WO1994016272A1

WO1994016272A1 - Heat exchanger element and method and device for producing same

Info

Publication number: WO1994016272A1
Application number: PCT/FR1994/000047
Authority: WO
Inventors: Joseph Le Mer
Original assignee: Joseph Le Mer
Priority date: 1993-01-15
Filing date: 1994-01-14
Publication date: 1994-07-21
Also published as: DE69402051D1; EP0678186B1; FR2700608A1; DE69402051T4; FR2700608B1; ES2101501T3; DE69402051T2; EP0678186A1

Abstract

A heat exchanger element consisting of a helically wound tube (1) for a flow of liquid heat transfer medium. The element has a flattened oval cross-section with its long axis substantially perpendicular to the helical axis (XX') or at an acute angle thereto, each tube turn (10) having plane surfaces (11) spaced apart from the adjacent turn surface by a gap having a constant height (h) which is substantially smaller than the width of the flattened tube cross-section. Braces (12) are provided for setting the spacing between the turns. Said element is useful for exchanging heat between two fluids.

Description

HEAT EXCHANGER ELEMENT, METHOD AND DEVICE FOR MANUFACTURING THE SAME

The present invention relates to a heat exchanger element. It also relates to the method of manufacturing this element as well as the device used to manufacture it. Finally, the invention also relates to a heat exchanger or a heat recovery unit using this type of element.

A heat exchanger element is traditionally formed from one or more tubes inside which circulates a first heat transfer fluid, for example water. In operation, the element is exposed to the thermal action of a second heat transfer fluid, for example air or combustion gases. The function of the element is to transfer heat from one of the two fluids to the other.

Thus, for example, in the case of a gas boiler, the function of the exchanger element is to heat the water circulating in the tubes from the hot gases resulting from the combustion of a gas burner.

In the case of an automobile radiator, the function of the exchanger element is to cool the engine water from the cold outside air, which is propelled by the fan in the form of a wind against the element. In all applications, the best possible yield is sought, this with a cost price and in a space which are, on the contrary, the lowest possible.

To obtain a significant heat exchange between the fluids located outside and inside the tubes, it is necessary to have the largest possible heat transfer surface. This generally leads to the use of very long tubes, folded into a serpentine, on which sometimes the fins are fixed (flat plates). Unfortunately, such an arrangement goes against both the compactness and the manufacturing price, because the fitting and fixing - generally by welding - of the fins on the tubes is a long and expensive operation. It has also been proposed, by document FR-A-2 476 808, to surround a radial burner with a sheet of rectilinear tubes, arranged along the generatrices of a cylinder coaxial with the burner. These tubes are fixed at each of their ends to water collecting boxes. The tubes have an oblong, flattened section, the major axis of which extends radially with respect to the axis of the burner. These tubes are spaced from each other by a gap which allows combustion gases to pass, but constitutes an explosion-proof barrier.

If this arrangement probably has the advantage of ensuring a suitable thermal transfer of the combustion gases to the liquid circulating in the tubes, it does not however solve the problem linked to the manufacturing cost, insofar as it is necessary to weld each of the tubes, at both ends, to the manifolds.

The Japanese patent abstract No. 63 220 091 relates to a heat exchanger element which consists of a helically wound tube in which a heat transfer fluid circulates. The tube has a flattened and oval cross section, the major axis of which is perpendicular to the axis of the propeller, an acute angle is formed with respect to the latter. This device performs a heat exchange between a fluid outside the tube, in particular air flowing radially from the outside towards the inside of the winding, and the inside fluid.

This document does not, however, give information on the relative dimensions of the thickness of the tube and the height of the gap between the turns of the winding. It also does not contain any indication of the constancy of the gap height.

However, it is essential to obtain a really efficient heat exchange, on the one hand that the gap height is very low compared to the thickness of the turn, and on the other hand that this height is perfectly calibrated and constant while throughout the winding. Otherwise, the flow of the external fluid is not uniform, and the heat transfer is poor because it is not homogeneous.

The main objective of the invention is to overcome these drawbacks, by proposing a heat exchanger element which is both extremely efficient in terms of efficiency, which is priced at low cost, can be easily mass produced, while being extremely compact.

Another object of the invention is to provide an element which can easily be associated with other identical or similar elements, so as to be able to meet all the needs of the clientele, both in terms of size and that of heat transfer capacity.

The heat exchanger element according to the invention consists of a tube of thermally conductive material, for example metallic, wound in a helix, in which is intended to circulate a heat transfer fluid, this element having a flattened and oval cross section whose major axis is substantially perpendicular to the axis of the helix or forms an acute angle with respect to the latter, each turn of the tube having planar faces which are spaced from the faces of the adjacent turn of a gap of constant height.

According to the invention, the height of the gap separating two adjacent turns is significantly smaller than the thickness of said cross section, and the spacing between two adjacent turns is calibrated by means of spacers. Preferably, the thickness of the flattened tube is 3 to 10 times greater than the thickness of the space between turns. Thus, the fluid flowing between the turns takes the form of a thin blade, which licks the large faces of the tube during its passage, with efficient heat transfer. Furthermore, the presence of spacers spacing gauge inter-turns, ensuring a rigorously constant character of the thickness of this blade of fluid in any zone of passage of the element, which is essential in terms of thermal efficiency.

Thus a primary role of the spacers is to ensure consistency of the transparency of the exchanger element. A second role - not least - is to prevent deformations of the wall of the flattened tube which can result from significant variations in internal pressure.

Furthermore, according to a certain number of additional, but not limiting, characteristics of this element:

- These spacers are bosses, or corrugations, formed in the wall of the tube, on at least one of the flat faces; - Said bosses extend radially relative to the axis of the propeller;

- The two ends of the tube are extended tangentially by sections connecting to portions forming cylindrical end pieces;

- The outer planar faces of these end turns are located substantially in planes parallel to each other, and perpendicular to the axis of the propeller.

Thus, thanks to the above arrangement, it is possible to stack several elements one after the other, coaxially, and the gap separating two elements will have the same characteristics, as for their height, as the gaps between two turns of the same element.

In one embodiment, the internal edge of the turns is embossed, in order to produce turbulence of the fluid before they pass between the turns, which has the effect of further increasing the quality of heat exchange.

The manufacture of such an element is done, in accordance with the method according to the invention, in the following manner: a) a cylindrical tube is bent helically; b) it is filled with a fluid; c) the wall of the tube is crushed so as to give it a flattened and oval section, the major axis of which is substantially perpendicular to the axis of the propeller, while simultaneously reducing the pitch of this propeller; d) maintaining, during step c), the fluid contained in the tube at a substantially constant and controlled pressure, so as to prevent the collapse of its wall.

Preferably, in step c) described above, shaping dies are used which have, in hollow, imprints of shape complementary to the bosses, or corrugations, intended to play the role of spacer between the turns and, at the end of the operation, the fluid contained in the tube is subjected to a high pressure to force its wall to conform to the shape of these imprints.

A device which can be used to carry out this method, a device which also forms part of the present invention, comprises: a press comprising a fixed sole and a movable plate;

- actuation means used to move the movable plate relative to the fixed base; - two sets of complementary half-dies, of generally semi-circular shape, capable of being positioned between the turns of the tube to be formed, these two sets being positioned, in the working position, between the fixed sole and the movable plate.

According to a certain number of advantageous, but not limiting, characteristics:

- One of these assemblies is movable as a block and can be removed from the press for the establishment of the tube to be formed, and - at the end of the operation - for the removal of the tube formed;

- These half-dies have flat faces used to crush the tube, these faces being inclined (during forming) relative to a plane perpendicular to the axis of the propeller;

- The constituent half-dies of each half-assembly are guided relative to each other by means of columns;

- These columns pass through elongated holes formed in the dies, which allow their lateral inclination;

- The device comprises cylinders used to separate the half-dies from each other;

- The device includes means for sealingly closing the two ends of the tube during forming, and for introducing a fluid under very high pressure therein.

In a possible embodiment of a heat exchanger using at least one element according to the invention, the latter is arranged in the vicinity of the burner in a position such that the combustion gases pass through the interstices separating its turns. In an improvement of this type of exchanger, it comprises several elements according to the invention, at least one of which is crossed by the combustion gases from the inside to the outside, while at least one other element is crossed by these gases in the opposite direction. A subject of the invention is also a heat recovery unit for a boiler, which comprises at least one element according to the invention, in which circulates water to be heated, and which is exposed to the flow of burnt (and hot) gases. escaping from the boiler. Other characteristics and advantages of the invention appear from the description and the accompanying drawings which show preferred embodiments thereof.

In these drawings:

- Figure 1 is a general view, in perspective and partially cut away in one of the turns, of an element according to the invention;

- Figure 2 is a side view of the element of Figure 1;

- Figure 3 is a detail view showing the juxtaposition of two turns constituting the element, these two turns being cut transversely by the plane III-III of Figure 4;

- The figure is a partial side view of the turns of Figure 3;

- Figure 5 is a side view of a round tube (circular section) helically preformed, from which the element is made; - Figure 6 is a perspective view of a "standard" forming half-die which is used for the manufacture of the element;

- Figure 7 is a cross and radial section of the matrix of Figure 6; - Figure 8 is a particular half-matrix, involved in the forming of one of the end turns of the element;

- Figure 9 is a schematic front view, partially cut away, of the element forming device;

- Figure 10 is a schematic view, partially broken away, of the movable assembly of half-dies;

- Figure 1 1 shows, seen in the separation plane of the two sets of half-dies, one of these sets inside the press, the latter being in the closed position, but empty (this is ie in the absence of a tube); - Figures 1 1A and 1 1B are schematic views, respectively from above and in cross section along the plane BB of Figure 1 1A, of the mounting of a half-matrix on guide columns, this mounting allowing a slight inclination lateral of the matrix; - Figure 12 is a sectional view of the device for sealingly introducing a fluid inside the tube during forming;

- Figure 13 is a schematic view showing a tube being preformed on a tube winding mandrel; - Figure 14 shows the press in the open position, a preformed tube having been introduced therein before the forming operation;

- Figures 15, 15A, 15B, 15C show the wall of the tube, between two dies, during the different stages of forming;

- Figure 16 is a section showing, partially, the device of Figure 12 during operation;

- Figure 16A is an end view of one of the ends of the tube constituting the element formed;

- Figure 17 is a view similar to Figure 14, showing the open press, at the end of forming; - Figure 18 shows, in axial section, a gas boiler heat exchanger equipped with a burner and comprising several elements similar to that of Figure 1;

- Figures 19 and 20 schematically show alternative designs of this heat exchanger; - Figure 21 is a schematic view showing a heat recovery unit using elements according to the invention;

- Figures 22 and 23 are possible variants of the heat recovery unit;

- Figures 24 and 24A are schematic top views of two exchangers according to the invention, showing two possible arrangements of the end portions of the exchanger;

- Figures 25 and 25A show possible variants as to the shape and arrangement of the corrugations provided on the flat face of a turn; - Figure 26 is a cross section of two adjacent turns, in an embodiment according to which the two flat faces of each turn are provided with bosses forming spacers;

- Figure 27 shows, in axial section, a double winding exchanger, composed of two elements whose coils are nested one inside the other;

- Figure 28 is a schematic top view of an assembly formed of two concentric elements;

- Figure 28A is a partial side view (a single turn) of the assembly of Figure 28;

- Figure 29 is a top view of a variant of the element of Figure 1;

- Figure 30 is a schematic sectional view of the element of Figure 29, along the section plane XXX-XXX of this figure; - Figure 30A is a sectional detail of two adjacent turns;

- Figures 31 and 31A are schematic detail views showing the tooling and illustrating the forming operation which makes it possible to produce the element of Figure 29; FIG. 32 schematically represents a heat exchanger which has several elements conforming to that of FIG. 29.

The heat exchanger element 1 shown in Figures 1 to 4 consists of an oval and flattened section tube wound in a helix so that the major axis of its cross section is substantially perpendicular to the axis XX 'of l 'propeller. This tube is preferably made of metal, for example stainless steel. It consists of a number of turns 10, for example four in number, whose large flat faces, referenced 11, are spaced from the faces of the adjacent turn by a gap of constant height. This height is significantly less than the thickness of the flat turns. The end portions 14, 14 ′ of the tube, rectilinear, extend tangentially towards the outside, and end in cylindrical ends 15, 1 ′. The transition between the flattened parts 14 and the cylindrical end pieces 15 takes place gradually. Each turn carries, on one of its flat faces, bosses (or corrugations) 12 formed in the wall of the tube, arranged substantially radially with respect to the axis XX '. Each boss 12 comes to bear against the flat face (not provided with bosses) of the adjacent turn. These bosses have a definite height which serve as spacers, precisely calibrating the height of the interstices separating the turns.

Similarly, the bosses 12 located on one of the outer turns of the winding, are intended to come to bear against the turn with a smooth flat face of another element, when combined, by stacking them coaxially , several identical or similar elements.

According to an important characteristic of the invention, the external faces of the two external turns of the winding are situated substantially in planes P, P '(see FIG. 2) which are parallel to each other and perpendicular to the axis XX'. Thanks to this arrangement, it is possible to stack several elements coaxially while maintaining a constant spacing of all the turns, whether or not they belong to the same element. Of course, this arrangement assumes a gradual variation in the thickness of the outer turns of the winding, as can be seen in particular in Figure 2. Furthermore, to obtain this flatness, a recess 16 must be provided in the most thick end coils, so as to allow the end portions 14, 14 'to pass.

Solder points, for example brazing 17, are advantageously provided at the periphery of the winding to maintain the latter in a state of slight axial compression, which ensures the correct application of all the turns against each other. others.

Preferably, the internal edge of the turns has a regularly embossed wall, these bosses being intended to disturb the flow of the fluid passing between the turns in order to improve the heat exchange, as will be explained below.

It is of course possible, if desired, to remove the cylindrical end caps 15 and 15 ′, for example by sawing as symbolized in FIG. 1 by the strong mixed lines S and S ′. The element which has just been described is for example made from a stainless steel tube having a diameter of 18 mm, a wall thickness of 0.5 mm, and which is preformed into a helix, as shown in the Figure 5, this propeller having an average winding diameter of 210 mm and a pitch of about 25 mm.

An element is then obtained, still wound in a helix, but with a noticeably smaller pitch, of the order of 6 to 6.5 mm. The mean diameter of the winding remains unchanged (around 210 mm). The width of the turns 10, referenced J_ in Figure 3, is of the order of 24 mm. Their thickness is of the order of 5 to 6 mm. The height h of the gap separating the turns, which also corresponds to the height of the bosses 12, is of the order of 0.5 to 1.5 mm.

It goes without saying that these different dimensional characteristics are very variable; they will be adapted to the functional characteristics required for the heat exchanger element, in particular as regards its heat exchange capacity and its size.

As already said, the winding 100 shown in FIG. 5 is produced from a cylindrical tube preformed into a helix. 101 and 101 ′ have been designated its rectilinear end portions, which extend tangentially with respect to the propeller and are intended to constitute the ends 14, 15 and respectively 14 ′, 15 ′ of the element. The turns of the winding 100 have been designated by the reference 102. Preferably, the internal edge of the tube is embossed, so as to present ring segments 103 corresponding to corrugations of the wall of the tube. In a particularly simple manner, this boss 103 can be obtained by winding the tube on a mandrel of diameter slightly too small compared to the winding that it is desired to obtain. There is thus a regular circumferential over-compression of the internal portion of the wall during the helical bending of the tube. Figures 6 and 7 show a "standard" half-matrix intended to be used for the shaping of the element, in association with other identical or similar half-matrices. It is intended to carry out the shaping of an intermediate half-turn. The half-matrix 2 shown has a general semi-circular shape. It has a semi-annular external part 20, of rectangular section, which is extended inwards by another annular part 21 of smaller thickness. The upper and lower faces 24 of the part 21 are flat. They are the ones that will be used to crush the tube, in order to give it a flattened shape, as will be explained below.

In one of the faces 24, in this case in the lower face when the half-matrix 2 is in the working position, substantially horizontal, is hollowed out a series of radial recesses whose shape is complementary to that of the bosses 12 that one wishes to achieve in the wall of the element.

The part 21 of thinner thickness is connected to the outer semi-annular part 20 by a flange 23. In the part 20 are drilled holes 22 which, as will be seen later, are intended to receive guide columns. These holes are slightly elongated, forming apertures whose major axis is parallel to the diametrical plane constituting the joint face 29 of the half-matrix. The ends of the elongated holes 22 are semi-cylindrical. The half-matrix 2 'represented in FIG. 8 is similar to that which has just been described, and that is why the corresponding elements have been assigned the same reference sign, but with the prime index ('). It is the lower matrix of one of the two sets of half-matrices which will be described later, and more precisely of the mobile assembly. This half-matrix is used for shaping one of the ends of the winding, the end which comprises a rectilinear section and a cylindrical end-piece. For this, the face of the central part 21 'which is used for crushing the tube extends only over a quarter of circumference and is extended by a rectilinear portion 25'. The latter opens at the level of the part 20 ′ in a semi-cylindrical cavity 26 ′. Of course, the half-matrix intended to cooperate with the half-matrix 2 ′ has, on its lower face, a complementary configuration, and in particular a part with semi-cylindrical groove coming to penetrate into the part 26 ′ to constitute a circular channel coming fit against the end portion of the tube, and contain it during forming, as will be explained later.

The device shown in Figure 9, referenced 3, consists of a hydraulic press comprising a horizontal fixed sole 30 carried by a frame 31, and a movable plate 32; the latter is also arranged horizontally, above the sole 30. It is fixed to a plate 340 mounted at the end of the rod 34 of a hydraulic cylinder 33. The latter is mounted on an element 310 of the fixed frame. The jack 33 is a relatively powerful double-acting jack, the extension of which causes the plate 32 to be lowered and brought closer to the sole 30 (closing of the press) while its retraction causes the plate 32 to rise ( press opening).

The tool associated with this press essentially comprises two sets of half-dies 2A and 2B of the type described above. The first assembly 2A is fixed and permanently mounted between the sole 30 and the plate 32. The other assembly 2B is mobile. It is fixed to a carriage 4, for example mounted on rollers, which can be moved in translation by means of a double-acting pneumatic or hydraulic cylinder 40, the rod of which is connected by a connecting piece 41 to the carriage 4. In FIG. 9, the mobile assembly has been artificially represented in the two extreme positions that it can occupy, the working position inside the press and a separated position - referenced 2B '- which, as will be seen further, allows to set up the tube to be formed, then to remove the formed element. In its movement, the carriage 4 is supported by a horizontal guide 42. In Figure 9, there is shown in broken lines the element 41 and the rod of the cylinder 40 when the latter is in the extended position, assembly 2B 'away from the press.

When the assembly 2B is inside the press, the half-dies composing this assembly are applied by their bearing faces 29 (see FIGS. 6-7) against the dies 2 of the other assembly, then forming a single assembly with circular dies, which describe an internal helical recess, because in fact each upper half-die has a side 29 in abutment with the lower half-die, and so on. Each set of half-dies is guided in translation, in the vertical direction, by vertical rods - or columns - 200. It is for example provided three guide columns per set, regularly distributed. However, in order to make the figures easier to read, only one column 200A, respectively 200B has been shown in FIG. 9 for each of the sets 2A, respectively 2B. These columns are fixed at their lower end in the lower half-matrix of each assembly. They penetrate through their upper end into bores formed in the movable plate 32 of the press. The amplitude of lifting of the movable plate 32 is sufficient for it to be able to disengage completely from these columns, so that the removal of the assembly 2B is possible, as is easily understood by simply observing FIG. 9 .

It should be noted that the two upper half-matrices, which serve to form one of the ends of the element, consist of a single piece 2 "fixed permanently to the plate 32. Half of this matrix 2" which comes in correspondence with the half-dies constituting the mobile assembly 2B has imprints similar to that of the part 2 ′ which has been described with reference to FIG. 8, because it serves to form the upper end of the element, and in particular the cylindrical end cap. When the movable plate 32 is in the high position, the dies 2A can be separated from each other using a series of suitable jacks, not shown. Thus, for example, three pneumatic cylinders are provided, regularly distributed around the periphery of the set of half-dies, and coming to actuate the upper half-die 2A. Connecting elements between the half-dies, such as tie rods, are provided so that the lifting of the upper matrix correlatively and successively causes the lifting of each of the dies, this with a well-defined spacing. Such an arrangement avoids having to resort to a set of jacks for each half-die. A similar arrangement, schematically represented in FIG. 10, is provided for lifting the half-dies 2B of the mobile assembly. This lifting is carried out using a jack 43 whose vertical rod (not shown) is fixed to the carriage 4. The body of the jack is fixed to the upper matrix 2B. This leads, through a 14

connecting piece 290, the half-matrix located below, but not the lowest movable half-matrix, located just above the fixed half-matrix 2 '. Indeed, it is moved by a set of jacks 44 independently of the others, for a reason which will be explained later. The lower and upper half-dies are supported respectively against the sole 30 and against the plate 32 by horizontal flat faces, perpendicular to the working direction of the press. These half-dies have a slightly bevelled shape, so that they are applied against the other half-dies according to planes inclined laterally, as can be seen in FIG. 1 1. It is this inclination which makes it possible to respect the propeller pitch. This provision is of course valid for the two sets of half-dies, but in opposite directions. This faculty of tilting, symbolized by the arrow G in FIG. 11B, results from the elongated shape of the holes 22 in which the columns 200 engage. It is on the other hand important that the half-dies cannot tilt in the other direction, so that the half-dies of the two assemblies remain well joined against each other, by their face of joint, during the forming operation.

The device 5 shown in FIG. 12 essentially comprises a body 50, of generally cylindrical shape, and a pneumatic cylinder 51 coaxial with the body 50 to which it is fixed. Along the axis of the assembly 50-51 can slide a rod 52 integral with a piston 521 moving inside the cylinder 51, and whose free end carries a head 520, also cylindrical, capable of s' fit without play inside the end 101 of the tube to be formed. The rod 52 is traversed by a central bore 522 which is connected by suitable means to a conduit 56 connected to a hydraulic unit H at high pressure, via a control valve 560. The piston 52 1 is double effect, and suitable conduits 57, 57 ′, which are connected to a distribution valve 570 make it possible to bring compressed air on one side or the other of the piston, from an air source tablet AC. Valve 570 is designed to bring the chamber on one side of the piston to atmospheric pressure when the other chamber is under pressure, and vice versa. The head 520 is surrounded by a part 54 in the form of a sleeve, forming an integral part of the body 50, the space 55 separating the wall of the head 520 from the internal wall of this sleeve corresponding to the wall thickness of the tube. In the space 55, behind the head 520 are provided _j anointed sealing. These are deformable rings 53, liable to deform radially as a result of the recoil of the rod 52.

The half-dies 2 'and 2B intended for the shaping of one of the end portions of the element, which are also partially represented in FIG. 12, have indentations which include complementary semi-cylindrical portions 260, 260' able to be applied against the outer wall of the sleeve 54. The indentations 26, 26 'are intended to contain the outer wall of the tube, in its cylindrical portion and in its connection portion with the flat part, during forming. As already said, the imprints 28 serve to form the bosses in the wall of the tube.

The helical preforming of the cylindrical tube is illustrated in FIG. 13. This shaping is done conventionally, when cold, on a mandrel 6 of generally cylindrical shape, carried by a rotary axis 60, as symbolized by the arrow F. In the wall of the cylinder 6 is formed a helical groove 61, of semi-cylindrical section. Its radius corresponds to the radius of the tube. The pitch of the groove corresponds to the pitch of the tubular winding 100 that it is desired to obtain. One 101 of the end portions of the tube is made integral with the rotary mandrel 6, and the tube is guided by suitable means on the mandrel. After shaping, the winding is extracted by unscrewing, that is to say rotating the mandrel in the opposite direction while the tube is immobilized.

We will now explain, with particular reference to FIGS. 14 to 17, in what way an exchanger element according to the invention is manufactured from this pre-formed helical tube.

The press and its tools are brought first of all to the state shown in FIG. 14, open press (cylinder 33 retracted) and movable assembly of half-dies spaced from the press (cylinder 40 in extension). The cylinders 43 and 44 are extended so that all of the half-dies 2B are in the mutual spacing position; similarly, the jacks ensuring the spacing of the half-matπces 2A are extended.

In this state of spacing of the dies, the height of which corresponds substantially to the pitch of the winding 100, it is possible to place the latter inside the set of movable half-dies, as illustrated in the figure. 14. Each turn is inserted between two half-dies. The lowest turn is inserted between the special 2 'matrix and a standard matrix. The upper coil remains clear. In this position, the rectilinear end portions 101 and 101 ′ of the tube (not shown) protrude laterally from the set of dies, on either side of it, transversely to the plane of FIG. 14. The operator then sets up on each of these parts 101, 101 'a device 5 for closing and supplying fluid. For this, it engages each of the devices on the end of the tube in such a way that this end comes to be fitted around the head 520, inside the part 54 in the form of a sleeve. The carriage 4 has means, not shown, for retaining the device 5 in the axial direction, after it has fitted into the tube. The tightness of the connection is obtained by actuation of the piston 521 in the backward direction, ensuring the compression of the seals 53.

The jack 40 is then retracted, in order to move the carriage 4 to bring the mobile assembly of the half-dies, as well as the tube 100 retained by it, inside the press. During this movement, the half-turns not contained in the half-dies 2B are inserted between the half-dies 2A. Each turn of the tube is thus perfectly trapped between complete dies.

The ability of the half-dies to tilt slightly in the lateral direction (arrow G, FIG. 1 1B) facilitates this positioning, the working faces 24 of the dies substantially following the pitch of the propeller.

The press is then put into action, by extension of the hydraulic cylinder 33, the movable plate 32 of the press engaging on the guide rods 200. At the same time, a liquid is introduced into the tube. One of the devices 5 is designed to bring this liquid, for example oil or water, while the other device 5, provided at the other end of the tube, allows the escape of air initially present in the tube. The liquid is then trapped in the tube, by means of valves suitable for moderate pressure, for example of the order of 10 ° Pascal (10 bars). A calibrated valve ensures that this pressure remains constant throughout the first phase of the process.

In Figure 15 is designated by the reference L l the liquid, at moderate and controlled pressure, which is contained in the tube. It will be noted by observing this figure the presence between two adjacent dies, in the annular portions 20, of an elastically deformable washer 210. In practice, several of these washers are regularly distributed over the entire circumference of the dies. They are housed in circular grooves made in the lower matrix. Their function will be explained later.

The closing movement of the press, symbolized by the arrow A1 in FIG. 15A, continuing, the wall of the tube 100 is progressively crushed between the faces 24 of the half-dies. During this operation, the presence of the liquid L1 inside the tube prevents the wall from sagging towards the inside of the tube, and a section of tube 100 ′ is obtained in oval shape, having two opposite perfectly flat faces and two perfectly rounded edges, practically in an arc.

In the absence of the liquid L l, the central part of the wall would deform, and the section would take the approximate shape of a Z. At the end of this step, the two half-dies come into abutment, one against l 'Other by the external parts 20, which limits the crushing of the wall of the tube; on the contrary, the elastic rings 210 are completely crushed inside their groove.

As already said, before this operation, the pressurized air was brought into the cylinder 51 by the conduit 57 ′, in front of the piston 521, which had the effect of causing the head 520 to move back and to compress the washers d sealing 53. The liquid cannot therefore escape from the tube. It is important that during forming the ends of the tube are perfectly contained between the half-dies and in the sleeve 54, so as to ensure a gradual transition between the cylindrical part (not deformed) and the flat part (shaping) of the end section. The press being kept in the closed state, the pressure of the liquid contained in the tube is then increased rapidly and significantly. The liquid under high pressure is referenced L2 in FIGS. 15B and 16. As an indication, its pressure is of the order of 6.75 x 10 ⁷ Pascal (675 bars). It will be noted that the pressure within the liquid (symbolized by arrows in FIG. 16) tends to strongly compress the sealing washers 53, the device being somehow "self-sealing". Under the effect of this high pressure, the wall of the tube deforms at the level of the recesses 28, which forms the bosses 12. It is important to note that, given the importance of the pressure used, the tube must be perfectly contained over its entire length and in particular in this end portion, to avoid the formation of hernias, causes of rupture of the wall. This is particularly true in the areas where the cylindrical ends meet the flat part of the tube.

The pressure of the liquid is then dropped, and it is expelled from the tube using compressed air. The movable plate 32 is then raised. Given the elasticity of the washers 210, which relax, the dies slightly deviate from one another, as symbolized by the arrow A2 in FIG. 1 C. The elastic stroke of the washers is chosen so that the mutual spacing of the dies is slightly greater than the depth of the recesses 28, which allows the extraction of the tube formed 100 "(arrow A3, FIG. 15C).

The mobile assembly of mobile half-dies is then moved away from the press, and brought into the position of FIG. 17. There is no difficulty in removing from the press the part of cylindrical end piece 15 of the upper coil of the press, since the die 2 ", which participated in the shaping of this nozzle, is lifted with the plate 32.

The piston rod 52 is advanced, by air intake behind the piston 521 on each side of the device 5, which allows the tube ends of these devices to be extracted. These are removed. The jack 44 is then extended to separate the penultimate half-matrix 2B from the lowest matrix 2'B. This spacing is sufficient to allow the passage of the cylindrical endpiece 15 '. Of course, the jacks 43 are not actuated, so as not to deform the turns of the formed tube, the pitch of which is substantially smaller than the pitch of the initial preformed tube.

The element 1 can be removed manually, by a horizontal translational movement. It then suffices to make the brazing points 17 to obtain the finished element.

It goes without saying that all the steps which have just been described can be easily mechanized and controlled by a programmable automaton; the establishment of the tube before forming and the removal of the formed tube can be carried out by a manipulator robot.

Referring to Figure 18, we will now describe a heat exchanger for a boiler equipped with a gas burner, which comprises a number of heat exchanger elements according to the invention, in this case four of these elements. The exchanger 8 shown in the figure comprises a cylindrical burner 7, of axis XX ', mounted inside a hollow body 8. The latter has a generally cylindrical shape and is provided with a bottom 84 having a flange (or sleeve) 80 coaxial with the axis of the burner, through which the mixture of gas and air to be burned. The exhaust of the burnt gases is done by a flange (or cuff) 81 disposed at the opposite end of the body 8.

The burner 7 is immobilized against the bottom 84 by means of a flange 83 retained by threaded rods 85. In the axial direction, the cylindrical burner 7 has a length substantially shorter than the length of the body 8. At the end of the burner 7 which is opposite the bottom 84 is fixed a ceramic disc 82, also fixed to the threaded rods 85. The disc 82, the diameter of which is slightly larger than that of the burner 7, comparti¬ lies inside the body 8 in two spaces 800, 801 located respectively at the level of the burner and beyond it. This exchanger is equipped with four elements 1 according to the invention, stacked coaxially on each other and arranged inside the body 8. Their diameter is a little larger than the diameter of the burner. Two of the elements, referenced la and lb are inside the space 800, that is to say facing the burner 7. The next element is straddling the two spaces 800, 801, sa central part therefore coming opposite the disc 82. Finally, the last element ld is in the space 801.

The diameter of the disc 82 corresponds substantially, apart from the engagement clearance, to the internal diameter of the elements 1, so that the edge of the disc comes into contact with the element 1 e.

The burner 7 has an annular wall pierced with a multitude of small holes arranged radially and allowing the passage of the air + gas mixture. Combustion takes place outside the burner, the base of the flames being against the external wall 71 of the burner.

Reference 70 has designated an electrode, of a type well known per se, used for igniting the burner and controlling the flame.

The wall 71 of the burner is located a short distance from the internal edge of the turns of the elements 1, for example approximately 20 mm from this edge. The boiler concerned is a domestic condensing boiler, which is used to heat water.

The cold water (EF) arrives via a conduit 149 and is connected by two bypass conduits 150c, 150b to the inlet portions of the two elements le, respectively l b. The outputs of these two elements are connected, via two taps 150'c and 1 50'd to a pipe 1 51 'which, in turn, brings water, via two taps 1 50' a and 150 'b respectively to the two elements la and l b. Finally, the water leaves these two elements by two diversions 150a, 1 50b connecting to a pipe 151 for evacuating hot water (EC). The connections of the various conduits to the end caps (cylindrical) of each element are made in a conventional manner, by connections known per se.

The elements are therefore connected in parallel two by two, and the two pairs are connected in series. In operation, the air-gas mixture (GA) is brought through the flange 80 inside the burner. Combustion takes place on the outer wall 71 thereof. The hot gases from combustion, the temperature of which, for information, is of the order of 1100 ° C., escape radially and pass through the interstices, of well calibrated height, separating the turns from the elements la, lb and of part of it. There is therefore a flow of hot gas blades, symbolized by the arrows HJ_, which will lick the flat faces of the turns of the exchanger, and heat the water circulating inside of it. The flow is very regular given the uniformity of thickness of the interstices. On the other hand, due to the large surface area of the flat faces, the heat transfer from the burnt gases to water is particularly efficient.

After their passage from the inside to the outside of the elements l a, l b and partially the, the partially cooled gases arrive in the annular space located inside the body 8, but outside the exchanger. They will then cross the interstices between the turns of the element l d and the other part of the element le, from the outside to the inside, as symbolized by the arrows H2. A large part of their residual heat is thus transferred to the liquid circulating in the exchanger. Finally, these gases, the temperature of which has dropped for example to around 50 ° C., escape through the collar 81, as symbolized by the arrows H3. Of course, this flange is connected to a discharge pipe, for example to a chimney pipe.

It should be noted that the circulation of water in the exchanger is counter-current to the circulation of gases. The cold water is first of all preheated by the flow H2, then heated by the flow Hl. As an indication, the water temperature is brought from ambient temperature to a temperature of the order of 60 ° C.

Of course, the presence of the disc 82 prevents the direct passage of the gases inside the exchanger from space 800 to space 801. In the simplified variant of FIG. 19, all of the exchanger elements 1 surrounds the burner 7. There is therefore no preheating of the water circulating in the exchanger. The air + gas mixture arrives via the collar 80 inside the burner 7 (arrows HO). After combustion, the hot gases pass radially, from the inside to the outside, the turns of the exchanger (arrows Hl). They are evacuated through the collar 81 (arrows H2). Note the presence, at the base of the body 8 of the exchanger of a connector 86 which allows the evacuation of condensates.

In the embodiment of FIG. 20, there are provided six juxtaposed (or stacked) exchanger elements coaxially, referenced l a, lb, ic, l d, le and lf. These elements are distributed in pairs, in this case la-l b, lc-l d and l e-lf. Each pair forms a parallel arrangement in terms of water circulation. The three pairs are connected in series. This boiler has a general configuration similar to that shown in Figure 18. Next to the space 800, which corresponds to the location of the burner, there are three elements, in this case the elements la, l b and le. Opposite the space 801 which is on the other side of the shutter disc 82, the elements l d and the are arranged. There is therefore, during operation, a path H0, H1 and H2 of the hot gases quite similar to that described with reference to FIG. 18. This embodiment differs from that of FIG. 18, however, in that the gases being in the space 801 will cross the exchanger again, in this case the interstices interstices of the element lf, from the inside to the outside, as is symbolized by the arrows H3. The cooled gases then escape through the flange 81 (arrows H4).

An annular shutter 87 disposed outside of the exchanger elements, between elements l e and l f prevents gases from passing directly through the exterior of the exchanger at this level.

This device performs in a way two successive preheats of the water, which makes it particularly efficient.

The device represented in FIG. 21 is a heat recovery unit intended to be placed at the outlet of a conventional boiler, or of any another device that releases gases at a temperature sufficient to heat a fluid, such as water. We have designated by the reference 9 the outlet of such an apparatus, which produces hot gases 10. This outlet has a flange 90 into which is fitted the flange 80 for input of the body 8 of the device, the output flange of which is designated 81.

The body 8 has a generally cylindrical shape. Inside the latter, and coaxially, is mounted a set of exchanger elements according to the invention, for example four elements referenced l a, l b, l e and l d.

These elements are connected in pairs in parallel, the two pairs being connected in series.

The element 1 placed on the side of the device 9 is placed against the inlet wall of the body 8. At the other end, the interior space of the exchanger is closed off by a partition 89.

The hot gases arrive inside the exchanger, and are divided into gas blades which cross the interstices of the different elements 1, as symbolized by the arrows j_l. The heat is thus transferred from the gases to the liquid circulating inside the exchanger. The cooled gases then pass through the annular space situated outside the exchanger and exit the device through the flange 81 (arrows 12).

In the embodiment of Figure 22, the device comprises two heat exchangers 1, 1 ', each formed of a stack of three elements according to the invention. The two exchangers are arranged parallel to each other inside the same body 8. The hot gases 30 leaving the device 9 firstly penetrate inside the exchanger 1. They s 'escape radially from the inside to the outside of it (arrows 31). They then pass through the exchanger 1 ′, this time from the outside to the inside (arrows 32) to then be evacuated (arrows 33).

Preferably, the two exchangers are connected in series, the water circulating in the opposite direction to the gases, that is to say passing first through element 1 'then element 1. The device illustrated in FIG. 23 consists of a parallel mounting of two devices similar to that of FIG. 21. The device comprises two exchangers 1 "each composed of a stack of elements in accordance with the invention. The gas flow hot KO leaving the device 9 is subdivided into two flows K l which are each brought inside a 1 "exchanger. The hot air passes through the interstices separating the turns of each exchanger from the inside to the outside (arrows K2). The cooled gases are grouped together to escape from the device by the flange 81 (arrow K3). Of course, different configurations providing series and / or parallel mounting of several exchangers can be provided, depending on the required heat exchange characteristics and the space available at the outlet of the device 9.

In the embodiment of the heat exchanger element described in FIGS. 1 and 2, the rectilinear portions 14 and 14 ′ of inlet and outlet of the element 1 are parallel, the end fittings 15, 1 5 ′ , being directed opposite each other, as illustrated in the figure

24.

It goes without saying that other configurations of the end portions are possible.

Thus, by way of example, there has been shown in FIG. 24A an arrangement according to which the end portions 14, 14 ′ are located directly above each other and intersect at right angles.

The bosses 12, which calibrate the spacing between the turns, do not necessarily have a radial arrangement.

Thus, in the embodiment of Figure 25, there are provided bosses 12 'arranged obliquely, that is to say forming an acute angle u_ relative to the radial direction.

In the variant of FIG. 25A, the bosses 12 "have an arcuate shape and their general direction is also slightly inclined relative to the radial direction, in the manner of the fins of a turbine.

Such an arrangement of the bosses has the effect of orienting the flow of air escaping from the interstices between the turns, and of forming a vortex capable, under certain conditions, of improving the mixing and circulation of gases.

In the variant of FIG. 26, a series of bosses 12a, 12b is provided on each of the two flat faces of the turns. This arrangement can be advantageous if it is desired that the distance between the turns is relatively large.

Indeed, the height of the bosses is necessarily reduced, because it involves a stretching of the wall of the tube during manufacture. Too much stretching would cause the wall to rupture. In the embodiment of FIG. 27, the heat exchanger element is a double pitch element, formed by the interweaving one into the other of two similar windings 1, 1 '. In such an arrangement, which remains within the framework of the present invention, each turn of one of the elements is located opposite a turn of the other element.

The embodiment of Figures 28 and 28A comprises two elements according to the invention which are coaxial. The outer element 1E has turns 10E whose winding diameter is greater than that of the turns 10J_ of the inner element IL, The end turns of the outer element 1J_ have wall recesses 16E sufficiently wide to allow the sections 14E and 14j_ of the two elements 1E and H. to pass respectively.

The two elements can advantageously be welded to one another. The advantage of such an arrangement is that the heat exchange surface is further increased.

In this regard, it should be noted that if we are dealing with a single tube, this surface is necessarily limited. In fact, there is a direct correlation between the diameter of the initial tube and the radius of its helical winding. For a given winding radius, a certain diameter of the tube cannot be exceeded, otherwise the tube will break during forming.

Element 1 which is the subject of the variant shown in Figures 29 and 30 differs essentially from that of Figure 1 by the fact that the main axes of the straight sections (flattened and oval) of the turns 10 are not perpendicular to the axis XX 'of the winding, but form an acute angle _y_ with the latter. In the example shown, this angle v_ is equal to 45 °. As for the embodiment of FIG. 1, the wall of the tube carries corrugations 12 (not shown in FIGS. 30 and 30A so as not to burden them unnecessarily) which serve as spacers calibrating the spacing (h) between turns, which is significantly smaller than the thickness (e) of the crushed tube (see Figure 30A). FIG. 31 shows the section of the half-dies 2 "which can be used to shape the starting helical tube 100 in order to obtain such a configuration. They have a thin annular part 20" of flat section and conical shape, whose half-angle at the top is equal to v. Of course, the part 20 "carries imprints (not shown) corresponding to the corrugations that it is desired to form.

The bringing together of the 2 "tool elements thus gives the turns a flattened and oval section, the large faces of which generate a truncated cone of semi-angle _y_. Of course, as for the first embodiment, the forming is done with internal hydraulic pressure of the tube.

Such an element configuration is particularly suitable for "vertical" operation, since it ensures excellent condensate flow. Thus, the heat exchanger 8 'shown in Figure 32, whose axis XX' has a vertical arrangement, uses six elements conforming to that of Figures 29 and 30, mounted coaxially (along XX ') and connected in series.

The four upper elements l a, l b, le, l d have turns whose taper diverges downwards. The two lower elements le, lf have an inverted conicity (angle at the top directed downwards).

A sheet metal piece 83 'interposed between the two series of elements ensures their perfect positioning at the place of their taper reversal.

The exchanger shown equips a gas boiler which comprises a cylindrical burner 80 'with surface combustion, arranged coaxially within the series of upper elements (la, lb, le, ld). The outer wall of the exchanger is referenced 800 '. The fluid to be heated, for example water, flows through the elements from bottom to top, that is to say in the following order: lf, le, ld, le, lb, l a. The air / gas mixture A + G is brought from above to the inside of the burner 80 ′, the combustion taking place on the external surface of the latter. The burnt and hot gases escape radially outwards, as symbolized by the arrows L1. They cross the interstices between turns of the first series of elements, obliquely downward (following the taper of the turns). They thus reach the annular space between the elements and the wall 800 '. Finally, they pass through the interstices between the turns of the lower elements le and lf, this time from the outside towards the inside, to exit by a lower evacuation flange 81 '(arrows L2).

During this course, the liquid circulating in the elements 1 to 1 is heated by heat transfer.

A simple observation of FIG. 32 shows how the arrangement with inverted conicities of the elements la, lb, le, ld on the one hand and le, lf on the other hand naturally directs and channels the flow of hot gases, as well as the condensates, from top to bottom inside the exchanger. The exchanger elements according to the invention can find different applications, the fluid circulating inside the element not necessarily being a liquid, and the external fluid not necessarily being a gas.

In certain applications, one could envisage, for the manufacture of the element, a plastic material, provided of course that this material has a certain thermal conductivity and that it remains solid and rigid under the conditions of its use.

Claims

1. Heat exchanger element (1) which consists of a tube of thermally conductive material wound in a helix, in which a heat transfer fluid is intended to circulate, this tube having a flat, oval cross section, the major axis of which is substantially perpendicular to the axis (XX ') of the helix or forms an acute angle (v) with respect to the latter, each turn (10) of the tube having planar faces (1 1) which are spaced from the faces of the adjacent turn d '' a gap of constant height (h), characterized in that the height (h) of the gap separating two adjacent turns (10) is substantially smaller than the thickness (e) of said cross section, and that l the spacing between two neighboring turns (10) is calibrated by means of spacers (12).

2. Element according to claim 1, characterized in that said spacers (12) are bosses, or corrugations, formed in the wall of the tube, on at least one of said flat faces (1 1).

3. Element according to claim 2, characterized in that said bosses (12) extend radially relative to the axis (XX ') of the propeller.

4. Element according to one of claims 1 to 3, characterized in that the two ends of the tube extend tangentially by sections (14, 14 ') connecting to cylindrical ends (15, 15').

5. Element according to one of claims 1 to 4, characterized in that the outer planar faces of its end turns are located substantially in planes (P, P ') parallel to each other, and perpendicular to the axis (XX ') of the propeller.

6. Element according to one of claims 1 to 5, characterized in that the internal edge (13) of the turns (10) is embossed.

7. A method of manufacturing a heat exchanger element according to one of claims 1 to 6, according to which: a) a cylindrical tube (100) is bent helically; b) it is filled with a fluid; c) the wall of the tube (100) is crushed so as to give it a flattened and oval section, the major axis of which is substantially perpendicular to the axis of the propeller, while simultaneously reducing the pitch of this propeller; d) maintaining, during step (c), the fluid contained in the tube at a substantially constant pressure, so as to prevent the collapse of its wall.

8. Method according to claim 7, for the manufacture of an element according to one of claims 4 or 5, characterized in that one uses, in step (c), forming dies (2) which have indentations (28). of complementary shape of said bosses, or corrugations, (12) and, that at the end of the operation, the fluid contained in the tube is subjected to a high pressure to force its wall to conform to the shape of said imprints (28).

9. Device for implementing the method according to one of claims 7 or 8, characterized in that it comprises: - a press (3) comprising a fixed sole (30) and a movable plate (32);

- actuation means (33, 34) used to move the movable plate (32) relative to the fixed base (30);

- two sets of complementary half-dies (2A, 2B), of generally semi-circular shape, capable of being positioned between the turns of the tube to be formed, and positioned, in the working position, between said fixed base (30) and said movable plate (32).

10. Device according to claim 9, characterized in that one (2B) of said assemblies is movable and can be removed from the press for the establishment of the tube to be formed, and the removal of the tube formed .

11. Device according to one of claims 9 or 10, characterized in that said half-dies have flat faces (24) used for crushing the tube, these faces being inclined relative to a plane perpendicular to the axis (XX ¹ ), of the propeller.

12. Device according to one of claims 9 to 1 1, characterized in that the constituent half-dies of each half-assembly are guided relative to each other by means of columns (200).

13. Device according to claims 1 1 and 12 taken in combination, characterized in that said columns (200) pass through elongated holes (22) formed in the dies, which allow their lateral inclination.

14. Device according to one of claims 9 to 13, characterized in that it comprises jacks (40, 41 ') used to separate the half-dies from each other.

15. Device according to one of claims 9 to 14, characterized in that it comprises means (5) for sealingly closing the two ends of the tube during forming, and for introducing a fluid therein under very High pressure.

16. Heat exchanger for a boiler equipped with a burner, which comprises at least one element according to one of claims 1 to 6, in which a fluid to be heated circulates, characterized in that said element (1) is disposed in the vicinity of the burner (7), in a position such that the combustion gases pass through the interstices separating its turns.

17. Exchanger according to claim 18, characterized in that it comprises several elements according to claims 1 to 6, and at least one of which is crossed by the combustion gases from the inside to the outside, while qu at least one other is crossed by these gases in the opposite direction.

18. Heat recovery unit for a boiler, which comprises at least one element (1) according to one of claims 1 to 6, in which circulates water to be heated, and which is exposed to the flow of burnt (and hot) gases. ) escaping from the boiler.