BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a ground loop heat exchanger, methods of manufacturing same, methods of using same, equipment to insert a ground loop heat exchanger into the ground and methods of doing business. More particularly, the invention relates to a direct insertion ground loop heat exchanger, and methods of making and using same and equipment to insert the ground loop heat exchanger into the ground, methods of making and using same.
2. Description of the Prior Art
Renewable energy is being heavily utilized and investigated in order to reduce our nation's contribution to greenhouse gases, as well as reducing our dependence on foreign oil. Heating homes and businesses is one of the largest energy costs realized by consumers. The search has been on for consistent, environmentally friendly and inexpensive methods of heating our homes and businesses. Solar energy, wind power and geothermal powers are all being investigated as a means of renewable energy. Currently, each of these methods have their own individual issues with cost, return on investment, environmental concerns, among other issues.
Of these methods, the green friendly method of geothermal heating and cooling is especially favorable because it meets many of the criteria, although traditionally it has been relatively expensive and labor intensive to install the requisite heat exchangers in the ground. Above all, it is well known that the earth can be used as a consistent source of heat or cool because it is consistent in temperature the deeper you go. After insertion of a ground loop heat exchanger into the earth, the temperature fluctuation becomes less and less as you go deeper. In fact, just 10 to 20 feet into the earth yields some fairly consistent temperatures, regardless of geography.
Geothermal engineers have been using this concept to power their geothermal heat pumps to deliver heating and cooling to their customers for many years. Geothermal, or ground source heat pumps, have proven themselves to be a more efficient heating and air conditioning source than other heat pumps. Conventional geothermal installations for heating and cooling of homes and businesses are well known in the art, and they have used either horizontally installed ground loops placed into ground excavation sites or deep trenches. Needless to say, such an installation requires removal of a great deal of surface soils and topography. In some cases of retro-fitting a ground source heat exchanger, pavement, driveways, trees, and other landscaping needed to be removed. The number of man hours and equipment and the attendant monetary costs in order to dig up all this terrain is enormous, and has been a barrier to its widespread use among the public.
It has become abundantly clear that there is a need for a more environmentally friendly, less expensive and efficient method for installing the heat exchangers necessary to operate a ground source heat pump. In an attempt to overcome the abovementioned obstacles, contractors have attempted to utilize vertically installed heat exchangers instead of the horizontally installed heat exchangers. However, installing these vertical heat exchangers, including the most common types of vertical ground loop heat exchangers, requires tremendous effort to properly bore a hole to then install the heat exchanger into the ground.
Typically a vibrating or rotating vertical boring machine needs to be used, and they become problems for the environment, ground source water contamination that is common among such vertical loop installations, and if any pockets of cavernous space need to become penetrated, the county inspectors would require a grout or cement back filling in order to stabilize and seal the borehole. The earth is full of underground water sources, and those water sources cannot be contaminated by drilling and excavation with a vertical boring machine. Such machines are so large that they create many problems for landscaping and noise prevention and water runoff, not to mention the vibration of the machinery itself cracking foundations and basement walls when drilling near other buildings. In highly populated areas, such an installation can wreak havoc with all of the neighbors, as well as the streets and driveways. Consequently, while a vertical heat loop installation may help reduce land area requirements, the traditional method that is used is not only troublesome for excavation reasons, but is much more expensive than an installer would like to have it be. This traditionally used specialized drilling equipment is not a piece of equipment that normal heating and cooling professionals would own because it costs tens of thousands to hundreds of thousands of dollars to purchase. Inevitably, the vertical installation may need to occur during a rainy period, and in order to prevent cave-ins, further precautions must be taken, which will not be addressed herein, because the present invention will alleviate this situation.
Therefore, there has been a long felt need in the industry for a convenient, inexpensive, environmentally friendly, and particularly effective method of installing vertical or angled heat exchangers or in ground installations that are not susceptible to environmental concerns like rain, cave-ins and ground water contamination. It is further desired to reduce this cost as much as possible, in order to provide more wide spread availability of ground loop heat exchanger installations.
SUMMARY OF THE INVENTION
In accordance with the above-noted desires of the industry, the present invention provides various aspects, including a direct insertion ground loop heat exchanger, an in ground installation means, a method of making, using and selling the same, and various methods of installing it and methods of doing business as well.
The present invention discloses a first aspect of a direct insertion ground loop heat exchanger having a novel drilling tip for easing insertion of the heat exchanger directly into the ground, without disturbing the surrounding earth, landscaping or buildings. Insertion is accomplished through many different aspects, including hand insertion, mechanical insertion, oscillating roller hammer insertion, hydraulic direct insertion, or any other suitable means of inserting into the ground. The direct insertion is achieved easily with the use of my novel device for inserting an HDPE (or other suitable) pipe that is designed as a ground loop heat exchanger into the ground. My specially designed steel (or other suitable material) driving tip having perforations bored therethrough is affixed to the direct insertion ground loop heat exchanger. By using oscillating downward and upward force, my specialized driving tip penetrates the soil and moves objects aside while water jets extending through the entire tip is ejected through the tip to loosen the soil ahead of the tip and lubricate the process allowing for a rapid insertion.
Especially useful is my concentric tube design wherein, in one aspect, one tube is inserted through the middle of another tube such that the tube utilized to direct water to loosen the soil and emit through the tip is afterward used as the outer wall of the annular flow cavity for heat exchanger fluid. In another aspect, the water flow tube is coextruded in a multilumen profile along with the downflow and upflow heat exchanger fluid concentric flow channels wherein the water flow utilized to loosen and lubricate the soil is used for this purpose only and is not used for heat exchanger fluid flow. The concentric tube design of both aspects provides the ability to insert a single insertion unit into the ground, while allowing for bi-directional flow.
This single insertion unit allows for the heat exchanger to exhibit two functions at the same time, i.e. it can be inserted into the ground and then also provide for heat exchanger fluid flow using the same assembly. Furthermore, additional benefits include having the ability to have laminar flow in the downflow pipe while turbulent flow in the up flow under an equal volumetric flow rate. This increases heat transfer in the ground coupled outer tube without increasing pump energy in the laminar flow inner pipe. In addition, this provides an easily insulated inner flow tube to help maintain temperatures for improved thermal efficiency once the installation is complete.
Although the invention will be described by way of examples herein below for specific aspects having certain features, it must also be realized that minor modifications that do not require undo experimentation on the part of the practitioner are also covered within the scope and breadth of this invention. Additional advantages and other novel features of the present invention will be set forth in the description that follows and in particular will be apparent to those skilled in the art upon examination or may be learned within the practice of the invention. Therefore, the invention is capable of many other different aspects and its details are capable of modifications of various aspects which will be helpful to those of ordinary skill in the art, all without departing from the spirit of the present invention. Accordingly, the rest of the description will be regarded as illustrative rather than restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental view illustrating the method and apparatus of the present invention;
FIG. 2A is a side elevation view of a driving tip made in accordance with the present invention;
FIG. 2B is a top plan view taken along lines A-A, showing the relative placement of the heat exchange core;
FIG. 2C is a top plan view of a vertical spacer;
FIG. 3 is an oblique bottom view showing the jet outlets;
FIG. 4 is a side vertical perspective view of the driving tip mechanism;
FIG. 5 is a top plan view of the clamping mechanism around the driving;
FIG. 6 is a side elevational view of a disassembled driving tip;
FIG. 7 is an exploded perspective view of the driving tip and how it is connected to the heat exchanger;
FIG. 8 is a perspective view of a baffle;
FIG. 9 illustrates a first aspect of the assembly clamp;
FIG. 10A shows a relative placement of the clamp aspect shown in FIG. 9;
FIG. 10B shows the relative placement of the clamp aspect in a closed configuration;
FIG. 11 is an environmental view of the clamp of FIGS. 9 and 10, and shows the operation;
FIG. 12 shows another possible driving means for syncing me heat exchanger into the ground;
FIG. 13 illustrates the next aspect of the driving mechanism;
FIG. 14 schematically diagrams an additional method of inserting the driving tip and heat exchanger into the ground;
FIG. 15 diagrams yet another aspect of the process for insertion of the heat exchanger into the ground;
FIG. 16 diagrams a typical geothermal heat exchanger assembly achievable with the present invention;
FIG. 17A is an oblique view of yet another aspect of the present invention for the driving tip;
FIG. 17B is a perspective view of a new aspect for the water jet;
FIG. 17C is a top plan view of the aspect of the invention shown in previous drawings;
FIG. 18 is a side elevational view of a direct exchanger; and
FIG. 19 is a side elevational view of a delivery tube.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with various aspects of the present invention, there is shown a novel insertion driving tip to be secured onto the end of a concentric tube heat exchanger assembly, a novel fluid flow construction, various novel equipment aspects and methods of driving the heat exchanger assembly into the ground to alleviate any environmental disruption, and numerous other considerations pertinent to the present invention. Specific aspects will be discussed, although there are many ways to utilize the present invention. Certain examples will be more fully described herein below. Any suitable method of driving the insertion tip and heat exchanger assembly into the ground down to the desired heated earth area is feasible and desirable, depending upon the soil conditions and equipment availability. Whether insertion is completed through hand driving, machine driving, hydraulic driving, oscillating hammer driving or jackhammer driving, will depend upon the individual circumstances of the job itself. With that in mind, we now investigate the various aspects of the invention that I have envisioned for success.
Referring now to the drawings in detail, FIG.1 is an environmental view of an operator utilizing a hydraulic insertion method for driving an insertion tip with a heat exchanger assembly appended thereto into the ground. The entire assembly is generally indicated by the numeral 10, which also includes an insertion tip 12 attached to a direct insertion ground loop heat exchanger 14 being driven into the ground by a hydraulic means using a high pressure hose 16 supported by a pipe magazine 18. A hose spool 20 feeds the hose by the power and control unit 22. Pump 24 pumps water from the water reservoir 30 as the motor or battery 28 drives the mechanism. Water reservoir 30 feeds pump 24. A pipe driving pressure transducer 32 senses the resistance of the heat exchanger being inserted into the ground and when it reaches a preset level, reverses the hydraulics to raise the heat exchanger a short distance and then the hydraulics again reverses to continue the downward insertion. This process is repeated and results in an up and down motion on the heat exchanger with the downward stroke distance being the dominant overall motion causing the heat exchanger to be inserted into the earth, driving the insertion tip deeper into the ground, seeking the stable temperature below the surface. Such a hydraulic driving of the direct insertion ground loop heat exchanger into the ground is but one method of insertion into the ground. This method is also very effective at extracting the heat exchanger assembly if necessary, without the need for digging up the dirt around it.
Still looking at FIG. 1, it can be seen that the hydraulic insertion method of the present invention is a complete insertion system with a small mobile footprint including an automatic rapid pipe clamping mechanism, described more fully hereinbelow. Pressure transducer 32 will regulate the up-and-down motion in all relevant soil types and is especially useful when encountering the nearly always present underground obstructions of rocks, tree roots, clay beds, and the like. Pipe magazine 18 is advantageous because it can act as a stabilizing mechanism for the pipe as well as a supply of numerous pipes for consecutive use. Furthermore, such an assembly can be battery or solar powered for quiet and environmentally friendly operations.
Experimentation has shown that to use the direct insertion ground loop heat exchanger of the present invention, it is best to drive the direct insertion ground loop heat exchanger into the ground to a depth of from about 6 meters to 15 meters to find the proper thermal zone to operate a standard heat pump. Further, we have found that it is advantageous to provide between about five to seven, and preferably six, heat exchanger insertions per ton of heat pump capacity depending upon the circumstances and the amount of thermal energy needed for the job.
Looking next to FIG. 2A, a side elevational view of the pertinent portions of the driving tip attached to the bottom of the direct insertion ground loop heat exchanger is generally denoted by the numeral 40, including a driving tip 42 having at least one orifice 44 emerging therefrom in the downwardly facing area. When the driving tip is inserted into the ground, and water flow 50 is flowing out at a rate of from about 8 liters/minute to about 20 liters/minute to soften the ground, obstructions are readily displaced to allow for easier insertion. This side view shows the inner workings of a direct insertion ground loop heat exchanger manufactured in accordance with the present invention. The direct insertion ground loop heat exchanger includes an outer tube 46 with an inner tube 48, providing a cavity for water jet down flow 50 flowing through a separation /termination fitting 54 to fill the water jet tube chamber exit orifices 44 that emits water to soften the ground that the direct insertion ground loop heat exchanger is being inserted into.
After the heat exchanger is inserted into the ground and the heat exchanger system is connected to a heat pump or a heat exchanger for a heat pump, heat exchanger fluid 52 is pumped through the inner tube 48 and escapes through perforations therein to the outer tube 46 and then back up to the surface for use in the heat pump. Heat exchanger fluid 52 enters into the cavity created by the outer tube via perforations in the inner tube 48, to be shown in more detail with relation to FIG. 8 below. Therefore, downflow water used for the insertion process 50 is pumped down through the water jet cavity to the tip 42 and is directed through the separation/termination fitting 54 and then into the water jet flow cavity. When exiting the jet flow cavity through the direct insertion ground loop heat exchanger itself, the downflow fluid becomes pressurized and exits the tip via orifices 44 into the receiving dirt below, thereby softening the dirt and allowing for an easy insertion.
FIG. 2B is a cross sectional view of FIG. 2A, taken along Sectional lines A-A of FIG. 2A, showing the relative placement of the water jet down flow 50 off to the left side via the water jet cavity, and the chambers created between outer tube 46 and inner tube 48 for the egress of heat exchanger fluid 52 through the center, and then up through the annular cavity created between outer and inner tubes 46 and 48, respectively.
It should be noted that there are many variations on the internal configurations for my concentric tube design. The concentric tube system may be a one piece extruded piece, or it may be a multiple piece construction. For the multiple piece construction, it can be a two piece design with separate elements of an outer tube sleeved over an inner tube, or it may even be a three piece design (See FIGS. 17A-17C below), which can be envisioned like a deconstructed version of the one piece extruded model, since there are three combined elements in each of the one, two or three piece designs. Depending upon the efficiencies of manufacturing and design preference, any of these designs will be found to be useful.
Looking next to FIG. 2C there is shown a star-shaped spacer ring, generally denoted by the numeral 204 including a plurality of fins 206 emanating circumferentially from an inner ring structure 208 (Lynn, in FIG. 2C, the elements are designated as 104, 106 and 108. Some of the jackhammer elements have the 104, 106 and 108 designation in FIG.12. This star-shaped spacer ring fits over the inner tube of the concentric tube design described hereinbelow, and includes semi-rigid fins made of plastic or other suitable materials. Star-shaped spacer ring 204 keeps the water flow continuing between the inner tube and the outer tube as it keeps a constant annular area between the inner tube and the outer tube. The flow rate for the heat transfer fluid used in the heat exchanger is dependent on the annular area and volume permitted. Star-shaped spacer ring 204 provides a means for keeping the inner tube equidistant from the outer tube, thereby providing a flow cavity that is maintained at a certain volume. The star-shaped spacer ring may either be glued, heat welded, spun welded or any other suitable method of attaching the star-shaped spacer ring to the inner tube shown in FIGS. 2A and 2B. It is preferred if the star-shaped spacer ring is permanently attached to the inner tube, and may comprise either a short width ring, on the order of ⅛ of an inch, or may be extruded into the inner tube itself, such that it is integrally formed directly into the inner tube material. In order to maintain proper fluid flow levels, these rings 204 may be spaced every 6 inches up to every few feet.
FIG. 3 is a close up illustration of the core concept of my invention, where I have a novel device for the insertion of a pipe designed as a direct insertion ground loop heat exchanger into the ground. Especially useful as a direct insertion ground loop heat exchanger is a high density polyethylene pipe (HDPE), although any suitable pipe may be used. A driving tip 42 is shown with a plurality of exit orifices 44 in position to emit water flow therefrom.
Preferably, the driving tip 42 is made of a steel or steel tipped aluminum, or any other suitable material affixed to HDPE pipe 46. Hence, by the use of downward force, the driving tip 42 penetrates the soil and moves any obstructing objects aside while the water jetting out from orifices 44 will loosen the soil and lubricate the process allowing for more rapid and easy insertion. In this aspect of the invention, an outer tube and an inner tube are used in combination to provide a means of giving exterior strength for support while driving into the ground, as well as providing concentric flow within the heat exchanger. Since the driving action does not require a very high force for insertion into the ground, the outer tube provides sufficient strength.
Still referring to FIG. 3, yet another aspect of the present invention may include one variation, such as a two piece construction or an articulated heat exchanger. The heat exchanger fluid flow pattern will be substantially similar for both of these variations. However, in the two piece variation, it is constructed of two separate pipes or tubes, such that a smaller diameter pipe will fit in one of a larger diameter. In another aspect, a single piece construction may be co-extruded to produce a single pipe or tube with multiple fluid passageways. In the two piece version, the outer tube may be forced into the ground, and thereafter the inner tube may be inserted and sealed to create essentially the same functionality as the one piece extruded aspect. Although certain variations may be made of articulated pipes or tubes, many of the features of the one piece design are still maintained, although more than one extrusion could be employed.
During the insertion process for the two piece heat exchanger aspect, the outer pipe or tube will be inserted into the ground first. In this aspect, water jets are supplied with water throughout the entire volume of the outer pipe. Either during manufacture, or following the insertion, an inner pipe with the downhole plug would be inserted into the outer pipe thereby creating an annular flow profile. In this aspect, the downhole plug will be designed to seal the end of the inner pipe and also to self center the inner pipe by directing the bottom end of the plug into the center of the driving tip by using a male shape cone feature on the plug. To aid in the self centering feature, a female cone is formed on the driving tip, as seen in FIGS. 6-8 below. An optional gasket or sealant may be used at the interface between the downhole plug and the driving tip to ensure a fluid tight seal.
This two piece aspect of the invention, using only the outer tube for ground insertion and removing the driving tip when insertion is completed, may be especially applicable in installing electrical races or irrigation piping under sidewalks and roadways, thereby providing other uses for the present device. Although the one piece design is unlikely to be used for these purposes, the two piece design using the inner tube for ground insertion and ancillary sidewall holes may be used for the production of water point wells, such as those used for drinking water or irrigation water. These types of installations are yet another aspect of the use for the present invention.
As shown in FIG. 2A, the separation/termination fitting 54 in the one piece design is similar in function to the above described downhole plug in order to close off the end of the inner tube, functioning to seal the outer tube, while providing a pathway for the downflow fluid to provide flow to the water jets integral in the driving tip 42. As one might imagine, in the one piece design, a water jet transfer cavity 44 in driving tip 42 would be abandoned for further use in the heat exchanger flow condition, as it is plugged at the tube top once ground insertion is completed.
In order to increase the efficiency of this heat exchanger device, thermal insulation may be added on either the inside or the outside of the inner tube to reduce heat transfer between the downflow fluid and the upflow fluid during the heat exchanger operation. Needless to say, in the heating cycle of a ground source heat pump, the downflow fluid will be at a lower temperature than the upflow fluid, as the upflow fluid will pick up heat from the ground on its way back up. For example, in a northern Michigan application, the downflow fluid would have had the heat removed from it during the heat pump operation, thereby lowering the temperature of the downflow fluid to between about 35 and 50 degrees, while the heat exchanger fluid as it is flowing up will pick upheat to raise the temperature of the heat exchanger fluid to between about 45 to 60 degrees Fahrenheit. This temperature gradient will allow the heat pump to remove the heat from the heat exchanger fluid, and this cooled fluid then becomes the downflow fluid. This is why the downflow fluid is at a lower temperature than the up flowing fluid. Without this temperature gradient, the geothermal heat pump would not be able to operate. As part of the design for both the one piece and two piece variations, the entire device can be engineered and designed to have laminar flow in the downflow inner pipe, thereby reducing heat transfer between the downflow and the upflow fluid streams, as well as reducing pressure drop for lower pump power requirements. This also provides a turbulent flow in the upflow annular area between the inner pipe and the outer pipe to increase heat transfer with the outer pipe and therefore the ground. These features in combination and singly improve the efficiency of the system.
Both one piece and two piece variations preferably use a multiple heat exchanger fluid downflow escape outlet to allow heat exchange fluid to pass from the inner pipe to the outer pipe. These outlets or perforations are described more fully hereinbelow with respect to FIG. 8.
FIG. 4 shows more views of a novel one piece concentric tube design made in accordance with my invention, where the direct insertion ground loop heat exchanger inner tube 48 is shown sleeved within direct insertion ground loop heat exchanger outer tube 46. Such a concentric tube assembly 46 is thereby created. In this aspect of the invention, it can be seen that a single insertion into the ground will achieve bi-directional flow of water, thereby providing a high thermal performance by my simple design. Simply put, the driving tip 42 is attached to the distal end of the direct insertion ground loop heat exchanger assembly, the tip is urged into the ground using the water jets as lubricant, and then the concentric tube design permits the heat exchanger assembly to work in-place, as inserted. A useful aspect of the next FIG. 5 shows how the design acts as a guide and insertion aid.
FIG. 5 is a top plan view of a compression clamping assembly 62 for surrounding the direct insertion ground loop heat exchanger and aiding in ground penetration. As before, the direct insertion ground loop heat exchanger has an inner tube 48 and an outer tube 46 creating a cavity for the upflow water 52 that returns from the bottom after being pumped through the center portion. Most advantageous is the use of a gripping liner 60 within the clamping assembly to help secure the compression clamping assembly around the outer tube 46. Preferably, elastomeric material is used to help grasp the pipe within the pipe clamp assembly. The conformal nature of the elastomeric material is very helpful in securing the pipe within the pipe clamp assembly.
FIG. 6 is an exploded view of the entire assembly, wherein driving tip 42 receives the separation/termination fitting 54 end of direct insertion ground loop heat exchanger inner tube 48 and outer tube 46. Exit orifices in separation/termination fitting 54 (not shown) urges water jet fluid through orifices 44 in driving tip 42. Self-centering conical male end 56 is complementary to a female indent (not shown) inside driving tip 42. This diagram shows how the inner tube 48, with the end plug on the inner tube, fits into driving tip 42 in the two tube option. This is what happens inside the tube after the outer tube is inserted into the ground and the inner tube with the plug end enters the driving tip 42. Hence, this is an . . . exploded view prior to connection of the inner tube with plug end into the driving tip. The plug end is also a separation/termination fitting.
For clarity, FIG. 7 is an even closer view of the separation/termination fitting 54 in relation to inner tube 48 and outer tube 46.
FIG. 8 shows several inner tubes 48 deconstructed to show the perforations 70 and 72 in the respective tubes. A useful thermocouple 74 is shown on one of these aspects to sense downhole temperatures, although it may be optionally used. Perforations 70 and 72 allow downflow water as shown above to go down into the earth, become heated or cooled, and then flow back up through my concentric tube design to bring the heat back up to the surface from the warmer or cooler deeper ground. Consequently, these perforations in the inner tube 48 allow flow from the downflow pipe into and through the annular area created between the inner downflow pipe and the outer upflow pipe.
FIG. 9 is a top plan view of one aspect of a pipe compression assembly constructed in accordance with the present invention, generally denoted by the numeral 80. A left clamping half 82 is hingeably connected to a right clamping half 84 to surround and secure pipe 90 therebetween. When the two halves 82 and 84 are pivoted into place around pipe 90, a securement hook 88 is useful to hook the two clamping halves together and then a compression clamp 86 applies pressure, squeezing the compression assembly around pipe 90 to soundly secure it for the ground insertion by an operator. Once the two clamping halves are secured together, a yoke 92 is useful for the operator to have a handle to finish the ground insertion process.
FIGS. 10A and 10B utilize like reference numerals to show this aspect of the pipe compression assembly, noting that the substantial length of the compression clamp provides sound securement for either driving into the ground or extraction therefrom. Left clamping half 82 is shown opened up in FIG. 10A, where pipe 90 is exposed prior to clamping by right clamping half 84. FIG. 10B shows the compression assembly 80 in a closed configuration. There may be at least one compression clamp 86, although in this configuration, two (2) or more may be advantageous. Considering the length of the left clamping half 82, it is preferable to apply a more even pressure on pipe 90, such that more than one clamp 86 will be more secure.
FIG. 11 now shows the fully constructed preferred pipe compression assembly 80 being used by an operator to insert a direct insertion ground loop heat exchanger into the earth. Using like element numerals to FIGS. 10A and 10B, FIG. 11 now shows a perspective view of the yoke 92 with an attached handle 94 for ease of use by the operator. Again, as mentioned above, there are many suitable methods for inserting pipe 90 into the ground. Providing handle 94 makes many of those aspects possible for a single operator to engage in the insertion without a large number of other contractors or employees to drive up the price of insertion.
FIG. 12 illustrates the use of yet another aspect method of insertion detailed in the present invention, and shows a jackhammer insertion method 100 drilling pipe 102 into the ground by utilizing the above described compression assembly 104 with a driver-to-pipe assembly 106 where jackhammer 108 can be attached. Jackhammer 108 applies force onto driver-to-pipe assembly 106, which transmits force onto the pipe compression assembly 104, and in turn to the pipe 102, thereby driving pipe 102 deeper into the ground.
FIG. 13 details yet another aspect of the method of the present invention, wherein a hydraulic driving platform is used for insertion. Pipe 90 may be securely clamped by my pipe compression assembly with left clamping half 82 mated against right clamping half 84, surrounding pipe 90. A hydraulic ram 110 applies downward and upward force through ram slide and connector 112 onto pipe compression assembly 80, urging pipe 90 into the ground using an up-and-down motion with the downward motion distance being dominant. Instead of mechanically clamping the two halves, this can also be accomplished by hydraulically closing half 82 and half 84 and compressing the heat exchanger pipe 34 (FIG. 1), thereby reducing the manual operation time. Any other suitable method may be employed.
FIG. 14 shows yet another mechanism and method of inserting the heat exchanger into the ground in accordance with another aspect of the invention. A tilted track pipe compression and drive unit for angular insertion is generally denoted by the numeral 120, wherein the heat exchanger pipe 132 is inserted with a bi-directional pipe motion indicated by 122. Utilizing a grooved pipe track, an easier method for insertion into the ground may be accomplished over the previously described hydraulic ram insertion method because in the hydraulic ram method, although it is very useful, a compression fitting must be repeatedly encased and compressed around the heat exchanger pipe, and the hydraulic ram is then used to insert the pipe deeper into the ground. Then the compression fitting must be released and raised up to as high as it can on the heat exchanger pipe and then the hydraulic ram is then reactivated and more of the pipe is inserted into the ground. Needless to say, this action of utilizing the compression clamp and pushing down until it hits the ground, then releasing and pulling it back up to the top recompressing, and pushing the pipe back down into the ground is a time consuming and labor intensive method. In the present aspect, the pipe compression and drive unit utilizes a grooved pipe track compression and drive 126 that utilizes a pressure transducer 124. Grooved pipe track 124 grips a grooved pipe track compression and drive 128 aids in providing the bi-directional pipe up and down motion 122 such that there is no need for any clamping and reclamping of any compression fittings. Rather, the groove pipe track generates enough friction to drive the heat exchanger pipe into the ground in its desired position. In this aspect, there is shown a one piece ground insertion heat exchanger drive point and tube assembly 132 attached to a hose to heat exchanger connector 134 for use with the water jets coming out of tip 130 at the distal end of the heat exchanger pipe. A high pressure hose 136 is in communication with the heat exchanger connector 134. Heat exchanger pipe magazine 140 is pivoted at pivot point 142 in order to facilitate the tilting of the tilt track drive unit 120. As with the hydraulic system, power unit 150, whether it is an internal combustion engine or a battery or any other source of power, is connected to a driving lubricant and grout or water reservoir and a water pump 154. A hose reel 156 feeds a high pressure hose to provide the water, lubricant, grout, or any combination thereof, during insertion. Although water will be the primary fluid used in most insertions, any other environmentally friendly lubricant could be used in some instances, or grout can also be used. If the heat exchanger is ever to be removed, the grout would be used to seal the hole during the desertion process. In any of the insertion processes described herein, any of these lubricants, grouts, or water may be used, along with combinations of these materials, or any other suitable fluid. Even though these various fluids may not have been described for each installation or insertion method, all suitable fluids are envisioned by the present invention, and should not be limited.
Looking next to FIG. 15, there is shown yet a further aspect of the present invention including a wheel pipe compression and drive unit generally denoted by the numeral 200 as an another method of inserting the direct insertion ground loop heat exchanger 218 into the ground with a driving tip 216. A pipe driving pressure transducer 210 works in combination with the wheel pipe compression and drive unit 212 to affect a bi-directional pipe motion 214, thereby inserting the heat exchanger driving tip 216 into the ground. As in the other aspects, a high pressure hose 220 is connected to a hose spool 236 run by a pump 234. Pump 234 receives its water or lubricant from a driving water/lubricant reservoir 232 and is powered by power supply 230, whether it is an internal combustion engine or battery. The water reservoir 240 provides water to the pump for use in the high pressure hose inside the heat exchanger 218 after insertion and provides water to emanate from the driving tip to aid in insertion. Typically, pump 234 pumps water from a water reservoir 240 as the motor or battery 230 drives the mechanism.
FIG. 16 illustrates a ground insertion heat exchanger loop system layout generally denoted by numeral 300, and includes vertically inserted ground loop heat exchanger 302 with interconnects with horizontal conduits 304 to provide an entryway 306 into house 308. Of course such a heat pump can be utilized with any building. The number of vertical ground loop heat exchanger elements 302 that will be useful for any application is to be determined by the engineers which design, engineer and install the geothermal heat pump system for any particular building. Of course, a small building with lower heating and cooling requirements would require fewer heat exchanger elements 302 than a large building.
With combined reference to FIGS. 17A, 17B and 17C, a three piece tube design in accordance with the present invention is shown. A concentric tube configuration is generally denoted by the numeral 400, including an outer tube 410 with a perforations 411 at the end of inner tube 412 therein. The downflow and upflow characteristics are the same as the earlier discussions with regards to one piece and two piece concentric tube configurations. Furthermore, inside outer tube 410 is the third piece of the three piece system, and that third piece is a water jet supply tube 414. At the most distal end of concentric tube 400 is a separation/termination fitting 416 having an orifice 417 formed therein to provide liquid down through the driving tip 418. Orifices 420 permit the egress of lubricating fluid 422, whether it be simply water or any other type of lubricating fluid, or grout to aid in sealing up the system. As one can imagine, the three pieces described here are the functional equivalents of the components of the one or the two piece construction described above.
FIG. 17B illustrates a depiction of the distal ends of water jet supply tube 414 and the inner tube 412 as being fusion welded to separation/termination fitting 416. The fusion weld connection 440 may be made during construction at the manufacturing facility or it may be made in the field. Water jet supply tube 414 and the inner tube 412 may be secured to the separation/termination fitting 416 in any suitable manner, including spin welding, fusion welding, ultrasonic welding, gluing or any other contact cement that may be advantageous. The water jet supply tube 414 should line up with the orifice 417 in the separation/termination fitting 416, so that the water travelling down the water jet supply tube 414 will be jetted out through orifices 420 of driving tip 418. Typically, the driving tip is thereafter secured to the outer tube, ready for insertion into the ground.
Looking now to FIG. 17C, the star-shaped spacer ring 430 is shown from the top in relation to the placement of water jet supply tube 414. During manufacture, inner tube 412 receives a plurality of star-shaped spacer rings 430 around its circumference. As described hereinabove, the star-shaped spacer rings help to keep the flow rate constant by centering the inner tube 412 within outer tube 410 (not shown in this FIG). Numerous spacer rings 430 are advantageous to keep the spacing between the inner tube 412 equidistant and in place. Water jet supply tube 414 can be inserted next to inner tube 412, and the star-shaped spacer ring can be made with a circular profile such that the water jet supply tube is accommodated and can be snugged between two of the circular shaped fins 440 of star-shaped spacer ring 430. These spacer rings can be used in any frequency desired to hold the inner tube 412 within outer tube 410. Typically the spacer rings will be anywhere from ⅛ inch in width to about one inch in width. Clearly, any number of them may be utilized. In addition to the fact that this invention provides for easy insertion into the ground, one must take notice of the fact that the tube inserted into the ground can also be easily extracted from the ground, as well. Unlike bored wells and pipes in trenches, which are very difficult, if not nearly impossible to extract once they have been inserted, the present invention provides a convenient, easy and effective means and devices for extraction. Bored wells and pipes in trenches are traditionally abandoned in their inserted location due to the difficulty of retrieving them. Since the equipment embedded into the ground is relatively costly, retrieval makes imminent economic sense, and is therefore a very desirable attribute for these systems. Especially helpful is the up-and-down movement of the various insertion methods, where a heat exchanger can easily be dislodged from its seat. Once movement starts throughout the length of the inserted heat exchanger, then extraction becomes relatively easy to accomplish.
As for using the present invention in accordance with a new business model, it is envisioned that this invention and its methods are particularly suitable for franchising to contractors wishing to have a new business for low cost direct insertion of any type of underground tubing, but of course especially for ground loop heat exchangers in order to enable usage of geothermal heat pump heating and cooling systems for buildings. As the present method of insertion by utilizing the inventive devices of the driving tip with water jet orifices and the concentric tube upflow and downflow heat exchanger system, the direct labor and materials costs are dramatically reduced over the prior art. Conventional methods for inserting heat exchangers are disruptive to the neighboring landscape and potentially building foundations and/or swimming pools, and etc. The present invention is much quieter, and merely disrupts a few inches of the topsoil rather than requiring massive digging and boring operations. In fact, even the equipment that is made possible by the present invention of the driving tip insertion device along with the concentric tubing is so much smaller and less weight, it can be rolled over septic tanks and sewer pipes that may be underground. Previously, the excavation and boring equipment utilized for inserting the ground loop heat exchanger could easily crack any underground pipes, plumbing or crack foundations when the vibration got to be too much if the machine got to close to a home, swimming pool, driveway, culverts, or the like.
Therefore, a novel business method is proposed for utilizing the services of an equipment leasing company to purchase the various aspects and/or variations of the compression and drive units described in greater detail hereinabove, along with the provision of the manufactured concentric tube and the novel driving tip to be attached to the bottom of the concentric tube.
The method of insertion may include two aspects, whether a first outer tube is initially inserted and then followed by the insertion of an inner tube which is kept in place by a spacer ring, or a single tube may be inserted that is a coextruded piece having three separate openings as described above. Any of the insertion equipment that is described with reference to FIGS. 1, 14 or 15, may be leased to a contractor along with provisions to that same contractor of the one or two piece heat exchanger tube systems in conjunction with the driving tip having water jet orifices for insertion into the ground. This type of franchise would be potentially very profitable, and therefore desirable to contractors looking to expand their contracting businesses. In the event that a contractor would like to place any kind of tubing close to a building or at an angle under a sidewalk or through rough terrain including rocks and/or clay, the present invention would be ideal to be leased and enable that contractor to expand his business to include the ancillary methodologies, including activities such as insertion of water point or irrigation wells, or any investigational procedure that the contractor may want to tap into, such as a water aquifer or a water pocket under the ground.
In that regard, the present invention may also be used in another aspect for simplifying the insertion of a monitoring device or for further investigational processes such as the use of the previously described novel driving tip to combine water jetting displacement capability with the novel driving process. My system can be used as a probe and has been found to be very useful in finding underground objects, such as septic tanks and the like, without the need for digging holes. Since the novel driving tip and the rest of the configuration of my invention can be used very quickly, utility can be realized for many operations. Given the system's ability to quickly penetrate the ground, the outer tube can be inserted into the ground by only using human power and up-and-down motion. In this aspect, the quick insertion feature may be useful for finding objects that are up to 10 feet underground or, if deeper insertion is needed, it may be utilized with the more highly mechanized installation trailer described hereinabove using my water jetting feature in combination with the up-and-down motion to probe for objects at levels deeper than 10 feet.
Looking now at FIG. 18, yet another aspect of the present invention is generally denoted by the 500, and includes a direct exchanger, rather than a fluid exchange heat loop system. A driving tip 502, similar to those disclosed herein above with regards to FIG. 2A especially, includes orifices 504 through which water is jetted in order to provide for easy insertion into the ground. After water is injected down outer tube 506 through cavity 508, a direct heat exchanger 512 may be inserted into cavity 508 and may thereafter be backfilled with grout 510. Grout 510 is preferably a heat transferring material, but maybe any material that will maintain temperature once it is inserted into the ground. In the other aspects of my invention, water is used as the exchange medium, but in this aspect, a solid or semi solid material 510may be embodied as grout in order to stabilize the heat exchanger, as well as to provide a thermal transfer material to come in direct contact with the direct heat exchanger 512. This invention envisions many aspects including solid materials, semisolid materials, or any type of suitable grout that can provide heat transfer without the need for water and other fluid exchanges.
Next we refer to FIG. 19, showing yet another aspect of the present invention as a delivery tube generally denoted by 600. Using the same driving tip 602 as previously used in figures before this, rather than planting a heat exchanger in the middle of it, a sensor 216 is inserted into the outer 2606 and may be utilized to collect information, such as whether or not water is leaking into the system, or gaseous components may be detected, or any other type of sensor configuration that may be desired. Again, driving 602 would include aim plurality of orifices 604 and a water would be injected from the top above the ground through outer tube 606 and how the orifices 604 in order to place the delivery tube 600 below the surface of the ground. Thereafter, sensor 612 could be dropped down through the outer tube 606 leaving the interior cavity 610 either empty, or filled with any type of desirable material, depending upon the application being sought. Sensor 612 may especially include monitoring devices for temperature, groundwater quality or for any other purpose of any construction that might fit into the inner diameter of our outer tube.
Using this simple design, heat exchangers that are closed loop systems, whether using water, or a water and anti-freeze solution or a refrigerant-based fluid or gas, may be inserted into the outer tube with the remaining space in the tubing being filled with water, the water and anti-freeze solution, or it actually may be filled with grout to facilitate heat transfer between outer tube 606, which is in thermal communication with the ground, and any heat exchanger or sensor that may be inserted into the outer tube.
In its most simple design, and by using only the outer tube and the water jetting displacement capability of my novel driving tip, my system can be also used as a probe useful for finding underground objects, such as the location of a septic tank. This operation can be done quickly and efficiently without the need for digging holes, which is the current technology. Given my system's ability to quickly penetrate the ground, the outer tube can be inserted into the ground by only using human power and emulating the up and down motion for shallow probes, or it may utilize the installation trailer described herein above using water jetting to probe for objects it deeper locations.
Therefore, in its most preferred aspect for use in the field of geothermal installations, disclosed is a direct insertion ground loop heat exchanger, comprising an at least partially hollow pointed driving tip having at least one orifice therethrough for dispersing water through the driving tip to ease insertion into the ground, such that placing the driving tip onto the ground and urging water through the orifices will separate and part the ground easily, permitting the insertion of the driving tip deeper and deeper into the ground and a hollow outer tube having an inner diameter attached to the driving tip, said tube extending upwardly from out of the driving tip and terminating above the ground for accessibility. The driving tip is preferably made of at least a semi-rigid material, such that the driving tip will not collapse upon insertion into the ground. The at least semi-rigid material is preferably made of a strong material resistant to crushing, such as a metal, or a high durometer plastic, a ceramic, or any other suitable hard material, or any combination thereof.
The at least one orifice is preferably evenly distributed around the outside surface of the driving tip in order to ensure even insertion into the ground. Further, the outer tube is preferably made of a semi flexible material, such as polyethylene, polyurethane, rubber, or any other suitable high-strength plastic. Within the outer tube, a concentrically located inner tube may be found within the inner diameter of the hollow outer tube, and within the concentrically located inner tube may be a heat exchanger, such that fluid can be urged downward into the warmer portion of the earth between the hollow outer tube and the concentrically located inner tube, and where the heat that is transferred from the warm earth to the heat transfer fluid flows back up to the surface for heat extraction. This fluid may be a heat transfer fluid as described more fully hereinabove, in order to carry heat from deep in the earth back up to the surface such that the heat may be extracted for geothermal implications.
In summary, numerous benefits have been described which result from employing any or all of the concepts and the features of the various specific embodiments of the present invention, or those that are within the scope of the invention.
The foregoing description of various preferred aspects of the invention have been presented for purposes of illustration and description. It is not intended to be exhaustive, nor to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings with regards to the specific aspects. These various aspects were chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various aspects and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims which are appended hereto.
INDUSTRIAL APPLICABILITY
The present invention finds utility for inserting a hollow tube into the ground without disturbing large amounts of real estate, and more particularly, the present invention is especially useful for the insertion of vertical ground loop heat exchanger installations.
Patent Application
20170268803
