Note: Descriptions are shown in the official language in which they were submitted.
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HEAT EXCHANGE PANEL
FIELD OF THE INVENTION
The present invention relates to a heat exchange panel that includes a
lower plate and an upper plate that when joined together form a plurality of
channels that are in fluid communication with a plurality of upper plate
extension passages. The lower plate has a plurality of upwardly extending
lower plate extensions, and the upper plate has a plurality of upwardly
extending hollow upper plate extensions. Each channel includes at least
one lower plate extension extending upwardly therefrom, and each upper
plate extension is positioned so as to receive an upper portion of one
lower plate extension therein. The interior surfaces of the hollow upper
plate extension and the exterior surfaces of the lower plate extension
received therein together define an upper plate extension passage that is
in fluid communication with an underlying channel. The combination of
upper plate extension passages and channels provide the heat exchange
panel of the present invention with improved heat exchange capabilities.
The heat exchange panel of the present invention may be a solar heat
exchange panel.
BACKGROUND OF THE INVENTION
Heat exchange panels, such as solar heat exchange panels, typically
include a plurality of channels through which a fluid, such as a heat
exchange fluid (e.g., water) is passed. Typically, a heat exchange panel is
oriented so as to expose the exterior surfaces of the channels thereof to a
source of thermal energy, such as radiant heat (e.g., the sun). The
channels are heated by exposure to the heat source, and thermal energy
is transferred to the fluid passing through the interior of the channels. The
heated fluid may be used directly (e.g., in the case of a heated shower) or
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indirectly, e.g., to heat another fluid, such as air or water, in which case
the
heated fluid is typically described as a heat exchange fluid.
Optimizing the design of a heat exchange panel for purposes of improved
efficiency, typically involves attempting to balance a number of factors,
including, for example: maximizing thermal transfer (i.e., of thermal energy
into the heat exchange fluid within the channels); maximizing the volume
of heat exchange fluid passing through the panel; and at the same time
minimizing the dimensions of the panel (e.g., width and length). The
factors of maximum thermal transfer, maximum heat exchange fluid
through-put, and minimum panel dimensions, are generally incompatible.
For example, as the rate of fluid through-put is increased, the amount of
thermal energy transferred into the heat exchange fluid is typically
decreased. In addition, as the dimensions of the panel are decreased, the
amount of thermal energy transferred into the heat exchange fluid is
typically also decreased. As such, attempting to arrive at a favorable
balance between such incompatible factors generally results in heat
exchange panel designs having less than optimum efficiencies.
Attempts have been made to improve the efficiency of solar heat
exchange panels by increasing the surface area of the exterior channel
surfaces that are exposed to radiant energy. For example, solar heat
exchange panels having V-shaped or triangular shaped exterior channel
surfaces have been disclosed. See for example, United States Patent
No.'s 4,290,413; 4,243,020; and 4,171,694.
It would be desirable to develop new heat exchange panels having
improved efficiencies. In particular, it would be desirable that such newly
developed heat exchange panels provide a favorable balance and
coupling of factors including, optimum thermal transfer, optimum heat
exchange fluid through-put, and minimum panel dimensions. In addition, it
would be further desirable that such newly developed heat exchange
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panels lend themselves to relative ease of manufacture, assembly and
use.
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SUMMARY OF THE INVENTION
These needs are met by providing a heat exchange panel that includes at
least a lower plate having an interior surface, and a plurality of lower plate
extensions extending upwardly from (e.g., away from or outward from)
said interior surface of said lower plate, each lower plate extension having
exterior surfaces; and an upper plate having an interior surface, an exterior
surface,
and a plurality of upper plate extensions extending upwardly from (e.g.,
away from or outward from) said exterior surface of said upper plate, each
upper plate extension having an aperture on said interior surface of said
upper plate and interior surfaces that define an interior space that is in
fluid
communication with said aperture, wherein said lower plate and said upper
plate are joined together such that said interior surface of said lower plate
and said interior surface of said upper plate together define a plurality of
channels, each channel having a terminal inlet and a terminal outlet, each
channel having at least one lower plate extension residing therein and
extending upwardly therefrom (and, correspondingly, there-above), and
each channel having the aperture and the interior space of at least one
upper plate extension positioned over said channel and in fluid
communication with said channel, the aperture and interior space of each
upper plate extension being aligned with and receiving an upper portion of
one lower plate extension therein (i.e., within the interior space of the so-
aligned upper plate extension), a portion of the interior surfaces defining
the interior space of said upper plate extension and a portion of the
exterior surfaces of the upper portion of said lower plate extension
received within said interior space, in each case, together defining an
upper plate extension passage, each upper plate extension passage being
in fluid communication with the channel residing there-under, and further
wherein a fluid introduced into the terminal inlet of said channel passes
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through each upper plate extension passage in fluid communication with
said channel and emerges from said terminal outlet of said channel.
The features that characterize the present invention are pointed out with
particularity in the claims, which are annexed to and form a part of this
disclosure. These and other features of the invention, its operating
advantages and the specific objects obtained by its use will be more fully
understood from the following detailed description and accompanying
drawings in which preferred (though non-limiting) embodiments of the
invention are illustrated and described.
As used herein and in the claims, terms of orientation and position, such
as, "upper", "lower", "inner", "outer", "right", "left", "vertical",
"horizontal",
"top", "bottom", and similar terms, are used to describe the invention as
oriented and depicted in the drawings. Unless otherwise indicated, the
use of such terms is not intended to represent a limitation upon the scope
of the invention, in that the invention may adopt alternative positions and
orientations.
Unless otherwise indicated, all numbers or expressions, such as those
expressing structural dimensions, quantities of ingredients, etc., as used in
the specification and claims are understood as modified in all instances by
the term "about".
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BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a representative perspective view of a heat exchange panel
according to the present invention.
Figure 2 is a representative top plan view of the heat exchange panel of
Figure 1.
Figure 3 is a representative perspective view of a longitudinal section of
the heat exchange panel of Figure 1.
Figure 4 is a magnified representative perspective view of a portion of the
longitudinal section of the heat exchange panel of Figure 3.
Figure 5 is a magnified representative elevational view of a portion of the
longitudinal section of the heat exchange panel of Figure 3.
Figure 6 is a representative perspective view of a lateral section of the
heat exchange panel of Figure 1.
Figure 7 is a magnified representative perspective view of a portion of the
lateral section of the heat exchange panel of Figure 6.
Figure 8 is a magnified representative elevational view of a portion of the
lateral section of the heat exchange panel of Figure 6.
Figure 9 is a magnified representative perspective view of an interior
portion of a corner of the sidewall structure of the heat exchange panel of
Figure 1.
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Figure 10 is a perspective view of an exploded representation of the heat
exchange panel of Figure 1.
Figure 11 is a representative perspective view of the interior surface side
of the lower plate of the heat exchange panel of Figure 1.
Figure 12 is a representative top plan view of a portion of the interior
surface side of the lower plate of the heat exchange panel of Figure 11,
showing a lateral passage in a rib.
Figure 13 is a magnified representative perspective view of a portion of the
interior surface side of the lower plate of the heat exchange panel of
Figure 11.
Figure 14 is a representative perspective view of the interior surface side
of the upper plate of the heat exchange panel of Figure 1.
Figure 15 is a magnified representative perspective view of a portion of the
interior surface of the upper plate of the heat exchange panel of Figure 14.
Figure 16 is a perspective view of an outside corner of the sidewall
structure of the heat exchange panel of Figure 1 in which some of the
terminal outlets of the channels are visible within the outlet header.
Figure 17(a) is a representative sectional view of a portion of a heat
exchange panel according to the present invention in which the ribs are
formed by lower plate ribs.
Figure 17(b) is a representative sectional view of a portion of a heat
exchange panel according to the present invention in which the ribs are
formed by upper plate ribs.
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Figure 17(c) is a representative sectional view of a portion of a heat
exchange panel according to the present invention in which the ribs are
formed by abutment of lower and upper plate ribs.
Figure 17(d) is a representative sectional view of a portion of a heat
exchange panel according to the present invention in which the ribs are
formed by a combination of non-abutting lower and upper plate ribs.
Figure 17(e) is a representative sectional view of a portion of a heat
exchange panel according to the present invention in which the ribs are
separate from and abuttingly interposed between the upper and lower
plates.
Figure 18 is a representative top plan view of the interior surface side of
the lower plate of the heat exchange panel of Figure 11.
Figure 19 is a further magnified representative elevational view of a portion
of the lateral section of the heat exchange panel of Figure 8, showing a
sectional view of a portion of the sidewall structure.
Figure 20 is the representative perspective view of a lateral section of the
heat exchange panel of Figure 8, further including a plate abutting the
upper terminus of the sidewall structure.
In Figures 1 through 20, like reference numerals designate the same
components and structural features, unless otherwise indicated.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawing Figures (e.g., Figures 1, 4, 5, 10 and 14) the
heat exchange panel 1 of the present invention includes a lower plate 11
and an upper plate 14. Lower plate 11 has an interior (or upper) surface
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17 and a plurality of lower plate extensions 20 extending upwardly (or
outwardly) from interior surface 17. Lower plate 11 also has an exterior (or
lower) surface 35 (not shown or visible in perspective in the drawings).
Upper plate 14 has an interior (or lower) surface 26 (Figures 14 and 15),
an exterior (or upper) surface 29 and a plurality of upper plate extensions
32 each extending upwardly (or outwardly) from exterior surface 29
thereof. Each upper plate extension 32 also has an exterior surface 38.
Each upper plate extension 32 has an aperture 42 on interior surface 26 of
upper plate 14, and interior surfaces 45 that define an interior space 48.
For each upper plate extension 32, the interior space 48 thereof is in fluid
communication (or is continuous) with the aperture 42 thereof. See
Figures 14 and 15. As such, each upper plate extension 32 is a hollow
upper plate extension having an interior hollow space 48, defined by
interior surfaces 45 thereof, which is in fluid communication with the
aperture 42 thereof on interior surface 26 of upper plate 14.
Lower plate 11 and upper plate 14 are joined together such that interior
surface 17 of lower plate 11 and interior surface 26 of upper plate 14
together define a plurality of channels 51 there-between. Each channel 51
has a terminal inlet 54 and a terminal outlet 57. The terminal inlets 54 and
outlets 57 of the channels are both only partially visible in the assembled /
non-exploded representations of heat exchange panel 1 of the drawings
(e.g., Figure 3). A partial representation of terminal inlets 54 and outlets
57 is depicted in the exploded representation of Figure 10, and the
representation of lower plate 11 alone in Figure 11. A depiction of some
terminal outlets 57 is provided in Figure 16. Terminal inlets 54 of heat
exchange panel 1 are substantially similar to terminal outlets 57, as
depicted in Figure 16.
The channels may each independently define (e.g., trace out) any suitable
path between opposite ends of the heat exchange panel (and the terminal
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inlets and outlets thereof), such as substantially straight (or longitudinal)
paths, serpentine paths, arcuate paths, angular paths, or any combination
thereof. Typically, each channel defines (or has) a substantially straight
path between opposite ends of the heat exchange panel (and the terminal
inlet and outlet thereof), and accordingly each channel is a substantially
longitudinal (or straight) channel (as depicted in the drawings).
For a given channel, the terminal inlet and terminal outlet thereof are
positioned at (or on) opposite ends of the heat exchange panel. The
designation of terminal inlet or terminal outlet with regard to a channel is
determined with regard to whether a fluid is introduced therethrough (in
which case it is a terminal inlet) or exits therefrom (in which case it is a
terminal outlet). As such, all of the terminal inlets may be located on the
same end (e.g., an inlet end 60) of the heat exchange panel, and all of the
terminal outlets may correspondingly be located on the same (more
particularly, the other/opposite) end (e.g., an outlet end 63) of the heat
exchange panel. Alternatively, some of the terminal inlets and some of the
terminal outlets may be located at/on the same end of the heat exchange
panel, in which case a fluid may flow in opposite directions through
separate channels of the heat exchange panel.
Each channel 51 has at least one lower plate extension 20 residing therein
and extending upward (or outward) therefrom. More typically, each
channel 51 has at least two lower plate extensions 20 residing therein and
extending upward therefrom. When two or more lower plate extensions
reside in and extend upward from a given channel, the lower plate
extensions are typically spaced separately from each other within (or
along) the channel. The lower plate extensions may be spaced at regular
(e.g., linearly even/equivalent) or non-regular (e.g., linearly uneven/non-
equivalent) internals within a particular channel. Typically, and as
depicted in the drawings, the lower plate extensions 20 are spaced
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separately from each other at substantially regular (or linearly
even/equivalent) intervals within each channel 51.
As each lower plate extension 20 resides within and extends upwardly
from a channel 51, each lower plate extension 20 has a lower portion 66
that resides within the channel 51, and an upper portion 69 that extends
upwardly from and above the channel 51. See, for example, Figures 4
and 13.
Each channel 51 has at least one upper plate extension 32 positioned
there-over. In particular, each channel 51 has the aperture 42 and
correspondingly the interior space 48 of at least one upper plate extension
32 positioned there-over, such that the aperture 42 and interior space 48
thereof are in fluid communication with the underlying channel 51. See,
for example Figure 5. More typically, two or more upper plate extensions
are so positioned over a given (and underlying) channel, as depicted in the
drawings.
With the upper plate extensions so positioned over the underlying
channels, the aperture 42 and interior space 48 of each upper plate
extension 32 is aligned with and receives an upper portion 69 of one (i.e.,
a single) lower plate extension 20 therein (i.e., within the interior space 48
of the so-aligned upper plate extension 32). See, for example, Figure 4.
As such, with the upper portion of a lower plate extension so received
therein, the interior space and aperture of the aligned upper plate
extension are typically not alone (or freely/unobstructively) in
communication with, but rather may be described as being obstructively in
communication with, the underlying channel 51, as will be described in
further detail herein with regard to the upper plate extension passages.
For each lower plate extension 20 and upper plate extension 32
associated pair, a portion of the interior surfaces 45 that define the
interior
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space 48 of the upper plate extension 32 (e.g., inlet surface 75 and outlet
surface 78), and a portion of the exterior surfaces 23 of the upper portion
69 of the lower plate extension 20 received within interior space 48 (e.g.,
inlet face 81 and outlet face 84), together define there-between an upper
plate extension passage 72. Each upper plate extension passage 72 is in
fluid communication with the longitudinal channel 51 that resides there-
under. See, for example, Figures 4 and 5. Typically, as a portion (e.g., an
abutting portion, such as first and second side faces) of the exterior
surfaces of each lower plate extension abuts a portion (e.g., an abutting
portion, such as first and second side surfaces) of the interior surfaces of
the upper plate extension into which it is received, only a portion (e.g., a
non-abutting portion, such as inlet and outlet faces 81 and 84 ) of the
exterior surfaces of the lower plate extension and a portion (e.g., a non-
abutting portion, such as inlet and outlet surfaces 75 and 78) of the interior
surfaces of the upper plate extension together define each upper plate
extension passage, as will be discussed in further detail herein.
The lower plate includes a plurality of lower plate extensions. For
example, the lower plate may include a total number of lower plate
extensions of from 5 to 500, typically from 25 to 400, and more typically
from 50 to 300. Since each lower plate extension is typically received
within the interior space of an upper plate extension, the upper plate
generally includes a total number of upper plate extensions that is
substantially equivalent to the total number of lower plate extensions of the
lower plate. For example, the upper plate may include a total number of
upper plate extensions of from 5 to 500, typically from 25 to 400, and more
typically from 50 to 300. With each lower plate extension typically being
received within the interior space of an upper plate extension, the lower
plate and upper plate extensions together form a plurality of associated
pairs of lower plate extensions and upper plate extensions. The heat
exchange panel typically includes a total number of associated pairs of
lower plate extensions and upper plate extensions that is equal to the total
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number of lower plate extensions or the total number of upper plate
extensions. For example, the heat exchange panel may include a total
number of associated pairs of lower plate extensions and upper plate
extensions of from 5 to 500, typically from 25 to 400, and more typically
from 50 to 300.
With the lower plate 11 and the upper plate 14 joined together, as
described in detail above, there is defined a plurality of channels 51
between the interior surfaces thereof (17 and 26), and at least one upper
plate extension passage 72 that is in fluid communication with the channel
51 there-under. As such, for each channel 51, a fluid (e.g., water)
introduced into the terminal inlet 54 thereof, passes through the channel
51 and each upper plate extension passage 72 in fluid communication
there-with, and accordingly emerges from the terminal outlet 57 of that
channel.
Since each upper plate extension is associated with and receives within its
interior space the upper portion of a lower plate extension, the spacing of
the upper plate extensions relative to each other along an underlying
channel is substantially the same as that of the associated lower plate
extensions within that same channel. More particularly, the upper plate
extensions may be spaced at regular (e.g., linearly even/equivalent) or
non-regular (e.g., linearly uneven/non-equivalent) internals along (or over)
a particular channel. Typically, and as depicted in the drawings, the upper
plate extensions 32 are spaced separately from each other at substantially
regular (or linearly even/equivalent) intervals along (or over) each
underlying channel 51.
The lateral arrangement of lower plate extensions as between (or across)
different channels (e.g., adjacent/neighboring channels, or alternating
channels) of the heat exchange panel may be selected from regular
patterns, non-regular (or irregular) patterns and combinations thereof.
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Typically, the lateral arrangement of lower plate extensions across
different channels of the heat exchange panel is selected from regular
patterns. More particularly, as between neighboring (or adjacent)
channels, the lateral arrangement of neighboring lower plate extensions
may be selected from substantially laterally aligned arrangements, laterally
offset (or staggered) arrangements, and combinations thereof. In a
particular embodiment of the present invention, the channels of the heat
exchange panel are longitudinal channels, and the lateral arrangement of
neighboring lower plate extensions, as between neighboring/ adjacent
channels, is selected from laterally offset/staggered arrangements. That
is, each lower plate extension is laterally staggered (rather than laterally
aligned) relative to each neighboring lower plate extension of an adjacent
channel, as depicted in the drawings.
With reference to Figure 18, lower plate extension 20(a) of channel 51(a)
is laterally staggered relative to neighboring lower plate extension 20(b) of
adjacent channel 51(b). Correspondingly, lower plate extension 20(b) of
channel 51(b) is laterally staggered relative to neighboring lower plate
extension 20(a) of adjacent channel 51(a). Channel 51(a) and channel
51(b) are neighboring or adjacent channels. Neighboring lower plate
extensions are free of one or more lower plate extensions interposed
there-between.
In an embodiment of the present invention: the channels of the heat
exchange panel are longitudinal channels; the lateral arrangement of
neighboring lower plate extensions, as between neighboring/ adjacent
channels, is selected from laterally offset/staggered arrangements; and
additionally, the lateral arrangement of each lower plate extension, as
between each first channel and each third channel (equivalently, every
other channel, or alternating pairs of channels), is selected from
substantially laterally aligned arrangements. Each first channel and each
third channel is separated by an interposed and common neighboring
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channel. Equivalently, each alternating pair of channels is separated by
an interposed and common neighboring channel. With reference to
Figure 18, lower plate extension 20(a) of channel 51(a) (here a first
channel) is substantially laterally aligned relative to lower plate extension
20(c) of channel 51(c) (here a third channel). Correspondingly, lower plate
extension 20(c) of channel 51(c) (here a first channel) is substantially
laterally aligned relative to lower plate extension 20(a) of channel 51(a)
(here a third channel). Channel 51(b) is interposed between and is a
common neighboring channel relative to each of channel 51(a) and
channel 51(c). Channels 51(a) and 51(c) may also be described as an
alternating pair of channels, having an interposed and common
neighboring channel 51(b) there-between.
In an embodiment of the present invention: the channels of the heat
exchange panel are longitudinal channels; the lateral arrangement of
neighboring lower plate extensions, as between neighboring/adjacent
channels, is selected from laterally offset/staggered arrangements; and
additionally, as between any three sequentially adjacent channels, the
lower plate extensions have a repeating pattern comprising in each case
five (5) lower plate extensions arranged in a lower plate extension X-
configuration having a single terminal lower plate extension at each of the
four corners (or terminal points) of the X-configuration, and a single central
lower plate extension at the center (or intersection) of the X-configuration.
The lower plate extensions accordingly form a plurality of lower plate
extension X-configurations. Each lower plate extension X-configuration is
typically a substantially symmetrical X-configuration. With reference to
Figure 18, an X-configuration 87 of lower plate extensions is illustrated
across sequentially adjacent channels 51(a), 51(b) and 51(c). The lower
plate extension X-configuration 87 includes a single terminal lower plate
extension 20(d), 20(e), 20(f) and 20(g) at each of the four corners of the X-
configuration, and a single central lower plate extension 20(h) at the center
or intersection of the X-configuration. Three sequentially adjacent
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channels typically include a first channel, e.g., channel 51(a), a third
channel, e.g., channel 51(c), and a second channel, e.g., channel 51(b)
interposed between and being a neighboring channel to (or adjacent to)
each of the first and second channels. For purposes of further illustration,
regarding lower plate extension X-configuration 87: the terminal or corner
lower plate extensions 20(d) and 20(f) each reside within first channel
51(a); the terminal or corner lower plate extensions 20(e) and 20(g) each
reside within third channel 51(c); and the center lower plate extension
20(h) resides within the second channel 51(b), which is interposed
between and adjacent to each of first channel 51(a) and third channel
51(c).
Since each upper plate extension is associated with and receives within its
interior space the upper portion of a lower plate extension, the lateral
arrangement of neighboring upper plate extensions as between (or across)
different channels (e.g., adjacent/neighboring channels, or alternating
channels) of the heat exchange panel, is substantially the same as that of
the associated lower plate extensions across the same channels. The
lateral arrangement of neighboring upper plate extensions as between (or
across) different underlying channels (e.g., adjacent/neighboring channels,
or alternating channels) of the heat exchange panel may be selected from
regular patterns, non-regular (or irregular) patterns and combinations
thereof. Typically, the lateral arrangement of neighboring upper plate
extensions across different underlying channels of the heat exchange
panel is selected from regular patterns. More particularly, as between
neighboring (or adjacent) channels, the lateral arrangement of neighboring
upper plate extensions may be selected from substantially laterally aligned
arrangements, laterally offset (or staggered) arrangements, and
combinations thereof. In a particular embodiment of the present invention,
the channels of the heat exchange panel are longitudinal channels, and
the lateral arrangement of neighboring upper plate extensions, as between
neighboring/adjacent underlying channels, is selected from laterally
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offset/staggered arrangements. That is, each upper plate extension is
laterally staggered (rather than laterally aligned) relative to each
neighboring upper plate extension of (i.e., associated with or over) an
adjacent channel, as depicted in the drawings. Neighboring upper plate
extensions are free of one or more upper plate extensions interposed
there-between.
As Figure 2 is a top plan view of heat exchange panel 1, and in particular
the exterior surface 29 side of upper plate 14 thereof, the channels (51)
underlying and defined in part by upper plate 14 are not visible. As such,
in Figure 2 the characters and lead-lines associated with the channels,
e.g., 51(a), 51(b) and 51(c), are presented for purposes of reference and
indicate the location of an underlying channel. With reference to Figure 2,
upper plate extension 32(a) of (or over) channel 51(a) is laterally
staggered relative to neighboring upper plate extension 32(b) of adjacent
channel 51(b). Correspondingly, upper plate extension 32(b) of channel
51(b) is laterally staggered relative to neighboring upper plate extension
32(a) of adjacent channel 51(a). Channel 51(a) and channel 51(b) are
neighboring or adjacent channels.
In an embodiment of the present invention: the channels of the heat
exchange panel are longitudinal channels; the lateral arrangement of
neighboring upper plate extensions, as between neighboring/adjacent
channels, is selected from laterally offset/staggered arrangements; and
additionally, the lateral arrangement of each upper plate extension, as
between each first channel and each third channel (equivalently, every
other channel, or alternating pairs of channels), is selected from
substantially laterally aligned arrangements. Each first channel and each
third channel are separated by an interposed and common neighboring
second channel. Equivalently, each alternating pair of channels is
separated by an interposed and common neighboring channel. With
reference to Figure 2, upper plate extension 32(a) of (or over) channel
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51(a) (here a first channel) is substantially laterally aligned relative to
upper plate extension 32(c) of channel 51(c) (here a third channel).
Correspondingly, upper plate extension 32(c) of channel 51(c) (here a first
channel) is substantially laterally aligned relative to upper plate extension
32(a) of channel 51(a) (here a third channel). Channel 51(b) is interposed
between and is a common neighboring channel relative to each of channel
51(a) and channel 51(c). Channels 51(a) and 51(c) may also be described
as an alternating pair of channels, having an interposed and common
neighboring channel 51(b) there-between.
In an embodiment of the present invention: the channels of the heat
exchange panel are longitudinal channels; the lateral arrangement of
neighboring upper plate extensions, as between neighboring/adjacent
channels, is selected from laterally offset/staggered arrangements; and
additionally, as between any three sequentially adjacent channels, the
upper plate extensions have a repeating pattern comprising five (5) upper
plate extensions arranged in an upper plate extension X-configuration
having a single terminal upper plate extension at each of the four corners
(or terminal points) of the X-configuration, and a single central upper plate
extension at the center (or intersection) of the X-configuration.
The upper plate extensions accordingly form a plurality of upper plate
extension X-configurations. Each upper plate extension X-configuration is
typically a substantially symmetrical X-configuration. With reference to
Figure 2, an X-configuration 90 of upper plate extensions is illustrated
across sequentially adjacent channels 51(a), 51(b) and 51(c). The upper
plate extension X-configuration 90 includes a single terminal upper plate
extension 32(d), 32(e), 32(f) and 32(g) at each of the four corners of the X-
configuration, and a single central upper plate extension 32(h) at the
center or intersection of the X-configuration. Three sequentially adjacent
channels typically include a first channel, e.g., channel 51(a), a third
channel, e.g., channel 51(c), and a second channel, e.g., channel 51(b)
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interposed between and being a neighboring channel to (or adjacent to)
each of the first and second channels. For purposes of further illustration,
regarding upper plate extension X-configuration 90: the terminal or corner
upper plate extensions 32(d) and 32(f) each reside over (or are associated
with) first channel 51(a); the terminal or corner upper plate extensions
32(e) and 32(g) each reside over (or are associated with) third channel
51(c); and the center upper plate extension 32(h) resides over (or is
associated with) the second channel 51(b), which is interposed between
and adjacent to each of first channel 51(a) and third channel 51(c).
Since each upper plate extension is associated with and receives within its
interior space the upper portion of a lower plate extension (so as to
together define an upper extension passage 72 there-between), the so-
associated plate extensions may be described in each case as an
associated pair of upper plate and lower plate extensions 93. See, for
example, Figure 4. Accordingly, the spacing of the associated pairs of
upper plate and lower plate extensions relative to each other along a
channel is substantially the same as that of, and as described previously
herein with regard to the lower plate extensions (20) and the upper plate
extensions (32). More particularly, the associated pairs of upper plate and
lower plate extensions may be spaced at regular (e.g., linearly
even/equivalent) or non-regular (e.g., linearly uneven/non-equivalent)
internals along (or over) a particular channel, relative to each other.
Typically, and as depicted in the drawings, the associated pairs of upper
plate and lower plate extensions are spaced separately from each other at
substantially regular (or linearly even/equivalent) intervals along (or over)
each channel 51.
Further correspondingly, the lateral arrangement of associated pairs of
upper plate and lower plate extensions as between (or across) different
channels (e.g., adjacent/neighboring channels, or alternating channels) of
the heat exchange panel, is substantially the same as that of, and as
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described previously herein with regard to the lower plate extensions and
the upper plate extensions. The lateral arrangement of associated pairs of
upper plate and lower plate extensions as between (or across) different
channels (e.g., adjacent/neighboring channels, or alternating channels) of
the heat exchange panel may be selected from regular patterns, non-
regular (or irregular) patterns and combinations thereof. Typically, the
lateral arrangement of associated pairs of upper plate and lower plate
extensions across different channels of the heat exchange panel is
selected from regular patterns. More particularly, as between neighboring
(or adjacent) channels, the lateral arrangement of neighboring associated
pairs of upper plate and lower plate extensions may be selected from
substantially laterally aligned arrangements, laterally offset (or staggered)
arrangements, and combinations thereof.
In a particular embodiment of the present invention, the channels of the
heat exchange panel are longitudinal channels, and the lateral
arrangement of neighboring associated pairs of upper plate and lower
plate extensions, as between neighboring/adjacent underlying channels, is
selected from laterally offset/staggered arrangements. That is, each
associated pair of upper plate and lower plate extensions is laterally
staggered (rather than laterally aligned) relative to each neighboring
associated pair of upper plate and lower plate extensions of a neighboring
channel, as depicted in the drawings. Neighboring associated pairs of
upper plate and lower plate extensions are free of one or more associated
pairs of upper plate and lower plate extensions interposed there-between.
The laterally staggered arrangement of neighboring associated pairs of
upper plate and lower plate extensions may be more particularly described
in accordance with the description provided previously herein with
reference to Figure 2 regarding the laterally staggered arrangement of
neighboring upper plate extensions 32(a) and 32(b).
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In an embodiment of the present invention: the channels of the heat
exchange panel are longitudinal channels; the lateral arrangement of
neighboring associated pairs of upper plate and lower plate extensions, as
between neighboring/adjacent channels, is selected from laterally
offset/staggered arrangements; and additionally, the lateral arrangement
of each associated pair of upper plate and lower plate extensions, as
between each first channel and each third channel (equivalently, every
other channel, or alternating pairs of channels), is selected from
substantially laterally aligned arrangements. Each first channel and each
third channel are separated by an interposed and common neighboring
second channel. Equivalently, each alternating pair of channels is
separated by an interposed and common neighboring channel. The
substantially laterally aligned arrangement of associated pairs of upper
plate and lower plate extensions, as between alternating pairs of channels,
may be more particularly described in accordance with the description
provided previously herein with reference to Figure 2 regarding the
laterally aligned arrangement of upper plate extensions 32(a) and 32(c).
In an embodiment of the present invention: the channels of the heat
exchange panel are longitudinal channels; the lateral arrangement of
neighboring associated pairs of upper plate and lower plate extensions, as
between neighboring/adjacent channels, is selected from laterally
offset/staggered arrangements; and additionally, as between any three
sequentially adjacent channels, the associated pairs of upper plate and
lower plate extensions have a repeating pattern comprising five (5)
associated pairs of upper plate and lower plate extensions arranged in an
associated X-configuration having a single terminal associated pair of
upper plate and lower plate extensions at each of the four corners (or
terminal points) of the X-configuration, and a single central associated pair
of upper plate and lower plate extensions at the center (or intersection) of
the X-configuration. Each associated X-configuration is typically a
substantially symmetrical X-configuration. The X-configuration
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arrangement of associated pairs of upper plate and lower plate extensions,
may be more particularly described in accordance with the description
provided previously herein with reference to Figure 2 regarding the X-
configuration arrangement of upper plate extensions 32(d), 32(e), 32(f),
32(g) and 32(h).
With regard to further defining the channels, the heat exchange panel of
the present invention may further include a plurality of ribs residing
interposedly between the interior surface of the lower plate and the interior
surface of the upper plate. The ribs are laterally spaced from each other
and form a plurality of paired ribs (paired adjacent ribs). Each pair of ribs
together define one (i.e., a single) channel there-between. The ribs may
be: separate from the lower plate and the upper plate; substantially
continuous with the lower plate; substantially continuous with the upper
plate; or combinations thereof. In addition to further defining the plurality
of channels, the inclusion of ribs between the upper and lower plates
provides additional benefits, such as dimensional stability (e.g., improved
stiffness) to the heat exchange panel.
With reference to Figure 17(e) two ribs 96 are depicted as residing
interposedly between interior surface 17 of lower plate 11 and interior
surface 26 of upper plate 14. Ribs 96 of Figure 17(e) are separate from
(i.e., are not continuous with) lower plate 11 or upper plate 14. Two
adjacent ribs 96 form a pair of adjacent ribs 99 that together define a
single channel 51 there-between. More particularly, each rib 96 has a
sidewall 102 that is in facing spaced opposition relative to the other rib 96
of the pair of ribs 99. The facing and opposed sidewall 102 of each rib 96
along with a portion of interior surface 17 of lower plate 11 and a portion of
interior surface 26 of upper plate 14, together define a single channel 51
therebetween.
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Each separate rib 96 may be held in place between interior surface 17 of
lower plate 11 and interior surface 26 of upper plate 14 by friction.
Alternatively, each separate rib 96 may be held in place between the
interior surfaces of the lower and upper plates by: tongue and groove
means (not shown); adhesive means (not shown); and/or one or more
fasteners (not shown) extending through the upper plate and/or the lower
plate and at least a portion of the rib interposed there-between. For
example, each separate rib 96 may have at least one longitudinal tongue
extending therefrom that is received within an aligned and dimensioned
longitudinal groove of interior surfaces of the lower and/or upper plates.
Each separate rib 96 may, for example, include at least one dimensioned
longitudinal groove into which is received an aligned longitudinal tongue
extending from the interior surface of the lower and/or upper plate. An
adhesive may be adhesively interposed between the upper and/or lower
surfaces of each separate rib 96 and the interior surfaces of the lower
and/or upper plates, or additionally present within the tongue and groove
means.
In an embodiment of the heat exchange panel of the present invention, at
least some of the ribs are lower plate ribs. Each lower plate rib is
continuous with the lower plate, and extends upward from the interior
surface of the lower plate. In addition, each lower plate rib abuts the
interior surface of the upper plate.
With reference to Figures 12, 13 and 17(a), lower plate 11 includes a
plurality of lower plate ribs 105, that together form a plurality of paired
adjacent lower plate ribs (or equivalently, rib pairs) 108. Each lower plate
rib 105 is continuous with lower plate 11, and extends upward from interior
surface 17 of lower plate 11. An upper (or terminal) surface 111 of each
lower plate rib 105 abuts a portion of interior surface 26 of upper plate 14.
As used herein and in the claims, abutment of each lower plate rib with a
portion of interior surface 26 of upper plate 14 is alternatively inclusive
of:
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an interposed adhesive (not shown) between upper surface 111 and
interior surface 26; tongue and groove means (not shown), with a tongue
extending from upper surface 111 into an aligned, dimensioned and
longitudinal groove in interior surface 26, and/or a tongue extending from
interior surface 26 into an aligned, dimensioned and longitudinal groove in
upper surface 111; or combinations thereof.
Two adjacent lower plate ribs 105 form a pair of adjacent lower plate ribs
108 that together define a single channel 51 there-between. As with the
separate ribs 96 (of Figure 17(e)), each lower plate rib 105 has a sidewall
102 that is in facing spaced opposition relative to the other lower plate rib
105 of the pair of lower plate ribs 108. The facing and opposed sidewalls
102 of each adjacent pair of lower plate ribs 108 along with a portion of
interior surface 17 of lower plate 11 and a portion of interior surface 26 of
upper plate 14, together define a single channel 51 there-between.
In yet a further embodiment, at least some of the ribs of the heat exchange
panel are upper plate ribs. Each upper plate rib is continuous with the
upper plate, extends downward from the interior surface of the upper plate,
and abuts the interior surface of the lower plate.
With reference to Figure 17(b), upper plate 14 includes a plurality of upper
plate ribs 114, that together form a plurality of paired adjacent upper plate
ribs (or equivalently, upper plate rib pairs) 117. Each upper plate rib 114 is
continuous with upper plate 14, and extends downward from interior
surface 26 of upper plate 14. A terminal (or lower) surface 120 of each
upper plate rib 114 abuts a portion of interior surface 17 of lower plate 11.
As used herein and in the claims, abutment of each upper plate rib with a
portion of interior surface 17 of lower plate 11 is alternatively inclusive
of:
an interposed adhesive (not shown) between terminal surface 120 and
interior surface 17; tongue and groove means (not shown), with a tongue
extending from terminal surface 120 into an aligned, dimensioned and
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longitudinal groove in interior surface 17, and/or a tongue extending from
interior surface 17 into an aligned, dimensioned and longitudinal groove in
terminal surface 120; or combinations thereof.
Two neighboring or adjacent upper plate ribs 114 form a pair of adjacent
upper plate ribs 117 that together define a single channel 51 there-
between. As with the separate ribs 96 (e.g., of Figure 17(e)) and lower
plate ribs 105 (e.g., of Figure 17(a)), each upper plate rib 114 has a
sidewall 102 that is in facing spaced opposition relative to the other upper
plate rib 114 of the pair of upper plate ribs 117. The facing and opposed
sidewall 102 of each upper plate rib 114 along with a portion of interior
surface 17 of lower plate 11 and a portion of interior surface 26 of upper
plate 14, together define a single channel 51 there-between.
In an embodiment, at least one pair of neighboring or adjacent ribs
comprises a lower plate rib and an upper plate rib, in which each rib is as
described previously herein (e.g., with regard to abutment thereof with the
interior surface of the lower plate or upper plate, as the case may be).
More particularly, and with reference to Figure 17(d), lower plate 11 has a
lower plate rib 105 that is neighbor/adjacent to an upper plate rib 114 of
upper plate 14 (which correspondingly is neighbor/adjacent to lower plate
rib 105). Lower plate rib 105 and upper plate rib 114 together form a pair
of neighboring/-adjacent ribs (e.g., a lower plate / upper plate rib pair)
123,
that together define a single channel 51 there-between. In particular with
lower plate / upper plate rib pair 123, sidewall 102 of lower plate rib 105 is
in facing spaced opposition relative to sidewall 102 of the adjacent upper
plate rib 114. The opposed and facing sidewalls 102 of rib pair 123 along
with a portion of interior surface 17 of lower plate 11 and a portion of
interior surface 26 of upper plate 14, together define a single channel 51
there-between.
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At least some of the ribs of the heat exchange panel of the present
invention may be formed, in each case, by abutment between a lower
plate rib and an upper plate rib (forming an abutting lower-upper plate rib),
in which the lower plate rib and the upper plate rib are each as described
previously herein. More particularly, the lower plate includes a plurality of
lower plate ribs, each of which is continuous with the lower plate, and
extends upward from the interior surface of the lower plate. The upper
plate includes a plurality of upper plate ribs, each of which is continuous
with the upper plate, and extends downward from the interior surface of
the upper plate. At least one lower plate rib is aligned with and abuts an
aligned upper plate rib, thereby forming at least one rib. In a particular
embodiment, each lower plate rib abuts one upper plate rib, and thereby
forms the plurality of ribs of the heat exchange panel.
With reference to Figure 17(c), lower plate 11 includes two adjacent lower
plate ribs 105 that together form a pair of adjacent lower plate ribs 108;
and upper plate 14 includes two adjacent upper plate ribs 114 that
together form a pair of adjacent upper plate ribs 117. Each lower plate rib
105 is aligned with and is in abutting relationship with an aligned upper
plate rib 114, and together form an abutting lower-upper plate rib 126. In
particular, for each abutting lower-upper plate rib 126, at least a portion of
the upper surface 111 of a lower plate rib abuts at least a portion of the
lower/terminal surface 120 of an aligned upper plate rib 114. The abutting
lower-upper plate ribs 126 may in each case be independently held in
abutting relationship by: friction; fasteners (e.g., extending through the
upper and/or lower plates and at least a portion of the abutting lower-upper
plate ribs); an adhesive interposed there-between (e.g., between surfaces
111 and 120); and/or tongue and groove means (e.g., interconnecting
tongues and grooves between surface-3 111 and '1210),
Two adjacent abutting lower-upper plate ribs 126 form a pair of adjacent
abutting lower-upper plate ribs 129 that together define a single channel
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51 there-between. Each abutting lower-upper plate rib has a sidewall 102
that is in facing spaced opposition relative to the sidewall 102 of the other
abutting lower-upper plate rib 126 of the pair of adjacent abutting lower-
upper plate ribs 129. The facing and opposed sidewalls 102 of the pair of
abutting lower-upper plate ribs 129 along with a portion of interior surface
17 of lower plate 11 and a portion of interior surface 26 of upper plate 14,
together define a single channel 51 there-between.
In a particular embodiment, and as depicted in the drawings, each channel
of the heat exchange panel is a longitudinal channel, each rib is a
longitudinal rib, and accordingly the plurality of paired
(adjacent/neighboring) ribs are a plurality of paired longitudinal ribs.
Correspondingly, each pair of adjacent longitudinal ribs together define
one longitudinal channel there-between. With reference Figures 12 and
13, longitudinal lower plate ribs 105 form pairs of adjacent longitudinal
lower plate ribs 108. Each pair of adjacent longitudinal ribs 108 together
define a longitudinal channel 51 there-between.
So as to provide fluid communication between at least one pair of adjacent
(or neighboring) channels, at least one rib residing interposedly between
the upper and lower plates of the heat exchange panel may include at
least one lateral passage therein. Each lateral passage provides fluid
communication between the pair of neighboring channels that are so
separated by the rib having one or more lateral passages therein. Fluid
communication between at least one pair of neighboring pair of channels
provides benefits including, for example, improved heat exchange
efficiencies of the heat exchange panel. In addition, such lateral fluid
communication between neighboring channels provides alternate
pathways for the flow of heat exchange fluid in the event that one of the
neighboring channels, or an upper plate extension passage in fluid
communication with that channel, becomes blocked or obstructed to the
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flow of heat exchange fluid there-through (e.g., due to scale build-up
and/or a foreign object lodged therein).
With reference to Figures 12 and 18, two channels 51(d) and 51(e) are
separated by a lower plate rib 105(L) and together form a pair of
neighboring channels 132. Lower plate rib 105(L) includes a first lateral
passage 135 and a second lateral passage 138, that each provide fluid
communication between channels 51(d) and 51(e) of pair of neighboring
channels 132. Only second lateral passage 138 is shown in Figure 12.
Each lateral passage through a rib may independently have any suitable
shape, orientation and position. For example, each lateral passage may
independently have a cross sectional shape selected from circular shapes,
oval shapes, polygonal shapes (e.g., triangles, rectangles, squares,
pentagons, hexagons, heptagons, octagons, etc., and combinations
thereof), irregular shapes, and any combination thereof.
The lateral passages may each independently form non-straight or indirect
paths (e.g., serpentine paths) through a particular rib. Typically, each
lateral passage forms a substantially straight (or direct) path through a
particular rib. The lateral passages may have any suitable size, in
particular with regard to width or diameter. While each lateral passage
may have a width that is equal to or greater than that of either of the pair
of
neighboring channels that it runs between, typically, each lateral passage
has a width that is less than that of each of the neighboring channels.
The lateral passages may have any suitable position along the length of a
particular rib, and in particular in relation to the upper plate extension
passages that are in fluid communication with each channel of the pair of
neighboring channels. For example, a lateral passage may be positioned
so as to be remote from any upper plate extension passage. Alternatively,
and as depicted in the drawing figures, a lateral passage may be
positioned proximate to and additionally so as to: be in partial fluid
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communication with an upper plate extension passage; and further
optionally provide partial fluid communication between separate upper
plate extension passages in each of the neighboring channels. Since
Figures 12 and 18 show top plan views of lower plate 11, the upper plate
extension passages 72 are not shown, but their positions can be
determined relative to each lower plate extension 20 (that defines them in
conjunction with the interior surfaces 45 of an associated upper plate
extension 32). With further reference to Figure 12, lateral passage 138 is
proximate to lower plate extension 20(l) of first channel 51(d) and lower
plate extension 20(J) of second channel 51(e). A portion of the exterior
surfaces of lower plate extensions 20(l) and 20(J) each define a separate
upper plate extension passage 72 with a portion of the interior surfaces 45
that define the interior space 48 of the upper plate extension 32 (not
shown in Figure 12) into which they are each received. As such, in
addition to providing fluid communication between first channel 51(d) and
second channel 51(e) of neighboring channels 132, lateral passage 138,
due to its position, also provides partial fluid communication between the
upper plate extension passage 72 defined in part by lower plate extension
20(l) and the upper plate extension passage 72 defined in part by lower
plate extension 20(J).
Each lateral passage may have any suitable orientation relative to the rib it
passes through and the neighboring channels it provides fluid
communication between. In an embodiment of the present invention, the
channels are substantially longitudinal channels and correspondingly the
ribs are substantially longitudinal ribs. Each lateral passage is a
substantially straight lateral passage having an elongated axis. The
elongated axis of each lateral passage typically forms an angle of less
than 180 and greater than 0 relative to the longitudinal axis of the
longitudinal rib through which it passes.
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As discussed previously herein, each lower plate extension 20 has a lower
portion 66 that resides within the channel 51, and an upper portion 69 that
extends upwardly from and above the channel 51 (e.g., see Figures 4 and
13). In a particular embodiment, the width of the lower portion of each
lower plate extension is substantially equivalent to the width of the channel
in which it resides, and correspondingly the channel is substantially
blocked by the lower portion of the lower plate extension residing therein.
With the channels so blocked by the lower portions of the lower plate
extensions residing therein, each channel comprises a plurality of channel
segments (e.g., 2 or more channel segments). For a given channel, each
channel segment thereof is separated from a neighboring/adjacent
channel segment (e.g., a preceding channel segment or a subsequent
channel segment) by one (i.e., a single) lower plate extension. In addition,
each channel segment is in fluid communication with at least one upper
plate extension passage. Typically, each channel segment is in fluid
communication with one or two (but not more than two) upper plate
extension passages.
With reference to Figures 12 and 13, lower portion 66 of lower plate
extension 20 has a width 141 that is substantially equivalent to width 144
of channel 51. While each lower plate extension and channel may have
different dimensions, in an embodiment, and as depicted in the drawings,
all of the lower plate extensions have substantially equivalent dimensions,
and all of the channels have substantially equivalent dimensions. As such,
each channel 51 is substantially blocked by the lower portion 66 of each
lower plate extension 20 residing therein.
As can be seen with reference to Figures 4, 5, 12 and 13, each channel 51
includes a plurality of channel segments that are separated from each
other by one lower plate extension 20. For purposes of further illustration,
the sectional view of the channel 51 shown in Figure 5 includes four (4)
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sequential channel segments 51(S-1), 51(S-2), 51(S-3) and 51(S-4), from
right to left.
Channel segment 51(S-3) is separated from neighboring channel segment
51(S-2) by one (i.e., a single) lower plate extension 20(K) that is
interposed between channel segment 51 (S-3) and channel segment 51 (S-
2). Relative to channel segment 51(S-3), neighboring channel segment
51(S-2) may also be referred to as a preceding neighboring channel
segment 51(S-2). In addition, channel segment 51(S-3) is separated from
neighboring channel segment 51(S-4) by lower plate extension 20(L) that
is interposed between channel segment 51(S-3) and channel segment
51(S-4). Relative to channel segment 51(S-3), neighboring channel
segment 51(S-4) may also be referred to as a subsequent neighboring
channel segment 51(S-4).
The designations of preceding and subsequent with regard to the channel
segments is typically established with regard to the flow of heat exchange
fluid through a particular channel. For example, in Figure 5, heat
exchange fluid (not shown) flows through channel 51 from right to left.
Accordingly, heat-exchange fluid (e.g., a slug thereof) would flow in
sequence through channel segments 51(S-1), 51(S-2), 51(S-3) and 51(S-
4). As such, relative to channel segment 51(S-3), channel segment 51(S-
2) is a preceding neighboring channel segment, and channel segment
51(S-4) is a subsequent neighboring channel segment.
Each channel segment is in fluid communication with at least one upper
plate extension passage. With further reference to Figure 5, channel
segment 51(S-3) is in fluid communication with the upper plate extension
passage 72 that is defined in part by lower plate extension 20(K), which
resides up-stream relative to channel segment 51(S-3). Channel segment
51(S-3) is also in fluid communication with the upper plate extension
passage 72 that is defined in part by lower plate extension 20(L), which
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resides down-stream relative to channel segment 51(S-3). Channel
segment 51 (S-3) may further be described as being in fluid communication
with both an up-stream upper plate extension passage 72, and a down-
stream upper plate extension passage 72.
Most channel segments of the heat exchange panel are in fluid
communication with two upper plate extension passages. When a channel
segment is a terminal channel segment (i.e., a channel segment that is
located at and in fluid communication with inlet end 60 or outlet end 63 of
the heat exchange panel), it is typically in fluid communication with a
single upper plate extension passage.
As described previously herein, the upper plate extension passages are in
each case defined by a portion of the interior surfaces of an upper plate
extension being in facing opposition with a portion of the exterior surfaces
of the upper portion of the lower plate extension received within the interior
space of the upper plate extension. Accordingly, for an associated lower
plate - upper plate extension pair, a further portion of the interior surfaces
of the upper plate extension, and a further portion of the exterior surfaces
of the upper portion of the lower plate extension do not define the upper
plate extension passage. In a particular embodiment, for an associated
lower plate - upper plate extension pair, a further portion of the interior
surfaces of the upper plate extension, and a further portion of the exterior
surfaces of the upper portion of the lower plate extension are in abutting
relationship, and substantially prevent the passage of fluid (e.g., heat
exchange fluid) there-between. Additionally, with the lower portion of the
lower plate extension substantially blocking the channel, heat exchange
fluid passing through a channel segment is forced up into the upper plate
extension passage that is in fluid communication there-with.
More particularly in regard to the further portion of the exterior surfaces of
the lower plate extensions, the exterior surfaces of the upper portion of
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each lower plate extension include at least one inlet face on an inlet side
of the lower plate extension, at least one outlet face on an outlet side of
the lower plate extension, at least one first side face on a first side of the
lower plate extension, and at least one second side face on a second side
of the lower plate extension. The inlet side and the outlet side of the lower
plate extension are on substantially opposite sides of the lower plate
extension. The inlet side of a lower plate extension is that side of the
lower plate extension that is closer or more proximate to the inlet side
(e.g., 60) of the heat exchange panel, relative to the outlet side thereof.
Correspondingly, the outlet side of a lower plate extension is that side of
the lower plate extension that is closer or more proximate to the outlet side
(e.g., 63) of the heat exchange panel, relative to the inlet side thereof. The
first side and the second side of the lower plate extension are on
substantially opposite sides of the lower plate extension.
The upper portion of the lower plate extension has a shape that is defined
by the exterior surfaces of the upper portion of the lower plate extension.
In an embodiment, the interior space of the upper plate extension has a
shape that substantially matches the shape of the upper portion of the
lower plate extension that is received within the interior space.
Regarding the further portions of the interior surfaces of the hollow upper
plate extensions, the interior surfaces defining the interior space thereof
include at least one inlet surface on an inlet side of the interior space, at
least one outlet surface on an outlet side of the interior space, at least one
first side surface on a first side of the interior space, and at least one
second side surface on a second side of the interior space. The inlet side
of the interior space of each upper plate extension is closer or more
proximate to the inlet side (e.g., 60) of the heat exchange panel, relative to
the outlet side thereof. Accordingly, the outlet side of the interior space of
each upper plate extension is closer or more proximate to the outlet side
(e.g., 63) of the heat exchange panel, relative to the inlet side thereof. The
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inlet side and the outlet side of the interior space are on substantially
opposite sides of the interior space, and the first side and the second side
of the interior space are on substantially opposite sides of the interior
space.
For each associated lower plate - upper plate extension pair, the inlet face
of the upper portion of the lower plate extension and the inlet surface of
the interior space together define an ascending inlet passage portion of
the upper plate extension passage. In addition, the outlet face of the
upper portion of the lower plate extension and the outlet surface of the
interior space together define a descending outlet passage portion of the
upper plate extension passage. The ascending inlet passage portion and
the descending outlet passage portion of the upper plate extension
passage are in fluid communication with each other.
Regarding the first and second side faces and the first and second side
surfaces, for each associated lower plate - upper plate extension pair, at
least one first side face of the upper portion of the lower plate extension
and at least one first side surface of the interior space are in abutting
relationship with each other. And on the other side, at least one second
side face of the upper portion of the lower plate extension and at least one
second side surface of the interior space are in abutting relationship with
each other. With the first and second side faces and the first and second
side surfaces, of each associated lower plate - upper plate extension pair
in the described abutting relationship, substantially no heat exchange fluid
passes there-through and/or there-between. Resultantly, heat exchange
fluid is directed and passes instead through the ascending inlet and
descending outlet passage portions of the upper plate extension passage.
For purposes of further illustrating the ascending inlet and descending
outlet passage portions of the upper plate extension passage, attention is
directed to Figures 4, 5, 7, 8, 12 and 13 of the drawings. With particular
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reference to Figure 12, each lower plate 20 extension has an inlet side
147, an outlet side 150, a first side 153 and a second side 156. Inlet side
147 and outlet side 150 are on opposite sides of lower plate extension 20,
relative to each other. First side 153 and second side 156 are on opposite
sides of lower plate extension 20, relative to each other. With particular
reference to Figures 4, 7 and 8, the interior space 48 of each upper plate
extension 32 has an inlet side 159, an outlet side 162, a first side 165 and
a second side 168. Inlet side 159 and outlet side 162 are on opposite
sides of interior space 48 relative to each other; and first side 165 and
second side 168 are on opposite sides of interior space 48, relative to
each other, of upper plate extension 32.
Inlet face 81 is on inlet side 147, and outlet face 84 is on outlet side 150
of
lower plate extension 20. A first side face 171 is on first side 153, and a
second side face 174 is on second side 156 of lower plate extension 20.
Inlet surface 75 is on inlet side 159, and outlet surface 78 is on outlet side
162 of interior space 48 of upper plate extension 32. A first side surface
177 is on first side 165, and a second side surface 180 is on second side
168 of interior space 48 of upper plate extension 32.
Inlet face 81 of upper portion 69 of lower plate extension 20, and inlet
surface 75 of interior space 48 of upper plate extension 32, are separated
and in facing opposition relative to each other, and together define an
ascending inlet passage portion 183 of upper plate extension passage 72.
Outlet face 84 of upper portion 69 of lower plate extension 20, and outlet
surface 78 of interior space 48 of upper plate extension 32, are separated
and in facing opposition relative to each other, and together define a
descending inlet passage portion 186 of upper plate extension passage
72. Ascending inlet passage portion 183 and descending outlet passage
portion 186 are in fluid communication with each other. See, for example,
Figures 4 and 5.
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In operation of the heat exchange panel of the present invention, a heat
exchange fluid introduced into a channel 51, and passes sequentially:
through a preceding channel segment (e.g., 51(S-P)); up through
ascending inlet passage portion 183; down through descending outlet
passage portion 186; and then into a subsequent channel segment (e.g.,
51(S-S)). See, for example, Figure 4.
Regarding the abutting faces and surfaces of each associated lower plate
- upper plate extension pair, reference is made in particular to Figures 7
and 8. First side face 171 of upper portion 69 of lower plate extension 20,
and first side surface 177 of interior space 48 of upper plate extension 32
abut each other. Second side face 174 of upper portion 69 of lower plate
extension 20, and second side surface 180 of interior space 48 of upper
plate extension 32 abut each other. Abutment between first side face 171
and first side surface 177, and between second side face 174 and second
side surface 180 is such that substantially no heat exchange fluid passes
through or between these abutting faces and surfaces during operation of
the heat exchange panel of the present invention.
Fluid communication between the ascending inlet passage portion 183
and the descending outlet passage portion 186 of the upper plate
extension passage 72 may be achieved by means of one or more
passages, bores or tunnels (not shown) that pass from inlet face 81 to
outlet face 84 through upper portion 69 of lower plate extension 20.
Alternatively or in addition thereto, fluid communication between the
ascending and descending passage portions may be provided by a
transverse passage portion that is defined by a portion of the exterior
surfaces of the lower plate extension and a portion of the interior surfaces
that define the interior space of the upper plate extension.
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In an embodiment of the present invention, the exterior surfaces of the
upper portion of the lower plate extension further includes an upper
transverse face. The interior surfaces that define the interior space of the
upper plate extension further include an upper transverse surface. The
upper transverse face of the lower plate extension and the upper
transverse surface of the interior space of the upper plate extension are in
spaced facing opposition relative to each other and together define a
transverse passage portion of the upper plate extension passage. The
transverse passage portion of the upper plate extension passage is in fluid
communication with each of the ascending inlet passage portion and the
descending outlet passage portion of the upper plate extension passage.
Accordingly, the transverse passage portion provides fluid communication
between the ascending inlet passage portion and the descending outlet
passage portion of the upper plate extension passage.
With reference to Figures 4 and 5, exterior surfaces 23 of upper portion 69
of lower plate extension 20 includes, at the top thereof, an upper
transverse face 189. The interior surfaces 45 that define interior space 48
of upper plate extension 32 further include, at the top thereof, an upper
transverse surface 192. Upper transverse face 189 and upper transverse
surface 192 are in spaced facing opposition relative to each other and
together define there-between a transverse passage portion 195 of the
upper plate extension passage 72. Transverse passage portion 195
provides fluid communication between ascending inlet passage portion
183 and descending outlet passage portion 186 of upper plate extension
passage 72.
In operation of the heat exchange panel of the present invention, a heat
exchange fluid introduced into a channel 51, passes sequentially: through
a preceding channel segment (e.g., 51(S-P)); up through ascending inlet
passage portion 183; across and through transverse passage portion 195;
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down through descending outlet passage portion 186; and then into a
subsequent channel segment (e.g., 51(S-S)). See, for example, Figure 4.
The upper portion of the lower plate extension has a shape that is defined
by the exterior surfaces of the upper portion of the lower plate extension.
In an embodiment, the shape of the upper portion of the lower plate
extension is selected from pyramidal shapes. As used herein and in the
claims with regard to the shape of the upper portion of the lower plate
extension, the term pyramidal shape, and similar terms means more
particularly a polyhedron having a polygonal base and triangles for sides
(or faces). The number of triangular sides being equal to the number of
sides of the polygonal base. The pyramidal shapes may be symmetrical
or non-symmetrical. Typically, the pyramidal shapes are substantially
symmetrical, and correspondingly: the sides of the polygonal base have
equivalent lengths; and the internal angles that each side of the pyramidal
shape form relative to horizontal are substantially equal (greater than 0
and less than 90 ).
The lower portion (e.g., 66) of the lower plate extension may have a shape
the is the same as or different than that of the upper portion (e.g., 69) of
the lower plate extension. In an embodiment, the lower portion (e.g., 66)
of the lower plate extension has a pyramidal shape that is substantially the
same as and is an extension of the pyramidal shape of the upper portion
(e.g., 69) of the lower plate extension.
The pyramidal shape of the upper portion of the lower plate extension may
be selected from rectangular pyramids, pentagonal pyramids, hexagonal
pyramids, heptagonal pyramids, octagonal pyramids, nonagonal pyramids,
decagonal pyramids, undecagonal pyramids, dodecagonal pyramids, etc.
In a particular embodiment, the shape of the upper portion of the lower
plate extension is selected from rectangular pyramids.
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The interior space 48 defined by the interior surface 45 of the upper plate
extension 32 may have a shape that substantially matches or is similar to
that of the shape defined by the exterior surfaces 23 of the upper portion
69 of the lower plate extension. In an embodiment, the shape of the upper
portion of the lower plate extension is selected from pyramidal shapes,
and the shape of the interior space 48 defined by the interior surfaces 45
of upper plate extension 32 are accordingly selected from a substantially
matching pyramidal shape, such as rectangular pyramids, pentagonal
pyramids, hexagonal pyramids, heptagonal pyramids, octagonal pyramids,
nonagonal pyramids, decagonal pyramids, undecagonal pyramids,
dodecagonal pyramids, etc. In a particular embodiment, the shape of the
upper portion of the lower plate extension is selected from rectangular
pyramidal shapes, and the shape of interior space 48 defined by the
interior surfaces 45 of upper plate extension 32 is selected from a
substantially matching rectangular pyramidal shape. The shape of the
interior space of the upper plate extension substantially matches the
shape of the lower plate extension, to an extent and provided that: the
ascending inlet passage portion, descending outlet passage portion and
optional transverse passage portion of the upper plate extension passage
are defined; and the faces and surfaces of the first and second sides
there-between are in abutting relationship, as described previously herein.
The separation between the exterior surfaces of the upper portion of the
lower plate extension and the interior surfaces of the upper plate extension
that allows for the upper plate extension passage and its optional portions
(e.g., ascending, transverse and descending portions) to be defined there-
between, may be established and maintained by spacers (not shown)
positioned abuttingly between the interior surfaces of the lower plate and
the upper plate. In an embodiment, the separation that allows for
definition of the upper plate extension passage and its optional portions is
established and maintained by abutment between the faces and surfaces
of the first and second sides of the lower plate extension and the surfaces
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that define the interior space of the upper plate extension. For example,
abutment between first side face 171 of upper portion 69 of lower plate
extension 20 and first side surface 177 of interior space 48 of upper plate
extension 32; and abutment between second side face 174 of upper
portion 69 of lower plate extension 20, and second side surface 180 of
interior space 48 of upper plate extension 32, keeps the upper plate
extension from sliding too far down over the upper portion of the lower
plate extension that is received within the interior space thereof, and thus
further serves to maintain the separation that allows for definition of the
upper plate extension passage and its optional portions
In an embodiment of the present invention, the shape of the upper portion
of the lower plate extension is selected from truncated pyramidal shapes
having an upper truncated face. The upper truncated face is and defines
the upper transverse face of the upper portion of the lower plate extension.
As used herein and in the claims, the term "truncated pyramidal shape"
and similar terms, such as truncated pyramid, means a pyramidal shape or
pyramid in which the upper terminus thereof is defined by an upper
truncated face, rather than a point. Relative to horizontal, the upper
truncated face may be substantially flat, or may be slanted (e.g., slanted
towards one of the inlet side, outlet side, first side or second side of the
lower plate extension).
The shape of the upper portion of the lower plate extension, in an
embodiment, is selected from truncated rectangular pyramidal shapes. In
a particular embodiment, the shape of the upper portion of the lower plate
extension is selected from substantially symmetrical truncated rectangular
pyramidal shapes, in which the sides of the rectangular base thereof have
substantially equivalent lengths.
With reference to Figures 4, 5 and 13, for each lower plate extension 20,
the exterior surfaces 23 of the upper portion thereof define a truncated
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pyramidal shape, which is more particularly a truncated rectangular
pyramidal shape. The truncated rectangular pyramidal lower plate
extensions 20 each have an upper truncated face that is defined by the
upper transverse face 189 of the lower plate extension. Upper truncated
face 189 is a substantially flat upper truncated face. Upper truncated face
189 and upper transverse surface 192 are in spaced facing opposition
relative to each other and together define there-between transverse
passage portion 195 of upper plate extension passage 72.
As can be seen in some of the sectional views of the drawings, such as
Figures 4, 5, 7 and 8, the interior space 48 of each upper plate extension
32 has a pyramidal shape, and in particular a truncated pyramidal shape
that substantially matches the truncated pyramidal shape of the upper
portion 69 of the lower plate extension 20 received therein. The truncated
pyramidal shape of the interior space of the upper plate extensions may be
further described as including an upper truncated surface that is defined
by the upper transverse surface of the interior space (e.g., upper
transverse surface 192).
At least some of the lower plate extensions may have interior surfaces that
define an interior space of the lower plate extension that is in fluid
communication with an aperture on the exterior or lower surface (e.g., 35)
thereof, in which case such lower plate extensions are hollow lower plate
extensions. In an embodiment, each lower plate extension is substantially
solid, and is substantially free of an interior hollow space.
The exterior surfaces of the upper plate extensions may define any
suitable exterior shape of the upper plate extensions. In particular,
exterior surfaces 38 of upper plate extension 32 define an exterior shape
(e.g., a pyramidal shape) that may be the same or different than the shape
of the interior space 48 of the upper plate extension. In an embodiment,
exterior surfaces 38 of upper plate extension 32 define an exterior shape
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that is substantially the same as the shape of the interior space 48 that is
defined by the interior surfaces 45 of the upper plate extension. In a
particular embodiment, exterior surfaces 38 of upper plate extension 32
define an exterior shape that is selected from a truncated pyramidal shape
that is substantially the same as the truncated pyramidal shape of the
interior space 48 thereof, and as depicted in the drawings more particularly
with regard to a truncated rectangular pyramidal shape in both cases.
The upper plate extension passages (e.g., 72) each have an upper plate
extension passage volume. Each upper plate extension passage volume
may, for example, be equal to the sum of the volumes of the ascending
inlet passage portion 183, transverse passage portion 195 and descending
outlet passage portion 186 thereof. The heat exchange panel may be
described as having a total upper plate extension passage volume, which
is equal to the sum of all the upper plate extension passage volumes.
Each channel (e.g., 51) of the heat exchange panel has a channel volume,
which is more particularly equal to the sum of the channel segment
volumes associated therewith. The heat exchange panel may be further
described as having a total channel volume, which is the sum of all the
channel volumes. Accordingly, the heat exchange panel has a total
internal volume, which is equal to the sum of the total upper plate
extension passage volume and the total channel volume of the panel.
The heat exchange panel has a percent total upper plate extension
passage volume, which is calculated according the following equation:
100 x {total upper plate extension passage volume / total internal volume}
The heat exchange panel has a percent total channel volume, which is
calculated according the following equation:
100 x {total channel volume / total internal volume}
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The heat exchange panel may have a percent total upper plate extension
passage volume of from, for example, 70 percent to 95 percent by volume,
typically from 75 percent to 90 percent by volume, and more typically from
80 percent to 90 percent by volume, based on the total internal volume of
the heat exchange panel. The heat exchange panel may have a percent
total channel volume of from 5 percent to 30 percent by volume, typically
from 10 percent to 25 percent by volume, and more typically from 10
percent to 20 percent by volume, based on the total internal volume of the
heat exchange panel. In an embodiment, the heat exchange panel has a
percent total upper plate extension passage volume of 85 percent by
volume, and a percent total channel volume of 15 percent by volume, in
each case, based on the total internal volume of the heat exchange panel.
Heat exchange fluid when passing through an upper plate extension
passage is exposed to more thermal energy (e.g., from an incident radiant
infrared energy source, such as the sun), than when passing through an
underlying channel, or more particularly an underlying channel segment.
As such, and for purposes of optimizing heat exchange properties and
efficiencies, it is desirable that the heat exchange panel of the present
invention have a percent total upper plate extension passage volume of at
least 50 percent by volume, based on total internal volume.
The heat exchange panel of the present invention may further include a
sidewall structure that surrounds the plurality of upper plate extensions.
The sidewall structure has interior surfaces, an upper terminus and a
height. The upper terminus of the sidewall structure resides above the
exterior (or upper) surface of the upper plate and defines an open top of
the sidewall structure. The sidewall structure extends substantially around
and encompasses the plurality of upper plate extensions. The interior
surfaces of the sidewall structure define an interior sidewall structure
space in which the plurality of upper plate extensions reside. The height of
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the sidewall structure is at least equivalent to (and accordingly is no lower
than) a maximum height of the plurality of upper plate extensions.
With reference to the drawings, heat exchange panel 1 includes a sidewall
structure 198 that has interior surfaces 201, exterior surfaces 226, an
upper terminus 204 and a height 207. The height 207 of sidewall structure
198 is the distance that the upper terminus 204 thereof resides above
exterior surface 29 of upper plate 14. See, for example, Figure 19. The
sidewall structure may be composed of a plurality of sidewall components
(or sidewalls), e.g., in the case of a polygonal sidewall structure, or a
single sidewall component (or sidewall), e.g., in the case of a circular or
oval sidewall structure. As depicted in the drawings, sidewall structure
198 is a polygonal sidewall structure, and more particularly a rectangular
sidewall structure having four sidewalls, 210, 213, 217 and 220, that are
substantially continuous with each other. See, for example, Figure 1.
The sidewall structure may be separate from and attached to the upper
plate of the heat exchange panel. In an embodiment, and as depicted in
the drawings, the sidewall structure 198 is continuous with the upper plate
14, and extends upwardly from the exterior surface 29 of upper plate 14.
See, for example, Figures 9, 15, 16 and 19.
Upper terminus 204 of sidewall structure 198 resides above exterior
surface 29 of upper plate 14 and defines an open top 223 of the sidewall
structure. The interior surfaces 201 of sidewall structure 198 define an
interior sidewall structure space 229. The plurality of upper plate
extensions 32 reside within interior sidewall structure space 229, as
sidewall structure 198 extends there-around. See, for example, Figure 9.
Sidewall structure 198 may have a height 207 of from 25 mm to 250 mm,
typically from 50 mm to 225 mm, and more typically from 75 mm to 200
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mm. In an embodiment, sidewall structure 198 has a height 207 of 125
mm.
Each upper plate extension 32 has an upper terminal exterior point or
surface 232 that is located above exterior surface 29 of upper plate 14.
The distance that upper terminal exterior surface 232 resides above
exterior surface 29 of upper plate 14 is the height of that particular upper
plate extension (Figures 9 and 19). The upper plate extensions may have
different heights, or in each case substantially the same height, relative to
exterior surface 29 of upper plate 14. One or more upper plate extensions
have, or in effect define, a maximum height 235 of the plurality of upper
plate extensions, relative to exterior surface 29 of upper plate 14. The
height 207 of sidewall structure 198 is at least equivalent to the maximum
height 235 of the plurality of upper plate extensions. See, for example,
Figure 19. The heat exchange panel is free of any upper plate extensions
having an upper terminal exterior surface 232 that extends above upper
terminus 204 of sidewall structure 198. As depicted in the drawings,
maximum height 235 of the plurality of upper plate extensions 32 is less
than height 207 of sidewall structure 198.
The maximum height 235 of the plurality of upper plate extensions 32 may
be from 20 mm to 230 mm, typically from 45 mm to 215 mm, and more
typically from 70 mm to 190 mm. In an embodiment, maximum height 235
of the plurality of upper plate extensions 32 is 120 mm.
The heat exchange panel may optionally further include a plate that covers
the open top defined by the sidewall structure. The plate is typically
substantially transparent to infrared radiation, and may rest on and
optionally be fixedly attached to the upper terminus of the sidewall
structure. As used herein and in the claims with regard to the covering
plate, the term "substantially infrared transparent" and similar terms means
the plate allows a major amount (e.g., at least 50 percent) of the incident
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infrared radiation to pass there-through and into the interior sidewall
structure space.
With reference to Figure 20, heat exchange panel 1 further includes a
plate 238 covering open top 223 of sidewall structure 198. Plate 238 rests
on or over upper terminus 204 of sidewall structure 198. Plate 238 may
optionally be fixedly attached to upper terminus 204 by art-recognized
means including, for example: adhesives (not shown) interposed there-
between; fasteners (not shown) extending through plate 238 and into
sidewall structure 198; and/or snap fittings (not shown). Plate 238 is
substantially transparent to infrared radiation, and substantially encloses
interior sidewall structure space 229.
In a further embodiment of the present invention, the sidewall structure
includes a shelf upon which the infrared transparent plate is placed. In
particular, the sidewall structure further includes a shelf having an upper
surface having a height above the exterior surface of the upper plate. The
shelf is positioned and extends inward (relative to the interior surfaces of
the sidewall structure) towards the interior sidewall structure space. With
the shelf embodiment, the height of the sidewall structure is greater than
the maximum height of the plurality of upper plate extensions. In addition,
the height of the upper surface of the shelf is: (i) less than the height of
the
sidewall structure; and (ii) at least equivalent to the maximum height of the
plurality of upper plate extensions. The substantially infrared transparent
plate covers the open top of the sidewall structure, and is positioned on or
over the upper surface of said shelf.
With reference to, for example, Figures 5, 8, 9 and 19, heat exchange
panel 1 further includes a shelf 241 that has an upper surface 244. Upper
surface 244 of shelf 241 has a height 247 above exterior surface 29 of
upper plate 14 (Figure 19). Shelf 241 is positioned inward towards interior
sidewall structure space 229. The shelf may be a substantially continuous
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shelf (e.g., as depicted in the drawings with regard to shelf 241), or may be
composed of a plurality of separate shelf elements or components (not
shown) each having an upper surface that is aligned with (i.e., has the
same height as) the upper surface of each neighboring shelf element.
With the shelf embodiment, and with further reference to Figure 19, the
height 207 of sidewall structure 198 (i.e., the height of the upper terminus
204 of sidewall structure 198, as discussed previously) above exterior
surface 29 of upper plate 14 is greater than the maximum height 235 of
the plurality of upper plate extensions 32. The height 247 of upper surface
244 of shelf 241 is: (i) less than the height 207 of sidewall structure 198;
and at the same time (ii) at least equivalent to the maximum height 235 of
the plurality of upper plate extensions 32.
Additionally with the shelf embodiment, heat exchange panel 1 further
includes a plate 250 that is substantially transparent to infrared radiation
(i.e., a substantially infrared transparent plate). Infrared transparent plate
250 covers the open top 223 of sidewall structure 198, and is positioned
on or over upper surface 244 of shelf 241. As discussed previously with
regard to infrared transparent plate 238 and upper terminus 204 of
sidewall structure 198, infrared transparent plate 250 may optionally be
fixedly attached to upper surface 244 of shelf 241 by art-recognized
means including, for example: adhesives (not shown) interposed there-
between; fasteners (not shown) extending through plate 250 and into shelf
241; and/or snap fittings (not shown).
The height 247 of upper surface 244 of shelf 241 (above exterior surface
29 of upper plate 14) may be from 20 mm to 230 mm, typically from 45
mm to 215 mm, and more typically from 70 mm to 190 mm. In an
embodiment, the height 247 of upper surface 244 of shelf 241 is 120 mm.
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Alternatively or in addition to a shelf (e.g., shelf 241), an upper portion of
the interior surfaces 201 of sidewall structure 198 may include an
elongated slot (not shown) that is dimensioned to receive and support a
peripheral portion of the infrared transparent plate therein. The slot has a
height above the exterior surface 29 of the upper plate 14 that is: (i) less
than the height 207 of sidewall structure 198; and at the same time (ii) at
least equivalent to the maximum height 235 of the plurality of upper plate
extensions 32. Typically, the slot extends through to the exterior surface
(e.g., 226) of one sidewall or two opposing sidewalls of the sidewall
structure, thus allowing the infrared transparent plate to be inserted (e.g.,
slid) into the slot from outside of the sidewall structure.
The substantially infrared transparent plate (e.g., plate 238 and/or plate
250) of the heat exchange panel, allows infrared radiation to enter interior
sidewall structure space 229, and be absorbed at least in part by exterior
surfaces 38 of upper plate extensions 32 and exterior surfaces 29 of upper
plate 14, such that at least some of the heat energy thereof is transferred
to a heat exchange fluid flowing through the upper plate extension
passages 72 and channels 51 residing there-under. In addition, the
infrared transparent plate prevents foreign materials (e.g., precipitation,
leaves and bird droppings) from entering interior sidewall structure space
229 and fouling the exterior surfaces 38 of the upper plate extensions 32.
The infrared transparent plate also allows a gas, such as air, to be
retained within interior sidewall structure space 229 and heated by the
incident infrared radiation, thus resulting in convective transfer of heat
energy from the heated entrapped gas to/through the upper plate
extensions 32 and exterior surfaces 29 of upper plate 14, and into the heat
exchange fluid flowing through the upper plate extension passages 72 and
channels 51 residing there-under.
The infrared transparent plate (e.g., 238 and/or 250) covering the open top
and enclosing the interior sidewall structure space of the sidewall structure
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may be fabricated from any suitable infrared transparent material, such as
glass and/or plastics, such as thermoset plastic materials and/or
thermoplastic materials (e.g., thermoplastic polycarbonate). Typically, the
infrared transparent plate is rigid and substantially self-supporting.
Each channel (e.g., 51) of the heat exchange panel has a terminal inlet
(e.g., 54) and a terminal outlet (e.g., 57). Some of the terminal inlets and
some of the terminal outlets may be located at/on the same end of the
heat exchange panel, in which case a heat exchange fluid flows in
opposite directions through separate channels of the heat exchange
panel. Typically, all of the terminal inlets are located on the same end
(e.g., an inlet end 60) of the heat exchange panel, and all of the terminal
outlets are correspondingly located on the same (more particularly, the
other/opposite) end (e.g., an outlet end 63) of the heat exchange panel.
Whether all are located on the same end (unidirectional flow of heat
exchange fluid through the channels) or mixed between opposite ends of
the heat exchange panel (counter-flow of heat exchange fluid through at
least some of the channels), the terminal inlets may each be in fluid
communication with a common inlet header, and the terminal outlets may
each be in fluid communication with a common outlet header.
In an embodiment, the heat exchange panel further includes an inlet
header having an inlet header interior space, and an outlet header having
an outlet header interior space. The inlet header interior space of the inlet
header is in fluid communication with the terminal inlet of each channel.
The outlet header interior space of the outlet header is in fluid
communication with the terminal outlet of each channel. In a particular
embodiment, the terminal inlet of each channel is located on the inlet end
(e.g., inlet end 60), and the terminal outlet of each channel is located on
the outlet end (e.g., outlet end 63) of the heat exchange panel, and
correspondingly the inlet header is located on the inlet end and the outlet
header is located on the outlet end of the heat exchange panel.
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For purposes of further illustration and with reference to the drawings, heat
exchange panel 1 includes an inlet header 253 having an inlet header
interior space 256, and an outlet header 259 having an outlet header
interior space 262. Inlet header 253 is located on inlet end 60, and outlet
header 259 are located on outlet end 63 of heat exchange panel 1. Inlet
end 60 and outlet end 63 are located at substantially opposites ends of the
heat exchange panel. Accordingly, inlet header 253 and outlet header 259
are located at substantially opposite ends of the heat exchange panel.
Inlet header interior space 256 of inlet header 253 is in fluid
communication with the terminal inlet 54 of each channel 51. See, for
example, Figures 3, 10 and 11. Outlet header interior space 262 of outlet
header 259 is in fluid communication with the terminal outlet 57 of each
channel 51. See, for example, Figure 16. Fluid communication between
inlet header interior space 256 and the terminal inlet 54 of each channel
51, is substantially the same as more clearly depicted in Figure 16 with
regard to the fluid communication between outlet header interior space
262 and the terminal outlet 57 of each channel 51.
The inlet header and the outlet header may each independently have one
or more ports that are in fluid communication with the respective interior
space thereof, so as to allow for heat exchange fluid to be respectively
introduced therein or removed therefrom. In an embodiment the inlet
header and the outlet header each have a separate port that is in fluid
communication with the respective interior space thereof.
As depicted in the drawings, inlet header 253 has an inlet header port 265
that is in fluid communication with inlet header interior space 256 thereof.
Outlet header 259 has an outlet header port 268 that is in fluid
communication with outlet header interior space 262 thereof. Inlet header
port 265 may be in fluid communication with: an inlet conduit (not shown)
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that is in fluid communication with a heat exchange fluid reservoir (not
shown); or the outlet header port (e.g., 268) of another heat exchange
panel 1 (not shown), for in-series coupling; or a master inlet header (not
shown) that is in parallel fluid communication with each inlet header port of
a plurality of heat exchange panels (for parallel coupling). Outlet header
port 268 may be in fluid communication with: an output conduit (not
shown) that is in fluid communication with a heat exchange fluid reservoir
(not shown) or a point of direct use (e.g., a shower or swimming pool); or
the inlet header port (e.g., 265) of another heat exchange panel 1 (not
shown), for in-series coupling; or a master outlet header (not shown) that
is in parallel fluid communication with each outlet header port of a plurality
of heat exchange panels (for parallel coupling).
In the drawings, for purposes of clarity and illustration, the inlet (253) and
outlet (259) headers are depicted as being open at the end opposite of the
inlet/outlet header port in each case thereof (e.g., so as to depict the
header interior spaces thereof). See, for example, Figures 1 and 16.
These open ends are typically capped with a separate cap (e.g., a welded,
screwed or glued cap), or an integral cap (e.g., an integral cap plate) that
is substantially continuous with at least a portion of the respective header.
The header caps are not shown in the drawings.
The inlet header and the outlet header may each be independently
separate from or substantially integral or unitary with the heat exchange
panel. When separate from the heat exchange panel, the headers may
each independently be attached to the respective inlet or outlet end of the
heat exchange panel by art-recognized means (e.g., by adhesives, a
plurality of conduits and couplings, and/or fasteners, such as bolts). In an
embodiment, portions of the inlet header and the outlet header are each
substantially continuous (e.g., integral or unitary) with the heat exchange
panel, and more particularly with the lower plate and upper plate thereof.
When the lower plate and upper plate are joined together, the separate
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header portions that are substantially continuous or unitary with the lower
plate and the upper plate are also joined together and form, in each case,
the inlet header and/or the outlet header.
With further regard to the headers being formed by separate header
portions upon joining the lower and upper plates of the heat exchange
panel together, in an embodiment, the lower plate includes a lower inlet
header portion positioned on an inlet side of the lower plate, and a lower
outlet header portion positioned on an outlet side of the lower plate. The
upper plate also includes an upper inlet header portion positioned on an
inlet side of the upper plate, and an upper outlet header portion positioned
on an outlet side of the upper plate. When the lower plate and the upper
plate are joined together, to form the heat exchange panel of the present
invention, the lower inlet header portion (of the lower plate) and the upper
inlet header portion (of the upper plate), which are aligned, are joined
together and form the inlet header. Correspondingly, the lower outlet
header portion (of the lower plate) and the upper outlet header portion (of
the upper plate), which are aligned, are joined together and form the outlet
header.
With reference to the drawings (e.g., Figures 10, 11, 12, 14, 15, 16 and
18), lower plate 11 includes a lower inlet header portion 272, which is
located on an inlet side 275 of lower plate 11. Lower plate 11 also
includes a lower outlet header portion 278 that is located on an outlet side
281 of lower plate 11. Upper plate 14 includes an upper inlet header
portion 284, which is located on an inlet side 287 of upper plate 14. Upper
plate 14 additionally includes an upper outlet header portion 290 that is
located on an outlet side 293 of upper plate 14.
When lower plate 11 and upper plate 14 are joined together to form heat
exchange panel 1, lower inlet header portion 272 and upper inlet header
portion 284, which are each on inlet end 60 and aligned with each other,
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are also joined together so as to form inlet header 253. Correspondingly,
lower outlet header portion 278 and upper outlet header portion 290, which
are each on outlet end 63 and aligned with each other, are joined together
so as to form outlet header 259. The lower and upper header portions
may be fixedly attached to each other by art-recognized means, including
for example; adhesives interposed between abutting portions; fasteners;
snap fittings; and/or clamps (none of which are shown in the drawings).
To assist in attachment there-between, the lower and upper header
portions may each include one or more flanges (or flange portions) that
abut each other, or are superposed relative to each other. In an
embodiment, lower inlet header portion 272 has an elongated lower inlet
flange portion 296 that extends outwardly therefrom, and lower outlet
header portion 278 has an elongated lower outlet flange portion 299 that
extends outwardly therefrom. Upper inlet header portion 284 has an
elongated upper inlet flange portion 302 that extends outwardly therefrom,
and upper outlet header portion 290 has an elongated upper outlet flange
portion 305 that extends outwardly therefrom.
Joining together of lower inlet header portion 272 and upper inlet header
portion 284, so as to form inlet header 253, also results in abutment or
super-positioning of elongated lower inlet flange portion 296 and
elongated upper inlet flange portion 302, which results in formation of
elongated inlet header flange 308 (Figures 1 and 3). Accordingly, joining
together of lower outlet header portion 278 and upper outlet header portion
290, so as to form outlet header 259, also results in abutment or super-
positioning of elongated lower outlet flange portion 299 and elongated
upper outlet flange portion 305, which results in formation of elongated
outlet header flange 311 (Figure 16). The elongated header flanges (inlet
header flange 308, and outlet header flange 311) may be fixedly held
together by art-recognized means, such as adhesives interposed between
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the abutting lower and upper elongated flange portions thereof; fasteners;
snap fittings; and/or clamps (none of which are shown in the drawings).
The heat exchange panel of the present invention, and the various
components thereof (e.g., the lower plate, lower plate extensions, ribs,
upper plate, upper plate extensions, sidewall structure, inlet header and
outlet header) may each be independently fabricated from any suitable
material or combinations of materials. Materials from which the heat
exchange panel of the present invention, and the various components
thereof, may be fabricated, include but are not limited to, metals (e.g.,
ferrous metals, titanium, copper and/or aluminum), cellulose based
materials, such as wood, ceramics, glass, and/or plastics (e.g.,
thermoplastic materials and/or thermoset plastic materials).
In an embodiment, the lower plate is a substantially unitary lower plate
molded from a first plastic material, and the upper plate is a substantially
unitary upper plate molded from a second plastic material. As used herein
and in the claims, the term "substantially unitary lower plate" and similar
terms, means the lower plate and all components thereof, such as the
lower plate extensions, are continuous with each other. As used herein
and in the claims, the term "substantially unitary upper plate" and similar
terms, means the upper plate and all components thereof, such as the
upper plate extensions, are continuous with each other. The first plastic
material and the second plastic material may each independently be
selected from thermoplastic materials, thermoset plastic materials and
combinations thereof.
As used herein and in the claims, the term "thermoset plastic material" and
similar terms, such as "thermosetting or thermosetable plastic materials"
means plastic materials having or that form a three dimensional
crosslinked network resulting from the formation of covalent bonds
between chemically reactive groups, e.g., active hydrogen groups and free
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isocyanate groups, or between unsaturated groups. Thermoset plastic
materials from which the various components of the heat exchange panel
may be fabricated include those known to the skilled artisan, e.g.,
crosslinked polyurethanes, crosslinked polyepoxides, crosslinked
polyesters (such as sheet molding compound compositions) and
crosslinked polyunsaturated polymers. The use of thermosetting plastic
materials typically involves the art-recognized process of reaction injection
molding. Reaction injection molding typically involves, as is known to the
skilled artisan, injecting separately, and preferably simultaneously, into a
mold, for example: (i) an active hydrogen functional component (e.g., a
polyol and/or polyamine); and (ii) an isocyanate functional component
(e.g., a diisocyanate such as toluene diisocyanate, and/or dimers and
trimers of a diisocyanate such as toluene diisocyanate). The filled mold
may optionally be heated to ensure and/or hasten complete reaction of the
injected components.
As used herein and in the claims, the term "thermoplastic material" and
similar terms, means a plastic material that has a softening or melting
point, and is substantially free of a three dimensional crosslinked network
resulting from the formation of covalent bonds between chemically reactive
groups (e.g., active hydrogen groups and free isocyanate groups) of
separate polymer chains and/or crosslinking agents. Examples of
thermoplastic materials from which the various components of the heat
exchange panel may be fabricated include, but are not limited to,
thermoplastic polyurethane, thermoplastic polyurea, thermoplastic
polyimide, thermoplastic polyamide, thermoplastic polyamideimide,
thermoplastic polyester, thermoplastic polycarbonate, thermoplastic
polysulfone, thermoplastic polyketone, thermoplastic polyolefins,
thermoplastic (meth)acrylates, thermoplastic acrylonitrile-butadiene-
styrene, thermoplastic styrene-acrylonitrile, thermoplastic acrylonitrile-
stryrene-acrylate and combinations thereof (e.g., blends and/or alloys of at
least two thereof).
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In an embodiment of the present invention, the thermoplastic material from
which each of the various components of the heat exchange panel may be
fabricated is independently selected from thermoplastic polyolefins. As
used herein and in the claims, the term "polyolefin" and similar terms, such
as "polyalkylene" and "thermoplastic polyolefin", means polyolefin
homopolymers, polyolefin copolymers, homogeneous polyolefins and/or
heterogeneous polyolefins. For purposes of illustration, examples of a
polyolefin copolymer include those prepared from ethylene and one or
more C3-C12 alpha-olefins, such as 1-butene, 1-hexene and/or 1-octene.
The polyolefins, from which the thermoplastic material of the various
components of the heat exchange panel may in each case be
independently selected, include heterogeneous polyolefins, homogeneous
polyolefins, or combinations thereof. The term "heterogeneous polyolefin"
and similar terms means polyolefins having a relatively wide variation in: (i)
molecular weight amongst individual polymer chains (i.e., a polydispersity
index of greater than or equal to 3); and (ii) monomer residue distribution
(in the case of copolymers) amongst individual polymer chains. The term
"polydispersity index" (PDI) means the ratio of Mw/M,,, where Mw means
weight average molecular weight, and Mn means number average
molecular weight, each being determined by means of gel permeation
chromatography (GPC) using appropriate standards, such as polyethylene
standards. Heterogeneous polyolefins are typically prepared by means of
Ziegler-Natta type catalysis in heterogeneous phase.
The term "homogeneous polyolefin" and similar terms means polyolefins
having a relatively narrow variation in: (i) molecular weight amongst
individual polymer chains (i.e., a polydispersity index of less than 3); and
(ii) monomer residue distribution (in the case of copolymers) amongst
individual polymer chains. As such, in contrast to heterogeneous
polyolefins, homogeneous polyolefins have similar chain lengths amongst
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individual polymer chains, a relatively even distribution of monomer
residues along polymer chain backbones, and a relatively similar
distribution of monomer residues amongst individual polymer chain
backbones. Homogeneous polyolefins are typically prepared by means of
single-site, metallocene or constrained-geometry catalysis. The monomer
residue distribution of homogeneous polyolefin copolymers may be
characterized by composition distribution breadth index (CDBI) values,
which are defined as the weight percent of polymer molecules having a
comonomer residue content within 50 percent of the median total molar
comonomer content. As such, a polyolefin homopolymer has a CDBI
value of 100 percent. For example, homogenous polyethylene / alpha-
olefin copolymers typically have CDBI values of greater than 60 percent or
greater than 70 percent. Composition distribution breadth index values
may be determined by art recognized methods, for example, temperature
rising elution fractionation (TREF), as described by Wild et al, Journal of
Polymer Science, Poly. Phys. Ed., Vol. 20, p. 441 (1982), or in United
States Patent No. 4,798,081, or in United States Patent No. 5,089,321.
An example of homogeneous ethylene / alpha-olefin copolymers are
SURPASS polyethylenes, commercially available from NOVA Chemicals
Inc.
The plastic materials of the various components of the heat exchange
panel may in each case independently and optionally include a reinforcing
material selected, for example, from glass fibers, glass beads, carbon
fibers, metal flakes, metal fibers, polyamide fibers (e.g., KEVLAR
polyamide fibers), cellulosic fibers, nanoparticulate clays, talc and mixtures
thereof. If present, the reinforcing material is typically present in a
reinforcing amount, e.g., in an amount of from 5 percent by weight to 60 or
70 percent by weight, based on the total weight of the component (i.e., the
sum of the weight of the plastic material and the reinforcing material). The
reinforcing fibers, and the glass fibers in particular, may have sizings on
their surfaces to improve miscibility and/or adhesion to the plastic
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materials into which they are incorporated, as is known to the skilled
artisan.
In an embodiment of the invention, the reinforcing material is in the form of
fibers (e.g., glass fibers, carbon fibers, metal fibers, polyamide fibers,
cellulosic fibers and combinations of two or more thereof). The fibers
typically have lengths (e.g., average lengths) of from 0.5 inches to 4
inches (1.27 cm to 10.16 cm). The various components of the heat
exchange panel may each independently include fibers having lengths that
are at least 50 or 85 percent of the lengths of the fibers that are present in
the feed materials from which the molded panel is (or portions thereof are)
prepared, such as from 0.25 inches to 2 or 4 inches (0.64 cm to 5.08 or
10.16 cm). The average length of fibers present in a plastic component of
the heat exchange panel (e.g., the lower and upper plates, etc.) may be
determined in accordance with art recognized methods. For example, the
plastic component may be pyrolyzed to remove the plastic material, and
the remaining or residual fibers microscopically analyzed to determine
their average lengths, as is known to the skilled artisan.
Fibers are typically present in the plastic components of the heat
exchange panel in amounts independently from 5 to 70 percent by weight,
10 to 60 percent by weight, or 30 to 50 percent by weight (e.g., 40 percent
by weight), based on the total weight of the plastic component (i.e., the
weight of the plastic material, the fiber and any additives). Accordingly,
the plastic components of the heat exchange panel may each
independently include fibers in amounts of from 5 to 70 percent by weight,
10 to 60 percent by weight, or 30 to 50 percent by weight (e.g., 40 percent
by weight), based on the total weight of the particular component.
The fibers may have a wide range of diameters. Typically, the fibers have
diameters of from 1 to 20 micrometers, or more typically from 1 to 9
micrometers. Generally, each fiber comprises a bundle of individual
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filaments (or monofilaments). Typically, each fiber is composed of a
bundle of 10,000 to 20,000 individual filaments.
Typically, the fibers are uniformly distributed throughout the plastic
material. During mixing of the fibers and the plastic material, the fibers
generally form bundles of fibers typically comprising at least 5 fibers per
fiber bundle, and preferably less than 10 fibers per fiber bundle. While not
intending to be bound by theory, it is believed, based on the evidence at
hand, that fiber bundles containing 10 or more fibers may result in a plastic
component (e.g., the lower plate) having undesirably reduced structural
integrity. The level of fiber bundles containing 10 or more fibers per
bundle, may be quantified by determining the Degree of Combing present
within a molded article. The number of fiber bundles containing 10 or
more fibers per bundle is typically determined by microscopic evaluation of
a cross section of the molded article, relative to the total number of
microscopically observable fibers (which is typically at least 1000). The
Degree of Combing is calculated using the following equation: 100 x
((number of bundles containing 10 or more fibers) / (total number of
observed fibers)). Generally, molded plastic components of the heat
exchange panel according to the present invention have a Degree of
Combing of less than or equal to 60 percent, and typically less than or
equal to 35 percent.
In addition or alternatively to reinforcing material(s), the plastic
components of the heat exchange panel may in each case independently
and optionally further include one or more additives. Additives that may be
present in the plastic components include, but are not limited to,
antioxidants, colorants, e.g., pigments and/or dyes, mold release agents,
fillers, e.g., calcium carbonate, ultraviolet light absorbers, fire retardants
and mixtures thereof. Additives may be present in the plastic material of
each plastic component in functionally sufficient amounts, e.g., in amounts
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independently from 0.1 percent by weight to 10 percent by weight, based
on the total weight of the particular plastic component.
The molded plastic components (e.g., the lower and upper plates) of the
heat exchange panel of the present invention may be prepared by art-
recognized methods, including, but not limited to, injection molding,
reaction injection molding, compression molding and sheet thermoforming.
The plastic components may be fabricated by a compression molding
process that includes: providing a compression mold comprising a lower
mold portion and an upper mold portion; forming (e.g., in an extruder) a
molten composition comprising plastic material and optionally reinforcing
material, such as fibers; introducing, by action of gravity, the molten
composition into the lower mold portion; compressively contacting the
molten composition introduced into the lower mold portion with the interior
surface of the upper mold portion; and removing the molded component
from the mold. The lower mold portion may be supported on a trolley that
is reversibly moveable between: (i) a first station where the molten
composition is introduced therein; and (ii) a second station where the
upper mold portion is compressively contacted with the molten
composition introduced into the lower mold portion.
The lower mold portion may be moved concurrently in time and space
(e.g., in x-, y- and/or z-directions, relative to a plane in which the lower
mold resides) as the molten composition is gravitationally introduced
therein. Such dynamic movement of the lower mold portion provides a
means of controlling, for example, the distribution, pattern and/or thickness
of the molten composition that is gravitationally introduced into the lower
mold portion. Alternatively, or in addition to movement of the lower mold
portion in time and space, the rate at which the molten composition is
introduced into the lower mold portion may also be controlled. When the
molten composition is formed in an extruder, the extruder may be fitted
with a terminal dynamic die having one or more reversibly positionable
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gates through which the molten composition flows before dropping into the
lower mold portion. The rate at which the molten composition is
gravitationally deposited into the lower mold portion may be controlled by
adjusting the gates of the dynamic die.
The compressive force applied to the molten plastic composition
introduced into the lower mold portion is generally less than or equal to
1000 psi (70.3 Kg/cm2), typically from 25 psi to 550 psi (1.8 to 38.7
Kg/cm2), more typically from 50 psi to 400 psi (3.5 to 28.1 Kg/cm2), and
further typically from 100 psi to 300 psi (7.0 to 21.1 Kg/cm2). The
compressive force applied to the molten plastic material may be constant
or non-constant. For example, the compressive force applied to the
molten plastic material may initially be ramped up at a controlled rate to a
predetermined level, followed by a hold for a given amount of time, then
followed by a ramp down to ambient pressure at a controlled rate. In
addition, one or more plateaus or holds may be incorporated into the ramp
up and/or ramp down during compression of the molten plastic material.
The molded plastic components of the heat exchange panel of the present
invention may, for example, each be independently prepared in
accordance with the methods and apparatuses described in United States
Patent No.'s: 6,719,551; 6,869,558; 6,900,547; and 7,208,219.
Alternatively, the molded plastic components (e.g., the lower and upper
plates) of the heat exchange panel of the present invention may be
prepared by a sheetless thermoforming process, in which a heated sheet
of thermoplastic material is formed (e.g., from an extruder coupled to a
sheet die) and then vacuum drawn over the internal surfaces of a mold
portion, while the extruded sheet is still thermoformable (and before it
cools to a non-thermoformable temperature). After cooling to a non-
thermoformable temperature, the molded article (e.g., in the form of the
lower plate or upper plate) is removed from the mold portion, and typically
subjected to post-molding operations, such as joining the molded lower
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plate and molded upper plate together. The heat exchange panel and the
various components thereof may be prepared by the sheetless
thermoforming processes as described, for example, in United States
Patent Application Publication Numbers US 2008/0258354 Al and US
2008/0258329 Al.
In an embodiment, the lower plate is a substantially unitary lower plate
molded from a first plastic material, and the upper plate is a substantially
unitary upper plate molded from a second plastic material, in which the
first and the second plastic materials are each independently selected
from thermoplastic materials, thermoset plastic materials and
combinations thereof, as discussed previously herein. Further to this
embodiment, the upper plate is substantially transparent to infrared
radiation, the lower plate is substantially optically opaque, and the interior
surface of the lower plate absorbs infrared radiation.
In a particular embodiment, the upper plate (including the upper plate
extensions thereof) is fabricated from a substantially optically transparent
plastic material that is also substantially transparent to infrared radiation,
such as polycarbonate or clarified polypropylene. The lower plate may be
rendered substantially optically opaque by the inclusion of one or more
pigments (e.g., carbon black, iron oxides and/or TiO2) in the plastic
material from which the lower plate is fabricated. The interior surface
(e.g., 17) of the lower plate (including the exterior surfaces 23 of the lower
plate extensions 20) may absorb infrared radiation as a result of the plastic
material from which the lower plate is fabricated (e.g., a thermoplastic
material filled with carbon black pigment). Alternatively or in addition
thereto, the interior surface of the lower plate (including the exterior
surfaces 23 of the lower plate extensions 20) may have an infrared
absorbent coating applied thereto, such as an acrylic based coating
composition having carbon black pigment dispersed therein.
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The first plastic material from which the lower plate is molded (including
the lower plate extensions) may further include a reinforcing agent, which
may be selected from those classes and examples as recited previously
herein. In an embodiment, the first plastic material, from which said lower
plate is molded (including the lower plate extensions), further includes a
reinforcing material selected from the group consisting of glass fibers,
glass beads, carbon fibers, metal flakes, metal fibers, polyamide fibers,
cellulosic fibers, nanoparticulate clays, talc and mixtures or combinations
thereof. While the second plastic material from which the upper plate is
molded (including the upper plate extensions) may also include a
reinforcing agent, in a particular embodiment: the second plastic material
from which the upper plate is molded is substantially free of a reinforcing
agent; and the first plastic material from which the lower plate is molded
further includes a reinforcing agent.
The heat exchange panel of the present invention may have any suitable
shape and dimensions. For example, the heat exchange panel may have
a generally circular or oval shape, a polygonal shape (e.g., triangular,
rectangular, pentagonal, hexagonal, heptagonal, octagonal shapes, etc.),
an irregular shape (e.g., so as to fit around another structure, such as a
structural beam or chimney), or any combination thereof. More generally,
the heat exchange panel may be a substantially flat heat exchange panel
(as depicted in the drawings), or a non-flat (e.g., arcuate) heat exchange
panel (not depicted). A non-flat heat exchange panel may, for example,
be used to fittingly and securely rest over the apex of a gabled roof
structure.
In an embodiment, the heat exchange panel is substantially flat and has a
substantially rectangular shape, in which the length is greater than the
width thereof, as depicted in the drawings. With reference to Figure 2,
heat exchange panel 1 may have a length 314 (exclusive of the inlet and
outlet headers) of from 0.5 m to 3.0 m, typically from 0.70 m to 2.75 m,
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and more typically from 0.75 m to 2.70 m. Heat exchange panel 1 may
have a width 317 (exclusive of the inlet and outlet headers) of from 0.5 m
to 3.0 m, typically from 0.70 m to 2.75 m, and more typically from 0.75 m
to 2.70 m. In an embodiment, the heat exchange panel has a length (e.g.,
314) of 2.4 m, and a width (e.g., 317) of 1.2 m.
The inlet and outlet headers (e.g., 253 and 259) of the heat exchange
panel may have any suitable shape and dimension, provided they allow a
sufficient amount and rate of flow of heat exchange fluid into and out of the
heat exchange panel, and more particularly the channels, channel
segments and upper plate extension passages thereof. In an
embodiment, the inlet and outlet headers (e.g., 253 and 259) each have a
substantially circular cross-section, and independently in each case have
an interior diameter of from 12 mm to 762 mm, typically from 15 mm to
300 mm, and more typically from 25 mm to 100 mm. In an embodiment,
the inlet and outlet headers each have a substantially circular cross-
section and an interior diameter of 25 mm or 51 mm.
Each lower plate extension (e.g., 20) of the heat exchange panel may
have any suitable height relative to the interior surface (e.g., 17) of the
lower plate (e.g., 11). In an embodiment, and with reference to Figure 4,
each lower plate extension 20 has substantially the same height 320, as
from interior surface 17 to the upper surface thereof (e.g., upper
transverse face 189) of from 20 mm to 230 mm, typically from 45 mm to
215 mm, and more typically from 70 mm to 190 mm. In an embodiment,
each lower plate extension 20 has a height 320 of 120 mm.
In an embodiment, the lower portion (e.g., 66) of each lower plate
extension (e.g., 20) typically has a width (e.g., 141) that is substantially
equivalent to the width of the channel (e.g., 51) in which the lower portion
resides, as described previously herein. See, for example, Figure 13. For
example, the lower portion (e.g., 66) of each lower plate extension (e.g.,
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20) may have a width (e.g., 141) of from 20 mm to 80 mm, typically from
25 mm to 70 mm, and more typically from 30 mm to 40 mm. In an
embodiment, the lower portion (e.g., 66) of each lower plate extension
(e.g., 20) has a width (e.g., 141) of 35 mm.
The width (e.g., 144) of each channel (e.g., 51) of the heat exchange
panel is typically substantially equivalent to the width (e.g., 141) of the
lower portion (e.g., 66) of each lower plate extension (e.g., 20) residing
with the channel. For example, each channel (e.g., 51) may have a width
(e.g., 144) of from 20 mm to 80 mm, typically from 25 mm to 70 mm, and
more typically from 30 mm to 40 mm. Each channel typically has a height
that is substantially equivalent to the height (e.g., 326) of the ribs (e.g.,
105) that define the channels there-between. For example, each channel
(e.g., 51) may have a height (e.g., substantially equivalent to rib height
326) of from 3 mm to 20 mm, typically from 5 mm to 15 mm, and more
typically from 10 mm to 12 mm. In an embodiment, each channel (e.g.,
51) has a width (e.g., 144) of 35 mm, and a height (e.g., substantially
equivalent to rib height 326) of 11 mm. See, for example, Figure 13.
The ribs (e.g., 105) that serve in part to define the channels (e.g., 51) of
the heat exchange panel, may have any suitable dimensions, in particular
with regard to the width and height thereof. In an embodiment, each rib
(e.g., 105) is a substantially elongated longitudinal rib and has
substantially the same dimensions. For example, and with reference to
Figure 13, each rib (e.g., 105) has a width (e.g., 323) of from 5 mm to 30
mm, typically from 7 mm to 25 mm, and more typically from 10 mm to 20
mm. Each rib (e.g., 105) may also have a height (e.g., 326) above interior
surface 17 of lower plate 11 of from 3 mm to 20 mm, typically from 5 mm
to 15 mm, and more typically from 10 mm to 12 mm. In an embodiment,
each rib (e.g., 105) has a width (e.g., 323) of 15 mm, and a height (e.g.,
326) of 11 mm.
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The heat exchange panel of the present invention may be used to absorb
thermal energy from any suitable source of thermal energy, such as: a
source of radiant thermal energy (e.g., infrared radiation from the sun); or
a source of convective thermal energy, such as a fluid heat sink or source
(e.g., a pool of heated liquid, such as water, or stream of heated gas, such
as air). In the case of a source of radiant thermal energy, the heat
exchange panel is typically oriented so as to expose the exterior surfaces
of the upper plate and the upper plate extensions to the source of radiant
thermal energy, such as the sun. The radiant thermal energy is
transferred primarily through the upper plate extensions (and to a lesser
extent also through the exterior surfaces of the upper plate), and into the
fluid (e.g., a heat exchange fluid) passing through the upper plate
extension passages and underlying channels. The heated fluid upon
exiting the heat exchange panel may be used directly (e.g., in the case of
a shower), or indirectly, e.g., to heat another fluid, such as water or air,
in
which case the fluid may be described as a heat exchange fluid. When
used to absorb radiant thermal energy from the sun, the heat exchange
panel may be described as a solar heat exchange panel.
Alternatively, the heat exchange panel of the present invention may itself
be used as a source of thermal energy. For example, a separately heated
fluid may be passed through the channels and upper plate extension
passages of the heat exchange panel, resulting in thermal energy being
transferred out of (rather than into) the upper plate extensions and into a
separate medium, such as a gas (e.g., air) or a liquid (e.g., water). The
separately heated fluid may be heated in and provided by one or more
separate heat exchange panels according to the present invention that are
set up so as to absorb thermal energy from another source of thermal
energy (e.g., the sun), and which are in fluid communication with the heat
exchange panel that is itself acting as a source of thermal energy.
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The present invention has been described with reference to specific details
of particular embodiments thereof. It is not intended that such details be
regarded as limitations upon the scope of the invention except insofar as
and to the extent that they are included in the accompanying claims.
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