US20080116592A1 - Method and Materials for Improving Evaporative Heat Exchangers - Google Patents

Method and Materials for Improving Evaporative Heat Exchangers Download PDF

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Publication number
US20080116592A1
US20080116592A1 US11/792,500 US79250006A US2008116592A1 US 20080116592 A1 US20080116592 A1 US 20080116592A1 US 79250006 A US79250006 A US 79250006A US 2008116592 A1 US2008116592 A1 US 2008116592A1
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water
core
heat exchange
wettable
air
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US11/792,500
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Robert Wilton James
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FF Seeley Nominees Pty Ltd
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FF Seeley Nominees Pty Ltd
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Assigned to FF SEELEY NOMINEES PTY LTD reassignment FF SEELEY NOMINEES PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JAMES, ROBERT WILTON
Publication of US20080116592A1 publication Critical patent/US20080116592A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/06Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00Layered products comprising a layer of paper or cardboard
    • B32B29/08Corrugated paper or cardboard
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F1/00Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
    • F24F1/0007Indoor units, e.g. fan coil units
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F1/00Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
    • F24F1/0007Indoor units, e.g. fan coil units
    • F24F1/0059Indoor units, e.g. fan coil units characterised by heat exchangers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24FAIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F5/00Air-conditioning systems or apparatus not covered by F24F1/00 or F24F3/00, e.g. using solar heat or combined with household units such as an oven or water heater
    • F24F5/0007Air-conditioning systems or apparatus not covered by F24F1/00 or F24F3/00, e.g. using solar heat or combined with household units such as an oven or water heater cooling apparatus specially adapted for use in air-conditioning
    • F24F5/0035Air-conditioning systems or apparatus not covered by F24F1/00 or F24F3/00, e.g. using solar heat or combined with household units such as an oven or water heater cooling apparatus specially adapted for use in air-conditioning using evaporation
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D5/00Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, using the cooling effect of natural or forced evaporation
    • F28D5/02Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, using the cooling effect of natural or forced evaporation in which the evaporating medium flows in a continuous film or trickles freely over the conduits
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F25/00Component parts of trickle coolers
    • F28F25/02Component parts of trickle coolers for distributing, circulating, and accumulating liquid
    • F28F25/08Splashing boards or grids, e.g. for converting liquid sprays into liquid films; Elements or beds for increasing the area of the contact surface
    • F28F25/087Vertical or inclined sheets; Supports or spacers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/022 layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/12Coating on the layer surface on paper layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554Wear resistance
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/724Permeability to gases, adsorption
    • B32B2307/7242Non-permeable
    • B32B2307/7246Water vapor barrier
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/726Permeability to liquids, absorption
    • B32B2307/7265Non-permeable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2597/00Tubular articles, e.g. hoses, pipes
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00Energy efficient heating, ventilation or air conditioning [HVAC]
    • Y02B30/54Free-cooling systems
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1002Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina

Definitions

  • the present invention relates to improvements in heat exchange capacity of evaporative heat exchangers.
  • one aspect of this invention relates to a material suited to use in forming heat exchange surfaces of evaporative heat exchangers. Additional inventions are disclosed that relate to the operation of evaporative coolers.
  • the aspects of this invention will be described in connection with the heat exchange core of counter flow evaporative coolers, as well as to methods, equipment and systems for the ventilation and cooling of enclosed spaces.
  • the various aspects of this invention can be applied to self-contained air conditioning units suitable for supplying cooled air to an enclosed space, and to self-contained conditioning units suitable for supplying cooled water for use in heat exchange units forming part of a system for the cooling of enclosed spaces.
  • evaporative air coolers for the cooling of enclosed spaces is well known in the art. These coolers are typically constructed with outer walls containing a wettable, permeable media, which is kept wet with water pumped from an internal reservoir. Air from outside the building is drawn through the wetted media by means of a fan located within the evaporative cooler, and delivered either directly into the enclosed space or through a system of ducting to the enclosed space.
  • the air delivered by an evaporative cooler is cooled to a temperature which is always greater than the Wet Bulb Temperature, to a degree determined by the efficiency of the design of the evaporative cooler.
  • the air delivered is also always more humid than the air entering the cooler.
  • This limitation in achievable temperature and the addition of moisture to the air severely limits the degree of cooling available by this method, as well as limiting the use of this means of cooling to relatively hot, dry climates.
  • the design condition for evaporative cooling is 38° C. Dry Bulb Temperature, 21° C. Wet Bulb Temperature.
  • a typical evaporative air cooler will deliver air at around 23.5° C., but which has been substantially humidified. This air is much less amenable to providing comfort conditions within the enclosed space than, say, a refrigeratively cooled air conditioning system, which might deliver air at 15° C., and to which no additional moisture has been added.
  • SU 979796 by Maisotsenko discloses a configuration wherein a main stream of air is passed along a dry duct, simultaneously passing an auxiliary air stream counter currently along a moist duct which is in heat-exchange relation with the dry duct.
  • the auxiliary stream is obtained by subdividing the total stream into main and auxiliary streams.
  • U.S. Pat. No. 4,977,753 A practical implementation and method of construction of the configuration of U.S. Pat. No. 4,977,753 is disclosed in U.S. Pat. No. 5,301,518 by Morozov et al.
  • U.S. Pat. No. 5,301,518 discloses a construction consisting of alternating dry ducts, which may be constructed from a variety of materials, and wet ducts constructed from capillary porous material.
  • the airflow configuration is arranged such that the air streams in the dry and wet ducts are in counter flow as in previous disclosures.
  • the configuration divides the heat exchanger into two separate stages for the purpose of achieving the requisite temperature reduction while relieving the high pressure drop inherent in the narrow air passages required for adequate heat transfer. Wetting of the porous material of the wet ducts is achieved by vertical wicking from a water reservoir beneath the heat exchanger.
  • a first aspect of the present invention provides a corrugated material for use in an evaporative heat exchanger, said material including a water retaining wettable surface and an opposed vapour resistant surface.
  • the shape of the corrugated pattern within the sheets may be varied to optimise thermal performance and airflow resistance when the corrugated material is used in a heat exchange core.
  • the present invention provides a method of making a corrugated laminate material as described herein, wherein a planar sheet of a water retaining medium is shaped with corrugations by being fed through corrugating rollers.
  • the present invention provides a heat exchange core for an evaporative heat exchanger formed from at least one sheet of corrugated material as described herein, wherein the at least one sheet is folded to form at least one pocket or fold such that the interior of each fold forms a wettable surface passage or channel or a vapour resistant passage or channel.
  • the present invention provides a heat exchange element for a core of an evaporative heat exchanger, said element being formed from at least two sheets of corrugated laminate material as described herein, wherein the two sheets are joined to form a passage having corrugated walls for airflow therethrough and wherein the corrugations on opposite sides of the passage are at intersecting angles.
  • the angle of intersection of the corrugations of adjacent corrugated sheets is varied so as to optimise thermal performance and airflow resistance of the heat exchange core.
  • a preferred indirect evaporative heat exchanger core is characterised by a construction consisting of individual corrugated wettable media sheets modified to include a vapour impermeable barrier on one side.
  • the individual sheets are constructed into open pockets sealed top and bottom with the vapour impermeable barrier on the inside of the pocket.
  • Said pockets are then assembled into a stack of pockets by sealing each of the non vapour barrier sides together at the air entry end of the stack of pockets such that a complete core is formed wherein warm, dry air enters the core through the pockets, passing all the way through the pockets.
  • a proportion of the air so delivered is returned through passages formed between the wettable non-vapour barrier sides of adjacent pockets, which form wet passages of the core.
  • the present invention provides a method of making a heat exchange core comprising taking a plurality of pairs of sheets of corrugated laminate material as described herein, forming a plurality of pockets from pairs of said sheets where the inner surfaces of each pocket are vapour resistant surfaces, adjacent edges of each pair of parallel spaced apart sides being sealed together to form open-ended pockets and stacking said pockets in parallel to form wettable surface airflow passages between each pair of adjacent pockets.
  • the present invention provides an evaporative cooler including a heat exchange core formed from at least one sheet of corrugated laminate material as described herein, wherein the at least one sheet is folded to form at least one pocket or fold such that the interior of each fold forms a wettable surface passage or channel or a vapour resistant passage or channel.
  • the present invention provides a method of effecting heat exchange between counter current airflows in a heat exchanger, said heat exchanger including a heat exchange core comprising wet and dry airflow channels in counter flow, said channels being formed with corrugated walls and wherein entry air is passed down the dry channels to exit as conditioned air, a portion of the exit air being reversed to pass through the wet channels and effect heat exchange between the dry and wet channels before being exhausted.
  • This gradient can only be achieved by wicking water from a reservoir to the point where it is to evaporate in prior art arrangements. Any surplus of water over this requirement to evaporate and keep the surfaces wet will degrade thermal performance and it will no longer be possible to approach the Dew Point in delivered air temperature. If the wetted surfaces were to be flood irrigated as is the practice with direct evaporative cooling, it would only be possible for the delivered air temperature to approach the Wet Bulb temperature of the incoming air. This temperature can be considerably above the Dew Point depending on incoming air psychrometrics.
  • an evaporative cooler which includes a heat exchange core wherein adjacent wet and dry airflow channels are in counter current airflow heat exchange relationship with water being supplied to the wet channels in a descending flow pattern, characterised in that water is supplied to the wet channels over a plurality of segments from an air entry end to an air outlet end of said core during operation of said cooler and wherein water is circulated through each segment relatively separately from adjacent segments such that an appropriate temperature gradient is established from an air inlet end to an air outlet end of the core by maintaining different circulating water temperatures in each segment.
  • the method of the eighth aspect is further characterised by the delivery of water through each water distributor from a respective pumping means associated with each water reservoir.
  • the water reservoirs are each connected to a common water conduit such that water levels in each reservoir are allowed to reach an equilibrium level.
  • the present invention provides a method of operating an evaporative cooler which includes a heat exchange core adapted for heat exchange airflow therethrough via a plurality of heat exchange channels, at least some of said channels being wet channels with water being applied to and retained by wettable material in the wet channels, characterised in that water is applied to the wet channels in an intermittently and generally uniformly descending flow pattern across the entire core and wherein the application of water to the wet channels of the core is repeated before the wettable material has dried out.
  • a single pumping means, water spreader and reservoir applies water to the evaporative core periodically.
  • the present invention provides an evaporative cooler including a heat exchange core as described herein having corrugated wet and dry passages or channels, a water distribution system including a plurality of water distributors for wetting the wettable surfaces of the passages or channels, said water distributors being positioned above the core and disposed in spaced apart parallel relation transversely of the core relative to an airflow direction through the core, each water distributor being located within a respective space above the core separate from adjacent water distributor spaces, each water distributor being supplied from a respective reservoir, and further including flow restriction means at an airflow exit of the vapour resistant channels for effecting counter flow of a portion of the exit air through the wet channels to an exhaust.
  • Such an indirect evaporative air cooler typically comprises a fan means for the delivery of air, an indirect evaporative heat exchanger and an air delivery means including an airflow resistance means.
  • FIG. 1 is an isometric view of the construction of a prior art corrugated evaporative media
  • FIG. 2 shows schematic views of airflow paths and a water distribution method of a prior art indirect evaporative cooler
  • FIG. 3 is a sectional view of a dry channel showing the construction of an embodiment of corrugated media in accordance with the invention
  • FIG. 4 shows a sectional view and schematic of a segment of an indirect evaporative cooler core made from the corrugated media of FIG. 3 ;
  • FIG. 5 is an isometric view, which shows an embodiment of the construction of a pocket segment of an indirect evaporative cooler core employing corrugated media of the present invention
  • FIG. 6 is an isometric view of an assembly of pocket segments of FIG. 5 when formed into an indirect evaporative cooler core;
  • FIG. 7 is a schematic showing the water distribution system of another aspect of the present invention where the heat exchange core is divided into segments.
  • FIG. 8 is an isometric view of an assembled indirect evaporative cooler core detailing water and airflow systems.
  • the prior art corrugated media is shown as a block of sheets of corrugated, wettable media within which dry air and water on the wetted surfaces interact.
  • the block 1 is constructed from individual sheets 4 of corrugated media (typically treated paper of a type which readily wicks water along its surface).
  • Individual corrugations 6 are impressed in the media during manufacture and the sheets arranged such that the corrugations are set at an angle 8 to the edges of the block of media.
  • Adjacent sheets 4 are typically glued together with reversed corrugation angles creating complex air and water passages within the matrix of the block.
  • water is introduced in the direction 3 and applied to the top surface of the block of media.
  • the water 3 descends through the matrix, it encounters numerous points within the matrix where the corrugations 6 of adjacent sheets 4 meet. At each of these intersection points, part of the water is directed one way around the intersection, and the remainder of the water the opposite way around the intersection. Since there are numerous such intersections within the matrix, the water is quickly spread evenly throughout the block of media, thereby ensuring even wetting of the surfaces.
  • the distribution of water within the matrix is further enhanced by the property of the media to readily wick water along its surface. Thus any deficiencies in the evenness of water distribution throughout the surfaces of the matrix are readily compensated and corrected.
  • Hot, dry air 5 enters the matrix and also encounters numerous intersections of the adjacent corrugated sheets. At each intersection, the air is divided into two streams ensuring uniform movement of air throughout the matrix. At each of these intersections there is intense interaction between the air and the wetted surfaces due to the rapid and frequent changes in direction of the airflow. This intense interaction results in rapid evaporation of water from the wetted surfaces, thereby humidifying the air and cooling the waters on the wetted surfaces. Since the wetted surfaces are then considerably cooler than the hot dry incoming air, heat exchange will then occur between the air and the wetted surface, thereby cooling the air. Air leaves the matrix block as cooled, humidified air 7 . The heat exchange during this process is also intensified due to the numerous interaction sites at the intersections of corrugations for the same reasons as for intensified evaporation espoused above.
  • FIG. 2 a prior art indirect evaporative cooler construction is shown. Hot, dry air 10 enters the dry air passage 12 , proceeding past the dry air passage boundary 14 . When the construction has been operating for at least a short period, the dry air passage boundary 14 will be cooler than the dry air entering the passage 12 . Heat exchange will occur and the dry air will be progressively cooled as it proceeds down the dry air passage.
  • the incoming hot dry air 10 has been cooled considerably when it leaves the dry air passage 14 at 15 .
  • a flow resistance device 28 is installed in the airflow path thereby causing an increase in air pressure at 15 .
  • This increase in pressure causes some of the now cool, dry air to turn at 26 , and proceed through the wet air passage 16 .
  • the wet air passage contains a wetted media 18 , kept moist by the wicking of water from a water reservoir 22 . Since the air has not yet had any change in its moisture content, evaporation takes place from the wetted media 18 thereby humidifying the air and cooling the water within the wetted media by the same mechanism described above for evaporative media.
  • Air which flows through the flow resistance 28 becomes the delivered air 24 .
  • This air has been cooled without the addition of moisture.
  • the temperature of delivered air 24 can approach the Dew Point of the incoming air.
  • FIG. 3 shows an element of the construction of the current invention.
  • a corrugated wettable media 40 (which may be made using similar materials and manufacturing methods to that of individual sheets 4 of the evaporative media described above) is manufactured with a vapour resistant membrane 42 adhered to one side.
  • the membrane 42 may be a polymer material, although the only essential property is that it resist the flow of water vapour. It may be applied by a number of methods, including hot calendaring of plastic, adhering plastic film or the application of liquid polymers (e.g. paint), or it may be formed by treatment of the surface of the wettable media.
  • the vapour membrane should be kept as thin as practicable for maximum heat transfer.
  • the wettable media 40 should also be as thin as practicable consistent with its requirement to keep the surface wet and wick water to areas not directly wetted in the constructed cooler.
  • the wettable media 40 from which the core elements 44 are made can be manufactured from any material which can be readily wetted. Practical materials include treated, wettable paper, moulded paper fibre slurry, wettable particulate sintered polymers and metallic or polymer films with treated or modified surfaces to promote wetting. Those skilled in the art will be aware of other wettable materials which may be used in the construction of the current invention.
  • the core elements 44 may be produced using a moulding process wherein the shape of the corrugated passages may be modified to further facilitate the optimisation of airflow and heat transfer.
  • the air passages through which exhaust air leaves the core may be shaped to reduce the airflow pressure losses associated with turning the air within the core from the general flow direction to a general exhaust direction.
  • FIG. 4 shows the component part described in FIG. 3 as part of the heat exchanger and evaporation core of the indirect evaporative cooler, the current invention.
  • dry, hot airflows through the dry air passage 50 where the dry air passage is contained between the vapour resistant surfaces 42 of the corrugated sheets 44 .
  • Adjacent wet passages 52 are formed between the wettable media surfaces 40 . Airflows through the dry passages 50 in general counter flow to the wet passages 52 .
  • the angle at which corrugations are set to the general direction of airflow is illustrated by the angle 54 .
  • This angle may be varied over a wide range to optimise the efficiency of heat transfer and resistance to airflow in the core. In general, a shallower angle 54 will result in lower airflow resistance at the penalty of reduced heat transfer efficiency.
  • the angle of corrugation 54 within the core is made relatively shallow, typically in the range 20 degrees to 35 degrees.
  • the shallow angles of corrugation significantly reduce the airflow resistance through the core to the detriment of heat transfer efficiency. Heat transfer efficiency can be regained by extending the overall length of the core. It is found that within the range of angles stated herein, an optimised combination of reduced airflow resistance and increased core length can be achieved for each construction, consistent with adequate heat transfer efficiency.
  • FIG. 5 shows the detail of construction of the components described in FIG. 4 to achieve the flow patterns and directions required.
  • Individual pockets 88 are constructed from two corrugated sheets with vapour resistant membranes 44 .
  • Each corrugated sheet 44 is positioned with the vapour resistant membrane 42 facing the vapour resistant membrane of the adjacent sheet.
  • the sheets are sealed together at the top seal 84 and bottom seal 86 , thus forming a complete pocket with all inner surfaces lined with a vapour resistant membrane 42 .
  • the top seal 84 and bottom seal 86 can be formed by methods including clinching, adhesives, plastics welding or fillers.
  • one of either the top seal or bottom seal can be formed by folding of a double size sheet of media and membrane combination.
  • This construction results in a sealed lined pocket through which hot dry air can flow with no physical contact with the wettable media in passage 80 .
  • FIG. 6 shows the stacking of several of the pockets 88 formed into an indirect cooler core 94 .
  • adjacent wettable media surfaces then form the wet passage 82 .
  • Air flowing through the wet passage 82 has no physical contact with the dry passage 80 , but heat exchange between the wet and dry passages and evaporation within the wet passage can readily take place with the intensity promoted by the corrugated construction.
  • Adjacent pockets 88 need to have the wet passages 82 separated from the dry passages 80 at the end of the core through which hot, dry air enters the core. This is achieved by sealing together adjacent pockets on the wettable media side with a seal line 90 formed by similar methods to the seals at the top and bottom of the pockets ( 84 and 86 ). With this construction, hot, dry air entering from 92 can only enter and flow through the pockets 88 lined with vapour resistant membranes 42 , and must travel all the way through the pocket until it exits at the opposite end 96 .
  • FIG. 7 shows an arrangement in accordance with an embodiment of the eighth aspect of the present invention for wetting of the wettable media in the wet passages in a segmented manner.
  • FIG. 1 divides the core 94 into a number of segments 62 (shown as five segments in FIG. 7 , but a lesser or greater number of segments could be used).
  • Each segment has its own pumping means 60 , its own water reservoir 66 and its own water distribution system 68 .
  • the segment 62 of core 94 with its corrugated construction tends to pass water from the water distributor 68 , through the core 94 to the water reservoir 66 with little mixing of water from adjacent segments. Since, in operation, all segments are circulating water simultaneously, any tendency of the circulating water in a segment to pass through to an adjacent segment is approximately balanced by an equal and opposite tendency for water to come back from that adjacent segment. Thus, for each segment water is circulated relatively independently of each of the adjacent segments.
  • the circulating water temperature in each of the segments can therefore be different, thus providing the temperature gradient necessary to thermal performance of the indirect evaporative cooler, and thus allow the delivered air temperature to approach the Dew Point.
  • This arrangement for water supply to the core has several advantages over the prior art, including removal of the restriction on core height due to the wicking capability of the wettable media; water flow surplus to the requirement for evaporation flushes away any salt concentration due to evaporation and water quality can be easily monitored for salt concentration and diluted before critical concentrations are reached.
  • the segmented water distribution system of FIG. 7 is replaced with a single, general uniform means of distributing water over the entire core, a single water pump means, and a single water reservoir at the bottom of the core 94 .
  • water is applied to the core intermittently.
  • the single water pump 60 is operated for a short period of time sufficient to uniformly wet all of the internal surfaces of the core, and is then turned off.
  • the indirect evaporative cooler is then continued in operation, cooling by means of evaporation of the water contained on its internal surfaces.
  • the wetted surfaces of the core will cool to temperatures similar to the temperatures of an indirect evaporative core wetted by means of wicking as in the prior art.
  • the requirements of thermal gradient within the wetted passages are met, and thermal performance of the core is not significantly degraded.
  • the wetting operation by means of the pump 60 is repeated before the wetted surfaces of the core are dried out, resulting in some degradation of thermal performance during the wetting phase.
  • the core can be wetted in 30-60 seconds, and the indirect cooler operated without further wetting for 15-20 minutes without the wetted surfaces in the core drying out significantly.
  • FIG. 8 shows the complete core 94 with the water distribution system 68 and the airflow system 104 in place.
  • Each water distributor is located within a space 101 kept separate from the water distributor space of adjacent segments by barriers 100 .
  • the sealed spaces 101 and barriers 100 are necessary to prevent airflow exiting from the wet passages of the core thereby causing air in the wet passages to travel all the way along the wet passages.
  • a similar sealing system is necessary to separate the water reservoir 66 from adjacent water reservoirs.
  • Each water reservoir 66 is sealed to the core by barriers 102 thus preventing any air from leaving the wet passages through the water reservoirs.
  • the wet passage space is left open at 106 .
  • the opening 106 allows the now moist, warn air flowing in the wet passages to exhaust from the core 94 .
  • an exhaust opening 106 is provided at both the top and bottom of the core although only the top opening is shown in FIG. 8 .
  • the opening 106 at the bottom of the core is impracticable, satisfactory performance can still be achieved with only the opening 106 at the top with some degradation of thermal performance.
  • the ratio of delivered air to exhaust air is adjusted by means of a flow restriction 108 in the delivered air stream.
  • Closing flow restriction 108 increases the pressure in chamber 109 at the delivery end of the core 94 , thereby increasing the flow of air back through the wet air passages.
US11/792,500 2005-01-11 2006-01-04 Method and Materials for Improving Evaporative Heat Exchangers Abandoned US20080116592A1 (en)

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CN106767051A (zh) * 2017-01-14 2017-05-31 陈祖卫 间接蒸发换热器及其冷却塔
JP2021527797A (ja) * 2018-09-25 2021-10-14 ブレントウッド・インダストリーズ・インコーポレイテッドBrentwood Industries, Inc. クロス波形媒体及び関連方法
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EP1836046A1 (en) 2007-09-26
DE06700305T1 (de) 2008-05-21
ES2293873T3 (es) 2022-04-07
US8636269B2 (en) 2014-01-28
CN101102888B (zh) 2011-01-19
EP1836046A4 (en) 2013-12-11
ES2293873T1 (es) 2008-04-01
IL183562A0 (en) 2007-09-20
EG25380A (en) 2011-12-22
MX345482B (es) 2017-01-18
WO2006074508A1 (en) 2006-07-20
CA2594528C (en) 2014-06-17
EP1836046B1 (en) 2021-12-29
MX2007008386A (es) 2007-11-08
US20110220333A1 (en) 2011-09-15
CN101102888A (zh) 2008-01-09
TR200704377T1 (tr) 2007-08-21
CA2594528A1 (en) 2006-07-20

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