Header for a heat exchanger and a heat exchanger

Abstract

The disclosure relates to a header connected to or formed as a part of a heat exchanger. The heat exchanger has a heat exchanger body with a plurality of discrete channels for a first fluid and a plurality of discrete channels for a second fluid. The header has a first end having a round configuration and a second end being provided with a plurality of discrete channels. The header is provided with a plurality of dividers dividing one or more internal channels of the circular pipe into the plurality of discrete channels at the second end. At least some of the dividers extend from the second end to the first end and define a plurality of channel mouths at the first end. The disclosure also relates to a heat exchanger.

Claims

1. A header adapted to be connected to and form part of or being integrally formed as a part of a heat exchanger, the heat exchanger having a heat exchanger body with a plurality of discrete channels for a first fluid and a plurality of discrete channels for a second fluid, the header having: a first end having a round configuration being adapted to be connected to a circular pipe and to form an inlet to, or an outlet from, the heat exchanger; and a second end being adapted to be connected to or be integrally formed with the heat exchanger body and being provided with a plurality of discrete channels, wherein each discrete channel at the second end of the header is adapted to be individually connected to or integrally formed with one discrete channel of the plurality of discrete channels for the first fluid in the heat exchanger body, wherein the header is provided with a plurality of dividers dividing one or more internal channels of the header into the plurality of discrete channels at the second end, wherein all of the plurality of dividers at the second end extend from the second end to the first end and define a plurality of channel mouths at the first end, the channel mouths together forming the round configuration of the first end, and wherein the plurality of channels at the second end of the header are configured in a line configuration in that, in a cross-section across the plurality of channels, the plurality of channels is sub-divided into a plurality of groups, each group including a plurality of channels arranged along a line extending along a first direction across the cross-section of the second end.

2. A header adapted to be connected to and form part of or being integrally formed as a part of a heat exchanger, the heat exchanger having a heat exchanger body with a plurality of discrete channels for a first fluid and a plurality of discrete channels for a second fluid, the header having: a first end having a round configuration being adapted to be connected to a circular pipe and to form an inlet to, or an outlet from, the heat exchanger; and a second end being adapted to be connected to or be integrally formed with the heat exchanger body and being provided with a plurality of discrete channels, wherein each discrete channel at the second end of the header is adapted to be individually connected to or integrally formed with one discrete channel of the plurality of discrete channels for the first fluid in the heat exchanger body, wherein the header is provided with a plurality of dividers dividing one or more internal channels of the circular pipe into the plurality of discrete channels at the second end, wherein all of the plurality of dividers extend from the second end to the first end and define a plurality of channel mouths at the first end, the channel mouths together forming the round configuration of the first end, wherein the plurality of channels at the second end of the header are configured in a line configuration in that, in a cross-section across the plurality of channels, the plurality of channels is sub-divided into a plurality of groups, each group including a plurality of channels arranged along a line extending along a first direction across the cross-section of the second end, and wherein at least a sub-set of the dividers extend, in a cross-section across the channel mouths, along curved lines across the round configuration of the first end.

3. The header according to claim 1, wherein any upstream channel, as seen in a main direction extending from the first end to the second end, is connected to one or more downstream channels in the main direction.

4. The header according to claim 1, wherein adjacent lines are along a second direction, transverse to the first direction, separated a distance adapted to provide space for an intertwining of the line configured plurality of channels for the first fluid with a line configured plurality of channels for the second fluid.

5. The header according to claim 1, wherein the plurality of discrete channels at the second end are provided in a grid having a rectangular configuration.

6. The header according to claim 1, wherein the one or more dividers have longitudinal extensions along a main direction extending from the first end to the second end being at least two times a minimum cross-sectional dimension of respective one of the plurality of channels at the second end.

7. A heat exchanger comprising: a central heat exchanger body with a plurality of discrete channels for a first fluid and a plurality of discrete channels for a second fluid; and the header according to claim 1.

8. The heat exchanger according to claim 7, wherein the plurality of discrete channels for the first fluid and the plurality of discrete channels for the second fluid are in the central heat exchanger body arranged in a checkered pattern as seen in a cross-section extending across the plurality of discrete channels in the central heat exchanger body.

9. The heat exchanger according to claim 7, further comprising a transition portion having: a first outer portion in connection with the header forming a first fluid header for the first fluid; a second outer portion in connection with a further header forming a second fluid header for the second fluid; and an inner portion in connection with the central heat exchanger body, wherein the first outer portion is provided with a plurality of channels for the first fluid forming first fluid channels arranged in a line configuration, wherein the second outer portion is provided with a plurality of channels for the second fluid forming second fluid channels arranged in a line configuration, and wherein the inner portion is provided with the first fluid channels and the second fluid channels arranged in a checkered pattern.

10. The heat exchanger according to claim 9, wherein the transition portion is configured to transform the line configuration of the first fluid channels by, between the first outer portion and the inner portion, gradually shifting every second first fluid channel in respective line relative to every other first fluid channel in respective line in a shift direction being transverse to the lines in the line configuration, and wherein the transition portion transforms the line configuration of the second fluid channels by, between the second outer portion and the inner portion, gradually shifting every second second fluid channel in respective line relative to every other second fluid channel in respective line in the shift direction, whereby said every second first fluid channels and said every second second fluid channels form lines across the shift direction alternating with lines formed of said every other first fluid channels and said every other second fluid channels.

11. The heat exchanger according to claim 9, wherein the transition portion is integrally formed with the header and/or with the central heat exchanger body.

12. The heat exchanger according to claim 9, wherein the heat exchanger comprises: a central heat exchanger body; two transition portions, one at either end of the central heat exchanger body; and four headers, at respective outer portions of the transition portions, integrally formed into a single body.

13. The heat exchanger according to claim 9, wherein the transition portion is integrally formed with the header.

14. The heat exchanger according to claim 9, wherein the transition portion is integrally formed with both the header and the central heat exchanger body.

15. The header according to claim 2, wherein any upstream channel, as seen in a main direction extending from the first end to the second end, is connected to one or more downstream channels in the main direction.

16. The header according to claim 2, wherein the dividers extend from the second end to the first end, wherein each of the channel mouths formed at the first end is associated with a discrete channel extending through the header, wherein the discrete channels extending through the header form the plurality of discrete channels at the second end of the header.

17. The header according to claim 3, wherein the dividers extend from the second end to the first end, wherein each of the channel mouths formed at the first end is associated with a discrete channel extending through the header, wherein the discrete channels extending through the header form the plurality of discrete channels at the second end of the header.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will by way of example be described in more detail with reference to the appended schematic drawings, which shows a presently preferred embodiment of the invention.

(2) FIG. 1 is a side view of a heat exchanger.

(3) FIG. 2 is another side view of the heat exchanger of FIG. 1.

(4) FIG. 3 is an end view of the heat exchanger of FIGS. 1 and 2.

(5) FIG. 4 is a side view of a header.

(6) FIG. 5 is an end view of the header as seen along line A-A in FIG. 4.

(7) FIG. 6 is a cross-sectional view of the header as seen along line B-B in FIG. 4.

(8) FIG. 7 is an end view of the header as seen along line C-C in FIG. 4.

(9) FIG. 8 is an end view of a header showing its round configuration at one end thereof.

(10) FIG. 9 shows schematically the other end of the header of FIG. 8.

(11) FIG. 10 shows schematically the end of FIG. 9 also indicating the position of channels from another header.

(12) FIG. 11 shows schematically a cross-section along line XI-XI in FIG. 2 disclosing a checkered pattern formed from the configuration of channels of a header of FIGS. 8 and 9.

(13) FIG. 12 is an end view of a header showing its round configuration at one end thereof.

(14) FIG. 13 shows schematically the other end of the header of FIG. 12.

(15) FIG. 14 shows schematically the end of FIG. 13 also indicating the position of channels from another header.

(16) FIG. 15 shows schematically a cross-section along line XI-XI in FIG. 2 disclosing a checkered pattern formed from the configuration of channels of a header of FIGS. 12 and 13.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(17) FIGS. 1-3 discloses a heat exchanger 1 comprising a central heat exchanger body 10, two transition portions 20a-b, one at either end of the central heat exchanger body 10, and four headers 30a-d, at respective outer portions of the transition portions. In the disclosed embodiment, the central heat exchanger body 10, the two transition portions 20a-b and the four headers 30a-d are integrally formed into a single body. In FIG. 1, a flow direction F.sub.1 for a first fluid and a flow direction F.sub.2 for a second fluid are indicated. The first fluid enters into the heat exchanger via the header 30b, through the transition portion 20a to the central heat exchanger body 10 from which it leaves through the transition portion 20b and out via header 30d. The second fluid enters into the heat exchanger via the header 30c, through the transition portion 20b to the central heat exchanger body 10 from which it leaves through the transition portion 20a and out via header 30a. The central heat exchanger body 10 comprises a plurality of discrete channels B.sub.ij for a first fluid and a plurality of discrete channels C.sub.ij for a second fluid. Typically the flows of fluid are counter each other in the central heat exchanger body 10 as shown in FIG. 1. However, it is also conceivable that the flows of fluid are along the same direction in the central heat exchanger body 10. In FIGS. 1-3, the first fluid flows along the straight line at both ends of the heat exchanger and the second fluid changes direction (90° in the figures) at both ends of the heat exchanger. It is also conceivable that the second fluid flows along a straight line at one of the ends and that the first fluid changes direction at that end of the heat exchanger. There are numerous other conceivable configurations and orientations of the headers relative to the central heat exchanger body. In one embodiment both headers 30a and 30b form an angle, such as 45°, relative to the flow direction F.sub.1 in the central heat exchanger body. The headers 30c and 30d may in such a case preferably also form corresponding angles, such as 45°.

(18) The headers 30a-d will be described in more detail with reference to FIGS. 4-7 and will be collectively referred to as a header 30. The header 30 is adapted to be connected to and form part of or being integrally formed as a part of a heat exchanger 1. As will be explained in more detail below, the heat exchanger 1 has a heat exchanger body 10 with a plurality of discrete channels for a first fluid and a plurality of discrete channels for a second fluid.

(19) As shown in FIGS. 4 and 5, the header 30 has a first end 31 having a round configuration. The first end 31 is adapted to be connected to a circular pipe and to form an inlet to, or an outlet from, the heat exchanger 1. As shown in FIGS. 4 and 7, the header 30 has a second end 32. The second end 32 is adapted to be connected to or be integrally formed with the heat exchanger body 10. As shown in FIG. 7, the second end 32 is provided with a plurality of discrete channels B.sub.ij corresponding to the plurality of discrete channels for the first fluid in the heat exchanger body 10. The plurality of discrete channels B.sub.ij are at the second end 32 provided in a grid having a rectangular configuration. Each discrete channel B.sub.ij at the second end 32 of the header 30 is individually connected to or integrally formed with one (single) discrete channel B.sub.ij for the first fluid in the heat exchanger body 10. Correspondingly, each discrete channel B.sub.ij for the first fluid in the heat exchanger body 10 is individually connected to or integrally formed with one (single) discrete channel B.sub.ij at the second end 32 of the header 30. The number of discrete channels B.sub.ij at the second end 32 of the header 30 is the same as the number of discrete channels B.sub.ij for the first fluid in the heat exchanger body 10. Each discrete channel B.sub.ij at the second end 32 of the header 30 is individually connected to or integrally formed with one discrete channel B.sub.ij for the first fluid in the heat exchanger body 10 via one (single) discrete channel B.sub.ij in the transition portion 20.

(20) As shown in FIG. 5, the header 30 is provided with a plurality of dividers 33 dividing the internal channel (or channels) of the circular pipe into the plurality of discrete channels B.sub.ij at the second end. The dividers 33 may also be referred to as internal walls. It may be noted that the dividers 33 or walls form a lattice or web across the first end 31 of the header 30. As is indicated in FIG. 4 and as becomes apparent from the cross-section B-B in FIG. 6, all the dividers 33 extend from the second end 32 to the first end 31. However, it may be noted that in a general concept the dividers 33 need not extend all the way to the first end 31. It is sufficient that the dividers 33 extend from the second end 32 towards the first end 31. However, to make the most use of the length of the header 30, at least some of the dividers 33 extend from the second end to the first end 31 and define a plurality of channel mouths A.sub.ij at the first end 31. In FIG. 5 one of the channel mouths A.sub.ij is indicated by a shading of the area of the channel mouth. As shown in FIG. 5, the channel mouths A.sub.ij together form the round configuration of the first end 31. In the disclosed embodiment, the dividers 33 or walls 33 are tight walls not allowing any fluid to flow from one channel associated with a first channel mouth A.sub.ij to any channel associated with any other channel mouth A.sub.ij. Thereby the header 30 is capable of dividing the flow into discrete channels. As indicated in FIGS. 4 and 7, the dividers 33 have longitudinal extensions L along the main direction MD being at least two times a minimum cross-sectional dimension w of respective one of the plurality of channels B.sub.ij at the second end 32.

(21) As shown in FIG. 5, at least a sub-set of the dividers 33 extend, in a cross-section across the channel mouths (FIG. 5), along curved lines (indicated by the dashed line 36) across the round configuration of the first end 31.

(22) As shown in FIGS. 4-7, any upstream channel, as seen in a main direction MD extending from the first end 31 to the second end 32 is uniquely connected to one downstream channel in the main direction MD. This may also be expressed as that each of the channel mouths A.sub.ij formed at the first end is uniquely associated with a discrete channel B.sub.ij extending through the header.

(23) This restriction would, when it comes to cases where some of the dividers extend to the first end and some dividers extend to one or more positions between the first and second ends, read that any upstream channel, as seen in a main direction MD extending from the first end 31 to the second end 32 is uniquely connected to one or more downstream channels in the main direction MD. In this case, some or all of the channels of respective one of the channel mouths A.sub.ij are destined to be divided, in one or more further steps, into the plurality of channels B.sub.ij at the second end 32. Thus, the number of channels B.sub.ij at the second end 32 of the header may be larger than the number of channel mouths A.sub.ij at the first end 31. The main direction does not necessarily coincide with the direction of the fluid flow through the header, since the fluid flow through the header may either be in the direction of the main direction or in the opposite direction of the main direction. The main direction is a way of defining relative locations. An upstream channel is located closer to the first end 31 than a downstream channel and a downstream channel is located closer to the second end 32 than an upstream channel.

(24) As shown in FIG. 7, the plurality of channels B.sub.ij at the second end 32 of the header 30 are configured in a line configuration. The line configuration may be defined as that, in a cross-section (FIG. 7) across the plurality of channels B.sub.ij, the plurality of channels is sub-divided into a plurality of groups, each group including a plurality of channels B.sub.1j, B.sub.2j, etc, arranged along a line extending along a first direction D.sub.1 across the cross-section of the second end 32. By sub-dividing the channels B.sub.ij into such a line configuration, it is prepared for in a following transition portion 20 changing the line configuration to a checkered configuration inside the central heat exchanger body 10 of the heat exchanger 1.

(25) In FIGS. 8-11, a transformation from a round configuration of channels for single fluid to a checkered configuration for two fluids is schematically disclosed. The header 30 has a first end 31 provided with a plurality of channel mouths A.sub.ij separated by a plurality of dividers 33. Each such channel mouth A.sub.ij is uniquely associated with a channel B.sub.ij at the second end 32. A.sub.11 is associated with B.sub.11; A.sub.21 is associated with B.sub.21, etc.

(26) As shown in FIG. 9, the adjacent lines, such as B.sub.1j and B.sub.2j, are separated a distance d as measured in the second direction D.sub.2, transverse to the first direction D.sub.1. As indicated in FIG. 10, this distanced is adapted to provide space for an intertwining of the line configured plurality of channels B.sub.ij for the first fluid with a line configured plurality of channels C.sub.ij for the second fluid.

(27) The plurality of discrete channels B.sub.ij for the first fluid and the plurality of discrete channels C.sub.ij for the second fluid is in the central heat exchanger body 10 arranged in a checkered pattern as seen in a cross-section (FIG. 11 and FIG. 15) extending across the plurality of discrete channels in the central heat exchanger body. It may be noted that the checkered pattern may be a truly checkered trough-out the cross-section of the central heat exchanger body (as shown in FIG. 15). The checkered pattern may also be checkered in the central portions and have along its perimeters a configuration slightly different from truly checkered. For instance, along one perimeter the pattern may be formed of first fluid channels alternating with blocked channel spaces and along the opposing perimeter the pattern may be formed of second fluid channels alternating with blocked channel spaces (as shown in FIG. 11).

(28) It should be noted that the number of channels is in practice often significantly greater than the number of channels indicated in the figures. In some aspects, the channels may have a square cross-section with the sides of 0.5 mm to 2 mm. In some aspects, the wall thickness between the channels may be about 0.05 mm to 0.4 mm.

(29) As mentioned above, the heat exchanger 1 further comprises transition portions 20a-b collectively denoted 20. The transition portion 20 has a first outer portion 22 in connection with a header 30 of the kind described above forming a first fluid header for the first fluid and a second outer portion 23 in connection with a further header 30 of the kind described above forming a second fluid header for the second fluid. The transition portion has an inner portion 21 in connection with the central heat exchanger body 10. The first outer portion 22 is provided with a plurality of channels for the first fluid forming first fluid channels arranged in a line configuration. The second outer portion 23 is provided with a plurality of channels for the second fluid forming second fluid channels arranged in a line configuration. The inner portion 21 is provided with the first fluid channels and the second fluid channels arranged in a checkered pattern. As mentioned above, this checkered pattern may be a truly checkered pattern or a checkered pattern with two opposing perimeters being only formed of the first fluid channels and the second fluid channels, respectively.

(30) The transition portion is configured to transform the line configuration of the first fluid channels B.sub.ij by, between the first outer portion and the inner portion, gradually shifting every second first fluid channel in respective line relative to every other first fluid channel in respective line in a shift direction D.sub.2 being transverse to the lines in the line configuration, and to transform the line configuration of the second fluid channels Cij by, between the second outer portion and the inner portion, gradually shifting every second second fluid channel in respective line relative to every other second fluid channel in respective line in the shift direction D.sub.2.

(31) This shift is illustrated in FIG. 10 to FIG. 11 and in FIG. 14 to FIG. 15.

(32) As can be seen in FIGS. 11 and 15, this results in a pattern where every second first fluid channels B.sub.ij and said every second second fluid channels C.sub.ij form lines across the shift direction D.sub.2 alternating along the shift direction D.sub.2 with lines across the shift direction D.sub.2 formed of said every other first fluid channels and said every other second fluid channels. This way the line configuration at the interface between the header and the transition portion is transformed into a checkered pattern.

(33) It may be noted that the header 30 may at its first end 31 have a configuration of the mouths A.sub.ij of the channels A.sub.ij having the configuration shown in FIG. 12, where every second one of the areas 35 are blocked in two opposing perimeter lines. This is a suitable preparation to achieve the configuration shown in FIG. 13 at the second end 32 of the header. This is in turn a configuration which is suitable as a preparation to achieve the true checkered pattern shown in FIG. 15.

(34) Alternatively, the header 30 may have all the potential mouths A.sub.ij open as shown in FIG. 8. This is a suitable preparation to achieve the configuration shown in FIG. 9 at the second end 32 of the header. This is in turn a configuration which is suitable as a preparation to achieve the checkered pattern shown in FIG. 11.

(35) The headers 30 may be formed by additive depositing of a material, such as a metallic material, preferably chosen from the group consisting of titanium or titanium based alloys, tantalum or tantalum based alloys, steel or steel based alloys, stainless steel or stainless steel based alloys. The material may be laser or electron sintered during the additive depositing of the metallic material, or sintered in an oven after the additive depositing.

(36) The transition portions 20 may be formed by additive depositing of a material, such as a metallic material, preferably chosen from the group consisting of titanium or titanium based alloys, tantalum or tantalum based alloys, steel or steel based alloys, stainless steel or stainless steel based alloys.

(37) The central heat exchanger body 10 may be formed by additive depositing of a material, such as a metallic material, preferably chosen from the group consisting of titanium or titanium based alloys, tantalum or tantalum based alloys, steel or steel based alloys, stainless steel or stainless steel based alloys. The material may be laser or electron sintered during the additive depositing of the metallic material, or sintered in an oven after the additive depositing.

(38) Preferably the headers 30 and the transition portions 20 are integrally formed by additive depositing of a material, such as a metallic material, preferably chosen from the group consisting of titanium or titanium based alloys, tantalum or tantalum based alloys, steel or steel based alloys, stainless steel or stainless steel based alloys.

(39) Preferably the central heat exchanger body 10, the transition portions 20 and the headers 30 are integrally formed by additive depositing of a material, such as a metallic material, preferably chosen from the group consisting of titanium or titanium based alloys, tantalum or tantalum based alloys, steel or steel based alloys, stainless steel or stainless steel based alloys.

(40) The material may be laser or electron sintered during the additive depositing of the metallic material, or sintered in an oven after the additive depositing.

(41) It is contemplated that there are numerous modifications of the embodiments described herein, which are still within the scope of the invention as defined by the appended claims.

(42) The channels may for instance have other cross-sectional shapes than the rectangular and quadratic shapes shown in the drawings. The first fluid channels may e.g. have a circular shape and the second fluid channels may have a shape as a four sided polygon with inwardly bulging sides to fit in the area formed at the intersection of four neighboring circular first fluid channels. Other shapes, such as ovals, triangles, etc, are also conceivable.