The present disclosure generally relates to heat exchangers, and more particularly relates to heat exchangers having a stack of a plurality of flat tubes that each carries a fluid through its interior, with the flat tubes being spaced apart by raised projections or dimples on the flat faces of the tubes, wherein the dimples of one tube contact the dimples of the adjacent tube so as to space the flat faces apart by twice the dimple height. In this manner, flow paths are defined between the spaced-apart flat faces for flow of another fluid so that heat exchange can take place with the fluid flowing through the interiors of the flat tubes. Typically, a fluid at a relatively high temperature is passed through the interiors of the tubes, a coolant at a lower temperature is passed through the spaces between the tubes, and heat is transferred between the fluids to cool the high-temperature fluid.
In such flat tube stacks, it is known that in addition to being useful for spacing the tubes apart, the external dimples are also effective for inducing turbulence in the fluid flowing through the spaces between the adjacent tubes. Accordingly, the dimples are also sometimes referred to as “turbulators” that induce “turbulation” in the fluid flow. Such turbulation can be beneficial for enhancing the heat transfer rate between the fluids, and can also help to prevent boiling of the fluid. Typically, the dimples are round in plan shape.
Round dimples provide moderate turbulation, but in many cases a greater degree of turbulation would be desirable.
Additionally, the top or outermost surfaces of the round dimples that contact each other are relatively small and thus do not provide much stability when stacking the tubes. Accordingly, it is not uncommon for assembly of the tube stack to be faulty because of one tube slipping relative to the adjacent tube such that the dimples “nest”, resulting in too small a spacing between the tubes. Furthermore, because of the small contact areas of the round dimples, even relatively small tolerances on the dimple locations can make it more likely that the dimples will nest. If not corrected, the resulting improper tube spacing would cause undue flow restriction in the coolant and impair proper performance of the heat exchanger.
The present disclosure relates to a flat tube and a heat exchanger having a stack of a plurality of such flat tubes, wherein a special dimple configuration and arrangement provide enhanced stability for stacking of the tubes. In some embodiments the dimples essentially preclude nesting of tubes. The dimple configuration and arrangement also provide enhanced turbulation relative to conventional round dimples.
In accordance with one embodiment of the invention, a flat tube comprises a tube having a first face that is generally flat and an opposite second face that is generally flat, the tube having an interior passage open at opposite first and second ends of the tube for flow of a fluid into one end and out the other end. A plurality of spaced-apart dimples are formed on each of the first and second faces. At least some of the dimples on each face have an elongate plan shape as viewed perpendicular to the respective face such that each elongate dimple has a length along a major axis greater than a width of the elongate dimple along a minor axis, at least some of the elongate dimples being obliquely oriented with the major axes forming oblique angles with a longitudinal axis of the tube. The obliquely oriented elongate dimples are positioned such that when two of the tubes are stacked, the obliquely oriented elongate dimples on opposing faces of the tubes contact one another and the major axes of each contacting pair of elongate dimples are non-parallel to each other. Each contacting pair of elongate dimples of adjacent tubes thus forms a “cross” or “X”. It is thought that such elongate dimples can substantially increase the amount of turbulation in the coolant flow.
Additionally, the crossing elongate dimples provide much larger contact areas than do round dimples, substantially reducing the likelihood of nesting.
In a preferred embodiment of the invention, the flat tube also includes orientation indicators comprising projections from each of the first and second faces and each having a height exceeding the height of the dimples but not exceeding twice the height of the dimples. The orientation indicators are located on each of the first and second faces of the tube in positions such that when two of the tubes are correctly oriented relative to each other in a tube stack the orientation indicators on the opposing faces of the tubes allow the elongate dimples on the opposing faces to contact one another to space the opposing faces apart by twice the height of the dimples. However, when the tubes are incorrectly oriented relative to each other (e.g., by reversing one tube end-over-end relative to its proper orientation) the orientation indicator on one tube contacts the orientation indicator on the other tube and prevents the elongate dimples from contacting each other, thereby indicating improper orientation of the tubes.
The orientation indicators can be used in a flat tube having the elongate dimples, but are also useful with flat tubes having other dimple configurations such as round dimples. In the case of flat tubes having the above-described obliquely oriented elongate dimples that cross when contacting one another, the orientation indicators prevent the tubes from being stacked in any way other than the proper way in which the elongate dimples contact one another in the crossing manner.
In one embodiment, the orientation indicator on the first face of the tube is positioned proximate to the first end of the tube, and the orientation indicator on the second face is positioned proximate to the second end of the tube. Each orientation indicator is positioned to align with a region of the flat face of an adjacent tube that is flat (i.e., where there is no dimple) when the two tubes are properly oriented with respect to each other.
In one embodiment, the elongate dimples are arranged on each face in a two or more rows extending parallel to the longitudinal axis and spaced apart in a width direction of the tube. In a particular embodiment, there are three and only three rows of elongate dimples on each face, and the elongate dimples in one of the rows (preferably the middle of the three rows) on each face have the major axes oriented substantially parallel to the longitudinal axis of the tube, while the elongate dimples in the other rows on each face have the major axes oriented obliquely to the longitudinal axis.
In one embodiment, the obliquely oriented elongate dimples in one of the rows on each face have the major axes inclined in an opposite direction from the longitudinal axis in comparison to the obliquely oriented elongate dimples in another of the rows.
The major axes of the obliquely oriented elongate dimples can form an angle relative to the longitudinal axis of about 20° to about 45°. The height of the elongate dimples is about 5% to 30% of a thickness of the tube measured between the first face and the second face. The length of each elongate dimple is about 10% to about 30% of a width of the tube measured perpendicular to the longitudinal axis between opposite side edges of the tube.
The present disclosure also relates to a heat exchanger having a shell defining an inner chamber, and a stack of the above-described flat tubes disposed in the inner chamber.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
The present disclosure relates to heat exchangers used for reducing the temperature of a fluid stream passed through the heat exchanger. The heat exchangers in accordance with this disclosure can be used with vehicles generally and, more particularly, can be used to cool an exhaust gas stream from an internal combustion engine. However, it will be readily understood by those skilled in the relevant technical field that the heat exchanger configurations of the present disclosure can be used in a variety of different applications.
The shell 32 is configured to surround the tube stack and includes a coolant inlet and a coolant outlet to facilitate passage of a desired cooling fluid or medium therethrough. The shell can be formed from suitable structural materials such as metals, metal alloys and the like having desired structural and mechanical properties enabling use in such a heat exchanger application. The shell can be formed of a single piece of material. In a preferred embodiment, the shell 32 is made from a stainless steel material. The shell can be made by molding process or by hydroforming or end expanding a seam-welded rectangular tube. The shell 32 is configured to surround the tube stack and facilitate a desired degree of coolant circulation therein to provide a desired degree of heat transfer contact with the tube stack.
As is shown in
The tube 38 can include a flow element 40 disposed therein. The flow element 40 can be provided in the form of a corrugated member or the like that extends a partial or complete length of the tube. The flow element 40 can be referred to as a fin or a turbulator, and can form a further flow path within the tube, operate to increase the gas or fluid contact surface area within the tube, and operate to increase flow turbulence therein, which can aid in cooling the fluid flowing through the tubes 38. Additionally, the fin or turbulator can function to add structural rigidity to the tube if desired.
As shown in
As shown in
As previously noted, the round projections or dimples 43 in this prior flat tube 38 have a number of drawbacks, which the present invention seeks to overcome or alleviate.
A flat tube 100 in accordance with one embodiment of the invention is shown in
The dimples 110, 112 on the tube 100 are configured and arranged such that when two tubes are stacked together with the face 102 of one tube opposing the face 104 of the other, and the tubes are properly oriented and aligned with each other, the elongate dimples 110 on the face 102 contact the elongate dimples 112 on the face 104.
As illustrated, at least some of the elongate dimples 110, 112 are oriented with their major axes A oblique with respect to a longitudinal axis of the tube 100. More specifically, the dimples 110 are arranged in three rows 110a, 110b, and 110c each of which extends parallel to the longitudinal axis of the tube, the rows being spaced apart in the width direction of the tube. The elongate dimples 110a in the row adjacent one longitudinal side edge of the tube are oriented with their major axes A forming a positive angle +α relative to the longitudinal axis of the tube. The elongate dimples 110b in the middle row are oriented with their major axes A substantially parallel to the longitudinal axis of the tube. The elongate dimples 110c adjacent the other longitudinal side edge of the tube have their major axes A forming a negative angle −α relative to the longitudinal axis of the tube. Thus, the elongate dimples 110a and 110c are arranged to form a “V” or chevron configuration.
As can be seen by comparing
The crossing pairs of elongate dimples 110, 112 offer the potential of enhanced turbulation of the coolant flow through the passages between the tubes, relative to conventional round dimples.
Additionally, as previously noted, a further advantage of the elongate dimples is a substantially increased amount of contact area between the dimples relative to round dimples. Furthermore, particularly when the dimples are obliquely arranged so they cross each other, the new dimple design provides a substantially reduced sensitivity to positional tolerances of the dimples in terms of the prevention of “nesting” of the dimples of adjacent tubes.
Thus, the oblique elongate dimples as described significantly improve upon round dimples in a number of respects. However, it is still possible (although less likely) for the dimples to nest if the tubes are not properly oriented relative to each other. Furthermore, if the tubes are not properly oriented, the oblique elongate dimples will not cross but rather will be parallel. For example, referring to
In order to prevent such improper orientation of the tubes, each tube 100 can include an orientation indicator 120 on the face 102 and a similar orientation indicator 122 on the other face 104 (see
However, if one tube is reversed end-for-end without rotating it about its longitudinal axis, or is rotated 180° about its longitudinal axis without reversing it end-for-end, and is stacked on the other tube, then the orientation indicator on one tube will contact the orientation indicator on the other tube. This is possible because the orientation indicators exceed about 1.2 times the dimple height, and thus when they are aligned, their contact with each other will prevent the dimples from contacting each other at the end of the tube stack where the orientation indicators are located. It will thus be readily apparent to the worker assembling the tube stack that the tubes are not properly oriented, and the error can be corrected.
The dimples on the flat tubes in accordance with the invention can be arranged in various ways. The previously described tube 100 has three rows of elongate dimples, but alternatively the dimples can be arranged in two or more rows. For example,
In the tubes 100, 200 described and illustrated thus far, the dimples are arranged in straight rows in the longitudinal direction and also in the widthwise or transverse direction of the tube. This arrangement of the dimples in straight rows in the longitudinal direction enables the tube to be made by roll-forming in a tube rolling mill. Alternatively, if the tube is made by other techniques (e.g., stamping of the sheet followed by bending the sheet into a tube shape), then the dimples may be staggered rather than in straight longitudinal rows.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.