, a plurality of holes communicating between said
cavity and an exterior of said rigid cap, and a spacer portion extends
toward said end panel, said second end portion of said porous desiccant
bag being received in said cavity.
31. The desiccant cartridge of claim 29 wherein maximum effective
hole diameters of the plurality of holes are substantially no greater
than a maximum effective grain diameters of a desiccant material
so as to retain said grains.
32. In an integrated receiver/condenser having a reservoir and
a pair of ports communicating with said reservoir, the improvement
comprising: a desiccant cartridge positioned in said reservoir,
said desiccant cartridge including a rigid stand-off member and
a porous desiccant bag; said rigid stand-off member having an inner
pad portion, an elongated stand-off portion terminating in said
inner pad portion, and an outer pad portion spaced from said inner
pad portion; and said porous desiccant bag being positioned between
said inner and outer pad portions, said porous desiccant bag being
affixed to at least one of said inner and outer pad portions.
33. The improvement as recited in claim 32 wherein said rigid stand-off
member includes an eccentric spacing rib portion spacing said inner
and outer pads.
34. The improvement as recited in claim 32 wherein: said rigid
stand-off member includes an eccentric spacing rib portion and a
clamp portion supported by said spacing rib portion between said
inner pad portion and said outer pad portion; and said porous desiccant
bag being secured by said clamp portion in a position between said
inner and outer pad portions.
35. The improvement as recited in claim 32 wherein: said rigid
stand-off member includes an eccentric spacing rib portion and a
clamp portion supported by said spacing rib portion between said
inner pad portion and said outer pad portion; said clamp portion
including a first clamping jaw supported by said spacer portion
and a second clamping jaw supported by said first clamping jaw through
a living hinge; said first and second clamping jaws defining complementary
detents for engagement to secure said clamp in embracing relationship
with said porous desiccant bag; and said porous desiccant bag being
secured by said clamp portion.
36. The improvement as recited in claim 32 wherein: said rigid
stand-off member includes an eccentric spacing rib portion and a
clamp portion supported by said spacing rib portion between said
inner pad portion and said outer pad portion; said clamp portion
including a first clamping jaw supported by said spacer portion
and a second clamping jaw supported by said first clamping jaw through
a living hinge; said first and second clamping jaws defining complementary
detents for engagement to secure said clamp in embracing relationship
with said porous desiccant bag and an outer annular channel for
receiving an annular seal; said clamp portion being positioned between
said pair of ports; an annular seal positioned in said channel and
engaged with an inner surface of said reservoir; and said porous
desiccant bag being secured by said clamp portion.
37. The improvement as recited in claim 32 wherein: said rigid
stand-off member includes a cylindrical cage portion spacing said
inner and outer portions; and said porous desiccant bag being secured
by said cage portion in a position between said inner and outer
pad portions.
38. The improvement as recited in claim 32 wherein: said rigid
stand-off member includes a cylindrical cage portion spacing said
inner and outer portions; said cage portion comprises a first cage
element coupled to said inner and outer pad portions and a second
cage element supported by said first cage element through a living
hinge; said first and second cage elements define complementary
detents for engagement to secure said cage portion in embracing
relationship with said porous desiccant bag; and said porous desiccant
bag is secured by said cage portion in a position between said inner
and outer pad portions.
39. The improvement as recited in claim 32 wherein: said at least
one of said inner and outer pad portions is composed of plastic;
and said porous desiccant bag is welded to said at least one of
said inner and outer pad portions.
40. The improvement as recited in claim 32 wherein: said rigid
stand-off portion includes a flange portion; and said inner pad
portion, said outer pad portion and said flange portion are each
of substantially the same size and shape as said reservoir so as
to promote positioning, and inhibit lateral movement, of said desiccant
cartridge in said reservoir.
41. The improvement as recited in claim 32 wherein said porous
desiccant bag contains a fluorescent dye wafer.
42. A method for making a desiccant cartridge for an integrated
receiver/condenser comprising the steps of: a) casting a rigid plastic
stand-off member having an inner pad portion, an elongated stand-off
portion terminating in said inner pad portion, and an outer pad
portion spaced from said inner pad portion; and b) affixing a porous
desiccant bag to at least one of said inner and outer pad portions.
43. The method as recited in claim 42 wherein: said step b) includes
affixing said porous desiccant bag to said at least one of said
inner and outer pad portions by means of a method selected from
the group consisting of ultrasonic welding, thermal welding and
vibration welding.
44. The method as recited in claim 42 wherein: said step b) includes
affixing said porous desiccant bag to said at least one of said
inner and outer pad portions by ultrasonic welding.
45. The method as recited in claim 42 wherein: said step a) includes
casting said rigid plastic stand-off member such that said rigid
stand-off member includes an eccentric spacing rib portion and a
clamp portion supported by said spacing rib portion between said
inner pad portion and said outer pad portion; and said method includes
the additional step of: c) securing said porous desiccant bag with
said clamp portion.
46. The method as recited in claim 42 wherein: said step a) includes
casting said rigid plastic stand-off member such that said rigid
stand-off member includes an eccentric spacing rib portion and a
clamp portion supported by said spacing rib portion between said
inner pad portion and said outer pad portion; said clamp portion
including a first clamping jaw supported by said spacer portion
and a second clamping jaw supported by said first clamping jaw through
a living hinge; said first and second clamping jaws defining complementary
detents for engagement to secure said porous desiccant bag in said
clamp; and said method includes the additional step of: c) closing
said first and second clamping jaws to engage said complementary
detents to secure said desiccant container in said clamp portion.
47. The method as recited in claim 42 wherein: said step a) includes
casting said rigid plastic stand-off member such that said rigid
stand-off member includes an eccentric spacing rib portion and a
clamp portion supported by said spacing rib portion between said
inner pad portion and said outer pad portion; said clamp portion
including a first clamping jaw supported by said spacer portion
and a second clamping jaw supported by said first clamping jaw through
a living hinge; said first and second clamping jaws defining complementary
detents for engagement to secure said clamp in embracing relationship
with said porous desiccant bag and an outer annular channel for
receiving an annular seal; and said method includes the additional
steps of: c) closing said first and second clamping jaws to engage
said complementary detents to secure said desiccant container in
said clamp portion, and d) positioning an annular seal in said annular
channel.
48. The method as recited in claim 42 wherein: said step a) includes
casting said rigid plastic stand-off member such that said rigid
plastic stand-off member has a cylindrical cage portion spacing
said inner and outer portions; and said method includes the additional
step of: c) securing said porous desiccant bag with said cage portion.
49. The method as recited in claim 42 wherein: said step a) includes
casting said rigid plastic stand-off member such that said rigid
plastic stand-off member has a cylindrical cage portion spacing
said inner and outer portions; said cage portion comprises a first
cage element coupled to said inner and outer pad portions and a
second cage element supported by said first cage element through
a living hinge; said first and second cage elements define complementary
detents for engagement to secure said cage portion in embracing
relationship with said porous desiccant bag; and said method includes
the additional step of: c) closing said first and second cage elements
to engage said complementary detents to secure said desiccant container
in said cage portion.
50. The method as recited in claim 42 wherein: said step a) includes
casting said rigid plastic stand-off member such that said rigid
plastic stand-off member has a cylindrical cage portion spacing
said inner and outer portions; said cage portion comprises a first
cage element coupled to said inner and outer pad portions and a
second cage element supported by said first cage element through
a living hinge; said first and second cage elements each comprise
a plurality of annularly-arrayed spacer bars extending between said
inner and outer pad portions, and a plurality of hoops extending
transversely of said plurality of annularly-arrayed spacer bars;
and said first and second cage elements define complementary detents
for engagement to secure said cage portion in embracing relationship
with said porous desiccant bag; and said method includes the additional
step of: c) closing said first and second cage elements to engage
said complementary detents to secure said desiccant container in
said cage portion.
51. The method of claim 42 wherein the inner pad further comprises
a tab portion to which the porous desiccant bag is affixed to by
one of ultrasonic welding, thermal welding and vibration welding.
52. The method as recited in claim 51 further comprising the steps
of casting a rigid plastic cap defining a cavity, the cap having
a plurality of holes communicating between said cavity and an exterior
of said cap, and a spacer portion extending away from said cavity,
and affixing a first end portion of the porous desiccant bag to
the tab portion and a second end portion of said porous desiccant
bag in said cavity.
53. The method of claim 52 further comprising includes casting
said rigid plastic cap such that said rigid plastic cap includes
a sleeve portion and a web portion closing one end of said sleeve
portion to define said cavity, said plurality of holes extends through
said web portion, and said spacer portion extends from said web
portion; and affixing said sleeve portion to said porous desiccant
bag by means selected from the group consisting of ultrasonic welding,
thermal welding and vibration welding.
54. The method of claim 53 further comprising inserting said desiccant
cartridge through an open end of said receiver into a reservoir
of said receiver, placing a fluorescent dye wafer in said porous
desiccant bag, and inserting a demountable plug with said open end
of said receiver.
Description CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/373185 filed Apr. 17 2002; 60/373386
filed Apr. 17 2002; and 60/374689 filed Apr. 23 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a desiccant-containing package
for use in an integrated condenser/receiver, and more particularly,
to a desiccant-containing package comprising a porous desiccant
bag (most preferably, a desiccant-containing packet or bag) secured
to a rigid member.
[0004] 2. Description of the Prior Art
[0005] Desiccant-containing packages have been employed in small
diameter receivers that are juxtaposed along one of the condenser
headers in an integrated condenser/receiver for an automotive air-conditioning
system or the like. These integrated condenser/receiver structures
eliminate the need for separate tubing to connect the condenser
with the receiver and have become popular due to their reduced spatial
requirements as compared with earlier designs. For instance, the
overall dimensions of one integrated condenser/receiver proposed
in U.S. Pat. No. 5813249 [hereinafter the "'249 patent"]
are from about 300 mm-400 mm in height and about 300 mm-600 mm in
width.
[0006] In the integrated condenser/receiver design proposed in
the '249 patent, the axes of the receiver canister and the associated
header lie parallel to that of the canister attached to, and contiguous
with, the header. The desiccant-containing package positioned in
the receiver dries refrigerant fluid (and the oil and moisture entrained
therein) before the dried refrigerant enters a supercooler unit
formed integrally with the condenser. Ultimately, the desiccant
material is spent, that is, saturated with contaminants, and must
be replaced.
[0007] U.S. Provisional Patent Application 60/178595 the disclosure
of which is incorporated herein by reference, discloses a desiccant
containing package comprising a pouch preferably formed from a tube
of porous polyester felt material. During manufacture, one end of
the tube is sealed, preferably by tucking a portion of the tube
side wall and flattening the end portion under conditions which
cause the polyester fibers to fuse together and seal the end of
the pouch. Desiccant material then is poured into the pouch. Most
preferably, the open end of the pouch then is ultrasonically welded
to an attachment ring of filter cap.
[0008] It can be difficult to insert, position and remove such
desiccant bags from the receivers of known integrated condenser/receivers
due to the compactness of the receivers. In particular, many known
receiver designs require the removal and disposal of significant
extraneous material with spent desiccant bags, thereby increasing
the expense associated with the replacement of the spent bags.
[0009] U.S. Pat. No. 5666791 proposes an insert for a vehicle
air conditioner. The insert is composed of two parts. One part contains
a filter screen. The other part is an extension part bridging the
distance from the filter screen to a detachable cover of the receiver.
[0010] According to the patent, the part which contains the filter
screen and which requires higher manufacturing expenditures may
be standardized for several sizes of condensers so that it can be
produced in the same shape in large piece numbers. Depending on
the size of the receiver, the part containing the filter screen
is supplemented by an extension part which has a relatively simple
shape and can therefore be produced at a reasonable price in different
lengths by means of a modular-construction tool. In addition, it
is taught that the construction reduces the amount of waste to be
disposed of when the desiccant is spent because it will be sufficient
to exchange and dispose of the part with the filter screen.
[0011] Nevertheless, the insert as a whole is likely to be relatively
complex and expensive to produce. In one embodiment taught in U.S.
Pat. No. 5666791 the container is provided on the inside with
a supporting screen. The container, which is made of plastic, is
molded around this supporting screen. The supporting screen may
consist of plastic or of a special steel, the former having the
advantage of being recyclable. In addition, it appears that a filter
screen comprising a filter nonwoven material or a needle felt is
assembled into the container. This mode of manufacture involves
multiple component parts and several manufacturing steps, the combination
of which likely increases the cost of manufacture.
[0012] U.S. Pat. No. 6170287 proposes that a tube of desiccant
material be installed and located within a receiver canister by
a stand-off comprised of a tight-fitting, notched, disk-shaped base
and a narrow central post which is comparable in length to the height
of the inlet above the lower end cap. The tight fit allows the tube
to be inserted up into the canister, well away from the bottom of
the canister and free of heat damage as an end cap of the canister
is attached. Later, in operation, the central post keeps the tube
located clear of inlet and outlet ports of the canister.
[0013] U.S. Pat. No. 6360560 proposes a condenser with an integral
receiver dryer. The receiver dryer includes a dryer capsule for
removing moisture from the refrigerant fluid. One drawback to the
dryer capsule proposed in the reference is its relative complexity
and likely expense of manufacture.
[0014] The dryer capsule proposed in U.S. Pat. No. 6360560 is
generally cylindrical in shape and includes a base, a housing extending
axially from the base and a cap closing an end of the housing. The
base is disposed adjacent a seat wall to create a seal and prevent
fluid from passing therebetween. The housing has a plurality of
apertures extending therethrough and a filter covering the apertures.
The dryer capsule includes a quantity of dryer material such as
desiccant disposed within the housing. The cap has a loop with an
aperture extending therethrough to allow a tool to engage the loop
to remove the dryer capsule from the receiver dryer. The loop also
acts as a spring to hold the base of the dryer capsule against the
seat wall when an end closure is in place over an open end of the
receiver dryer.
[0015] The end closure proposed in U.S. Pat. No. 6360560 has
a head extending radially and a threaded shaft extending axially.
The end closure also includes a seal disposed about the threaded
shaft and adjacent the head. The threaded shaft engages the threaded
open end such that the seal engages the side and the head overlaps
the side bounding the open end.
[0016] It is known to place a fluorescent tracer dye wafer or the
like in the desiccant package so that leaks in the refrigeration
system can be readily detected by use of an ultraviolet light source.
See for instance U.S. Pat. Nos. 5149453 and 5440910.
[0017] There remains a need in the art for improvements to desiccant
cartridges for integrated condenser/receivers which simplify the
manufacture, installation and removal of the cartridges and which
minimize the extraneous material which must be disposed of with
spent desiccant bags.
SUMMARY OF THE INVENTION
[0018] This need and others are addressed by means of an improvement
to an integrated condenser/receiver comprising a desiccant cartridge
for insertion into the receiver of the integrated condenser/receiver.
A preferred desiccant cartridge comprises a porous desiccant bag
and a rigid member. A preferred porous desiccant bag defines sealed
first and second end portions, at least one of which has a flat
seal. The flat seal of the porous desiccant bag is secured to the
tab portion of the rigid member.
[0019] A preferred desiccant cartridge comprises a rigid, preferably
plastic, stand-off member and a porous desiccant bag or packet.
The preferred rigid stand-off member comprises an inner pad portion,
an elongated stand-off portion terminating in the inner pad portion
and an outer pad portion spaced from the inner pad portion. The
porous desiccant bag is positioned between the inner and outer pads
and affixed to one or both of the inner and outer pad portions.
[0020] In accordance with a preferred embodiment, the rigid member
is a rigid dongle including a skirt portion. A web portion closes
an end of the skirt portion to form a cavity. One or more holes
extending through the skirt portion from the cavity to an exterior
surface of the skirt portion facilitate removal of the desiccant
cartridge from the reservoir.
[0021] In accordance with one especially preferred embodiment,
the rigid stand-off member further comprises a spacer bar portion
and a clamp portion supported by the spacer bar portion for securing
the porous desiccant bag. The preferred clamp portion includes a
first clamping jaw supported by the spacer bar portion and a second
clamping jaw supported by the first clamping jaw through a living
hinge. The first and second clamping jaws each define complementary
detents for engagement to secure the porous desiccant bag in the
clamp portion. Most preferably, the first and second clamping jaws
each define an outer annular channel for receiving an annular seal.
This allows the clamp portion to act as a baffle preventing flow
through the integrated condenser/receiver from bypassing desiccant
material in the porous desiccant bag.
[0022] In accordance with another especially preferred embodiment,
the rigid stand-off member further comprises a cage portion extending
between the first and second pad portions. The preferred cage portion
includes a first cage element coupled to the inner and outer pad
portions. The preferred cage portion further includes a second cage
element supported by the first cage element through a living hinge.
The first and second cage elements define complementary detents
for engagement to secure the porous desiccant bag in the cage portion.
Most preferably, the first and second cage elements each comprise
a plurality of annularly-arrayed spacer bars extending between the
inner and outer pad portions as well as a plurality of hoops extending
transversely of the plurality of annularly-arrayed spacer bars.
[0023] One advantage of the preferred desiccant cartridge is relative
ease and inexpense of manufacture. In accordance with one aspect
of the invention, the rigid stand-off member is cast as a unitary
member from a suitable plastic or polymeric material. The porous
desiccant bag, which preferably comprises a porous desiccant packet
or bag, is affixed to one or both of the inner and outer pad portions.
Preferred means for affixing the porous desiccant bag to the inner
and outer pad portions include ultrasonic welding, although other
means (such as thermal or vibration welding) will be apparent to
those of ordinary skill in the art. In certain preferred embodiments
in which the rigid stand-off member includes a clamp portion or
a cage portion, the clamp or cage portion is closed so as to engage
the complementary detents to secure the porous desiccant bag.
[0024] The structure of the rigid member serves to reduce the likelihood
that the porous desiccant bag will be damaged as the rigid member
is welded to the porous desiccant bag. Most preferably, the flat
end seat which is to be welded to the tab portion of the rigid member
is extended away from the bulk of the porous desiccant bag to protect
the bulk of the porous desiccant bag from the energy used to form
the weld.
[0025] Another advantage of the preferred desiccant cartridge is
that it facilitates installation and removal of the porous desiccant
bag. Inner and outer pad portions, for example, guide the porous
desiccant bag into and out of the receiver during installation and
removal. The combination of the inner and outer pad portions with
the clamp or cage portions, in various exemplary embodiments, serve
to immobilize the porous desiccant bag relative to the rigid stand-off
member so as to promote smooth installation and removal.
[0026] During installation, the preferred desiccant cartridge is
pressed through an open end of the reservoir so as to abut the spacer
portion of the rigid cap against an end panel of the receiver. A
demountable end closure or plug is engaged with an open end of the
reservoir to provide fluid-tight closure of the receiver. Once installed,
an elongated, relatively thin stand-off portion of either the rigid
member or the end closure serves to position the desiccant cartridge
in the reservoir. The desiccant cartridge is extracted from the
reservoir by removing the demountable cap and then engaging a hook
with a hole or eye defined in the rigid member so as to pull the
desiccant cartridge from the reservoir.
[0027] Yet another advantage of the preferred desiccant cartridge
is that it minimizes the extraneous material which must be discarded
with a spent desiccant bag. The preferred desiccant cartridge, that
is, the rigid stand-off member and the porous desiccant bag, can
be removed from the receiver as a unit. Even assuming that the rigid
stand-off member then is disposed of with the porous desiccant bag,
the simplicity of the preferred rigid stand-off minimizes the amount
of extraneous material which is discarded.
[0028] In accordance with yet another alternative embodiment of
the invention, the preferred desiccant cartridge comprises a rigid,
preferably plastic, stand-off member and a porous desiccant bag
or pouch. The preferred rigid stand-off member comprises an inner
pad portion, an elongated stand-off portion terminating in the inner
pad portion and an attachment tab extending transversely to from
the inner pad portion. The porous desiccant bag includes first and
second flat end seals, one of which is secured to the attachment
tab.
[0029] This alternative embodiment likewise is susceptible of relatively
simple and inexpensive manufacture. Most preferably, the porous
desiccant bag is manufactured by forming the first flat end seal
in a first open end of a porous tube, as by ultrasonic welding;
pouring desiccant into the porous tube; and forming the second flat
end seal in a second open end of the porous tube. The rigid stand-off
member is molded as a single piece. Then, the first or second flat
end seal is secured to the attachment tab of the rigid stand-off
member, as by ultrasonic welding. During this welding process, the
first or second flat end seal is extended away from the bulk of
the porous desiccant bag, so as to minimize damage to the porous
desiccant bag during welding.
[0030] Still other embodiments of the desiccant cartridge comprise
a porous cap in addition to the rigid stand-off member and porous
desiccant bag. The preferred rigid cap defines a cavity which receives
the second end portion of the porous desiccant bag.
[0031] The rigid cap also defines a plurality of perforations or
holes which communicate between the cavity and an exterior of the
rigid cap. This plurality of holes permits fluid to flow from the
porous desiccant bag through the rigid cap. It is desirable that
these holes be so dimensioned as to permit the flow of refrigerant
fluid while retaining the desiccant material and inhibiting the
flow of moisture, oil and other contaminants. In this manner, the
perforations provide additional filtering of the refrigerant fluid
which percolates through the desiccant material in the porous desiccant
bag.
[0032] In accordance with an especially preferred embodiment, the
rigid cap also defines a spacer portion extending away from the
cavity defined in the rigid cap. The spacer is designed to abut
against an end panel of the receiver to help position the desiccant
cartridge in the reservoir.
[0033] One advantage of the preferred desiccant cartridge is relative
ease and inexpense of manufacture. In accordance with one aspect
of the invention, the rigid stand-off member and the rigid cap are
each molded as one-piece castings from suitable plastic or polymeric
materials. The preferred rigid stand-off member includes a tab portion
which extends transversely from the inner pad portion in a direction
opposite that of the elongated stand-off portion. The first end
portion of the porous desiccant bag takes the form of a flat end
seal which is secured to the tab portion of the rigid stand-off
member. Preferred means for affixing the flat end seal of the porous
desiccant bag to the tab portion of the rigid stand-off member include
ultrasonic welding, although other means such as thermal or vibration
welding will be apparent to those of ordinary skill in the art.
[0034] The preferred rigid cap includes a sleeve portion and a
web portion which closes an end of the sleeve portion to define
the cavity. The preferred spacer portion takes the form of a cylindrical
spacer bar which extends from a central portion of the web portion.
The plurality of holes extend through the web portion surrounding
the central portion from which the spacer portion extends. Most
preferably, the second end portion of the porous desiccant bag is
secured to the sleeve portion of the rigid cap. Preferred means
for affixing the second end portion of the porous desiccant bag
to the sleeve portion of the rigid cap include ultrasonic welding,
although other means such as thermal or vibration welding will be
apparent to those of ordinary skill in the art.
[0035] Another advantage of the preferred desiccant cartridge is
that it facilitates installation and removal of the porous desiccant
bag. During installation, the preferred desiccant cartridge is pressed
through an open end of the reservoir so as to abut the spacer portion
of the rigid cap against an end panel of the receiver. A demountable
cap is engaged with the open end of the reservoir to provide fluid-tight
closure of the receiver. Once installed, the spacer portion of the
rigid cap and the elongated stand-off portion of the rigid stand-off
member serve to position the desiccant cartridge in the reservoir.
The desiccant cartridge is extracted from the reservoir by removing
the demountable cap and then pulling on the elongated stand-off
portion of the rigid stand-off member to pull the desiccant cartridge
from the reservoir.
[0036] Yet another advantage of the preferred desiccant cartridge
is that it minimizes the extraneous material which must be discarded
with a spent desiccant bag. The preferred desiccant cartridge, that
is, the rigid stand-off member, the porous desiccant bag and the
rigid cap, can be removed from the receiver as a unit. Even assuming
that the rigid stand-off member then is disposed of with the porous
desiccant bag, the simplicity of the preferred rigid stand-off member
and of the rigid cap minimizes the amount of extraneous material
which is discarded.
[0037] Therefore, one object of the invention is to simplify the
manufacture, installation and removal of the cartridges. Another
object of the invention is to minimize the extraneous material which
must be disposed of with spent desiccant bags. The invention will
be further described in conjunction with the appended drawings and
following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a perspective view of an integrated condenser/receiver;
[0039] FIG. 2 is sectional view of a first embodiment of the receiver
of FIG. 1 taken along the line 2-2 in FIG. 1;
[0040] FIG. 3 is a first perspective view of a preferred rigid
dongle for use in the embodiment of FIG. 2;
[0041] FIG. 4 is a second perspective view of the rigid dongle
of FIG. 3 partially cut away to show an interior cavity and energy
directors on a tab portion of the rigid dongle;
[0042] FIG. 5 is a perspective view of a plug or end closure for
the receiver of FIG. 2;
[0043] FIG. 6 is a schematic sectional view of a portion of an
integral condenser/receiver with the preferred desiccant cartridge
positioned in the receiver of the integrated condenser/receiver;
[0044] FIG. 7 is sectional view of a second embodiment of the receiver
of FIG. 1 taken along the line 2-2 in FIG. 1;
[0045] FIG. 8 is a perspective view of a desiccant cartridge for
use in the receiver of FIG. 7;
[0046] FIG. 9 is sectional view, taken along line 2-2 in FIG. 1
of the integrated condenser/receiver of FIG. 1 wherein the desiccant
cartridge includes a rigid stand-off member and a porous desiccant
bag which is partially broken away to reveal a portion of the rigid
stand-off member;
[0047] FIG. 10 is a perspective view of a rigid stand-off member
for the first preferred desiccant cartridge shown in Fig.9;
[0048] FIG. 11 is a sectional view of a clamp portion of the rigid
stand-off member of FIGS. 9 and 10 in an open position, with the
closed position suggested in phantom;
[0049] FIG. 12 is a schematic sectional view of a portion of an
improved integrated condenser/receiver in accordance with the invention;
[0050] FIG. 13 is a perspective view of a second embodiment of
a desiccant cartridge for use in a receiver such as that shown in
FIG. 1;
[0051] FIG. 14 is a perspective view of a third embodiment of a
desiccant cartridge for use in a receiver such as that shown in
FIG. 1;
[0052] FIG. 15 is a sectional view of the desiccant cartridge of
FIG. 14 taken along the line 8-8 in FIG. 14;
[0053] FIG. 16 is sectional view of the receiver of FIG. 1 taken
along the line 1-1 in FIG. 1;
[0054] FIG. 17 is a perspective view of a preferred desiccant cartridge
in accordance with the invention, which is also shown in section
in FIG. 16;
[0055] FIG. 18 is an exploded view of a portion of the sectional
view of FIG. 16 showing a rigid cap of the preferred desiccant
cartridge of FIG. 17; and
[0056] FIG. 19 is a schematic sectional view of a portion of an
integral condenser/receiver with the preferred desiccant cartridge
positioned in the receiver of the integrated condenser/receiver.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0057] Referring initially to FIG. 1 of the drawings, a receiver
10 includes a canister 12 defining a pair of bosses 14 and 16; a
plug 18; and an end panel 20. As shown in FIG. 2 the canister 12
defines a reservoir 22 which communicates through an inlet port
24 extending through the boss 14 and an outlet port extending through
the boss 16.
[0058] With continuing reference to FIG. 2 a preferred desiccant
cartridge 30 positioned in the reservoir 22 comprises a rigid member
or dongle 32 and a porous desiccant pouch or bag 34 containing a
powdered or granulated desiccant material 36. The preferred reservoir
22 is substantially cylindrical in shape, having an open end 27
presenting internal threads 28. As shown in FIG. 3 the preferred
rigid dongle 32 includes a web portion 40; a cylindrical skirt portion
42; and a tab portion 44 extending transversely from the web portion
40. As shown in FIG. 4 the web portion 40 closes an end of the
skirt portion 42 to define a cavity 46. The preferred skirt portion
42 further has a pair of holes 50 and 52 extending from the cavity
46 to an exterior surface of the skirt portion 42 for use in removing
the desiccant cartridge 30 (FIG. 2) from the receiver 10 (FIG. 2).
As shown in FIGS. 3 and 4 the preferred tab portion 44 defines
an engaging surface 60 most preferably flat, and the dongle 32
includes a plurality of energy directors 62 extending from the engaging
surface 60.
[0059] Most preferably, as shown in FIG. 2 the end closure 18
serves to position the desiccant cartridge 30 in the reservoir 22.
Referring to FIG. 5 the preferred end closure 18 includes a plug
portion 70 and an elongated, cylindrical stand-off portion 72 which
is relatively thin in the sense that the elongated stand-off portion
72 is thinner in cross-section than the plug portion 72. The plug
portion 70 presents external threads 80 for positioning and securing
the plug portion 70 and at least one annular groove (two shown at
82 in FIG. 5) for receiving at least one annular seal (two shown
at 86 in FIG. 2) such as O-ring seals.
[0060] Returning to FIG. 2 the desiccant cartridge 30 is susceptible
of a relatively simple method of production. The preferred rigid
dongle 32 is formed as a one-piece, plastic casting by means of
a conventional casting process. The preferred porous desiccant bag
34 is manufactured from a tube (not shown) of porous polyester material
or the like. Most preferably, the porous tube (not shown) is formed
of point bonded nylon, specifically PBN-II available from Cerex
Advanced Fabrics. The preferred desiccant bag 34 is manufactured
by forming a first flat end seal 90 in a first open end (not shown)
of the tube (not shown); pouring the desiccant material 36 into
the porous tube; and forming a second flat end seal 92 in a second
open end (not shown) of the porous tube. Optionally, a fluorescent
tracer dye wafer or the like 94 is placed in the porous desiccant
bag 34 with the desiccant material 36 so that leaks in the refrigeration
system (not shown) of which the receiver 10 is a part can be readily
detected by use of an ultraviolet light source (not shown) in a
conventional manner. Most preferably, the first and second flat
end seals 90 92 are formed by ultrasonic welding.
[0061] Once the porous desiccant bag 34 is manufactured, one of
the first and second flat end seals 90 92 is affixed to the flat
engaging surface 60 (FIG. 3) of the tab portion 44 of the rigid
dongle 32 most preferably by ultrasonic welding. (The second flat
end seal 92 is shown affixed to the tab portion 44 in FIG. 2.) The
energy directors 62 (FIGS. 3 and 4) facilitate the welding of the
first or second flat end seal 90 92 to the tab portion 44. Most
preferably, the first or second flat end seal 90 92 which is to
be welded to the tab portion 44 is extended away from the bulk of
the porous desiccant bag 32 so as to minimize damage to the porous
desiccant bag 34 during welding. Although ultrasonic welding is
the preferred method for forming the first and second flat end seals
90 92 and for affixing one of the end seals 90 92 to the tab portion
44 other suitable techniques (such as thermal or vibration welding)
will be apparent to those of ordinary skill in the art.
[0062] The design of the desiccant cartridge 30 facilitates installing
and positioning the desiccant cartridge 30 in the reservoir 22 of
the receiver 10. During installation, the desiccant cartridge 30
is pressed as a unit through the open end 27 of the reservoir 22.
Once the desiccant cartridge 30 is installed in the reservoir 22
the end closure 18 is inserted into the open end 27 of the reservoir
22 to seal the open end 27. Most preferably, the plug portion 70
of the end closure 18 and the open end 27 of the reservoir 22 present
complementary threads 28 80 so as to allow the end closure 18 to
be threadedly engaged and retained in the open end 27. The one or
more annular seals 86 mounted on the end closure 18 inhibit flow
between the end closure 18 and the outer surface bounding the open
end 27.
[0063] The elongated stand-off portion 72 of the end closure 18
serves to position the desiccant cartridge 30 so that the porous
desiccant bag 34 straddles the inlet and outlet ports 24 26. More
specifically, the preferred elongated stand-off portion 72 extends
into the cavity 46 and abuts against the web portion 42 of the rigid
dongle 32. As the end closure 18 is inserted into the open end 27
of the reservoir 22 the elongated stand-off portion 72 presses
against the rigid dongle 32 to position the desiccant cartridge
30 in the reservoir 22.
[0064] The operation of the receiver 10 (FIG. 1) is illustrated
in FIG. 6. In FIG. 6 the receiver 10 is shown juxtaposed with a
header tank 110 of a condenser (not shown) for an automotive air
conditioner or the like (not shown). The header tank 110 is divided
into a first chamber 120 and a second chamber 122. A plurality of
passages 124 communicate with the first chamber 120 while another
plurality of passages 126 communicate with the second chamber 122.
Those skilled in the art will recognize that the configurations
of the condenser (not shown) and of the header tank 110 are not
critical to the invention.
[0065] Refrigerant fluid (and oil and moisture entrained therein,
none shown) entering the first chamber 120 through the plurality
of passages 124 flows through the inlet port 24 into the reservoir
22 of the receiver 10. The fluid (not shown) within the reservoir
22 enters the sides of the porous desiccant bag 34 and percolates
through the desiccant material 36 (FIG. 2). The desiccant material
36 (FIG. 2) adsorbs oil, moisture and other contaminants from the
refrigerant fluid (not shown) as the fluid percolates through the
porous desiccant bag 34.
[0066] It is within the contemplation of the invention to place
a collar or the like (not shown) around the porous desiccant bag
34 for inhibiting flow through the reservoir 22 bypassing the porous
desiccant bag 34. In accordance with one embodiment, such a collar
(not shown) has an external annular groove (not shown) for mounting
an annular seal (not shown) for sealing the portion of the reservoir
22 surrounding the porous desiccant bag. Most preferably, such collar
(not shown) is positioned over the porous desiccant bag 34 so as
to lie between the inlet port 24 and the outlet port 26 when the
desiccant cartridge 30 is positioned in the reservoir 22.
[0067] The refrigerant fluid (not shown) exiting the porous desiccant
bag 34 passes from the reservoir 22 through the outlet port 26.
From the outlet port 26 the refrigerant fluid (not shown) proceeds
to the condenser (not shown) through the plurality of passages 126.
[0068] The design of the desiccant cartridge 30 also facilitates
the removal of the desiccant cartridge 30 from the reservoir 22
when the desiccant material 36 is spent. In accordance with one
preferred method, one of the holes 50 (FIG. 4), 52 is engaged by
a hook or the like (not shown) and then the desiccant cartridge
is pulled as a unit through the open end 27 of the reservoir 22.
[0069] Referring to FIG. 7 a second preferred receiver 210 for
an integrated condenser/receiver (not shown) includes a canister
212 defining a pair of bosses 214 and 216; a demountable plug or
end closure 218; and an end panel 220. The canister 212 defines
a reservoir 222 which communicates with the exterior of the receiver
210 through an inlet port 224 extending through the boss 214 and
an outlet port 226 extending through the boss 216. The preferred
reservoir 222 is substantially cylindrical in shape, having an open
end 227 presenting internal threads 228.
[0070] A second preferred embodiment of a desiccant cartridge 230
positioned in the reservoir 222 comprises a rigid stand-off member
232 and a porous desiccant pouch or bag 234 containing a powdered
or granulated desiccant material 236. As shown in FIG. 8 the preferred
rigid stand-off member 232 includes a web portion or inner pad portion
240; an elongated, relatively thin stand-off portion 242 terminating
in the web portion 240; and a tab portion 244 extending transversely
from the web portion 240. The preferred elongated stand-off portion
242 includes a flange 248 positioned along the elongated stand-off
portion 242 intermediate the web portion 240 and a free end of the
elongated stand-off portion 242. The flange 248 is of substantially
the same size and shape as the web portion 240. The preferred rigid
stand-off member 232 also has an eye 252 extending through a boss
254 formed in the elongated stand-off portion 242.
[0071] The desiccant cartridge 230 is susceptible of a relatively
simple method of production. The preferred rigid stand-off member
232 is formed as a one-piece, plastic casting by means of a conventional
casting process. The preferred porous desiccant bag 234 is manufactured
by forming a first flat end seal 290 in a first open end (not shown)
of a tube (not shown) of porous polyester felt material or the like;
pouring the desiccant material (not shown) into the porous tube;
and forming a second flat end seal 292 in a second open end (not
shown) of the porous tube. Optionally, a fluorescent tracer dye
wafer or the like 294 (FIG. 7) is placed in the porous desiccant
bag 134 with the desiccant material (not shown) so that leaks in
the system (not shown) in which the receiver 10 (FIG. 1) is used
can be readily detected by use of an ultraviolet light source (not
shown).
[0072] Once the porous desiccant bag 234 is manufactured, one of
the first and second flat end seals 290 292 (the second flat end
seal 292 in FIG. 6) is affixed to the tab portion 244 of the rigid
stand-off member 232. The first and second flat end seals 290 292
are preferably formed, and one of the first and second flat end
seals 290 292 is affixed to the tab portion 244 by ultrasonic
welding, although other suitable techniques (such as thermal or
vibration welding) will be apparent to those of ordinary skill in
the art. Most preferably, the first or second flat end seal 290
292 which is to be welded to the tab portion 244 is extended away
from the bulk of the porous desiccant bag 234 so as to minimize
damage to the porous desiccant bag 234 during welding.
[0073] Returning to FIG. 7 the design of the desiccant cartridge
230 facilitates installing and positioning the desiccant cartridge
230 into the reservoir 222 of the receiver 210. During installation,
the desiccant cartridge 230 is pressed as a unit through the open
end 227 of the reservoir 222. The rigid stand-off member 232 serves
to position the porous desiccant bag 234 so that the porous desiccant
bag 234 straddles the inlet and outlet ports 224 226. Once the
desiccant cartridge 230 is installed in the reservoir 222 the plug
218 is inserted into the open end 227 of the reservoir 222 to seal
the open end 227. Most preferably, the plug 218 and the open end
227 of the reservoir 222 present complementary threads 228 and 300
so as to allow the plug 218 to be threadedly engaged and retained
in the open end 227. One or more annular seals 302 such as 0-rings
are mounted on the plug 218 to inhibit flow between the plug 218
and the outer surface bounding the open end 227.
[0074] The plug 218 abuts against the rigid stand-off member 232
to retain the desiccant cartridge 230 in position in the reservoir
222. Meanwhile, the web portion 240 and the flange 248 are each
of substantially the same size and shape as a cross-section of the
reservoir 222 so as to promote correct positioning, and inhibit
lateral motion, of the desiccant cartridge 230 in the reservoir
222.
[0075] The design of the desiccant cartridge 230 also facilitates
the removal of the desiccant cartridge 230 from the reservoir 222
when the desiccant material 236 is spent. In accordance with one
preferred method, the eye 252 is engaged by a hook or the like (not
shown) and then the desiccant cartridge 230 is pulled as a unit
from the reservoir 222. Alternatively, the elongated stand-off portion
242 is gripped to permit the desiccant cartridge 230 to be pulled
form the reservoir 222 as a unit.
[0076] The second preferred desiccant cartridge 230 (FIGS. 7 and
8) operates in substantially the same manner as the first preferred
desiccant cartridge 30 (FIGS. 2-4) and shares the same advantages
of relatively simple manufacture, installation and removal. In addition,
it will be appreciated that the only extraneous material removed
from the receiver 10 (FIG. 2), 210 (FIG. 7) with either of the porous
desiccant bags 34 (FIG. 2), 234 (FIG. 7) is the rigid dongle 32
(FIGS. 2-4) or rigid stand-off member 232 (FIGS. 7 and 8). It will
be apparent that each of the rigid members 32 (FIGS. 2-4), 232 (FIGS.
7 and 8) is relatively simple in design and inexpensive to produce.
Thus, it is highly economic to either discard the desiccant cartridge
30 (FIGS. 2-4), 230 (FIGS. 7 and 8) as a unit or to destroy the
desiccant cartridge 30 (FIGS. 2-4), 230 (FIGS. 7 and 8) to recover
the desiccant material 36 (FIG. 2), 236 (FIG. 7) for either regeneration
or separate disposal.
[0077] FIGS. 9-13 illustrate another embodiment of the desiccant
cartridge 130 comprising a rigid stand-off member 132 and a porous
desiccant pouch or bag 134 containing a powdered or granulated desiccant
material 136. As shown in FIG. 10 a preferred rigid stand-off member
132 includes an inner pad portion 140; an outer pad portion 142;
an elongated stand-off portion 144 terminating in the inner pad
portion 140; a spacing rib portion 146 eccentrically spacing the
inner and outer pad portions 140 142; and a clamp portion 148 supported
by the spacing rib 146. The elongated stand-off portion 144 and
the spacing rib portion 146 extend from opposite sides of the inner
pad portion 140 in opposite directions. The preferred elongated
stand-off portion 144 includes a flange 150 and an eye 152 surrounded
by a rigid boss 154.
[0078] As shown in FIG. 11 the clamp portion 148 includes a first
clamping jaw 160 supported by the spacing rib portion 146 and a
second clamping jaw 162 supported by the first clamping jaw 160.
The first and second clamping jaws 160 162 also cooperate to define
an annular channel 164.
[0079] More specifically, the first clamping jaw 160 and the second
clamping jaw 162 are separated by a partial cleft 170 which leaves
thin plastic connectors 172 (only one shown) defining a living hinge
between the first and second clamping jaws 160 162. The second
clamping jaw 162 is able to pivot about the thin plastic connectors
172 between an open position (shown by first and second clamping
jaws 160 162) and a closed position (shown by first and second
clamping jaws 160 162').
[0080] The first and second clamping jaws 160 162 mount complementary
detents 180 182 for engagement to secure the first and second clamping
jaws 160 162 in the closed position. As shown in FIG. 11 one configuration
of the complementary detents 180 182 includes a clasp 180 mounted
by the second clamping jaw 162 and a complementary socket 182 mounted
by the first clamping jaw 60 for receipt of the clasp 180. The design
of the complementary detents 180 182 is not critical to the invention
and other suitable detent configurations will be apparent to those
of ordinary skill in the art.
[0081] Returning to FIG. 9 the desiccant cartridge 130 is susceptible
of a relatively simple method of production. The preferred rigid
stand-off member 132 is formed as a one-piece, plastic casting by
means of a conventional casting process. The preferred porous desiccant
bag 134 is manufactured by forming a first flat end seal 190 in
a first open end (not shown) of a tube (not shown) of porous polyester
felt material or the like; pouring the desiccant material 136 into
the porous tube; and forming a second flat end seal 192 in a second
open end (not shown) of the porous tube. Most preferably, the porous
tube (not shown) is formed of point bonded nylon, specifically PBN-II
available from Cerex Advanced Fabrics. Other materials such as porous
polyester felt or others may also be mentioned. The first and second
flat end seals 190 192 of the tube are formed by ultrasonic welding.
Other suitable techniques (such as thermal or vibration welding)
will be apparent to those of ordinary skill in the art. Optionally,
a fluorescent tracer dye wafer or the like 193 is placed in the
porous desiccant bag 134 with the desiccant material 136 so that
leaks in the system (not shown) in which the receiver 10 is used
can be readily detected by use of an ultraviolet light source (not
shown).
[0082] Once the rigid stand-off member 132 and the porous desiccant
bag 134 are formed, the porous desiccant bag 134 is secured to the
rigid stand-off member 132. Most preferably, one or both of the
first and second flat end seals 190 192 are secured to the inner
and outer pad portions 140 142 by ultrasonic welding, although
other suitable techniques (such as thermal or vibration welding)
will be apparent to those of ordinary skill in the art. The clamp
portion 148 is closed about a middle portion of the porous desiccant
bag 134 to secure the porous desiccant bag to the spacer rib portion
146 (FIGS. 10 and 11). This serves to immobilize the porous desiccant
bag 134 relative to the rigid stand-off member 132 to facilitate
installation and removal of the desiccant cartridge 130. Finally,
an annular seal 194 such as an "O"0 ring is placed in
the annular channel 164 defined by the clamp portion 148.
[0083] The operation of the receiver 10 (FIG. 1) is illustrated
in FIG. 12 and is similar to that shown in FIG. 6. In FIG. 12 the
receiver 10 is shown juxtaposed with a header tank 110 of a condenser
(not shown) for an automotive air conditioner or the like (not shown).
The header tank 110 is divided into a first chamber 120 and a second
chamber 122. A plurality of passages 124 communicate with the first
chamber 120 while another plurality of passages 126 communicate
with the second chamber 122. Those skilled in the art will recognize
that the configurations of the condenser (not shown) and of the
header tank 110 are not critical to the invention.
[0084] Refrigerant fluid (and the oil and moisture entrained therein,
none shown) entering the first chamber 120 through the plurality
of passages 124 flows through the inlet port 24 into the reservoir
22 of the receiver 10. The fluid (not shown) within the reservoir
22 enters the sides of the porous desiccant bag 134 and percolates
through the desiccant material 136 (FIG. 9). The desiccant material
136 (FIG. 9) adsorbs oil, moisture and other contaminants from the
refrigerant fluid (not shown) as the fluid percolates through the
porous desiccant bag 134. Meanwhile, the annular seal 194 mounted
on the clamp portion 148 of the rigid stand-off member 132 acts
as a baffle to inhibit flow bypassing the porous desiccant bag 134.
The refrigerant fluid (not shown) leaves the porous desiccant bag
134 downstream of the clamp portion 148 and passes from the reservoir
22 through the outlet port 26 whence it flows to the condenser
(not shown) through the plurality of passages 132.
[0085] Returning to FIG. 9 the design of the desiccant cartridge
130 facilitates installing and positioning the desiccant cartridge
130 into the reservoir 22 of the receiver 10. During installation,
the desiccant cartridge 130 is pressed as a unit through an open
end 196 of the canister 112 until the outer pad portion lies near,
or in abutment with, the end panel 20. The elongated stand-off portion
132 serves to position the porous desiccant bag 134 so that the
porous desiccant bag 134 straddles the inlet and outlet ports 24
26. Most preferably, the desiccant cartridge 130 is positioned so
that the clamp portion 148 lies between the inlet and outlet ports
24 26. When so arranged, the annular seal 194 engages an inner
surface of the canister 112 bounding the reservoir 22 so as to inhibit
flow between the inlet and outlet ports 24 26 bypassing the porous
desiccant bag 134.
[0086] Once the desiccant cartridge 130 is installed in the reservoir
22 the plug 118 is inserted into the open end 196 of the reservoir
22 to seal the open end 196. Most preferably, the plug 118 and the
open end 196 of the reservoir 22 present complementary threads so
as to allow the plug 118 to be threadedly engaged and retained in
the open end 196. One or more annular seals 100 inhibit flow between
the plug 118 and the outer surface bounding the open end 196.
[0087] The plug 118 abuts against the elongated stand-off member
132 to retain the desiccant cartridge 130 in position in the reservoir
22. Meanwhile, the inner pad portion 140 the outer pad portion
142 and the flange 150 are each configured in size and shape to
closely fit within the reservoir 22 so as to promote correct positioning,
and inhibit lateral motion, of the desiccant cartridge 130 in the
reservoir 22.
[0088] The design of the desiccant cartridge 130 also facilitates
the removal of the desiccant cartridge 130 from the reservoir 22
when the desiccant material 136 is spent. In accordance with one
preferred method, the desiccant cartridge 130 from the reservoir
22 the eye 152 is engaged by a hook or the like (not shown) and
then the desiccant cartridge 130 is pulled as a unit from the reservoir
22. Alternatively, the elongated stand-off portion 144 is gripped
to permit the desiccant cartridge 130 to be pulled form the reservoir
22 as a unit.
[0089] FIG. 13 shows another preferred embodiment of a desiccant
cartridge 130 for installation in a receiver 10 of the same design
as the receiver 10 in FIG. 1 and FIG. 9. The desiccant cartridge
130 comprises a rigid stand-off member 132 and a porous desiccant
pouch or bag 134. The preferred rigid stand-off member 132 includes
an inner pad portion 140; an elongated stand-off portion 144 terminating
in the inner pad portion 140; and a tab portion 149 extending transversely
from the inner pad portion 140. The preferred elongated stand-off
portion 144 includes a flange 150 which cooperates with the inner
pad portion 140 to promote correct positioning, and inhibit lateral
motion, of the desiccant cartridge 130 in the reservoir 22.
[0090] The desiccant cartridge 130 of FIG. 13 is susceptible of
a relatively simple method of production. The preferred rigid stand-off
member 132 is formed as a one-piece, plastic casting by means of
a conventional casting process. The preferred porous desiccant bag
134 is manufactured by forming a first flat end seal 190 in a first
open end (not shown) of a tube (not shown) of porous polyester felt
material or the like; pouring the desiccant material (not shown)
into the porous tube; and forming a second flat end seal 192 in
a second open end (not shown) of the porous tube. Optionally, a
fluorescent tracer dye wafer or the like (not shown) is placed in
the porous desiccant bag 134 with the desiccant material (not shown)
so that leaks in the system (not shown) in which the receiver 10
(FIG. 1) is used can be readily detected by use of an ultraviolet
light source (not shown). Once the porous desiccant bag 134 is manufactured,
one of the first and second flat end seals 190 192 (the first flat
end seal 190 in FIG. 13) is affixed to the tab portion 149 of the
rigid stand-off member 132. The first and second flat end seals
190 192 are preferably formed, and one of the first and second
flat end seals 190 192 is affixed to the tab portion 149 by ultrasonic
welding, although other suitable techniques (such as thermal or
vibration welding) will be apparent to those of ordinary skill in
the art. Most preferably, the first or second flat end seal 190
192 which is to be welded to the tab portion 149 is extended away
from the bulk of the porous desiccant bag 134 so as to minimize
damage to the porous desiccant bag 134 during welding.
[0091] FIG. 14 shows yet another embodiment of a desiccant cartridge
330 for installation in a receiver of the same design as the receiver
10 in FIGS. 1 and 9. The desiccant cartridge 330 comprises a rigid
stand-off member 332 and a porous desiccant pouch or bag 334 containing
a powdered or granulated desiccant material 336 (FIG. 15). The preferred
rigid stand-off member 332 includes an inner pad portion 340; an
outer pad portion 342; an elongated stand-off portion 344 terminating
in the inner pad portion 340; and a plurality of annularly-arrayed
spacer bars 346 extending between the inner and outer pad portions
340 342 to define, in cooperation with a plurality of hoops 347
extending transversely of the spacer bars 346 a cage portion 348.
The preferred elongated stand-off portion 344 includes a flange
350 and an eye 352 surrounded by a rigid boss 354.
[0092] As shown in FIG. 15 the cage portion 348 includes a first
cage element 360 and a second cage element 362. The first cage element
360 is supported at opposite ends of the spacer bars 346 by the
inner and outer pads 340 342. The second cage element 362 is supported
by the first cage element 360. More specifically, the first cage
element 360 and the second cage element 362 are separated by partial
radial clefts 370 (only one shown) through each of the hoops 347
(only one shown) which leave thin plastic connectors 372 (only one
shown) defining living hinges between the first and second cage
elements 360 362. The second cage element 362 is able to pivot
about the thin plastic connectors 372 between an open position (not
shown) and a closed position (shown in FIG. 15).
[0093] The first and second cage elements 360 362 mount complementary
detents 380 and 382 for engagement to secure the first and second
cage elements 360 362 in the closed position. As shown in FIG.
15 one configuration of the complementary detents 380 382 includes
a clasp 380 mounted by the second cage element 362 and a complementary
socket 382 mounted by the first cage element 360 for receipt of
the clasp 380. The design of the complementary detents 380 382
is not critical to the invention and other suitable detent configurations
will be apparent to those of ordinary skill in the art.
[0094] The desiccant cartridge 330 is also susceptible of a relatively
simple method of production. The preferred rigid stand-off member
332 is formed as a one-piece, plastic casting by means of a conventional
casting process. The porous desiccant bag 334 preferably is manufactured
in the same manner as the porous desiccant bags 34 and 134 of previous
embodiments so as to leave first and second flat end seals 390
392. One or both of the first and second flat end seals 390 392
are secured to the inner and outer pad portions 340 342 by ultrasonic
welding, although other suitable techniques (such as thermal or
vibration welding) will be apparent to those of ordinary skill in
the art. Then the cage portion 348 is closed about the porous desiccant
bag 334 thereby immobilizing the porous desiccant bag 334 relative
to the rigid stand-off member 332 to facilitate installation and
removal of the desiccant cartridge 130.
[0095] The embodiments of FIG. 13 and FIGS. 14 and 15 operate in
substantially the same manner as the embodiment of FIGS. 9-12 and
share the same advantages of relatively simple installation and
removal. In particular, it will be appreciated that the only extraneous
material removed from the receiver 10 with any of the porous desiccant
bags 134 (FIG. 9 and FIG. 13) and 334 (FIG. 14) is the rigid stand-off
member 132 (FIGS. 9-11), 132 (FIG. 13), 332 (FIGS. 14 and 15). It
will be apparent that each of the rigid stand-off members 132 332
is relatively simple in design and inexpensive to produce. Thus,
it is highly economic to either discard the desiccant cartridge
130330 as a unit or to destroy the desiccant cartridge 130 330
to recover the desiccant material 136 336 for either regeneration
or separate disposal.
[0096] With reference to FIGS. 16-19 another exemplary embodiment
of a preferred desiccant cartridge 430 is illustrated. The desiccant
cartridge is similar to previous embodiments in that it is positioned
in the reservoir 422 and comprises a rigid stand-off member 432
and a porous desiccant pouch or bag 434 containing a powdered or
granulated desiccant material 436. However, the embodiment of FIGS.
16-19 also includes a cylindrical cap 438.
[0097] Referring to FIG. 18 the cap 438 includes an annular sleeve
portion 460; a web portion 462 closing a distal end of the annular
sleeve portion 460 to define an interior cavity 464; and a spacer
portion 466 in the form of a cylindrical spacer bar extending outwardly
from the web portion 462. A plurality of small holes 470 through
the web portion 462 communicate between the cavity 464 and the exterior
of the cap 438. The annular sleeve portion 460 mounts an annular
seal or collar portion 476 which extends radially outwardly from
the sleeve portion 460. Most preferably, the annular seal portion
476 is sufficiently thin to provide the annular seal portion 476
with a degree of resilient flexibility when subjected to shear forces.
[0098] Returning to FIG. 17 the desiccant cartridge 430 is susceptible
of a relatively simple method of production. The preferred rigid
stand-off member 432 is formed as a one-piece, plastic casting by
means of a conventional casting process. The preferred porous desiccant
bag 434 is manufactured by sealing a first open end (not shown)
of a tube (not shown) of porous polyester felt material or the like;
pouring the desiccant material (not shown) into the porous tube;
and forming a flat end seal 480 in a second open end (not shown)
of the porous tube. Once the porous desiccant bag 434 is manufactured,
one of the flat end seal 480 is affixed to the tab portion 446 of
the rigid stand-off member 432. The flat end seals 480 is preferably
formed and affixed to the tab portion 446 by ultrasonic welding,
although other suitable techniques (such as thermal or vibration
welding) will be apparent to those of ordinary skill in the art.
[0099] The operation of the receiver 10 (FIG. 1) is illustrated
in FIG. 19. In FIG. 19 the receiver 10 is shown juxtaposed with
a header tank 110 of a condenser (not shown) for an automotive air
conditioner or the like (not shown). The header tank 110 is divided
into a first chamber 120 and a second chamber 122. A plurality of
passages 130 communicate with the first chamber 120 while another
plurality of passages 132 communicate with the second chamber 122.
Those skilled in the art will recognize that the configurations
of the condenser (not shown) and of the header tank 110 are not
critical to the invention.
[0100] Refrigerant fluid (and the oil and moisture entrained therein,
none shown) entering the first chamber 120 through the plurality
of passages 130 flows through the inlet port 24 into the reservoir
422 of the receiver 10. The fluid (not shown) within the reservoir
422 enters the sides of the porous desiccant bag 434 and percolates
through the desiccant material 436 (FIG. 17). The desiccant material
436 (FIG. 17) adsorbs oil, moisture and other contaminants from
the refrigerant fluid (not shown) as the fluid percolates through
the porous desiccant bag 434. Meanwhile, the annular seal 476 of
the rigid cap 438 acts as a baffle to inhibit flow bypassing the
porous desiccant bag 434.
[0101] The refrigerant fluid (not shown) flows out of the desiccant
bag 434 through the plurality of holes 470 (FIG. 18) through the
web portion 462 (FIG. 18) of the rigid cap 438. It is desirable
that the plurality of holes 470 (FIG. 18) be so dimensioned as to
permit the flow of refrigerant fluid (not shown) while retaining
the desiccant material 436 (FIG. 16) and inhibiting the flow of
moisture, oil and other contaminants. In this manner, the plurality
of holes 470 (FIG. 18) provides additional filtering of the refrigerant
fluid (not shown) which percolates through the desiccant material
436 (FIG. 16) in the porous desiccant bag 434. Most preferably,
the desiccant material 436 (FIG. 16) is in the form of grains defining
maximum effective grain diameters; the plurality of holes 470 (FIG.
18) define maximum effective hole diameters; and the maximum effective
hole diameters are substantially no greater than the maximum effective
grain diameters so as to retain the desiccant material 436 (FIG.
16) and inhibit the flow of moisture, oil and other contaminants
(not shown) through to the outlet port 26.
[0102] The refrigerant fluid (not shown) passes from the reservoir
422 through the outlet port 26. From the outlet port 26 the refrigerant
fluid (not shown) proceeds to the condenser (not shown) through
the plurality of passages 132
[0103] Returning to FIG. 16 the design of the desiccant cartridge
430 facilitates installing and positioning the desiccant cartridge
430 in the reservoir 422 of the receiver 10. During installation,
the desiccant cartridge 430 is pressed as a unit through an open
end 496 of the canister 412 until the spacer portion 466 of the
cap 438 abuts against the end panel 20. The spacer portion 466 of
the cap 438 and the elongated stand-off portion 432 of the rigid
stand-off member 432 cooperate to position the porous desiccant
bag 434 so that the porous desiccant bag 434 straddles the inlet
and outlet ports 24 26.
[0104] Once the desiccant cartridge 430 is installed in the reservoir
422 the plug 418 is inserted into the open end 496 of the reservoir
422 to seal the open end 96. Most preferably, the plug 418 and the
open end 496 of the reservoir 422 present complementary threads
so as to allow the plug 418 to be threadedly engaged and retained
in the open end 496. One or more annular seals 100 inhibit flow
between the plug 418 and the outer surface bounding the open end
496.
[0105] The plug 418 abuts against the elongated stand-off member
432 to retain the desiccant cartridge 430 in position in the reservoir
422. Meanwhile, the inner pad portion 440 and the flange 450 are
each configured in size and shape to closely fit within the reservoir
422 so as to cooperate with the annular seal portion 476 of the
cap 438 to promote correct positioning, and inhibit lateral motion,
of the desiccant cartridge 430 in the reservoir 422.
[0106] The design of the desiccant cartridge 430 also facilitates
the removal of the desiccant cartridge 430 from the reservoir 422
when the desiccant material 436 is spent. In accordance with one
preferred method, the desiccant cartridge 430 from the reservoir
422 the eye 452 is engaged by a hook or the like (not shown) and
then the desiccant cartridge 430 is pulled as a unit from the reservoir
422. Alternatively, the elongated stand-off portion 442 is gripped
to permit the desiccant cartridge 430 to be pulled form the reservoir
422 as a unit.
[0107] Those skilled in the art will appreciate that the only extraneous
material removed from the receiver 10 with the porous desiccant
bag 434 is the rigid stand-off member 432 and the rigid cap 438.
It will be apparent that the rigid stand-off member 432 and the
rigid cap 438 are relatively simple in design and inexpensive to
produce. Thus, it is highly economic to either discard the desiccant
cartridge 430 as a unit or to destroy the desiccant cartridge 430
to recover the desiccant material 436 for either regeneration or
separate disposal.
[0108] Although this invention has been described in conjunction
with certain specific forms and modifications thereof, it will be
appreciated that a wide variety of other modifications can be made
without departing from the spirit and scope of the invention. |