WO2016144888A1 - Échangeur de chaleur compact à ailettes empilées - Google Patents

Échangeur de chaleur compact à ailettes empilées Download PDF

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Publication number
WO2016144888A1
WO2016144888A1 PCT/US2016/021221 US2016021221W WO2016144888A1 WO 2016144888 A1 WO2016144888 A1 WO 2016144888A1 US 2016021221 W US2016021221 W US 2016021221W WO 2016144888 A1 WO2016144888 A1 WO 2016144888A1
Authority
WO
WIPO (PCT)
Prior art keywords
fins
air
fin
heat exchanger
alternating
Prior art date
Application number
PCT/US2016/021221
Other languages
English (en)
Inventor
Jeremy Rice
Original Assignee
J R Thermal LLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by J R Thermal LLC filed Critical J R Thermal LLC
Publication of WO2016144888A1 publication Critical patent/WO2016144888A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
    • F28D9/0037—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the conduits for the other heat-exchange medium also being formed by paired plates touching each other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F12/00—Use of energy recovery systems in air conditioning, ventilation or screening
    • F24F12/001—Use of energy recovery systems in air conditioning, ventilation or screening with heat-exchange between supplied and exhausted air
    • F24F12/006—Use of energy recovery systems in air conditioning, ventilation or screening with heat-exchange between supplied and exhausted air using an air-to-air heat exchanger
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D9/0062—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by spaced plates with inserted elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2230/00—Sealing means
    • 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
    • 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
    • F28F2275/14—Fastening; Joining by using form fitting connection, e.g. with tongue and groove
    • 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]
    • Y02B30/56—Heat recovery units

Definitions

  • Air to air heat exchangers are used in many heat transfer and heat recovery applications.
  • metal foil often aluminum, is used as the boundary to prevent mixing between the two airstreams.
  • FIG 1 at the edge of the fins 103, it is necessary to block airflow 100 from entering the gap between one pair of fins 103, while allowing the same stream of airflow 101 to enter the neighboring gap.
  • This alternating pattern of allowing airflow to enter only pre-determined channels keeps a first airflow stream 101 and second airflow stream 102 separate, and allows heat to be transferred via the metal foil 103.
  • One method that is often used to prevent air 100 from entering a predetermined gap is rolling 104 the edges of adjacent fins 103, 106 to create a mechanical seal preventing airflow from one airstream 100 to enter that particular channel. While this method is used quite frequently, the formation of the rolled edge 104 is a time consuming process, since the edge can't be formed with a simple up/down progressive stamping machine, which can add to the product cost. Additionally, the fin pitch 105 has to be relatively large to allow for the roll 104 to be formed. The lower manufacturing limits on this pitch is around 2.0mm, but more typically heat exchangers are designed for fin pitches of 4mm to 8mm fin pitch.
  • the result of the higher fin pitch and time it takes to create the rolled edge 104 is the heat exchanger' s volumes are relatively large for the airflow and heat exchanged.
  • the heat exchangers tend to be long in the direction of the airflow paths 101, 102 which leads to higher pressure losses.
  • the present invention enables tight fin pitches, down to approximately 1.0mm, for air to air heat exchangers, with air streams separated by metal foil. These fin pitches can enable twice the fin density and twice the heat transfer coefficient, leading to a quadrupling of the heat transfer that may be exchanged in the same volume.
  • the formation of the fin stack and the sealing of the alternating channels, is separated, which allows for high manufacturing process efficiency.
  • the fin stack formation step there are two major process steps, the fin stack formation and the sealing of the edges with a spray coating process.
  • the fin stack is mechanically held together by interlocking fins, in which each fin interlocks with the adjacent fin.
  • the fin stack can be held together by several rods or tubes that pass through the interior of the fins with an interference fit.
  • the fins can either press fit onto the rods, or, alternatively, the tubes can be expanded. In either case, the interference fit maintains the fin spacing.
  • the edge of every other fin is formed into a 90 degree edge that is intended to touch the neighboring fin, and thus block air from entering the channels adjacent to this 90 degree formation.
  • the coating process helps seal the remaining gaps on the edge that remain as a result of tolerances on the creation of the formed edge. Additionally, the sealing helps bond the formation and neighboring fin together, thus strengthening the fins.
  • FIG 1 is a schematic drawing of a rolled edge design in accordance with prior art
  • FIG 2 is a top perspective view of the heat exchanger and airstreams in one embodiment of the present invention.
  • FIG 3 is a close-up view of the top front corer of the heat exchanger and airstreams of teh foregoing embodiment;
  • FIG 4 is a schematic drawing depicting one embodiment of the edge sealing of stacked fins by a coating process
  • FIG 5 is a schematic drawing depicting a fin stack before the coating process
  • FIG 6 is a schematic drawing depicting the fin stack of FIG. 5 after the coating process is complete
  • FIG 7 is a schematic drawing depicting a fin stack held in place by interlocking fins
  • FIG 8 is a schematic drawing depicting a fin stack held in place by a tube
  • FIG 9 is a schematic drawing depicting a lap joint sealing of the stacked fins by a coating process
  • FIG 10 is a schematic drawing depicting a fin stacking method onto a rotating table with a single fin type
  • FIG 11 is a schematic drawing depicting a fin
  • FIG 12 is a schematic drawing depicting a fin stacking method utilizing two stamping presses.
  • the present invention is directed to a compact stacked fin heat exchanger.
  • the configuration and use of the presently preferred embodiments are discussed in detail below. It should be appreciated, however, that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of contexts other than a stacked fin heat exchanger. Accordingly, the specific embodiments discussed are merely illustrative of specific ways to make and use the invention, and do not limit the scope of the invention. [00021] A representation of one embodiment of the present invention is presented in
  • a first airstream 101 has a relatively high temperature when entering the heat exchanger 107, and releases heat to a second airstream 102 that has a relatively low temperature when entering the heat exchanger 107.
  • the first airstream 101 and the second airstream 102 are separated by a series of fins 108, as is represented in a close-up depiction of one embodiment of the invention in FIG 3.
  • the first airstream 101 is blocked by a series of alternating folded edges 109 on every other fin 108, preventing the first airstream 101 from mixing with the second airstream 102.
  • the second airstream 102 is blocked by a second series of alternating folded edges 110 preventing the second airstream 102 from mixing with the first airstream 101.
  • a schematic of the folded edged 109 is represented in FIG 4.
  • the edge 109 is part of a fin or plate 114 that keeps the first airstream 101 and second airstream 102 separate.
  • the edge 109 is created with a 90 degree bend from the fin 114, and nearly touches the neighboring fin 113. Since the fin 114 is made from a mechanical process, the edge 109 and the neighboring fin 113 do not come into perfect contact, therefore a small gap 112 is created. Since the first airstream 101 and the second airstream 102 are desired to not mix, the gap 112 must be sealed.
  • a secondary coating process such as spray paint or powder coating, may be applied to the surface. This coating process creates a film 111 that can penetrate and seal the gap 112, thus preventing the first airstream 101 and the second airstream 102 from mixing.
  • the coating may be required to apply the coating in multiple passes to ensure the coating penetrates the gaps. If a powder coating process is used, a thicker coating may be used than conventional liquid coatings, without running. The powder coating process will need to be cured so that the particles (powder) can melt and bond to the base surface. Since the coating bonds to the base surface (fin), it has a beneficial effect of strengthening the fin's edge. Since the metal fin is thin (0.1mm to 0.5mm thick), the stiffness of the edge increases significantly as a result of bonding two flat fins with a 90 degree connection. This stiffening is similar to an I-beam element used to strengthen structures.
  • FIG 5 A view of a fin stack with edges 109 formed by a progressive stamping process is represented in FIG 5. Since the fins may be created by a thin piece of metal foil ranging from 0.1mm to 0.5mm thick, the strength of the fin is limited. Due to the fin's limited strength, the fin is subject to deformation, thus creating a gap 112 of varying size. In an effort to minimize this gap 112, a spacer feature 115 can be added to the gaps in which an airstream 101 is allowed to flow through. This spacer 115 limits the span in which the edge 109 is not reinforced, and helps keep the gap 112 within a tolerance that may be sealed by the coating process. A view of the fin stack after the coating process is presented in FIG 6. In this image, there are no more visible gaps 112 indicating that a seal was formed, and mixing can be prevented between the two airstreams.
  • each fin 114 may be created independently from the previous fin 114 and stacked. Additionally, the fins 114 may have a tighter fin pitch, down to 1.0mm, versus a rolled edge, which has a lower bound fin pitch of approximately 2.0mm.
  • the tighter fin pitch enables twice the fin area per unit length as well as twice the heat transfer coefficient from airstream 101 to fin 114, since the distance from the bulk airstream temperature to the fin 114 is half. The combined effect of the increased fin area and heat transfer coefficient is that the same total amount of heat may be transferred with approximately 25% of the heat exchanger length.
  • the fin stack may be held together by interlocking features 116. These features keep the fins 114 from being pulled apart as well as being pressed together.
  • the interlocking feature can be used in lieu of or in conjunction with the spacers 115.
  • the interlocking features must be present on opposing sides of the fin, to ensure the fin stack is secure in all three dimensions.
  • the fin stack may be held in place by a tube 120 or tubes.
  • the tube and fins can be forced together with an interference fit, which may be created by two techniques.
  • the first technique the cut-out in the fin, which the tube penetrates, may have an internal diameter that is smaller than the outer diameter of the tube.
  • the fin may be pressed onto the tube, creating a friction or interference fit between the tube and the fins.
  • the process may be repeated to create the fin stack.
  • the diameter of the cut-out in the fin may be larger than the outer diameter of the tube.
  • the fin stack may first be loosely stacked onto the tube (or tubes).
  • the stack may be compressed with a controlled amount of force to get a close fit on the fin's edges 109, but not too much force to deform the fins.
  • the tube may be expanded until the outer diameter of the tube is larger than the cut-out diameter in the fin, thus creating an interference fit.
  • the shape of the fins, and thus the heat exchanger, is highly customizable by the methods set forth herein. Rectangular, hexagonal, circular and many other shapes may be used. Additionally, the airstreams may be designed to flow in a cross-flow or counter-flow pattern, depending on the application and constraints. Additionally, the fin pitch on each airstream may be different. This feature may be useful in situations where one air stream has a high humidity level or even a higher volumetric flow with respect to a second air stream, in which the heat transfer requirements are not balanced. In the case with an air stream with a high humidity level, condensation is likely to occur when that airstream is cooled.
  • fins with a hydrophilic coating may be used, so that the condensed water does not form droplets on the fins. Additionally, this feature gives flexibility in designing the heat exchanger, where one air stream may have a relatively large cross-section for entering air, the second may have a smaller cross-section. Each application will require its own optimization.
  • the fins described so far are generally flat and thin.
  • the general construction of the heat exchanger may be kept the same, with features added to the fins to enhance the heat transfer, as well as increase the structural integrity of the fins.
  • Some of these features include ribs or waves, than can be implemented in a variety of manners. Embossing features may be used that are tall enough so that they touch the neighboring fin in the middle of the channel. These features can extend the allowable pressure difference between the air streams. Since the foil is relatively thin, it is expected that the useful pressure difference between airstreams is limited by approximately 5000 Pa.
  • FIG 9 Another embodiment is presented in FIG 9, which includes a first air stream 101 and second air stream 102, which are separated by plates 117 and 118.
  • a lap joint 119 prevents the first airstream 101 from mixing with the second airstream 102.
  • a coating 111 may be applied to the face of the heat exchanger, thus creating a seal in the lap joint 119 between a first plate 117 folded under and a second plate 118 folder over.
  • the fold on the second/outer plate 118 is shorter than the fold on the first/inner plate 117, thereby exposing a portion 121 of the outer surface of the inner fin 117 for the coating to land.
  • the plates of a heat exchanger are integrally held together by a tube or tubes 120
  • the plates may be stamped on a stamping press 201 and stacked onto the alignment stakes 121 which are held in place on a table 203, as represented in FIG 10.
  • the alignment stakes go into the same holes 210 in the plate as the tubes 120 but can have a smaller diameter than the tubes, or a pointed tip, allowing for easier placement of the fins.
  • the sheet metal flows 202 from a roll, to the press 201 and then onto the table 203.
  • the tubes 120 can replace the stakes 121 during another process and then can be expanded to form an interference fit with the plates.
  • a single plate type is stacked onto the stakes, and the table 203 is rotated in 90 degree alternating clockwise and counterclockwise directions, in the time between the placement of each individual plate.
  • FIG 11. One embodiment of a plate utilized in this process is represented in FIG 11.
  • the main surface 209 of the plate is generally square, however, a first direction 204 is shorter than a second direction 205 by two times the plate thickness plus stamping and stacking tolerances.
  • the first set of edges 206 on the opposing ends of the first direction 204 are folded upward, while the second set of edges 207 on the opposing ends of the third direction 205 are folded downward.
  • the second set of edges 207 are shorter than the first set of edges 206.
  • the second set of edges 207 form the outer surface of the lap joint 119, while the first set of edges 206 form the inner surface of the lap joint 119.
  • the plate has holes 210 that must align with the stakes 121 during the stacking process.
  • the location of the holes 210 must align to the same location, on a fixed reference plane, when the plate is rotated by 90 degrees.
  • the plates are often a metal foil, therefore, embossings 216 may be used to maintain a desired spacing, add strength and increase the heat transfer effect on the fins.
  • hexagonally shaped plates may be used for air streams that are desired to flow counter to each other rather than cross each other.
  • a similar fin stacking and table rotating approach may be used for a hexagonal fin, however the table must be rotated 180 degrees between the stacking of the plates versus 90 degrees.
  • the first fin type can flow 213 from a metal coil through a first press 211 onto a stacking table 215.
  • a second fin type can flow 214 from a second metal coil through a second press 212 onto the same stacking table 215.
  • the presses have to be timed to stack fins in an alternating sequence from the first press 211 followed by the second press 212.
  • the stacking table 215 may allow for stacking of two heat exchangers in parallel, and rotate in 180 degree increments, to allow for both presses to run continuously.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Abstract

L'invention concerne un procédé et un système dans lesquels un échangeur de chaleur air-air maintient deux flux d'air séparés par le biais d'ailettes métalliques. Les bords d'ailettes alternées sont pliés de sorte que l'extrémité soit à proximité de l'ailette adjacente et que l'espace restant soit scellé. La pile d'ailettes est maintenue par des éléments de verrouillage mutuel ou par l'utilisation d'un tube, auquel cas les piles d'ailettes peuvent être frappées et empilées sur des pieux d'alignement pendant la production au moyen des mêmes trous que les tubes. L'échangeur de chaleur peut être utilisé de manière prolongée pour éliminer l'humidité et la chaleur d'un flux d'air humide et chaud. L'échangeur de chaleur est utile dans des systèmes de ventilation à récupération de chaleur, des sèche-linge à récupération de chaleur ou d'autres procédés d'échange de chaleur air-air où la différence de pression entre les flux d'air est inférieure à environ 5000 Pa.
PCT/US2016/021221 2015-03-09 2016-03-07 Échangeur de chaleur compact à ailettes empilées WO2016144888A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201562130063P 2015-03-09 2015-03-09
US62/130,063 2015-03-09

Publications (1)

Publication Number Publication Date
WO2016144888A1 true WO2016144888A1 (fr) 2016-09-15

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PCT/US2016/021221 WO2016144888A1 (fr) 2015-03-09 2016-03-07 Échangeur de chaleur compact à ailettes empilées

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US (1) US20160265854A1 (fr)
WO (1) WO2016144888A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110425914A (zh) * 2019-06-28 2019-11-08 中国空间技术研究院 一种基于纳米超润湿界面的低阻强化传热结构

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109564909A (zh) * 2016-07-11 2019-04-02 飞利浦照明控股有限公司 折叠金属片散热器
DK3457066T3 (da) * 2017-09-15 2022-09-26 Alfa Laval Corp Ab Ledeplade
US11168943B2 (en) * 2018-10-12 2021-11-09 Api Heat Transfer Thermasys Corporation Channel fin heat exchangers and methods of manufacturing the same

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6145588A (en) * 1998-08-03 2000-11-14 Xetex, Inc. Air-to-air heat and moisture exchanger incorporating a composite material for separating moisture from air technical field
WO2005089153A2 (fr) * 2004-03-11 2005-09-29 Thermal Corp. Echangeur de chaleur air-air
US20060096746A1 (en) * 2004-11-09 2006-05-11 Venmar Ventilation Inc. Heat exchanger core with expanded metal spacer component
US20140238651A1 (en) * 2013-02-28 2014-08-28 General Electric Company Heat Exchanger Assembly
US20140290920A1 (en) * 2013-03-27 2014-10-02 Modine Manufacturing Company Air to air heat exchanger

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Publication number Priority date Publication date Assignee Title
ATE432790T1 (de) * 2000-12-28 2009-06-15 Brazing Co Ltd Plattenwärmetauscher und verfahren zu seiner herstellung

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6145588A (en) * 1998-08-03 2000-11-14 Xetex, Inc. Air-to-air heat and moisture exchanger incorporating a composite material for separating moisture from air technical field
WO2005089153A2 (fr) * 2004-03-11 2005-09-29 Thermal Corp. Echangeur de chaleur air-air
US20060096746A1 (en) * 2004-11-09 2006-05-11 Venmar Ventilation Inc. Heat exchanger core with expanded metal spacer component
US20140238651A1 (en) * 2013-02-28 2014-08-28 General Electric Company Heat Exchanger Assembly
US20140290920A1 (en) * 2013-03-27 2014-10-02 Modine Manufacturing Company Air to air heat exchanger

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110425914A (zh) * 2019-06-28 2019-11-08 中国空间技术研究院 一种基于纳米超润湿界面的低阻强化传热结构

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