Heat exchanger incorporating out-of-plane features

Abstract

The present invention is directed towards a heat exchanger incorporating integral fin and turbulence enhancement features which are designed to improve hydraulic efficiency and heat transfer rates. The heat exchanger device comprises a top surface, a bottom surface, a front surface, a back surface, and two opposing side surfaces to define a main body unit. The heat exchanger device further comprises a plurality of laminar elements, or plates, having surface configurations to provide for to fluid flow therein. In order to increase heat transfer rates through the mixing of fluid, the heat exchanger device in accordance with the present invention contains features which enhance and increase flow turbulence and heat transfer surface area, referred to as out-of-plane structures. In one embodiment, the heat exchanger device contains features which form vertical out-of-plane structures. Alternatively, the heat exchanger device contains features which form horizontal out-of-plane structures.

Description

FIELD OF THE INVENTION

The present invention relates to heat exchangers, to improved heat exchangers incorporating out-of-plane features, and more particularly to heat exchangers with modified fins and turbulence enhancement features.

BACKGROUND OF THE INVENTION

Heat exchangers may be employed whenever it is desirous to remove heat from or add heat to a system. Typically a heat exchanger will utilize a working fluid, liquid or gaseous, to facilitate this transfer of energy. Simple heat exchangers, sometimes referred to as heat sinks, such as those used to cool microprocessors, typically employ a plurality of fins to efficiently radiate excess heat from the microprocessor to the surrounding air. As the air close to the hot fins is warmed, convection causes the air to rise and cooler air replaces the warmed air. A fan may be employed to increase the flow of air over the fins to improve heat removal.

More complex heat exchangers may employ flowing liquids that may or may not be recirculated during operation. A primary design goal for heat exchangers is the heat transfer rate. An exchanger's effectiveness is the ratio of the actual heat transferred relative to the heat that could be transferred by an infinitely large heat exchanger. While the heat transfer rate is important, it is not the only design goal. In addition to high thermal efficiency, the heat exchanger must also be efficient to operate and efficient to manufacture. Operational efficiency requires that the fluid pressure drop across the heat exchanger be minimal. Since a pump or other fluid forcing means will likely be employed to move fluid through the heat exchanger, the energy and hence the cost to operate this pump must also be considered when designing a heat exchanger. A heat exchanger with a low-pressure drop will require less pumping energy than a similar exchanger with a higher pressure drop. Manufacturing efficiency and final product cost must also be considered when designing a heat exchanger. A heat exchanger with the highest possible heat transfer rate may have an extremely high pressure drop, be terribly difficult to manufacture, and very expensive. So, as a practical matter, heat exchanger design must consider not only heat transfer rates but also manufacturability and product cost.

Two methods have frequently been employed to improve heat transfer. First, increasing the surface area of the heat transfer elements is a common method to improve the heat transfer rate. This may be accomplished in some types of heat exchangers by the addition of fins. The fins may be made of sheet metal and typically comprise a plurality of closely spaced flat plates. In a shell and tube type heat exchanger, increasing the number of tubes may be employed to increase heat transfer surface area. A variety of other methods have been employed to improve heat transfer through increased surface area. Most of these methods involve the addition of materials and increased manufacturing complexity.

A second method used to improve heat transfer ability is that of increasing turbulence in the fluid flow. When fluid flows in a smooth walled, straight tube, (the tube need not be round) the flow will be predominantly laminar, having a Reynolds number of approximately 2000 or less. In a laminar flow environment there is very little mixing of the fluid and heat transfer within this fluid is primarily through conduction. This mode of heat transfer is extremely inefficient. When the fluid flow is turbulent, heat transfer within the fluid is predominantly in the form of eddy transport, so it is useful to increase these eddies through increased turbulence. Turbulence may be increased by introducing deformations in the wall of the tube such as corrugations or “dimples.” Similarly, turbulence may be increased by placing obstacles such as pegs, fins or other objects in the fluid flow path.

In flow situations where the Reynolds number is greater than 2000, but less than 6000, turbulence may, or may not be present. As the Reynolds number associated with the flow increases, turbulence, and hence, heat transfer increases. Flow regimes with Reynolds numbers of 6000 or greater are generally considered to be fully turbulent. Increasing heat transfer rate through either increased surface area or through increased flow turbulence comes at a price. In both cases, additional material and manufacturing processes are likely to be required and importantly, the operating pressure drop increases. Additionally, common manufacturing methods are somewhat “linear” in that, for example, doubling the number of fins will require twice as much effort to be expended.

The introduction of deformations to the flow path to increase turbulence requires additional effort and increases flow resistance and hence pressure drop across the device. Unless the application of increased surface area or turbulence introduction is precisely controlled, these methods of increasing heat exchanger efficiency can be costly to the manufacturer as well as to the end user. A method has been developed that permits any manner and number of fins or other structures to be precisely produced to enhance thermal transfer. This same method may be employed to enhance turbulence through the introduction of obstacles in the fluid flow path.

The heat exchanger and methods of making the heat exchanger in accordance with the present invention overcome many of the shortcomings of previous designs particularly with respect to hydraulic efficiency and heat transfer rate.

DESCRIPTION OF THE PRIOR ART

Heat exchangers having surface protrusions are known are known in the art. For example, U.S. Pat. No. 7,905,274 is described as disclosing a wing-spanning thermal-dissipating device which is described as having a plurality of thermal-dissipating sheets. Each of the thermal-dissipating sheets is described as having a connecting portion, at least one thermal-dissipating fin and a plurality of sub-thermal-dissipating fins. The connecting portions of the thermal-dissipating sheets connect with each other. The thermal-dissipating fin is extended outwardly and spread out from the connecting portion. The sub-thermal-dissipating fins are extended from at least one side of the thermal-dissipating fin.

U.S. Pat. No. 7,568,518 is described as disclosing a heat sink which is described as a fin unit having a plurality of fins which are arranged parallel to each other. A flow channel is described as being formed between any of two neighboring fins for an airflow flowing there though. Three protrusions are arranged on each of the fins and each defines a through hole therein. The through hole is described as communicating with two neighboring flow channels of the fin for the airflow flowing there through from one of the two neighboring flow channels to the other one of two neighboring flow channels of the fin. The fins however, fail to contain twists or bends.

U.S. Pat. No. 7,040,386 is described as disclosing corrugated fins or plate fins which are described as being formed with meandering projections. A fluid such as air is described as striking bent parts of the meandering projections or grooves at the back sides while flowing along the fins. As the fluid flows, it becomes turbulent and therefore flows while meandering so as to be directed toward the surfaces of the tubes. Fluid flow is described as contacting the front and back surfaces of the fins without leaving any dead space as well as striking the surfaces of the tubes. The specification states that no boundary layers are formed at the surfaces of the fins or tubes, so heat conduction is promoted and therefore the heat exchange efficiency between a first fluid such as a refrigerant flowing through the insides of the tubes and a second fluid such as air flowing outside is remarkably improved.

U.S. Pat. No. 6,267,178 is described as disclosing a built-up heat exchanger which is described as including a seat and a plurality of radiators superposed on a top of the seat. The seat is made of a thermal conductive material in sheet form and has at least two notches formed on a top surface thereof. The plurality of radiators are made of a thermal conductive material in sheet form and are punched to form a plurality of upward extended fins and at least two downward projected ridges corresponding to the at least two notches on the seat, such that any of the radiators may be superposed on the top surface of the seat with the at least two downward projected ridges fitly received in the at least two notches.

U.S. Pat. No. 6,056,048 is described as disclosing a heat exchanger tube which is described as including ribs which are formed in protrusion on an internal surface of the tube and extending spirally with a suitable distance between adjacent ribs, concavities formed on the external surface of the tube and extending spirally with a suitable distance between adjacent concavities, and a plurality of independent projections formed on the external surface of the tube and laid out spirally. The projections are further described as being formed with a recess on their top surfaces in such a way that a portion aligned with the ribs on the internal surface of the tube is lower than a portion aligned with an area between the ribs. Further, the concavities on the external surface of the tube and the ribs on the internal surface of the tube are formed at mutually aligned positions.

United States Patent Application 2008/0271877 is described as disclosing an apparatus for increasing heat exchange when using multiple tubes. An embodiment of the multi-tube heat exchanger is described as having a first tube for receiving a heating or cooling medium. The first tube has a first end and a second end wherein the first end and the second end provide a medium inlet and a medium outlet, an outer surface, and a plurality of turbulence inducers wherein a single turbulence inducer is a smooth raised fin disposed on the outer surface of the first tube and further wherein the plurality of turbulence inducers are disposed in rows around the outer surface of the first tube with the rows arranged perpendicular to a laminar flow direction of a flowable or pumpable product.

SUMMARY OF THE INVENTION

The present invention is directed towards a heat exchanger incorporating integral fin and turbulence enhancement features which are designed to improve hydraulic efficiency and heat transfer rates. The heat exchanger device comprises a top surface, a bottom surface, a front surface, a back surface, and two opposing side surfaces to define a main body. The heat exchanger device further comprises a plurality of laminar elements, or plates, having surface configurations to provide for fluid flow therein. In order to increase heat transfer rates through the mixing of fluid, the heat exchanger device in accordance with the present invention contains features which enhance and increase flow turbulence and heat transfer surface area, referred to as out-of-plane structures. In one embodiment, the heat exchanger device contains features which form vertical out-of-plane structures. Alternatively, the heat exchanger device contains features which form horizontal out-of-plane structures.

In one embodiment, the invention is directed towards heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties comprising: a main body having a top surface, a bottom surface, and an interior portion therebetween, said interior portion adapted to provide at least one fluid to flow therein; a plurality of individual laminar elements, said individual laminar elements having surface configurations adapted to allow fluid flow, each said individual laminar elements stacked against adjacent laminar elements, wherein said surface configurations of each individual laminar elements are arranged relative to adjacent surface configurations of each said adjacent laminar elements to form a three dimensional structure; and at least one out-of-plane structure, said at least one out-of-plane structure adapted to alter fluid flow path within said interior region to increase turbulence

The present invention is also drawn to a method of removing heat from a system comprising the steps of: providing a heat exchanging unit having structures adapted to provide hydraulic efficiency and desirable heat transfer properties to a system, said heat exchanging unit comprising a main body having a top surface, a bottom surface, and an interior portion therebetween, said interior portion adapted to provide at least one fluid to flow therein; a plurality of individual laminar elements, said individual laminar elements having surface configurations adapted to allow fluid flow, each said individual laminar elements stacked against adjacent laminar elements, wherein said surface configurations of each individual laminar elements are arranged relative to adjacent surface configurations of each said adjacent laminar elements to form a three dimensional structure; at least one out-of-plane structure, said at least one out-of-plane structure adapted to alter fluid flow path within said interior region to increase turbulence; at least one fluid inlet, and at least one fluid outlet; arranging said out-of-plane structures to allow fluid flow directed therein to flow in a particular manner; whereby said out-of-plane structures enhance turbulence through the introduction of obstacles in the laminar flow path of a fluid flowing therein.

Accordingly, it is an objective of the present invention to provide an improved heat exchanging device adapted to improve hydraulic efficiency and heat transfer rates.

It is a further objective of the present invention to provide a heat exchanging device incorporating integral fin and turbulence enhancement features.

It is yet another objective of the present invention to provide a heat exchanging device having structures which alter fluid flow path to increase turbulence.

It is a still further objective of the invention to provide an economically produced heat exchanging device having structures which alter fluid flow path to increase turbulence.

It is a further objective of the present invention to provide a heat exchanging device incorporating integral fin and turbulence enhancement features whereby the size, shape, alignment and position of these fins and turbulence enhancement elements, are precisely controlled.

It is yet another objective of the present invention to provide a heat exchanging device incorporating integral fin and turbulence enhancement features which reduces pressure drops.

It is a still further objective of the present invention to provide a process of making a heat exchanging device incorporating integral fin and turbulence enhancement features which enhances thermal efficiencies.

It is a further objective of the present invention to provide an economical process for manufacturing a heat exchanging device incorporating integral fin and turbulence enhancement features which enhances thermal efficiencies which minimizes manufacturing costs.

Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of an illustrative example of the heat exchanger incorporating out-of-plane features;

FIG. 2 is a perspective view of an illustrative example of a laminar element, illustrating a first top surface;

FIG. 3 is a perspective view of the laminar element shown in FIG. 2, illustrating a second bottom surface;

FIG. 4 is a partial cut-away view of the heat exchanger incorporating out-of-plane features;

FIG. 5A is a partial view of the heat exchanger incorporating out-of-plane features showing a plurality of finger-like shaped vertical horizontal out-of-plane structures;

FIG. 5B illustrates fluid flow for the partial view of the heat exchanger incorporating out-of-plane features illustrated in FIG. 5A;

FIG. 6A is a perspective view of an illustrative example of a plurality of laminar elements stacked together to form a column-like shaped vertical out-of-plane structure;

FIG. 6B is a top view of the plurality of laminar elements illustrated in FIG. 6A;

FIG. 6C is an elevation view of the plurality of laminar elements illustrated in FIG. 6A;

FIG. 7A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a wedge-shaped mixed vertical-horizontal out-of-plane structure;

FIG. 7B is a top view of the plurality of laminar elements illustrated in FIG. 7A;

FIG. 7C is an elevation view of the plurality of laminar elements illustrated in FIG. 7A;

FIG. 8A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a diamond-shaped mixed vertical-horizontal out-of-plane structure;

FIG. 8B is a top view the plurality of laminar elements illustrated in FIG. 8A;

FIG. 8C is an elevation view of the plurality of laminar elements illustrated in FIG. 8A;

FIG. 9A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a rounded edge horizontal out-of-plane structure;

FIG. 9B is a top view of the plurality of laminar elements illustrated in FIG. 9A;

FIG. 9C is an elevation view of the plurality of laminar elements illustrated in FIG. 9A;

FIG. 10A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a pyramidal rounded wedge shape vertical out-of-plane structure;

FIG. 10B is a top view of the plurality of laminar elements illustrated in FIG. 10A

FIG. 10C is an elevation view of the plurality of laminar elements illustrated in FIG. 10A;

FIG. 11A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a vertical out-of-plane structure and a horizontal out-of-plane structure which assumes an irregular shape formed by a plurality of stacked laminar elements having curved foils;

FIG. 11B is a top view of the plurality of laminar elements illustrated in FIG. 11A

FIG. 11C is an elevation view of the plurality of laminar elements illustrated in FIG. 11A;

FIG. 12A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a vertical out-of-plane structure and a horizontal out-of-plane structure having spike like structures;

FIG. 12B is a top view of the plurality of laminar elements illustrated in FIG. 12A

FIG. 12C is an elevation view of the plurality of laminar elements illustrated in FIG. 12A;

FIG. 13A is a perspective view of an alternative example of a plurality of laminar elements stacked together to form a particular out-of-plane structure have both vertical and horizontal out-of-plane features;

FIG. 13B is a top view of the plurality of laminar elements illustrated in FIG. 13A;

FIG. 13C is an elevation view of the plurality of laminar elements illustrated in FIG. 13A;

FIG. 14 is a detail view of an alternative example of a plurality of laminar elements stacked together to form pluralities of out-of-plane structures, incorporating both vertical and horizontal out-of-plane features.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred, albeit not limiting, embodiment with the understanding that the present disclosure is to be considered an exemplification of the present invention and is not intended to limit the invention to the specific embodiments illustrated.

Referring to FIG. 1, an illustrative example of a heat exchanger device with out-of-plane features, referred to generally as 10, is illustrated. The heat exchanger device with out-of-plane features 10 in accordance with the present invention contains similar features as the heat exchanging device, and methods of making, described and illustrated in U.S. Patent Publication Number US20130056186A1, entitled “HEAT EXCHANGER PRODUCED FROM LAMINAR ELEMENTS” the contents, in its entirety, of which are herein incorporated by reference. Although described in the '051 Application, the heat exchanger device with out-of-plane features 10 contains a plurality of stacked elements, each element having a cut out portion or pattern specifically sized, shaped, and/or configured to align with adjacent stacked element's cut out portion or pattern to form a three dimensional shape or configuration.

The heat exchanger device with out-of-plane features contains a top surface 12, a bottom surface 14, a front surface 16, a back surface 18, and two opposing side surfaces 20 and 22 to define a main body unit. The heat exchanger device with out-of-plane features 10 contains a plurality of stacked, laminar elements, illustrated herein as a generally planar plate, referred to generally as 24, and individually as 24A, 24B, 24C, and the like. Each of the laminar plates 24 contains a first front surface 26, see FIG. 2, and a second back surface 28, see FIG. 3. The plurality of laminar plates 24 is preferably stacked so that the bottom surface 28 of one plate rests on the top surface 26 of an adjacent plate. In this configuration, the heat exchanger with out-of-plane features 10 contains a bottom plate 24A, a top plate 24M, and an interior region 30 therebetween, see FIG. 4. Referring to FIG. 4, a partial cross sectional view of the heat exchanger with out-of-plane features 10 shown in FIG. 1 is illustrated. The plurality of stacked, laminar elements comprises plates 24B-24L, each plate formed to provide one portion of the overall shape configuration. The ultimate shaped configuration defines the core portion of the heat exchanger 10.

The plurality of stacked, laminar plates 24 can be secured together to form geometrical shapes and/or to form walls 32 and passages 34 within the inner portion 30. The formation of the walls 32 and the passages 34 can be precisely controlled creating shapes or channels within the individual stacked, laminar plates 24, which when stacked in a particular orientation, form the walls 32 and passages 34 of particular size, shape, and/or orientation. The walls 32 and passages 34 may be fashioned by photochemical machining, fineblanking, CNC machining, laser or water-jet cutting or any other suitable process. Because the geometry of the laminar elements is capable of being precisely controlled and can be very complex, the walls 32 and passages 34 created when these laminar elements are stacked to form a three-dimensional structure may also be precisely controlled and very complex while maintaining a low pressure drop. This degree of complexity permits very detailed fluid flow structures to be realized. The walls 32 created can serve to hydraulically separate multiple fluids while the passages 34 provide a conduit for fluid flow. In this case, a counter-flow fluid heat exchanger is described.

As illustrated in FIGS. 1 and 2, the heat exchanger device with out-of-plane features 10 provides for multiple fluids to flow therein. As such, a first fluid flow inlet port 36 with a first fluid outlet port 38 is provided. Similarly, a second fluid inlet port 40 and a second fluid outlet port 42 are also provided. In this arrangement, heat will be transferred from one fluid to a second fluid but the fluids will remain hydraulically isolated. While the present embodiment illustrates a counter-flow fluid heat exchanger, such embodiment is not intended to be limiting and a device with single inlet and outlet ports may be utilized.

In order to increase heat transfer rates through the fluid, the heat exchanger device with out-of-plane features 10 contains features which enhance and increase flow turbulence and heat transfer surface area. Such features are referred to as out-of-plane structures. As used herein, the term “out-of-plane” is defined as at least one portion of the laminar elements, including but not limited to one or more protrusions, extensions, finger-like members, which extend from the upper surface 26, or lower surface 28, or combinations thereof, of the reference surface or plate. Preferably, the reference surface is the base plate 24A, but may also include corresponding surface planes of each of the adjacent laminar plates. The portion of the laminar element(s) (i.e. base plate or individual plates) may extend outwardly from the surfaces at various degrees (greater than zero degrees and less than 180 degrees) and/or orientations (twisting, bending) relative to the reference surface. Such features may be termed a “vertical out-of-plane structure(s)”. The vertical out-of-plane structure(s) may include, but are not limited to directionally twisted members which have a handedness twist or curvature, such as a right-handed twist in which at least some portion of the member twists/curves toward the right, a left-handed twist in which are least some proton of the member twists/curves to the left, an upwards bend in which a member bends and/or extends outwardly away from and/or above the upper surface 26, and a downward bend in which a member bends and/or extends outwardly away from and/or below the upper surface 26. The term “vertical out-of-plane structure(s)” may also include the shaped structures formed from a plurality of individual plates stacked upon each other so that platelets from each of the individual plates stack in a certain orientation to form the vertical out-of-plane structure. These structures are built upwardly from the surface of the reference surface, preferably the base plate 24A.

In addition, the term “out-of-plane” may define or refer to the arrangement in which the three-dimensional structure formed by the stacked plates includes one or more of the individual portions and/or plates which form the three dimensional structure being misaligned, or shifted to the left or right relative to adjacent adjacent platelets with respect to the horizontal plane formed by the reference surface, preferably the horizontal plane formed by the lowest plate. Such features may be termed a “horizontal out-of-plane structure(s).” In addition to the shifting a one or more plates, if multiple three dimensional structures are used, shifting of one or more of three dimensional structures relative to others three dimensional structures forms a horizontal out-of-plane structure. Portions of the vertically stacked three dimensional structures formed by the stacking of the individual plates may include regions, i.e. wedge shape or diamond shapes) which extend horizontally to the reference surface. Such portions cause fluid flow to deviate from its normal, or undeviated flow pattern to include full or partial horizontal fluid flow relative to reference surface and therefore form a combination vertical-horizontal out-of-plane feature. A heat exchanger may have a combination of out-of-plane structures, including one or more vertical out-of-plane structures and one or more horizontal out-of-plane structures.

Referring to FIG. 4, vertical out-of-plane structures, referred to generally as 44 are illustrated. Such structures are preferably formed as extensions of portions of the laminar elements or plates 24 and are configured to extend into the fluid passages and into the active fluid flow region. The vertical out-of-plane structures 44, illustrated as finger-like shaped structures, serve two important heat transfer functions. First, the finger-like shaped vertical out-of-plane structures 44 provide increased heat transfer surface area, thereby promoting efficient heat transfer from the first fluid to the second fluid. Second, since the finger-like shaped vertical out-of-plane structures 44 are preferably designed to protrude into active fluid flow regions, the finger-like shaped vertical out-of-plane structures 44 promote turbulence and eddy transport.

Referring to FIG. 5A, a partial view of the heat exchanger incorporating out-of-plane features 10 in accordance with the present invention is shown, illustrating a plurality of finger-like shaped vertical out-of-plane structures. While the twisting or bending of the finger like structure forms a vertical out-of-plane feature, the body of the finger not bent or twisted forms a horizontal out of-plane feature. The partial view of the heat exchanger incorporating out-of-plane features 10 includes a plurality of stacked, laminar elements comprising plates 24B, 24C, 24D, 24E, and 24F. The plates contain a plurality of the finger-like shaped vertical out-of-plane structures 44. For example, to increase effectiveness, the finger-like shaped vertical out-of-plane structures 44 may be bent or twisted in the regions where the fingers are to come into contact with the fluid. The finger-like shaped vertical out-of-plane structures 44 therefore are sized, shaped, and placed to alter fluid flow in a desired manner. The type, twist to the left, twist to the right, bent upward, bent downward, and/or the number of finger-like shaped vertical out-of-plane structures 44 can be varied either on a single plate or relative to adjacent plates. As such, depending on the need, various fluid flow patterns can be created with the flow of fluid being directed in multiple directions and patterns.

Referring to FIG. 5B, fluid flow lines, referred to generally as 46, are shown to indicate the path of fluid through fluid passages areas. A finger-like shaped vertical out-of-plane structure having a right handed twist orientation, 44R, illustrates the alteration of fluid flow lines toward a narrowed region 48. A finger-like shaped vertical out-of-plane structure having a left-handed twist orientation, 44L, alters the fluid flow but in a different direction than that of the right handed twist. The pinching action of the fluid stream between finger-like shaped vertical out-of-plane structures 44R and finger-like shaped vertical out-of-plane structures 44L may increase fluid turbulence as well as increase the fluid pressure drop. In some cases this pinching action may not be desired. Such fluid flow may be avoided by suitably juxtapositioning the finger-like shaped vertical out-of-plane structures 44 and selecting the twist direction. In either case, the relationship between finger-like shaped vertical out-of-plane structures 44 placement and direction of rotation may be as desired to achieve optimal fluid flow and heat transfer. Accordingly, the number and placement of the finger-like shaped vertical out-of-plane structures can be varied within one single plate 24 or varied relative to adjacent plates to create varied fluid flow and/or turbulence.

As illustrated in the FIG. 5A, the partial view of a plurality of stacked plates shows that the vertical out-of-plane structures, both the twists and bends, can be variably positioned along an individual plate, relative to adjacent plates, or combinations thereof. Accordingly, the upper most platelet 25E contains a right handed twisted vertical out-of-plane structure 44R arranged about a portion of the plate, such as the longitudinal axis 45 of the plate, and a downward bend 44D positioned at some distance from the right handed twisted vertical out-of-plane structure 44R. The right handed twisted vertical out-of-plane structure 44R and the downward bend 44U extend into the flow path formed by platelet 25D. Adjacent plate 25D is illustrated having an upward bend 44U which extend towards platelet 25E. Platelet 25C is shown having a combination of a left handed twisted vertical out-of-plane structure 44L and a downward bend 44D. Platelet 25A is shown having multiple pairs of upward bends 44U.

The heat exchanger incorporating out-of-plane features 10 may also include one or more finger-like shaped vertical out-of-plane structures shaped in an up-bent orientation, 44U, or down-bent orientation, 44D. Similar to the right and left handed-twisted structures 44R and 44L, the fluid flow around the finger-like shaped vertical out-of-plane structures shaped in an up-bent orientation, 44U, or down-bent orientation, 44D results in increased turbulence and enhanced heat transfer. Accordingly, the number and placement of the finger-like shaped vertical out-of-plane structures can be varied within one single plate 24 or varied relative to adjacent plates to create varied fluid flow and/or turbulence.

Flexibility in out-of-plane designs by the present invention enables low pressure drop out-of-plane features not practical by other manufacturing methods. Such flexibility for instance can be used to economically create complex fins that would be manufacturable only by costly 5-axis machining. In addition to, or as an alternative embodiment, the finger-like shaped vertical out-of-plane structures may have a straight, untwisted, unbent orientation. Support stringers 50 may be provided to support the finger-like shaped vertical out-of-plane structures 44 while maintaining an open fluid flow path. One or more blanks or gaps 52 may be provided regardless of the type of finger-like shaped vertical out-of-plane structures used.

Formation of the finger-like shaped vertical out-of-plane structures 44, i.e. the bending or twisting, preferably takes place prior to assembly of the laminar elements or plates 24 and may be accomplished by any of the usual means known to one of skill in the art, such as for example press-forming or hydro-forming. The laminar elements 24 may be bonded, joined or otherwise affixed to one another by a variety of processes. For example, suitable bonding methods include, but are not limited to, soldering, brazing or diffusion bonding. If soldering or brazing is to be employed, the soldering or brazing alloy may be applied to one or both of the surfaces, 26 or 28, to be bonded. Further, the alloy may be in the form of cladding or a plated layer on the laminar material, which when heated, bonds the adjacent layers. Brazing may also be accomplished by furnace- brazing, dip-brazing, or other suitable processes as long as the process does not significantly interfere with desirable fluid path geometries.

In lieu of, or in addition to bonding adjacent layers by diffusion bonding, brazing or soldering, any suitable welding process may be employed to bond adjacent layers without the use of a brazing alloy. Alternately, successive layers of laminar material may be joined at their periphery by soldering, brazing or welding. Welding processes may include, but are not limited to, laser welding, electron-beam welding, ultrasonic welding, resistance welding, press welding, any of the processes referred to as “arc-welding,” such as gas metal arc welding (GMAW), metal inert gas (MIG) welding, tungsten inert gas welding (TIG) or the like.

The above laminar element bonding or welding processes assume that the heat exchanger laminar element(s) is comprised of metal or a metal alloy. The structure could however be comprised, without being limiting, of other materials such as ceramics, polymers, glasses or composites. Adhesives such as epoxies, cyanoacrylates, silicones or other materials may be employed to bond adjacent layers and/or seal the periphery of the heat exchanger element instead of or in addition to brazing and/or welding. In the case of ceramics, diffusion bonding, brazing or soldering may also be employed to bond the laminar materials.

Referring to FIGS. 6A-13C, several embodiments of vertical and horizontal out-of-plane structures are illustrated. The vertical and horizontal out-of-plane structures are formed from a stack of laminar elements 24 that when combined, produce a vertical out-of-plane structure which is built upon the lowest laminar element. As described previously, the laminar elements contain surface configurations which form individual platelets, see 25A-25F. The individual platelets 25A-25F are stacked and secured together to form a vertical out-of-plane structure that acts as a fin-like and turbulence generator structure, named a “platelet structure” and labeled as 25. The configuration of the individual platelets 25A-25D form the overall shape of the vertical out-of-plane structure. Referring specifically to FIGS. 6A-6C, the vertical out-of-plane structure, referred to generally as 54, is formed from a plurality of laminar plates having platelets 25A-25E, each containing a generally rectangular portion formed therein, which when combined with the other laminar elements 24 form an overall column-like shaped vertical out-of-plane structure 54A. While this structure is not necessarily hydrodynamically efficient, it promotes turbulence and eddy transport.

FIGS. 7A-7C illustrate an alternative embodiment in which the vertical out-of-plane structure 54B assumes a generally wedge shape, having a narrowly triangular shape which is wider at the apex 56 and tapering toward the base shape 58. The wedge-shaped vertical out-of-plane structure 54B is useful to split fluid flow and promote eddy transport. The wedge shape also comprises a horizontal out-of-plane feature relative to the reference surface as seen in FIG. 7B. Having a wider apex provides for the formed structure to include regions which extend horizontally to the reference surface. Such portions provide fluid flow to partially deviate from its normal flow pattern (relative to the orientation of the reference surface) to include partial deviated fluid flow relative to reference surface.

FIGS. 8A-8C illustrate an alternative embodiment in which the vertical out-of-plane structure 54C assumes a generally diamond shape. The diamond-shaped vertical out-of-plane structure 54C may be employed in situations where it is desirable to reduce hydrodynamic pressure losses. In this case, the diamond shape also provides for horizontal out-of-plane features.

FIGS. 9A-9C illustrate an alternative embodiment in which the vertical out-of-plane structure 54D assumes a rounded edge shape, having a rounded edges 60 and 62. Similar to the wedge-shape structure 54B, rounded edge vertical out-of-plane structure 54D has a narrowly triangular shape which is wider at one end 60 and tapering toward the base end 62. The rounded edge vertical out-of-plane structure 54D functions similarly to the wedge-shape structure 54B, however, it is more refined and is designed to further reduce pressure loss.

FIGS. 10A-10C illustrate an alternative embodiment in which the vertical out-of-plane structure 54E assumes a pyramidal rounded wedge shape. The pyramidal rounded wedge shape vertical out-of-plane structure 54E is designed to provide a thermoconductively functional gradient as it is wider at the base 64 than at the tip 66. Such shape is accomplished by providing individual laminar plates having platelets 25A-25E having varying widths, with platelet 25A forming the base and having the widest length and platelet 25E forming the tip, and having the shortest width. Each platelet 25B-25D in between, from base to tip, has a narrower width then the platelet below.

FIGS. 11A-11C illustrate an alternative embodiment in which the out-of-plane structure 54F assumes an irregular shape formed by a plurality of stacked laminar elements having curved “foils” platelets 25A-25E shaped and aligned to provide both vertical and horizontal out-of-plane features. Each of the curved foil platelets 25A-25E has varying degrees of curvature to provide controlled fluid turbulence as a function of the column height. For example, curved foil platelets 25C may contain no or minimal curvature. The curved or straight shapes, as well as the relative placement, for example shifting left and right or alternating left right patterns, of the shapes with respect to adjacent layers may comprise a horizontal out-of-plane feature.

The curved foil shaped platelets 25D and 25E may contain concave surfaces along their first surfaces 64, while curved foil shaped laminar elements 24E and 24F may contain convex shaped surfaces along their first surfaces 64. The second surfaces, not shown, will be arranged in an opposite manner, with curved foil shaped platelets 25D and 25E containing convex surfaces along their second surfaces, and with curved foil shaped platelets 25A and 25B containing concave surfaces along their second surfaces. Additionally, the curved foil shaped laminar elements of the curved foil shaped vertical and horizontal out-of-plane structure 54F may have varying widths to form a functional gradient as described above.

FIG. 14 illustrates an alternative embodiment of the curved foil vertical and horizontal out-of-plane structure. In this embodiment, a plurality of structures having both horizontal and vertical stacking out-of-plane structures 55 is shown. Each plurality of structures having both horizontal and vertical stacking out-of-plane structures 55 comprises a plurality of stacked laminar plates 24 containing platelets 25 having a generally columnar form. The plurality of structures having vertical and horizontal out-of-plane features 55 are grouped in a predetermined manner. The juxtaposition of a grouping of these columnar forms illustrates that the structures may be employed to control fluid flow 57 within a heat exchanger body. In this case, for clarity, the body is not shown. Fluid flow path 57 is a function of the width of the columnar elements, the curvature of the elements, the degree of “roundness” of the leading and trailing edges of the columnar form and the juxtaposition of the columnar forms.

Note that in this case, the laminar elements, the platelets, or combinations thereof of each successive layer may be rotated slightly from that of the preceding layer. Further, the size, degree of curvature and/or planar position (including degree of rotation) of each laminar element may be altered from adjacent laminar elements. Such a structure can be employed to produce a functionally gradient element, with the element possessing both thermally and hydraulically gradient functionality. The flexibility of such a system cannot be overstated. The device of the instant invention permits production of extremely precise structures that can be tailored to virtually any desired degree of thermal transfer or hydrodynamic design.

FIGS. 12A-12C illustrate an alternative embodiment in which the vertical and horizontal out-of-plane structure 54G assumes a spike like configuration. The vertical and horizontal out-of-plane structure having spike like structures is designed to provide increased surface area. In this manner, the surface area is increased through the application of spike-like fingers and 68 that protrude laterally from the main columnar structure portion 70, similar to the diamond shape illustrated in FIGS. 8A-8C and are cantilevered over the reference base structure. The number and placement of the diamond, spike-like shaped fingers 66 may be varied on. The widths and/or the lengths of adjacent diamond, spike-like shaped fingers 66 corresponding to adjacent platelets can be the same to form a uniform column. Alternatively, the widths and/or the lengths of the diamond, spike-like shaped fingers 66 corresponding to adjacent platelets can be varied, thereby forming varied patterns and misalignments, see 66A and 66B or 66C and 66D. The diamond, spike-like shaped fingers 66 may also be shifted left or right to form off-center orientations relative to the above or below diamond, spike-like shaped fingers 66.

FIGS. 13A-13C illustrate an alternative embodiment in which the vertical and horizontal out-of-plane structure 54H is designed to include structures that increase surface area, similar to that of the horizontal out-of-plane structure 54G as well as the vertical out-of-plane structures illustrated in FIGS. 1-5B. In this case, the structure providing the increase in surface area also comprises the out-of-plane feature.

All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

Claims

1. A heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties comprising: a main body having a top surface, a bottom surface, and an interior portion therebetween, said interior portion adapted to provide at least one fluid to flow therein;a plurality of individual laminar elements, said individual laminar elements having surface configurations adapted to allow fluid flow, each said individual laminar elements stacked against adjacent laminar elements, wherein said surface configurations of each individual laminar elements are arranged relative to adjacent surface configurations of each said adjacent laminar elements to form a three dimensional structure; andat least one out-of-plane structure, said at least one out-of-plane structure adapted to alter fluid flow path within said interior region to increase turbulence

2. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 1 wherein said out-of-plane structure includes at least one vertical out-of-plane structure, at least one horizontal out-of-plane structure, or combinations thereof.

3. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 1 wherein said at least one out-of-plane feature is integrally formed from at least one adjacent laminar element.

4. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 2 wherein said vertical out-of-plane feature includes at least one finger like protrusion.

5. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 4 wherein said at least one finger like protrusion has a twisted configuration, a bent configuration, or combinations thereof.

6. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 2 wherein said vertical out-of-plane structure includes a plurality of vertically stacked laminar elements having platelets which when aligned with adjacent laminar elements platelets form a vertical out-of-plane structure having a predetermined shape.

7. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 6 wherein said predetermined shape is generally rectangular shape.

8. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 6 wherein said shape is a wedge shape.

9. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 6 wherein said shape is a diamond shape.

10. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 6 wherein at least one said platelet has a width that differs from at least one adjacent platelet.

11. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according claim 6 wherein said shape includes at least laminar elements having a concave surface and at least one laminar element having a convex surface.

12. The heat exchanging unit having structures adapted to provide hydraulic efficiency and heat transfer properties according to claim 11 wherein said cut out portions of said vertically stacked laminar elements are shifted relative to cut out portions of said adjacent laminar elements, said shifting forming a horizontal out-of-plane structure.

13. A method of removing heat from a system comprising the steps of: providing a heat exchanging unit having structures adapted to provide hydraulic efficiency and desirable heat transfer properties to a system, said heat exchanging unit comprising a main body having a top surface, a bottom surface, and an interior portion therebetween, said interior portion adapted to provide at least one fluid to flow therein; a plurality of individual laminar elements, said individual laminar elements having surface configurations adapted to allow fluid flow, each said individual laminar elements stacked against adjacent laminar elements, wherein said surface configurations of each individual laminar elements are arranged relative to adjacent surface configurations of each said adjacent laminar elements to form a three dimensional structure; at least one out-of-plane structure, said at least one out-of-plane structure adapted to alter fluid flow path within said interior region to increase turbulence; at least one fluid inlet, and at least one fluid outlet;arranging said out-of-plane structures to allow fluid flow directed therein to flow in a particular manner;whereby said out-of-plane structures enhance turbulence through the introduction of obstacles in the laminar flow path of a fluid flowing therein.

14. The method of removing heat from a system according to claim 13 wherein said out-of-plane structures create areas of laminar flow, turbulent flow, or combinations thereof.

15. The method of removing heat from a system according to claim 13 wherein said areas of localized turbulent flow is created.

16. The method of removing heat from a system according to claim 13 wherein said out-of-plane structures promote eddy transport.

17. The method of removing heat from a system according to claim 13 wherein said out-of-plane structure includes at least one vertical out-of-plane structure, at least one horizontal out-of-plane structure, or combinations thereof.

18. The method of removing heat from a system according to claim 17 wherein said at least one out-of-plane feature is integrally formed from at least one adjacent laminar element.

19. The method of removing heat from a system according to claim 13 wherein said vertical out-of-plane feature includes at least one finger like protrusion.

20. The method of removing heat from a system according to claim 19 wherein said at least one finger like protrusion has a twisted configuration, a bent configuration, or combinations thereof.

21. The method of removing heat from a system according to claim 20 wherein said twisted configuration is a left handed twist or a right handed twist.

22. The method of removing heat from a system according to claim 20 wherein said bent configuration is an upward bend or a downward bend.

23. The method of removing heat from a system according to claim 13 wherein said vertical out-of-plane structure includes a plurality of vertically stacked laminar elements having a platelets which when aligned with adjacent laminar elements form vertical out-of-plane structures having a predetermined shape.

24. The method of removing heat from a system according to claim 23 wherein said platelets have a generally rectangular shape.

25. The method of removing heat from a system according to claim 24 wherein said platelets have a wedge shape.

26. The method of removing heat from a system according to claim 24 wherein said platelets have a diamond shape.

27. The method of removing heat from a system according to claim 24 wherein said platelets include at least one end having a rounded surface.

28. The method of removing heat from a system according to claim 24 wherein said least one platelet includes at least one concave surface and at least one independent platelet has at least one convex surface.

29. The method of removing heat from a system according to claim 24 wherein said platelets are shifted relative to said platelets formed by adjacent laminar elements, said shifting forming a horizontal out-of-plane structure.

30. The method of removing heat from a system according to claim 24 wherein said widths of adjacent platelets are variable.

31. The method of removing heat from a system according to claim 24 wherein said platelets further include at least one spike protrusion.

32. The method of removing heat from a system according to claim 24 wherein said platelets further include a finger like protrusion.