System and method for energy-saving inductive heating of evaporators and other heat-exchangers

Abstract

A novel method of deicing utilizing a fins-on-tubes type evaporator/heat exchanger system that is optimized for energy-saving inductive heating thereof, by configuring it to increase its resistance to a value at which the system's reactance at its working frequency is comparable to its electrical resistance. The system includes a set of tubes configured for flow of cooling material therethrough, and also includes a set of fins positioned and disposed perpendicular to, and along, the tubes, in such a way that at least a portion of the fins comprises longitudinal excisions therein.

Claims

1. A method for deicing a fins-on-tubes evaporator system with a predetermined electrical resistance, the method comprising: inducing an electric current in the fins-on-tubes evaporator system, wherein the system comprises: a plurality of cooling material flow tubes electrically connected in parallel to one another; wherein each of the cooling material flow tubes comprises at least a first electrically conductive section electrically connected in series to a second electrically conductive section, and wherein inducing the electric current causes the electric current to flow through the first electrically conductive section and the second electrically conductive section; and a plurality of fins attached to the cooling material flow tubes.

2. The method of claim 1, wherein the plurality of fins are perpendicularly attached to the cooling material flow tubes.

3. The method of claim 1, wherein the plurality of fins links the plurality of cooling material flow tubes.

4. The method of claim 3, wherein the plurality of fins are electrically conductive elements.

5. The method of claim 1, wherein the cooling material flow tubes are linked through two or more bus bars that electrically connect the cooling material flow tubes in parallel to one another.

6. The method of claim 1, wherein the cooling material flow tubes are linked through an electrically conductive manifold electrically connecting the cooling material flow tubes to one another.

7. The method of claim 1, wherein the first electrically conductive section and the second electrically conductive section of each cooling material flow tube are interconnected by a U-turn.

8. The method of claim 1, wherein the electric current is an alternating current.

9. The method of claim 1, wherein the electric current is induced using a 115 VAC/60 Hz power supply or a 230 VAC/50 Hz power supply.

10. The method of claim 1, wherein the system comprises two or more separate cooling material flow tubes electrically connected in parallel to one another.

11. The method of claim 1, wherein the induced electrical current removes frost accumulated on the system.

12. The method of claim 10, comprising flowing refrigerant fluid through the two or more separate cooling material flow tubes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings, wherein like reference characters denote corresponding or similar elements throughout the various figures:

(2) FIG. 1A shows a diagram of an exemplary first embodiment of an inventive evaporator/heat exchanger configured for advantageous utilization of inductive energy-saving rapid heating/defrost techniques, and supplied with a PETD defrost system by way of example;

(3) FIG. 1B shows a diagram of an exemplary second embodiment of an inventive evaporator/heat exchanger configured, by way of example, as a PETD enabled evaporator having two electrically conductive sections connected in series, and two cooling material flow circuits connected in parallel;

(4) FIG. 1C shows a diagram of an alternate exemplary embodiment of an inventive evaporator/heat exchanger configured, by way of example, as a PETD enabled evaporator having two electrically conductive sections connected in series, and four cooling material flow circuits connected in parallel;

(5) FIG. 2A shows a front longitudinal view of an exemplary embodiment of the inventive evaporator/heat exchanger which has been configured to comprise one series electric circuit formed by separate sequential evaporator sections resulting from at least one excision made in at least one predetermined fin, and a separate at least one parallel cooling material flow circuit, formed by the tubes and the U-turns;

(6) FIG. 2B shows a back longitudinal view of the inventive evaporator/heat exchanger embodiment of FIG. 2A;

(7) FIG. 3 shows an exemplary tubing orientation and exemplary cooling material flow through multiple parallel cooling material flow circuits of the inventive evaporator/heat exchanger;

(8) FIG. 4A shows a front isometric view of the inventive evaporator/heat exchanger embodiment with a plurality of parallel cooling material flow circuits;

(9) FIG. 4B shows a rear isometric view of the inventive evaporator/heat exchanger embodiment of FIG. 4A;

(10) FIG. 4C shows a side cross-sectional view of the inventive evaporator/heat exchanger embodiment of FIG. 4A;

(11) FIG. 4D shows a front longitudinal view of the inventive evaporator/heat exchanger embodiment of FIG. 4A;

(12) FIG. 4E shows a rear longitudinal view of the inventive evaporator/heat exchanger embodiment of FIG. 4A; and

(13) FIG. 5 shows an isometric view of a prior art conventional fin-on-tubes evaporator/heat exchanger.

DETAILED DESCRIPTION

(14) The present invention provides various advantageous embodiments of a novel fins-on-tubes type evaporator/heat exchanger system that is optimized for energy-saving rapid inductive heating thereof, for example by way of application of Pulse Electro-Thermal Deicing/Defrosting (PETD), or equivalent technique thereto, by configuring an evaporator/heat exchanger to comprise a target resistance value suitable for efficient heating by inductive currents. In accordance with the present invention, for systems employing alternating current electrical power supplies, this target electrical resistance value is preferably of a magnitude that is at least as high as a magnitude of an inductive reactance value of the inventive evaporator/heat-exchanger system.

(15) The present invention provides a novel, but simple and efficient technique for significantly increasing an evaporators' resistance while keeping its inductance and a refrigerant pressure drop at approximately the same stable value, or even reducing it. The application of the inventive techniques described herein, to modify conventional evaporators, reduces the current required for high-power heating (such as PETD) by at least several orders of magnitude, and furthermore greatly increases the efficiency of such heating.

(16) Advantageously, the inventive system may be configured to comprise the same form factor and interface as various conventional fins-on-tubes type evaporator/heat exchanger components, such that the inventive evaporator/heat exchanger system may be readily utilized for replacement thereof.

(17) Referring now to FIG. 1A to FIG. 4E, the inventive evaporator/heat exchanger system includes a set of tubes configured for enabling flow of cooling material (such as refrigerant fluid or gas) therethrough, and also includes a set of fins positioned and disposed perpendicular to, and along, the tubes, in such a way that at least a portion of the fins comprise N number of longitudinal excisions therein, where N=1, 2, 3 . . . etc., each of a predetermined length, and each oriented in a direction parallel to the tubes.

(18) In a preferred embodiment of the present invention, the excisions are positioned and configured to partition the inventive evaporator/heat exchanger system into an N+1 number of sequential electrically conductive evaporator sections, such that the tubes form an electrically conductive series connection between the sequential evaporator sections, and such that the excisions cause an increase in the electrical resistance of the evaporator system by a factor of about (N+1).sup.2, thereby facilitating utilization of energy-saving inductive heating means (such as PETD) therewith.

(19) It should be noted, that the above-mentioned utilization of excisions or cuts configured and positioned to modify the evaporator fins to thereby split the inventive system into plural sequential electrically conductive evaporator sections, is not intended as a limitation to any other type of modifications to the evaporator components that may be made, as a matter of design choice and without departing from the spirit of the present invention, to achieve the same purpose of forming a series “electrical circuit” comprising sequential partitioned sections of the evaporator/heat exchanger system, that greatly increases the system's electrical resistance.

(20) Referring now to FIG. 1A, in which an exemplary inventive evaporator/heat exchanger system 10 is shown, the evaporator/heat exchanger system 10 includes the cooling material flow tubes/conductive fins component 12, with each of the tubes' flow inlets and outlets being connected to electrically conductive elements 14 (e.g., bus bars, etc.). The system 10 may also include a primary power supply 18, such as a conventional 115 VAC/60 Hz or 230 VAC/50 Hz electrical power line, connected to the electrically conductive elements 14, and may optionally also include a line current increasing component 16, operable to increase the line current to a magnitude sufficient to heat the evaporator to a desirable temperature over limited time interval. The line current increasing component 16 may be a conventional step-down transformer, or an intermittent-action step down transformer (which is smaller and cheaper than a conventional transformer), or an electronic transformer that includes either an AC-AC inverter or an AC-DC inverter.

(21) In at least one embodiment of the system 10 of the present invention, the power supply 18 may also include an electrical switch 20, and may further include an optional resonant capacitor 22 that is operable to compensate for an inductive reactance of the evaporator/heat exchanger system 10.

(22) Referring now to FIG. 1B, a second embodiment of the inventive evaporator/heat exchanger system is shown as an exemplary evaporator/heat exchanger system 50, having a multi-part main component 52 comprising cooling material flow tubes 56 and conductive fins 54, configured with multiple electrically conductive system sections connected in a series electrically conductive configuration, as well as multiple cooling material flow circuits configured in a parallel configuration (two electrically conductive sections and two cooling material flow circuits are shown by way of example only). The evaporator/heat exchanger system 50 is readily configured to function with various electrical power systems and optionally with current increasing components (and optional subcomponents), such as components 16 to 22 of FIG. 1A, above, in a similar manner as the system 10, except in a different connection configuration, as provided below.

(23) The evaporator/heat exchanger system 50 includes the cooling tubes 56 flow inlets 58A and flow outlets 58B being connected to a first electrically conductive element 60A (e.g., bus bar, etc.) that is preferably connected to the ground and one electrical potential of a line current increasing component (such as component 16 of FIG. 1A) (e.g., to a low potential end of a transformer's secondary winding), and also includes a second electrically conductive element 60B (e.g., bus bar, etc.), positioned substantially at a midpoint of the multi-part main component 52, that is preferably connected to the ground and to another electrical potential of the line current increasing component (such as component 16 of FIG. 1A) (e.g., to a high potential end of a transformer's secondary winding).

(24) In accordance with the present invention, when multiple separate parallel cooling material flow circuits are being utilized, for optimal system performance, it is preferable to ensure that all of the system cooling material flow circuits are maintained in substantially similar thermal conditions.

(25) It should be noted, that while the use of dielectric unions in evaporator/heat exchanger systems brings a number of drawbacks and challenges in terms of increased manufacturing complexity, greater expense, and reduced long-term reliability, in certain cases, the inventive system may employ dielectric unions on a limited basis to provide an advantageous embodiment of the present invention in which the cooling material pressure drop between multiple cooling material flow circuits could be very significantly reduced.

(26) Referring now to FIG. 1C, an alternate embodiment of the inventive evaporator/heat exchanger system is shown as an exemplary evaporator/heat exchanger system 100, having a multi-part main component 102 comprising cooling material flow tubes 106 and conductive fins 104, configured with multiple electrically conductive system sections connected in a series electrically conductive configuration, as well as multiple cooling material flow circuits configured in a parallel configuration. The evaporator/heat exchanger system 100 is readily configured to function with various electrical power systems and optionally with current increasing components (and optional subcomponents), such as components 16 to 22 of FIG. 1A, above, in a similar manner as the system 10, except in a different connection configurations and additional elements 110A, 110B and 114, as provided below.

(27) The evaporator/heat exchanger system 100 includes a cooling material flow inlet 108A connected to cooling material flow tubes 106 flow inlets by way of a first conductive flow distribution manifold 110A (functioning as a first electrically conductive element) that is preferably connected to the ground and one electrical potential of a line current increasing component (such as component 16 of FIG. 1A) (e.g., to a low potential end of a transformer's secondary winding), and also includes a cooling material flow outlet 108B connected to cooling material flow tubes 106 flow outlets by way of a second conductive flow distribution manifold 110B (functioning as a second electrically conductive element) that is preferably connected to another electrical potential of a line current increasing component (such as component 16 of FIG. 1A) (e.g., to a high potential end of a transformer's secondary winding). However, unlike the systems 10, and 50 of FIGS. 1A and 1B, respectively, preferably the system 100 includes at least one dielectric union 114 positioned between the electrical connection of the second conductive manifold 110B and the rest of the system 100.

(28) The various above-mentioned exemplary embodiments of the novel evaporator/heat exchanger system (in which N=5), would have (N+1).sup.2=6.sup.2=36 times higher electrical resistance, R, than that of a conventional evaporator, such as the one shown in FIG. 5. Because the heating power generated by an electric current I, is equal to P=R.Math.I.sup.2, the current required to heat the inventive exemplary evaporators, is six times less than that required for a conventional previously known evaporator shown, by way of example, as an evaporator 500 in FIG. 5.

(29) As is known in the art of refrigeration, the number of parallel liquid circuits available for flow of refrigerant has a very significant effect on the magnitude of a cooling material (hereinafter referred to as “refrigerant”) pressure drop across the evaporator, and on the overall evaporator heat-exchange rate. For that reason, is very desirable to be able to vary the number of the liquid refrigerant flow circuits without reducing a high electrical resistance of the evaporator achievable by this invention.

(30) As it seen from FIG. 2A to FIG. 4E it is possible to select, as a matter of design choice, and without departing from the spirit of the invention, the desired number of parallel circuits for flow of the refrigerant, without requiring any changes to the electrical series connections of the evaporator/heat exchanger sections. For instance, by way of example only, FIGS. 1A, and 2A, 2B show exemplary embodiments of the inventive evaporators/heat exchangers 10, 150 having one, two and four flow circuits for the refrigerant respectively, while FIG. 3 shows an alternate embodiment of the inventive evaporator 200 having three parallel cooling material flow circuits with all three inlets and all three outlets connected to the same electrically conductive bus bar 202. This arrangement is particularly advantageous because it eliminates the need for using any dielectric unions which raise system expense (and manufacturing complexity), as well as reduce long term reliability.

(31) Yet another alternate embodiment of the inventive evaporator having six parallel refrigerant flow circuits is shown, in various views, in FIGS. 4A to 4E as an evaporator/heat exchanger 250.

(32) Additional advantageous results can be achieved by using at least one dielectric union (or any equivalent component or element suitable for the same or similar purpose) to cross-link the evaporator tubes. Such cross-links do not effect the electrical parameters (such as resistance) of the evaporator, but allow to design the evaporator with a desirable amount of parallel liquid circuits. Referring now to FIG. 2A to FIG. 4E, exemplary configurations of multiple parallel cooling material flow circuits are shown by way of illustrative examples.

(33) Advantageously, the inventive evaporator/heat exchanger system enable utilization of very efficient rapid defrosting techniques, such as PETD, to efficiently and quickly defrost evaporators/heat exchangers with only minimal changes to the existing manufacturing processes.

(34) Thus, while there have been shown and described and pointed out fundamental novel features of the inventive apparatus as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.