Not applicable.
Not applicable.
Not applicable.
The present invention relates to a heat exchanger, and more particularly to a plate heat exchanger in which two different media alternately flow in heat exchange fashion in spaces between stacked plates of the heat exchanger.
Plate heat exchangers of a type generally corresponding to those corresponding to the present invention are shown in EP 14 00 772 A2 (assigned to the assignee of this application, published Mar. 24, 2004) and corresponding U.S. Publication No. 2004/112579 A1 (also assigned to the assignee of this application, and published Jun. 17, 2004), the full disclosures of which are hereby incorporated by reference. The plate heat exchanger disclosed therein is suitable for heat exchange between media under a relatively high pressure, as prevails, for example, in an air conditioning loop on the refrigerant side. However, while those publications disclose an advantageous pressure-stable design of the collecting and distribution channels (i.e., the output and input) for the refrigerant (e.g., CO2) passing through the stacked plates, they disclose flow channels between the plates for CO2 gas which the present invention may advantageously improve upon.
WO 03/054468 A1 discloses a device for exchanging heat which is also a component of an air conditioning loop. In this device, all of the heat exchanger plates are difficult to manufacture, and the device may be viewed as still taking up more space than desired in many applications in which space limitations are critical. In these respects, the heat exchanger disclosed in WO 01/69157 A2 (corresponding to U.S. Publication No. 2004/26071 A1) appears to be more advantageous for a vehicle air conditioner. However, a so-called intermediate heat exchanger is otherwise disclosed in which refrigerant at a higher temperature is in heat exchange with the same refrigerant at lower temperature. Fine channels are provided there in all the flow channels of the heat exchanger, which channels are produced by manufacturing methods involving addition or removal of material on or in the heat exchanger plates.
The present invention is directed toward overcoming one or more of the problems set forth above.
According to one aspect of the present invention, a plate heat exchanger is provided for exchanging heat between a first media and a second media, including a plurality of first heat exchanger plates alternately stacked with a plurality of second heat exchanger plates between a base plate and a cover plate. The first and second heat exchanger plates have at least four passages therethrough which align to define a first collecting channel and a first distribution channel for the first media and a second collecting channel and a second distribution channel for the second media. First flow channels for the first media each are defined in a space between one side of the first heat exchanger plate and a facing one side of the adjacent second heat exchanger plate. Second flow channels for the second media each are defined between the other side of the first heat exchanger plate and the other side of the adjacent second heat exchanger plate. The second flow channels are defined by recesses defined in the surface of the other side of at least one of the first and second heat exchanger plates, and the other sides are metallically connected along their surfaces.
In one form of this aspect of the present invention, the recesses are embossments in the at least one of the first and second heat exchanger plates.
In another form of this aspect of the present invention, the recesses are groove-like furrows in the first heat exchanger plates, with the second flow channels being defined by the groove-like furrows and the facing flat surface of the second heat exchanger plates aligned over the furrows.
In still another form of this aspect of the present invention, the second flow channels provide a hydraulic connection between the second collecting channel and the second distribution channel and the recesses are defined in a significant portion of the at least one of the first and second heat exchanger plates, whereby the passages defining the second collecting and distribution channels extend through the significant portion.
In yet another form of this aspect of the present invention, the recesses are groove-like furrows arranged in a mirror symmetry about an axis of the heat exchanger plates whereby second flow channels of generally equal length are present on opposite sides of the axis.
According to another form of this aspect of the present invention, the recesses are defined in the second heat exchanger plates, and the second heat exchanger plates have a significantly greater plate thickness than the first heat exchanger plates. According to an alternate form of this aspect of the present invention, the first and second heat exchanger plates have the same plate thickness.
According to still another form of this aspect of the present invention, the recesses are defined in a significant portion of the at least one of the first and second heat exchanger plates, and the passages defining the first collecting and distribution channels extend through the first and second heat exchanger plates outside of the significant portion. According to a further form, the first heat exchanger plates are metallically joined to the second heat exchanger plates at adjacent surfaces outside of the significant portion.
According to yet another form of this aspect of the present invention, the first and second heat exchanger plates have a continuous bent edge at which adjacent heat exchanger plates are metallically connected to each other. According to a further form, the recesses are defined in the surface of the plurality of the second heat exchanger plates, and the bent edges of the plurality of first heat exchanger plates are longer than the bent edge of the plurality of the second heat exchanger plates.
In another form of this aspect of the present invention, the recesses are defined in a significant portion of the second heat exchanger plates, where the recesses include a plurality of substantially parallel groove-like furrows surrounding an enclosed portion of the significant portion, and the recesses further include additional groove-like furrows in the enclosed portion defining regions between selected groove-like furrows with a flat surface on the other side of the second heat exchanger plates. According to a further form, the groove-like furrows wind around within the enclosed portion, and not all of the groove-like furrows in the enclosed portion are generally parallel.
In still another form of this aspect of the present invention, the first heat exchanger plates include a flat surface and the second heat exchanger plates include flat surfaces between the recesses, and adjacent flat surfaces of the first heat exchanger plates and second heat exchanger plates are metallically joined together. According to a further form, the recesses are defined in a significant portion of the second heat exchanger plates, and the recesses include a plurality of substantially parallel groove-like furrows surrounding an enclosed portion of the significant portion, and additional groove-like furrows in the enclosed portion define regions between selected groove-like furrows with a flat surface on the other side of the second heat exchanger plates. Also according to this further form, the first and second heat exchanger plates are metallically joined at adjacent flat surfaces defined outside of the significant portion, at adjacent flat surfaces in the defined regions, and between the furrows, whereby the second flow channels defined by the furrows are discrete.
In yet another form of this aspect of the present invention, turbulence inserts are in the first flow channels between the spaced one sides of the first and second heat exchanger plates.
In a still further form of this aspect of the present invention, the recesses are defined by embossed sides of one of the plurality of first and second heat exchanger plates, the other side of the other of the plurality of first and second heat exchanger plates is substantially flat, and the first media is engine coolant and the second media is CO2 refrigerant of a vehicle air conditioner. According to a further form, a rod-like element is in the second collecting and distribution channels adapted to increase the pressure stability of the plate heat exchanger.
In a further form of this aspect of the present invention, one of the media is oil and the other of the media is water.
Plate heat exchangers according to the present invention may be advantageously used, for example, for heat exchange between the refrigerant (e.g., CO2) and the coolant of the a vehicle engine and, in such use, may be integrated in a suitable fashion both in the refrigerant loop of the air conditioner and in the coolant loop.
In the depicted embodiments, the plates 20, 22 of the plate heat exchanger 24 consist of aluminum sheets coated with solder. Though the plates 20, 22 are illustrated as hexagonally shaped as may be advantageously used in the described structure, it should be understood that plates which are not hexagonally shaped may be advantageously used within the scope of the present invention, with the shape chosen according to the intended use. The heat exchanger plates 20 and 22 are produced from aluminum sheets so as to be trough-like with a beveled edge 26 (in the
Each plate 20, 22, as well as the cover plate 28, is provided with four passages or openings 30. These openings 30, when stacked, form collecting and distribution channels (i.e., inlets and outlets) for the media which flows through the heat exchanger for the purpose of exchanging heat. Specifically, distribution channel 32 receives coolant and distributes it through a first plurality of flow channels between the plates (described below), through which the coolant flows to the collecting channel 34. Distribution channel 36 receives refrigerant and distributes it through a second plurality of alternating flow channels between the plates (described below), through which the refrigerant flows to the collecting channel 38. Suitable connectors 42, 44, 46, 48 may be advantageously provided with the heat exchanger 24 to facilitate connection to the system (e.g., vehicle engine and air conditioner) with which it is to be used. The connectors 46, 48 for the refrigerant may advantageously be suitable high-pressure fittings to accommodate the high-pressure of the refrigerant.
In the particular embodiment illustrated in
As previously indicated, the heat exchanger plates 20, 22 are assembled into a stack. One plurality of alternating flow channels 60 for the coolant is provided in a space between the plates 20, 22 (in the
Fins 68 may be advantageously provided in the coolant flow channels 60 between the spaced sides of the plates 20, 22. Such fins 68 may be configured so as to enhance heat exchange efficiency with the coolant traversing the fins 68 in channels 60, and may also contribute to greater pressure resistance by soldering to the facing sides of the plates 20, 22.
Coolant flow is shown by the arrows 70 in
Every other flow channel 62 (i.e., alternating flow channels) in the illustrated practical example is hydraulically connected to the distribution and collecting channels 36, 38. Further, since the flow channels 60, 62 formed by the heat exchanger plates 20, 22 alternate, the first flow channels 60 are hydraulically connected to the other distribution and collecting channels 32, 34. As is illustrated in
The base plate 50 may consist of a bottom plate 80 over a flange plate 82 with a reducing piece 84 which is soldered in the lower end 86 of a reinforcing element 88 to provide the required pressure stability. The CO2 refrigerant can flow in an annular gap 90 situated between the reinforcing element 88 and the edge of the distribution or collecting channel 36, 38 (note that, in
Referring now to the flow channels 62 for CO2 refrigerant (which is typically at high pressure), in accordance with the present invention, these channels 62 may be advantageously formed by connection of one surface side of an embossed heat exchanger plate 22 with the flat surface side of an unembossed facing heat exchanger plate 20. The other flow channels 60 (for the coolant) are bounded by the other surface side of the embossed heat exchanger plate 22 and the other spaced surface side of the unembossed heat exchanger plate 20.
It should be appreciated that while the embossment illustrated in
Island-like regions 94 are advantageously provided within the embossment design within the section 92. As a result, a strong metallic connection (e.g., soldering) may be achieved between adjacent plate surfaces in those regions which is able to support the extremely high pressures of up to 300 bar which may occur. Such strength may also be achieved with the heat exchanger plates 20 being much thinner than the other heat exchanger plate 22. (A metallic connection with the thinner heat exchanger plate 20 is naturally also present on the walls 96 (see
It should also be appreciated that advantageous manufacturing may further be achieved inasmuch as so-called strippers are formed in the embossing die (not shown) at least in some of these island-like regions 94, which ensure that the heat exchanger plate 22 can be readily removed from the die after an embossing process.
Areas 98 lying outside of the embossed section 92 are also connected flat to the other heat exchanger plate 20 over a broad expanse of surface to further assist in securing the plates 20, 22 together as desired. Moreover, it should be recognized that an excellent metallic connection between the walls 96 (
As previously noted, the hexagonal shape of the illustrated heat exchanger plates 20, 22 are merely exemplary to one possible application. However, it should be appreciated that this shape may advantageously provide the additional area 98 for securing the plates 20, 22 together, and may also advantageously allow for the design in which the collecting and distribution channels 32, 34 for the coolant lie outside of section 92 whereas the collecting and distribution channels 36, 38 for the refrigerant (e.g., CO2) are arranged within the section 92.
It should also be recognized (see particularly
It will be appreciated that the cross-sectional size and hydraulic diameter of the flow channels can be varied depending upon the application. For example, advantageous hydraulic diameters of the flow channels for the refrigerant may lie between about 0.5 and 1.0 mm, but the hydraulic diameter of the flow channel may advantageously be above this value with water/oil heat exchangers.
It should thus be appreciated that plate heat exchanger according to the present invention may be produced cost effectively for advantageous use with media under high pressure (e.g., for heat exchange between the refrigerant in air conditioners and a liquid). For example, it should be appreciated that embossings formed in accordance with the present invention may be cost-effectively machined in one pass. Further, it should be appreciated that the present invention may allow the plate thickness of the two types of heat exchanger plates to be significantly different from each other (e.g., the unembossed heat exchanger plates may advantageously be significantly thinner than the embossed heat exchanger plates, leading to a material and weight saving notwithstanding the necessity to maintain media under high pressure. Moreover, embossing of the flow channels permits designs which achieve desired heat exchange effects which could not be achieved in the extrusion method known in the prior art.
Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.
Number | Date | Country | Kind |
---|---|---|---|
10 2004 010 640 | Mar 2004 | DE | national |
Number | Name | Date | Kind |
---|---|---|---|
2528013 | Morris | Oct 1950 | A |
2616671 | Wakeman | Nov 1952 | A |
2733244 | Sanberger et al. | Jan 1956 | A |
4987955 | Bergqvist et al. | Jan 1991 | A |
5462113 | Wand | Oct 1995 | A |
5544703 | Joel et al. | Aug 1996 | A |
6354002 | Wright et al. | Mar 2002 | B1 |
6530425 | Wehrmann et al. | Mar 2003 | B2 |
6843311 | Evans et al. | Jan 2005 | B2 |
6918434 | Strähle | Jul 2005 | B2 |
6953081 | Klingler et al. | Oct 2005 | B2 |
20040026071 | Hesse et al. | Feb 2004 | A1 |
20050155749 | Memory et al. | Jul 2005 | A1 |
Number | Date | Country |
---|---|---|
3215961 | Nov 1983 | DE |
1 400 772 | Jul 2003 | EP |
2679021 | Jan 1993 | FR |
2249621 | May 1992 | GB |
WO 0169157 | Sep 2001 | WO |
WO 03054468 | Jul 2003 | WO |
Number | Date | Country | |
---|---|---|---|
20050194123 A1 | Sep 2005 | US |