Arrangement of Helical Tubes for Efficient Packing and Apparatus Implementing the Same

Abstract

An improved packing efficiency of helical tube bundles in a heat exchanger is achieved by positioning three 3-tube bundles, two twisted in one direction and the third twisted in the opposite direction, and selecting the angular orientation of the tube bundles so as to allow them to nest together in phase so that peaks of adjacent tube bundles are located between each other, forming a bundle overlap. An exemplary application is an EGR cooler.

Claims

1. A heat exchanger for transferring heat between a first fluid and a second fluid comprising: a first tube bundle comprising a first set of three tubes adapted to allow the first fluid to flow therethrough, the tubes each having an inlet forming a first set of inlets, the tubes each having an outlet forming a first set of outlets, the first set of inlets being attached to an inlet support at an inlet end, the first set of outlets being attached to an outlet support at an outlet end, each of the first set of tubes following a helical path along a first common helical axis, the helical path of each of the first plurality of tubes having the same twist direction, substantially the same helical pitch and helical radius and symmetric peaks and valleys along the bundle length; a second tube bundle comprising a second set of three tubes adapted to allow the first fluid to flow therethrough, the second set of tubes each having an inlet forming a second set of inlets, the second set of tubes each having an outlet forming a second set of outlets, the second set of inlets being attached to the inlet support at the inlet end, the second set of outlets being attached to the outlet support at the outlet end, each of the second set of tubes following a helical path along a second common helical axis in the same twist direction as that of the first tube bundle, the helical path of each of the second set of tubes having substantially the same helical pitch and helical radius and symmetric peaks and valleys along the bundle length as the first set of tubes; a third tube bundle comprising a third set of three tubes adapted to allow the first fluid to flow therethrough, the third set of tubes each having an inlet forming a third set of inlets, the third set of tubes each having an outlet forming a third set of outlets, the third set of inlets being attached to the inlet support at the inlet end, the third set of outlets being attached to the outlet support at the outlet end, each of the third set of tubes following a helical path along a third common helical axis in the opposite twist direction from that of the first and second tube bundles, the helical path of each of the third set of tubes having substantially the same helical pitch and helical radius and symmetric peaks and valleys along the bundle length as the first set of tubes; and a shell surrounding the first, second and third tube bundles, the shell having an inlet port and an outlet port for flowing the second fluid through the shell past the first, second and third tube bundles and symmetric peaks and valleys along the bundle length; wherein the helical axes of the first, second and third bundles are parallel to and radially offset from each other and the bundles are positioned for bundle overlap so that peaks of each bundle are in the valleys between the peaks of each adjacent bundle.

2. The heat exchanger of claim 1 wherein each bundle has a coil diameter D, a tube diameter d and a bundle center located at the bundle axis and the distance between the centers of adjacent bundles is less than the sum of the diameter length and the tube diameter length.

3. A heat exchanger for transferring heat between a first fluid and a second fluid comprising: a first row of tube bundles, each bundle comprising a set of three tubes adapted to allow the first fluid to flow therethrough, the tubes each having an inlet forming a first set of inlets, the tubes each having an outlet forming a first set of outlets, the first set of inlets being attached to an inlet support at an inlet end, the first set of outlets being attached to an outlet support at an outlet end, each of the tubes following a helical path along a first common helical axis, the helical path of each bundle of tubes having the same twist direction, substantially the same helical pitch and helical radius and symmetric peaks and valleys along the bundle length; a second row of tube bundles, each bundle comprising a second set of three tubes adapted to allow the first fluid to flow therethrough, the tubes each having an inlet forming a second set of inlets, the tubes each having an outlet forming a second set of outlets, the second set of inlets being attached to the inlet support at the inlet end, the second set of outlets being attached to the outlet support at the outlet end, each of the tubes following a helical path along a second common helical axis in the opposite twist direction from that of the tube bundles in the first row of tube bundles, the helical path of each second row bundle having substantially the same helical pitch and helical radius and symmetric peaks and valleys along the bundle length as the tubes in the first row; a third row of tube bundles, each bundle comprising a third set of three tubes adapted to allow the first fluid to flow therethrough, the tubes each having an inlet forming a third set of inlets, the tubes each having an outlet forming a third set of outlets, the third set of inlets being attached to the inlet support at the inlet end, the third set of outlets being attached to the outlet support at the outlet end, each of the tubes following a helical path along a third common helical axis in the same twist direction as that of the tube bundles in the first row of tube bundles, the helical path of each third row bundle having substantially the same helical pitch and helical radius and symmetric peaks and valleys along the bundle length as the tubes in the first row; and a shell surrounding the rows of bundles, the shell having an inlet port and an outlet port for flowing the second fluid through the shell past all of the tube bundles; wherein the helical axes of the bundles in the first, second and third rows are parallel to and radially offset from each other and the bundles are positioned for bundle overlap so that peaks of each bundle are in the valleys between the peaks of each adjacent bundle.

4. The heat exchanger of claim 3 further including a plurality of additional rows of tube bundles wherein rows of tube bundles identical to the first row of tube bundles and rows of tube bundles identical to the second row of tube bundles are positioned so that adjacent rows contain tube bundles of opposite twist, the helical axis of each tube bundle is parallel to the helical axes of the other tube bundles, and each tube bundle is positioned for bundle overlap so that peaks of each bundle are in the valleys between the peaks of adjacent tube bundles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is an end and side view of a helically wound tube.

[0010] FIG. 2 is an end and side view of a bundle of 3 helically wound tubes.

[0011] FIG. 3 is a close-up of the end view of FIG. 2.

[0012] FIG. 4 shows a pair of adjacent 2-tube bundles of helically wound tubes.

[0013] FIG. 5 shows a pair of adjacent 2-tube bundles of helically wound tubes positioned with peaks of one bundle aligned with valleys of the other.

[0014] FIG. 6 shows a pair of 4-tube bundles.

[0015] FIG. 7 shows a pair of tube bundles positioned in phase according to the claimed invention.

[0016] FIG. 8 shows a pair of tube bundles positioned so that the peaks of one bundle are centered in the valleys of the adjacent bundle and depicting where the tubes touch tangent.

[0017] FIG. 9 shows end views of alternate tube bundle combinations.

[0018] FIG. 10 shows the geometry of bundle overlap when tube bundles are positioned in phase according to the present invention.

[0019] FIG. 11 depicts the end-on dimensions of a typical tube bundle.

[0020] FIG. 12 shows an encasement of an EGR cooler embodiment of the present invention.

[0021] FIG. 13 shows a preferred tube bundle for implementation of the embodiment of FIG. 12.

[0022] FIG. 14 is an end view of a bundle configuration for implementation of the embodiment of FIG. 13.

[0023] FIG. 15 is a cross section view of multiple bundles in the embodiment of FIG. 13.

[0024] FIG. 16 is a side view of the tube components of the embodiment of FIG. 13.

[0025] FIG. 17 is an end view of a bundle pattern of 3-tube bundles comprising two bundles having twist in one direction and the other having twist in the opposite direction.

[0026] FIG. 18 is an end view showing multiple iterations of the bundle pattern of FIG. 17.

[0027] FIG. 19 is an end view of the bundle pattern of FIG. 17 with the bundles rotated according to the present invention.

[0028] FIG. 20 is an end view of the arrangement of FIG. 18 with the bundles rotated and offset according to the present invention.

[0029] FIG. 21 shows the reduction in packing area resulting from the bundle pattern of FIG. 17.

[0030] FIG. 22 shows an encasement of an EGR cooler embodiment implementing the arrangement of FIG. 18.

[0031] FIG. 23 shows a depiction of typical opposite twist bundles for inclusion in the embodiment of FIG. 22.

[0032] FIG. 24 is an end view of a bundle configuration for implementation in the embodiment of FIG. 22.

[0033] FIG. 25 is a cross section view of multiple bundles in the embodiment of FIG. 23.

[0034] FIG. 26 is a side view of the tube components of the embodiment of FIG. 22.

[0035] FIG. 27 is a close-up end view of the embodiment of FIG. 26.

DETAILED DESCRIPTION

[0036] A helix can be mathematically defined by a system of parametric equations. A mathematical helix (defined as a curve for which the tangent makes a constant angle with a fixed line) with a diameter D and pitch P, can be parameterized by is:

[00001]$x\left(\right)=\frac{D}{2}\cos$$y\left(\right)=\frac{D}{2}\sin$$z\left(\right)=-\frac{.Math.P}{2}=-\frac{.Math.P}{360}$

[0037] The centerline 100 of a cylindrical tube 101 or wire formed into a helix is shown in FIG. 1. Viewed from the side the centerline of tube 101 is a wave in which D is the distance between the peak 102 and valley 103 of the centerline, and P is the length of the wave from peak 102 to the following peak 104. Viewed end on, D is the coil diameter of the tube helix and d is the diameter of the tube itself. As tubes are added to the bundle, with the coil diameter and tube diameter remaining the same, the wave is replicated and shifted. See, e.g., FIGS. 2, 4 and 6. When the tubes are equally spaced about the helix axis, we can define the phase angle as:

[00002]$=\frac{360}{\#\mathrm{of}\mathrm{Tubes}\mathrm{per}\mathrm{Bundle}}=\frac{360}{N}$

[0038] FIG. 2 shows a bundle of 3 tubes in terms of (instead of z). The waves of additional tubes are spaced at an angle of . This makes the centerline equations of additional tubes of the bundle:

[00003]$y_{\mathrm{Tube}n}\left(\right)=\frac{D}{2}\sin \left(+\left(n-1\right)\right)$

As used herein, d will refer to the outside diameter of the tube, so the helical bundle outside diameter is D+d, as seen in FIG. 3.

[0039] Obviously, as seen in FIG. 4, two adjacent bundles can be spaced apart at least as close as one bundle outside diameter:

[00004]$\mathrm{Bundle}\mathrm{Spacing}=2.Math.\mathrm{Bundle}\mathrm{Radius}=2.Math.\left(\frac{D+d}{2}\right)=D+d$

However, the waves of the helical tube bundle create peaks 120 and valleys 130. When adjacent bundles have the same pitch, they can be rotationally positioned or phased such that the peaks of one bundle align with the valleys of the adjacent bundle. FIG. 5 shows that adjacent bundles can be phased with each other (e.g., by rotating the bundle so as to shift the peaks and valleys of the helical tubes forward or backwards relative to the adjacent bundle) such that there is clearance 110 between the bundles. The greatest available clearance occurs when the peak 120 of one bundle aligns with the valley 130 of the adjacent bundle. Such clearance means that adjacent bundles can be oriented (FIG. 6) and positioned (FIG. 7) for bundle overlap, with the peaks of one bundle between the peaks of an adjacent bundle, making the bundles closer to each other than one bundle outside diameter. This results in: Bundle Spacing<(D+d). For clarity, the presence of bundle overlap is described herein as a condition wherein the peaks of one bundle are positioned between the peaks (i.e., in the valleys) of an adjacent bundle. Stated otherwise, at least one peak of a bundle is positioned to intersect the imaginary line connecting the two closest peaks of the adjacent bundle.

[0040] When the number of tubes per bundle increases, the clearance, and thus the possible amount of bundle overlap, is reduced, as illustrated with 4-tube bundles in FIG. 6. There, the clearance 111 between bundles is less than the clearance 110 in the case of 2-tube bundles. Even though the potential bundle overlap may be small, some portion of the peaks of adjacent multiple tube bundles will always fit between each other.

[0041] To center the peaks 120 of one tube bundle in the valleys 130 of an adjacent bundle, permitting the minimum bundle spacing, the phase shift between bundles is:

[00005]$\frac{360-}{2}=180-\frac{}{2}$

which is depicted graphically in FIG. 7.

[0042] This derivation shifts the corresponding tube of an adjacent bundle such that the valley of the corresponding adjacent tube wave is phased with the peak of the initial tube wave. The peak and valley of a sine wave are 180 apart. However, when there are more than two (2) tubes per bundle, N>2, this phase shift is greater than necessary as the corresponding tube of the adjacent bundle could be shifted to be in phase with a different tube of the initial bundle. In actuality, bundles of an odd number of tubes do not require a phase shift to be in phase with an adjacent bundle, whereas bundles of an even number of tubes require a minimum phase shift of (/2).

[0043] The minimum bundle spacing is where the helical tubes or wires touch tangent to each other. FIG. 8 shows adjacent tube bundles 115 and 116 positioned for minimum bundle spacing. The peaks 120 of each bundle are aligned with the valleys 130 of the adjacent bundle. The walls of adjacent tubes touch tangent at 125 and the clearance 110 between tube bundles is minimized and the center-to-center spacing is less than the outside diameter of the tube bundles D+d.

[0044] As discussed above, pairs of same-twist helical tube bundles can be positioned adjacent to each other to yield closer spacing than the standard D+d boundary. In a multi-tube heat exchanger, many tube bundles must be packed together. The fact that pairs of bundles can be phased with each other does not necessarily generate close spacing throughout the enclosure.

[0045] It has been discovered that when the number of bundles in a pattern is an integer times the number of tubes in bundle, then a special situation occurs where the last bundle of the pattern falls in phase with the first bundle of the pattern. This allows the maximum bundle overlap between the last bundle of the pattern and the first bundle of the pattern. This holds true for pattern units of two or four 2-tube bundles, three 3-tube bundles, four 4-tube bundles and five 5-tube bundles. See FIG. 9. Any of these pattern units can be replicated throughout the enclosure, leaving adjacent bundles in phase with each other.

[0046] A tube and shell heat exchanger, comprising an encasement carrying one fluid and a plurality of tubes carrying another fluid is an example of an apparatus that benefits from inserting the maximum practical number of tubes inside the casing. A particular embodiment of such a heat exchanger is an EGR cooler that cools the exhaust gas of a diesel engine. EGR cooler designs are discussed in U.S. Pat. Nos. 9,605,912 and 9,964,077, both of which are incorporated by reference hereby. These patents explain the advantages of helical coil tube components and an arrangement of opposite-twist coils that increases the number of tubes in a defined cooler enclosure.

[0047] The improved configuration of tubes disclosed in U.S. Pat. No. 9,605,912 works only with an even number of bundles per pattern unit. Where a configuration using an odd number (such as 3) bundles per pattern unit is desired, at least 2 of the helical tubes must have the same hand twist. Although adjacent tube bundles of the same hand twist cannot be positioned as close together as adjacent bundles of opposite hand twist, the current discovery that adjacent bundles of the same hand twist can be spaced closer than S=D+d when positioned in phase does yield a packing efficiency improvement.

[0048] The advantage achieved by positioning tube bundles as described herein may be seen by calculating two parameters: bundle spacing and packing efficiency. If the centerline of a helical, constant diameter tube is modeled by

[00006]$\stackrel{.fwdarw.}{r}=\left(y\left(t\right),z\left(t\right)\right)$

Then its outside surface is a parallel curve can be described by the equation

[00007]${\stackrel{.fwdarw.}{r}}_k=\stackrel{.fwdarw.}{r}\left(t\right)+k\stackrel{.fwdarw.}{n}\left(t\right)$

Where |k| is the normal distance from the centerline to the parallel curve and {right arrow over (n)}(t) is the unit normal vector. (Note that the parameter has been replaced with t to reduce confusion). The distance |k| would be the tube radius, or

[00008]$k=\frac{d}{2}$

Two adjacent bundles with tubes having the centerline equations

[00009]${\stackrel{.fwdarw.}{r}}_1=\left(y_1\left(t\right),z\left(t\right)\right)$${\stackrel{.fwdarw.}{r}}_2=\left(y_2\left(t\right),z\left(t\right)\right)$

Would have outside surfaces

[00010]${\stackrel{.fwdarw.}{r}}_{k_1}={\stackrel{.fwdarw.}{r}}_1\left(t\right)+\frac{d_1}{2}{\stackrel{.fwdarw.}{n}}_1\left(t\right)$${\stackrel{.fwdarw.}{r}}_{k_2}={\stackrel{.fwdarw.}{r}}_2\left(t\right)-\frac{d_2}{2}{\stackrel{.fwdarw.}{n}}_2\left(t\right)$

Where d.sub.1 is the tube diameter of bundle 1 and d.sub.2 is the tube diameter of bundle 2. The unit normal vector {right arrow over (n)}(t) of {right arrow over (r)}.sub.k.sub.1 is positive denoting the upper surface of the tube whereas {right arrow over (n)}.sub.k.sub.2 is negative denoting the lower surface of the tube.
The tubes would have a minimum bundle spacing and touch tangent where

[00011]${\stackrel{.fwdarw.}{r}}_{k_1}\left(t_1\right)={\stackrel{.fwdarw.}{r}}_{k_2}\left(t_2\right)$

And

[00012]${\stackrel{.fwdarw.}{r}}_{k_1}^{}\left(t_1\right)={\stackrel{.fwdarw.}{r}}_{k_2}^{}\left(t_2\right)$

If y.sub.2(t) is of the form

[00013]$y_2\left(t\right)=y\left(t\right)+S_{\min }$

Then this system of equations can be solved to find the minimum bundle spacing S.sub.min.

[0049] A simplified example utilizing identical adjacent tube bundles, each tube having a constant helix diameter, pitch, and tube diameter, positioned perfectly in phase may be analyzed with reference in FIG. 10.

The centerline 121 of a tube of bundle 1 is

[00014]$y_1\left(\right)=\frac{D}{2}\sin$$z\left(\right)=-\frac{.Math.P}{2}=-\frac{.Math.P}{360}$

The centerline 122 of a tube of bundle 2 which is perfectly phased with bundle 1 making its centerline

Where

[00015]$y_2\left(\right)=\frac{D}{2}\sin \left(+180-\frac{}{2}\right)+S_{\min }=S_{\min }-\frac{D}{2}\sin \left(-\frac{}{2}\right)$

[00016]$z_1\left(\right)=z_2\left(\right)$

The tubes of the adjacent bundles have outside surfaces 123 and 124 offset by a tube radius 126. The two adjacent tube centerlines are spaced at a normal distance of a tube diameter d 127 (2 tube radii). If the outside surface 123 of the tube, parameterized by t, is

[00017]${\stackrel{.fwdarw.}{r}}_k=\left(y_k\left(t\right),z_k\left(t\right)\right)$

Where

[00018]$k=\frac{d}{2},$

then the point of contact 125 occurs at

[00019]$z_k\left(t\right)=z\left({}_{\mathrm{Tangency}}\right)$$y_k\left(t\right)=\frac{S_{\min }}{2}$

Therefore, the minimum possible bundle spacing S.sub.min or maximum possible bundle overlap q.sub.max is dependent on the number of tubes per bundle N, the pitch P, the helix diameter D, and the tube diameter d.

[0050] The performance of a heat exchanger is directly related to the amount of surface area available to transfer heat. The amount of heat transfer capacity that can be fit into a given sized heat exchanger describes the volumetric efficiency of the heat exchanger. In the case of a tube and shell heat exchanger, more tubes inside of a given sized shell allows for more heat transferring surface area thus improving the volumetric efficiency. The packing efficiency of a tube and shell heat exchanger can be expressed as a fraction of the total volume that is occupied by tubes. Since each tube usually has one inlet, one outlet, and is of constant diameter along its length, this can be simplified from a volumetric efficiency to a two-dimensional area efficiency:

[00020]$\mathrm{Packing}\mathrm{Efficiency}=\frac{\mathrm{Total}\mathrm{Tube}\mathrm{Area}}{\mathrm{Packing}\mathrm{Area}}$

To compare the packing efficiency of different helical tube bundle pattern units, the packing area can be defined as the area of the polygon having its corners at the helical axis of the bundles in the pattern unit. The tube area is the cross-sectional area of tubing within this polygon.

[0051] For comparison purposes, bundle overlap and packing efficiency were calculated in the context of tubing for an EGR cooler. In general, one of the design and manufacturing limitations of an EGR heat exchanger is the tube-to-tube spacing. The tubes may require sufficient flow and surface area available for heat exchange to avoid certain adverse effects such as localized boiling. Production of the end bulkhead or tube sheet may require a minimum web distance between holes. Reducing the spacing between tubes would increase the packing efficiency. So, for comparison purposes, it is advantageous to hold the tube-to-tube spacing t constant across all bundle configurations. This spacing applies not only to the spacing between tubes of the same bundle, but to the spacing between tubes of adjacent bundles as well.

[0052] With reference to FIG. 11, for a constant tube diameter d and tube spacing t,

[00021]$D=\frac{d+t}{\sin \left(\frac{}{2}\right)}=\frac{d+t}{\sin \left(\frac{}{N}\right)}$

[0053] Using this model, one can calculate bundle overlap, bundle spacing and packing efficiency. In an EGR cooler manufactured for use as disclosed in U.S. Pat. No. 9,605,912, the preferred standard helical tube dimensions are d=0.250, t=0.0531 (due to manufacturing tooling) and p=2.500. The results are shown in Table 1.

TABLE-US-00001 TABLE 1 N B Tubes per Bundles Helical q q S S Packing Pattern Bundle per Pattern Direction Bundle Overlap Bundle Spacing Efficiency Square 3 4 Counter .0556 .5444 49.69% Rectangular 3 4 Counter .0750 .0494 .5250 .5506 50.94% Square 2 4 Counter .1391 .4141 57.26% Square 3 4 Same .0144 .5856 42.95% Square 2 4 Same .0806 .4726 43.96% Equilateral 3 3 Same .0416 .5584 54.52% Triangle

[0054] It is also possible to achieve bundle to bundle spacing less than the outside diameter (D+d) by positioning in phase certain dissimilar adjacent bundles. Table 2 shows bundle overlap, bundle spacing and packing efficiency for square patterns of 4 bundles per pattern where adjacent bundles with standard dimension t=0.0531 have dissimilar pitch P, number of tubes N, and/or tube diameter d.

TABLE-US-00002 TABLE 2 q S Bundle Bundle Packing Overlap Spacing Efficiency d = .250 N = 2 P.sub.1 = 2.5 P.sub.2 = 7.5 .0198 .5333 34.52% d = .250 N.sub.1 = 2 N.sub.2 = 4 P.sub.1 = 2.5 P.sub.2 = 5 .0480 .5679 45.66% d.sub.1 = .250 d.sub.2 = .375 N = 2 P = 2.5 .0901 .5880 46.14%

EXAMPLE EMBODIMENT

[0055] A preferred embodiment of the invention is an EGR cooler implementing a 33 pattern unit (3 bundle patterns of 3-tube bundles). See FIGS. 14 & 15. In the illustrative embodiment of FIG. 12, heat exchanger 10 comprises an EGR cooler having gas inlet end 12 and a gas outlet end 14 adapted to receive a flow of exhaust gas from a diesel engine. Gas inlet end 12 comprises a tube header consisting of a bulkhead 16 having a plurality of perforations 18. A plurality of hollow passageways such as tubes 20, 22 and 24 (FIG. 15) are mechanically coupled to bulkhead 16 in registry with perforations 18 (e.g., by welding, brazing or similar rigid attachment) to form a fluid-tight seal between the tubes and the bulkhead. Bulkhead 26 located at gas outlet end 14 is of identical construction and therefore will not be discussed in detail herein. Bulkhead 16 and bulkhead 26 are fluidically connected (e.g., by appropriate flanged connections and exhaust system pipes, not shown) to the diesel engine exhaust system.

[0056] A shell 28 extends between bulkhead 16 and bulkhead 26 and is mechanically coupled to bulkhead 16 and to bulkhead 26 (e.g., by welding, brazing, or similar rigid attachment) to form a fluid-tight seal between the bulkheads and the shell. Shell 28 is provided with a coolant inlet passage 30 and a coolant outlet passage 32 to enable a flow of coolant to flow into shell 28 past the tubes contained within shell 28 and then out of shell 28 to an external radiator or other means of discharging the heat rejected from tubes 20-24. Although in the illustrative embodiment of FIG. 12 heat exchanger 10 comprises a parallel flow heat exchanger with coolant inlet passage 30 adjacent gas inlet end 12, the invention should not be considered as limited to the parallel flow heat exchanger embodiment. For example, a counter flow heat exchanger in which coolant inlet passage 30 is adjacent gas outlet end 14 is considered within the scope of the invention.

[0057] With additional reference to FIG. 13, in the illustrative embodiment the tubes running between bulkhead 16 and bulkhead 26 are arranged into a plurality of tube bundles such as tube bundle 34. Each tube bundle 34 is composed of a plurality of individual tubes, e.g., three individual tubes 20, 22, 24. Each of the individual tubes has a relatively short straight section 36, 38, 40 at the gas inlet end 12 and a relatively short straight section 42, 44, 46 at gas outlet end 14. In between the relatively short straight sections, each of the three individual tubes 20, 22, 24 is wound into a helix, each of which has the same helical pitch, helical radius, and helical twist direction (e.g., right-hand or left-hand). All of the individual tubes 20, 22, 24 of tube bundle 34 share a common helical axis 48.

[0058] With additional reference to FIG. 14, tube bundle 34 is shown adjacent to a second tube bundle 50 and a third tube bundle 60. Tube bundle 50 is composed of a plurality of individual tubes, e.g., three individual tubes 52, 54 and 56. Each of the individual tubes has a relatively short straight section (not shown) at the gas inlet end 12 and a relatively short straight section (not shown) at gas outlet end 14. In between the relatively short straight sections, each of the three individual tubes 52, 54 and 56 is wound into a helix, each of which has the same helical pitch, helical diameter, and helical twist direction. All of the individual tubes 52, 54 and 56 of tube bundle 50 share a common helical axis 58. Helical axis 58 is parallel to helical axis 48. Tube bundle 60 is composed of a plurality of individual tubes, e.g., three individual tubes 62, 64 and 66. Each of the individual tubes has a relatively short straight section (not shown) at the gas inlet end 12 and a relatively short straight section (not shown) at gas outlet end 14. In between the relatively short straight sections, each of the three individual tubes 62, 64 and 66 is wound into a helix, each of which has the same helical pitch, helical diameter, and helical twist direction. All of the individual tubes 62, 64 and 66 of tube bundle 60 share a common helical axis 68. Helical axis 68 is parallel to helical axis 48 and parallel to helical axis 58.

[0059] Tube bundles 34, 50 and 60 are positioned in phase with one another. The outer surface of tube 24, constituting the peak of tube bundle 34, is aligned with the valley between tubes 64 and 66 (of tube bundle 60). The outer surface of tube 66 is aligned with the valley formed by tubes 52 and 56 (of tube bundle 50). The outer surface of tube 52 is aligned with the valley formed by tubes 22 and 24 (of tube bundle 34). As discussed in connection with FIGS. 7 and 8, adjacent tube bundles are positioned so that the bundle spacing is less than the sum of the helical (coil) diameter of a bundle (D) plus the diameter of a tube (d), a distance shown as 35, 55 and 65 in the respective bundles. In some embodiments adjacent tube bundles actually touch tangent to each other.

[0060] The 33 pattern unit, comprising three adjacent 3-tube bundles, can be repeated to form a matrix of tube bundles, as seen in FIG. 15.

[0061] With additional reference to FIG. 16, in the illustrative embodiment, heat exchanger 10 comprises fourteen tube bundles attached between bulkhead 16 and bulkhead 26. The upper horizontal row of tube bundles consists of a tube bundle 34a consisting of tubes 20a, 22a and 24a all of which have a left-hand helical twist. Immediately adjacent to tube bundle 34a is an identical tube bundle 34b consisting of tubes 20b, 22b and 24b all of which also have a left-hand helical twist. Immediately below and adjacent to both tube bundle 34a and 34b is an identical tube bundle 34c consisting of tubes 20c, 22c and 24c all of which have a left-hand helical twist. The three tube bundles are arranged in a triangular array in which the helical axes 48a, 48b, and 48c are parallel. As can be seen from FIG. 16, the remainder of the tube bundles are arranged with the helical axes laid out in a series of triangular arrays forming a triangular matrix such that the helical axes of each tube bundle are equidistance from all adjacent tube bundle helical axes. In the matrix, each tube bundle is adjacent on all sides to tube bundles having the same helical twist.

Combining Twist Orientations

[0062] As shown above, helical tube bundles of 3 tubes each of the same hand twist can be arranged more efficiently in a triangular pattern over bundles of 3 tubes each of opposite hand twists arranged in a rectangular pattern. See Table 1. Prior discovery, disclosed in U.S. Pat. No. 9,601,952, demonstrates that bundles of opposite hand helical tubes can be spaced closer together than bundles of same hand tubes. A variation of improved packing efficiency has been discovered when combining both ideas of opposite hand helical tube bundles of 3 tubes each into a triangular pattern.

[0063] As previously discussed, the minimum bundle spacing of opposite hand tubes is a function of the minimum tube to tube spacing allowed by thermal fluid design or manufacturing processes. With reference to FIG. 17, in a triangular pattern, at least two adjacent tube bundles must be of the same hand twist direction. Two same hand bundles 201 and 202 are spaced at a distance S with a third bundle 203 of opposite hand twist spaced at a distance S, such that the spacing m between individual tubes of adjacent bundles is minimized to the same size as the spacing t between the tubes of each bundle. For convenience, this spacing will be referred to as t, the same as the intra-bundle tube spacing. All bundles are in the same initial rotational orientation. Because adjacent bundles of opposite hands can be spaced closer together than bundles of the same hand twist, S is slightly less than S, presenting an isosceles triangle rather than an equilateral one. Although this puts the opposite hand bundle slightly out of rotational phase relative to the adjacent bundles there is sufficient clearance between the tubes due to the opposite hand twist to not create any interference for many tube bundle configurations (various D, d, and P).

[0064] The isosceles triangle unit pattern can be repeated, as shown in FIG. 18. There, a row of right hand twist bundles 211 is positioned between rows of left hand twist bundles 210 and 212.

[0065] The distance S to the opposite hand bundle can be further reduced if the initial rotational orientation is adjusted, as illustrated in FIG. 19 (designating the distance as Smin). The same hand bundles can be rotated to an initial rotational position and the opposite hand bundle positioned and rotated such that such that the distances m between tubes of adjacent bundles are spaced at the minimum distance t. Note that the highlighted line segments 215 are all equal lengths of d+t.

[0066] However, patterning the next row of bundles, oriented and rotated such that the spacing between tubes of adjacent bundles is minimized, requires that row to be offset. With reference to FIG. 20, right hand twist row 222 is positioned and rotated such that the distance between the tubes of row 222 and the tubes of adjacent left hand twist row 221 are spaced at the minimum distance t. Left hand twist row 223, positioned on the opposite side of row 222 and is offset 220 from the lateral position of row 221. This offset creates an arrangement of adjacent tube bundles in a scalene triangle 225 not an equilateral triangle. Although the vertical spacing between the second row 222 and third row 223 of tube bundles is greater than that of the spacing between rows of bundles with the same initial rotational orientation, the overall spacing between the first row 221 and third row 223 is reduced.

[0067] The rotational orientation of bundles in the third row 223 is identical to the bundles in the first row 221, making it repeatable, albeit with a horizontal offset to each additional odd numbered row (i.e. not a square pattern). The orientation of the bundles can be adjusted such that the distance between tubes of adjacent bundles is not minimized yet still reduces row to row spacing and row offset. This can create bundle arrangements of additional rows that are achievable but not patterns of previous rows. Such arrangements may be advantageous in certain situations.

[0068] Packing efficiency of the isosceles triangle arrangement is shown with reference to FIG. 21. Since S is slightly less than S, the Packing Area occupied by the tube pattern is reduced from that of an equilateral triangular pattern of tube bundles all spaced at a distance S apart from each other. The Packing Efficiency is thus increased due to the reduction in the Packing Area occupied by the same quantity of tubes according to the relationship:

[00022]$\mathrm{Packing}\mathrm{Efficiency}=\frac{\mathrm{Total}\mathrm{Tube}\mathrm{Area}}{\mathrm{Packing}\mathrm{Area}}$

[0069] As noted above, when the initial orientation of tube bundles is rotated, resulting in a scalene triangle pattern, S can be further reduced. Applying the methodology described above for calculating packing efficiency tabulated in Table 1, it can be seen that the total packing area of the pattern of tube bundles can be decreased for bundles of certain parameters (D, d, and P) such that the Packing Efficiency of the entire pattern is increased. This is shown in Table 3 with Calculations for helical tube bundle patterns with d=0.250, t=0.0531, and P=2.500.

TABLE-US-00003 TABLE 3 N B Tubes Bundles q q' S S per per Helical Bundle Bundle Packing Pattern Bundle Pattern Direction Overlap Spacing Efficiency Square 3 4 Counter .0556 .5444 49.69% Rectangular 3 4 Counter .0750 .0494 .5250 .5506 50.94% Square 2 4 Counter .1391 .4141 57.26% Square 3 4 Same .0144 .5856 42.95% Square 2 4 Same .0806 . 4726 43.96% Equilateral 3 3 Same .0416 .5584 54.52% Triangle Isosceles 3 3 Counter .0416 .0668 .5584 .5332 58.06% Triangle Skewed 3 3 Counter .0416 .0668* .5584 .5227* 58.30% Triangular

EXAMPLE EMBODIMENT

[0070] An embodiment of the isosceles triangle configuration in an EGR cooler is illustrated in FIGS. 22-24. A preferred embodiment of the invention is an EGR cooler implementing a 33 isosceles pattern unit (3 bundle patterns of 3-tube bundles with one bundle having opposite twist). See FIGS. 22 & 23. In the illustrative embodiment of FIG. 22, heat exchanger 250 comprises an EGR cooler having gas inlet end 251 and a gas outlet end 252 adapted to receive a flow of exhaust gas from a diesel engine. Gas inlet end 251 comprises a tube header consisting of a bulkhead 253 having a plurality of perforations 254. A plurality of hollow passageways such as tubes 260, 261 and 262 (FIG. 23) are mechanically coupled to bulkhead 253 in registry with perforations 254 (e.g., by welding, brazing or similar rigid attachment) to form a fluid-tight seal between the tubes and the bulkhead. Bulkhead 255 located at gas outlet end 252 is of identical construction and therefore will not be discussed in detail herein. Bulkhead 253 and bulkhead 255 are fluidically connected (e.g., by appropriate flanged connections and exhaust system pipes, not shown) to the diesel engine exhaust system.

[0071] A shell 256 extends between bulkhead 253 and bulkhead 255 and is mechanically coupled to bulkhead 253 and to bulkhead 255 (e.g., by welding, brazing, or similar rigid attachment) to form a fluid-tight seal between the bulkheads and the shell. Shell 256 is provided with a coolant inlet passage 257 and a coolant outlet passage 258 to enable a flow of coolant to flow into shell 256 past the tubes contained within shell 256 and then out of shell 256 to an external radiator or other means of discharging the heat rejected from tubes 260-262. Although in the illustrative embodiment of FIG. 22 heat exchanger 250 comprises a parallel flow heat exchanger with coolant inlet passage 257 adjacent gas inlet end 251, the invention should not be considered as limited to the parallel flow heat exchanger embodiment. For example, a counter flow heat exchanger in which coolant inlet passage 257 is adjacent gas outlet end 252 is considered within the scope of the invention.

[0072] With additional reference to FIG. 23, in the illustrative embodiment the tubes running between bulkhead 253 and bulkhead 255 are arranged into a plurality of tube bundles such as tube bundles 301 and 302. Each tube bundle is composed of a plurality of individual tubes, e.g., three individual tubes 260, 261, 262 in bundle 301 and 263, 264, 265 in bundle 302. Each of the individual tubes has a relatively short straight section 271, 272, 273 at the gas inlet end 251 and a relatively short straight section 274, 275, 276 at gas outlet end 252. In between the relatively short straight sections, each of the three individual tubes is wound into a helix, each of which has the same helical pitch, helical radius, and helical twist direction (e.g., right-hand or left-hand), around a common helical axis. In FIG. 23, tube bundle 301 is composed of individual tubes 260, 261, 262, wound with a left-hand twist around common helical axis 280. Tube bundle 302 is composed of individual tubes 263, 264, 265, wound with a right-hand twist around common helical axis 281.

[0073] With additional reference to FIG. 24, tube bundle 301 is shown adjacent to tube bundle 302 and a third tube bundle 303. Tube bundle 303 is composed of a plurality of individual tubes, e.g., three individual tubes 285, 286, 287. Each of the individual tubes has a relatively short straight section (not shown) at the gas inlet end 251 and a relatively short straight section (not shown) at gas outlet end 252. In between the relatively short straight sections, each of the three individual tubes 285, 286, 287 is wound into a helix, having the same helical pitch, helical diameter, and helical twist direction about a common helical axis 282 that is parallel to axes 280 and 281. Tube bundle 303 has left-hand twist, the same as tube bundle 301 and opposite that of tube bundle 302.

[0074] Tube bundles 301, 302 and 303 are positioned in the isosceles triangle configuration described above. The 33 pattern unit, comprising three adjacent 3-tube bundles, can be repeated to form a matrix of tube bundles, as seen in FIG. 25.

[0075] With additional reference to FIGS. 26 and 27, in the illustrative embodiment, heat exchanger 250 comprises 42 tubes 254, arranged into fourteen tube bundles, attached between bulkhead 253 and bulkhead 255. The upper horizontal row 310 of tube bundles consists of three 3-tube bundles, 320, 321, 322, all having a right-hand twist. Row 311, immediately below, consists of three 3-tube bundles having a left-hand twist. Below that, row 312 consists of three 3-tube bundles with right-hand twist. An additional row of left-hand twist bundles is below row 312. The bundles are positioned as discussed above with respect to FIGS. 17 and 18.

[0076] With reference to the figures and in particular the example embodiments, incorporating features of the present invention may be used as a heat exchanger for a variety of purposes in which it is desired to transfer heat from one fluid medium to another fluid. In one example, the heat exchanger may be used as an exhaust gas recirculation (EGR) cooler. A heat exchanger incorporating features of the present invention may, however, used in connection with any appropriate application to transfer heat from a fluid on one side of a barrier to a fluid on the other side of the barrier without bringing the fluids into contact. A heat exchanger incorporating the teachings of the present invention may be used with all types of fluids, for example air-to-air, air-to-liquid, liquid-to-liquid as appropriate to meet the particular needs of the application.

[0077] Although certain illustrative embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the invention. Additionally, although the tubes forming the tube bundles in the illustrative embodiment are circular in cross section, tubes having non-circular cross sections may be advantageously used in a heat exchanger incorporating features of the present invention and therefore are considered within the scope of the invention. Also, it should be observed that although the helical axis of the tube bundles extends from bulkhead-to-bulkhead, it is not necessary that the tube bundles be continuously helical from bulkhead-to-bulkhead as long as they are helical about a common helical axis over some portion of their length. Accordingly, it is intended that the invention should be limited only to the extent required by the appended claims and the rules and principles of applicable law. Additionally, as used herein, references to direction such as up or down are intended to be exemplary and are not considered as limiting the invention and, unless otherwise specifically defined, the terms generally, substantially, or approximately when used with mathematical concepts or measurements mean within 10 degrees of angle or within 10 percent of the measurement, whichever is greater.