US20190022807A1 - Modular heat exchanger with sections interconnected by connectors - Google Patents
Modular heat exchanger with sections interconnected by connectors Download PDFInfo
- Publication number
- US20190022807A1 US20190022807A1 US16/143,548 US201816143548A US2019022807A1 US 20190022807 A1 US20190022807 A1 US 20190022807A1 US 201816143548 A US201816143548 A US 201816143548A US 2019022807 A1 US2019022807 A1 US 2019022807A1
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- United States
- Prior art keywords
- modules
- heat exchanger
- duct
- flue
- series
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/22—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating
- F24H1/24—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating with water mantle surrounding the combustion chamber or chambers
- F24H1/30—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating with water mantle surrounding the combustion chamber or chambers the water mantle being built up from sections
- F24H1/32—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating with water mantle surrounding the combustion chamber or chambers the water mantle being built up from sections with vertical sections arranged side by side
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/14—Arrangements for connecting different sections, e.g. in water heaters
- F24H9/146—Connecting elements of a heat exchanger
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/26—Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/26—Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators
- F28F9/262—Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators for radiators
- F28F9/264—Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators for radiators by sleeves, nipples
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/088—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal for domestic or space-heating systems
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/02—Fastening; Joining by using bonding materials; by embedding elements in particular materials
- F28F2275/025—Fastening; Joining by using bonding materials; by embedding elements in particular materials by using adhesives
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/08—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
- F28F3/086—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning having one or more openings therein forming tubular heat-exchange passages
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
-
- Y02B30/108—
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
Definitions
- the invention relates to a heat exchanger comprising interconnected modules.
- Heat exchangers for use in for example domestic central heating boilers and/or tap water boilers are known in the art to be made for example of iron, steel or light metal, such as aluminum or aluminum alloy. These heat exchangers are known to for example be cast using lost core technology. It is known to cast a complete heat exchanger body in one piece, which negates the necessity of assembling the heat exchanger body but requires relatively large molds and casting equipment, and furthermore requires a different mold for each type or size of heat exchanger, for example for adjusting the capacity of the heat exchanger.
- flue passages and water ducts are provided for exchanging heat between flue gasses from a burner flowing through the flue ducts and water flowing through the water ducts.
- the core has to be complicated and has to be removed after casting.
- openings have to be provided through which the core can be removed.
- the ducts and passages then have to be thoroughly cleaned through said openings, after which the openings then have to be machined for receiving closures, such as screw stop with sealing O-rings, or stops are to be welded into the openings.
- closures such as screw stop with sealing O-rings, or stops are to be welded into the openings.
- heat exchangers which comprise a series of individually cast modules.
- the modules can be assembled into a heat exchanger having a desired capacity by adjusting the number of modules.
- the smaller size of the modules makes casting and handling easier.
- Each module will comprise part of the flue duct or ducts and part of the water ducts. Obviously this has the effect that the modules have to be assembled, whereby the parts of the water duct or ducts and parts of the flue duct or ducts of the modules have to be interconnected in order to form continuous ducts.
- EP0404259 discloses a modular heat exchanger in which different modules are use for the flue ducts and the water ducts. These are alternatingly placed in a row, forming a heat exchanger body. Each module having a water duct has an individual inlet and outlet at diametrical opposing positions. Though not disclosed in EP0404259, the inlets and outlets of the modules will be connected by an inlet manifold and an outlet manifold respectively, for forming one water circuit through the respective modules. This requires individual connections for each inlet and each outlet to the respective manifolds. A combustion chamber is formed extending through all modules, integrating a burner in the heat exchanger.
- EP0645591 discloses a modular heat exchanger comprising a series of modules interconnected to form flue ducts and water ducts. Each module comprises two side metal assemblies, each including a closed gap for forming a single space for water. From a wall of said gap fins extend outward, such that when two such modules are placed adjacent to each other, such that a zig-zag flue duct is formed by the fins.
- the spaces for water in each of the modules will be connected by an inlet manifold and an outlet manifold respectively, for forming one water circuit through the respective modules. This requires individual connections for each inlet and each outlet to the respective manifolds.
- a combustion chamber is formed extending through all modules, integrating a burner in the heat exchanger, fed by a fan sending a mixture of gas and air into said burner space.
- EP0843135 discloses a modular heat exchanger comprising a series of modules, each having at least a water duct part and a flue duct forming part with heat exchanging elements.
- the flue duct forming parts are open to one side and in contact with a water duct part extending through said module for exchanging heat between flue gasses and water.
- At least the parts of the water ducts of successive modules are interconnected, forming at least one continuous water duct through and along a number of said modules.
- each water duct part of a module comprises an inlet and an outlet.
- each module is individually provided with a burner and fan.
- the present disclosure aims at providing an alternative modular heat exchanger.
- the present disclosure aims at providing a compact modular heat exchanger.
- the present disclosure aims at providing an modular heat exchanger reducing or mitigating at least one of the disadvantages of the known heat exchangers.
- the present disclosure aims at providing a modular heat exchanger which can be scaled easily to different capacities.
- the present disclosure aims at providing a method for forming an alternative modular heat exchanger.
- At least one of these and/or other aims is obtained with a heat exchanger, module, boiler and/or method according to this disclosure.
- a heat exchanger can comprise a series of interconnected modules, each module comprising at least part of a water duct and part of a flue duct. At least the parts of the water ducts of successive modules are interconnected, forming at least one continuous water duct through and/or along a number of said modules. Water duct parts of two adjacent modules are interconnected by a connector inserted into an opening in at least one of the modules forming a sealing connection.
- At least part of the manifolds connecting the water duct parts of the different modules may be integrated in the modules, connected by the connectors.
- the water duct parts of the modules are directly coupled to each other, without the necessity of providing a manifold along the heat exchanger modules.
- this negates the necessity of individually connecting the water duct parts to such manifold extending alongside the heat exchanger modules.
- this provides for automatic adjustment of the length of the manifold thus formed, by way of one or more connecting ducts incorporating the connectors, to the number of modules used in a heat exchanger.
- the heat exchanger integrates in this way three connecting ducts for interconnecting the water duct parts of the different modules of a heat exchanger, such that the combined water duct through the heat exchanger has substantially a Tichelmann design.
- a Tichelmann design is a known principle of lay out of ducts in heating systems wherein the length of the ducts to and from a heating system should be the same for each component. Applied to a heat exchanger according to the present disclosure this means that the length and flow capacity between an inlet of the combined water duct system of the heat exchanger to the outlet of said water duct system should be the same for all paths through the different modules.
- the said inlet and outlet of the heat exchanger's combined water duct system are provided at the same longitudinal end of the series of modules, for example at an end module, such that connection to an appropriate heating system is made even more easy.
- the manifolds are integrated in the modules, including said connectors, also because this will prevent undesired cooling of the water in the manifold, as will happen in the known heat exchangers with external manifolds, since these are subject to temperatures outside the heat exchanger, for example room temperature.
- FIG. 1 shows a heat exchanger, partly in cross section, having four modules
- FIG. 2 shows part of a module of a heat exchanger, with a connector, in cross sectional view
- FIG. 3 shows in cross sectional view part of two modules, connected by a connector
- FIG. 4 shows in cross sectional view part of two modules interconnected by a connector and an injector
- FIG. 5 schematically shows the water flow of water through the heat exchanger.
- a heat exchanger as to be understood as an exchanger for exchanging heat between heated flue gasses from a burner and water flowing through one or more water channels within said heat exchanger.
- a flame receiving space is provided over and/or into which a burner can be inserted, such that said heated flue gasses are actively created, during use, within said heat exchanger.
- the burner can be at least partly integrated in the heat exchanger, for example by extrusion, casting and/or machining.
- Such heat exchangers are especially, but not exclusively suitable in domestic and commercial heating systems such as boilers and central heating systems, such as for space heating and/or tap water heating systems.
- some or all of the parts can also be made by casting, such as but not limited to injection moulding, sand or otherwise lost core moulding or casting or the like, possibly combined with machining, such as but not limited to grinding, turning, milling, drilling and the like known machining methods. Also or alternatively other techniques can be used, where applicable, such as but not limited to extrusion.
- light metal is at least to be understood as including non-ferro metal and non-ferro metal alloy having a density of less than 4500 kg/m 3 .
- Preferred materials are aluminum and aluminum alloy.
- top and bottom and sides are used as references only, without limiting the possible positioning of the heat exchanger or parts thereof in use.
- top and bottom are used as defined in FIGS. 1, 2 and 4 , where the flame receiving space is shown at the top and the outlet for gas is at the bottom.
- bonding has to be understood as forming an adhesive connection between two or more parts using an elastic bonding agent.
- a glue or adhesive which after curing is still flexible and elastically deformable.
- the bonding agent is heat resistant to temperatures above 120° C., preferably above 150° C., more preferably above 170° C.
- a glue can be used having a temperature resistance up to 180° C. or above.
- a glue can be used having a use temperature range between about ⁇ 4 and +120° C., preferably between about ⁇ 20 and +150° C., more preferably between about ⁇ 40 and +170° C., even more preferably between at least ⁇ 55 and 180° C. or higher (e.g. PSI S406).
- a temperature range should be understood as a range of temperatures in which the glue maintains at least most of its elastic and bonding properties, such that in a heat exchanger at least the bonding maintains pressure resistant and fluid and gas tight.
- Pressure resistant is in this context to be understood as at least resistant to pressures in an adjoining space of above 2 bar, preferably above 4 bar, more preferably at least to 10 bar.
- the desired pressure resistance can be as high as 20 bar or above.
- One bar is 100.000 Pascal or 0.1 MPa.
- Elastic bonding agent such as glue or adhesive should be understood as an agent which, after curing, has during use, a high yield strength and high yield limit. This means it can be stretched to a relatively high degree before breaking.
- the elasticity is preferably such that the yield limit is more than about 300%, preferably more than about 400%, more preferably more than about 550% and in particular preferably about 650% or more.
- this high yield limit is maintained over the temperature range during use of the heat exchanger.
- the yield limit can e.g. be measured according to ASTM D412.
- the bonding agent can be a silicone or elastomeric based adhesive, preferably curing at about room temperature to a rubber like component which is water and gas tight.
- a bonding layer formed by said bonding agent is preferably pressure resistant to at least about 4 Bar, more preferably to about 10 Bar and even more preferably to about 20 Bar or above, wherein the bonding agent is preferably applied to unprimed metal of the parts.
- An example of such bonding agent is Dow Corning 7091, which has a normal temperature range of use between ⁇ 55 and +180° C., and a yield limit of about 680%.
- Dow Corning® 7091 Adhesive/Sealant is a high-performance, neutral-cure silicone that cures at room temperature to a tough, flexible rubber, suitable for the use described herein.
- Dow Corning 7091 remains flexible and stable from ⁇ 55° to 180° C. ( ⁇ 67° to 356° F.), and is a one-component, non-sag sealant. It can have a tear strength of 86 ppi and a tensile strength of about 363 psi. This adhesive is only provided by way of example and should not be considered limiting the scope in any way.
- parts of the heat exchanger can be connected to each other, forming fluid, especially water, and gas tight seals without having to add gaskets, seals or the like, which will remain fluid and gas tight over a large temperature range.
- seals are relatively inexpensive and are pressure resistant to relatively high pressures.
- due to the high flexibility problems with different expansion rates and directions of the different parts bonded together are avoided.
- FIG. 1 shows a heat exchanger 1 comprising a series of modules 2 , in side to side relationship.
- the heat exchanger 1 comprises four modules, interconnected by connectors 3 .
- the heat exchanger 1 thus comprises a series of interconnected modules 2 .
- Each module comprises at least a part 4 of a water duct 5 and a part 6 of a flue duct 7 .
- At least the parts 4 of the water duct 5 of successive modules 2 are interconnected, forming at least one continuous water duct 5 through and/or along a number of said modules 2 for example shown in FIG. 5 .
- Water duct parts 4 of two adjacent modules 2 are interconnected by the connector or connectors 3 , to which end the connector 3 is inserted into an opening 8 in at least one of the modules 2 , forming a sealing connection.
- the connector can be bonded or glued in the at least one opening 8 .
- it can be fixed in a different manner, for example by press fitting, screwing or the like. Bonding or gluing can have the advantage that the opening does not have to be machined after casting, as is necessary for most if not all other means for mounting.
- the connector or connectors 3 are elements initially separate from the modules 2 , and are inserted into openings 8 in two adjacent modules 2 as shown for example in FIG. 2-4 .
- the connectors 3 can thus be made separately, from a material which can be the same or different from the material of the modules.
- the connectors 3 can be placed after casting of the modules 2 and after cleaning of some or all of the ducts or duct parts 4 , 6 therein.
- one or more or even all of the connectors can be made integrally with a module 2 , at least in part.
- the said connector 3 is made of plastic and the modules 2 are made of metal.
- the modules 2 are made of light metal or light metal alloy, more preferably aluminum or aluminum alloy.
- the heat exchanger 1 comprises two central or intermediate modules 2 A, a first end module 2 B and a second end module 2 C.
- the central modules 2 A can be of identical construction.
- the central modules 2 A can be substantially mirror symmetrical over a mid-plane V, extending parallel to opposite side planes Q at which the modules 3 are interconnected.
- more than two or just one central module 2 A could be used in a heat exchanger, between the end modules 2 B, 2 C, for example for adjusting the heat capacity of the heat exchanger.
- Each central module 2 A comprises a central section 9 comprising two walls 10 A, 10 B extending in this embodiment substantially parallel to each other and to the planes V and Q, wherein between the walls 10 A, B, cross walls 10 C are provided, forming the part 4 of the water duct 5 , having a meandering flow path between an inlet 11 and an outlet 12 .
- the inlet 11 is shown at a lower end and the outlet 12 is shown at an upper end of the duct part 4 .
- the duct part 4 can extend around an opening 13 near the upper end.
- the opening 13 extends though the mirror plane V and opens into both sides of the module, such that a continuous opening 13 extends through the series of modules, closed off at one longitudinal end by an end wall 14 of the second end module 2 C, as will be explained later on.
- the area formed by the combined openings 13 can form a burner chamber 15 for the heat exchanger.
- each pair of adjacent modules at least two connectors 3 are provided, near two opposite sides of the heat exchanger 1 , such that both inlets 11 and outlets 12 of the duct parts 4 of the different modules 2 can be connected.
- a connector 3 is shown in one of the connecting ducts 25 , 26 , 56 , as will be discussed. This is the same or similar for all these ducts.
- at least one such connector 3 is provided near an upper end 16 and at least one near a lower end 17 of the heat exchanger 1 .
- the series of modules 2 is provided, at two opposite longitudinal end, with an end module 2 B, 2 C, wherein preferably a first series of connectors 3 connecting pairs of modules 2 form part of a first connecting duct 25 and a second series of connectors 3 connecting pairs of modules 2 form part of a second connecting duct 26 , the first and second connecting ducts 25 , 26 connecting opposite ends of the series of water duct parts 4 of the modules 2 .
- each central module 2 A comprises a first channel part 27 having a longitudinal direction L 27 extending at an angle to and preferably substantially perpendicular to the planes Q, V, at a the lower side of the heat exchanger, and a second channel part 28 having a longitudinal direction L 28 extending at an angle to and for example substantially perpendicular to the planes Q, V, at a the upper side of the heat exchanger 1 .
- the longitudinal axis L 27 , L 28 can be substantially parallel to each other.
- Each channel part 27 , 28 can comprise a mid section 29 , 30 , for example at or near the plane V, into which the inlet 11 or outlet 12 respectively opens.
- an opening 8 for insertion of a part of a connector 3 can be formed on either side of the mid section 29 , 30 .
- These openings 8 can be part of the channel part 27 , 28 , can be substantially cylindrical having a longitudinal axis parallel to and preferably coinciding with the longitudinal axis L 27 , L 28 respectively.
- the openings 8 can have a cross section D 8 slightly larger than the cross section D 29 , D 30 of the mid section 29 , 30 , such that a shoulder 31 is formed on either side of the mid section, defining a maximum insertion depth for the connector 3 .
- Each end module 2 B, 2 C similarly comprises a channel part 27 A, 28 A, and an opening 8 at at least one side. The opposite side can either be closed, for example by a wall or stop, or can be open, for connecting a further duct part, as will be explained.
- the channel parts 27 , 28 are connected for forming said connecting ducts 25 , 26 , having for example longitudinal axis L 27 , L 28 extending parallel to each other and connecting the various water duct parts 4 .
- the central modules 2 A have two opposite sides 63 , such as on either side of the plane Q, each side comprising an area 18 defining a part 6 of the flue duct 7 .
- Each of said areas 18 preferably comprises heat exchanging surface increasing elements 19 .
- These elements 19 can for example be pins, ribs, notches and the like, or combinations thereof, as are well known from the art as for example disclosed in EP0645591 or EP0843135.
- the end modules 2 B, 2 C each have only one such area 18 .
- the areas 18 and elements 19 are provided such that when a pair of adjacent modules 2 is interconnected, facing areas 18 of the modules form a flue duct portion 6 A, preferably with a labyrinth path for flue gasses passing through said duct portion 6 A from an inlet side 20 near the opening 13 to an outlet side 21 at the lower end of the heat exchanger, connected to an exhaust in a known manner, for example including a condensate collecting provision.
- the elements 19 extend from a wall 10 of the water duct part 4 and intensify the heat exchange between flue gas flowing through the flue duct 7 and the liquid, such as water, flowing through the water duct 5 .
- the elements 19 can extend substantially perpendicular to the planes Q and/or V and can have free ends 22 lying substantially in the plane Q.
- the modules 2 comprise a flue inlet 20 and a flue outlet 21 , wherein the part 6 of the flue duct 7 of each module 2 connects said flue inlet 20 with said flue outlet 21 .
- the inlet 11 for the part 4 of the water duct 5 in said module 2 can be closer to the flue outlet 21 than to the flue inlet 20 .
- the outlet 12 for the part 4 of the water duct 5 in said module 2 can be closer to the flue inlet 20 than to the flue outlet 21 .
- a counter flow pattern can be obtained between the flue gasses and the liquid, especially water.
- each connector 3 has a substantially cylindrical hollow configuration.
- the internal cross section Dc can be similar to the cross section D 29 , D 30 of the mid sections 29 , 30 of the channel parts 27 , 28 .
- the connector 3 can comprise an outer surface 32 with protrusions 33 extending outward, profiled such that seen in an insertion direction Fin into the opening 8 the protrusions 33 have an inclined surface 34 leaning backward.
- the protrusions can have a top 35 engaging an inner surface 36 of the opening 8 , such that these protrusions 33 counteract retraction of the connector 3 from the opening 8 when positioned therein.
- the protrusions preferably are compressed at least partly when inserted into said opening 8 .
- the outer surface 32 of the connector 3 and the inner surface 36 spaces 37 are formed.
- the wall 38 of the connector at least one opening 39 is provided opening into at least one of said spaces 37 .
- openings 39 are formed, opening in a series of such spaces, more preferably all such spaces 37 .
- modules 2 are provided with connectors 3 inserted into appropriate openings 8 .
- a connector 3 When assembling a heat exchanger according to the present invention, modules 2 are provided with connectors 3 inserted into appropriate openings 8 .
- a connector 3 When a connector 3 is placed in an opening 8 of a module, it is inserted to the appropriate depth, for example until it abuts the shoulder 31 , as shown in FIG. 2 .
- a bonding agent or glue is injected into at least some and preferably all of said spaces 37 in said opening 8 , and allowed to set, bonding the connector 3 to the module 2 .
- the module 2 is then provided with a bonding agent, for example the same or a similar bonding agent as used for the connector, on a side 63 thereof to be connected to an adjacent module, where after the two modules 2 are connected to each other, inserting part of the connectors 3 bonded to one of the modules into the appropriate openings 8 of the adjacent module 2 , as shown in FIG. 3 for one of the connectors.
- bonding agent is injected into spaces, preferably all remaining spaces defined by the connectors 3 and module 2 .
- an injector 40 can be inserted through an open end of the channel part 26 , 26 , passed the mid section 29 , 30 into the end of the connector 3 to be bonded, as schematically shown in FIG. 4 .
- the injector 40 can comprise channels 40 B connected to the openings 39 and a pump 40 A for forcing bonding agent into the spaces 37 .
- the opening 8 can be provided with an outside end 41 , which is provided with a first fitting element 42 , for example a beveled or chamfered edge 43 , wherein the connector 3 is provided with at least one protruding second fitting element 44 , for example a complementary beveled or chamfered ring, for cooperation with the first fitting element 42 .
- first and second fitting elements 42 , 44 can aid in defining an insertion position of the connector 3 , and can moreover further sealing and connection of the heat exchanger modules 2 .
- the heat exchanger 2 can have a Tichelmann flow pattern, as shown schematically in FIG. 5 .
- the water duct 5 is laid out such that the length of the flow path for the water between an inlet 50 and outlet 51 of the water duct 5 is substantially the same through each of the duct parts 4 of modules 2 .
- the first connecting duct 25 extends at the lower side of the heat exchanger and comprises the inlet 50 at a first longitudinal side 52 of the heat exchanger 1 , for example for connecting to a return line of a heating circuit (not shown).
- the opposite end 53 of the first connecting duct 25 can be closed, preferably by a wall of the relevant end module 2 .
- the second connecting duct 26 extends substantially parallel to the first connecting duct 25 , at an upper side of the heat exchanger 1 .
- This second connecting duct can have a first end 54 at the first longitudinal end 52 of the heat exchanger which can be closed off, for example by a wall 14 of the end module 2 A.
- the longitudinally opposite end 55 can be open and can form the outlet 51 of the water duct, for example for connecting to a feed line of a heating circuit (not shown).
- a third connecting duct 56 is shown, having a longitudinal direction L 56 substantially parallel to that of the first and second connecting duct 25 , 26 and positioned at the upper side of the heat exchanger 1 .
- the third connecting duct 56 can be a duct external to the modules of the heat exchanger but is preferably integrated.
- the third connecting duct 56 is formed in the same or a similar way as the first and second connecting ducts 25 , 26 .
- the modules 2 can each be provided with a third channel part similar to or identical to the first and second channel parts 27 , 28 , and provided with openings 8 for receiving a connector 3 , which again can be bonded or glued or otherwise fixed in the modules 2 .
- the open end 55 of the second connecting duct 26 can be connected to an end 58 of the third connecting duct 56 at the second longitudinal end 59 of the heat exchanger, whereas the outlet 51 can be formed at the opposite end of the third connecting duct 56 , at the first longitudinal end 52 at the heat exchanger, that is at the same side of the heat exchanger as the inlet 50 .
- This can be beneficial for connecting the heat exchanger to a heating circuit, improve compactness, increase heat transfer and efficiency and have other advantages.
- the third connecting duct 56 can be closed, apart from both longitudinal opposite ends.
- the second and third connecting ducts 26 , 56 can be connected by a properly bent, for example substantially U-shaped pipe 60 , bonded to the ends of the connecting ducts 26 , 56 , to which end the end module 2 can for example be provided with appropriate openings, for example similar to the openings 8 .
- the connecting pipe 60 can be integrally formed with, for example in the end module 2 C. such that when mounting the end module 2 C to an adjacent intermediate module 2 A the connection between the connecting ducts 26 , 56 is made automatically.
- the connectors 3 are preferably bonded into the modules, such that they form heat and pressure resistant connections for the water duct, which will during use be at the highest pressure in the heat exchanger.
- the water duct parts 4 in the modules can further be integrally formed and thus need no further sealing.
- An advantage of the present heat exchanger can be that it can be build up gradually, by for example starting with an end module, for example the first end module 2 B, then mounting subsequently a series of intermediate modules 2 A to said end module 2 B or a previous intermediate module 2 A respectively, and finally mounting the second end module 2 C to the last intermediate module 2 A of the series.
- Such series can comprise any desired number of intermediate modules, whereas a heat exchanger could even be formed by the two end modules 2 B, 2 C only.
- the end surfaces of the modules to be connected to each other can be formed mainly by end surfaces or ridges of relatively thin walls of the heat exchanger modules 2 .
- the second end module 2 can have a substantially closed end surface or wall 14 , with for example only the an outlet 51 of a water duct 5 .
- Said wall 14 can form part of a wall 10 of the water duct part 4 and can close the opening 31 of said module 2 .
- the opposite first end module can similarly be provided with a substantially closed end wall 14 , forming part of a wall 10 of the relevant water duct part 4 , and can be provided with an opening 13 for mounting a provision for creating flue gasses, such as a burner or fan, for example a modulating fan, a gas supply, ignition means and the like as known in the art.
- the first end module 2 B can be provided with the inlet 50 .
- the one end module can be closed at one side and comprise the pipe 60 , whereas the opposite end module can have the inlet 50 and outlet 51 , as discussed.
- heat exchangers according to the present invention have been disclosed by way of example only. These should by no means be understood as limiting the scope of the invention as disclosed. Many variations are possible, including but not limited to all combinations of parts and features of the embodiments specifically disclosed. Furthermore for example openings in modules, especially end modules can be closed by stops or the like, for example bonded or welded in placed, instead of by wall parts of the modules.
- the water duct parts and flue duct parts could be formed and shaped in a different manner, for example for obtaining a different flow path, altered resistance, or for amending the efficiency.
- the connectors and openings can be shaped differently, for example non cylindrical, such that the connectors can have one or more defined position in the opening.
- the modules and/or connectors can be made of different materials or by different methods.
- a heat exchanger could be provided with two or more separate water ducts, for example one for heating water to be used in a space heating circuit and one for heating tapping water. These any many such variations are considered falling within the scope of this disclosure.
Abstract
Description
- This application is a continuation of U.S. application Ser. No. 14/261,530 filed Apr. 25, 2014, now allowed, which claims the benefit of priority of Dutch application NL 2010725, filed Apr. 26, 2013. The contents of each of these prior applications is hereby incorporated by reference in its entirety.
- The invention relates to a heat exchanger comprising interconnected modules.
- Heat exchangers for use in for example domestic central heating boilers and/or tap water boilers are known in the art to be made for example of iron, steel or light metal, such as aluminum or aluminum alloy. These heat exchangers are known to for example be cast using lost core technology. It is known to cast a complete heat exchanger body in one piece, which negates the necessity of assembling the heat exchanger body but requires relatively large molds and casting equipment, and furthermore requires a different mold for each type or size of heat exchanger, for example for adjusting the capacity of the heat exchanger. Inside the heat exchanger flue passages and water ducts are provided for exchanging heat between flue gasses from a burner flowing through the flue ducts and water flowing through the water ducts. For forming these ducts the core has to be complicated and has to be removed after casting. To this end openings have to be provided through which the core can be removed. The ducts and passages then have to be thoroughly cleaned through said openings, after which the openings then have to be machined for receiving closures, such as screw stop with sealing O-rings, or stops are to be welded into the openings. This is very time consuming and costly and prone to failure. Moreover, the relatively large volume of the heat exchanger body can easily lead to damage to the body, for example during cooling and handling.
- In order to accommodate for smaller molds and easier adaptation to size and capacity heat exchangers have been proposed which comprise a series of individually cast modules. The modules can be assembled into a heat exchanger having a desired capacity by adjusting the number of modules. The smaller size of the modules makes casting and handling easier. Each module will comprise part of the flue duct or ducts and part of the water ducts. Obviously this has the effect that the modules have to be assembled, whereby the parts of the water duct or ducts and parts of the flue duct or ducts of the modules have to be interconnected in order to form continuous ducts.
- EP0404259 discloses a modular heat exchanger in which different modules are use for the flue ducts and the water ducts. These are alternatingly placed in a row, forming a heat exchanger body. Each module having a water duct has an individual inlet and outlet at diametrical opposing positions. Though not disclosed in EP0404259, the inlets and outlets of the modules will be connected by an inlet manifold and an outlet manifold respectively, for forming one water circuit through the respective modules. This requires individual connections for each inlet and each outlet to the respective manifolds. A combustion chamber is formed extending through all modules, integrating a burner in the heat exchanger.
- EP0645591 discloses a modular heat exchanger comprising a series of modules interconnected to form flue ducts and water ducts. Each module comprises two side metal assemblies, each including a closed gap for forming a single space for water. From a wall of said gap fins extend outward, such that when two such modules are placed adjacent to each other, such that a zig-zag flue duct is formed by the fins. Though not disclosed in EP0645591, the spaces for water in each of the modules will be connected by an inlet manifold and an outlet manifold respectively, for forming one water circuit through the respective modules. This requires individual connections for each inlet and each outlet to the respective manifolds. A combustion chamber is formed extending through all modules, integrating a burner in the heat exchanger, fed by a fan sending a mixture of gas and air into said burner space.
- EP0843135 discloses a modular heat exchanger comprising a series of modules, each having at least a water duct part and a flue duct forming part with heat exchanging elements. The flue duct forming parts are open to one side and in contact with a water duct part extending through said module for exchanging heat between flue gasses and water. At least the parts of the water ducts of successive modules are interconnected, forming at least one continuous water duct through and along a number of said modules. To this end each water duct part of a module comprises an inlet and an outlet. The inlets of the modules are connected by a feed manifold and the outlets are connected by a return manifold, the feed manifold and the return manifold comprising tubes extending alongside the series of modules, each inlet and outlet individually coupled to the respective manifold. In EP0843135 each module is individually provided with a burner and fan.
- These known heat exchangers are modular but need complicated assembling, especially of the manifolds to the water duct parts of the different modules. Moreover, these known heat exchangers are nor very compact, due to inter alia the externally provided manifolds. Furthermore these manifolds have to be tailored to the number of modules in a series. This means that for different capacities of heat exchangers different manifolds are needed.
- The present disclosure aims at providing an alternative modular heat exchanger. The present disclosure aims at providing a compact modular heat exchanger. The present disclosure aims at providing an modular heat exchanger reducing or mitigating at least one of the disadvantages of the known heat exchangers. The present disclosure aims at providing a modular heat exchanger which can be scaled easily to different capacities. The present disclosure aims at providing a method for forming an alternative modular heat exchanger.
- At least one of these and/or other aims is obtained with a heat exchanger, module, boiler and/or method according to this disclosure.
- In a first aspect a heat exchanger according to this disclosure can comprise a series of interconnected modules, each module comprising at least part of a water duct and part of a flue duct. At least the parts of the water ducts of successive modules are interconnected, forming at least one continuous water duct through and/or along a number of said modules. Water duct parts of two adjacent modules are interconnected by a connector inserted into an opening in at least one of the modules forming a sealing connection.
- In a heat exchanger according to the disclosure at least part of the manifolds connecting the water duct parts of the different modules may be integrated in the modules, connected by the connectors. In such embodiments by connecting the modules via at least said connectors, the water duct parts of the modules are directly coupled to each other, without the necessity of providing a manifold along the heat exchanger modules. Moreover this negates the necessity of individually connecting the water duct parts to such manifold extending alongside the heat exchanger modules. Furthermore this provides for automatic adjustment of the length of the manifold thus formed, by way of one or more connecting ducts incorporating the connectors, to the number of modules used in a heat exchanger.
- In a preferred embodiment the heat exchanger integrates in this way three connecting ducts for interconnecting the water duct parts of the different modules of a heat exchanger, such that the combined water duct through the heat exchanger has substantially a Tichelmann design. A Tichelmann design is a known principle of lay out of ducts in heating systems wherein the length of the ducts to and from a heating system should be the same for each component. Applied to a heat exchanger according to the present disclosure this means that the length and flow capacity between an inlet of the combined water duct system of the heat exchanger to the outlet of said water duct system should be the same for all paths through the different modules. In other words approximately the same amount of water should be fed per minute through each of the modules, in order to prevent intolerable temperature differences between the modules. Preferably the said inlet and outlet of the heat exchanger's combined water duct system are provided at the same longitudinal end of the series of modules, for example at an end module, such that connection to an appropriate heating system is made even more easy.
- In a heat exchanger according to the present disclosure preferably the manifolds are integrated in the modules, including said connectors, also because this will prevent undesired cooling of the water in the manifold, as will happen in the known heat exchangers with external manifolds, since these are subject to temperatures outside the heat exchanger, for example room temperature.
- The present invention shall be further elucidated in the following description, with reference to the drawings, in which:
-
FIG. 1 shows a heat exchanger, partly in cross section, having four modules; -
FIG. 2 shows part of a module of a heat exchanger, with a connector, in cross sectional view; -
FIG. 3 shows in cross sectional view part of two modules, connected by a connector; -
FIG. 4 shows in cross sectional view part of two modules interconnected by a connector and an injector; and -
FIG. 5 schematically shows the water flow of water through the heat exchanger. - In this description different embodiments of heat exchangers and parts thereof, as well as heating circuits equipped therewith are disclosed and described by way of example only. In these embodiments the same or similar parts have the same or similar reference signs. Combinations of parts of the embodiments shown are also considered to have been disclosed herein. In this description a heat exchanger as to be understood as an exchanger for exchanging heat between heated flue gasses from a burner and water flowing through one or more water channels within said heat exchanger. Preferably a flame receiving space is provided over and/or into which a burner can be inserted, such that said heated flue gasses are actively created, during use, within said heat exchanger. In an alternative the burner can be at least partly integrated in the heat exchanger, for example by extrusion, casting and/or machining. Such heat exchangers are especially, but not exclusively suitable in domestic and commercial heating systems such as boilers and central heating systems, such as for space heating and/or tap water heating systems.
- In the following description some or all of the parts can also be made by casting, such as but not limited to injection moulding, sand or otherwise lost core moulding or casting or the like, possibly combined with machining, such as but not limited to grinding, turning, milling, drilling and the like known machining methods. Also or alternatively other techniques can be used, where applicable, such as but not limited to extrusion.
- In this description light metal is at least to be understood as including non-ferro metal and non-ferro metal alloy having a density of less than 4500 kg/m3. Preferred materials are aluminum and aluminum alloy.
- In this description wording like top and bottom and sides are used as references only, without limiting the possible positioning of the heat exchanger or parts thereof in use. In this description top and bottom are used as defined in
FIGS. 1, 2 and 4 , where the flame receiving space is shown at the top and the outlet for gas is at the bottom. - In this description words like substantially and about indicate that slight deviations from a dimension or orientation to which they refer is allowable, for example less than 20%, more preferably less than 15%, for example up to 10%.
- In this description bonding has to be understood as forming an adhesive connection between two or more parts using an elastic bonding agent. Especially suitable is a glue or adhesive which after curing is still flexible and elastically deformable. Preferably the bonding agent is heat resistant to temperatures above 120° C., preferably above 150° C., more preferably above 170° C. A glue can be used having a temperature resistance up to 180° C. or above. A glue can be used having a use temperature range between about −4 and +120° C., preferably between about −20 and +150° C., more preferably between about −40 and +170° C., even more preferably between at least −55 and 180° C. or higher (e.g. PSI S406). A temperature range should be understood as a range of temperatures in which the glue maintains at least most of its elastic and bonding properties, such that in a heat exchanger at least the bonding maintains pressure resistant and fluid and gas tight. Pressure resistant is in this context to be understood as at least resistant to pressures in an adjoining space of above 2 bar, preferably above 4 bar, more preferably at least to 10 bar. The desired pressure resistance can be as high as 20 bar or above. One bar is 100.000 Pascal or 0.1 MPa. Reference can be made to adhesion to peel, according to ASTM C794.
- Elastic bonding agent, such as glue or adhesive should be understood as an agent which, after curing, has during use, a high yield strength and high yield limit. This means it can be stretched to a relatively high degree before breaking. The elasticity is preferably such that the yield limit is more than about 300%, preferably more than about 400%, more preferably more than about 550% and in particular preferably about 650% or more. Preferably this high yield limit is maintained over the temperature range during use of the heat exchanger. The yield limit can e.g. be measured according to ASTM D412.
- The bonding agent can be a silicone or elastomeric based adhesive, preferably curing at about room temperature to a rubber like component which is water and gas tight. A bonding layer formed by said bonding agent is preferably pressure resistant to at least about 4 Bar, more preferably to about 10 Bar and even more preferably to about 20 Bar or above, wherein the bonding agent is preferably applied to unprimed metal of the parts. An example of such bonding agent is Dow Corning 7091, which has a normal temperature range of use between −55 and +180° C., and a yield limit of about 680%.
- All kinds of combinations can be contemplated of yield limit, pressure resistance and temperature range.
- Dow Corning® 7091 Adhesive/Sealant is a high-performance, neutral-cure silicone that cures at room temperature to a tough, flexible rubber, suitable for the use described herein. Dow Corning 7091 remains flexible and stable from −55° to 180° C. (−67° to 356° F.), and is a one-component, non-sag sealant. It can have a tear strength of 86 ppi and a tensile strength of about 363 psi. This adhesive is only provided by way of example and should not be considered limiting the scope in any way.
- By using such a flexible bonding agent parts of the heat exchanger can be connected to each other, forming fluid, especially water, and gas tight seals without having to add gaskets, seals or the like, which will remain fluid and gas tight over a large temperature range. Moreover, such seals are relatively inexpensive and are pressure resistant to relatively high pressures. Furthermore, due to the high flexibility, problems with different expansion rates and directions of the different parts bonded together are avoided.
- Alternative or additional to bonding other connecting techniques and materials could be used, such as but not limited to welding, screws, nuts and bolts, clamping.
-
FIG. 1 shows aheat exchanger 1 comprising a series ofmodules 2, in side to side relationship. In this embodiment theheat exchanger 1 comprises four modules, interconnected byconnectors 3. Theheat exchanger 1 thus comprises a series ofinterconnected modules 2. Each module comprises at least apart 4 of awater duct 5 and apart 6 of aflue duct 7. At least theparts 4 of thewater duct 5 ofsuccessive modules 2 are interconnected, forming at least onecontinuous water duct 5 through and/or along a number of saidmodules 2 for example shown inFIG. 5 .Water duct parts 4 of twoadjacent modules 2 are interconnected by the connector orconnectors 3, to which end theconnector 3 is inserted into anopening 8 in at least one of themodules 2, forming a sealing connection. To this end the connector can be bonded or glued in the at least oneopening 8. Alternatively it can be fixed in a different manner, for example by press fitting, screwing or the like. Bonding or gluing can have the advantage that the opening does not have to be machined after casting, as is necessary for most if not all other means for mounting. - In preferred embodiments the connector or
connectors 3 are elements initially separate from themodules 2, and are inserted intoopenings 8 in twoadjacent modules 2 as shown for example inFIG. 2-4 . Theconnectors 3 can thus be made separately, from a material which can be the same or different from the material of the modules. Theconnectors 3 can be placed after casting of themodules 2 and after cleaning of some or all of the ducts orduct parts module 2, at least in part. In embodiments the saidconnector 3 is made of plastic and themodules 2 are made of metal. Preferably themodules 2 are made of light metal or light metal alloy, more preferably aluminum or aluminum alloy. - In the embodiment of
FIG. 1 theheat exchanger 1 comprises two central orintermediate modules 2A, afirst end module 2B and asecond end module 2C. Thecentral modules 2A can be of identical construction. Thecentral modules 2A can be substantially mirror symmetrical over a mid-plane V, extending parallel to opposite side planes Q at which themodules 3 are interconnected. Obviously more than two or just onecentral module 2A could be used in a heat exchanger, between theend modules central module 2A comprises acentral section 9 comprising two walls 10A, 10B extending in this embodiment substantially parallel to each other and to the planes V and Q, wherein between the walls 10A, B,cross walls 10C are provided, forming thepart 4 of thewater duct 5, having a meandering flow path between aninlet 11 and anoutlet 12. In the drawings theinlet 11 is shown at a lower end and theoutlet 12 is shown at an upper end of theduct part 4. As can be seen inFIG. 1 theduct part 4 can extend around anopening 13 near the upper end. Theopening 13 extends though the mirror plane V and opens into both sides of the module, such that acontinuous opening 13 extends through the series of modules, closed off at one longitudinal end by anend wall 14 of thesecond end module 2C, as will be explained later on. The area formed by the combinedopenings 13 can form aburner chamber 15 for the heat exchanger. - Between each pair of adjacent modules at least two
connectors 3 are provided, near two opposite sides of theheat exchanger 1, such that bothinlets 11 andoutlets 12 of theduct parts 4 of thedifferent modules 2 can be connected. InFIG. 2-4 aconnector 3 is shown in one of the connectingducts such connector 3 is provided near anupper end 16 and at least one near alower end 17 of theheat exchanger 1. As indicated the series ofmodules 2 is provided, at two opposite longitudinal end, with anend module connectors 3 connecting pairs ofmodules 2 form part of a first connectingduct 25 and a second series ofconnectors 3 connecting pairs ofmodules 2 form part of a second connectingduct 26, the first and second connectingducts water duct parts 4 of themodules 2. To his end eachcentral module 2A comprises afirst channel part 27 having a longitudinal direction L27 extending at an angle to and preferably substantially perpendicular to the planes Q, V, at a the lower side of the heat exchanger, and asecond channel part 28 having a longitudinal direction L28 extending at an angle to and for example substantially perpendicular to the planes Q, V, at a the upper side of theheat exchanger 1. The longitudinal axis L27, L28 can be substantially parallel to each other. Eachchannel part mid section inlet 11 oroutlet 12 respectively opens. On either side of themid section opening 8 for insertion of a part of aconnector 3 can be formed. Theseopenings 8 can be part of thechannel part openings 8 can have a cross section D8 slightly larger than the cross section D29, D30 of themid section shoulder 31 is formed on either side of the mid section, defining a maximum insertion depth for theconnector 3. Eachend module channel part 27A, 28A, and anopening 8 at at least one side. The opposite side can either be closed, for example by a wall or stop, or can be open, for connecting a further duct part, as will be explained. - By connecting the
modules connectors 3, thechannel parts ducts water duct parts 4. - The
central modules 2A have twoopposite sides 63, such as on either side of the plane Q, each side comprising anarea 18 defining apart 6 of theflue duct 7. Each of saidareas 18 preferably comprises heat exchangingsurface increasing elements 19. Theseelements 19 can for example be pins, ribs, notches and the like, or combinations thereof, as are well known from the art as for example disclosed in EP0645591 or EP0843135. Theend modules such area 18. Theareas 18 andelements 19 are provided such that when a pair ofadjacent modules 2 is interconnected, facingareas 18 of the modules form aflue duct portion 6A, preferably with a labyrinth path for flue gasses passing through saidduct portion 6A from aninlet side 20 near theopening 13 to anoutlet side 21 at the lower end of the heat exchanger, connected to an exhaust in a known manner, for example including a condensate collecting provision. In the embodiments shown theelements 19 extend from a wall 10 of thewater duct part 4 and intensify the heat exchange between flue gas flowing through theflue duct 7 and the liquid, such as water, flowing through thewater duct 5. Theelements 19 can extend substantially perpendicular to the planes Q and/or V and can havefree ends 22 lying substantially in the plane Q. Themodules 2 comprise aflue inlet 20 and aflue outlet 21, wherein thepart 6 of theflue duct 7 of eachmodule 2 connects saidflue inlet 20 with saidflue outlet 21. Theinlet 11 for thepart 4 of thewater duct 5 in saidmodule 2 can be closer to theflue outlet 21 than to theflue inlet 20. Theoutlet 12 for thepart 4 of thewater duct 5 in saidmodule 2 can be closer to theflue inlet 20 than to theflue outlet 21. Thus a counter flow pattern can be obtained between the flue gasses and the liquid, especially water. - In embodiments as shown in for example
FIG. 1-4 eachconnector 3 has a substantially cylindrical hollow configuration. In embodiments the internal cross section Dc can be similar to the cross section D29, D30 of themid sections channel parts connector 3 can comprise anouter surface 32 withprotrusions 33 extending outward, profiled such that seen in an insertion direction Fin into theopening 8 theprotrusions 33 have aninclined surface 34 leaning backward. The protrusions can have a top 35 engaging aninner surface 36 of theopening 8, such that theseprotrusions 33 counteract retraction of theconnector 3 from theopening 8 when positioned therein. The protrusions preferably are compressed at least partly when inserted into saidopening 8. Between theprotrusions 33, which may be circumferential to theouter surface 32, or can be at least partly formed like screw threads or otherwise suitably formed, theouter surface 32 of theconnector 3 and theinner surface 36spaces 37 are formed. Through thewall 38 of the connector at least oneopening 39 is provided opening into at least one of saidspaces 37. Preferablyseveral openings 39 are formed, opening in a series of such spaces, more preferably allsuch spaces 37. - When assembling a heat exchanger according to the present invention,
modules 2 are provided withconnectors 3 inserted intoappropriate openings 8. When aconnector 3 is placed in anopening 8 of a module, it is inserted to the appropriate depth, for example until it abuts theshoulder 31, as shown inFIG. 2 . Then a bonding agent or glue is injected into at least some and preferably all of saidspaces 37 in saidopening 8, and allowed to set, bonding theconnector 3 to themodule 2. Themodule 2 is then provided with a bonding agent, for example the same or a similar bonding agent as used for the connector, on aside 63 thereof to be connected to an adjacent module, where after the twomodules 2 are connected to each other, inserting part of theconnectors 3 bonded to one of the modules into theappropriate openings 8 of theadjacent module 2, as shown inFIG. 3 for one of the connectors. Then bonding agent is injected into spaces, preferably all remaining spaces defined by theconnectors 3 andmodule 2. To this end for example aninjector 40 can be inserted through an open end of thechannel part mid section connector 3 to be bonded, as schematically shown inFIG. 4 . Theinjector 40 can comprisechannels 40 B connected to theopenings 39 and apump 40 A for forcing bonding agent into thespaces 37. - The
opening 8 can be provided with anoutside end 41, which is provided with a firstfitting element 42, for example a beveled or chamferededge 43, wherein theconnector 3 is provided with at least one protruding secondfitting element 44, for example a complementary beveled or chamfered ring, for cooperation with the firstfitting element 42. Such first and secondfitting elements connector 3, and can moreover further sealing and connection of theheat exchanger modules 2. - In advantageous embodiments the
heat exchanger 2 can have a Tichelmann flow pattern, as shown schematically inFIG. 5 . In such flow pattern thewater duct 5 is laid out such that the length of the flow path for the water between aninlet 50 andoutlet 51 of thewater duct 5 is substantially the same through each of theduct parts 4 ofmodules 2. In the embodiment ofFIG. 5 the first connectingduct 25 extends at the lower side of the heat exchanger and comprises theinlet 50 at a firstlongitudinal side 52 of theheat exchanger 1, for example for connecting to a return line of a heating circuit (not shown). Theopposite end 53 of the first connectingduct 25 can be closed, preferably by a wall of therelevant end module 2. The second connectingduct 26 extends substantially parallel to the first connectingduct 25, at an upper side of theheat exchanger 1. This second connecting duct can have afirst end 54 at the firstlongitudinal end 52 of the heat exchanger which can be closed off, for example by awall 14 of theend module 2A. The longitudinallyopposite end 55 can be open and can form theoutlet 51 of the water duct, for example for connecting to a feed line of a heating circuit (not shown). - In the embodiment shown in
FIG. 5 a third connectingduct 56 is shown, having a longitudinal direction L56 substantially parallel to that of the first and second connectingduct heat exchanger 1. The third connectingduct 56 can be a duct external to the modules of the heat exchanger but is preferably integrated. In preferred embodiments the third connectingduct 56 is formed in the same or a similar way as the first and second connectingducts modules 2 can each be provided with a third channel part similar to or identical to the first andsecond channel parts openings 8 for receiving aconnector 3, which again can be bonded or glued or otherwise fixed in themodules 2. In such embodiments theopen end 55 of the second connectingduct 26 can be connected to anend 58 of the third connectingduct 56 at the secondlongitudinal end 59 of the heat exchanger, whereas theoutlet 51 can be formed at the opposite end of the third connectingduct 56, at the firstlongitudinal end 52 at the heat exchanger, that is at the same side of the heat exchanger as theinlet 50. This can be beneficial for connecting the heat exchanger to a heating circuit, improve compactness, increase heat transfer and efficiency and have other advantages. The third connectingduct 56 can be closed, apart from both longitudinal opposite ends. In embodiments the second and third connectingducts U-shaped pipe 60, bonded to the ends of the connectingducts end module 2 can for example be provided with appropriate openings, for example similar to theopenings 8. Alternatively the connectingpipe 60 can be integrally formed with, for example in theend module 2C. such that when mounting theend module 2C to an adjacentintermediate module 2A the connection between the connectingducts - In a
heat exchanger 1 according to the present disclosure, theconnectors 3 are preferably bonded into the modules, such that they form heat and pressure resistant connections for the water duct, which will during use be at the highest pressure in the heat exchanger. Thewater duct parts 4 in the modules can further be integrally formed and thus need no further sealing. By bonding the end surfaces Q of themodules 2 to each other, theflue duct parts 6 of the modules and theopenings 13 for forming the burner space are also properly connected and sealed, especially gas tight. The gas pressure shall normally be lower than the water pressure. - An advantage of the present heat exchanger can be that it can be build up gradually, by for example starting with an end module, for example the
first end module 2B, then mounting subsequently a series ofintermediate modules 2A to saidend module 2B or a previousintermediate module 2A respectively, and finally mounting thesecond end module 2C to the lastintermediate module 2A of the series. Such series can comprise any desired number of intermediate modules, whereas a heat exchanger could even be formed by the twoend modules - In embodiments the end surfaces of the modules to be connected to each other can be formed mainly by end surfaces or ridges of relatively thin walls of the
heat exchanger modules 2. As can be seen inFIG. 1 thesecond end module 2 can have a substantially closed end surface orwall 14, with for example only the anoutlet 51 of awater duct 5. Saidwall 14 can form part of a wall 10 of thewater duct part 4 and can close theopening 31 of saidmodule 2. The opposite first end module can similarly be provided with a substantiallyclosed end wall 14, forming part of a wall 10 of the relevantwater duct part 4, and can be provided with anopening 13 for mounting a provision for creating flue gasses, such as a burner or fan, for example a modulating fan, a gas supply, ignition means and the like as known in the art. Furthermore thefirst end module 2B can be provided with theinlet 50. In embodiments having the inlet and outlet at the samelongitudinal end 52 of theheat exchanger 1 the one end module can be closed at one side and comprise thepipe 60, whereas the opposite end module can have theinlet 50 andoutlet 51, as discussed. - In the present disclosure embodiments of heat exchangers according to the present invention have been disclosed by way of example only. These should by no means be understood as limiting the scope of the invention as disclosed. Many variations are possible, including but not limited to all combinations of parts and features of the embodiments specifically disclosed. Furthermore for example openings in modules, especially end modules can be closed by stops or the like, for example bonded or welded in placed, instead of by wall parts of the modules. The water duct parts and flue duct parts could be formed and shaped in a different manner, for example for obtaining a different flow path, altered resistance, or for amending the efficiency. The connectors and openings can be shaped differently, for example non cylindrical, such that the connectors can have one or more defined position in the opening. The modules and/or connectors can be made of different materials or by different methods. A heat exchanger could be provided with two or more separate water ducts, for example one for heating water to be used in a space heating circuit and one for heating tapping water. These any many such variations are considered falling within the scope of this disclosure.
Claims (20)
Priority Applications (1)
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US16/143,548 US20190022807A1 (en) | 2013-04-26 | 2018-09-27 | Modular heat exchanger with sections interconnected by connectors |
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NL2010725A NL2010725C2 (en) | 2013-04-26 | 2013-04-26 | Modular heat exchanger with sections interconnected by connectors. |
NL2010725 | 2013-04-26 | ||
US14/261,530 US10105801B2 (en) | 2013-04-26 | 2014-04-25 | Modular heat exchanger with sections interconnected by connectors |
US16/143,548 US20190022807A1 (en) | 2013-04-26 | 2018-09-27 | Modular heat exchanger with sections interconnected by connectors |
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US16/143,548 Abandoned US20190022807A1 (en) | 2013-04-26 | 2018-09-27 | Modular heat exchanger with sections interconnected by connectors |
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NL2010442C2 (en) * | 2013-03-12 | 2014-09-16 | Dejatech Ges B V | Heat exchanger and body therefore, and a method for forming a heat exchanger body. |
DE102014222563A1 (en) * | 2014-11-05 | 2016-05-12 | Mahle International Gmbh | Method for producing an assembly with a tubular body and a component |
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Also Published As
Publication number | Publication date |
---|---|
CN104236375A (en) | 2014-12-24 |
US10105801B2 (en) | 2018-10-23 |
EP2796803A1 (en) | 2014-10-29 |
NL2010725C2 (en) | 2014-10-29 |
US20140318739A1 (en) | 2014-10-30 |
TR201905765T4 (en) | 2019-05-21 |
EP2796803B1 (en) | 2019-02-27 |
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