Heat Exchange Panel

Abstract

A heat exchange panel (1) that includes a lower plate (11) and an upper plate (14) that together define a plurality of channels (51) there-between, which are in fluid communication with a plurality of upper plate extension passages (72), is described. The lower plate (11) includes a plurality of lower plate extensions (20) that extend upwardly from the interior surface (17) of the lower plate. Each channel (51) has at least one lower plate extension (20) extending upwardly therefrom. The upper plate (14) includes a plurality of upwardly extending hollow upper plate extensions (32). The aperture (42) and interior hollow space (48) of each upper plate extension (32) is aligned with and receives an upper portion (69) of a single lower plate extension (20) therein. A portion of the interior surfaces (45) that define the interior hollow space (48) of the upper plate extension (32), and a portion of the exterior surfaces (23) of the upper portion (69) of the lower plate extension (20) received within the interior hollow space (48) together define, in each case, an upper plate extension passage (72). Each upper plate extension passage (72) is in fluid communication with a channel (51) residing there-under. In operation, a fluid introduced into a terminal inlet (54) of a channel (51) passes through each upper plate extension channel (72) in fluid communication with that channel, and passes out from the terminal outlet (57) of the channel. The combination of a plurality of upper plate extension passages (72) and channels (51) in common fluid communication provide the heat exchange panel of the present invention with improved heat exchange efficiencies.

Description

FIELD OF THE INVENTION

The present invention relates to a heat exchange panel that includes a lower plate and an upper plate that when joined together form a plurality of channels that are in fluid communication with a plurality of upper plate extension passages. The lower plate has a plurality of upwardly extending lower plate extensions, and the upper plate has a plurality of upwardly extending hollow upper plate extensions. Each channel includes at least one lower plate extension extending upwardly therefrom, and each upper plate extension is positioned so as to receive an upper portion of one lower plate extension therein. The interior surfaces of the hollow upper plate extension and the exterior surfaces of the lower plate extension received therein together define an upper plate extension passage that is in fluid communication with an underlying channel. The combination of upper plate extension passages and channels provide the heat exchange panel of the present invention with improved heat exchange capabilities. The heat exchange panel of the present invention may be a solar heat exchange panel.

BACKGROUND OF THE INVENTION

Heat exchange panels, such as solar heat exchange panels, typically include a plurality of channels through which a fluid, such as a heat exchange fluid (e.g., water) is passed. Typically, a heat exchange panel is oriented so as to expose the exterior surfaces of the channels thereof to a source of thermal energy, such as radiant heat (e.g., the sun). The channels are heated by exposure to the heat source, and thermal energy is transferred to the fluid passing through the interior of the channels. The heated fluid may be used directly (e.g., in the case of a heated shower) or indirectly, e.g., to heat another fluid, such as air or water, in which case the heated fluid is typically described as a heat exchange fluid.

Optimizing the design of a heat exchange panel for purposes of improved efficiency, typically involves attempting to balance a number of factors, including, for example: maximizing thermal transfer (i.e., of thermal energy into the heat exchange fluid within the channels); maximizing the volume of heat exchange fluid passing through the panel; and at the same time minimizing the dimensions of the panel (e.g., width and length). The factors of maximum thermal transfer, maximum heat exchange fluid through-put, and minimum panel dimensions, are generally incompatible. For example, as the rate of fluid through-put is increased, the amount of thermal energy transferred into the heat exchange fluid is typically decreased. In addition, as the dimensions of the panel are decreased, the amount of thermal energy transferred into the heat exchange fluid is typically also decreased. As such, attempting to arrive at a favorable balance between such incompatible factors generally results in heat exchange panel designs having less than optimum efficiencies.

Attempts have been made to improve the efficiency of solar heat exchange panels by increasing the surface area of the exterior channel surfaces that are exposed to radiant energy. For example, solar heat exchange panels having V-shaped or triangular shaped exterior channel surfaces have been disclosed. See for example, U.S. Pat. Nos. 4,290,413; 4,243,020; and 4,171,694.

It would be desirable to develop new heat exchange panels having improved efficiencies. In particular, it would be desirable that such newly developed heat exchange panels provide a favorable balance and coupling of factors including, optimum thermal transfer, optimum heat exchange fluid through-put, and minimum panel dimensions. In addition, it would be further desirable that such newly developed heat exchange panels lend themselves to relative ease of manufacture, assembly and use.

SUMMARY OF THE INVENTION

These needs are met by providing a heat exchange panel that includes at least a lower plate having an interior surface, and a plurality of lower plate extensions extending upwardly from (e.g., away from or outward from) said interior surface of said lower plate, each lower plate extension having exterior surfaces; and an upper plate having an interior surface, an exterior surface,

and a plurality of upper plate extensions extending upwardly from (e.g., away from or outward from) said exterior surface of said upper plate, each upper plate extension having an aperture on said interior surface of said upper plate and interior surfaces that define an interior space that is in fluid communication with said aperture, wherein said lower plate and said upper plate are joined together such that said interior surface of said lower plate and said interior surface of said upper plate together define a plurality of channels, each channel having a terminal inlet and a terminal outlet, each channel having at least one lower plate extension residing therein and extending upwardly therefrom (and, correspondingly, there-above), and each channel having the aperture and the interior space of at least one upper plate extension positioned over said channel and in fluid communication with said channel, the aperture and interior space of each upper plate extension being aligned with and receiving an upper portion of one lower plate extension therein (i.e., within the interior space of the so-aligned upper plate extension), a portion of the interior surfaces defining the interior space of said upper plate extension and a portion of the exterior surfaces of the upper portion of said lower plate extension received within said interior space, in each case, together defining an upper plate extension passage, each upper plate extension passage being in fluid communication with the channel residing there-under, and further wherein a fluid introduced into the terminal inlet of said channel passes through each upper plate extension passage in fluid communication with said channel and emerges from said terminal outlet of said channel.

The features that characterize the present invention are pointed out with particularity in the claims, which are annexed to and form a part of this disclosure. These and other features of the invention, its operating advantages and the specific objects obtained by its use will be more fully understood from the following detailed description and accompanying drawings in which preferred (though non-limiting) embodiments of the invention are illustrated and described.

As used herein and in the claims, terms of orientation and position, such as, “upper”, “lower”, “inner”, “outer”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, and similar terms, are used to describe the invention as oriented and depicted in the drawings. Unless otherwise indicated, the use of such terms is not intended to represent a limitation upon the scope of the invention, in that the invention may adopt alternative positions and orientations.

Unless otherwise indicated, all numbers or expressions, such as those expressing structural dimensions, quantities of ingredients, etc., as used in the specification and claims are understood as modified in all instances by the term “about”.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representative perspective view of a heat exchange panel according to the present invention.

FIG. 2 is a representative top plan view of the heat exchange panel of FIG. 1.

FIG. 3 is a representative perspective view of a longitudinal section of the heat exchange panel of FIG. 1.

FIG. 4 is a magnified representative perspective view of a portion of the longitudinal section of the heat exchange panel of FIG. 3.

FIG. 5 is a magnified representative elevational view of a portion of the longitudinal section of the heat exchange panel of FIG. 3.

FIG. 6 is a representative perspective view of a lateral section of the heat exchange panel of FIG. 1.

FIG. 7 is a magnified representative perspective view of a portion of the lateral section of the heat exchange panel of FIG. 6.

FIG. 8 is a magnified representative elevational view of a portion of the lateral section of the heat exchange panel of FIG. 6.

FIG. 9 is a magnified representative perspective view of an interior portion of a corner of the sidewall structure of the heat exchange panel of FIG. 1.

FIG. 10 is a perspective view of an exploded representation of the heat exchange panel of FIG. 1.

FIG. 11 is a representative perspective view of the interior surface side of the lower plate of the heat exchange panel of FIG. 1.

FIG. 12 is a representative top plan view of a portion of the interior surface side of the lower plate of the heat exchange panel of FIG. 11, showing a lateral passage in a rib.

FIG. 13 is a magnified representative perspective view of a portion of the interior surface side of the lower plate of the heat exchange panel of FIG. 11.

FIG. 14 is a representative perspective view of the interior surface side of the upper plate of the heat exchange panel of FIG. 1.

FIG. 15 is a magnified representative perspective view of a portion of the interior surface of the upper plate of the heat exchange panel of FIG. 14.

FIG. 16 is a perspective view of an outside corner of the sidewall structure of the heat exchange panel of FIG. 1 in which some of the terminal outlets of the channels are visible within the outlet header.

FIG. 17( a) is a representative sectional view of a portion of a heat exchange panel according to the present invention in which the ribs are formed by lower plate ribs.

FIG. 17( b) is a representative sectional view of a portion of a heat exchange panel according to the present invention in which the ribs are formed by upper plate ribs.

FIG. 17( c) is a representative sectional view of a portion of a heat exchange panel according to the present invention in which the ribs are formed by abutment of lower and upper plate ribs.

FIG. 17( d) is a representative sectional view of a portion of a heat exchange panel according to the present invention in which the ribs are formed by a combination of non-abutting lower and upper plate ribs.

FIG. 17( e) is a representative sectional view of a portion of a heat exchange panel according to the present invention in which the ribs are separate from and abuttingly interposed between the upper and lower plates.

FIG. 18 is a representative top plan view of the interior surface side of the lower plate of the heat exchange panel of FIG. 11.

FIG. 19 is a further magnified representative elevational view of a portion of the lateral section of the heat exchange panel of FIG. 8, showing a sectional view of a portion of the sidewall structure.

FIG. 20 is the representative perspective view of a lateral section of the heat exchange panel of FIG. 8, further including a plate abutting the upper terminus of the sidewall structure.

In FIGS. 1 through 20, like reference numerals designate the same components and structural features, unless otherwise indicated.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawing Figures (e.g., FIGS. 1, 4, 5, 10 and 14) the heat exchange panel 1 of the present invention includes a lower plate 11 and an upper plate 14. Lower plate 11 has an interior (or upper) surface 17 and a plurality of lower plate extensions 20 extending upwardly (or outwardly) from interior surface 17. Lower plate 11 also has an exterior (or lower) surface 35 (not shown or visible in perspective in the drawings).

Upper plate 14 has an interior (or lower) surface 26 (FIGS. 14 and 15), an exterior (or upper) surface 29 and a plurality of upper plate extensions 32 each extending upwardly (or outwardly) from exterior surface 29 thereof. Each upper plate extension 32 also has an exterior surface 38. Each upper plate extension 32 has an aperture 42 on interior surface 26 of upper plate 14, and interior surfaces 45 that define an interior space 48. For each upper plate extension 32, the interior space 48 thereof is in fluid communication (or is continuous) with the aperture 42 thereof. See FIGS. 14 and 15. As such, each upper plate extension 32 is a hollow upper plate extension having an interior hollow space 48, defined by interior surfaces 45 thereof, which is in fluid communication with the aperture 42 thereof on interior surface 26 of upper plate 14.

Lower plate 11 and upper plate 14 are joined together such that interior surface 17 of lower plate 11 and interior surface 26 of upper plate 14 together define a plurality of channels 51 there-between. Each channel 51 has a terminal inlet 54 and a terminal outlet 57. The terminal inlets 54 and outlets 57 of the channels are both only partially visible in the assembled/non-exploded representations of heat exchange panel 1 of the drawings (e.g., FIG. 3). A partial representation of terminal inlets 54 and outlets 57 is depicted in the exploded representation of FIG. 10, and the representation of lower plate 11 alone in FIG. 11. A depiction of some terminal outlets 57 is provided in FIG. 16. Terminal inlets 54 of heat exchange panel 1 are substantially similar to terminal outlets 57, as depicted in FIG. 16.

The channels may each independently define (e.g., trace out) any suitable path between opposite ends of the heat exchange panel (and the terminal inlets and outlets thereof), such as substantially straight (or longitudinal) paths, serpentine paths, arcuate paths, angular paths, or any combination thereof. Typically, each channel defines (or has) a substantially straight path between opposite ends of the heat exchange panel (and the terminal inlet and outlet thereof), and accordingly each channel is a substantially longitudinal (or straight) channel (as depicted in the drawings).

For a given channel, the terminal inlet and terminal outlet thereof are positioned at (or on) opposite ends of the heat exchange panel. The designation of terminal inlet or terminal outlet with regard to a channel is determined with regard to whether a fluid is introduced therethrough (in which case it is a terminal inlet) or exits therefrom (in which case it is a terminal outlet). As such, all of the terminal inlets may be located on the same end (e.g., an inlet end 60) of the heat exchange panel, and all of the terminal outlets may correspondingly be located on the same (more particularly, the other/opposite) end (e.g., an outlet end 63) of the heat exchange panel. Alternatively, some of the terminal inlets and some of the terminal outlets may be located at/on the same end of the heat exchange panel, in which case a fluid may flow in opposite directions through separate channels of the heat exchange panel.

Each channel 51 has at least one lower plate extension 20 residing therein and extending upward (or outward) therefrom. More typically, each channel 51 has at least two lower plate extensions 20 residing therein and extending upward therefrom. When two or more lower plate extensions reside in and extend upward from a given channel, the lower plate extensions are typically spaced separately from each other within (or along) the channel. The lower plate extensions may be spaced at regular (e.g., linearly even/equivalent) or non-regular (e.g., linearly uneven/non-equivalent) internals within a particular channel. Typically, and as depicted in the drawings, the lower plate extensions 20 are spaced separately from each other at substantially regular (or linearly even/equivalent) intervals within each channel 51.

As each lower plate extension 20 resides within and extends upwardly from a channel 51, each lower plate extension 20 has a lower portion 66 that resides within the channel 51, and an upper portion 69 that extends upwardly from and above the channel 51. See, for example, FIGS. 4 and 13.

Each channel 51 has at least one upper plate extension 32 positioned there-over. In particular, each channel 51 has the aperture 42 and correspondingly the interior space 48 of at least one upper plate extension 32 positioned there-over, such that the aperture 42 and interior space 48 thereof are in fluid communication with the underlying channel 51. See, for example FIG. 5. More typically, two or more upper plate extensions are so positioned over a given (and underlying) channel, as depicted in the drawings.

With the upper plate extensions so positioned over the underlying channels, the aperture 42 and interior space 48 of each upper plate extension 32 is aligned with and receives an upper portion 69 of one (i.e., a single) lower plate extension 20 therein (i.e., within the interior space 48 of the so-aligned upper plate extension 32). See, for example, FIG. 4. As such, with the upper portion of a lower plate extension so received therein, the interior space and aperture of the aligned upper plate extension are typically not alone (or freely/unobstructively) in communication with, but rather may be described as being obstructively in communication with, the underlying channel 51, as will be described in further detail herein with regard to the upper plate extension passages.

For each lower plate extension 20 and upper plate extension 32 associated pair, a portion of the interior surfaces 45 that define the interior space 48 of the upper plate extension 32 (e.g., inlet surface 75 and outlet surface 78), and a portion of the exterior surfaces 23 of the upper portion 69 of the lower plate extension 20 received within interior space 48 (e.g., inlet face 81 and outlet face 84), together define there-between an upper plate extension passage 72. Each upper plate extension passage 72 is in fluid communication with the longitudinal channel 51 that resides there-under. See, for example, FIGS. 4 and 5. Typically, as a portion (e.g., an abutting portion, such as first and second side faces) of the exterior surfaces of each lower plate extension abuts a portion (e.g., an abutting portion, such as first and second side surfaces) of the interior surfaces of the upper plate extension into which it is received, only a portion (e.g., a non-abutting portion, such as inlet and outlet faces 81 and 84) of the exterior surfaces of the lower plate extension and a portion (e.g., a non-abutting portion, such as inlet and outlet surfaces 75 and 78) of the interior surfaces of the upper plate extension together define each upper plate extension passage, as will be discussed in further detail herein.

The lower plate includes a plurality of lower plate extensions. For example, the lower plate may include a total number of lower plate extensions of from 5 to 500, typically from 25 to 400, and more typically from 50 to 300. Since each lower plate extension is typically received within the interior space of an upper plate extension, the upper plate generally includes a total number of upper plate extensions that is substantially equivalent to the total number of lower plate extensions of the lower plate. For example, the upper plate may include a total number of upper plate extensions of from 5 to 500, typically from 25 to 400, and more typically from 50 to 300. With each lower plate extension typically being received within the interior space of an upper plate extension, the lower plate and upper plate extensions together form a plurality of associated pairs of lower plate extensions and upper plate extensions. The heat exchange panel typically includes a total number of associated pairs of lower plate extensions and upper plate extensions that is equal to the total number of lower plate extensions or the total number of upper plate extensions. For example, the heat exchange panel may include a total number of associated pairs of lower plate extensions and upper plate extensions of from 5 to 500, typically from 25 to 400, and more typically from 50 to 300.

With the lower plate 11 and the upper plate 14 joined together, as described in detail above, there is defined a plurality of channels 51 between the interior surfaces thereof (17 and 26), and at least one upper plate extension passage 72 that is in fluid communication with the channel 51 there-under. As such, for each channel 51, a fluid (e.g., water) introduced into the terminal inlet 54 thereof, passes through the channel 51 and each upper plate extension passage 72 in fluid communication there-with, and accordingly emerges from the terminal outlet 57 of that channel.

Since each upper plate extension is associated with and receives within its interior space the upper portion of a lower plate extension, the spacing of the upper plate extensions relative to each other along an underlying channel is substantially the same as that of the associated lower plate extensions within that same channel. More particularly, the upper plate extensions may be spaced at regular (e.g., linearly even/equivalent) or non-regular (e.g., linearly uneven/non-equivalent) internals along (or over) a particular channel. Typically, and as depicted in the drawings, the upper plate extensions 32 are spaced separately from each other at substantially regular (or linearly even/equivalent) intervals along (or over) each underlying channel 51.

The lateral arrangement of lower plate extensions as between (or across) different channels (e.g., adjacent/neighboring channels, or alternating channels) of the heat exchange panel may be selected from regular patterns, non-regular (or irregular) patterns and combinations thereof. Typically, the lateral arrangement of lower plate extensions across different channels of the heat exchange panel is selected from regular patterns. More particularly, as between neighboring (or adjacent) channels, the lateral arrangement of neighboring lower plate extensions may be selected from substantially laterally aligned arrangements, laterally offset (or staggered) arrangements, and combinations thereof. In a particular embodiment of the present invention, the channels of the heat exchange panel are longitudinal channels, and the lateral arrangement of neighboring lower plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements. That is, each lower plate extension is laterally staggered (rather than laterally aligned) relative to each neighboring lower plate extension of an adjacent channel, as depicted in the drawings.

With reference to FIG. 18, lower plate extension 20(a) of channel 51(a) is laterally staggered relative to neighboring lower plate extension 20(b) of adjacent channel 51(b). Correspondingly, lower plate extension 20(b) of channel 51(b) is laterally staggered relative to neighboring lower plate extension 20(a) of adjacent channel 51(a). Channel 51(a) and channel 51(b) are neighboring or adjacent channels. Neighboring lower plate extensions are free of one or more lower plate extensions interposed there-between.

In an embodiment of the present invention: the channels of the heat exchange panel are longitudinal channels; the lateral arrangement of neighboring lower plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements; and additionally, the lateral arrangement of each lower plate extension, as between each first channel and each third channel (equivalently, every other channel, or alternating pairs of channels), is selected from substantially laterally aligned arrangements. Each first channel and each third channel is separated by an interposed and common neighboring channel. Equivalently, each alternating pair of channels is separated by an interposed and common neighboring channel. With reference to FIG. 18, lower plate extension 20(a) of channel 51(a) (here a first channel) is substantially laterally aligned relative to lower plate extension 20(c) of channel 51(c) (here a third channel). Correspondingly, lower plate extension 20(c) of channel 51(c) (here a first channel) is substantially laterally aligned relative to lower plate extension 20(a) of channel 51(a) (here a third channel). Channel 51(b) is interposed between and is a common neighboring channel relative to each of channel 51(a) and channel 51(c). Channels 51(a) and 51(c) may also be described as an alternating pair of channels, having an interposed and common neighboring channel 51(b) there-between.

In an embodiment of the present invention: the channels of the heat exchange panel are longitudinal channels; the lateral arrangement of neighboring lower plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements; and additionally, as between any three sequentially adjacent channels, the lower plate extensions have a repeating pattern comprising in each case five (5) lower plate extensions arranged in a lower plate extension X-configuration having a single terminal lower plate extension at each of the four corners (or terminal points) of the X-configuration, and a single central lower plate extension at the center (or intersection) of the X-configuration. The lower plate extensions accordingly form a plurality of lower plate extension X-configurations. Each lower plate extension X-configuration is typically a substantially symmetrical X-configuration. With reference to FIG. 18, an X-configuration 87 of lower plate extensions is illustrated across sequentially adjacent channels 51(a), 51(b) and 51(c). The lower plate extension X-configuration 87 includes a single terminal lower plate extension 20(d), 20(e), 20(f) and 20(g) at each of the four corners of the X-configuration, and a single central lower plate extension 20(h) at the center or intersection of the X-configuration. Three sequentially adjacent channels typically include a first channel, e.g., channel 51(a), a third channel, e.g., channel 51(c), and a second channel, e.g., channel 51(b) interposed between and being a neighboring channel to (or adjacent to) each of the first and second channels. For purposes of further illustration, regarding lower plate extension X-configuration 87: the terminal or corner lower plate extensions 20(d) and 20(f) each reside within first channel 51(a); the terminal or corner lower plate extensions 20(e) and 20(g) each reside within third channel 51(c); and the center lower plate extension 20(h) resides within the second channel 51(b), which is interposed between and adjacent to each of first channel 51(a) and third channel 51(c).

Since each upper plate extension is associated with and receives within its interior space the upper portion of a lower plate extension, the lateral arrangement of neighboring upper plate extensions as between (or across) different channels (e.g., adjacent/neighboring channels, or alternating channels) of the heat exchange panel, is substantially the same as that of the associated lower plate extensions across the same channels. The lateral arrangement of neighboring upper plate extensions as between (or across) different underlying channels (e.g., adjacent/neighboring channels, or alternating channels) of the heat exchange panel may be selected from regular patterns, non-regular (or irregular) patterns and combinations thereof. Typically, the lateral arrangement of neighboring upper plate extensions across different underlying channels of the heat exchange panel is selected from regular patterns. More particularly, as between neighboring (or adjacent) channels, the lateral arrangement of neighboring upper plate extensions may be selected from substantially laterally aligned arrangements, laterally offset (or staggered) arrangements, and combinations thereof. In a particular embodiment of the present invention, the channels of the heat exchange panel are longitudinal channels, and the lateral arrangement of neighboring upper plate extensions, as between neighboring/adjacent underlying channels, is selected from laterally offset/staggered arrangements. That is, each upper plate extension is laterally staggered (rather than laterally aligned) relative to each neighboring upper plate extension of (i.e., associated with or over) an adjacent channel, as depicted in the drawings. Neighboring upper plate extensions are free of one or more upper plate extensions interposed there-between.

As FIG. 2 is a top plan view of heat exchange panel 1, and in particular the exterior surface 29 side of upper plate 14 thereof, the channels (51) underlying and defined in part by upper plate 14 are not visible. As such, in FIG. 2 the characters and lead-lines associated with the channels, e.g., 51(a), 51(b) and 51(c), are presented for purposes of reference and indicate the location of an underlying channel. With reference to FIG. 2, upper plate extension 32(a) of (or over) channel 51(a) is laterally staggered relative to neighboring upper plate extension 32(b) of adjacent channel 51(b). Correspondingly, upper plate extension 32(b) of channel 51(b) is laterally staggered relative to neighboring upper plate extension 32(a) of adjacent channel 51(a). Channel 51(a) and channel 51(b) are neighboring or adjacent channels.

In an embodiment of the present invention: the channels of the heat exchange panel are longitudinal channels; the lateral arrangement of neighboring upper plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements; and additionally, the lateral arrangement of each upper plate extension, as between each first channel and each third channel (equivalently, every other channel, or alternating pairs of channels), is selected from substantially laterally aligned arrangements. Each first channel and each third channel are separated by an interposed and common neighboring second channel. Equivalently, each alternating pair of channels is separated by an interposed and common neighboring channel. With reference to FIG. 2, upper plate extension 32(a) of (or over) channel 51(a) (here a first channel) is substantially laterally aligned relative to upper plate extension 32(c) of channel 51(c) (here a third channel). Correspondingly, upper plate extension 32(c) of channel 51(c) (here a first channel) is substantially laterally aligned relative to upper plate extension 32(a) of channel 51(a) (here a third channel). Channel 51(b) is interposed between and is a common neighboring channel relative to each of channel 51(a) and channel 51(c). Channels 51(a) and 51(c) may also be described as an alternating pair of channels, having an interposed and common neighboring channel 51(b) there-between.

In an embodiment of the present invention: the channels of the heat exchange panel are longitudinal channels; the lateral arrangement of neighboring upper plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements; and additionally, as between any three sequentially adjacent channels, the upper plate extensions have a repeating pattern comprising five (5) upper plate extensions arranged in an upper plate extension X-configuration having a single terminal upper plate extension at each of the four corners (or terminal points) of the X-configuration, and a single central upper plate extension at the center (or intersection) of the X-configuration.

The upper plate extensions accordingly form a plurality of upper plate extension X-configurations. Each upper plate extension X-configuration is typically a substantially symmetrical X-configuration. With reference to FIG. 2, an X-configuration 90 of upper plate extensions is illustrated across sequentially adjacent channels 51(a), 51(b) and 51(c). The upper plate extension X-configuration 90 includes a single terminal upper plate extension 32(d), 32(e), 32(f) and 32(g) at each of the four corners of the X-configuration, and a single central upper plate extension 32(h) at the center or intersection of the X-configuration. Three sequentially adjacent channels typically include a first channel, e.g., channel 51(a), a third channel, e.g., channel 51(c), and a second channel, e.g., channel 51(b) interposed between and being a neighboring channel to (or adjacent to) each of the first and second channels. For purposes of further illustration, regarding upper plate extension X-configuration 90: the terminal or corner upper plate extensions 32(d) and 32(f) each reside over (or are associated with) first channel 51(a); the terminal or corner upper plate extensions 32(e) and 32(g) each reside over (or are associated with) third channel 51(c); and the center upper plate extension 32(h) resides over (or is associated with) the second channel 51(b), which is interposed between and adjacent to each of first channel 51(a) and third channel 51(c).

Since each upper plate extension is associated with and receives within its interior space the upper portion of a lower plate extension (so as to together define an upper extension passage 72 there-between), the so-associated plate extensions may be described in each case as an associated pair of upper plate and lower plate extensions 93. See, for example, FIG. 4. Accordingly, the spacing of the associated pairs of upper plate and lower plate extensions relative to each other along a channel is substantially the same as that of, and as described previously herein with regard to the lower plate extensions (20) and the upper plate extensions (32). More particularly, the associated pairs of upper plate and lower plate extensions may be spaced at regular (e.g., linearly even/equivalent) or non-regular (e.g., linearly uneven/non-equivalent) internals along (or over) a particular channel, relative to each other. Typically, and as depicted in the drawings, the associated pairs of upper plate and lower plate extensions are spaced separately from each other at substantially regular (or linearly even/equivalent) intervals along (or over) each channel 51.

Further correspondingly, the lateral arrangement of associated pairs of upper plate and lower plate extensions as between (or across) different channels (e.g., adjacent/neighboring channels, or alternating channels) of the heat exchange panel, is substantially the same as that of, and as described previously herein with regard to the lower plate extensions and the upper plate extensions. The lateral arrangement of associated pairs of upper plate and lower plate extensions as between (or across) different channels (e.g., adjacent/neighboring channels, or alternating channels) of the heat exchange panel may be selected from regular patterns, non-regular (or irregular) patterns and combinations thereof. Typically, the lateral arrangement of associated pairs of upper plate and lower plate extensions across different channels of the heat exchange panel is selected from regular patterns. More particularly, as between neighboring (or adjacent) channels, the lateral arrangement of neighboring associated pairs of upper plate and lower plate extensions may be selected from substantially laterally aligned arrangements, laterally offset (or staggered) arrangements, and combinations thereof.

In a particular embodiment of the present invention, the channels of the heat exchange panel are longitudinal channels, and the lateral arrangement of neighboring associated pairs of upper plate and lower plate extensions, as between neighboring/adjacent underlying channels, is selected from laterally offset/staggered arrangements. That is, each associated pair of upper plate and lower plate extensions is laterally staggered (rather than laterally aligned) relative to each neighboring associated pair of upper plate and lower plate extensions of a neighboring channel, as depicted in the drawings. Neighboring associated pairs of upper plate and lower plate extensions are free of one or more associated pairs of upper plate and lower plate extensions interposed there-between. The laterally staggered arrangement of neighboring associated pairs of upper plate and lower plate extensions may be more particularly described in accordance with the description provided previously herein with reference to FIG. 2 regarding the laterally staggered arrangement of neighboring upper plate extensions 32(a) and 32(b).

In an embodiment of the present invention: the channels of the heat exchange panel are longitudinal channels; the lateral arrangement of neighboring associated pairs of upper plate and lower plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements; and additionally, the lateral arrangement of each associated pair of upper plate and lower plate extensions, as between each first channel and each third channel (equivalently, every other channel, or alternating pairs of channels), is selected from substantially laterally aligned arrangements. Each first channel and each third channel are separated by an interposed and common neighboring second channel. Equivalently, each alternating pair of channels is separated by an interposed and common neighboring channel. The substantially laterally aligned arrangement of associated pairs of upper plate and lower plate extensions, as between alternating pairs of channels, may be more particularly described in accordance with the description provided previously herein with reference to FIG. 2 regarding the laterally aligned arrangement of upper plate extensions 32(a) and 32(c).

In an embodiment of the present invention: the channels of the heat exchange panel are longitudinal channels; the lateral arrangement of neighboring associated pairs of upper plate and lower plate extensions, as between neighboring/adjacent channels, is selected from laterally offset/staggered arrangements; and additionally, as between any three sequentially adjacent channels, the associated pairs of upper plate and lower plate extensions have a repeating pattern comprising five (5) associated pairs of upper plate and lower plate extensions arranged in an associated X-configuration having a single terminal associated pair of upper plate and lower plate extensions at each of the four corners (or terminal points) of the X-configuration, and a single central associated pair of upper plate and lower plate extensions at the center (or intersection) of the X-configuration. Each associated X-configuration is typically a substantially symmetrical X-configuration. The X-configuration arrangement of associated pairs of upper plate and lower plate extensions, may be more particularly described in accordance with the description provided previously herein with reference to FIG. 2 regarding the X-configuration arrangement of upper plate extensions 32(d), 32(e), 32(f), 32(g) and 32(h).

With regard to further defining the channels, the heat exchange panel of the present invention may further include a plurality of ribs residing interposedly between the interior surface of the lower plate and the interior surface of the upper plate. The ribs are laterally spaced from each other and form a plurality of paired ribs (paired adjacent ribs). Each pair of ribs together define one (i.e., a single) channel there-between. The ribs may be: separate from the lower plate and the upper plate; substantially continuous with the lower plate; substantially continuous with the upper plate; or combinations thereof. In addition to further defining the plurality of channels, the inclusion of ribs between the upper and lower plates provides additional benefits, such as dimensional stability (e.g., improved stiffness) to the heat exchange panel.

With reference to FIG. 17(e) two ribs 96 are depicted as residing interposedly between interior surface 17 of lower plate 11 and interior surface 26 of upper plate 14. Ribs 96 of FIG. 17(e) are separate from (i.e., are not continuous with) lower plate 11 or upper plate 14. Two adjacent ribs 96 form a pair of adjacent ribs 99 that together define a single channel 51 there-between. More particularly, each rib 96 has a sidewall 102 that is in facing spaced opposition relative to the other rib 96 of the pair of ribs 99. The facing and opposed sidewall 102 of each rib 96 along with a portion of interior surface 17 of lower plate 11 and a portion of interior surface 26 of upper plate 14, together define a single channel 51 therebetween.

Each separate rib 96 may be held in place between interior surface 17 of lower plate 11 and interior surface 26 of upper plate 14 by friction. Alternatively, each separate rib 96 may be held in place between the interior surfaces of the lower and upper plates by: tongue and groove means (not shown); adhesive means (not shown); and/or one or more fasteners (not shown) extending through the upper plate and/or the lower plate and at least a portion of the rib interposed there-between. For example, each separate rib 96 may have at least one longitudinal tongue extending therefrom that is received within an aligned and dimensioned longitudinal groove of interior surfaces of the lower and/or upper plates. Each separate rib 96 may, for example, include at least one dimensioned longitudinal groove into which is received an aligned longitudinal tongue extending from the interior surface of the lower and/or upper plate. An adhesive may be adhesively interposed between the upper and/or lower surfaces of each separate rib 96 and the interior surfaces of the lower and/or upper plates, or additionally present within the tongue and groove means.

In an embodiment of the heat exchange panel of the present invention, at least some of the ribs are lower plate ribs. Each lower plate rib is continuous with the lower plate, and extends upward from the interior surface of the lower plate. In addition, each lower plate rib abuts the interior surface of the upper plate.

With reference to FIGS. 12, 13 and 17(a), lower plate 11 includes a plurality of lower plate ribs 105, that together form a plurality of paired adjacent lower plate ribs (or equivalently, rib pairs) 108. Each lower plate rib 105 is continuous with lower plate 11, and extends upward from interior surface 17 of lower plate 11. An upper (or terminal) surface 111 of each lower plate rib 105 abuts a portion of interior surface 26 of upper plate 14. As used herein and in the claims, abutment of each lower plate rib with a portion of interior surface 26 of upper plate 14 is alternatively inclusive of: an interposed adhesive (not shown) between upper surface 111 and interior surface 26; tongue and groove means (not shown), with a tongue extending from upper surface 111 into an aligned, dimensioned and longitudinal groove in interior surface 26, and/or a tongue extending from interior surface 26 into an aligned, dimensioned and longitudinal groove in upper surface 111; or combinations thereof.

Two adjacent lower plate ribs 105 form a pair of adjacent lower plate ribs 108 that together define a single channel 51 there-between. As with the separate ribs 96 (of FIG. 17(e)), each lower plate rib 105 has a sidewall 102 that is in facing spaced opposition relative to the other lower plate rib 105 of the pair of lower plate ribs 108. The facing and opposed sidewalls 102 of each adjacent pair of lower plate ribs 108 along with a portion of interior surface 17 of lower plate 11 and a portion of interior surface 26 of upper plate 14, together define a single channel 51 there-between.

In yet a further embodiment, at least some of the ribs of the heat exchange panel are upper plate ribs. Each upper plate rib is continuous with the upper plate, extends downward from the interior surface of the upper plate, and abuts the interior surface of the lower plate.

With reference to FIG. 17(b), upper plate 14 includes a plurality of upper plate ribs 114, that together form a plurality of paired adjacent upper plate ribs (or equivalently, upper plate rib pairs) 117. Each upper plate rib 114 is continuous with upper plate 14, and extends downward from interior surface 26 of upper plate 14. A terminal (or lower) surface 120 of each upper plate rib 114 abuts a portion of interior surface 17 of lower plate 11. As used herein and in the claims, abutment of each upper plate rib with a portion of interior surface 17 of lower plate 11 is alternatively inclusive of: an interposed adhesive (not shown) between terminal surface 120 and interior surface 17; tongue and groove means (not shown), with a tongue extending from terminal surface 120 into an aligned, dimensioned and longitudinal groove in interior surface 17, and/or a tongue extending from interior surface 17 into an aligned, dimensioned and longitudinal groove in terminal surface 120; or combinations thereof.

Two neighboring or adjacent upper plate ribs 114 form a pair of adjacent upper plate ribs 117 that together define a single channel 51 there-between. As with the separate ribs 96 (e.g., of FIG. 17(e)) and lower plate ribs 105 (e.g., of FIG. 17(a)), each upper plate rib 114 has a sidewall 102 that is in facing spaced opposition relative to the other upper plate rib 114 of the pair of upper plate ribs 117. The facing and opposed sidewall 102 of each upper plate rib 114 along with a portion of interior surface 17 of lower plate 11 and a portion of interior surface 26 of upper plate 14, together define a single channel 51 there-between.

In an embodiment, at least one pair of neighboring or adjacent ribs comprises a lower plate rib and an upper plate rib, in which each rib is as described previously herein (e.g., with regard to abutment thereof with the interior surface of the lower plate or upper plate, as the case may be). More particularly, and with reference to FIG. 17(d), lower plate 11 has a lower plate rib 105 that is neighbor/adjacent to an upper plate rib 114 of upper plate 14 (which correspondingly is neighbor/adjacent to lower plate rib 105). Lower plate rib 105 and upper plate rib 114 together form a pair of neighboring/-adjacent ribs (e.g., a lower plate/upper plate rib pair) 123, that together define a single channel 51 there-between. In particular with lower plate/upper plate rib pair 123, sidewall 102 of lower plate rib 105 is in facing spaced opposition relative to sidewall 102 of the adjacent upper plate rib 114. The opposed and facing sidewalls 102 of rib pair 123 along with a portion of interior surface 17 of lower plate 11 and a portion of interior surface 26 of upper plate 14, together define a single channel 51 there-between.

At least some of the ribs of the heat exchange panel of the present invention may be formed, in each case, by abutment between a lower plate rib and an upper plate rib (forming an abutting lower-upper plate rib), in which the lower plate rib and the upper plate rib are each as described previously herein. More particularly, the lower plate includes a plurality of lower plate ribs, each of which is continuous with the lower plate, and extends upward from the interior surface of the lower plate. The upper plate includes a plurality of upper plate ribs, each of which is continuous with the upper plate, and extends downward from the interior surface of the upper plate. At least one lower plate rib is aligned with and abuts an aligned upper plate rib, thereby forming at least one rib. In a particular embodiment, each lower plate rib abuts one upper plate rib, and thereby forms the plurality of ribs of the heat exchange panel.

With reference to FIG. 17(c), lower plate 11 includes two adjacent lower plate ribs 105 that together form a pair of adjacent lower plate ribs 108; and upper plate 14 includes two adjacent upper plate ribs 114 that together form a pair of adjacent upper plate ribs 117. Each lower plate rib 105 is aligned with and is in abutting relationship with an aligned upper plate rib 114, and together form an abutting lower-upper plate rib 126. In particular, for each abutting lower-upper plate rib 126, at least a portion of the upper surface 111 of a lower plate rib abuts at least a portion of the lower/terminal surface 120 of an aligned upper plate rib 114. The abutting lower-upper plate ribs 126 may in each case be independently held in abutting relationship by: friction; fasteners (e.g., extending through the upper and/or lower plates and at least a portion of the abutting lower-upper plate ribs); an adhesive interposed there-between (e.g., between surfaces 111 and 120); and/or tongue and groove means (e.g., interconnecting tongues and grooves between surfaces 111 and 120).

Two adjacent abutting lower-upper plate ribs 125 form a pair of adjacent abutting lower-upper plate ribs 129 that together define a single channel 51 there-between. Each abutting lower-upper plate rib has a sidewall 102 that is in facing spaced opposition relative to the sidewall 102 of the other abutting lower-upper plate rib 126 of the pair of adjacent abutting lower-upper plate ribs 129. The facing and opposed sidewalls 102 of the pair of abutting lower-upper plate ribs 129 along with a portion of interior surface 17 of lower plate 11 and a portion of interior surface 26 of upper plate 14, together define a single channel 51 there-between.

In a particular embodiment, and as depicted in the drawings, each channel of the heat exchange panel is a longitudinal channel, each rib is a longitudinal rib, and accordingly the plurality of paired (adjacent/neighboring) ribs are a plurality of paired longitudinal ribs. Correspondingly, each pair of adjacent longitudinal ribs together define one longitudinal channel there-between. With reference FIGS. 12 and 13, longitudinal lower plate ribs 105 form pairs of adjacent longitudinal lower plate ribs 108. Each pair of adjacent longitudinal ribs 108 together define a longitudinal channel 51 there-between.

So as to provide fluid communication between at least one pair of adjacent (or neighboring) channels, at least one rib residing interposedly between the upper and lower plates of the heat exchange panel may include at least one lateral passage therein. Each lateral passage provides fluid communication between the pair of neighboring channels that are so separated by the rib having one or more lateral passages therein. Fluid communication between at least one pair of neighboring pair of channels provides benefits including, for example, improved heat exchange efficiencies of the heat exchange panel. In addition, such lateral fluid communication between neighboring channels provides alternate pathways for the flow of heat exchange fluid in the event that one of the neighboring channels, or an upper plate extension passage in fluid communication with that channel, becomes blocked or obstructed to the flow of heat exchange fluid there-through (e.g., due to scale build-up and/or a foreign object lodged therein).

With reference to FIGS. 12 and 18, two channels 51(d) and 51(e) are separated by a lower plate rib 105(L) and together form a pair of neighboring channels 132. Lower plate rib 105(L) includes a first lateral passage 135 and a second lateral passage 138, that each provide fluid communication between channels 51(d) and 51(e) of pair of neighboring channels 132. Only second lateral passage 138 is shown in FIG. 12. Each lateral passage through a rib may independently have any suitable shape, orientation and position. For example, each lateral passage may independently have a cross sectional shape selected from circular shapes, oval shapes, polygonal shapes (e.g., triangles, rectangles, squares, pentagons, hexagons, heptagons, octagons, etc., and combinations thereof), irregular shapes, and any combination thereof.

The lateral passages may each independently form non-straight or indirect paths (e.g., serpentine paths) through a particular rib. Typically, each lateral passage forms a substantially straight (or direct) path through a particular rib. The lateral passages may have any suitable size, in particular with regard to width or diameter. While each lateral passage may have a width that is equal to or greater than that of either of the pair of neighboring channels that it runs between, typically, each lateral passage has a width that is less than that of each of the neighboring channels.

The lateral passages may have any suitable position along the length of a particular rib, and in particular in relation to the upper plate extension passages that are in fluid communication with each channel of the pair of neighboring channels. For example, a lateral passage may be positioned so as to be remote from any upper plate extension passage. Alternatively, and as depicted in the drawing figures, a lateral passage may be positioned proximate to and additionally so as to: be in partial fluid communication with an upper plate extension passage; and further optionally provide partial fluid communication between separate upper plate extension passages in each of the neighboring channels. Since FIGS. 12 and 18 show top plan views of lower plate 11, the upper plate extension passages 72 are not shown, but their positions can be determined relative to each lower plate extension 20 (that defines them in conjunction with the interior surfaces 45 of an associated upper plate extension 32). With further reference to FIG. 12, lateral passage 138 is proximate to lower plate extension 20(I) of first channel 51(d) and lower plate extension 20(J) of second channel 51(e). A portion of the exterior surfaces of lower plate extensions 20(I) and 20(J) each define a separate upper plate extension passage 72 with a portion of the interior surfaces 45 that define the interior space 48 of the upper plate extension 32 (not shown in FIG. 12) into which they are each received. As such, in addition to providing fluid communication between first channel 51(d) and second channel 51(e) of neighboring channels 132, lateral passage 138, due to its position, also provides partial fluid communication between the upper plate extension passage 72 defined in part by lower plate extension 20(I) and the upper plate extension passage 72 defined in part by lower plate extension 20(J).

Each lateral passage may have any suitable orientation relative to the rib it passes through and the neighboring channels it provides fluid communication between. In an embodiment of the present invention, the channels are substantially longitudinal channels and correspondingly the ribs are substantially longitudinal ribs. Each lateral passage is a substantially straight lateral passage having an elongated axis. The elongated axis of each lateral passage typically forms an angle of less than 180° and greater than 0° relative to the longitudinal axis of the longitudinal rib through which it passes.

As discussed previously herein, each lower plate extension 20 has a lower portion 66 that resides within the channel 51, and an upper portion 69 that extends upwardly from and above the channel 51 (e.g., see FIGS. 4 and 13). In a particular embodiment, the width of the lower portion of each lower plate extension is substantially equivalent to the width of the channel in which it resides, and correspondingly the channel is substantially blocked by the lower portion of the lower plate extension residing therein. With the channels so blocked by the lower portions of the lower plate extensions residing therein, each channel comprises a plurality of channel segments (e.g., 2 or more channel segments). For a given channel, each channel segment thereof is separated from a neighboring/adjacent channel segment (e.g., a preceding channel segment or a subsequent channel segment) by one (i.e., a single) lower plate extension. In addition, each channel segment is in fluid communication with at least one upper plate extension passage. Typically, each channel segment is in fluid communication with one or two (but not more than two) upper plate extension passages.

With reference to FIGS. 12 and 13, lower portion 66 of lower plate extension 20 has a width 141 that is substantially equivalent to width 144 of channel 51. While each lower plate extension and channel may have different dimensions, in an embodiment, and as depicted in the drawings, all of the lower plate extensions have substantially equivalent dimensions, and all of the channels have substantially equivalent dimensions. As such, each channel 51 is substantially blocked by the lower portion 66 of each lower plate extension 20 residing therein.

As can be seen with reference to FIGS. 4, 5, 12 and 13, each channel 51 includes a plurality of channel segments that are separated from each other by one lower plate extension 20. For purposes of further illustration, the sectional view of the channel 51 shown in FIG. 5 includes four (4) sequential channel segments 51(S-1), 51(S-2), 51(S-3) and 51(S-4), from right to left.

Channel segment 51(S-3) is separated from neighboring channel segment 51(S-2) by one (i.e., a single) lower plate extension 20(K) that is interposed between channel segment 51(S-3) and channel segment 51(S-2). Relative to channel segment 51(S-3), neighboring channel segment 51(S-2) may also be referred to as a preceding neighboring channel segment 51(S-2). In addition, channel segment 51(S-3) is separated from neighboring channel segment 51(S-4) by lower plate extension 20(L) that is interposed between channel segment 51(S-3) and channel segment 51(S-4). Relative to channel segment 51(S-3), neighboring channel segment 51(S-4) may also be referred to as a subsequent neighboring channel segment 51(S-4).

The designations of preceding and subsequent with regard to the channel segments is typically established with regard to the flow of heat exchange fluid through a particular channel. For example, in FIG. 5, heat exchange fluid (not shown) flows through channel 51 from right to left. Accordingly, heat-exchange fluid (e.g., a slug thereof) would flow in sequence through channel segments 51(S-1), 51(S-2), 51(S-3) and 51(S-4). As such, relative to channel segment 51(S-3), channel segment 51(S-2) is a preceding neighboring channel segment, and channel segment 51(S-4) is a subsequent neighboring channel segment.

Each channel segment is in fluid communication with at least one upper plate extension passage. With further reference to FIG. 5, channel segment 51(S-3) is in fluid communication with the upper plate extension passage 72 that is defined in part by lower plate extension 20(K), which resides up-stream relative to channel segment 51(S-3). Channel segment 51(S-3) is also in fluid communication with the upper plate extension passage 72 that is defined in part by lower plate extension 20(L), which resides down-stream relative to channel segment 51(S-3). Channel segment 51(S-3) may further be described as being in fluid communication with both an up-stream upper plate extension passage 72, and a down-stream upper plate extension passage 72.

Most channel segments of the heat exchange panel are in fluid communication with two upper plate extension passages. When a channel segment is a terminal channel segment (i.e., a channel segment that is located at and in fluid communication with inlet end 60 or outlet end 63 of the heat exchange panel), it is typically in fluid communication with a single upper plate extension passage.

As described previously herein, the upper plate extension passages are in each case defined by a portion of the interior surfaces of an upper plate extension being in facing opposition with a portion of the exterior surfaces of the upper portion of the lower plate extension received within the interior space of the upper plate extension. Accordingly, for an associated lower plate—upper plate extension pair, a further portion of the interior surfaces of the upper plate extension, and a further portion of the exterior surfaces of the upper portion of the lower plate extension do not define the upper plate extension passage. In a particular embodiment, for an associated lower plate—upper plate extension pair, a further portion of the interior surfaces of the upper plate extension, and a further portion of the exterior surfaces of the upper portion of the lower plate extension are in abutting relationship, and substantially prevent the passage of fluid (e.g., heat exchange fluid) there-between. Additionally, with the lower portion of the lower plate extension substantially blocking the channel, heat exchange fluid passing through a channel segment is forced up into the upper plate extension passage that is in fluid communication there-with.

More particularly in regard to the further portion of the exterior surfaces of the lower plate extensions, the exterior surfaces of the upper portion of each lower plate extension include at least one inlet face on an inlet side of the lower plate extension, at least one outlet face on an outlet side of the lower plate extension, at least one first side face on a first side of the lower plate extension, and at least one second side face on a second side of the lower plate extension. The inlet side and the outlet side of the lower plate extension are on substantially opposite sides of the lower plate extension. The inlet side of a lower plate extension is that side of the lower plate extension that is closer or more proximate to the inlet side (e.g., 60) of the heat exchange panel, relative to the outlet side thereof. Correspondingly, the outlet side of a lower plate extension is that side of the lower plate extension that is closer or more proximate to the outlet side (e.g., 63) of the heat exchange panel, relative to the inlet side thereof. The first side and the second side of the lower plate extension are on substantially opposite sides of the lower plate extension.

The upper portion of the lower plate extension has a shape that is defined by the exterior surfaces of the upper portion of the lower plate extension. In an embodiment, the interior space of the upper plate extension has a shape that substantially matches the shape of the upper portion of the lower plate extension that is received within the interior space.

Regarding the further portions of the interior surfaces of the hollow upper plate extensions, the interior surfaces defining the interior space thereof include at least one inlet surface on an inlet side of the interior space, at least one outlet surface on an outlet side of the interior space, at least one first side surface on a first side of the interior space, and at least one second side surface on a second side of the interior space. The inlet side of the interior space of each upper plate extension is closer or more proximate to the inlet side (e.g., 60) of the heat exchange panel, relative to the outlet side thereof. Accordingly, the outlet side of the interior space of each upper plate extension is closer or more proximate to the outlet side (e.g., 63) of the heat exchange panel, relative to the inlet side thereof. The inlet side and the outlet side of the interior space are on substantially opposite sides of the interior space, and the first side and the second side of the interior space are on substantially opposite sides of the interior space.

For each associated lower plate—upper plate extension pair, the inlet face of the upper portion of the lower plate extension and the inlet surface of the interior space together define an ascending inlet passage portion of the upper plate extension passage. In addition, the outlet face of the upper portion of the lower plate extension and the outlet surface of the interior space together define a descending outlet passage portion of the upper plate extension passage. The ascending inlet passage portion and the descending outlet passage portion of the upper plate extension passage are in fluid communication with each other.

Regarding the first and second side faces and the first and second side surfaces, for each associated lower plate—upper plate extension pair, at least one first side face of the upper portion of the lower plate extension and at least one first side surface of the interior space are in abutting relationship with each other. And on the other side, at least one second side face of the upper portion of the lower plate extension and at least one second side surface of the interior space are in abutting relationship with each other. With the first and second side faces and the first and second side surfaces, of each associated lower plate—upper plate extension pair in the described abutting relationship, substantially no heat exchange fluid passes there-through and/or there-between. Resultantly, heat exchange fluid is directed and passes instead through the ascending inlet and descending outlet passage portions of the upper plate extension passage.

For purposes of further illustrating the ascending inlet and descending outlet passage portions of the upper plate extension passage, attention is directed to FIGS. 4, 5, 7, 8, 12 and 13 of the drawings. With particular reference to FIG. 12, each lower plate 20 extension has an inlet side 147, an outlet side 150, a first side 153 and a second side 156. Inlet side 147 and outlet side 150 are on opposite sides of lower plate extension 20, relative to each other. First side 153 and second side 156 are on opposite sides of lower plate extension 20, relative to each other. With particular reference to FIGS. 4, 7 and 8, the interior space 48 of each upper plate extension 32 has an inlet side 159, an outlet side 162, a first side 165 and a second side 168. Inlet side 159 and outlet side 162 are on opposite sides of interior space 48 relative to each other; and first side 165 and second side 168 are on opposite sides of interior space 48, relative to each other, of upper plate extension 32.

Inlet face 81 is on inlet side 147, and outlet face 84 is on outlet side 150 of lower plate extension 20. A first side face 171 is on first side 153, and a second side face 174 is on second side 156 of lower plate extension 20.

Inlet surface 75 is on inlet side 159, and outlet surface 78 is on outlet side 162 of interior space 48 of upper plate extension 32. A first side surface 177 is on first side 165, and a second side surface 180 is on second side 168 of interior space 48 of upper plate extension 32.

Inlet face 81 of upper portion 69 of lower plate extension 20, and inlet surface 75 of interior space 48 of upper plate extension 32, are separated and in facing opposition relative to each other, and together define an ascending inlet passage portion 183 of upper plate extension passage 72. Outlet face 84 of upper portion 69 of lower plate extension 20, and outlet surface 78 of interior space 48 of upper plate extension 32, are separated and in facing opposition relative to each other, and together define a descending inlet passage portion 186 of upper plate extension passage 72. Ascending inlet passage portion 183 and descending outlet passage portion 186 are in fluid communication with each other. See, for example, FIGS. 4 and 5.

In operation of the heat exchange panel of the present invention, a heat exchange fluid introduced into a channel 51, and passes sequentially: through a preceding channel segment (e.g., 51(S-P)); up through ascending inlet passage portion 183; down through descending outlet passage portion 186; and then into a subsequent channel segment (e.g., 51(S-S)). See, for example, FIG. 4.

Regarding the abutting faces and surfaces of each associated lower plate—upper plate extension pair, reference is made in particular to FIGS. 7 and 8. First side face 171 of upper portion 69 of lower plate extension 20, and first side surface 177 of interior space 48 of upper plate extension 32 abut each other. Second side face 174 of upper portion 69 of lower plate extension 20, and second side surface 180 of interior space 48 of upper plate extension 32 abut each other. Abutment between first side face 171 and first side surface 177, and between second side face 174 and second side surface 180 is such that substantially no heat exchange fluid passes through or between these abutting faces and surfaces during operation of the heat exchange panel of the present invention.

Fluid communication between the ascending inlet passage portion 183 and the descending outlet passage portion 186 of the upper plate extension passage 72 may be achieved by means of one or more passages, bores or tunnels (not shown) that pass from inlet face 81 to outlet face 84 through upper portion 69 of lower plate extension 20. Alternatively or in addition thereto, fluid communication between the ascending and descending passage portions may be provided by a transverse passage portion that is defined by a portion of the exterior surfaces of the lower plate extension and a portion of the interior surfaces that define the interior space of the upper plate extension.

In an embodiment of the present invention, the exterior surfaces of the upper portion of the lower plate extension further includes an upper transverse face. The interior surfaces that define the interior space of the upper plate extension further include an upper transverse surface. The upper transverse face of the lower plate extension and the upper transverse surface of the interior space of the upper plate extension are in spaced facing opposition relative to each other and together define a transverse passage portion of the upper plate extension passage. The transverse passage portion of the upper plate extension passage is in fluid communication with each of the ascending inlet passage portion and the descending outlet passage portion of the upper plate extension passage. Accordingly, the transverse passage portion provides fluid communication between the ascending inlet passage portion and the descending outlet passage portion of the upper plate extension passage.

With reference to FIGS. 4 and 5, exterior surfaces 23 of upper portion 69 of lower plate extension 20 includes, at the top thereof, an upper transverse face 189. The interior surfaces 45 that define interior space 48 of upper plate extension 32 further include, at the top thereof, an upper transverse surface 192. Upper transverse face 189 and upper transverse surface 192 are in spaced facing opposition relative to each other and together define there-between a transverse passage portion 195 of the upper plate extension passage 72. Transverse passage portion 195 provides fluid communication between ascending inlet passage portion 183 and descending outlet passage portion 186 of upper plate extension passage 72.

In operation of the heat exchange panel of the present invention, a heat exchange fluid introduced into a channel 51, passes sequentially: through a preceding channel segment (e.g., 51(S-P)); up through ascending inlet passage portion 183; across and through transverse passage portion 195; down through descending outlet passage portion 186; and then into a subsequent channel segment (e.g., 51(S-S)). See, for example, FIG. 4.

The upper portion of the lower plate extension has a shape that is defined by the exterior surfaces of the upper portion of the lower plate extension. In an embodiment, the shape of the upper portion of the lower plate extension is selected from pyramidal shapes. As used herein and in the claims with regard to the shape of the upper portion of the lower plate extension, the term pyramidal shape, and similar terms means more particularly a polyhedron having a polygonal base and triangles for sides (or faces). The number of triangular sides being equal to the number of sides of the polygonal base. The pyramidal shapes may be symmetrical or non-symmetrical. Typically, the pyramidal shapes are substantially symmetrical, and correspondingly: the sides of the polygonal base have equivalent lengths; and the internal angles that each side of the pyramidal shape form relative to horizontal are substantially equal (greater than 0° and less than 90°).

The lower portion (e.g., 66) of the lower plate extension may have a shape the is the same as or different than that of the upper portion (e.g., 69) of the lower plate extension. In an embodiment, the lower portion (e.g., 66) of the lower plate extension has a pyramidal shape that is substantially the same as and is an extension of the pyramidal shape of the upper portion (e.g., 69) of the lower plate extension.

The pyramidal shape of the upper portion of the lower plate extension may be selected from rectangular pyramids, pentagonal pyramids, hexagonal pyramids, heptagonal pyramids, octagonal pyramids, nonagonal pyramids, decagonal pyramids, undecagonal pyramids, dodecagonal pyramids, etc. In a particular embodiment, the shape of the upper portion of the lower plate extension is selected from rectangular pyramids.

The interior space 48 defined by the interior surface 45 of the upper plate extension 32 may have a shape that substantially matches or is similar to that of the shape defined by the exterior surfaces 23 of the upper portion 69 of the lower plate extension. In an embodiment, the shape of the upper portion of the lower plate extension is selected from pyramidal shapes, and the shape of the interior space 48 defined by the interior surfaces 45 of upper plate extension 32 are accordingly selected from a substantially matching pyramidal shape, such as rectangular pyramids, pentagonal pyramids, hexagonal pyramids, heptagonal pyramids, octagonal pyramids, nonagonal pyramids, decagonal pyramids, undecagonal pyramids, dodecagonal pyramids, etc. In a particular embodiment, the shape of the upper portion of the lower plate extension is selected from rectangular pyramidal shapes, and the shape of interior space 48 defined by the interior surfaces 45 of upper plate extension 32 is selected from a substantially matching rectangular pyramidal shape. The shape of the interior space of the upper plate extension substantially matches the shape of the lower plate extension, to an extent and provided that: the ascending inlet passage portion, descending outlet passage portion and optional transverse passage portion of the upper plate extension passage are defined; and the faces and surfaces of the first and second sides there-between are in abutting relationship, as described previously herein.

The separation between the exterior surfaces of the upper portion of the lower plate extension and the interior surfaces of the upper plate extension that allows for the upper plate extension passage and its optional portions (e.g., ascending, transverse and descending portions) to be defined there-between, may be established and maintained by spacers (not shown) positioned abuttingly between the interior surfaces of the lower plate and the upper plate. In an embodiment, the separation that allows for definition of the upper plate extension passage and its optional portions is established and maintained by abutment between the faces and surfaces of the first and second sides of the lower plate extension and the surfaces that define the interior space of the upper plate extension. For example, abutment between first side face 171 of upper portion 69 of lower plate extension 20 and first side surface 177 of interior space 48 of upper plate extension 32; and abutment between second side face 174 of upper portion 69 of lower plate extension 20, and second side surface 180 of interior space 48 of upper plate extension 32, keeps the upper plate extension from sliding too far down over the upper portion of the lower plate extension that is received within the interior space thereof, and thus further serves to maintain the separation that allows for definition of the upper plate extension passage and its optional portions

In an embodiment of the present invention, the shape of the upper portion of the lower plate extension is selected from truncated pyramidal shapes having an upper truncated face. The upper truncated face is and defines the upper transverse face of the upper portion of the lower plate extension. As used herein and in the claims, the term “truncated pyramidal shape” and similar terms, such as truncated pyramid, means a pyramidal shape or pyramid in which the upper terminus thereof is defined by an upper truncated face, rather than a point. Relative to horizontal, the upper truncated face may be substantially flat, or may be slanted (e.g., slanted towards one of the inlet side, outlet side, first side or second side of the lower plate extension).

The shape of the upper portion of the lower plate extension, in an embodiment, is selected from truncated rectangular pyramidal shapes. In a particular embodiment, the shape of the upper portion of the lower plate extension is selected from substantially symmetrical truncated rectangular pyramidal shapes, in which the sides of the rectangular base thereof have substantially equivalent lengths.

With reference to FIGS. 4, 5 and 13, for each lower plate extension 20, the exterior surfaces 23 of the upper portion thereof define a truncated pyramidal shape, which is more particularly a truncated rectangular pyramidal shape. The truncated rectangular pyramidal lower plate extensions 20 each have an upper truncated face that is defined by the upper transverse face 189 of the lower plate extension. Upper truncated face 189 is a substantially flat upper truncated face. Upper truncated face 189 and upper transverse surface 192 are in spaced facing opposition relative to each other and together define there-between transverse passage portion 195 of upper plate extension passage 72.

As can be seen in some of the sectional views of the drawings, such as FIGS. 4, 5, 7 and 8, the interior space 48 of each upper plate extension 32 has a pyramidal shape, and in particular a truncated pyramidal shape that substantially matches the truncated pyramidal shape of the upper portion 69 of the lower plate extension 20 received therein. The truncated pyramidal shape of the interior space of the upper plate extensions may be further described as including an upper truncated surface that is defined by the upper transverse surface of the interior space (e.g., upper transverse surface 192).

At least some of the lower plate extensions may have interior surfaces that define an interior space of the lower plate extension that is in fluid communication with an aperture on the exterior or lower surface (e.g., 35) thereof, in which case such lower plate extensions are hollow lower plate extensions. In an embodiment, each lower plate extension is substantially solid, and is substantially free of an interior hollow space.

The exterior surfaces of the upper plate extensions may define any suitable exterior shape of the upper plate extensions. In particular, exterior surfaces 38 of upper plate extension 32 define an exterior shape (e.g., a pyramidal shape) that may be the same or different than the shape of the interior space 48 of the upper plate extension. In an embodiment, exterior surfaces 38 of upper plate extension 32 define an exterior shape that is substantially the same as the shape of the interior space 48 that is defined by the interior surfaces 45 of the upper plate extension. In a particular embodiment, exterior surfaces 38 of upper plate extension 32 define an exterior shape that is selected from a truncated pyramidal shape that is substantially the same as the truncated pyramidal shape of the interior space 48 thereof, and as depicted in the drawings more particularly with regard to a truncated rectangular pyramidal shape in both cases.

The upper plate extension passages (e.g., 72) each have an upper plate extension passage volume. Each upper plate extension passage volume may, for example, be equal to the sum of the volumes of the ascending inlet passage portion 183, transverse passage portion 195 and descending outlet passage portion 186 thereof. The heat exchange panel may be described as having a total upper plate extension passage volume, which is equal to the sum of all the upper plate extension passage volumes. Each channel (e.g., 51) of the heat exchange panel has a channel volume, which is more particularly equal to the sum of the channel segment volumes associated therewith. The heat exchange panel may be further described as having a total channel volume, which is the sum of all the channel volumes. Accordingly, the heat exchange panel has a total internal volume, which is equal to the sum of the total upper plate extension passage volume and the total channel volume of the panel.

The heat exchange panel has a percent total upper plate extension passage volume, which is calculated according the following equation:

100×{total upper plate extension passage volume/total internal volume}

The heat exchange panel has a percent total channel volume, which is calculated according the following equation:

100×{total channel volume/total internal volume}

The heat exchange panel may have a percent total upper plate extension passage volume of from, for example, 70 percent to 95 percent by volume, typically from 75 percent to 90 percent by volume, and more typically from 80 percent to 90 percent by volume, based on the total internal volume of the heat exchange panel. The heat exchange panel may have a percent total channel volume of from 5 percent to 30 percent by volume, typically from 10 percent to 25 percent by volume, and more typically from 10 percent to 20 percent by volume, based on the total internal volume of the heat exchange panel. In an embodiment, the heat exchange panel has a percent total upper plate extension passage volume of 85 percent by volume, and a percent total channel volume of 15 percent by volume, in each case, based on the total internal volume of the heat exchange panel.

Heat exchange fluid when passing through an upper plate extension passage is exposed to more thermal energy (e.g., from an incident radiant infrared energy source, such as the sun), than when passing through an underlying channel, or more particularly an underlying channel segment. As such, and for purposes of optimizing heat exchange properties and efficiencies, it is desirable that the heat exchange panel of the present invention have a percent total upper plate extension passage volume of at least 50 percent by volume, based on total internal volume.

The heat exchange panel of the present invention may further include a sidewall structure that surrounds the plurality of upper plate extensions. The sidewall structure has interior surfaces, an upper terminus and a height. The upper terminus of the sidewall structure resides above the exterior (or upper) surface of the upper plate and defines an open top of the sidewall structure. The sidewall structure extends substantially around and encompasses the plurality of upper plate extensions. The interior surfaces of the sidewall structure define an interior sidewall structure space in which the plurality of upper plate extensions reside. The height of the sidewall structure is at least equivalent to (and accordingly is no lower than) a maximum height of the plurality of upper plate extensions.

With reference to the drawings, heat exchange panel 1 includes a sidewall structure 198 that has interior surfaces 201, exterior surfaces 226, an upper terminus 204 and a height 207. The height 207 of sidewall structure 198 is the distance that the upper terminus 204 thereof resides above exterior surface 29 of upper plate 14. See, for example, FIG. 19. The sidewall structure may be composed of a plurality of sidewall components (or sidewalls), e.g., in the case of a polygonal sidewall structure, or a single sidewall component (or sidewall), e.g., in the case of a circular or oval sidewall structure. As depicted in the drawings, sidewall structure 198 is a polygonal sidewall structure, and more particularly a rectangular sidewall structure having four sidewalls, 210, 213, 217 and 220, that are substantially continuous with each other. See, for example, FIG. 1.

The sidewall structure may be separate from and attached to the upper plate of the heat exchange panel. In an embodiment, and as depicted in the drawings, the sidewall structure 198 is continuous with the upper plate 14, and extends upwardly from the exterior surface 29 of upper plate 14. See, for example, FIGS. 9, 15, 16 and 19.

Upper terminus 204 of sidewall structure 198 resides above exterior surface 29 of upper plate 14 and defines an open top 223 of the sidewall structure. The interior surfaces 201 of sidewall structure 198 define an interior sidewall structure space 229. The plurality of upper plate extensions 32 reside within interior sidewall structure space 229, as sidewall structure 198 extends there-around. See, for example, FIG. 9.

Sidewall structure 198 may have a height 207 of from 25 mm to 250 mm, typically from 50 mm to 225 mm, and more typically from 75 mm to 200 mm. In an embodiment, sidewall structure 198 has a height 207 of 125 mm.

Each upper plate extension 32 has an upper terminal exterior point or surface 232 that is located above exterior surface 29 of upper plate 14. The distance that upper terminal exterior surface 232 resides above exterior surface 29 of upper plate 14 is the height of that particular upper plate extension (FIGS. 9 and 19). The upper plate extensions may have different heights, or in each case substantially the same height, relative to exterior surface 29 of upper plate 14. One or more upper plate extensions have, or in effect define, a maximum height 235 of the plurality of upper plate extensions, relative to exterior surface 29 of upper plate 14. The height 207 of sidewall structure 198 is at least equivalent to the maximum height 235 of the plurality of upper plate extensions. See, for example, FIG. 19. The heat exchange panel is free of any upper plate extensions having an upper terminal exterior surface 232 that extends above upper terminus 204 of sidewall structure 198. As depicted in the drawings, maximum height 235 of the plurality of upper plate extensions 32 is less than height 207 of sidewall structure 198.

The maximum height 235 of the plurality of upper plate extensions 32 may be from 20 mm to 230 mm, typically from 45 mm to 215 mm, and more typically from 70 mm to 190 mm. In an embodiment, maximum height 235 of the plurality of upper plate extensions 32 is 120 mm.

The heat exchange panel may optionally further include a plate that covers the open top defined by the sidewall structure. The plate is typically substantially transparent to infrared radiation, and may rest on and optionally be fixedly attached to the upper terminus of the sidewall structure. As used herein and in the claims with regard to the covering plate, the term “substantially infrared transparent” and similar terms means the plate allows a major amount (e.g., at least 50 percent) of the incident infrared radiation to pass there-through and into the interior sidewall structure space.

With reference to FIG. 20, heat exchange panel 1 further includes a plate 238 covering open top 223 of sidewall structure 198. Plate 238 rests on or over upper terminus 204 of sidewall structure 198. Plate 238 may optionally be fixedly attached to upper terminus 204 by art-recognized means including, for example: adhesives (not shown) interposed there-between; fasteners (not shown) extending through plate 238 and into sidewall structure 198; and/or snap fittings (not shown). Plate 238 is substantially transparent to infrared radiation, and substantially encloses interior sidewall structure space 229.

In a further embodiment of the present invention, the sidewall structure includes a shelf upon which the infrared transparent plate is placed. In particular, the sidewall structure further includes a shelf having an upper surface having a height above the exterior surface of the upper plate. The shelf is positioned and extends inward (relative to the interior surfaces of the sidewall structure) towards the interior sidewall structure space. With the shelf embodiment, the height of the sidewall structure is greater than the maximum height of the plurality of upper plate extensions. In addition, the height of the upper surface of the shelf is: (i) less than the height of the sidewall structure; and (ii) at least equivalent to the maximum height of the plurality of upper plate extensions. The substantially infrared transparent plate covers the open top of the sidewall structure, and is positioned on or over the upper surface of said shelf.

With reference to, for example, FIGS. 5, 8, 9 and 19, heat exchange panel 1 further includes a shelf 241 that has an upper surface 244. Upper surface 244 of shelf 241 has a height 247 above exterior surface 29 of upper plate 14 (FIG. 19). Shelf 241 is positioned inward towards interior sidewall structure space 229. The shelf may be a substantially continuous shelf (e.g., as depicted in the drawings with regard to shelf 241), or may be composed of a plurality of separate shelf elements or components (not shown) each having an upper surface that is aligned with (i.e., has the same height as) the upper surface of each neighboring shelf element.

With the shelf embodiment, and with further reference to FIG. 19, the height 207 of sidewall structure 198 (i.e., the height of the upper terminus 204 of sidewall structure 198, as discussed previously) above exterior surface 29 of upper plate 14 is greater than the maximum height 235 of the plurality of upper plate extensions 32. The height 247 of upper surface 244 of shelf 241 is: (i) less than the height 207 of sidewall structure 198; and at the same time (ii) at least equivalent to the maximum height 235 of the plurality of upper plate extensions 32.

Additionally with the shelf embodiment, heat exchange panel 1 further includes a plate 250 that is substantially transparent to infrared radiation (i.e., a substantially infrared transparent plate). Infrared transparent plate 250 covers the open top 223 of sidewall structure 198, and is positioned on or over upper surface 244 of shelf 241. As discussed previously with regard to infrared transparent plate 238 and upper terminus 204 of sidewall structure 198, infrared transparent plate 250 may optionally be fixedly attached to upper surface 244 of shelf 241 by art-recognized means including, for example: adhesives (not shown) interposed there-between; fasteners (not shown) extending through plate 250 and into shelf 241; and/or snap fittings (not shown).

The height 247 of upper surface 244 of shelf 241 (above exterior surface 29 of upper plate 14) may be from 20 mm to 230 mm, typically from 45 mm to 215 mm, and more typically from 70 mm to 190 mm. In an embodiment, the height 247 of upper surface 244 of shelf 241 is 120 mm. Alternatively or in addition to a shelf (e.g., shelf 241), an upper portion of the interior surfaces 201 of sidewall structure 198 may include an elongated slot (not shown) that is dimensioned to receive and support a peripheral portion of the infrared transparent plate therein. The slot has a height above the exterior surface 29 of the upper plate 14 that is: (i) less than the height 207 of sidewall structure 198; and at the same time (ii) at least equivalent to the maximum height 235 of the plurality of upper plate extensions 32. Typically, the slot extends through to the exterior surface (e.g., 226) of one sidewall or two opposing sidewalls of the sidewall structure, thus allowing the infrared transparent plate to be inserted (e.g., slid) into the slot from outside of the sidewall structure.

The substantially infrared transparent plate (e.g., plate 238 and/or plate 250) of the heat exchange panel, allows infrared radiation to enter interior sidewall structure space 229, and be absorbed at least in part by exterior surfaces 38 of upper plate extensions 32 and exterior surfaces 29 of upper plate 14, such that at least some of the heat energy thereof is transferred to a heat exchange fluid flowing through the upper plate extension passages 72 and channels 51 residing there-under. In addition, the infrared transparent plate prevents foreign materials (e.g., precipitation, leaves and bird droppings) from entering interior sidewall structure space 229 and fouling the exterior surfaces 38 of the upper plate extensions 32. The infrared transparent plate also allows a gas, such as air, to be retained within interior sidewall structure space 229 and heated by the incident infrared radiation, thus resulting in convective transfer of heat energy from the heated entrapped gas to/through the upper plate extensions 32 and exterior surfaces 29 of upper plate 14, and into the heat exchange fluid flowing through the upper plate extension passages 72 and channels 51 residing there-under.

The infrared transparent plate (e.g., 238 and/or 250) covering the open top and enclosing the interior sidewall structure space of the sidewall structure may be fabricated from any suitable infrared transparent material, such as glass and/or plastics, such as thermoset plastic materials and/or thermoplastic materials (e.g., thermoplastic polycarbonate). Typically, the infrared transparent plate is rigid and substantially self-supporting.

Each channel (e.g., 51) of the heat exchange panel has a terminal inlet (e.g., 54) and a terminal outlet (e.g., 57). Some of the terminal inlets and some of the terminal outlets may be located at/on the same end of the heat exchange panel, in which case a heat exchange fluid flows in opposite directions through separate channels of the heat exchange panel. Typically, all of the terminal inlets are located on the same end (e.g., an inlet end 60) of the heat exchange panel, and all of the terminal outlets are correspondingly located on the same (more particularly, the other/opposite) end (e.g., an outlet end 63) of the heat exchange panel. Whether all are located on the same end (unidirectional flow of heat exchange fluid through the channels) or mixed between opposite ends of the heat exchange panel (counter-flow of heat exchange fluid through at least some of the channels), the terminal inlets may each be in fluid communication with a common inlet header, and the terminal outlets may each be in fluid communication with a common outlet header.

In an embodiment, the heat exchange panel further includes an inlet header having an inlet header interior space, and an outlet header having an outlet header interior space. The inlet header interior space of the inlet header is in fluid communication with the terminal inlet of each channel. The outlet header interior space of the outlet header is in fluid communication with the terminal outlet of each channel. In a particular embodiment, the terminal inlet of each channel is located on the inlet end (e.g., inlet end 60), and the terminal outlet of each channel is located on the outlet end (e.g., outlet end 63) of the heat exchange panel, and correspondingly the inlet header is located on the inlet end and the outlet header is located on the outlet end of the heat exchange panel.

For purposes of further illustration and with reference to the drawings, heat exchange panel 1 includes an inlet header 253 having an inlet header interior space 256, and an outlet header 259 having an outlet header interior space 262. Inlet header 253 is located on inlet end 60, and outlet header 259 are located on outlet end 63 of heat exchange panel 1. Inlet end 60 and outlet end 63 are located at substantially opposites ends of the heat exchange panel. Accordingly, inlet header 253 and outlet header 259 are located at substantially opposite ends of the heat exchange panel.

Inlet header interior space 256 of inlet header 253 is in fluid communication with the terminal inlet 54 of each channel 51. See, for example, FIGS. 3, 10 and 11. Outlet header interior space 262 of outlet header 259 is in fluid communication with the terminal outlet 57 of each channel 51. See, for example, FIG. 16. Fluid communication between inlet header interior space 256 and the terminal inlet 54 of each channel 51, is substantially the same as more clearly depicted in FIG. 16 with regard to the fluid communication between outlet header interior space 262 and the terminal outlet 57 of each channel 51.

The inlet header and the outlet header may each independently have one or more ports that are in fluid communication with the respective interior space thereof, so as to allow for heat exchange fluid to be respectively introduced therein or removed therefrom. In an embodiment the inlet header and the outlet header each have a separate port that is in fluid communication with the respective interior space thereof.

As depicted in the drawings, inlet header 253 has an inlet header port 265 that is in fluid communication with inlet header interior space 256 thereof. Outlet header 259 has an outlet header port 268 that is in fluid communication with outlet header interior space 262 thereof. Inlet header port 265 may be in fluid communication with: an inlet conduit (not shown) that is in fluid communication with a heat exchange fluid reservoir (not shown); or the outlet header port (e.g., 268) of another heat exchange panel 1 (not shown), for in-series coupling; or a master inlet header (not shown) that is in parallel fluid communication with each inlet header port of a plurality of heat exchange panels (for parallel coupling). Outlet header port 268 may be in fluid communication with: an output conduit (not shown) that is in fluid communication with a heat exchange fluid reservoir (not shown) or a point of direct use (e.g., a shower or swimming pool); or the inlet header port (e.g., 265) of another heat exchange panel 1 (not shown), for in-series coupling; or a master outlet header (not shown) that is in parallel fluid communication with each outlet header port of a plurality of heat exchange panels (for parallel coupling).

In the drawings, for purposes of clarity and illustration, the inlet (253) and outlet (259) headers are depicted as being open at the end opposite of the inlet/outlet header port in each case thereof (e.g., so as to depict the header interior spaces thereof). See, for example, FIGS. 1 and 16. These open ends are typically capped with a separate cap (e.g., a welded, screwed or glued cap), or an integral cap (e.g., an integral cap plate) that is substantially continuous with at least a portion of the respective header. The header caps are not shown in the drawings.

The inlet header and the outlet header may each be independently separate from or substantially integral or unitary with the heat exchange panel. When separate from the heat exchange panel, the headers may each independently be attached to the respective inlet or outlet end of the heat exchange panel by art-recognized means (e.g., by adhesives, a plurality of conduits and couplings, and/or fasteners, such as bolts). In an embodiment, portions of the inlet header and the outlet header are each substantially continuous (e.g., integral or unitary) with the heat exchange panel, and more particularly with the lower plate and upper plate thereof. When the lower plate and upper plate are joined together, the separate header portions that are substantially continuous or unitary with the lower plate and the upper plate are also joined together and form, in each case, the inlet header and/or the outlet header.

With further regard to the headers being formed by separate header portions upon joining the lower and upper plates of the heat exchange panel together, in an embodiment, the lower plate includes a lower inlet header portion positioned on an inlet side of the lower plate, and a lower outlet header portion positioned on an outlet side of the lower plate. The upper plate also includes an upper inlet header portion positioned on an inlet side of the upper plate, and an upper outlet header portion positioned on an outlet side of the upper plate. When the lower plate and the upper plate are joined together, to form the heat exchange panel of the present invention, the lower inlet header portion (of the lower plate) and the upper inlet header portion (of the upper plate), which are aligned, are joined together and form the inlet header. Correspondingly, the lower outlet header portion (of the lower plate) and the upper outlet header portion (of the upper plate), which are aligned, are joined together and form the outlet header.

With reference to the drawings (e.g., FIGS. 10, 11, 12, 14, 15, 16 and 18), lower plate 11 includes a lower inlet header portion 272, which is located on an inlet side 275 of lower plate 11. Lower plate 11 also includes a lower outlet header portion 278 that is located on an outlet side 281 of lower plate 11. Upper plate 14 includes an upper inlet header portion 284, which is located on an inlet side 287 of upper plate 14. Upper plate 14 additionally includes an upper outlet header portion 290 that is located on an outlet side 293 of upper plate 14.

When lower plate 11 and upper plate 14 are joined together to form heat exchange panel 1, lower inlet header portion 272 and upper inlet header portion 284, which are each on inlet end 60 and aligned with each other, are also joined together so as to form inlet header 253. Correspondingly, lower outlet header portion 278 and upper outlet header portion 290, which are each on outlet end 63 and aligned with each other, are joined together so as to form outlet header 259. The lower and upper header portions may be fixedly attached to each other by art-recognized means, including for example; adhesives interposed between abutting portions; fasteners; snap fittings; and/or clamps (none of which are shown in the drawings).

To assist in attachment there-between, the lower and upper header portions may each include one or more flanges (or flange portions) that abut each other, or are superposed relative to each other. In an embodiment, lower inlet header portion 272 has an elongated lower inlet flange portion 296 that extends outwardly therefrom, and lower outlet header portion 278 has an elongated lower outlet flange portion 299 that extends outwardly therefrom. Upper inlet header portion 284 has an elongated upper inlet flange portion 302 that extends outwardly therefrom, and upper outlet header portion 290 has an elongated upper outlet flange portion 305 that extends outwardly therefrom.

Joining together of lower inlet header portion 272 and upper inlet header portion 284, so as to form inlet header 253, also results in abutment or super-positioning of elongated lower inlet flange portion 296 and elongated upper inlet flange portion 302, which results in formation of elongated inlet header flange 308 (FIGS. 1 and 3). Accordingly, joining together of lower outlet header portion 278 and upper outlet header portion 290, so as to form outlet header 259, also results in abutment or super-positioning of elongated lower outlet flange portion 299 and elongated upper outlet flange portion 305, which results in formation of elongated outlet header flange 311 (FIG. 16). The elongated header flanges (inlet header flange 308, and outlet header flange 311) may be fixedly held together by art-recognized means, such as adhesives interposed between the abutting lower and upper elongated flange portions thereof; fasteners; snap fittings; and/or clamps (none of which are shown in the drawings).

The heat exchange panel of the present invention, and the various components thereof (e.g., the lower plate, lower plate extensions, ribs, upper plate, upper plate extensions, sidewall structure, inlet header and outlet header) may each be independently fabricated from any suitable material or combinations of materials. Materials from which the heat exchange panel of the present invention, and the various components thereof, may be fabricated, include but are not limited to, metals (e.g., ferrous metals, titanium, copper and/or aluminum), cellulose based materials, such as wood, ceramics, glass, and/or plastics (e.g., thermoplastic materials and/or thermoset plastic materials).

In an embodiment, the lower plate is a substantially unitary lower plate molded from a first plastic material, and the upper plate is a substantially unitary upper plate molded from a second plastic material. As used herein and in the claims, the term “substantially unitary lower plate” and similar terms, means the lower plate and all components thereof, such as the lower plate extensions, are continuous with each other. As used herein and in the claims, the term “substantially unitary upper plate” and similar terms, means the upper plate and all components thereof, such as the upper plate extensions, are continuous with each other. The first plastic material and the second plastic material may each independently be selected from thermoplastic materials, thermoset plastic materials and combinations thereof.

As used herein and in the claims, the term “thermoset plastic material” and similar terms, such as “thermosetting or thermosetable plastic materials” means plastic materials having or that form a three dimensional crosslinked network resulting from the formation of covalent bonds between chemically reactive groups, e.g., active hydrogen groups and free isocyanate groups, or between unsaturated groups. Thermoset plastic materials from which the various components of the heat exchange panel may be fabricated include those known to the skilled artisan, e.g., crosslinked polyurethanes, crosslinked polyepoxides, crosslinked polyesters (such as sheet molding compound compositions) and crosslinked polyunsaturated polymers. The use of thermosetting plastic materials typically involves the art-recognized process of reaction injection molding. Reaction injection molding typically involves, as is known to the skilled artisan, injecting separately, and preferably simultaneously, into a mold, for example: (i) an active hydrogen functional component (e.g., a polyol and/or polyamine); and (ii) an isocyanate functional component (e.g., a diisocyanate such as toluene diisocyanate, and/or dimers and trimers of a diisocyanate such as toluene diisocyanate). The filled mold may optionally be heated to ensure and/or hasten complete reaction of the injected components.

As used herein and in the claims, the term “thermoplastic material” and similar terms, means a plastic material that has a softening or melting point, and is substantially free of a three dimensional crosslinked network resulting from the formation of covalent bonds between chemically reactive groups (e.g., active hydrogen groups and free isocyanate groups) of separate polymer chains and/or crosslinking agents. Examples of thermoplastic materials from which the various components of the heat exchange panel may be fabricated include, but are not limited to, thermoplastic polyurethane, thermoplastic polyurea, thermoplastic polyimide, thermoplastic polyamide, thermoplastic polyamideimide, thermoplastic polyester, thermoplastic polycarbonate, thermoplastic polysulfone, thermoplastic polyketone, thermoplastic polyolefins, thermoplastic (meth)acrylates, thermoplastic acrylonitrile-butadiene-styrene, thermoplastic styrene-acrylonitrile, thermoplastic acrylonitrile-stryrene-acrylate and combinations thereof (e.g., blends and/or alloys of at least two thereof).

In an embodiment of the present invention, the thermoplastic material from which each of the various components of the heat exchange panel may be fabricated is independently selected from thermoplastic polyolefins. As used herein and in the claims, the term “polyolefin” and similar terms, such as “polyalkylene” and “thermoplastic polyolefin”, means polyolefin homopolymers, polyolefin copolymers, homogeneous polyolefins and/or heterogeneous polyolefins. For purposes of illustration, examples of a polyolefin copolymer include those prepared from ethylene and one or more C₃-C₁₂ alpha-olefins, such as 1-butene, 1-hexene and/or 1-octene.

The polyolefins, from which the thermoplastic material of the various components of the heat exchange panel may in each case be independently selected, include heterogeneous polyolefins, homogeneous polyolefins, or combinations thereof. The term “heterogeneous polyolefin” and similar terms means polyolefins having a relatively wide variation in: (i) molecular weight amongst individual polymer chains (i.e., a polydispersity index of greater than or equal to 3); and (ii) monomer residue distribution (in the case of copolymers) amongst individual polymer chains. The term “polydispersity index” (PDI) means the ratio of M_w/M_n, where M_w means weight average molecular weight, and M_n means number average molecular weight, each being determined by means of gel permeation chromatography (GPC) using appropriate standards, such as polyethylene standards. Heterogeneous polyolefins are typically prepared by means of Ziegler-Natta type catalysis in heterogeneous phase.

The term “homogeneous polyolefin” and similar terms means polyolefins having a relatively narrow variation in: (i) molecular weight amongst individual polymer chains (i.e., a polydispersity index of less than 3); and (ii) monomer residue distribution (in the case of copolymers) amongst individual polymer chains. As such, in contrast to heterogeneous polyolefins, homogeneous polyolefins have similar chain lengths amongst individual polymer chains, a relatively even distribution of monomer residues along polymer chain backbones, and a relatively similar distribution of monomer residues amongst individual polymer chain backbones. Homogeneous polyolefins are typically prepared by means of single-site, metallocene or constrained-geometry catalysis. The monomer residue distribution of homogeneous polyolefin copolymers may be characterized by composition distribution breadth index (CDBI) values, which are defined as the weight percent of polymer molecules having a comonomer residue content within 50 percent of the median total molar comonomer content. As such, a polyolefin homopolymer has a CDBI value of 100 percent. For example, homogenous polyethylene/alpha-olefin copolymers typically have CDBI values of greater than 60 percent or greater than 70 percent. Composition distribution breadth index values may be determined by art recognized methods, for example, temperature rising elution fractionation (TREF), as described by Wild et al, Journal of Polymer Science, Poly. Phys. Ed., Vol. 20, p. 441 (1982), or in U.S. Pat. No. 4,798,081, or in U.S. Pat. No. 5,089,321. An example of homogeneous ethylene/alpha-olefin copolymers are SURPASS polyethylenes, commercially available from NOVA Chemicals Inc.

The plastic materials of the various components of the heat exchange panel may in each case independently and optionally include a reinforcing material selected, for example, from glass fibers, glass beads, carbon fibers, metal flakes, metal fibers, polyamide fibers (e.g., KEVLAR polyamide fibers), cellulosic fibers, nanoparticulate clays, talc and mixtures thereof. If present, the reinforcing material is typically present in a reinforcing amount, e.g., in an amount of from 5 percent by weight to 60 or 70 percent by weight, based on the total weight of the component (i.e., the sum of the weight of the plastic material and the reinforcing material). The reinforcing fibers, and the glass fibers in particular, may have sizings on their surfaces to improve miscibility and/or adhesion to the plastic materials into which they are incorporated, as is known to the skilled artisan.

In an embodiment of the invention, the reinforcing material is in the form of fibers (e.g., glass fibers, carbon fibers, metal fibers, polyamide fibers, cellulosic fibers and combinations of two or more thereof). The fibers typically have lengths (e.g., average lengths) of from 0.5 inches to 4 inches (1.27 cm to 10.16 cm). The various components of the heat exchange panel may each independently include fibers having lengths that are at least 50 or 85 percent of the lengths of the fibers that are present in the feed materials from which the molded panel is (or portions thereof are) prepared, such as from 0.25 inches to 2 or 4 inches (0.64 cm to 5.08 or 10.16 cm). The average length of fibers present in a plastic component of the heat exchange panel (e.g., the lower and upper plates, etc.) may be determined in accordance with art recognized methods. For example, the plastic component may be pyrolyzed to remove the plastic material, and the remaining or residual fibers microscopically analyzed to determine their average lengths, as is known to the skilled artisan.

Fibers are typically present in the plastic components of the heat exchange panel in amounts independently from 5 to 70 percent by weight, 10 to 60 percent by weight, or 30 to 50 percent by weight (e.g., 40 percent by weight), based on the total weight of the plastic component (i.e., the weight of the plastic material, the fiber and any additives). Accordingly, the plastic components of the heat exchange panel may each independently include fibers in amounts of from 5 to 70 percent by weight, 10 to 60 percent by weight, or 30 to 50 percent by weight (e.g., 40 percent by weight), based on the total weight of the particular component.

The fibers may have a wide range of diameters. Typically, the fibers have diameters of from 1 to 20 micrometers, or more typically from 1 to 9 micrometers. Generally, each fiber comprises a bundle of individual filaments (or monofilaments). Typically, each fiber is composed of a bundle of 10,000 to 20,000 individual filaments.

Typically, the fibers are uniformly distributed throughout the plastic material. During mixing of the fibers and the plastic material, the fibers generally form bundles of fibers typically comprising at least 5 fibers per fiber bundle, and preferably less than 10 fibers per fiber bundle. While not intending to be bound by theory, it is believed, based on the evidence at hand, that fiber bundles containing 10 or more fibers may result in a plastic component (e.g., the lower plate) having undesirably reduced structural integrity. The level of fiber bundles containing 10 or more fibers per bundle, may be quantified by determining the Degree of Combing present within a molded article. The number of fiber bundles containing 10 or more fibers per bundle is typically determined by microscopic evaluation of a cross section of the molded article, relative to the total number of microscopically observable fibers (which is typically at least 1000). The Degree of Combing is calculated using the following equation: 100×((number of bundles containing 10 or more fibers)/(total number of observed fibers)). Generally, molded plastic components of the heat exchange panel according to the present invention have a Degree of Combing of less than or equal to 60 percent, and typically less than or equal to 35 percent.

In addition or alternatively to reinforcing material(s), the plastic components of the heat exchange panel may in each case independently and optionally further include one or more additives. Additives that may be present in the plastic components include, but are not limited to, antioxidants, colorants, e.g., pigments and/or dyes, mold release agents, fillers, e.g., calcium carbonate, ultraviolet light absorbers, fire retardants and mixtures thereof. Additives may be present in the plastic material of each plastic component in functionally sufficient amounts, e.g., in amounts independently from 0.1 percent by weight to 10 percent by weight, based on the total weight of the particular plastic component.

The molded plastic components (e.g., the lower and upper plates) of the heat exchange panel of the present invention may be prepared by art-recognized methods, including, but not limited to, injection molding, reaction injection molding, compression molding and sheet thermoforming. The plastic components may be fabricated by a compression molding process that includes: providing a compression mold comprising a lower mold portion and an upper mold portion; forming (e.g., in an extruder) a molten composition comprising plastic material and optionally reinforcing material, such as fibers; introducing, by action of gravity, the molten composition into the lower mold portion; compressively contacting the molten composition introduced into the lower mold portion with the interior surface of the upper mold portion; and removing the molded component from the mold. The lower mold portion may be supported on a trolley that is reversibly moveable between: (i) a first station where the molten composition is introduced therein; and (ii) a second station where the upper mold portion is compressively contacted with the molten composition introduced into the lower mold portion.

The lower mold portion may be moved concurrently in time and space (e.g., in x-, y- and/or z-directions, relative to a plane in which the lower mold resides) as the molten composition is gravitationally introduced therein. Such dynamic movement of the lower mold portion provides a means of controlling, for example, the distribution, pattern and/or thickness of the molten composition that is gravitationally introduced into the lower mold portion. Alternatively, or in addition to movement of the lower mold portion in time and space, the rate at which the molten composition is introduced into the lower mold portion may also be controlled. When the molten composition is formed in an extruder, the extruder may be fitted with a terminal dynamic die having one or more reversibly positionable gates through which the molten composition flows before dropping into the lower mold portion. The rate at which the molten composition is gravitationally deposited into the lower mold portion may be controlled by adjusting the gates of the dynamic die.

The compressive force applied to the molten plastic composition introduced into the lower mold portion is generally less than or equal to 1000 psi (70.3 Kg/cm²), typically from 25 psi to 550 psi (1.8 to 38.7 Kg/cm²), more typically from 50 psi to 400 psi (3.5 to 28.1 Kg/cm²), and further typically from 100 psi to 300 psi (7.0 to 21.1 Kg/cm²). The compressive force applied to the molten plastic material may be constant or non-constant. For example, the compressive force applied to the molten plastic material may initially be ramped up at a controlled rate to a predetermined level, followed by a hold for a given amount of time, then followed by a ramp down to ambient pressure at a controlled rate. In addition, one or more plateaus or holds may be incorporated into the ramp up and/or ramp down during compression of the molten plastic material. The molded plastic components of the heat exchange panel of the present invention may, for example, each be independently prepared in accordance with the methods and apparatuses described in U.S. Pat. Nos. 6,719,551; 6,869,558; 6,900,547; and 7,208,219.

Alternatively, the molded plastic components (e.g., the lower and upper plates) of the heat exchange panel of the present invention may be prepared by a sheetless thermoforming process, in which a heated sheet of thermoplastic material is formed (e.g., from an extruder coupled to a sheet die) and then vacuum drawn over the internal surfaces of a mold portion, while the extruded sheet is still thermoformable (and before it cools to a non-thermoformable temperature). After cooling to a non-thermoformable temperature, the molded article (e.g., in the form of the lower plate or upper plate) is removed from the mold portion, and typically subjected to post-molding operations, such as joining the molded lower plate and molded upper plate together. The heat exchange panel and the various components thereof may be prepared by the sheetless thermoforming processes as described, for example, in United States Patent Application Publication Numbers US 2008/0258354 A1 and US 2008/0258329 A1.

In an embodiment, the lower plate is a substantially unitary lower plate molded from a first plastic material, and the upper plate is a substantially unitary upper plate molded from a second plastic material, in which the first and the second plastic materials are each independently selected from thermoplastic materials, thermoset plastic materials and combinations thereof, as discussed previously herein. Further to this embodiment, the upper plate is substantially transparent to infrared radiation, the lower plate is substantially optically opaque, and the interior surface of the lower plate absorbs infrared radiation.

In a particular embodiment, the upper plate (including the upper plate extensions thereof) is fabricated from a substantially optically transparent plastic material that is also substantially transparent to infrared radiation, such as polycarbonate or clarified polypropylene. The lower plate may be rendered substantially optically opaque by the inclusion of one or more pigments (e.g., carbon black, iron oxides and/or TiO₂) in the plastic material from which the lower plate is fabricated. The interior surface (e.g., 17) of the lower plate (including the exterior surfaces 23 of the lower plate extensions 20) may absorb infrared radiation as a result of the plastic material from which the lower plate is fabricated (e.g., a thermoplastic material filled with carbon black pigment). Alternatively or in addition thereto, the interior surface of the lower plate (including the exterior surfaces 23 of the lower plate extensions 20) may have an infrared absorbent coating applied thereto, such as an acrylic based coating composition having carbon black pigment dispersed therein.

The first plastic material from which the lower plate is molded (including the lower plate extensions) may further include a reinforcing agent, which may be selected from those classes and examples as recited previously herein. In an embodiment, the first plastic material, from which said lower plate is molded (including the lower plate extensions), further includes a reinforcing material selected from the group consisting of glass fibers, glass beads, carbon fibers, metal flakes, metal fibers, polyamide fibers, cellulosic fibers, nanoparticulate clays, talc and mixtures or combinations thereof. While the second plastic material from which the upper plate is molded (including the upper plate extensions) may also include a reinforcing agent, in a particular embodiment: the second plastic material from which the upper plate is molded is substantially free of a reinforcing agent; and the first plastic material from which the lower plate is molded further includes a reinforcing agent.

The heat exchange panel of the present invention may have any suitable shape and dimensions. For example, the heat exchange panel may have a generally circular or oval shape, a polygonal shape (e.g., triangular, rectangular, pentagonal, hexagonal, heptagonal, octagonal shapes, etc.), an irregular shape (e.g., so as to fit around another structure, such as a structural beam or chimney), or any combination thereof. More generally, the heat exchange panel may be a substantially flat heat exchange panel (as depicted in the drawings), or a non-flat (e.g., arcuate) heat exchange panel (not depicted). A non-flat heat exchange panel may, for example, be used to fittingly and securely rest over the apex of a gabled roof structure.

In an embodiment, the heat exchange panel is substantially flat and has a substantially rectangular shape, in which the length is greater than the width thereof, as depicted in the drawings. With reference to FIG. 2, heat exchange panel 1 may have a length 314 (exclusive of the inlet and outlet headers) of from 0.5 m to 3.0 m, typically from 0.70 m to 2.75 m, and more typically from 0.75 m to 2.70 m. Heat exchange panel 1 may have a width 317 (exclusive of the inlet and outlet headers) of from 0.5 m to 3.0 m, typically from 0.70 m to 2.75 m, and more typically from 0.75 m to 2.70 m. In an embodiment, the heat exchange panel has a length (e.g., 314) of 2.4 m, and a width (e.g., 317) of 1.2 m.

The inlet and outlet headers (e.g., 253 and 259) of the heat exchange panel may have any suitable shape and dimension, provided they allow a sufficient amount and rate of flow of heat exchange fluid into and out of the heat exchange panel, and more particularly the channels, channel segments and upper plate extension passages thereof. In an embodiment, the inlet and outlet headers (e.g., 253 and 259) each have a substantially circular cross-section, and independently in each case have an interior diameter of from 12 mm to 762 mm, typically from 15 mm to 300 mm, and more typically from 25 mm to 100 mm. In an embodiment, the inlet and outlet headers each have a substantially circular cross-section and an interior diameter of 25 mm or 51 mm.

Each lower plate extension (e.g., 20) of the heat exchange panel may have any suitable height relative to the interior surface (e.g., 17) of the lower plate (e.g., 11). In an embodiment, and with reference to FIG. 4, each lower plate extension 20 has substantially the same height 320, as from interior surface 17 to the upper surface thereof (e.g., upper transverse face 189) of from 20 mm to 230 mm, typically from 45 mm to 215 mm, and more typically from 70 mm to 190 mm. In an embodiment, each lower plate extension 20 has a height 320 of 120 mm.

In an embodiment, the lower portion (e.g., 66) of each lower plate extension (e.g., 20) typically has a width (e.g., 141) that is substantially equivalent to the width of the channel (e.g., 51) in which the lower portion resides, as described previously herein. See, for example, FIG. 13. For example, the lower portion (e.g., 66) of each lower plate extension (e.g., 20) may have a width (e.g., 141) of from 20 mm to 80 mm, typically from 25 mm to 70 mm, and more typically from 30 mm to 40 mm. In an embodiment, the lower portion (e.g., 66) of each lower plate extension (e.g., 20) has a width (e.g., 141) of 35 mm.

The width (e.g., 144) of each channel (e.g., 51) of the heat exchange panel is typically substantially equivalent to the width (e.g., 141) of the lower portion (e.g., 66) of each lower plate extension (e.g., 20) residing with the channel. For example, each channel (e.g., 51) may have a width (e.g., 144) of from 20 mm to 80 mm, typically from 25 mm to 70 mm, and more typically from 30 mm to 40 mm. Each channel typically has a height that is substantially equivalent to the height (e.g., 326) of the ribs (e.g., 105) that define the channels there-between. For example, each channel (e.g., 51) may have a height (e.g., substantially equivalent to rib height 326) of from 3 mm to 20 mm, typically from 5 mm to 15 mm, and more typically from 10 mm to 12 mm. In an embodiment, each channel (e.g., 51) has a width (e.g., 144) of 35 mm, and a height (e.g., substantially equivalent to rib height 326) of 11 mm. See, for example, FIG. 13.

The ribs (e.g., 105) that serve in part to define the channels (e.g., 51) of the heat exchange panel, may have any suitable dimensions, in particular with regard to the width and height thereof. In an embodiment, each rib (e.g., 105) is a substantially elongated longitudinal rib and has substantially the same dimensions. For example, and with reference to FIG. 13, each rib (e.g., 105) has a width (e.g., 323) of from 5 mm to 30 mm, typically from 7 mm to 25 mm, and more typically from 10 mm to 20 mm. Each rib (e.g., 105) may also have a height (e.g., 326) above interior surface 17 of lower plate 11 of from 3 mm to 20 mm, typically from 5 mm to 15 mm, and more typically from 10 mm to 12 mm. In an embodiment, each rib (e.g., 105) has a width (e.g., 323) of 15 mm, and a height (e.g., 326) of 11 mm.

The heat exchange panel of the present invention may be used to absorb thermal energy from any suitable source of thermal energy, such as: a source of radiant thermal energy (e.g., infrared radiation from the sun); or a source of convective thermal energy, such as a fluid heat sink or source (e.g., a pool of heated liquid, such as water, or stream of heated gas, such as air). In the case of a source of radiant thermal energy, the heat exchange panel is typically oriented so as to expose the exterior surfaces of the upper plate and the upper plate extensions to the source of radiant thermal energy, such as the sun. The radiant thermal energy is transferred primarily through the upper plate extensions (and to a lesser extent also through the exterior surfaces of the upper plate), and into the fluid (e.g., a heat exchange fluid) passing through the upper plate extension passages and underlying channels. The heated fluid upon exiting the heat exchange panel may be used directly (e.g., in the case of a shower), or indirectly, e.g., to heat another fluid, such as water or air, in which case the fluid may be described as a heat exchange fluid. When used to absorb radiant thermal energy from the sun, the heat exchange panel may be described as a solar heat exchange panel.

Alternatively, the heat exchange panel of the present invention may itself be used as a source of thermal energy. For example, a separately heated fluid may be passed through the channels and upper plate extension passages of the heat exchange panel, resulting in thermal energy being transferred out of (rather than into) the upper plate extensions and into a separate medium, such as a gas (e.g., air) or a liquid (e.g., water). The separately heated fluid may be heated in and provided by one or more separate heat exchange panels according to the present invention that are set up so as to absorb thermal energy from another source of thermal energy (e.g., the sun), and which are in fluid communication with the heat exchange panel that is itself acting as a source of thermal energy.

The present invention has been described with reference to specific details of particular embodiments thereof. It is not intended that such details be regarded as limitations upon the scope of the invention except insofar as and to the extent that they are included in the accompanying claims.

Claims

1. A heat exchange panel (1) comprising: (a) a lower plate (11) having an interior surface (17), and a plurality of lower plate extensions (20) extending upwardly from said interior surface of said lower plate, each lower plate extension having exterior surfaces; and(b) an upper plate (14) having an interior surface (26), an exterior surface (29), and a plurality of upper plate extensions (32) extending upwardly from said exterior surface of said upper plate, each upper plate extension having an aperture (42) on said interior surface of said upper plate and interior surfaces that define an interior space that is in fluid communication with said aperture,wherein said lower plate and said upper plate are joined together such that said interior surface of said lower plate and said interior surface of said upper plate together define a plurality of channels (51) there-between, each channel having a terminal inlet (54) and a terminal outlet (57);each channel having at least one lower plate extension (20) residing therein and extending upwardly therefrom, and each channel having the aperture and the interior space of at least one upper plate extension positioned over said channel and in fluid communication with said channel,the aperture and interior space of each upper plate extension being aligned with and receiving an upper portion of one lower plate extension therein,a portion of the interior surfaces defining the interior space of said upper plate extension and a portion of the exterior surfaces of the upper portion of said lower plate extension received within said interior space, in each case, together defining an upper plate extension passage, each upper plate extension passage (72) being in fluid communication with the channel residing there-under, andfurther wherein a fluid introduced into the terminal inlet of said channel passes through each upper plate extension passage in fluid communication with said channel and emerges from said terminal outlet of said channel.

2. The heat exchange panel of claim 1 wherein said heat exchange panel further comprises a plurality of ribs (96) residing interposedly between said interior surface of said lower plate and said interior surface of said upper plate, said ribs being laterally spaced from each other and forming a plurality of paired ribs (99), each pair of ribs together defining one channel there-between.

3. The heat exchange panel of claim 2 wherein at least some of said ribs are lower plate ribs, each lower plate rib is continuous with said lower plate, extends upward from said interior surface of said lower plate, and abuts said interior surface of said upper plate.

4. The heat exchange panel of claim 2 wherein at least some of said ribs are upper plate ribs, each upper plate rib is continuous with said upper plate, extends downward from said interior surface of said upper plate, and abuts said interior surface of said lower plate.

5. The heat exchange panel of claim 2 wherein, said lower plate comprises a plurality of lower plate ribs, each lower plate rib is continuous with said lower plate, and extends upward from said interior surface of said lower plate;said upper plate comprises a plurality of upper plate ribs, each upper plate rib is continuous with said upper plate, and extends downward from said interior surface of said upper plate; andeach lower plate rib abutting one upper plate rib thereby forming each of said plurality of ribs.

6. The heat exchange panel of claim 2 wherein at least one rib comprises at least one lateral passage, each lateral passage providing fluid communication between a pair of neighboring channels separated by said rib having at least one lateral passage.

7. The heat exchange panel of claim 1 wherein each channel is a longitudinal channel.

8. The heat exchange panel of claim 2 wherein each channel is a longitudinal channel, each rib is a longitudinal rib, said plurality of paired ribs is a plurality of paired longitudinal ribs, and each pair of longitudinal ribs together define one longitudinal channel there-between.

9. The heat exchange panel of claim 1 wherein each lower plate extension comprises a lower portion having a width, and each channel has a width; further wherein, the width of said lower portion of said lower plate extension being substantially equivalent to the width of the channel that said lower portion of said lower plate extension resides in, and said channel being substantially blocked by said lower portion of said lower plate extension residing within said channel;said channel thereby comprising a plurality of channel segments, each channel segment being separated from a neighboring channel segment by one lower plate extension, andeach channel segment being in fluid communication with at least one upper plate extension passage.

10. The heat exchange panel of claim 9 wherein; said exterior surfaces of the upper portion of said lower plate extension comprise at least one inlet face on an inlet side of said lower plate extension, at least one outlet face on an outlet side of said lower plate extension, at least one first side face on a first side of said lower plate extension, and at least one second side face on a second side of said lower plate extension, said inlet side and said outlet side of said lower plate extension being on substantially opposite sides of said lower plate extension, said first side and said second side of said lower plate extension being on substantially opposite sides of said lower plate extension, and the upper portion of said lower plate extension having a shape defined by said exterior surfaces of the upper portion of said lower plate extension;said interior space of said upper plate extension having a shape substantially matching the shape of the upper portion of said lower plate extension received within said interior space of said upper plate extension;the interior surfaces defining said interior space of said upper plate extension comprising at least one inlet surface on an inlet side of said interior space, at least one outlet surface on an outlet side of said interior space, at least one first side surface on a first side of said interior space, and at least one second side surface on a second side of said interior space, said inlet side and said outlet side of said interior space being on substantially opposite sides of said interior space, said first side and said second side of said interior space being on substantially opposite sides of said interior space;each inlet face of the upper portion of said lower plate extension and each inlet surface of said interior space together defining an ascending inlet passage portion of said upper plate extension passage,each outlet face of the upper portion of said lower plate extension and each outlet surface of said interior space together defining a descending outlet passage portion of said upper plate extension passage, said ascending inlet passage portion and said descending outlet passage portion of said upper plate extension passage being in fluid communication with each other,at least one first side face of the upper portion of said lower plate extension and at least one first side surface of said interior space abutting each other, andat least one second side face of the upper portion of said lower plate extension and at least one second side surface of said interior space abutting each other.

11. The heat exchange panel of claim 10 wherein; said exterior surfaces of the upper portion of said lower plate extension further comprise an upper transverse face, and the interior surfaces defining said interior space of said upper plate extension further comprise an upper transverse surface;said upper transverse face of said lower plate extension and said upper transverse surface of said interior space of said upper plate extension together defining a transverse passage portion of said upper plate extension passage;said transverse passage portion being in fluid communication with each of said ascending inlet passage portion and said descending outlet passage portion of said upper plate extension passage.

12. The heat exchange panel of claim 10 wherein said shape of the upper portion of said lower plate extension is selected from pyramidal shapes.

13. The heat exchange panel of claim 11 wherein said shape of the upper portion of said lower plate extension is selected from truncated pyramidal shapes having an upper truncated face, said upper truncated face being said upper transverse face.

14. The heat exchange panel of claim 13 wherein said shape of the upper portion of said lower plate extension is selected from truncated rectangular pyramidal shapes.

15. The heat exchange panel of claim 1 wherein said heat exchange panel further comprises a sidewall structure 198 having an interior surface 201, an exterior surface 226, an upper terminus 204 and a height 207, said upper terminus of said sidewall structure residing above said exterior surface of said upper plate and defining an open top of said sidewall structure, said sidewall structure extending around said plurality of upper plate extensions, said interior surfaces of said sidewall structure defining an interior sidewall structure space, said plurality of upper plate extensions residing within said interior sidewall structure space, and said height of said sidewall structure being at least equivalent to a maximum height of said plurality of upper plate extensions.

16. The heat exchange panel of claim 15 wherein said heat exchange panel further comprises a plate covering said open top of said sidewall structure, said plate being positioned on said upper terminus of said sidewall structure, and said plate being substantially transparent to infrared radiation.

17. The heat exchange panel of claim 15 wherein; said sidewall structure further comprises a shelf 241 having an upper surface 244 having a height 247 above said exterior surface 29 of said upper plate, said shelf being positioned inward towards said interior sidewall structure space 229,said height of said sidewall structure being greater than said maximum height of said plurality of upper plate extensions, said height of said upper surface of said shelf being less than said height of said sidewall structure and at least equivalent to said maximum height of said plurality of upper plate extensions, andsaid heat exchange panel further comprising a substantially infrared transparent plate covering said open top of said sidewall structure, and being positioned on said upper surface of said shelf.

18. The heat exchange panel of claim 15 wherein said sidewall structure is continuous with said upper plate, and extends upwardly from said exterior surface of said upper plate.

19. The heat exchange panel of claim 1 further comprising an inlet header 253 having an inlet header interior space 256, and an outlet header 259 having an outlet header interior space 268, said inlet header interior space being in fluid communication with the terminal inlet of each channel, and said outlet header interior space being in fluid communication with the terminal outlet of each channel.

20. The heat exchange panel of claim 19 wherein; said lower plate further comprises a lower inlet header portion 272 positioned on an inlet side 275 of said lower plate, and a lower outlet header portion 278 positioned on an outlet side 281 of said lower plate, said upper plate further comprises an upper inlet header portion 284 positioned on an inlet side 287 of said upper plate, and an upper outlet header portion 290 positioned on an outlet side 293 of said upper plate,further wherein said lower plate and said upper plate are joined together such that said lower inlet header portion and said upper inlet header portion are joined together and form said inlet header, and said lower outlet header portion and said upper outlet header portion are joined together and form said outlet header.

21. The heat exchange panel of claim 1 wherein said lower plate is a substantially unitary lower plate molded from a first plastic material, said upper plate is a substantially unitary upper plate molded from a second plastic material, and said first plastic material and said second plastic material are each independently selected from thermoplastic material, thermoset plastic material and combinations thereof.

22. The heat exchange panel of claim 21 wherein said upper plate is substantially transparent to infrared radiation, said lower plate is substantially optically opaque, and said interior surface of said lower plate absorbs infrared radiation.

23. The heat exchange panel of claim 21 wherein said first plastic material, from which said lower plate is molded, further comprises a reinforcing material selected from the group consisting of glass fibers, glass beads, carbon fibers, metal flakes, metal fibers, polyamide fibers, cellulosic fibers, nanoparticulate clays, talc and mixtures thereof.

24. The heat exchange panel of claim 1 wherein; said heat exchange panel has a total upper plate extension passage volume, a total channel volume, and a total internal volume equal to a sum of said total upper plate extension passage volume and said total channel volume;further wherein said heat exchange panel has a percent total upper plate extension passage volume of from 50 percent to 95 percent, based on said total internal volume, and a percent total channel volume of from 5 percent to 50 percent, based on said total internal volume.

25. The heat exchange panel of claim 1 wherein; each channel is a longitudinal channel;each lower plate extension is laterally staggered relative to each neighboring lower plate extension of each adjacent channel; andeach upper plate extension is laterally staggered relative to each neighboring upper plate extension of each adjacent channel.

26. The heat exchange panel of claim 25 wherein as amongst any three sequentially adjacent channels; said lower plate extensions form a plurality of lower plate extension X-configurations each comprising five lower plate extensions with a single terminal lower plate extension located at each corner of said lower plate extension X-configuration, and a single central lower plate extension located at the intersection of said lower plate extension X-configuration, andsaid upper plate extensions form a plurality of upper plate extension X-configurations each comprising five upper plate extensions with a single terminal upper plate extension located at each corner of said upper plate extension X-configuration, and a single central upper plate extension located at the intersection of said upper plate extension X-configuration.