Note: Descriptions are shown in the official language in which they were submitted.
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Title: RADIATOR HAVING A REVERSE FLOW MANIFOLD
Technical Field
[0001] The
embodiments disclosed herein relate generally to radiators for heating
rooms and other spaces, and, in particular to radiators having a plurality of
fluid conduits
for carrying a thermal fluid such as water.
Introduction
[0002] The
following paragraphs are not an admission that anything discussed in
them is prior art or part of the knowledge of persons skilled in the art.
[0003]
Radiators are used to heat rooms within buildings. Some heating systems
have boilers that heat water and circulate hot water through the radiators. In
these
cases, the radiator may have one or more pipes or fluid conduits for carrying
the hot
water. Fins can be attached to the pipes, which may enhance heating
capabilities.
[0004]
Conventional radiators are generally configured to operate using supply
water at temperatures of at least 140 F, and usually around 180 F or more.
This poses
a problem because recently developed high-efficiency condensing boilers supply
water
at much lower temperatures of 128 F or less. Conventional radiators tend to
perform
poorly when using this low temperature water.
[0005] One way
of improving performance of conventional radiators is to increase
the operating temperature of the condensing boilers in order to supply hotter
water (e.g.
at temperatures of 140 F to 180 F). While this can improve performance of the
radiator,
it significantly decreases efficiency of the condensing boiler, which can be
undesirable.
[0006]
Accordingly, there is a need for a new or improved radiator, and in
particular, there is a need for a radiator that is capable of operating with
low
temperature water.
Summary
[0007]
According to some embodiments, there is a radiator comprising a heat
exchanger that includes a plurality of fluid conduits for carrying a thermal
fluid. Each
fluid conduit extends along a longitudinal axis between a first end and a
second end. At
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least some of the fluid conduits are laterally offset from each other. The
radiator also
comprises a direct-flow manifold and a reverse-flow manifold. The direct flow
manifold is
for conveying the thermal fluid along a first flow direction between the first
ends of the
fluid conduits and a first radiator line. The reverse-flow manifold is for
conveying the
thermal fluid along a second flow direction between the second ends of the
fluid
conduits and an elbow passageway, and along a third flow direction between the
elbow
passageway and a second radiator line. The third flow direction is opposite to
the
second flow direction.
[0008]
According to some embodiments, there is a radiator comprising a heat
exchanger that includes a plurality of fluid conduits for carrying a thermal
fluid. Each
fluid conduit extends along a longitudinal axis between a first end and a
second end. At
least some of the fluid conduits are vertically offset from each other. The
radiator also
comprises a direct-flow manifold and a reverse-flow manifold. The direct-flow
manifold
is coupled to the first ends of the fluid conduits. The direct-flow manifold
has a first fluid
passageway that is in fluid communication with the fluid conduits and that
extends
downward for connection to a first radiator line. The reverse-flow manifold is
coupled to
the second ends of the fluid conduits. The reverse-flow manifold has a second
fluid
passageway and a third fluid passageway. The second fluid passageway is in
fluid
communication with the fluid conduits and extends upward. The third fluid
passageway
is in fluid communication with the second fluid passageway and extends
downward for
connection to a second radiator line.
[0009]
According to some embodiments, there is a radiator comprising a heat
exchanger that includes a plurality of fluid conduits for carrying a thermal
fluid. Each
fluid conduit extends along a longitudinal axis between a first end and a
second end. At
least some of the fluid conduits are laterally offset from each other. The
radiator also
comprises a direct-flow manifold and a reverse-flow manifold. The direct-flow
manifold
is coupled to the first ends of the fluid conduits. The direct-flow manifold
has a first fluid
passageway that is in fluid communication with the fluid conduits and that
extends along
a first lateral direction for connection to a first radiator line. The reverse-
flow manifold is
coupled to the second ends of the fluid conduits. The reverse-flow manifold
has a
second fluid passageway and a third fluid passageway. The second fluid
passageway is
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in fluid communication with the fluid conduits and extends along a second
lateral
direction that is opposite to the first lateral direction. The third fluid
passageway is in
fluid communication with the second fluid passageway and extends along a third
lateral
direction for connection to a second radiator line. The third lateral
direction is generally
opposite to the second lateral direction.
[0010] The fluid conduits may be arranged in a grid having a plurality of
columns
and a plurality of rows.
[0011] The first fluid passageway of the direct-flow manifold may be
centrally and
symmetrically aligned between the columns of the fluid conduits, and the
second fluid
passageway of the reverse-flow manifold may be centrally and symmetrically
aligned
between the columns of the fluid conduits.
[0012] At least one of the first and second fluid passageways may have a
cross-
sectional area that changes between the rows of the fluid conduits. The change
in the
cross-sectional area between adjacent rows of fluid conduits may generally
correspond
to cross-sectional fluid flow area of the fluid conduits within each row.
[0013] The reverse-flow manifold may have an elbow passageway providing
fluid
communication between the first fluid passageway and the second fluid
passageway.
[0014] The heat exchanger may include a plurality of fins arranged along
the fluid
conduits. Each fin may include a main plate arranged transverse to the fluid
conduits.
The main plate may have a plurality of openings for receiving the fluid
conduits
therethrough. Each fin may also include a plurality of collars that project
outward from
the main plate. Each collar may circumscribe one of the openings and may
provide
thermal contact between the main plate and one of the fluid conduits.
[0015] The main plate may have a plurality of indentations.
[0016] The main plate may be 5.5-inches long and 2.7-inches wide.
[0017] The openings may be arranged in a grid having two columns and three
rows. The columns may be spaced apart by about 1.2-inches, and the rows may be
spaced apart by about 1.8-inches.
[0018] The collars may have a depth of about 0.2-inches.
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[0019] The heat exchanger may be at least about 3-feet long.
[0020] The radiator may further comprise an enclosure containing the heat
exchanger, the direct-flow manifold, and the reverse-flow manifold. The
enclosure may
include a back portion and at least one support bracket for supporting the
heat
exchanger on the back portion. The support bracket may include: an upper
bracket
portion mounted to the back portion above the heat exchanger; a lower bracket
portion
mounted to the back portion below the heat exchanger; and a cage removably
coupled
to the upper bracket portion and the lower bracket portion for holding the
heat
exchanger in place. The radiator may also comprise a vibration isolator
between the
support bracket and the heat exchanger.
[0021] Other aspects and features will become apparent, to those ordinarily
skilled in the art, upon review of the following description of some exemplary
embodiments.
Brief Description of the Drawings
[0022] The drawings included herewith are for illustrating various examples
of
articles, methods, and apparatuses of the present specification. In the
drawings:
[0023] FIG. 1 is an exploded perspective view of a radiator according to
one
embodiment;
[0024] FIG. 2 is a perspective view of the radiator of FIG. 1 with an
enclosure and
some fins removed for clarity;
[0025] FIG. 3 is a partial cross-sectional view of the radiator of FIG. 2
taken along
line 3-3 showing a direct-flow manifold and a reverse-flow manifold; and
[0026] FIG. 4 is a perspective view of a fin of the radiator of FIG. 1.
Detailed Description
[0027] Various apparatuses or processes will be described below to provide
an
example of an embodiment of each claimed invention. No embodiment described
below
limits any claimed invention and any claimed invention may cover processes or
apparatuses that differ from those described below. The claimed inventions are
not
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limited to apparatuses or processes having all of the features of any one
apparatus or
process described below or to features common to multiple or all of the
apparatuses
described below. It is possible that an apparatus or process described below
is not an
embodiment of any claimed invention. Any invention disclosed below that is not
claimed
in this document may be the subject matter of another protective instrument,
for
example, a continuing patent application, and the applicants, inventors or
owners do not
intend to abandon, disclaim or dedicate to the public any such invention by
its
disclosure in this document.
[0028]
Referring to FIG. 1, there is a radiator 10, which may be used to heat a
space such as a room within a building. In some embodiments, the radiator 10
may be
configured to operate with low temperature fluids. For example high-efficiency
condensing boilers may output water or another thermal fluid at a temperature
of less
than about 140 F, or more particularly about 128 F or less. These temperatures
are
much lower than water used with conventional boilers and radiators. Based on
the
ability to operate at with low temperature fluids, the radiator 10 may be
referred to as a
"low-temperature" radiator.
[0029] As
shown in FIG. 1, the radiator 10 may include an enclosure 14. The
enclosure 14 may include a back portion 16 and a front portion 18, which may
also be
referred to as a "cover". The front portion 18 may be removably secured to the
back
portion 16.
[0030] The
radiator 10 includes a heat exchanger 20, which may be contained
within the enclosure 14. Referring to FIG. 2, the heat exchanger 20 includes a
plurality
of fluid conduits 22 for carrying a thermal fluid such as water or glycol. The
fluid
conduits 22 may be made from a metal such as brass or copper, or another
thermally
conductive material. A plurality of fins 24 may be arranged along the fluid
conduits 22.
The fins 24 may be thermal contact with the fluid conduits 22 for conducting
thermal
energy therebetween. For example, the fins 24 may be press-fit onto the fluid
conduits
22. In some embodiments, the fins 24 may be welded or brazed on to the fluid
conduits
22.
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[0031] Each
fluid conduit 22 extends along a longitudinal axis A between a first
end 26 and a second end 28. As shown, some of the fluid conduits 22 are
laterally
offset from each other along one or more lateral directions that are generally
transverse
or perpendicular to the longitudinal axis A. For example, the fluid conduits
22 may be
vertically offset, horizontally offset, or both.
[0032] In the
illustrated embodiment, the fluid conduits 22 are arranged in a grid.
More particularly, the fluid conduits 22 are arranged in a grid of two columns
and three
rows. In other embodiments, there may be a different number of columns or
rows.
[0033]
Referring still to FIG. 2, the radiator 10 includes a first manifold 30, and a
second manifold 32. Each manifold 30, 32 is coupled to an end 26, 28 of the
fluid
conduits 22. The manifolds 30, 32 may also be referred to as "end caps". The
manifolds
30, 32 may be made from a metal such as brass, or another suitable material.
[0034] As
shown, the first manifold 30 may be coupled to a first radiator line 34,
and the second manifold 32 may be coupled to a second radiator line 36. The
first
radiator line 34 may be a supply line, and the second radiator line 36 may be
a return
line. Accordingly, thermal fluid may flow left to right as shown in FIG. 2.
[0035] With
reference now to FIG. 3, the first manifold 30 conveys thermal fluid
along a first flow direction D1 between the first radiator line 34 and the
fluid conduits 22.
As shown, the first flow direction D1 may be an upward direction. Since
thermal fluid
flows directly between the first radiator line 34 and the fluid conduits 22
along the first
flow direction D1, the first manifold 30 may be referred to as a "direct-flow
manifold".
[0036] In
contrast to the first manifold 30, the second manifold 32 conveys
thermal fluid along two different directions. In particular, the second
manifold 32
conveys fluid along a second flow direction D2 between the fluid conduits 22
and a
reversing point 38, and along a third flow direction D3 between the reversing
point 38
and the second radiator line 36. As shown, the third flow direction D3 may be
generally
opposite to the second flow direction D2 (e.g. the second flow direction may
be upward,
and the third flow direction may be downward). Since thermal fluid flows along
two
opposing directions, the second manifold 32 may be referred to as a "reverse-
flow
manifold".
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[0037] As
described above, the first manifold 30 may be coupled to the supply
line 34 and the second manifold 32 may be coupled to the return line 36.
Accordingly,
the first flow direction D1 may be a forward or upward direction from the
supply line 34
to the fluid conduits 22. Furthermore, the second flow direction 02 may be a
forward or
upward direction from the fluid conduits 22 to the reversing point 38, and the
third flow
direction D3 may be a reverse or downward direction from the reversing point
38 to the
return line 36. In other embodiments, the directions D1, D2 and D3 could be
different.
For example, if the first manifold 30 were coupled to the return line and the
second
manifold 32 were coupled to the supply line, the thermal fluid would flow in
the opposite
direction (i.e. right to left) and the directions D1, D2 and D3 would be
opposite to that
described above.
[0038] I n
some embodiments, the first and second flow directions D1 and D2 may
be generally similar to one another. For example, in the illustrated
embodiment, the first
and second flow directions D1 and D2 are parallel to each other and point in
the same
general direction. In other embodiments, the first and second flow directions
D1 and D2
could be different and might be angled with respect to each other.
[0039]
Referring still to FIG. 3, the structure of the direct-flow manifold 30 and
the
reverse-flow manifold 32 will now be described in greater detail.
[0040] The
direct-flow manifold 30 is coupled to the first ends 26 of the fluid
conduits 22. For example, the direct-flow manifold 30 may have a plurality of
fluid
couplings coupled to the fluid conduits 22 (e.g. inlet couplings 41A, 41B,
41C).
[0041] The
direct-flow manifold 30 has a first fluid passageway 40 in fluid
communication with the fluid conduits 22 (e.g. via the couplings 41A, 41B,
41C). The
first fluid passageway 40 extends along a first lateral direction for
connection to the first
radiator line 34. The first lateral direction may be generally parallel to the
first flow
direction D1 and may extend downward from the fluid conduits 22 to the supply
line 34.
[0042] The
reverse-flow manifold 32 is coupled to the second ends 28 of the fluid
conduits 22. For example, the reverse-flow manifold 32 may have a plurality of
fluid
couplings coupled to the fluid conduits 22 (e.g. outlet couplings 43A, 43B,
43C).
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[0043] The
reverse-flow manifold 32 has two fluid passageways, namely, a
second fluid passageway 42 and a third fluid passageway 44. The second and
third fluid
passageways may extend in generally opposite directions. An elbow passageway
46
may provide fluid communication between the second fluid passageway 42 and the
third
fluid passageway 44. The elbow passageway 46 may define the reversing point
38.
[0044] As
shown, the second fluid passageway 42 is in fluid communication with
the fluid conduits 22 and extends along a second lateral direction, which may
be
generally similar to the second flow direction D2 and may extend upward from
the fluid
conduits 22. The third fluid passageway 44 is in fluid communication with the
second
fluid passageway 42 and extends along a third lateral direction for connection
to the
second radiator line 36. The third lateral direction may be generally similar
to the third
flow direction D3 and may extend downward for connection to the second
radiator line
36.
[0045] As
shown, the first, second, and third lateral directions of the fluid
passageways 40, 42, 44 are generally transverse to the longitudinal axis A.
For
example, as shown, the first, second, and third lateral directions may be
generally
perpendicular to the longitudinal axis A. Alternatively, the first, second,
and third lateral
directions could be at oblique angles to the longitudinal axis A.
[0046] Using
the direct-flow manifold 30 and the reverse-flow manifold 32 might
enhance thermal performance of the radiator 10. This can be particularly
beneficial
when using low temperature water of 128 F or less (e.g. as supplied by a high-
efficiency
condensing boiler). One possible reason for enhanced thermal performance is
that that
each row of fluid conduits 22 might have a more uniform fluid flow
distribution in
comparison to conventional radiators that have direct-flow manifolds on each
end of the
fluid conduits 22. Having a more evenly distributed flow fluid within the
fluid conduits 22
might provide a more uniform temperature gradient across the heat exchanger
20, and
thus, might enhance thermal performance.
[0047] The
even flow distribution might be due to reducing or equalizing flow
restrictions through the fluid conduits 22. For example, with reference to
FIG. 3, the first,
second, and third fluid conduits 22A, 22B, 22C might each receive a portion of
total fluid
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flow. Fluid flow through the first fluid conduit 22A might be associated with
a first inlet
flow restriction through the first inlet coupling 41A, and a first outlet flow
restriction
through the first outlet coupling 43A. Furthermore, fluid flow through the
second fluid
conduit 22B might be associated with a second inlet flow restriction through
the second
inlet coupling 41B, and a second outlet flow restriction through the second
outlet
coupling 43B. Finally, fluid flow through the third fluid conduit 220 might be
associated
with a third inlet flow restriction through the third inlet coupling 41C, and
a third outlet
flow restriction through the third outlet coupling 43C.
[0048] The reverse-flow manifold 32 might help balance or match flow
restrictions
with the direct-flow manifold 30 in reverse order. For example, the combined
flow
restrictions through the first inlet and outlet couplings 41A, 43A might be
similar to that
of the second inlet and outlet couplings 41B, 43B, and similar to that of the
third inlet
and outlet couplings 41C, 43C. It is believed that matching the flow
restrictions through
the fluid conduits 22 in this way might help equalize pressure drop through
each fluid
conduit 22, and thus, distribute fluid flow more uniformly, and possibly
enhance thermal
performance.
[0049] In contrast, if two direct-flow manifolds were used, the flow
restrictions
through the first inlet and outlet couplings 41A, 43A might be different to
that of the
second inlet and outlet couplings 41B, 43B, and different to that of the third
inlet and
outlet couplings 410, 430. This might result in uneven flow through the fluid
conduits
22, which might decrease thermal performance.
[0050] Referring again to FIGS. 2 and 3, the manifolds 30, 32 may be
symmetrically aligned with the columns of fluid conduits 22 (e.g. along the
cross-
sectional plane defined by the line 3-3). For example, the first fluid
passageway 40 of
the direct-flow manifold 30 may be centrally and symmetrically aligned between
the two
columns of fluid conduits 22. Furthermore, the second fluid passageway 42 of
the
reverse-flow manifold 32 may be centrally and symmetrically aligned between
the at
least two columns of fluid conduits. Having the manifolds 30, 32 symmetrically
aligned
with the fluid conduits 22 in this way might help maintain uniform fluid flow
through each
fluid conduit within a particular row.
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[0051] In some
embodiments, the fluid passageways 40, 42 of the manifolds 30,
32 might have a cross-sectional area that changes between rows of fluid
conduits 22.
For example, as shown FIG. 3, the fluid passageway 40 of the direct-flow
manifold 30
might have a cross-sectional area that decreases from a proximal row of fluid
conduits
(e.g. the first fluid conduits 22A) to a distal row of fluid conduits (e.g.
the third fluid
conduits 220).
[0052] In some
embodiments, the change in cross-sectional area of the fluid
passageway between adjacent rows of fluid conduits 22 may correspond to cross-
sectional fluid flow area of those fluid conduits 22. For example, the
decrease in cross-
sectional area of the fluid passageway 40 between the first fluid conduit 22A
and the
second fluid conduit 22B may correspond to the cross-sectional area of the two
first fluid
conduits 22A. Similarly, the decrease in cross-sectional area of the first
fluid
passageway 40 between the second fluid conduit 22B and the third fluid conduit
22C
may correspond to cross-sectional area of the two second fluid conduits 22B.
Configuring the cross-sectional areas in this way might help maintain a fluid
flow
velocity that is generally similar through the fluid passageways 40, 42 as
well as the
fluid conduits 22, and thus, help maintain a more uniform fluid flow through
the fluid
conduits 22.
[0053] As
described above, the radiator 10 may include a plurality of fins 24.
Referring to FIGS. 2 and 4, each fin 24 may include a main plate 50 arranged
transverse to the fluid conduits 22. The fin 24 may have a generally
rectangular shape.
For example, as shown, the main plate 50 may have a length L of about 5.5-
inches, and
a width W of about 2.7-inches. In other embodiments, the fin 24 could have
other
shapes and sizes.
[0054] The
main plate 50 has a plurality of openings 52 for receiving the fluid
conduits 22 therethrough. As shown, the openings 52 may be arranged in a grid.
For
example, there are two columns and three rows of openings 52 in the
illustrated
embodiment. The columns may be spaced apart by a column spacing 70 (e.g. of
about
1.2-inches), and the rows may be spaced apart by a row spacing 72 (e.g. of
about 1.8-
inches). Furthermore, the first and last columns may be spaced from the edge
of the fin
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24 by about half of the column spacing 70 (e.g. about 0.6-inches), and the
first and last
rows may be spaced from the edge of the fin 24 by about half of the row
spacing 72
(e.g. about 0.9-inches). In other embodiments, there could be a different
number of
openings, and the openings could have different spacing and geometric
arrangements.
[0055] Each
fin 24 may also include a plurality of collars 54 that project outwardly
from the main plate 50. Each collar 54 may circumscribe or define one of the
openings
52. The collars 54 may provide thermal contact between the main plate 50 and
the fluid
conduits 22. The collars may have a collar depth 55 (e.g. of about 0.2-
inches).
[0056] In some
embodiments, the main plate 50 may have a plurality of
indentations 56. The indentations 56 may be formed as elongate, wave-like
ripples in
the main plate 50. The indentations 56 may increase the surface area of the
fin 24,
which may enhance thermal performance.
[0057]
Referring again to FIG. 1, the enclosure 14 may contain the heat
exchanger 20, the direct-flow manifold 30, and the reverse-flow manifold 32.
Furthermore, the enclosure 14 may include one or more support brackets 80 for
supporting the heat exchanger 20. More particularly, in the illustrated
embodiment,
there are two support brackets 80 for supporting the heat exchanger 20 on the
back
portion 16 of the enclosure 14. Each support bracket 80 may include an upper
bracket
portion 82 mounted to the back portion 16 above the heat exchanger 20, and a
lower
bracket portion 84 mounted to the back portion 16 below the heat exchanger 20.
[0058] The
support bracket 80 may also include a grate or cage 86 that is
removably coupled to the bracket portions 82, 84 for holding the heat
exchanger 20 in
place. The cage 86 may be formed from a wire that is hooked into a slot on the
lower
bracket portion 84. The wire cage 86 may also have ends 88 that extend through
apertures in the upper bracket portion 82. The cage 86 may be removed by
squeezing
the middle of the wire cage 86 together so as to deflect the cage 86 inwards
and pull the
wire ends 88 through the apertures in the upper bracket portion 82. The bottom
of the
cage 86 can then be unhooked from the lower bracket portion 84 to remove the
cage
86. After removal, the heat exchanger 20 can be disconnected from the radiator
lines
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34, 36 and then removed from the enclosure 14. The heat exchanger 20 can be
installed by reversing this process.
[0059] I n
some embodiments, the radiator 10 may also include a vibration isolator
90 between the support bracket 80 and the heat exchanger 20. For example, the
vibration isolator 90 may be a silicone pad that is pressed between the wire
cage 86
and the fins 24 of the heat exchanger 20. This may help reduce noise such as
rattling.
[0060] The
radiator 10 may be made in a variety of lengths. For example, in the
illustrated example, the radiator 10 may be approximately 3-feet long. This
may allow
attachment of the radiator 10 to a supply line 34 and a return line 36 that
are
approximately 3-feet apart. In other embodiments, the radiator 10 may be
longer or
shorter. For exemplary purposes only, the radiator 10 may be manufactured in
standard
lengths ranging from 2-feet to 10-feet (e.g. in one foot increments). Having a
variety of
lengths can be particularly useful when the radiator is designed for drop-in
replacement
for existing radiators that are being replaced.
[0061] While
the above description provides examples of one or more apparatus,
methods, or systems, it will be appreciated that other apparatus, methods, or
systems
may be within the scope of the claims as interpreted by one of skill in the
art.
