Note: Descriptions are shown in the official language in which they were submitted.
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HEAT EXCHANGER UTILIZING TUBULAR STRUCTURES HAVING INTERNAL
FLOW ALTERING MEMBERS AND EXTERNAL CHAMBER ASSEMBLIES
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates generally to heat exchanger tubes and
heat exchangers
and, more specifically, to heat exchanger tubes and heat exchangers with a
cylindrical tubular
member having a plurality of flow altering members within each tubular member.
The flow
altering members are each paired with a chamber assembly attached to the
external surface of
the cylindrical tubular member.
[0003] Discussion of the Related Art
[0004] Heat exchangers are commonly utilized in systems where it is desired
for heat to be
removed. Typical basic heat exchangers are made of generally straight pipes,
which channel
heat exchanging medium within. Headers or manifolds are typically attached to
each end of
the pipes. These headers and manifolds act as receptacles for the heat
exchanging medium.
The efficienc), of pipe heat exchangers is limited by the amount of surface
area available for
the transfer of heat. In a tube and chamber heat exchanger, a plurality of
tube and chamber
assemblies extend in spaced relation between a pair of headers or manifolds,
forming the core
of a heat exchanger. Heat exchanging performance of the heat exchanger is
dictated by the
overall surface area provided by the plurality of tube and chamber assemblies.
[0005] To increase surface area to enhance heat exchange performance, typical
heat
exchangers such as condensers, incorporate a flat-tube design, usually of
extruded tubular
material with extended surfaces provided by corrugated fin material, the
corrugated fin
material being generally interposed between a pair of extruded tubular
materials. This type of
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heat exchanger typically includes flattened tubes having a fluid passing
therethrough and a
plurality of corrugated fins extending between the tubes. The fins are
attached to the tubes to
effectively increase the surface area of the tubes, thereby enhancing the heat
transfer
capability of the tubes. A number of tubes and fins may be stacked on top of
each other, with
a small opening to allow passage of air therethrough. To further improve heat
transfer
efficiency, the tube's wall thickness may be made thinner. As a result, the
parts are lighter in
weight, which in turn makes the overall heat exchanger lighter in weight.
However, the
pressure resistance is reduced, and the thinner tubes are more prone to
damage. Also, the
assembly process is complicated due to the fragile nature of the parts. In
addition, extruded
tubes are prone to plugging during the manufacturing process, particularly if
a brazing
process is utilized. The complexity of the extruding process results in higher
costs and higher
defect rates. Furthermore, as flat tubes are generally extruded into shape
utilizing metal
extrusion processes, only material that can be easily extruded into shape is
typically made
into flat tubes, restricting the available materials for flat tubes generally
to aluminum and
various aluminum alloys known in the art.
[0006] The overall cost for the flat tube heat exchanging system is higher
because a powerful
compressor is necessary to move the heat exchanging medium through the smaller
openings
of the tubes. Conversely, if a higher powered compressor is not utilized, then
additional tubes
are necessary to obtain the desired heat exchanging performance because the
smaller tubes
reduce the flow of the heat exchange medium significantly. The addition of
tubes increase the
overall cost for the heat exchanging system. Currently, this type of heat
exchanger is used in
applications requiring high heat exchanging capabilities, such as automotive
air conditioner
condensers.
[0007] In another tube-and-fin design, the tube can be of a serpentine design,
therefore
eliminating the need for headers or manifolds, as the tube is bent back and
forth in an "S"
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shape to create a similar effect. Typical applications of this type of heat
exchanger, besides
condensers, are evaporators, oil coolers, and heater cores. This tube-and-fin
design is also
utilized in radiators for automobiles. Outside of the automotive field, the
tube and fin design
is implemented by industrial oil coolers, compressor oil coolers, and in other
similar
applications requiring a higher efficiency heat exchanger. The serpentine
design is
essentially a single, long tube material with a single chamber to transfer a
heat exchange
medium from the inlet of the serpentine design heat exchanger to the outlet,
thereby
increasing the pressure resistance of heat exchange medium travelling through
the heat
exchanger. This is detrimental to the performance of a heat exchanger,
especially in an
application such as an evaporator, wherein pressure drop significantly
diminishes the
performance of the compressor, for example.
[0008] A variation on the tube-based heat exchanger involves stacking flat
ribbed plates.
When stacked upon each other, these ribbed plates create chambers for
transferring heat
exchanging medium. In essence, this type of heat exchanger performs
substantially the same
as tube-and-fin type heat exchangers, but is fabricated differently. This type
of heat
exchanger is commonly implemented by contemporary evaporators.
[0009] In another variation of a tube heat exchanger, a bundle of tubes are
arranged to form a
heat exchanger generally known in the art as shell-and-tube heat exchanger. In
a shell-and-
tube heat exchanger, a plurality of generally straight tubes are bundled
together. leaving
sufficient space between the tubes to allow a first heat exchanging medium to
flow around
the exterior of the individual tubes, and a second heat exchanging medium to
flow within the
individual tubes. The heat exchanging medium that flows on the exterior of the
individual
tubes and the heat exchanging medium that flows within the individual tubes
may be of the
same type of heat exchanging medium, or may be of different types. This type
of a heat
exchanger typically involves having a first end of bundled tubes to be coupled
to a first
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manifold, and a second end of the bundled tubes to be coupled to a second
manifold. The
entire tube bundle is typically enclosed in a water-tight vessel. Shell-and-
tube heat
exchangers are generally used in application requiring extremely high
pressure, and typically
employ two heat exchange mediums, with one heat exchange medium flowing inside
the tube
bundle, and a second heat exchange medium flowing around the tube bundle
within the
water-tight vessel. Shell-and-tube heat exchangers are also commonly utilized
in large scale
heat exchanging devices for commercial and industrial applications requiring
large heat
exchanging capacity. Shell-and-tube heat exchangers typically bundle together
generally
straight tubes with no surface enhancements either to the inside or the
outside of the tubes,
resulting in limited heat exchanging performance characteristics. This causes
shell-and-tube
heat exchanger to be larger in size to meet a desired heat exchanging
performance, thus
requiring a large footprint for installation purposes.
[0010] Another variation of a heat exchanger is a chamber and tube design with
a medium
directing member inserted within the chamber assembly. The chamber and tube
design heat
exchanger functions by preventing the heat exchange medium from flowing in a
straight line,
and causing turbulent flow within the heat exchanger by forcing the heat
exchange medium to
constantly change directions within the heat exchanger, first by a medium
directing member
and then by a chamber assembly. As a heat exchange medium enters the chamber
and tube
design heat exchanger, the heat exchange medium flows in a straight line
through a straight
tube section. At the end of the straight tube section is the medium directing
member. The
function of the medium directing member is to alter the direction of the heat
exchange
medium flow from the generally straight line flow to almost a perpendicular
flow, while
leading the heat exchange medium into the chamber section of the heat
exchanger. The
chamber section is connected to the tube section, and is generally of a larger
diameter than
the tube section. As the heat exchange medium is introduced into the chamber
assembly, the
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flow of heat exchange medium follows in two semi-circular paths. At the end of
the semi-
circular paths, the heat exchange medium again encounters the medium directing
member.
As the heat exchange medium again encounters the medium directing member, the
flow is
restored into a generally straight flow, as the heat exchange medium is led to
yet another tube
5 section of the heat exchanger. This process repeats itself within the length
of a chamber and
tube design heat exchanger.
SUMMARY OF THE INVENTION
[0011] The present invention is an enhanced tubular heat exchanger comprising
a cylindrical
tubular member with a plurality of chamber assemblies coupled to the external
surface of the
cylindrical tubular member. The cylindrical tubular member is hollow, allowing
fluid flow
within, with plurality of flow altering members coupled at predetermined
intervals within the
fluid flow path of the cylindrical tubular member along the longitudinal
length of the
cylindrical tubular member. The flow altering members positioned inside the
cylindrical
tubular member substantially alter the flow path of the heat exchange medium
flowing inside
the cylindrical tubular member, preventing the heat exchange medium from
continually
flowing in a generally straight line from the inlet of the cylindrical tubular
member to the
outlet of the cylindrical tubular member.
[0012] The flow altering members placed inside the cylindrical tubular member
may be each
paired with an inlet orifice and an outlet orifice formed on the wall of the
cylindrical tubular
member. The flow altering member has an angled plane on the side facing the
flow of heat
exchange medium within the cylindrical tubular member. The inlet orifice and
the outlet
orifice are formed on the wall of the cylindrical tubular member, each inlet
orifice and outlet
orifice going through the entire thickness of the material forming the
cylindrical tubular
member, creating a flow path for heat exchange medium from the interior of the
cylindrical
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tubular member to the exterior of the cylindrical tubular member. A plurality
of chamber
assemblies are coupled on the exterior of the cylindrical tubular member. The
chamber
assemblies are generally of larger diameter than the diameter of the
cylindrical tubular
member, and have an axial span generally drastically shorter than the axial
span of the
cylindrical tubular member. The chamber assemblies are hollow, allowing for
fluid flow
within. Chamber assemblies may be circular, but can be a cylinder,
rectangular, or of other
geometric shapes. Chamber assemblies are positioned along the length of the
cylindrical
tubular member, each chamber assembly overlapping a pairing of an inlet
orifice and an
outlet orifice formed in the wall of the cylindrical tubular member. One end
of the
to cylindrical tubular member may connect to a header or a manifold. A second
end of the
cylindrical tubular manifold may connect to another header or a manifold.
[0013] Heat exchange medium flows from the header or the manifold into the
cylindrical
tubular member. The heat exchange medium within the cylindrical tubular member
flows in
a first line of flow generally parallel to the cylindrical tubular member. The
heat exchange
medium, flowing in the first line of flow inside the cylindrical tubular
member, travels
towards a flow altering member. The flow altering member has an angled surface
facing the
flow of heat exchange medium and directs the flow of heat exchange medium
towards the
first inlet orifice formed in the wall of the cylindrical tubular member, said
inlet orifice going
through the entire thickness of the wall forming the cylindrical tubular
member. Flow
altering members generally feature an angled surface on the side facing the
flow of the heat
exchange medium, allowing a smooth, yet substantial change in directional flow
of the heat
exchange medium.
[00141 The heat exchange medium flowing in the cylindrical tubular member
initially flows
in a first line of flow. A plurality of flow altering members are coupled
within the inner
surface of the cylindrical tubular member. The heat exchange medium, as it
encounters the
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flow altering member. is directed to flow in a second line of flow. The second
line of flow is
generally at an acute angle. approaching an angle, in some embodiment of the
present
invention, that is generally perpendicular to the first line of flow, guiding
the flow of heat
exchange medium towards the inlet orifice. A chamber assembly, being hollow,
is coupled to
the external surface of the cylindrical tubular member. The chamber assembly
generally is of
larger diameter than the cylindrical tubular member, with an axial length
generally
substantially shorter than that of the cylindrical tubular member. The chamber
assembly is in
fluid communication with the inlet orifice of the cylindrical tubular member.
The heat
exchange medium exits the cylindrical tubular member through the inlet orifice
and enters the
chamber assembly. Once inside the chamber assembly, the heat exchange medium
is
dispersed within the chamber assembly, led towards the outlet orifice formed
in the wall of
the cylindrical tubular member.
[0015] Although not to be limiting, the outlet orifice is positioned on a side
of the wall of the
cylindrical tubular member that is generally opposite the side on which the
inlet orifice is
positioned. In other embodiments, the position of the inlet orifice and the
outlet orifice may
be offset. The chamber assembly is in fluid communication with both the inlet
orifice and the
outlet orifice formed on the wall of the cylindrical tubular member. This
arrangement allows
the heat exchange medium that exits the cylindrical tubular member through the
inlet orifice
to enter the chamber assembly and to re-enter the cylindrical tubular member
through the
outlet orifice. The heat exchange medium flowing back into the cylindrical
tubular member
through the outlet orifice encounters a flow altering member. The flow
altering member has
an angled surface on a side facing the outlet of the cylindrical tubular
member and generally
restores the heat exchange medium's directional flow to that of the first line
of flow. This
process is repeated throughout the length of the cylindrical tubular member.
At the end of the
tubular member, heat exchange medium may exit to a second header or a
manifold.
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[0016] As the heat exchange medium flows through the cylindrical tubular
member and a
plurality of chamber assemblies, heat contained within the heat exchange
medium is absorbed
by the material comprising the cylindrical tubular member and the chamber
assemblies.
Heat absorbed by the tubular member and the chamber assemblies is then
released to the
environment external to the assemblies.
[0017] In an embodiment of the present invention, the heat exchange medium
flows into the
cylindrical tubular member from the first manifold, attached on a first end of
the cylindrical
tubular member. The heat exchange medium flows in a first line of flow in the
cylindrical
tubular member, generally along the long axis of the cylindrical tubular
member. As the heat
exchange medium approaches a first flow altering member, the heat exchange
medium is
directed to flow in a second line of flow, generally perpendicular to the
first line of flow.
The flow altering members are generally coupled to the inner surface of the
cylindrical
tubular member. As the heat exchange medium is directed in the second line of
flow by the
flow altering member, the heat exchange medium exits the cylindrical tubular
member
through the inlet orifice formed on the wall of the cylindrical tubular member
and enters the
chamber assembly. Once inside the chamber assembly, the heat exchange medium
is
directed to flow in a third line of flow, the flow dictated by the inner
contour of the chamber
assembly. Although not meant to be limiting, the third line of flow of heat
exchange medium
may be at least one semi-circular flow pattern. The heat exchange medium then
exits the
chamber assembly and re-enters the cylindrical tubular member through the
outlet orifice, the
outlet orifice being formed on the wall of the cylindrical tubular member.
Once the heat
exchange medium re-enters the cylindrical tubular member, the heat exchange
medium is
directed to flow generally in the first line of flow by the flow altering
member, the flow
altering member featuring an angled surface on the side facing the heat
exchange medium
flow. The process repeats itself within the cylindrical tubular member, until
the heat
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exchange medium reaches the end of the cylindrical tubular member, which
medium then
exits the cylindrical tubular member and enters the second header or a
manifold.
[0018] In embodiments of the present invention, the cylindrical tubular member
may
comprise a seamless tubular structure, or a seamed tubular structure. Seamless
tubular
structures may be formed by extrusion, by casting, or by other forming
methods. Seamed
tubular structures may be formed by high frequency welding, other welding
methods, or
mechanical means.
[0019] In an embodiment of the present invention, heat exchanging
characteristics may be
enhanced by adding additional plate materials on the surface of the
cylindrical tubular
member or on one or more surfaces of the chamber assemblies. Adding additional
plate
materials on the surface, increases the overall surface area of the heat
exchanger, and the
performance of the heat exchanger is enhanced by having more surface area to
dissipate heat
away from the heat exchanger. The additional plate material may comprise a
substantially
thinner material in comparison to the material comprising the cylindrical
tubular member,
thereby further enhancing the heat transfer performance of a heat exchanger
for particular
applications.
[0020] In an embodiment of the present invention, the cylindrical tubular
member and the
chamber assemblies for a heat exchanger are provided, for example, for a
condenser,
evaporator, radiator, etc. The heat exchanger may also be a heater core,
intercooler, or an oil
cooler for an automotive application (e.g., steering, transmission, engine,
etc.) as well as for
non-automotive applications. An advantage of the present invention is that the
heat exchanger
has a larger surface area for radiating heat over a shorter distance than that
of a conventional
heat exchanger, with the surface area provided by both the cylindrical tubular
member and
the chamber assemblies. With the provision of a large surface area for
exchanging heat. the
efficiency of the heat exchanger is greatly increased. Additionally, the
structural rigidity
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provided by having the cylindrical tubular member comprised of a single
seamless or seamed
tube lends itself for use in high internal or external pressure applications.
[0021] Another advantage of the present invention is that the overall length
of the enhanced
tube for heat exchanging applications may be shortened compared to a
conventional heat
5 exchanger, which in turn provides for a lower overall cost, as less raw
material and less
packaging are necessary. Additionally, the cylindrical tubular member may be
made from a
thicker gage material, allowing the heat exchanger to be used for high
pressure applications.
Furthermore, the smaller footprint of the present invention lends itself to be
used in
applications where space is limited. Yet another advantage of the present
invention over a
10 conventional heat exchanger is that the manufacturing process may be
simpler because the
present invention requires less fragile components and less manufacturing
steps. The present
invention provides an easy to assemble heat exchanger, providing enhanced heat
exchanging
performance while being cost effective. The present invention also excels in
high pressure
applications typical of commercial and industrial applications, by providing a
rigid
cylindrical tubular member, which can be manufactured of thick gage tubular
material. The
entire unit may be brazed together, or any portion of the unit can be brazed
first, and then
additional components may be brazed, soldered together, or attached by
mechanical means,
with or without utilization of gaskets.
[0022] The present invention also lends itself for ease of assembly by having
a single piece
cylindrical tubular member. The cylindrical tubular member may be a single
piece tubular
structure with a plurality of inlet orifices and outlet orifices formed at
predetermined intervals
in the wall of the cylindrical tubular member. The orifices can be machine
drilled, punched
out by pressing, or formed by other mechanical means, as long as the method
used creates
orifices that go through the entire thickness of the wall of the cylindrical
tubular member. A
plurality of flow altering members may be inserted inside the cylindrical
tubular member to
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align with an inlet orifice and an outlet orifice pairing. In an embodiment of
the present
invention, a plurality of flow altering members may be formed from a single
piece of material,
or a plurality of flow altering members may be coupled together to form a
single piece of
material with a plurality of flow altering features. In another embodiment of
the present
invention, a plurality of flow altering members may be inserted inside the
cylindrical tubular
member, with the length of each flow altering members predetermined, so that
once the
individual flow altering members are inserted into the cylindrical tubular
member end-to-end,
each flow altering member aligns to a pairing of an inlet orifice and an
outlet orifice. On the
outer surface of the cylindrical tubular member, a plurality of chamber
assemblies are
coupled, each chamber assembly being positioned over a pair comprising of an
inlet orifice
and an outlet orifice.
[0023] Chamber assemblies may be mechanically coupled to the outer surface of
the
cylindrical tubular member, or may be attached by other means, such as
brazing, soldering, or
welding, for example. A plurality of chamber assemblies may be first combined
together to
form a unitary unit of a plurality of chamber assemblies, prior to coupling
the chamber
assemblies to the cylindrical tubular members. By combining a plurality of
chamber
assemblies prior to coupling to the cylindrical tubular members, the assembly
process is
simplified. Additionally, a plurality of chamber assemblies may be formed from
a single
piece of material, by stamping, casting, hydroforming, or other machining
processes.
[0024] In another embodiment of the present invention, fins or plate members
may be
attached to the outside surface of the cylindrical tubular member, to the
outer surface of
chamber assemblies or to surfaces of both the cylindrical tubular member and
the chamber
assemblies. Fins or plate members attached to the outer surface further
increase the surface
area of a heat exchanger, thereby enhancing the performance characteristics of
the heat
exchanger. Fins and plate members provide an economical means to increase the
heat
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exchanging capability of a heat exchanger by enhancing the surface area
available for heat
transfer, without greatly increasing the size of a heat exchanger or costing
more to produce a
heat exchanger.
[0025] In yet another embodiment of the present invention, the chamber
assembly size may
vary from one chamber assembly to the next.
[0026] In another embodiment of the present invention, a plurality of
cylindrical tubular
member may be bundled together to form a heat exchanger with a plurality of
cylindrical
tubular members. One end of the bundled cylindrical tubular member may connect
to a first
manifold or a header, and a second end of the bundled cylindrical tubular
member may
connect to a second manifold or a header. In an embodiment of the present
invention, the
size of the cylindrical tubular member may vary from one cylindrical tubular
member to the
next.
[0027] In yet another embodiment of the present invention, a plurality of
cylindrical tubular
member may be bundled together, leaving enough space between each of the
bundled tubes
to allow flow of heat exchange medium around the exterior of the individual
cylindrical
tubular member. The first end of the bundled cylindrical tubular member may
connect to a
first manifold or a header. The second end of the bundled cylindrical tubular
member may
connect to a second manifold or a header. The entire area comprising the
bundled
cylindrical tubular member may be sealed in a water tight vessel, allowing a
heat exchange
medium to flow on the outer surface of the bundled cylindrical tubular member.
The vessel
may have an inlet to allow a first heat exchange medium to flow inside the
vessel. The vessel
may also have an outlet to allow the first heat exchange medium to exit the
vessel.
Furthermore, the vessel may feature baffles to direct flow of heat exchange
medium within
the vessel. In an embodiment of the present invention, a second heat exchange
medium may
flow within the bundled cylindrical tubular member. The first heat exchange
medium
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flowing outside the bundled cylindrical tubular member and the second heat
exchange
medium flowing inside the bundled cylindrical tubular member may be a gas, a
liquid, or a
combination of both.
[0028] In a further embodiment of the present invention, each chamber assembly
may
disperse heat exchanging medium throughout the chamber, which further enhances
the heat
exchanging capabilities of the present invention. Also, the cylindrical
tubular member may
also mix heat exchanging medium.
[0029] In another embodiment of the present invention, the inner surface of
the cylindrical
tubular member may feature indentations to increase the surface area. Also, in
yet another
embodiment of the present invention, the inner surface of the chamber assembly
may also
feature indentations to increase the surface area. In a further embodiment of
the present
invention, the flow altering member may also feature indentations. In an
embodiment of the
present invention, the chamber assembly may have other surface features such
as, but not
limited to, indentations, louvers, dimples, as well as other extended surface
features to alter
the fluid flow characteristics within the chamber assembly.
[0030] The cylindrical tubular member and the chamber assemblies may be made
of
aluminum, either with cladding or without cladding. The flow altering member
may be made
of aluminum, either with cladding or without cladding. The cylindrical tubular
member, the
chamber assemblies, and the flow altering members may also be made of
stainless steel,
copper or other ferrous or non-ferrous materials. The cylindrical tubular
member, the
chamber assemblies, and the flow altering members may also be a plastic
material or other
composite materials.
[0031] The cylindrical tubular member, the chamber assemblies, and the flow
altering
members may be manufactured by stamping, cold forging, casting, hydroforming,
or
machining.
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[0032] Other features and advantages of the present invention will be readily
appreciated, as
the same becomes better understood after reading the subsequent description
taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. IA is a perspective view of a heat exchanger comprising a
cylindrical tubular
member with a plurality of chamber assembly attachments according to
embodiments of the
present invention;
[0034] FIG. I B is a side view of a prior art tubular structure typically used
in a pipe heat
exchanger;
[0035] FIG. IC is a perspective view of a tubular structure according to
embodiments of the
present invention;
[0036] FIG. I D illustrates a cross-sectional view of a cylindrical tubular
member with a
plurality of chamber assemblies coupled to the outer surface of a tubular
structure, and with a
plurality of flow altering members positioned in predetermined locations
within the
cylindrical tubular member according to embodiments of the present invention;
[0037] FIG. 2A illustrates another cross-sectional view of the heat exchanger,
according to
an embodiment of the present invention;
[0038] FIG. 2B is a side view of the tubular structure according to
embodiments of the
present invention;
[0039] FIG. 2C illustrates a side view of the flow altering member, according
to an
embodiment of the present invention;
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[0040] FIG. 2D illustrate a side view of the chamber assemblies, according to
an
embodiment of the present invention;
[0041] FIG. 2E is a perspective view of a chamber assembly, according to
embodiments of
the present invention;
5 [0042] FIG 3A illustrates flow patterns of a heat exchange medium inside the
cylindrical
tubular member, according to embodiments of the present invention;
[0043] FIG. 38 is a cross-sectional view of a heat exchanger according to
embodiments of
the present invention;
[0044] FIG. 3C is a cross-sectional view of the tubular structure according to
embodiments
10 of the present invention;
[0045] FIG. 3D is a cross-sectional view of a plurality of flow-altering
members according to
an embodiment of the present invention;
[0046] FIG. 3E is a cross-sectional view of another chamber assembly,
according to
embodiments of the present invention;
15 [0047] FIG. 4A is a perspective view of a heat exchanger, according to
embodiments of the
present invention;
[0048] FIG 4B is a side view of a heat exchanger, according to embodiments of
the present
invention:
[0049] FIG. 4C is a top view of a heat exchanger, according to embodiments of
the present
invention;
[0050] FIG. 4D is a perspective view of another heat exchanger, according to
embodiments
of the present invention;
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[0051] FIG. 4E is a side view of a heat exchanger, according to another
embodiment of the
present invention;
[0052] FIG. 4F is a top view of a heat exchanger, according to another
embodiment of the
present invention;
[0053] FIG. 5A is a perspective view of a flow altering member, according to
embodiments
of the present invention;
[0054] FIG. 5B is a top view of a flow altering member, according to
embodiments of the
present invention;
[0055] FIG. 5C is a forward view of a flow altering member, according to
embodiments of
the present invention;
[0056] FIG. 5D is a side view of a flow altering member, according to
embodiments of the
present invention;
[0057] FIG. 5E is a perspective view of another embodiment of a flow altering
member,
according to embodiments of the present invention;
[0058] FIG. 5F is a side view of a plurality of flow altering member,
according to
embodiments of the present invention;
[0059] FIG 6A is a side view of a heat exchanger, according to another
embodiment of the
present invention;
[0060] FIG 6B is a perspective view of a heat exchanger, according to another
embodiment
of the present invention:
[0061] FIG 6C is a top view of a heat exchanger, according to another
embodiment of the
present invention:
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[0062] FIG 6D is a side view of a cylindrical tubular member, according to
another
embodiment of the present invention;
[0063] FIG 6E is a perspective view of a cylindrical tubular member, according
to another
embodiment of the present invention;
[0064] FIG 6F is a top view of a cylindrical tubular member, according to
another
embodiment of the present invention;
[0065] FIG 7A is a perspective view of a flow altering member, according to
another
embodiment of the present invention;
[0066] FIG 7B is a frontal view of a flow altering member, according to
another embodiment
of the present invention;
[0067] FIG 7C is a back view of a flow altering member, according to another
embodiment
of the present invention;
[0068] FIG 7D is a perspective view of a flow altering member, according to
another
embodiment of the present invention:
[0069] FIG 8A is a frontal view of a heat exchanger, and illustrates flow
patterns of a heat
exchange medium inside the cylindrical tubular member and the chamber
assemblies,
according to embodiments of the present invention;
DETAILED DESCRIPTION
[0070] Referring to the drawings and in particular FIG IA, an embodiment of a
cylindrical
tubular member 100 is shown. The cylindrical tubular member 100 has an inlet 5
to
introduce a heat exchange medium into the cylindrical tubular member 100, and
an outlet 10
to allow the heat exchange medium to flow out of the cylindrical tubular
member 100. The
cylindrical tubular member 100 has a tubular structure 15. Referring also to
FIG 1D, the
exterior surface of the tubular structure 15 has a plurality of chamber
assemblies 20 attached
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to the exterior surface of the tubular structure 15. Referring to FIG IC, the
tubular structure
15 features a plurality of inlet orifices 30 and outlet orifices 35, to allow
heat exchange
medium to flow out of the tubular structure 15, and enter a chamber assembly
20, then allow
the heat exchange medium to re-enter the tubular structure 15 from the chamber
assembly 20
through the outlet orifice 35. Referring to FIG IC and FIG ID, the inlet
orifice 30 and the
outlet orifice 35 are formed on the wall of the tubular structure IS, the
orifices 30 and 35
going through the entire thickness of the material forming the tubular
structure S. Each inlet
orifice 30 is paired with an outlet orifice 35, the outlet orifice 35 is
positioned on the side of
the tubular structure 15 which is opposite the side on which the paired inlet
orifice member
30 is disposed. Referring to FIG ID, each pairing of an inlet orifice 30 and
an outlet orifice
35 is paired with a flow altering member 25. Flow altering member 25 is
coupled to the inner
wall of the tubular structure IS. Flow altering regimes, each comprising an
inlet orifice
member 30, a chamber assembly 20, an outlet orifice 35, and a flow altering
member 25, are
repeated throughout the length of the tubular structure IS. A plurality of
flow altering
regimes are disposed throughout the cylindrical tubular member 100. In
comparison,
referring now to FIG 1B, a typical prior art tube type heat exchanger has a
tubular structure
I5a, which is hollow and extends axially in a generally straight line,
permitting flow of a heat
exchange medium within the tubular structure. The interior and exterior of the
tubular
structure are generally smooth and contain no through holes. The tubular
structure has an
inlet 5a to introduce heat exchange medium into the tubular structure 15a and
an outlet 10a to
allow heat exchange medium to exit the tubular structure 15a. The prior art
tubular structure
15a may have surface enhancement features such as fins on the inside as well
as on the
outside of the tubular structure to enhance heat transfer characteristics.
[0071] Referring to FIG 2A, another embodiment of the present invention is
shown. The
cylindrical tubular member 100 has an inlet 5 to introduce heat exchange
medium into the
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cylindrical tubular member 100, and an outlet 10 to allow the heat exchange
medium to flow
out of the cylindrical tubular member 100. The cylindrical tubular member 100
has a tubular
structure 15. Referring now to FIG 28, the tubular structure 15 has plurality
of inlet orifices
30 and outlet orifices 35 formed on the tubular structure 15, the orifices
going through the
entire thickness of the material forming the tubular structure 15. Each inlet
orifice 30 is
paired to an outlet orifice 35. Referring to FIG 2A and FIG 2C, inserted
inside the tubular
structure 15 is a plurality of flow altering members 25 attached together by
an attachment
member 45, creating a single unit of an insert 40 with a plurality of flow
altering members 25.
The insert 40 is placed within the tubular structure 15, so that each flow
altering member is
aligned to a pairing of an inlet orifice 30 and an outlet orifice 35. The
attachment member 45
of the insert 40 is positioned so that the material forming the attachment
member 45 does not
obstruct the inlet orifice 30 or the outlet orifice 35 formed on the tubular
structure 15.
[0072] Referring to FIG 2A, on the exterior surface of the tubular structure
IS, a plurality of
chamber assemblies 20 are coupled, each chamber assembly forming a watertight
fit with the
exterior surface of the tubular structure 15. Referring to FIG 2D and 2E, the
chamber
assembly 20 comprises of a first planar wall 90 and a second planar wall 95,
the second
planar wall 95 is set apart at a distance from the first planar wall 90,
leaving a space between
the first planar wall 90 and the second planar wall 95. Interconnecting the
first planar wall 90
and the second planar wall 95 is a lateral wall 85. The first planar wall 90,
the second planar
wall 95, and the lateral wall 85 form a watertight connection, leaving a
chamber 50 within the
chamber assembly 20. Through the first planar wall 90 and the second planar
wall 95, an
orifice 55 is formed. The orifice 55 has a size, e.g., a diameter, slightly
larger than the size,
e.g., the diameter of the exterior dimension of the tubular structure 15,
allowing the chamber
assembly 20 and a tubular structure to form a tight fit when the tubular
structure 15 is
inserted inside the orifice 55. A plurality of said chamber assemblies 20 are
coupled to the
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exterior surface of the tubular structure 15, as illustrated in FIG 2A. Each
chamber assembly
20 is positioned so that each chamber assembly 20 is aligned to a pairing of
an inlet orifice 30
and an outlet orifice 35 formed in the tubular structure 15. Flow altering
regimes, each
comprising an inlet orifice member 30, a chamber assembly 20, an outlet
orifice member 35,
5 and the flow altering member 25, are repeated throughout the length of the
tubular structure
15. Thus, a plurality of flow altering regimes are provided by the cylindrical
tubular member
100.
[0073] Referring now to FIG 3A and FIG 3B, another embodiment of the present
invention
is shown. In this embodiment, tubular structure 15 is fabricated with a
plurality of inlet
10 orifices 30 and outlet orifices 35. Chamber assembly 60 is a unitary unit,
having a plurality
of chamber units 20 positioned with a predetermined spacing therebetween. The
chamber
units 20 are connected with each other by a tubular section 70 (See FIG 3B ad
FIG 3E). A
tubular structure 15, with inlet orifices 30 and outlet orifices 35, is shown
by itself in FIG 3C.
Inlet orifices 30 and outlet orifices 35 are positioned on the tubular
structure 15 so that each
15 inlet orifice 30 is paired with an outlet orifice 35. The positioning of
the inlet orifice 30 and
outlet orifice 35 on the tubular structure 15 is made so that an outlet
orifice 35 is on a side
generally opposite to an inlet orifice 30, although the positioning of the
outlet orifice 35 may
also be offset in some embodiments of the present invention. For each pairing
of an inlet
orifice 30 and an outlet orifice 35, a flow altering member is positioned, so
that the flow of
20 heat exchange medium entering the inlet 5 of the tubular structure IS,
encounters the flow
altering member 25, a first side 75 of the flow altering member 25 having an
angled surface,
causing the flow of the heat exchange medium to be led towards the inlet
orifice 30. For each
flow altering member 25 positioned within the tubular structure 15, the first
face 75 of the
flow altering member 25 faces the inlet orifice 30 and a second face 80 of the
flow altering
member 25 faces the outlet orifice 35 (see FIG 3D in relation to FIG 3C).
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[0074] Referring to FIG 4A and FIG 43, an embodiment of a heat exchanger 200
is shown.
The heat exchanger 200 includes a pair of manifolds 210 and 230. A plurality
of cylindrical
tubular members 100 extend in a spaced relation relative to each other between
the manifolds
210 and 230. One free end of a cylindrical tubular member 100 is coupled to
the first
manifold 210. The other free end of the cylindrical tubular member 100 is
coupled to the
second manifold 230. The first manifold 210 has an inlet 220 to introduce a
heat exchange
medium in to the heat exchanger 200. The second manifold 230 has an outlet 240
to allow
the heat exchange medium to exit the heat exchanger 200. The heat exchange
medium
introduced into the first manifold 210 may be dispersed to a plurality of
cylindrical tubular
members 100. The second manifold 230 may receive the heat exchange medium from
a
plurality of cylindrical tubular members 100. The manifolds 210 and 230 may
feature baffles
so that the flow pattern may be a simple single directional flow from a first
manifold to a
second manifold, or a more complex multiple flow pattern, wherein multiple
flow patterns
exist between the first manifold and the second manifold.
[0075] In another embodiment of the present invention, referring to FIG 4C,
FIG 4D, and
FIG 4E, the heat exchanger 300 includes a pair of manifolds 210 and 230. A
plurality of
cylindrical tubular members 100 extend between the pair of manifolds 210 and
230. One free
end of a cylindrical tubular member 100 is coupled to a first manifold 210.
The other free
end of the cylindrical tubular member 100 is coupled to a second manifold 230.
The space
between the pair of manifolds 210 and 230 is fully enclosed in a vessel 350.
The vessel
provides a water-tight enclosure, having a vessel inlet 310 and a vessel
outlet 320, to allow
flow of a heat exchange medium in and out of the vessel 350 surrounding the
cylindrical
tubular members 100. The first manifold 210 has an inlet 220 to introduce a
first heat
exchange medium into the plurality of cylindrical tubular members 100. The
second
manifold 230 has an outlet 240 to allow the first heat exchange medium to exit
the plurality
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of cylindrical tubular members 100. The manifolds 210 and 230 may feature
baffles within
so that the flow pattern may be a simple single direction flow from a first
manifold to a
second manifold, or more complex multiple flow pattern, wherein multiple flow
patterns exist
between the first manifold and the second manifold. The second heat exchange
medium
enters the vessel 350 through the vessel inlet 310. The second heat exchange
medium flows
around the plurality of cylindrical tubular members 100 positioned within the
vessel 350.
The second heat exchange medium flows out of the vessel 350 through the vessel
outlet 320.
[0076] Thus, in embodiments of the present invention, the heat exchanger (e.g.
300),
features two heat exchange mediums, one heat exchange medium flowing inside
the plurality
of cylindrical tubular members 100, and second heat exchange medium flowing
outside the
plurality of cylindrical tubular members 100. The first heat exchange medium
flowing inside
the plurality of cylindrical tubular members 100 may contain heat,
transferring heat to the
second heat exchange medium flowing outside of the plurality of cylindrical
tubular members
100. In another embodiment of the present invention, the heat exchange medium
flowing
inside the plurality of cylindrical tubular members 100 may absorb heat from
the second heat
exchange medium flowing outside the plurality of cylindrical tubular members
100.
[0077] In another embodiment of the present invention, both an inlet and an
outlet can be
positioned on a first manifold, with a second manifold facilitating the return
of heat exchange
medium towards the first manifold. Referring to FIG 4F, the heat exchanger 355
includes a
pair of manifolds 215 and 235. A plurality of cylindrical tubular members 100
(as in FIG 4C)
extend in a spaced relation between the pair of manifolds 215 and 235. One
free end of a
cylindrical tubular member 100 is coupled to the first manifold 215. The other
free end of the
cylindrical tubular member 100 is coupled to the second manifold 235. The
first manifold
215 has an inlet 220 to introduce heat exchange medium in to the heat
exchanger 355 and an
outlet 245 to allow the heat exchange medium to exit the heat exchanger 355.
The first
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manifold 215 has a partition within to segregate a portion of the plurality of
cylindrical
tubular members 100 into at least two groups. One portion of the plurality of
cylindrical
tubular members 100 functions to allow flow of the heat exchange medium from
the first
manifold 215 to the second manifold 235, and the rest of the plurality of
cylindrical tubular
members 100 functions to allow flow of the heat exchange medium from the
second manifold
235 to the first manifold 215. The second manifold 235 receives the heat
exchange medium
from the first manifold 215, through the plurality of cylindrical tubular
members 100 in the
first partition of the first manifold 215. Once the second manifold receives
the heat exchange
medium, the heat exchange medium is returned to the first manifold 215 through
the plurality
of cylindrical tubular member in the second partition of the first manifold
215. The inlet 220
is connected to the first partition of the first manifold 215, and the outlet
245 is connected to
the second partition of the first manifold 215.
[0078] Referring to FIG 3A, a flow pattern for the heat exchange medium within
the
cylindrical tubular member 100 is shown. One free end of the cylindrical
tubular member
100 is an inlet 5. The other free end of the cylindrical tubular member 100 is
an outlet 10. A
heat exchange medium enters the cylindrical tubular member through the inlet 5
flows in a
first line of flow, generally flowing parallel to the tubular structure IS.
The heat exchange
medium flowing in the first line of flow encounters a flow altering member 25.
A plurality of
flow altering members 25 are preferably positioned at a predetermined spacing
within the
tubular structure 15. Referring to FIG 3A, FIG 3D, FIG 5A, and FIG 5D, the
flow altering
member 25 features an angled surface 75 on the surface that faces toward the
inlet of the
cylindrical tubular member 100, allowing the heat exchange medium flowing in
the first line
of flow to be directed to a second line of flow within the tubular structure
15. Referring to
FIGS 5A and 5C, the external circumference of the flow altering member 25 is
generally
contoured to match the inner circumference of the tubular structure 15. The
heat exchange
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medium directed in the second line of flow by the flow altering member 25,
flows towards
the inlet orifice 30 on the tubular structure 15. Once the heat exchange
medium reaches the
inlet orifice 30, the heat exchange medium exits the tubular structure 15 and
enters the
chamber assembly 20. Within the chamber assembly 20, the heat exchange medium
flows
within the chamber assembly, following the inner contour of the chamber
assembly, which is
hollow to facilitate flow of the heat exchange medium within. Although not
meant to be
limiting, the chamber assembly 20 has a cylindrical shape, the diameter of the
chamber
assembly being larger than the diameter of the tubular structure 15. The axial
span of the
chamber assembly 20 is substantially shorter than the axial span of the
tubular structure 15,
allowing a plurality of chamber assemblies 20 to be coupled to the tubular
structure 15. The
heat exchange medium flowing within a chamber assembly 20 flows in at least
one semi-
circular flow pattern. The heat exchange medium flowing within the chamber
assembly re-
enters the tubular structure 15 through the outlet orifice 35 formed on the
wall forming the
tubular structure 15. Once the heat exchange medium re-enters the tubular
structure 15, the
heat exchange medium encounters the flow altering member 25. Referring to FIG
5D, the
flow altering member has an angled surface 80 on the side of the flow altering
member facing
the outlet 10, which generally restores the first directional flow of the heat
exchange medium
within the tubular structure 15. The process repeats itself until the heat
exchange medium
introduced into the cylindrical tubular member 100 from the inlet 5 exits
through the outlet
10 of said cylindrical tubular member 100.
[0079] Now referring to FIG 5E and 5F, another embodiment of a flow altering
member is
shown. In an embodiment of a flow altering member presented in FIG 5E and FIG
5F, a
plurality of flow altering features may be formed from a single piece of
material, or a
plurality of flow altering members may be coupled together to form a singular
unit with a
plurality of flow altering features, shown as a flow altering member 40 in FIG
5E. Along the
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lateral span of the flow altering member 40, a plurality of flow altering
surfaces 75 are
featured. The flow altering surfaces 75 facing the inlet 5 of the tube
assembly 15 features an
angled surface, and directs the heat exchange medium flowing in the first line
of flow within
the tube assembly 15 to change course and flow in a second line of flow,
directing the heat
5 exchange medium into the chamber assembly 20 through the inlet orifice 30.
The flow
altering member 40 also features a plurality of flow altering surfaces 80, the
flow altering
surfaces 80 facing the outlet 10 of the tube assembly 15. The surface of the
flow altering
surfaces 80 is set at an angle in relation to the outlet 10 of the tube
assembly 15. The flow
altering surfaces 80 directs the flow of the heat exchange medium exiting the
chamber
10 assembly 20 and entering the tube assembly 15 through the outlet orifice
35, to flow in the
first line of flow. The flow altering member 40 features connecting members 45
forming the
lateral wall of the flow altering member 40. The general exterior contour of
the connecting
members 45 conforms to the inner contour of the tube assembly 15, coupling the
exterior
surface of the flow altering member 40 to the inner surface of the tubular
member 15.
15 [0080] Now referring to FIG 6A, FIG 6B, and FIG 6E, another embodiment of
the present
invention is shown, wherein such embodiment employs a cylindrical tubular
member 105
which includes a tubular structure 110 and pairs of chamber assemblies 125,
126. Referring
to FIG 6E in particular, a tubular structure 110 forms a structural foundation
of a heat
exchanger, with a plurality of inlet orifices and outlet orifices formed on
the tubular structure
20 110. Referring to FIG 7A, positioned at predetermined intervals within the
tubular structure
110 are plurality of flow altering members 150. On the exterior of the tubular
structure, a
plurality of chamber assemblies 125 and 126 are coupled to the exterior
surface of the tubular
structure 110. Referring to FIG 6C and FIG 7A, a flow altering member 150 has
a channel
on a plane of the flow altering member surface facing the inlet 115 of the
tubular structure
25 110,
with an angled planar surface 170 facing the inlet 115 of the tubular
structure 110. The
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channel on the flow altering member 150 comprises a first lateral wall 155
defining a first
wall of a channel, a second lateral wall 160 defining a second wall of a
channel, and a base
wall 165 defining a base of the channel. Each flow altering member 150 is
paired with a
plurality of inlet orifices 130 and 135. Referring to FIG 6B, FIG 6C, and FIG
8A, each inlet
orifice 130 is paired with a chamber assembly 125. A chamber assembly 125 is
coupled to
the exterior surface of the tubular structure 110, the chamber assembly being
hollow,
permitting fluid flow within.
[0081] The heat exchange medium flowing in the tubular structure 110 initially
flows in a
first line of flow. As the heat exchange medium travels within the tubular
structure 110, the
heat exchange medium comes into contact with a flow altering member 150. As
the heat
exchange medium contacts the flow altering member 150, the flow of the heat
exchange
medium is directed towards a second line of flow, the directional change being
dictated by
the angled planar surface 170 of the flow altering member 150, and by the
channel formed by
the first lateral wall 155, the second lateral wall 160, and the base wall 165
of the flow
altering member 150. The heat exchange medium directed in the second line of
flow is then
led out of the tubular structure 110 into a chamber assembly 125. Referring to
FIG 8A, a
portion of the heat exchange medium is directed into the inlet orifice 130 and
flows into a
first chamber assembly 125, more specifically into a semi-cylindrical chamber
180. Another
portion of the heat exchange medium is directed into the inlet orifice 135 and
flows into a
second chamber assembly 126, more specifically into a semi-cylindrical chamber
182. The
flow of heat exchange medium within the respective chamber assemblies 125/126
is dictated
by the inner contour of the chamber assemblies, generally following a semi-
circular flow
pattern dictated by the respective semi-cylindrical chambers 180. 182. The
heat exchange
medium flowing in the first chamber assembly 125 is directed towards the
outlet orifice 140.
Upon reaching the outlet orifice 140, the heat exchange medium travelling
within the first
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chamber assembly 125 exits the chamber assembly 125, and re-enters the tubular
structure
110. The heat exchange medium flowing in the second chamber assembly 126 is
directed
towards the outlet orifice 145. Upon reaching the outlet orifice 145, the heat
exchange
medium travelling within the second chamber assembly 126 exits the chamber
assembly 126,
and re-enters the tubular structure 110. The heat exchange medium that has
travelled within
the first chamber assembly 125 and the second chamber assembly 126 converge
within the
tubular structure 110. Referring to FIG 7C, the heat exchange medium that has
re-entered the
tubular structure 110 comes in contact with the flow altering member 150,
affecting the
directional flow of the heat exchange medium. The flow altering member 150 has
an angled
planar surface 185 facing the outlet 120 of the tubular structure 110. The
plane of the surface
facing the outlet 120 of the tubular structure has a channel defined by a
first lateral wall 190,
a second lateral wall 195, and a base wall 205 as shown in FIG 7C. As the heat
exchange
medium exits the first chamber assembly 125 and the second chamber assembly
126 through
the outlet orifice 140 and 145, the heat exchange medium comes into contact
with the angled
planar surface 185 of the flow altering member 150. As the heat exchange
medium comes
into contact with the angled surface 185 of the flow altering member 150, the
directional flow
is restored generally to that of first line of flow. This process repeats
itself within the tubular
structure 110, until the heat exchange medium exits the tubular structure 110
through the
outlet 120.
[0082] Referring to FIG 7A, a plurality of flow altering members 150 may be
arranged
within the tubular structure 110, preferably at a predetermined intervals. Now
referring to
FIG 71), in another embodiment of the present invention, plural flow altering
members 150
may be coupled together forming a unitary unit. In this embodiment, a first
lateral wall 155
and a second lateral wall 160 of a second flow altering member 150 engages a
first lateral
wall 190 and second lateral wall 195 of a first altering member. In this
embodiment.
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individual flow altering member 150 may be coupled together, or a unitary unit
with multiple
flow altering features may be formed from a single piece of material, or any
combination in
between.
[0083] Throughout the transport of the heat exchange medium through the
cylindrical
tubular member 105, the heat contained within the heat exchange medium is
transferred to
the material comprising the cylindrical tubular member 105. The heat absorbed
by the
cylindrical tubular member 105 is then transferred to the environment outside
of the
cylindrical tubular member 105. Although not meant to be limiting, common heat
exchange
medium known in the art includes various refrigerants (i.e.: R-134A, R-410A),
ammonium,
gases, water, oils, and various mixtures of chemicals.
[0084] As previously explained, a first heat exchange medium may flow within
the
cylindrical tubular member 105 and a second heat exchange medium may flow on
the outside
of the cylindrical tubular member 105. The First heat exchange medium may be a
heat
exchange medium known in the art, such as various refrigerants (i.e.; R-134A,
R-410A),
ammonium, gases, water, oils, and various mixtures of chemicals. The second
heat exchange
medium may also be various refrigerants (i.e.; R-134A, R-410A), ammonium,
gases, water,
oils, and various mixtures of chemicals. When more than one heat exchange
medium is
utilized, heat from the first heat exchange medium may be absorbed by the
second heat
exchange medium, or vice versa.
[0085] Referring to FIG IC and FIG 6E, the tubular structure 15, 110 in the
illustrated
embodiments, is hollow and circular. In other embodiments, the tubular
structure may be
hollow but non-circular, such as an oval, rectangular shape, or other
geometric shapes.
[0086] Referring to FIG 2E, in the illustrated embodiment, the chamber
assembly 20 is
hollow and cylindrical in shape. In other embodiments, the chamber assembly 20
may be
hollow, but non-cylindrical in shape, such as an oval cylinders or a box
shape, for example.
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[0087] The tubular structure 15, 110 and chamber assembly 20, 125, 126 may be
made of
aluminum, either with cladding or without cladding. The tubular structure and
chamber
assembly may also be made of stainless steel, copper, or other ferrous or non-
ferrous material.
The tubular structure and chamber assembly may also be a plastic material or
other composite
materials. Likewise, the flow altering member may also be made of aluminum,
either with
cladding or without cladding. The flow altering member may also be made of
stainless steel,
copper or other ferrous or non-ferrous materials. The flow altering member may
also be a
plastic material or other composite materials. Also, an embodiment of the
present invention
allows for the tubular structure and chamber assembly to be made of different
material from
each other. Additionally, a gasket material may be used to seal between the
tubular structure
and the chamber assembly.
[0088] The tubular structure may be made of seamless tube, utilizing an
extrusion process.
The tubular structure may also be made of a seamed tube, utilizing ultrasonic
welding, roll-
forming process, or other mechanical means or casting methods.
[0089] Many modifications and variations of the present invention are possible
in light of the
above teachings. For example, the various embodiments of the flow altering
members may
be used in conjunction with tubular structures other than in the combinations
described above
and illustrated in the drawings Therefore, within the scope of the appended
claims, the
present invention may be practiced other than as specifically described.
