Enthalpy Exchanger Element, Enthalpy Exchanger Comprising Such Elements And Method For Their Production
20190186846 ยท 2019-06-20
Inventors
- Christian Hirsch (Eibenstock, DE)
- Stefan Brandt (Haar, DE)
- Christian Bier (Miesbach, DE)
- Martin MAYERSHOFER (Scheuring, DE)
Cpc classification
F28F2245/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F21/065
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C43/222
PERFORMING OPERATIONS; TRANSPORTING
B29C51/145
PERFORMING OPERATIONS; TRANSPORTING
B29C51/00
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/18
PERFORMING OPERATIONS; TRANSPORTING
B29C43/021
PERFORMING OPERATIONS; TRANSPORTING
F28D21/0015
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C2043/023
PERFORMING OPERATIONS; TRANSPORTING
F28F3/048
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F2245/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C51/10
PERFORMING OPERATIONS; TRANSPORTING
International classification
F28D21/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F21/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
F28F3/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C51/14
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention provides enthalpy exchanger elements (E, E, PR, PF) and enthalpy exchangers comprising such elements. Furthermore, the invention discloses a method for producing such enthalpy exchanger elements and enthalpy exchangers, comprising the steps of a) providing an air-permeable sheet element (1); b) laminating at least one side (1a, 1b) of the sheet element (1) with a thin polymer film (3, 4) with water vapor transmission characteristics; and c) forming the laminated sheet element (1) into a desired shape exhibiting a three-dimensional corrugation pattern (5, 5, . . . ).
Claims
1. A method for producing enthalpy exchanger elements (E, E, PF, PL) comprising the steps of: a) providing an air-permeable sheet element (1); b) laminating at least one side (1a, 1b) of the sheet element (1) with a thin polymer film (3, 4) with water vapor transmission characteristics; c) forming the laminated sheet element (1) into a desired shape exhibiting a three-dimensional corrugation pattern (5, 5, . . . ).
2. The method according to claim 1, wherein the sheet material of the sheet element (1) comprises a polymer.
3. The method according to claim 1, wherein the sheet element (1) is a fabric, preferably a nonwoven fabric.
4. The method according to claim 3, wherein a fraction, preferably at least 50% by weight, of the fibers (6) of the fabric are multi-component, preferably bi-component fibers.
5. The method according to claim 1, to wherein the laminating step b) comprises at least one of bonding, preferably heat bonding, welding and gluing, of the thin polymer film (3, 4) to the sheet element (1).
6. The method according to claim 1, wherein the at least one thin polymer film (3, 4) on the at least one side (1a, 1b) of the sheet element (1) is an air-impermeable polymer film.
7. The method according to claim 1, wherein the thin polymer film (3, 4) is a multilayer film comprising a sequence of polymer layers of different polymer types.
8. The method according to claim 7, wherein the polymer type of each polymer layer is selected from the group consisting of polyether ester, polyether amide and polyether urethane.
9. The method according to claim 7, wherein the total thickness of the thin polymer multilayer film is between 5 m and 200 m, more preferably between 10 m and 150 m.
10. The method according to claim 7, wherein the thickness of each individual polymer layer within the thin polymer multilayer film is between 1 m and 20 m, preferably between 4 m and 20 m, and more preferably between 4 m and 15 m.
11. The method according to claim 1, wherein the forming step c) is a thermoforming step, preferably a vacuum forming step or a pleating step.
12. The method according to claim 11, wherein at least a first mold part having first corrugation formations defining or co-defining the predetermined corrugation pattern of the enthalpy exchanger element (E, E) to be manufactured, is provided for and used in the thermoforming step c).
13. The method according to claim 12, wherein a second mold part having second corrugation formations complementary to the first corrugation formations co-defining the predetermined corrugation pattern of the enthalpy exchanger element (E, E) to be manufactured, is provided for and used in the thermoforming step c).
14. The method according to claim 10, wherein nozzles connected to a pressurized air source provided for and used in the thermoforming step c).
15. The method according to claim 14, wherein the nozzles are provided in the vicinity of the first mold part and/or the second mold part.
16.-24. (canceled)
25. The method of claim 1 further comprising: d) repeating steps a), b) and c) to produce a plurality of laminated and formed sheet elements exhibiting a three-dimensional corrugation pattern; e) stacking the plurality of laminated and formed sheet elements; and f) fixing the stacked laminated and formed sheet elements to each other.
26. (canceled)
27. An enthalpy exchanger element (E; E, PR, PF), produced using the method as defined in claim 1, including an air-permeable sheet element (1) and a predetermined three-dimensional corrugation pattern (5, 5, . . . ), wherein a first thin polymer film (3) is laminated to a first side (1a) of the sheet element (1) and/or a second thin polymer film (4) is laminated to a second side (1b) of the sheet element (1), the one or both thin polymer films (3, 4) having characteristics for selective water vapor transmission.
28. The enthalpy exchanger element (E, PR, PF) according to claim 27, wherein the first thin polymer film (3) and the second thin polymer film (4) are identical to each other.
29. The enthalpy exchanger element (E, PR, PF) according to claim 27, wherein the first thin polymer film (3) and the second thin polymer film (4) are different from each other.
30.-32. (canceled)
33. An enthalpy exchanger having at least three sheet-like or plate-like enthalpy exchanger elements (E1, E2, E3; E1, E2, E3) as defined in claim 27, which are stacked onto and fixed to each other, preferably by means of welding such as pinch welding, laser welding or ultrasonic welding or by means of gluing, with their respective three-dimensional corrugation patterns (5, 5, . . . ) in orthogonal or parallel orientation to form orthogonal or parallel fluid paths allowing fluids to flow there through.
Description
[0092] In the following description, two non-limiting embodiments of the invention are described in further detail below with reference to the drawings, wherein:
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[0106] In
[0107] In a first step S1, an air-permeable sheet element 1 having voids or openings 2 is provided.
[0108] In a second step S2, both sides 1a, 1b of the sheet element 1 are laminated with a thin polymer film 3, 4 with water vapor transmission characteristics.
[0109] In a third step S3, the laminated sheet element 1 is formed into a desired shape exhibiting a three-dimensional corrugation pattern 5.
[0110] The sheet element 2 is a non-woven fabric including thermoplastic fibers only or a combination of thermoset fibers and thermoplastic fibers. The fabric may include bicomponent fibers together with standard thermoset and/or thermoplastic fibers.
[0111] The thin polymer film 3, 4 is a multilayer film which may comprise a sequence (not shown) of polymer layers of different polymer types.
[0112] The forming step S3 is a thermoforming step, preferably a vacuum forming step. At least a first mold part (e.g. lower tool, not shown) having first corrugation formations co-defining the predetermined corrugation pattern 5 of the enthalpy exchanger element E, E to be manufactured, is used in the thermoforming step S3. In addition to the at least first mold part, a second mold part (e.g. upper tool, not shown) having second corrugation formations complementary to the first corrugation formations and/or a forming vacuum co-defining the predetermined corrugation pattern of the enthalpy exchanger element E, E to be manufactured, is/are used in the thermoforming step S3.
[0113] The resulting enthalpy exchanger element E having a first thin polymer film 3 on the first side 1a of the sheet element 1 and a second thin polymer film 4 on the second side 1b of the sheet element 1 comprises a corrugated structure 5 with alternating squeezed portions 5a and squeezed/stretched portions 5b. The squeezed portion 5a extend in a first direction (horizontal direction in
[0114] In
[0115] In
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[0117] The laminating step b) may comprise bonding, preferably heat bonding and/or gluing, of the thin polymer films 3, 4 to the sheet element 1. A thermoplastic adhesive (hot melt adhesive) may be used for the bonding between the polymer film 3 and 4 and the sheet element 1.
[0118] The sheet element 1 is a nonwoven fabric comprising a plurality of fibers 6. The fibers 6 may be thermoplastic fibers only or a combination of thermoset fibers and/or mineral fibers on the one hand and thermoplastic fibers on the other hand. Most preferably, the fabric includes multicomponent or bicomponent fibers together with standard thermoset and/or thermoplastic fibers. As can be best seen by comparing
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[0120] The forming step c) may be a pleating step or thermoforming step, preferably a vacuum forming step. At least a first mold part (e.g. lower tool, not shown) having first corrugation formations defining or co-defining the predetermined corrugation pattern of the enthalpy exchanger element E, E to be manufactured, is provided for and used in the thermoforming step. In addition to the at least first mold part, a second mold part (e.g. upper tool, not shown) having second corrugation formations complementary to the first corrugation formations and/or a forming vacuum co-defining the predetermined corrugation pattern of the enthalpy exchanger element E, E to be manufactured, may be provided in the thermoforming step.
[0121] The first mold part (e.g. lower tool) may comprise nozzles or through holes pneumatically connected to a vacuum source providing a vacuum for the vacuum forming step.
[0122] In addition to the first mold part and/or the second mold part used in the forming step c), preferably for supporting the vacuum action in the vacuum forming step, nozzles connected to a pressurized air source may be provided. These nozzles may be provided in the vicinity of, preferably adjacent to, the first mold part and/or the second mold part. Preferably, the pressurized air source comprises an air heating device for heating the pressurized air.
[0123] The combined use of the first tool and the vacuum source in the thermoforming step c) can be supplemented by the second tool and/or the pressurized air source, preferably with an air heating device. As a result, using at least some of these supplements, a sheet element 1 laminated with a first thin polymer film 3 and an optional second thin polymer film 4 can be pressed more strongly against the first corrugation formations of the first mold part, thus producing an enthalpy exchanger element E with a better copy of the first corrugation formations of the first mold part defining or co-defining the predetermined corrugation pattern of the enthalpy exchanger element E to be manufactured.
[0124] The sheet element 1 of the enthalpy exchanger element E has its fibers 6 much more densely packed than the sheet element 1 of
[0125] As a result, after cooling and hardening of the thermoplastic fibers or the multicomponent or bicomponent fibers of the plurality of fibers 6, the fabric sheet element 1 with its first thin polymer film 3 and its second thin polymer film 4 is transformed into an enthalpy exchanger element E according to the invention with a more compact fiber structure in the fabric sheet element 1 and with a three-dimensional corrugation pattern.
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[0129] In plan view, the first and second cross-flow regions CF1 and CF2 are delimited by a triangular contour line, i.e. they have a triangular shape. Each cross-flow region CF1 and CF2 comprises a plurality of air guiding walls 15 and 16, respectively. The air guiding walls 15 are substantially parallel to each other and substantially parallel to one side of the triangular shape of the first cross-flow region CF1. Similarly, the air guiding walls 16 are substantially parallel to each other and parallel to one side of the triangular shape of the second cross-flow region CF2. The air guiding walls 15 of the first cross-flow region CF1 and the air guiding walls 16 of the second cross-flow region CF2 both extend in a direction forming an angle of about 45 with the direction of the corrugations 5 of the parallel flow/counter-flow region PF. As a result, in the enthalpy exchanger stack with alternating right-handed enthalpy exchanger sheet elements PR and left-handed enthalpy exchanger sheet elements PL, the air guiding walls 15 of adjacent right-handed and left-handed sheet elements PR and PL extend in directions forming an angle of about 90 with respect to each other, thus defining the first cross-flow region CF1 of the enthalpy exchanger stack. Similarly, in the enthalpy exchanger stack with alternating right-handed enthalpy exchanger sheet elements PR and left-handed enthalpy exchanger sheet elements PL, the air guiding walls 16 of adjacent right-handed and left-handed sheet elements PR and PL extend in directions forming an angle of about 90 with respect to each other, thus defining the second cross-flow region CF2 of the enthalpy exchanger stack.
[0130] A first transition region 18 extends between the first cross-flow region CF1 and the parallel flow/counter-flow region PF. A second transition region 19 extends between the second cross-flow region CF2 and the parallel flow/counter-flow region PF. Both transition regions 18 and 19 comprise open ends and closed ends of the corrugations 5 and the parallel air ducts formed by the corrugations such that each closed-ended duct has an adjacent open-ended duct. The end wall of each closed-ended duct is sloped such that the wall forms an angle of 5 to 60 with respect to the longitudinal direction of the parallel air ducts. As a result, in the enthalpy exchanger stack with alternating right-handed enthalpy exchanger sheet elements PR and left-handed enthalpy exchanger sheet elements PL, resistance to air flow is minimized in the first transition regions 18 of the enthalpy exchanger stack and in the second transition regions 19 of the enthalpy exchanger stack.
[0131] The plate-like enthalpy exchanger element PR has a plurality of steps along its outer contour line. In the example shown in
[0132] Also, the plate-like enthalpy exchanger element PR has an offset 17 located about halfway along the length of each duct formed by the corrugations 5. As a result, in the enthalpy exchanger stack with alternating right-handed enthalpy exchanger sheet elements PR and left-handed enthalpy exchanger sheet elements PL, adjacent enthalpy exchanger sheet elements can be correctly positioned and are prevented from slipping into each other during the stacking operation.
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[0135] The difference between the second embodiment and the first embodiment is the type and number of offsets. Other than that, the right-handed plate-like enthalpy exchanger elements PR and left-handed plate-like enthalpy exchanger elements PL of the first and second embodiments are identical. In the drawings of the first and second embodiments, the same reference numerals are used for identical features in both embodiments.
[0136] Unlike the first embodiment where the right-handed plate-like enthalpy exchanger elements PR (
[0137] The first offset 171 and the second offset 172 each are formed as a curved longitudinal section or as an arcuate longitudinal section within the longitudinally extending corrugations 5 in the plate elements PR and PF. As shown in
[0138] Again, a plurality of such right-handed enthalpy exchanger sheet elements PR (as shown in
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REFERENCE NUMERALS
[0140] 1 fabric sheet element [0141] 1a first surface [0142] 1b second surface [0143] 2 voids or openings [0144] 3 first thin polymer film [0145] 4 second thin polymer film [0146] 5 corrugation(s) [0147] 5a squeezed portion [0148] 5b squeezed and/or stretched portion [0149] S1 providing step [0150] S2 laminating step [0151] S3 forming step (co-forming) [0152] O air flow direction towards viewer [0153] X air flow direction away from viewer [0154] 6 fiber [0155] angle (in corrugation pattern) [0156] PR plate-like enthalpy exchanger element, right-handed [0157] PL plate-like enthalpy exchanger element, left-handed [0158] 11 step [0159] 12 step [0160] 13 step [0161] 14 step [0162] CF1 first cross flow region of PR [0163] CF2 second cross flow region of PR [0164] PF parallel flow/counter flow region of PR [0165] CF1 first cross flow region of PL [0166] CF2 second cross flow region of PL [0167] PF parallel flow/counter flow region of PL [0168] 15 air guiding walls (in CF1) [0169] 16 air guiding walls (in CF2) [0170] 17 offset [0171] 171 first offset [0172] 172 second offset [0173] 18 first transition region (at CF1 side) [0174] 19 second transition region (at CF2 side) [0175] angle between directions of corrugations and air guiding walls