Modular heat exchanger with sections interconnected by connectors
10105801 ยท 2018-10-23
Assignee
Inventors
Cpc classification
Y02B30/00
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
F28F21/088
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F21/084
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F9/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H1/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F9/264
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y10T29/4935
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
F28F2275/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H9/146
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F28F9/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H1/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H9/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Heat exchanger, comprising a series of interconnected modules, each module comprising at least part of a water duct and part of a flue duct, wherein at least the parts of the water ducts of successive modules are interconnected, forming at least one continuous water duct through and/or along a number of said modules, wherein water duct parts of two adjacent modules are interconnected by a connector inserted into an opening in at least one of the modules forming a sealing connection.
Claims
1. Heat exchanger, comprising a series of interconnected modules, each module comprising at least part of a water duct and part of a flue duct, wherein at least the parts of the water ducts of successive modules are interconnected, forming at least one continuous water duct through and/or along a number of said modules, wherein water duct parts of two adjacent modules are interconnected by a connector inserted into an opening in at least one of the modules forming a sealing connection, wherein the connector is provided with at least one opening, extending through a wall part thereof, for injecting a bonding agent between an outer surface part of the connector and an inner surface part of the opening in the at least one of the modules.
2. Heat exchanger according to claim 1, wherein the connector is inserted into openings in both modules.
3. Heat exchanger according to claim 1, wherein the connector is bonded into position by the bonding agent.
4. Heat exchanger according to claim 1, wherein between each pair of adjacent modules at least two connectors are provided, near two opposite sides of the heat exchanger.
5. Heat exchanger according to claim 1, wherein said connector is made of plastic and the modules are made of metal.
6. Heat exchanger according to claim 1, wherein said connector comprises an outer surface with protrusions extending outward, profiled such that seen in an insertion direction into the opening the protrusions have an inclined surface leaning backward, having a top engaging an inner surface of the opening, such that these protrusions counteract retraction of the connector from the opening when positioned therein.
7. Heat exchanger according to claim 1, wherein said at least one opening is a series of openings.
8. Heat exchanger according to claim 1, wherein the opening, into which the connector is inserted, is provided with an outside end, which is provided with a first fitting element, and wherein the connector is provided with at least one protruding second fitting element for cooperation with the first fitting element, for defining an insertion position of the connector.
9. Heat exchanger according to claim 1, wherein modules comprise an flue inlet and a flue outlet, and wherein the part of the flue duct of each module connects said flue inlet with said flue outlet, wherein an inlet for the part of the water duct in said module is closer to the flue outlet than to the flue inlet and wherein an outlet for the part of the water duct in said module is closer to the flue inlet than to the flue outlet.
10. Heat exchanger according to claim 1, wherein the modules have two opposite sides, each comprising an area defining said part of a flue duct, wherein each of said areas preferably comprises heat exchanging surface increasing elements, such that when a pair of adjacent modules is interconnected by at least said one connector, facing areas of the modules form a flue duct portion.
11. Heat exchanger according to claim 1, wherein the series of modules is provided, at two opposite ends, with an end module, wherein a first series of connectors connecting pairs of modules form part of a first connecting duct and a second series of connectors connecting pairs of modules form part of a second connecting duct, the first and second connecting ducts connecting opposite ends of the series of water duct parts of the modules.
12. Heat exchanger according to claim 1, wherein each module has an edge portion extending around at least part of the duct forming part thereof, wherein said edge portions of adjacent modules have been glued together, connecting the modules and sealing the flue duct forming parts for forming a flue duct between said adjacent modules.
13. Heat exchanger according to claim 1, wherein the connectors have an internal passage having a cross section perpendicular to a direction of flow through said passage which is larger than the largest cross section of the parts of the water ducts formed in the modules.
14. Module comprising at least part of a water duct and part of a flue duct, the module further comprising a connector inserted into the part of the water duct, wherein the connector is provided with at least one opening, extending through a wall part thereof, for injecting a bonding agent between an outer surface part of the connector and an inner surface of the module, said connector configured for forming a sealing connection between the part of the water duct and a part of a water duct of a successive module when interconnected.
15. Heating boiler comprising a heat exchanger according to claim 1.
16. Heat exchanger according to claim 3, wherein the bonding agent is glue that forms at least part of the sealing connection.
17. Heat exchanger according to claim 4, wherein the two opposite sides of the heat exchanger, near which the at least two connectors are provided, are respectively an upper end and a lower end of the heat exchanger.
18. Heat exchanger according to claim 5, wherein the metal is aluminum or an aluminum alloy.
19. Heat exchanger according to claim 6, wherein the protrusions are compressed when inserted into said opening.
20. Heat exchanger according to claim 8, wherein the first fitting element is beveled or chamfered.
21. Heat exchanger according to claim 10, wherein the flue duct portion includes a labyrinth path for flue gasses passing through said duct portion.
22. Heat exchanger according to claim 12, wherein the edge portion extends around all of the duct forming part thereof.
23. Heat exchanger, comprising a series of interconnected modules, each module comprising at least part of a water duct and part of a flue duct, wherein at least the parts of the water ducts of successive modules are interconnected, forming at least two continuous water ducts through and/or along a number of said modules, wherein water duct parts of two adjacent modules are interconnected by a connector inserted into an opening in at least one of the modules forming a sealing connection, wherein the modules each further comprise a flue inlet and a flue outlet, and wherein the part of the flue duct of each module connects said flue inlet with said flue outlet, wherein an inlet for the part of the water duct in said module is closer to the flue outlet than to the flue inlet and wherein an outlet for the part of the water duct in said module is closer to the flue inlet than to the flue outlet, and wherein each of said interconnected modules further comprises a duct part extending around an opening near an upper end of the module, wherein said part of the flue duct comprises said opening and extends through each module, providing a continuous opening through the series of modules that forms a burner chamber for the heat exchanger, wherein a first of said at least two continuous water ducts extends above said burner chamber and a second of said at least two continuous water ducts extends below said burner chamber.
24. Heat exchanger according to claim 23, wherein the flue outlet of each module in said series of modules is provided at a lower end of the heat exchanger, including a condensate collecting provision.
25. Heat exchanger according to claim 23, wherein each module in said series of modules has two opposite sides, each side comprising an area defining said part of a flue duct and comprising heat exchanging surface increasing elements, such that when said water duct parts of said two adjacent modules are interconnected by said connector, facing areas of said two modules form a flue duct portion, wherein the series of modules is provided, at two opposite ends, with an end module, wherein a first series of connectors connecting pairs of modules form part of a first connecting duct and a second series of connectors connecting pairs of modules form part of a second connecting duct, the first and second connecting ducts connecting opposite ends of the water duct parts of the modules, wherein the flue inlets of the series of modules form a first continuous flue duct suitable for receiving a burner and the flue outlets of the series of modules form a second continuous flue duct through the series of modules.
26. Heat exchanger according to claim 25, wherein the first and second connecting ducts extend substantially parallel to each other, wherein a third series of connectors connecting pairs of modules form part of a third connecting duct, extending substantially parallel to the first and second connecting ducts, wherein a duct part is provided, connecting ends of the second and third connecting duct, wherein the first and second connecting ducts each have one closed end, such that an open end of the first connecting duct is positioned at the same side of the series of modules as an open end of the third connecting duct.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention shall be further elucidated in the following description, with reference to the drawings, in which:
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DETAILED DESCRIPTION
(7) In this description different embodiments of heat exchangers and parts thereof, as well as heating circuits equipped therewith are disclosed and described by way of example only. In these embodiments the same or similar parts have the same or similar reference signs. Combinations of parts of the embodiments shown are also considered to have been disclosed herein. In this description a heat exchanger as to be understood as an exchanger for exchanging heat between heated flue gasses from a burner and water flowing through one or more water channels within said heat exchanger. Preferably a flame receiving space is provided over and/or into which a burner can be inserted, such that said heated flue gasses are actively created, during use, within said heat exchanger. In an alternative the burner can be at least partly integrated in the heat exchanger, for example by extrusion, casting and/or machining. Such heat exchangers are especially, but not exclusively suitable in domestic and commercial heating systems such as boilers and central heating systems, such as for space heating and/or tap water heating systems.
(8) In the following description some or all of the parts can also be made by casting, such as but not limited to injection moulding, sand or otherwise lost core moulding or casting or the like, possibly combined with machining, such as but not limited to grinding, turning, milling, drilling and the like known machining methods. Also or alternatively other techniques can be used, where applicable, such as but not limited to extrusion.
(9) In this description light metal is at least to be understood as including non-ferro metal and non-ferro metal alloy having a density of less than 4500 kg/m.sup.3. Preferred materials are aluminum and aluminum alloy.
(10) In this description wording like top and bottom and sides are used as references only, without limiting the possible positioning of the heat exchanger or parts thereof in use. In this description top and bottom are used as defined in
(11) In this description words like substantially and about indicate that slight deviations from a dimension or orientation to which they refer is allowable, for example less than 20%, more preferably less than 15%, for example up to 10%.
(12) In this description bonding has to be understood as forming an adhesive connection between two or more parts using an elastic bonding agent. Especially suitable is a glue or adhesive which after curing is still flexible and elastically deformable. Preferably the bonding agent is heat resistant to temperatures above 120 C., preferably above 150 C., more preferably above 170 C. A glue can be used having a temperature resistance up to 180 C. or above. A glue can be used having a use temperature range between about 4 and +120 C., preferably between about 20 and +150 C., more preferably between about 40 and +170 C., even more preferably between at least 55 and 180 C. or higher (e.g. PSI S406). A temperature range should be understood as a range of temperatures in which the glue maintains at least most of its elastic and bonding properties, such that in a heat exchanger at least the bonding maintains pressure resistant and fluid and gas tight. Pressure resistant is in this context to be understood as at least resistant to pressures in an adjoining space of above 2 bar, preferably above 4 bar, more preferably at least to 10 bar. The desired pressure resistance can be as high as 20 bar or above. One bar is 100.000 Pascal or 0.1 MPa. Reference can be made to adhesion to peel, according to ASTM C794.
(13) Elastic bonding agent, such as glue or adhesive should be understood as an agent which, after curing, has during use, a high yield strength and high yield limit. This means it can be stretched to a relatively high degree before breaking. The elasticity is preferably such that the yield limit is more than about 300%, preferably more than about 400%, more preferably more than about 550% and in particular preferably about 650% or more. Preferably this high yield limit is maintained over the temperature range during use of the heat exchanger. The yield limit can e.g. be measured according to ASTM D412.
(14) The bonding agent can be a silicone or elastomeric based adhesive, preferably curing at about room temperature to a rubber like component which is water and gas tight. A bonding layer formed by said bonding agent is preferably pressure resistant to at least about 4 Bar, more preferably to about 10 Bar and even more preferably to about 20 Bar or above, wherein the bonding agent is preferably applied to unprimed metal of the parts. An example of such bonding agent is Dow Corning 7091, which has a normal temperature range of use between 55 and +180 C., and a yield limit of about 680%.
(15) All kinds of combinations can be contemplated of yield limit, pressure resistance and temperature range.
(16) Dow Corning 7091 Adhesive/Sealant is a high-performance, neutral-cure silicone that cures at room temperature to a tough, flexible rubber, suitable for the use described herein. Dow Corning 7091 remains flexible and stable from 55 to 180 C. (67 to 356 F.), and is a one-component, non-sag sealant. It can have a tear strength of 86 ppi and a tensile strength of about 363 psi. This adhesive is only provided by way of example and should not be considered limiting the scope in any way.
(17) By using such a flexible bonding agent parts of the heat exchanger can be connected to each other, forming fluid, especially water, and gas tight seals without having to add gaskets, seals or the like, which will remain fluid and gas tight over a large temperature range. Moreover, such seals are relatively inexpensive and are pressure resistant to relatively high pressures. Furthermore, due to the high flexibility, problems with different expansion rates and directions of the different parts bonded together are avoided.
(18) Alternative or additional to bonding other connecting techniques and materials could be used, such as but not limited to welding, screws, nuts and bolts, clamping.
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(20) In preferred embodiments the connector or connectors 3 are elements initially separate from the modules 2, and are inserted into openings 8 in two adjacent modules 2 as shown for example in
(21) In the embodiment of
(22) Between each pair of adjacent modules at least two connectors 3 are provided, near two opposite sides of the heat exchanger 1, such that both inlets 11 and outlets 12 of the duct parts 4 of the different modules 2 can be connected. In
(23) By connecting the modules 2A, 2B, 2C as shown, by the connectors 3, the channel parts 27, 28 are connected for forming said connecting ducts 25, 26, having for example longitudinal axis L.sub.27, L.sub.28 extending parallel to each other and connecting the various water duct parts 4.
(24) The central modules 2A have two opposite sides 63, such as on either side of the plane Q, each side comprising an area 18 defining a part 6 of the flue duct 7. Each of said areas 18 preferably comprises heat exchanging surface increasing elements 19. These elements 19 can for example be pins, ribs, notches and the like, or combinations thereof, as are well known from the art as for example disclosed in EP0645591 or EP0843135. The end modules 2B, 2C each have only one such area 18. The areas 18 and elements 19 are provided such that when a pair of adjacent modules 2 is interconnected, facing areas 18 of the modules form a flue duct portion 6A, preferably with a labyrinth path for flue gasses passing through said duct portion 6A from an inlet side 20 near the opening 13 to an outlet side 21 at the lower end of the heat exchanger, connected to an exhaust in a known manner, for example including a condensate collecting provision. In the embodiments shown the elements 19 extend from a wall 10 of the water duct part 4 and intensify the heat exchange between flue gas flowing through the flue duct 7 and the liquid, such as water, flowing through the water duct 5. The elements 19 can extend substantially perpendicular to the planes Q and/or V and can have free ends 22 lying substantially in the plane Q. The modules 2 comprise a flue inlet 20 and a flue outlet 21, wherein the part 6 of the flue duct 7 of each module 2 connects said flue inlet 20 with said flue outlet 21. The inlet 11 for the part 4 of the water duct 5 in said module 2 can be closer to the flue outlet 21 than to the flue inlet 20. The outlet 12 for the part 4 of the water duct 5 in said module 2 can be closer to the flue inlet 20 than to the flue outlet 21. Thus a counter flow pattern can be obtained between the flue gasses and the liquid, especially water.
(25) In embodiments as shown in for example
(26) When assembling a heat exchanger according to the present invention, modules 2 are provided with connectors 3 inserted into appropriate openings 8. When a connector 3 is placed in an opening 8 of a module, it is inserted to the appropriate depth, for example until it abuts the shoulder 31, as shown in
(27) The opening 8 can be provided with an outside end 41, which is provided with a first fitting element 42, for example a beveled or chamfered edge 43, wherein the connector 3 is provided with at least one protruding second fitting element 44, for example a complementary beveled or chamfered ring, for cooperation with the first fitting element 42. Such first and second fitting elements 42, 44 can aid in defining an insertion position of the connector 3, and can moreover further sealing and connection of the heat exchanger modules 2.
(28) In advantageous embodiments the heat exchanger 2 can have a Tichelman flow pattern, as shown schematically in
(29) In the embodiment shown in
(30) In a heat exchanger 1 according to the present disclosure, the connectors 3 are preferably bonded into the modules, such that they form heat and pressure resistant connections for the water duct, which will during use be at the highest pressure in the heat exchanger. The water duct parts 4 in the modules can further be integrally formed and thus need no further sealing. By bonding the end surfaces Q of the modules 2 to each other, the flue duct parts 6 of the modules and the openings 13 for forming the burner space are also properly connected and sealed, especially gas tight. The gas pressure shall normally be lower than the water pressure.
(31) An advantage of the present heat exchanger can be that it can be build up gradually, by for example starting with an end module, for example the first end module 2B, then mounting subsequently a series of intermediate modules 2A to said end module 2B or a previous intermediate module 2A respectively, and finally mounting the second end module 2C to the last intermediate module 2A of the series. Such series can comprise any desired number of intermediate modules, whereas a heat exchanger could even be formed by the two end modules 2B, 2C only.
(32) In embodiments the end surfaces of the modules to be connected to each other can be formed mainly by end surfaces or ridges of relatively thin walls of the heat exchanger modules 2. As can be seen in
(33) In the present disclosure embodiments of heat exchangers according to the present invention have been disclosed by way of example only. These should by no means be understood as limiting the scope of the invention as disclosed. Many variations are possible, including but not limited to all combinations of parts and features of the embodiments specifically disclosed. Furthermore for example openings in modules, especially end modules can be closed by stops or the like, for example bonded or welded in placed, in stead of by wall parts of the modules. The water duct parts and flue duct parts could be formed and shaped in a different manner, for example for obtaining a different flow path, altered resistance, or for amending the efficiency. The connectors and openings can be shaped differently, for example non cylindrical, such that the connectors can have one or more defined position in the opening. The modules and/or connectors can be made of different materials or by different methods. A heat exchanger could be provided with two or more separate water ducts, for example one for heating water to be used in a space heating circuit and one for heating tapping water. These any many such variations are considered falling within the scope of this disclosure.