HEAT EXCHANGER

Abstract

A modular system for heat exchange between fluids includes two end plates. At least one end plate is configured with inlets and outlets for fluids. The modular system includes a number of heat exchanger elements and a number of guiding elements. Each heat exchanger element includes a folded sheet material including a plurality of slits extending in a longitudinal direction of the folded sheet material, which longitudinal extending slits form the fluids flow paths. The folded sheet material is cast in one piece in an outer casing. A central opening of the outer casing covers an outer circumference of the folded sheet material, exposing a front side and a back side of the folded sheet material where two through holes, forming the inlets and outlets for each fluid, are provided on opposite sides of the central opening of the outer casing. Each guiding element includes two inlets and two outlets for fluids, and a bead or edge, provided on one side, forming an enclosure around the inlet and outlet for a first fluid, and a bead or edge on an opposite side, forming an enclosure around the inlet and outlet for a second fluid. Heat exchanger elements and guiding elements are arranged successively following each other. The heat exchanger elements are arranged that two adjacent heat exchanger elements on sides facing each other carry the same fluid.

Claims

1. A modular system for heat exchange between fluids, comprising two end plates, wherein at least one end plate is configured with inlets and outlets for fluids, the modular system comprising: a number of heat exchanger elements and a number of guiding elements, wherein each heat exchanger element comprises a folded sheet material comprising a plurality of slits extending in a longitudinal direction of the folded sheet material, which longitudinal extending slits form the fluids flow paths, the folded sheet material being cast in one piece in an outer casing, wherein a central opening of the outer casing covers an outer circumference of the folded sheet material, exposing a front side and a back side of the folded sheet material where two through holes, forming the inlets and outlets for each fluid, are provided on opposite sides of the central opening of the outer casing, wherein each guiding element comprises two inlets and two outlets for fluids, and a bead or edge, provided on one side, forming an enclosure around the inlet and outlet for a first fluid, and a bead or edge on an opposite side, forming an enclosure around the inlet and outlet for a second fluid, wherein heat exchanger elements and guiding elements are arranged successively following each other, the heat exchanger elements being arranged such that two adjacent heat exchanger elements on sides facing each other carry the same fluid.

2. The modular system according to claim 1, wherein the sheet material is made of titanium.

3. The modular system (S) according to claim 1, wherein a ratio between a slit width and slit depth of a slit is less than 0.15.

4. The modular system according to claim 1, wherein in walls of the slits in the folded sheet material are configured as planar faces, part circles or arcs.

5. The modular system according to claim 1, wherein the guiding element further comprises at least a filter provided on either end of the guiding element.

6. (canceled)

7. The modular system according to claim 1, wherein at least one end plate comprises an inlet and outlet for each of the fluids to be heat exchanged.

8. The modular system according to claim 1, wherein the end plates are provided with a plurality of recesses around a circumference of the end plate, wherein a corresponding number of locking elements cooperate with the plurality of recesses to assemble and fasten the end plates, guiding elements and heat exchanger elements.

9. A method for manufacturing of a heat exchanger element for heat exchange between fluids, the heat exchanger element comprising a sheet material and an outer casing, wherein the method comprises: folding the sheet material into a plurality of slits extending in a longitudinal direction of the sheet material, placing the folded sheet material into a mould, and adding a material into the mould to cast the folded sheet material and the outer casing in one piece, wherein a central opening of the outer casing covers an outer circumference of the folded sheet material, thereby exposing opposite sides of the folded sheet material.

10. The method according to claim 9, the method further comprising: adding a plurality of handles into the mould.

11. The modular system according to claim 2, wherein in walls of the slits in the folded sheet material are configured as planar faces, part circles or arcs.

12. The modular system according to claim 3, wherein in walls of the slits in the folded sheet material are configured as planar faces, part circles or arcs.

13. The modular system according to claim 7, wherein the end plates are provided with a plurality of recesses around a circumference of the end plate, wherein a corresponding number of locking elements cooperate with the plurality of recesses to assemble and fasten the end plates, guiding elements and heat exchanger elements.

Description

[0056] The present invention will now be described in more detail with reference to the following figures, wherein

[0057] FIGS. 1A-1F show a heat exchanger element for heat exchange between two or more fluids according to the present invention, where FIG. 1A shows the components of the heat exchanger element in an exploded view and from above, FIG. 1B shows the heat exchanger element in an assembled or casted state, in a perspective view, FIG. 1C shows the heat exchanger element from above, from a side and from an underside and upper side, FIGS. 1D-1F show an alternative exemplary embodiment of the heat exchanger element according to FIGS. 1A-1C, where FIG. 1D show the components of the heat exchanger element in an exploded view and from above, FIG. 1E shows the heat exchanger element in an assembled or casted state, in a perspective view and FIG. 1F shows the heat exchanger element from above, from a side and from an underside and upper side,

[0058] FIGS. 2A-2C show a sheet material of the heat exchanger element according to FIGS. 1A-1F, where FIG. 2A shows the sheet material prior to a folding of the sheet material, FIG. 2B shows an exemplary embodiment of the sheet material when folded, in a perspective view, and FIG. 2C shows an alternative exemplary embodiment of the sheet material according to FIG. 2B,

[0059] FIGS. 3A-3B show an embodiment of a modular heat exchanger system according to the present invention, where FIG. 3A shows the modular heat exchanger system in an exploded view and FIG. 3B shows an alternative embodiment of the modular heat exchanger system according to FIG. 3A,

[0060] FIGS. 4A-4F show alternative embodiments of the modular heat exchanger system according to FIG. 3A-3B, seen from above, from a side and from an underside and upper side, where FIGS. 4A-4B comprise one heat exchanger element, FIGS. 4C-4D comprise two heat exchanger elements and FIGS. 4E-4F comprise four heat exchanger elements,

[0061] FIGS. 5A-5C show a guiding element according to the present invention, where FIG. 5A shows an exemplary embodiment of the guiding element from an underside (or upper side), FIG. 5B shows an alternative embodiment of the guiding element according to FIG. 5A, in an exploded view, and FIG. 5C shows the guiding element in an assembled state, and

[0062] FIGS. 6A-6B show a front panel and back panel of the modular heat exchanger system according to FIGS. 4A-4F.

[0063] FIGS. 1A-1F show alternative embodiments of a heat exchanger element 1 for heat exchange between two or more fluids according to the present invention, where FIGS. 1A-1C show an embodiment of the heat exchanger element 1 comprising a folded sheet material 2 and an outer casing 3.

[0064] A first embodiment of a heat exchanger element 1 is shown in FIGS. 1A-1C, where the heat exchanger element 1 is manufactured through a method comprising the following steps: the sheet material 2 is folded to provide a plurality of slits 7 in the sheet material 2, where the sheet material 2, when folded, will have four end surfaces 2A-2D and two opposite heat transfer surfaces 2E, 2F (only one is seen), where the slits 7 will extend in a longitudinal direction L of the folded sheet material 2. Thereafter, the folded sheet material 2 comprising the plurality of slits 7 is placed in a mould (not shown), whereafter a material, for instance polyurethane (PU), is poured into the mould (not shown) to cast the folded sheet material 2 into a frame which will form the outer casing 3 in the heat exchanger element 1, the moulding providing a one-piece heat exchanger element 1 where the outer casing 3 covers only the end surfaces 2A-2D of the folded sheet material 2 and leaving the two opposite heat transfer surfaces 2E-2F exposed through a central opening 4, the moulding further providing two through holes 5 on opposite sides of the central opening 4 of the outer casing 3, the two through holes 5 forming the inlets and outlets for each fluid.

[0065] The outer casing 3 will thus cover only an outer circumference of the folded sheet material 2, thereby providing a central opening 4 in the outer casing 3 such that the central opening 4 exposes both sides of the folded sheet material 2, i.e. both an upper side and an underside of the heat exchanger element 1 (or a front side and a backside), each of the two sides forming the heat transfer surface 2E, 2F of the heat exchanger element 1.

[0066] The finished heat exchanger element 1 according to the first embodiment and manufactured by the above described method is shown in FIG. 1B.

[0067] An alternative embodiment of a heat exchanger element 1 is shown in FIG. 1D, where this heat exchanger element 1 is manufactured in the same way as the heat exchanger element 1 according to FIG. 1A-1C, but where the heat exchanger element 1 in this embodiment in addition comprises a plurality of handles 6 being integrated in the heat exchanger element 1; the folded sheet material 2 provided with a plurality of slits 7 and having four end surfaces 2A-2D and two opposite heat transfer surfaces 2E, 2F is placed, together with four handles 6, in a mould (not shown), whereafter a material, for instance polyurethane (PU), is poured into the mould (not shown) to cast the folded sheet material 2, the plurality of handles 6 and the outer casing 3 in one piece, where the moulding will provide a heat exchanger element 1 where the outer casing 3 covers only the end surfaces 2A-2D of the folded sheet material 2 and leaving the two opposite heat transfer surfaces 2E-2F exposed through a central opening 4, the moulding further providing two through holes 5 on opposite sides of the central opening 4 of the outer casing 3, the two through holes 5 forming the inlets and outlets for each fluid.

[0068] FIG. 1E shows the finished heat exchanger element 1 according to the second embodiment and manufactured by the above described method.

[0069] However, a person skilled in the art would know that also other materials than polyurethane could be used when manufacturing the heat exchanger element 1, for instance an epoxy or the like.

[0070] The outer casing 3 of the heat exchanger element 1 will thus integrate with and cover the folded sheet material 2 around a circumference of the folded sheet material 2 (i.e. the end surfaces 2A-2D), while the two opposite heat transfer surfaces 2E-2F will be open and exposed to the surroundings.

[0071] The above method for manufacturing of the heat exchanger element 1 will provide a fluid tight connection between the outer casing 3 and the folded sheet material 2, whereby the heat exchanger element 1 may be manufactured without the use of gaskets, seals or the like.

[0072] In one embodiment the heat exchanger element 1 may be manufactured in that one end surface, for instance 2A, of the folded sheet material 2 is placed in the mould (not shown) and a material, for instance polyurethane (PU) is poured into the mould. When this has solidified, the process is repeated for an opposite end surface 2B of the folded sheet material 2. Thereafter the process is repeated for each of the two remaining end surfaces 2C-2D of the folded sheet material 2.

[0073] The heat exchanger element 1 may be manufactured with or without the one or more handles 6. When the heat exchanger element 1 is manufactured with the one or more handles 6, the one or more handles will be added in the mould with the folded sheet material 2.

[0074] FIGS. 1B-1C show the first embodiment of the heat exchanger element 1 in a perspective view, from a side view, a front view, a top view and a back view, while FIGS. 1D-1F show the second embodiment of the heat exchanger element 1 in a perspective view, from a side view, a front view, a top view and a back view.

[0075] FIGS. 2A-2C show the sheet material 2 of the heat exchanger element 1, where it can be seen that the sheet material 2 is configured with a number of subsequent stamped portions 8 and non-stamped portions 9, where the non-stamped portions 9 are arranged between two adjacent stamped portions 8. The stamped portions 8 will, when the sheet material 2 is folded, constitute the slits 7 in the heat exchange element 1, through which slits 7 a fluid is to flow. The non-stamped portions 9 will then form the “folding areas” for the sheet material 2, i.e. the sheet material 2 is folded at the non-stamped portions 9.

[0076] The stamping of the stamped portions 8 will provide necessary strength in the heat exchanger element 1 to prevent the heat exchanger element 1 from collapsing if the differential pressure across the heat exchanger element 1 becomes too large and will provide a turbulent flow in the fluids that are run through the heat exchanger element 1.

[0077] Although the stamping of the stamped portions 8 in this embodiment is shown to have a “V-form”, a person skilled in the art would know that the stamping may also have other “patterns” or forms.

[0078] The stamping may, for example, be done in a press (not shown) or the like, where the sheet material 2 is fed through the press, a portion 8 of the sheet material 2 is stamped, then the press (not shown) is lifted and a new length of the sheet material 2 is advanced into the press, whereafter the press stamps a new portion 8 of the sheet material 2. This process is repeated until the desired number of stamped portions 8 has been obtained.

[0079] The sheet material 2 will then through a “folding process” be folded about the non-stamped portions 9, such that the sheet material 2 will have a form as shown in FIGS. 2B-2C. This will provide a folded sheet material 2, where two stamped portions 8 will form a slit 7 in the heat exchanger element 1, where the first fluid that flows through a slit 7 on one side of the folded sheet material 2 will be “surrounded” by two slits 7 on the other side of the folded sheet material 2, through which two slits 7 the second fluid flows.

[0080] Although the slits 7 in FIGS. 2A-2C are shown as planar faces, it should be understood that they may be configured as part circles, arcs or the like.

[0081] Furthermore, the non-stamped portions 9 may have a width, as an example, of 2.5 mm-3.5 mm, but this width may also be more or less, depending on the specific application of the heat exchanger element 1.

[0082] The first and the last portion of the sheet material 2 will be configured with an extra “folding point”. The fold 10 is made so that a part of this first and last portion of the sheet material 2 will be arranged perpendicular to the subsequent stamped portion 8; see also FIGS. 2B-2C. This folded portion 10, i.e., the portion that projects perpendicularly out from the folded sheet material 2, will then constitute attachment points to the outer casing 3.

[0083] FIG. 2B shows an embodiment where the fold 10 is made to be half a width or height of the stamped portion 8, while FIG. 2C shows an embodiment where the fold 10 is made to be at a “bottom” of the folded sheet material 2.

[0084] FIGS. 3A-3B show embodiments of a modular system S for heat exchange between fluids according to the present invention, where FIG. 3A shows a first embodiment of the modular system S in an exploded view, and FIG. 3B shows a second embodiment of the modular system S in an exploded view.

[0085] The modular system S for heat exchange between fluids in this exemplary embodiment comprises two end plates 11 (or a front plate and a back plate), where two guiding elements 12 and one heat exchanger element 1 are arranged between the two end plates 11, one guiding element 12 being arranged on each side of the heat exchanger element 1.

[0086] The heat exchanger element 1 is arranged between the two guiding elements 12, such that the modular system S for heat exchange between fluids will be assembled in the following way: a front plate 11, a first guiding element 12, a heat exchanger element 1, a second guiding element 12 and a back plate 11.

[0087] Each end plate 11 is provided with a plurality of recesses 13 or notches around a circumference of the end plate 11, such that a corresponding number of locking elements 14 may be used to assemble and fasten the end plates 11, guiding elements 12 and heat exchanger element 1.

[0088] The locking elements 14 may be rods, bars or the like, where the locking elements 14 are provided with threads so as to be connected with a nut.

[0089] An inlet filter (not shown) is in a suitable way, for example, with the aid of bolts or the like, connected to one of the end plates 11, which inlet filter will reduce the danger of physical blockages in the modular system S for heat exchange between fluids, as a result of contaminants in one or both of the fluids to be heat exchanged.

[0090] One of the end plates 11 is further configured with an inlet and outlet 15, 16; 17, 18 (see also FIG. 6A) for each of the fluids to be heat exchanged, where the inlet and outlet 15, 16 for a first fluid and the inlet and outlet 17, 18 for a second fluid are arranged on opposite edges of the end plate 11.

[0091] The inlet 15 for the first fluid will then be arranged diagonally opposite to the inlet 17 for the second fluid, and similarly the outlet 16 for the first fluid will be arranged diagonally opposite the outlet 18 for the second fluid. Thus, the fluids that are to be heat exchanged will flow in the opposite direction to each other when the system S for heat exchange between fluids is used, so as to achieve optimal heat transfer between the fluids.

[0092] How the pipes (not shown) for supply of the fluids to be heat exchanged are to be connected to the modular system S for heat exchange between fluids is not described in any detail here, as a person of skill in the art will know how this is to be done.

[0093] The heat exchanger elements 1, when the modular system S for heat exchange between fluids comprises more than one heat exchanger element 1, are so arranged between the end plates 11 that two sides facing each other in two adjacent heat exchanger elements 1 will carry the same fluid, which mean, that a first and a second heat exchanger element 1 on the sides facing each other will carry the first fluid, whilst sides in the second and a third heat exchanger element 1 will then carry the second fluid.

[0094] In the embodiment shown in FIG. 3A the modular system S for heat exchange between fluids comprises two guiding elements 12 and one heat exchanger element 2 that are not manufactured with handles 6, while the modular system S for heat exchange between fluids shown in FIG. 3B comprises two guiding elements 12 and one heat exchanger element 2 that are manufactured with handles 6.

[0095] However, a person skilled in the art would understand that a greater or smaller number of heat exchanger elements 1 and guiding elements 12 may be arranged between the two end plates 11, where the number of heat exchanger elements 1 and guiding elements 12 depends on space available, desired capacity, back-up capacity and development potential. The guiding elements 12 and the heat exchangers elements 1 are then arranged successively following one another. Furthermore, the heat exchanger elements 2 are arranged such that two adjacent or consecutive heat exchanger elements 2 (with a guiding element 12 arranged between them) carry the same fluid between the sides that faces each other.

[0096] When the modular system S for heat exchange between fluids is assembled, the system S may, in appropriate ways, be connected to a stand 30 or rack in order to hold the modular system S in a fixed position.

[0097] The above is shown in FIGS. 4A-4F, where FIGS. 4A-4B show a modular system S for heat exchange between fluids in an assembled state and comprising one heat exchange element 1 and two guiding elements 12, where the heat exchange element 1 and the two guiding elements 12 are shown without handles in FIG. 4A and provided with handles 6 in FIG. 4B; FIGS. 4C-4D show a modular system S for heat exchange between fluids in an assembled state and comprising two heat exchange elements 1 and three guiding elements 12, where the two heat exchange elements 1 and the three guiding elements 12 are shown without handles in FIG. 4C and provided with handles 6 in FIG. 4D; and FIGS. 4E-4F show a modular system S for heat exchange between fluids in an assembled state and comprising four heat exchange elements 1 and five guiding elements 12, where the four heat exchange elements 1 and the five guiding elements 12 are shown without handles in FIG. 4E and provided with handles 6 in FIG. 4F.

[0098] FIGS. 5A-5C show a guiding element 12 according to the present invention, where the guiding element 12 is arranged adjacent to the heat exchanger element 1 in order to direct and force the fluid to flow through the slits 7 in the heat exchanger element 1.

[0099] Furthermore, each guiding element 12 is configured with inlet and outlet 15, 16; 17, 18 for each of the fluids to be heat exchanged, where the inlet and outlet 15, 16 for a first fluid and the inlet and outlet 17, 18 for a second fluid are arranged on opposite edges of the guiding element 12.

[0100] As explained for the end plate 11, the inlet 15 for the first fluid will then be arranged diagonally opposite to the inlet 17 for the second fluid, and similarly the outlet 16 for the first fluid will be arranged diagonally opposite the outlet 18 for the second fluid. Thus, the fluids that are to be heat exchanged will flow in the opposite direction to each other when the system S for heat exchange between fluids is used, so as to achieve optimal heat transfer between the fluids.

[0101] Each guiding element 12 is also provided with a filter 19 arranged on one side of the guiding element 12, and where the guiding element 12 is provided with a bead or edge 20 arranged to form an enclosure around the inlet 15 and outlet 16 for the first fluid.

[0102] Similarly, an opposite side of the guiding element 12 may also be provided with a bead or edge 21 arranged to form an enclosure around the inlet 17 and outlet 18 for the second fluid.

[0103] Guiding elements 12 will help leading or forcing the fluid through the inlets and outlets of the heat exchanger elements 1 and also through the heat exchanger elements 1.

[0104] Each guiding element 12 will also contribute with a strength to withstand a fluid pressure inside the modular system S for heat exchange between fluids (both the actual fluid pressure and the differential pressure, i.e. the pressure difference between the fluids.

[0105] A height and/or width of a guiding element 12 may therefore be larger than a height and/or width of a heat exchanger element 1.

[0106] FIGS. 5B-5C show an alternative embodiment of the guiding element 12 according to FIG. 5A, where handles 6 are integrated in the guiding element 12 in this embodiment; FIG. 5B showing the guiding element 12 in an exploded view and FIG. 5C showing the assembled guiding element 12.

[0107] FIGS. 6A-6B show a front plate and a back plate 11 of the modular system S for heat exchange between fluids, where each end plate 11 is provided with a plurality of recesses 13 or notches around a circumference of the end plate 11, such that a corresponding number of locking elements 14 may be used to assemble and fasten the end plates 11, guiding elements 12 and heat exchanger element 1.

[0108] The locking elements 14 may be rods or the like, where the locking elements 14 are provided with threads so as to be connected with a nut.

[0109] The front plate 11 is further configured with an inlet and outlet 15, 16; 17, 18 for each of the fluids to be heat exchanged, where the inlet and outlet 15, 16 for a first fluid and the inlet and outlet 17, 18 for a second fluid are arranged on opposite edges of the end plate 11.

[0110] The inlet 15 for the first fluid will then be arranged diagonally opposite to the inlet 17 for the second fluid, and similarly the outlet 16 for the first fluid will be arranged diagonally opposite the outlet 18 for the second fluid. Thus, the fluids that are to be heat exchanged will flow in the opposite direction to each other when the system S for heat exchange between fluids is used, so as to achieve optimal heat transfer between the fluids.

[0111] Furthermore, the inlets and outlets 15, 16, 17, 18 for fluids provided in the end plate(s) 11, the guiding elements 12 and the heat exchanger elements 1 are provided such that, when the modular system S for heat exchange between fluids is assembled, the inlets and outlets 15, 16, 17, 18 for fluids in each element 1, 11, 12 will align with corresponding inlets and outlets 15, 16, 17, 18 in remaining elements, so that there is no need to seal against fluid in different planes or heights.

[0112] The invention has now been explained with reference to a non-limiting exemplary embodiment. A person of skill in the art will understand however that a number of variations and modifications can be made to the system for heat exchange between fluids and the open element as described within the scope of the invention, as defined in the appended claims.