Folded conduit for heat exchanger applications

Abstract

A heat exchange conduit includes a body having a first portion including a first flow channel and a second portion including a second flow channel. A cross-section of the heat exchange conduit varies over a length of the heat exchange conduit.

Claims

1. A heat exchange conduit, comprising: a body having a leading edge, a trailing edge, a first surface, and a second surface, the body including a first portion having an interior extending between the leading edge, the first surface, a first portion of the second surface, and a first internal side, and a second portion having an interior extending between the trailing edge, the first surface, a second portion the second surface, and a second internal side; wherein the interior of the first portion includes at least one first flow channel and the interior of the second portion includes a second flow channel; wherein the body includes a generally planar sheet of material folded such that a single surface of the sheet of material forms the leading edge, the first surface, the first portion of the second surface, and the first internal side of the first portion and each of the trailing edge, the first surface, the second portion of the second surface, and the second internal side of the second portion; wherein a width of the generally planar sheet of material varies over a length of the heat exchange conduit such that a number of first flow channels formed in the first portion varies over a length of the heat exchange conduit.

2. The heat exchange conduit according to claim 1, wherein a configuration of the at least one first flow channel and the second flow channel varies over the length of the heat exchange conduit.

3. The heat exchange conduit according to claim 1, wherein a hydraulic diameter of at least one of the at least one first flow channel and the second flow channel varies over the length of the heat exchange conduit.

4. The heat exchange conduit according to claim 3, wherein a ratio of a length of the at least one first flow channel or second flow channel of the heat exchange conduit to a hydraulic diameter of the at least one first flow channel or second flow channel, respectively, is optimized based on the type and phase of a fluid configured to flow through the heat exchange conduit.

5. The heat exchange conduit according to claim 4, wherein when the fluid is at least one of a liquid and a two-phase refrigerant, a ratio of the length to the hydraulic diameter of at least one of the at least one first flow channel and the second flow channel is about 15 to about 65.

6. The heat exchange conduit according to claim 4, wherein when the fluid is a vapor refrigerant, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 1.5 to about 5.

7. The heat exchange conduit according to claim 4, wherein when the fluid is water, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 50 to about 200.

8. The heat exchange conduit according to claim 4, wherein when the fluid is a brine, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 150 to about 600.

9. The heat exchange conduit according to claim 1, wherein an interior surface of the heat exchange conduit includes a texture or pattern to form a boundary layer disruption of a fluid passing through the heat exchange conduit.

10. The heat exchange conduit according to claim 1, wherein an exterior surface of the heat exchange conduit includes a texture or pattern to form a boundary layer disruption of a fluid passing around the heat exchange conduit.

11. A heat exchanger, comprising: a first header; a second header; a plurality of heat exchange conduits arranged in spaced parallel relationship and fluidly coupling the first header and second header, at least one of the plurality of heat exchange conduits including a body having a leading edge, a trailing edge, a first surface, and a second surface, the body including a first portion having an interior extending between the leading edge, the first surface, a first portion of the second surface, and a first internal side and a second portion having an interior extending between the trailing edge, the first surface, a second portion of the second surface, and a second internal side, the interior of the first portion including at a first flow channel and the interior of the second portion including a second flow channel; wherein the body of the at least one heat exchanger conduit includes a generally planar sheet of material folded such that a single surface of the sheet of material forms the leading edge, the first surface, the first portion of the second surface and the first internal side of the first portion and the trailing edge, the first surface, the second portion of the second surface, and the second internal side of the second portion; wherein a width of the generally planar sheet of material varies over a length of the heat exchange conduit such that a number of flow channels formed in at least one of the first portion and the second portion varies along a length of the heat exchange conduit.

12. The heat exchanger according to claim 11, wherein the first portion has one or more first flow channels and the second portion has one or more second flow channels, wherein at least one of a cross-sectional area and a cross-sectional shape of the one or more first flow channels or the one or more second flow channels varies over the length of the heat exchange conduit.

13. The heat exchanger according to claim 12, wherein the first portion is part of a first tube bank and the second portion is part of a second tube bank.

14. The heat exchanger according to claim 11, wherein a hydraulic diameter of the at least one first flow channel and second flow channel varies over the length of the heat exchange conduit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The subject matter, which is regarded as the present disclosure, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the present disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

(2) FIG. 1 is an example of a conventional heat exchanger;

(3) FIG. 2 is a perspective, partly sectioned view of an example of a parallel flow

(4) FIG. 3 is a cross-sectional view of a portion of the parallel flow heat exchanger of FIG. 2;

(5) FIG. 4 is a cross-sectional view of a folded heat exchange conduit according to an embodiment;

(6) FIG. 5 is a cross-sectional view of another folded heat exchange conduit according to an embodiment;

(7) FIG. 6 is a top view of a sheet of material used to form a folded heat exchange conduit according to an embodiment;

(8) FIG. 6a is a cross-sectional view of the folded heat exchange conduit formed from the sheet of material of FIG. 6 according to an embodiment;

(9) FIG. 7 is a top view of another sheet of material used to form a folded heat exchange conduit according to an embodiment;

(10) FIG. 7a is a cross-sectional view of the folded heat exchange conduit formed from the sheet of material of FIG. 7 according to an embodiment;

(11) FIG. 7b is a perspective view of an insert for use with a folded heat exchange conduit according to an embodiment;

(12) FIG. 8 is a top view of another sheet of material used to form a folded heat exchange conduit according to an embodiment;

(13) FIG. 8a is a cross-sectional view of the folded heat exchange conduit formed from the sheet of material of FIG. 8 at various locations along the length of the conduit according to an embodiment;

(14) FIG. 9 is a top view of another sheet of material used to form a folded heat exchange conduit according to an embodiment; and

(15) FIG. 9a is a cross-sectional view of the folded heat exchange conduit formed from the sheet of material of FIG. 9 at various locations along the length of the conduit according to an embodiment.

(16) The detailed description explains embodiments of the present disclosure, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION

(17) Referring now to FIG. 1, an example of a parallel flow heat exchanger is illustrated. The heat exchanger 20 includes a first manifold or header 30, a second manifold or header 40 spaced apart from the first manifold 30, and a plurality of heat exchange conduits 50 extending in a spaced parallel relationship between and fluidly connecting the first manifold 30 and the second manifold 40. In the illustrated, non-limiting embodiments, the first header 30 and the second header 40 are oriented generally horizontally and the heat exchange conduits 50 extend generally vertically between the two headers 30, 40. By arranging the conduits 50 vertically, water condensate collected on the conduits 50 is more easily drained from the heat exchanger 30. In the non-limiting embodiments illustrated in the FIGS., the headers 30, 40 comprise hollow, closed end cylinders having a circular cross-section. However, headers 30, 40 having other cross-sectional shapes, such as semi-elliptical, square, rectangular, hexagonal, octagonal, or other cross-sections for example, are within the scope of the disclosure. The heat exchanger 20 may be used as either a condenser or an evaporator in a vapor compression system, such as for example a heat pump system, an air conditioning system, or the like.

(18) Referring now to FIGS. 2 and 3, each heat exchange conduit 50 comprises a leading edge 52, a trailing edge 54, a first surface 56, and a second surface 58. The leading edge 52 of each heat exchanger conduit 50 is upstream of its respective trailing edge 54 with respect to the flow of a second heat transfer fluid A (e.g., air, air having dilute ethylene gas therein, nitrogen, and the like) through the heat exchanger 20. The interior flow passage of each heat exchange conduit 50 may be divided by interior walls 59 into a plurality of discrete flow channels 60 that establish fluid communication between the respective first and second manifolds 30, 40. The flow channels 60 may have a circular cross-section, a rectangular cross-section, a trapezoidal cross-section, a triangular cross-section, or another non-circular cross-section (e.g. elliptical, star shaped, closed polygon having straight or curved sides). The heat exchange conduits 50 including the discrete flow channels 60 may be formed using known techniques and materials, including extrusion.

(19) A plurality of heat transfer features 70 (FIG. 3) may be disposed between and rigidly attached, e.g., by a furnace braze process, welding process, or the like, to the heat exchange conduits 50, in order to enhance external heat transfer and provide structural rigidity to the heat exchanger 20. The heat transfer features may be selected from lancings, louveres, slots, and fins for example. Heat exchange between the fluid within the heat exchanger conduits 50 and the air flow A, occurs through the outside surfaces 56, 58 of the heat exchange conduits 50 collectively forming the primary heat exchange surface, and also through the heat exchange surface of heat transfer features 70, which form the secondary heat exchange surface.

(20) Referring now to FIGS. 4-9, the heat exchange conduits 50 will be described in more detail. The heat exchange conduits 50 and the plurality of flow channels 60 defined therein are formed by folding a generally planar piece or sheet of material 62. Examples of the type of material that may be used include, but are not limited to, sheet metal and non-metallic materials, such as polymers, thermally enhanced polymer based composites, or other suitable materials for example. An example of a folded heat exchanger conduit 50 is illustrated in FIG. 4. As shown, a flat piece of material 62 has been folded such that a single surface 63 of the piece of material 62 defines the leading edge 52, trailing edge 54, first surface 56, and second surface 58. By folding opposing edges 64, 66 of the sheet of material 62 to extend between the first and second surfaces 56, 58 of the conduit 50, a first portion 67 and a second portion 68 of the heat exchange conduit 50 are formed, each having a single flow channel 60. In the illustrated, non-limiting embodiments, the first portion 67 and the second portion 68 are substantially identical. However, embodiments where the first portion 67 and the second portion 68 vary in size and/or configuration are also within the scope of the disclosure.

(21) In addition, a portion of the heat exchange conduit 50, for example the portion of the first surface 56, arranged generally between the first portion 67 and the second portion 68 identified by numeral 69 in FIG. 4, may be slotted or perforated to reduce the total material of the heat exchange conduit 50 and to allow for drainage to prevent the collection of condensate on the external surface (e.g., single surface 63) of the conduit 50.

(22) As illustrated and described herein, each heat exchange conduit 50 includes both a first portion 67 and a second portion 68. Depending on the configuration of the heat exchanger 20, in some embodiments such as when the heat exchanger 20 has a multi-pass configuration for example, the first portion 67 of the heat exchange conduit 50 may be configured as a first tube bank having a first flow configuration and the second portion 68 of the conduit 50 may be configured as a second tube bank having a second flow configuration. For example, one or more of the conduits 50 may be configured such that the first portion 67 of the heat exchange conduit 50 receives a fluid flow in a first direction, and the second portion 68 of the same heat exchange conduit 50 receives a fluid flow in an opposite direction. However, both the first portion 67 and the second portion 68 of an adjacent conduit 50 of the heat exchanger 20 may, but need not be configured to receive a fluid flow in the same direction.

(23) In another embodiment, illustrated in FIG. 5, at least one of the opposing ends 64, 66 of the sheet of material 62 is bent to define a plurality of flow channels 60 within the first portion 67 and/or second portion 68 of the heat exchange conduit 50, respectively. Although the ends 64, 66 of the sheet of material 62 are illustrated as being bent to form a plurality of similar flow channels 60 having a generally rectangular cross-section, embodiments where the flow channels 60 vary in size, shape, cross-sectional flow area, have varying surface characteristics (e.g., having differing surface roughness or textures, coatings, embossed patterns, and the like), or further include inserts of same or different configuration are also within the scope of the disclosure.

(24) With reference now to FIGS. 6 and 6a, at least a portion of the surface 65 of the sheet of material 62 that forms an interior surface of the conduit 50 may be stamped, embossed, coated, or sprayed. When the sheet 62 is folded into a heat exchanger conduit 50, the textured surface forms a feature extending over at least a portion of the interior surface 65 of the flow channels 60. This feature may aid in heat transfer, for example by enhancing nucleate boiling, thin film condensation, or boundary layer re-initiation of a fluid as it flows through the flow channels 60. Although this feature is described as being formed on an interior surface 65 of the flow channels 60, the feature may alternatively or additionally be formed on the exterior surface 63 of the heat exchange conduit 50. Alternatively, or in addition, a pattern may be formed by at least partially removing portions from the sheet of material 62, such as by punching, machining, etching, abrasion (e.g., grinding), drilling, and the like for example. When the sheet of material 62 is folded, the portions of the sheet 62 that include the pattern can form fins, similar to serrated fins. These fins can create a boundary layer re-initiation zone which can enhance heat transfer. Although the pattern is described as forming fins, other enhancements, such as louvers, lances, winglets, and other vortex generators for example, are also within the scope of this disclosure.

(25) With reference to FIGS. 7, 7a, and 7h, at least a portion of the unfolded piece of material 62 has been manufactured (e.g., punched) with a plurality of features 73, such as generally hollow rectangular lances as shown in the FIGS. for example. In other embodiments, a separate component 75 having a plurality of features 73 formed therein may be inserted into an interior of the one or more flow channels 60. As a result of the pattern formed, when the sheet of material 62 is folded, the plurality of features 73 form a plurality of internal features 74 which may be arranged in a non-linear configuration. As shown in FIG. 7a, a portion of the internal features 74, such as illustrated in broken lines, are shifted laterally relative to an adjacent portion (e.g., shifted relative to an adjacent upstream and/or downstream feature 74) of the internal features 74, such that portions of the internal features 74 are offset from one another. This offset may be achieved by forming an offset in the features 73 of the sheet 62. For example, a first feature 73 may be shifted by up to half a distance of a width of an opening formed at least in part by an adjacent upstream feature 73. Accordingly, the length L extending between offset features 73, in the illustrated embodiment for example, defines a distinct flow channel 60 such that when the conduit 50 is formed via folding, adjacent internal features 74 with respect to the direction of flow of heat transfer fluid through the conduit 50, form offset flow channels 60, 60′.

(26) Referring now to FIGS. 8 and 9, a cross-section of the folded heat exchange conduit 50, for example a configuration of the flow channels 60 formed therein, may vary over the length of the heat exchange conduit 50. Unless specified otherwise, the term cross-section as used herein can refer to the shape or area of an intersection of the flow channel with a plane passing there through and perpendicular to the longest axis of the flow channel 60 described. By altering the sheet of material 62, such as via the fold pattern or by removing material for example, the hydraulic diameter of the heat exchange conduit 50 may vary over the length of a flow path defined by the heat exchanger conduit 50. For example, the sheet of material 62 is cut before being folded to form multiple sections. Each section 62a, 62b, 62c . . . 62n, arranged at a different positon along a length of the sheet of material 62 may have a different width. As a result of this configuration, the internal profile of the heat exchange conduit 50 and the flow channels 60 formed therein varies along the length of the conduit 50 between sections.

(27) In the non-limiting embodiment illustrated in FIGS. 8 and 8a, the sheet of material 62 is cut to form a first section 62a having a first flow channel configuration and a second section 62b having a second flow channel configuration distinct from the first flow channel configuration. Similarly, in the example illustrated in FIGS. 9 and 9a, the sheet of material 62 is cut to define three sections 62a, 62b, 62c, each having a different flow channel configuration than the others. In the illustrated, non-limiting embodiments, the variation in flow channel configuration occurs as a result of a change in cross-sectional flow area over the length of the conduit 50. However, it should be understood that other parameters, including, but not limited to cross-sectional shape and number of leading edges disposed in the flow path of the flow channel 60 (also referred to as flow impingements) for example, may be varied to achieve a different flow channel configuration, and therefore cross-section of the conduit 50.

(28) The hydraulic diameter of a flow channel 60 is calculated as DH=4A/P where A is the cross-sectional area of the flow channel 60 and P is the perimeter of the flow channel 60 in contact with the fluid flow. To achieve optimal performance, the ratio of the length of a flow channel 60 to the hydraulic diameter of the flow channel 60 (L/Dh) may be selected based on any pertinent parameter. For example, such parameters can include the type of fluid, the fluid phase, the fluid characteristics e.g., density, viscosity, velocity, ratios thereof, and the like) flowing through at least a portion of the heat exchanger conduit 50. In embodiments where the fluid is a liquid or two phase refrigerant, the ratio of the length to hydraulic diameter of the flow channels 60 may be between about 15 and 65. Alternatively, in embodiments where the fluid is a vaporized refrigerant, the ratio of the length to hydraulic diameter of the flow channels 60 may be between about 1.5 and 5. In embodiments where the fluid is water, the ratio of the length to hydraulic diameter of the conduits 50 is about 50 to 200 and when the fluid is a brine, the ratio of the length to hydraulic diameter of the conduits 50 is between about 150 and 600.

(29) A heat exchanger 20 including folded heat exchange conduits 50 as described herein have improved heat transfer and pressure drop characteristics compared to conventional heat exchangers. The folded conduits 50 may additionally provide added corrosion durability and reliability while reducing the complexity and cost of the heat exchanger 20.

(30) Embodiment 1: A heat exchange conduit, comprising: a body having a first portion including a first flow channel and a second portion including a second flow channel, wherein a cross-section of the heat exchange conduit varies over a length of the heat exchange conduit.

(31) Embodiment 2: The heat exchange conduit according to embodiment 1, wherein a configuration of at least one of the first flow channel and the second flow channel varies over the length of the heat exchange conduit.

(32) Embodiment 3: The heat exchange conduit according to either embodiment 1 or embodiment 2, wherein a hydraulic diameter of at least one of the first flow channel and the second flow channel varies over the length of the heat exchange conduit.

(33) Embodiment 4: The heat exchange conduit according to embodiment 3, wherein a ratio of the length of the first flow channel or second flow channel of the heat exchange conduit to a hydraulic diameter of the first flow channel or second flow channel, respectively, is optimized based on the type and phase of a fluid configured to flow through the heat exchange conduit.

(34) Embodiment 5: The heat exchange conduit according to embodiment 4, wherein when the fluid is at least one of a liquid and a two-phase refrigerant, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 15 to about 65.

(35) Embodiment 6: The heat exchange conduit according to embodiment 4, wherein when the fluid is a vapor refrigerant, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 1.5 to about 5.

(36) Embodiment 7: The heat exchange conduit according to embodiment 4, wherein when the fluid is water, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 50 to about 200.

(37) Embodiment 8: The heat exchange conduit according to embodiment 4, wherein when the fluid is a brine, a ratio of the length to the hydraulic diameter of at least one of the first flow channel and the second flow channel is about 150 to about 600.

(38) Embodiment 9: The heat exchange conduit according to any of the preceding claims, wherein the body includes a generally planar sheet of material folded to form the first portion and the second portion.

(39) Embodiment 10: The heat exchange conduit according to any of the preceding embodiments, wherein an interior surface of the heat exchange conduit includes a texture or pattern to form a boundary layer disruption of a fluid passing through the tube.

(40) Embodiment 11: The heat exchange conduit according to any of the preceding embodiments, wherein an exterior surface of the heat exchange conduit includes a texture or pattern to form a boundary layer disruption of a fluid passing around the tube.

(41) Embodiment 12: A heat exchanger, comprising: a first header; a second header; a plurality of heat exchange conduits arranged in spaced parallel relationship and fluidly coupling the first header and second header, wherein a configuration of at least one of the plurality of heat exchange conduits has varies along a length of the heat exchange conduit.

(42) Embodiment 13: The heat exchanger according to embodiment 12, wherein the at least one of the plurality of heat exchange conduits includes a first folded portion having one or more first flow channels and a second folded portion having one or more second flow channels, wherein at least one of a cross-sectional area and a cross-sectional shape of the one or more first flow channels or the one or more second flow channels varies over the length of the heat exchange conduit.

(43) Embodiment 14: The heat exchanger according to embodiment 13, wherein the first folded portion is part of a first tube bank and the second folded portion is part of a second tube bank.

(44) Embodiment 15: The heat exchanger according to any of the preceding embodiments, wherein a hydraulic diameter of the at least one first flow channel and second flow channel varies over the length of the heat exchange conduit.

(45) Embodiment 16: A method of forming a heat exchange conduit, comprising: providing a generally planar piece of material; folding a first end of the piece of material to form a first portion of the heat exchange conduit, the first portion including at least one first flow channel; and folding a second, opposite end of the piece of material to form a second portion of the heat exchange conduit, the second portion including at least one second flow channel, wherein a cross-section of the heat exchange conduit is non-uniform over a the length of the tube.

(46) Embodiment 17: The method according to claim 16, wherein a single surface of the piece of material forms a leading edge, trailing edge, first surface and second surface of the heat exchange conduit.

(47) Embodiment 18: The method according to either claim 16 or claim 17 wherein forming the first portion includes forming a plurality of first flow channels.

(48) Embodiment 19: The method according to any of the preceding claims, further comprising removing part of the piece of material such that a first section of the piece of material has a first width and a second section of the piece of material has a second width, the first width being different than the second width.

(49) Embodiment 20: The method according to any of the preceding claims, further comprising altering the piece of material to include a texture or pattern before folding the material, wherein when the piece of material is folded to form the heat exchange conduit, the texture or pattern is arranged at an interior surface of the heat exchange conduit.

(50) While the present disclosure has been particularly shown and described with reference to the exemplary embodiments as illustrated in the drawing, it will be recognized by those skilled in the art that various modifications may be made without departing from the scope of the present disclosure. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as, but that the disclosure will include all embodiments falling within the scope of the appended claims.