TECHNICAL FIELD
The present disclosure relates to a heat exchanger and, more particularly, to a heat exchanger for pumps.
BACKGROUND
Pumps heat the fluid they pump, particularly gas. In many applications, removing some of the heat that a pump adds to fluid improves the operation of the device that the pump supplies. For example, cooling the air a turbomachine discharges can improve the operation of the engine that it supplies. To cool the discharge of a pump, a heat exchanger is often plumbed between the outlet of the pump and the system the pump supplies.
In many applications, however, space constraints complicate or prevent using plumbing to connect a heat exchanger between the outlet of a pump and the system it supplies. For example, in a multi-stage turbocharging system, limited space may preclude plumbing a heat exchanger between the outlet of a first compressor and the inlet of a second compressor.
At least one pump design enables cooling the pumped fluid without plumbing a heat exchanger between the outlet of the pump and the device it supplies. For example, U.S. Patent Application No. 2004/0055740 (“the '740 application”) shows a rotary compressor with a ring-shaped heat exchanger in the housing of the rotary compressor. The heat exchanger is disposed between a compressor wheel of the rotary compressor and an outlet of the housing, such that fluid discharged by the compressor wheel flows across the heat exchanger before leaving the housing. The heat exchanger includes ring-shaped tanks on its ends and numerous tubes extending axially between, and connecting, the ring-shaped tanks. A connection between each tube and each ring-shaped tank is effected by a tight mechanical fit between the tube and a tube slot and, optionally, solder or braze metal.
Although the rotary compressor of the '740 application includes a heat exchanger for cooling the pumped fluid, the design includes disadvantages. Applying solder or braze metal at the numerous connections between the ring-shaped tanks and the tubes requires significant labor. Each of the connections between the ring-shaped tanks and the tubes presents a risk of developing a fluid leak. The housing of the rotary heat exchanger restricts physical access to the heat exchanger, which may complicate repairing any fluid leaks that the numerous connections develop.
The pump and heat exchanger of the present disclosure solves one or more of the problems set forth above.
SUMMARY OF THE INVENTION
One disclosed embodiment includes a pump that may include an impeller with impeller blades that extend radially outward. The pump may further include a pump housing that surrounds a radial perimeter of the impeller. Additionally, the pump housing may include an inlet opening in fluid communication with the impeller and a discharge channel. The pump may further include a heat exchanger supported within the pump housing between the inlet opening and at least one connection port of the pump housing. The heat exchanger may include one or more tubing coils that extend around an axis.
Another embodiment relates to a method of constructing a heat exchanger. The method may include forming a first section of tube assembly, including bending a ribbon parallel to its major surfaces multiple times around a fixture to form the ribbon into multiple fins. Additionally, forming the first section of tube assembly may include securing the ribbon around a first section of tube with the fins formed by the ribbon extending from the first section of tube.
Another embodiment relates to an assembly that may include a first set of helical tubing coils that may extend in a series in a first direction along a central axis. The assembly may further include a second set of helical tubing coils that may extend in a series in a second direction along the central axis. At least some of the tubing coils of the second set of helical tubing coils may extend between at least some of the tubing coils of the first set of helical tubing coils. As a result, at least some of the tubing coils of the first set of helical tubing coils may be disposed in alternating positions along the central axis with at least some of the tubing coils of the second set of helical tubing coils.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a sectional illustration of one embodiment of a pump according to the present disclosure;
FIG. 1B is a sectional illustration of the pump shown in FIG. 1A, through line 1B-1B of FIG. 1A;
FIG. 2A is a section illustration of another embodiment of a pump according to the present disclosure;
FIG. 2B is a sectional illustration of the pump shown in FIG. 2A, through line 2B-2B of FIG. 2A;
FIG. 3A is a perspective illustration of one embodiment of a heat exchanger according to the present disclosure;
FIG. 3B is a sectional illustration of the heat exchanger shown in FIG. 3A, through line 3B-3B of FIG. 3A;
FIG. 3C is a sectional illustration of the heat exchanger shown in FIGS. 3A and 3B, through line 3C-3C of FIG. 3A;
FIG. 4 is a perspective illustration of another embodiment of a heat exchanger according to the present disclosure;
FIG. 5 is a perspective illustration of another embodiment of a heat exchanger according to the present disclosure;
FIG. 6A is a perspective illustration of a tube with fins and spacers attached according to the present disclosure;
FIG. 6B is a sectional illustration of the tube, fins, and spacers shown in FIG. 6A, through line 6B-6B of FIG. 6A;
FIG. 7A is a perspective illustration of one embodiment of a method of manufacturing fins for a heat exchanger according to the present disclosure;
FIG. 7B is a plan illustration of the method illustrated in FIG. 7A;
FIG. 8A is a perspective illustration of one embodiment of a method of shaping fins for a heat exchanger according to the present disclosure;
FIG. 8B is a sectional illustration through line 8B-8B of FIG. 8A;
FIG. 9A is a perspective illustration of another embodiment of a method of shaping fins for a heat exchanger according to the present disclosure;
FIG. 9B is a sectional illustration through line 9B-9B of FIG. 9A;
FIG. 10 is a plan illustration of one embodiment of a method of bending a tube for a heat exchanger according to the present disclosure;
FIG. 11 is an illustration of one manufacturing method that may be used in the construction of the heat exchanger shown in FIGS. 3A-3C;
FIG. 12 is an elevational illustration of one embodiment of a method of attaching heat exchanger sections to a spacer according to the present disclosure.
DETAILED DESCRIPTION
FIG. 1A provides a sectional view of a pump 10 according to an exemplary disclosed embodiment, and FIG. 1B shows a section of pump 10 through line 1B-1B of FIG. 1A. Pump 10 includes a pump housing 12, an impeller 14, and a heat exchanger 16. Pump 10 may be a compressor of a turbocharger or supercharger.
Pump housing 12 may support impeller 14 and allow rotation of impeller 14 around an impeller rotation axis 18. Pump housing 12 may define an inlet opening 20. Pump housing 12 may also define a discharge channel 22 that may extend from adjacent a radial perimeter 24 of impeller 14 to one or more connection ports 26, 28. Inlet opening 20 may be in fluid communication with connection ports 26, 28 through discharge channel 22. Pump housing 12 may also surround radial perimeter 24 of impeller 14. In other words, with the exception of any openings defined by any connection ports 26, 28, pump housing 12 may enclose radial perimeter 24 of impeller 14 in directions parallel to impeller rotation axis 18 and directions perpendicular to impeller rotation axis 18.
As is best shown in FIG. 1A, discharge channel 22 may define flow paths 31 from radial perimeter 24 of impeller 14 to connection ports 26, 28. Discharge channel 22 may include a radial inlet slot 30 that extends around radial perimeter 24 of impeller 14. Discharge channel 22 may further include an annular space 32 extending around impeller rotation axis 18.
Discharge channel 22 is not limited to the configuration shown in FIGS. 1A and 1B. In place of radial inlet slot 30, discharge channel 22 may include one or more passages with other shapes and/or other orientations. Additionally, discharge channel 22 may include cavities of other shapes, such as elliptical or rectangular, in addition to, or in place of, annular space 32. Furthermore, annular space 32, or any cavity of another shape in place thereof, may be defined at some other place along impeller rotation axis 18. For example, annular space 32 may be defined around impeller 14, with annular space 32 connecting directly to an outer portion of radial inlet slot 30.
As best shown by FIG. 1A, connection ports 26, 28 define discharge openings 34, 36 in pump housing 12 and include features that facilitate connecting other components in fluid communication with discharge openings 34, 36. Connection port 26 may include a cylindrical boss, which may facilitate connecting a tube in fluid communication with discharge opening 34 by clamping the tube around the cylindrical boss. Connection port 28 may include a portion of pump housing 12 that defines a cylindrical inner surface around discharge opening 36. Connection port 28 may facilitate connecting a plumbing fitting in fluid communication with discharge opening 36 by engaging a cylindrical outer surface of the plumbing fitting with the cylindrical inner surface of connection port 28, such as by adhesive, metallic bond, or press fit. A connection port 26, 28 may be connected to a fluid-consuming component. For example, connection port 26 may be connected to an engine (not shown), such that pump 10 may supply combustion air to the engine through connection port 26. Additionally, a connection port 26, 28 may be connected to devices that do not consume fluid, but monitor one or more conditions of fluid pumped by pump 10. For example, connection port 28 may be connected to a pressure or temperature sensor (not shown).
Connection ports 26, 28 are not limited to the configurations illustrated in FIG. 1A. Connection ports 26, 28 may implement many other types of features that facilitate connection of other components in fluid communication with discharge openings 34, 36. For example, connection ports 26, 28 may include fastening features such as threads, grooves, or ribs that facilitate connecting other components in fluid communication with discharge openings 34, 36. Connection ports 26, 28 may further include flanges surrounding discharge openings 34, 36, facilitating clamping another component in fluid communication with discharge openings 34, 36.
Impeller 14 includes impeller blades 38 that extend radially away from impeller rotation axis 18. Impeller blades 38 may extend straight out from impeller rotation axis 18, or impeller blades 38 may extend radially away from impeller rotation axis 18 in a slanted or curved manner.
Heat exchanger 16 may reside within pump housing 12 between inlet opening 20 and one or more connection ports 26, 28. For example, heat exchanger 16 may reside in discharge channel 22. Heat exchanger 16 may reside within annular space 32. Heat exchanger 16 may include one or more tubing coils 58 that extend around impeller rotation axis 18. Tubing coil, as the term is used herein, refers to a length of tubing that extends one full loop around an axis. As best shown in FIG. 1A, heat exchanger 16 may include multiple tubes 54, and, as is best shown in FIG. 1B, one or more of tubes 54 may form multiple tubing coils 58. Tube, as the term is used herein, refers to a continuous length of tubing formed as a unit. As can be seen in FIG. 1B, tubing coils 58 may be spiral tubing coils. Each tube 54 may form tubing coils 58 by spiraling from one end 60 of tube 54 radially outwardly to another end 62 of tube 54. As can be best seen in FIG. 1B, heat exchanger 16 may include one manifold 50 that connects to each of tubes 54 and another manifold 52 that also connects to each of tubes 54. As is best shown in FIG. 1A, heat exchanger 16 may be disposed within discharge channel 22 such that radially outer portions of tubing coils 58 are closer along flow paths 31 to radial perimeter 24 of impeller 14 than are radially inner portions of tubing coils 58. Tubing coils 58 may be constructed of a malleable material, such as aluminum, copper, another metal, or a metallic alloy. Moreover, tubing coils 58 may be constructed of material with high thermal conductivity.
Heat exchanger 16 is not limited to the configuration shown in FIGS. 1A and 1B. For example, tubing coils 58 may extend in paths of other shapes, such as elliptical or rectangular, around impeller rotation axis 18. Additionally, while FIGS. 1A and 1B show round tubing forming tubing coils 58, tubing of any shape may form tubing coils 58. Furthermore, heat exchanger 16 may omit one or more of tubes 54. Additionally, heat exchanger 16 may omit one or both of manifolds 50, 52. Moreover, heat exchanger 16 may include fins joined to tubing coils 58. Additionally, heat exchanger 16 may include spacers attached to such fins.
FIGS. 2A and 2B show a pump 41 consistent with another embodiment. Pump 41 may include a pump housing 43, a first impeller 45, a second impeller 47, and heat exchanger 16. Pump 41 may be a compressor of a two-stage turbocharger or supercharger.
Pump housing 43 may support first impeller 45 and second impeller 47 and allow rotation of first impeller 45 and second impeller 47 around an impeller rotation axis 51. Pump housing 43 may define an inlet opening 53. Pump housing 43 may also define a discharge channel 55 that may extend from adjacent a radial perimeter 57 of first impeller 45 to one or more connection ports 59, 61. Inlet opening 53 may be in fluid communication with connection ports 59, 61 through discharge channel 55. Pump housing 43 may also surround radial perimeter 57 of first impeller 45. In other words, with the exception of any openings defined by any connection ports 59, 61, pump housing 43 may enclose radial perimeter 57 of first impeller 45 in directions parallel to impeller rotation axis 51 and directions perpendicular to impeller rotation axis 51. Similarly, pump housing 43 may surround a radial perimeter 87 of second impeller 47.
As is best shown in FIG. 2A, discharge channel 55 may define flow paths 63 from radial perimeter 57 of first impeller 45 to connection ports 59, 61. Discharge channel 55 may include a radial inlet slot 65 that extends around radial perimeter 57 of first impeller 45. Discharge channel 55 may further include an annular chamber 67 disposed around impeller rotation axis 51. Discharge channel 55 may also include a second-impeller chamber 69, within which second impeller 47 may reside.
Discharge channel 55 is not limited to the configuration shown in FIGS. 2A and 2B. In place of radial inlet slot 65, discharge channel 55 may include one or more passages with other shapes and/or other orientations.
Additionally, discharge channel 55 may include chambers of other shapes, such as elliptical or rectangular, in addition to, or in place of, annular chamber 67. Furthermore, annular chamber 67 may be defined at some other place along impeller rotation axis 51. For example, annular chamber 67 may connect to and surround radial inlet slot 65.
As best shown by FIG. 2A, connection ports 59, 61 define discharge openings 71, 73 in pump housing 43 and include features that facilitate connecting other components in fluid communication with discharge openings 71, 73. Connection port 59 may include a cylindrical boss, which may facilitate connecting a tube in fluid communication with discharge opening 71 by clamping the tube around the cylindrical boss. Connection port 61 may include a portion of pump housing 43 that defines a cylindrical inner surface around discharge opening 73. Connection port 61 may facilitate connecting a plumbing fitting in fluid communication with discharge opening 73 by engaging a cylindrical outer surface of the plumbing fitting with the cylindrical inner surface of connection port 61, such as by adhesive, metallic bond, or press fit. A connection port 59, 61 may be connected to a fluid-consuming component. For example, connection port 59 may be connected to an engine (not shown), such that pump 10 may supply combustion air to the engine through connection port 59. Additionally, a connection port 59, 61 may be connected to devices that do not consume fluid, but monitor one or more conditions of fluid pumped by pump 10. For example, connection port 61 may be connected to a pressure or temperature sensor (not shown).
Connection ports 59, 61 are not limited to the configurations illustrated in FIG. 2A. Connection ports 59, 61 may implement many other types of features that facilitate connection of other components in fluid communication with discharge openings 71, 73. For example, connection ports 59, 61 may include fastening features such as threads, grooves, or ribs that facilitate connection of other components in fluid communication with discharge openings 71, 73. Connection ports 59, 61 may further include flanges surrounding discharge openings 71, 73, facilitating clamping another component in fluid communication with discharge openings 71, 73.
First impeller 45 and second impeller 47 include impeller blades 75 that extend radially away from impeller rotation axis 51. Impeller blades 75 may extend straight out from impeller rotation axis 51, or impeller blades 75 may extend away from impeller rotation axis 51 in a slanted or curved manner.
Heat exchanger 16 may reside within pump housing 43 between inlet opening 53 and one or more connection ports 59, 61. For example, heat exchanger 16 may reside in discharge channel 55 between first impeller 45 and second impeller 47 along flow paths 63. Heat exchanger 16 may be disposed in annular chamber 67. Tubing coils 58 of heat exchanger 16 may extend around impeller rotation axis 51. As is best shown in FIG. 2A, heat exchanger 16 may be disposed in discharge channel 55 such that radially outer portions of tubing coils 58 are disposed closer along flow paths 63 to radial perimeter 57 of first impeller 45 than are radially inner portions of tubing coils 58. Tubing coils 58 may be constructed of material with relatively high thermal conductivity.
FIGS. 3A-3C show another embodiment of a heat exchanger 42 suitable for use in pump 10 or pump 41. Heat exchanger 42 may be similar to the configuration of heat exchanger 16 shown in FIGS. 1A-2B, with the addition of fins 56 and spacers 46. FIG. 3A is a perspective view of heat exchanger 42, FIG. 3B is a sectional view of heat exchanger 42 through line 3B-3B of FIG. 3A, and FIG. 3C is a sectional view of heat exchanger 42 through line 3C-3C of FIG. 3A. As best shown in FIG. 3B, heat exchanger 42 may include multiple heat exchanger sections 44. Heat exchanger 42 may also include manifolds 50 and 52 connected to heat exchanger sections 44.
Each heat exchanger section 44 may include a tube assembly 39, including tube 54 and fins 56 joined thereto, and spacers 46 on opposite sides of tube assembly 39. As is best shown by FIG. 3C, each tube assembly 39 of each heat exchanger section 44 may be formed in a radially-outwardly extending spiral including multiple tubing coils 58 that spiral radially outwardly around central axis 48 between end 60 of tube 54 and end 62 of tube 54. As can be seen in FIG. 3C, fins 56 joined to each tubing coil 58 of each tube assembly 39 may be misaligned with fins 56 joined to radially-adjacent tubing coils 58. This misalignment may improve performance of heat exchanger 42 by creating turbulence in fluid that flows radially across heat exchanger 42. Each tube 54, fins 56, and spacers 46 may be constructed of material with relatively high thermal conductivity.
Each spacer 46 may attach to fins 56 of one or more tube assemblies 39. Each spacer 46 may spiral substantially parallel to an adjacent tube assembly 39, radially outwardly around central axis 48. Each spacer 46 between adjacent tube assemblies 39 may attach to fins 56 of both of the adjacent tube assemblies 39, thereby attaching adjacent tube assemblies 39 to one another. Tube assemblies 39 may be connected to one another in such a manner that they spiral radially outward substantially parallel to one another. Additionally, ends 60 of tubes 54 may be disposed adjacent one another, and ends 62 of tubes 54 may be disposed adjacent one another. Manifold 50 may connect to ends 60 of tubes 54. Similarly, manifold 52 may connect to ends 62 of tubes 54.
Heat exchanger 42 is not limited to the configuration shown in FIGS. 3A-3C. For example, while FIGS. 3A-3C show each of tube assembly 39 forming a planar spiral, one or more of tube assemblies 39 may form a conical spiral. Additionally, while tubes 54 are shown as having a circular cross-section, they may have cross-sections of other shapes. Furthermore, heat exchanger 42 may implement different configurations of fins 56 and spacers 46, as described in greater detail below in connection with FIGS. 6A and 6B.
According to certain embodiments, pump 10 or pump 41 may include heat exchanger 42. For example, heat exchanger 42 could be mounted within annular chamber 32 of pump 10 in place of heat exchanger 16. Heat exchanger 42 may reside within discharge channel 22 with tubing coils 58 extending around impeller rotation axis 18. Additionally, heat exchanger 42 could be mounted within annular chamber 67 of pump 41 in place of heat exchanger 16. Heat exchanger 42 may reside within discharge channel 55 with tubing coils 58 extending around impeller rotation axis 51.
FIG. 4 shows another embodiment of a heat exchanger 64 suitable for use in pump 10 or pump 41. Heat exchanger 64 may include a first set of helical tubing coils 70 that may extend in series in a first direction 68 along a central axis 66. Heat exchanger 64 may also include a second set of helical tubing coils 74 that may also extend in series in first direction 68 along central axis 66. A first end 79 of first set of helical tubing coils 70 may be fluidly connected to a first end 81 of second set of helical tubing coils 74. For example, a connector 72, such as a 1800 tubing elbow, may be fluidly connected between first end 79 of first set of helical tubing coils 70 and first end 81 of second set of helical tubing coils 74. At least a portion of first set of helical tubing coils 70 and at least a portion of second set of helical tubing coils 74 may extend along a same portion of central axis 66. As is shown in FIG. 4, some or all of helical tubing coils 70 may extend between some of helical tubing coils 74, such that some or all of helical tubing coils 70 are disposed in alternating positions with helical tubing coils 74 along central axis 66. A second end 83 of first set of helical tubing coils 70 may be connected to a first tube ending 76. A second end 85 of second set of helical tubing coils 74 may be connected to a second tube ending 78. First tube ending 76 and second tube ending 78 may be disposed adjacent one another. Tubing coils 70, 74 may be constructed of a malleable material such as aluminum, copper, another metal, or a metallic alloy. Furthermore, tubing coils 70, 74 may be constructed of a material with relatively high thermal conductivity.
Heat exchanger 64 is not limited to the configuration shown in FIG. 4. For example, while FIG. 4 shows helical tubing coils 70 and helical tubing coils 74 having a same radial dimension, helical tubing coils 70 may have a greater or smaller radial dimension than helical tubing coils 74. Additionally, the radial dimension of helical tubing coils 70 and/or the radial dimension of helical tubing coils 74 may vary along central axis 66. Furthermore, heat exchanger 64 may omit first set of helical tubing coils 70 and/or second set of helical tubing coils 74. Alternatively, heat exchanger 64 may include other tubing coils in addition to helical tubing coils 70 and 74. Such additional tubing coils may have shapes other than helical. Furthermore, heat exchanger 64 may include portions that are not formed in tubing coils.
Consistent with certain disclosed embodiments, pump 10 or pump 41 may include heat exchanger 64. For example, heat exchanger 64 may reside within annular chamber 32 of pump 10 in place of heat exchanger 16. Heat exchanger 64 may reside within discharge channel 22 with tubing coils 70, 74 extending around impeller rotation axis 18. Additionally, heat exchanger 64 may reside within annular chamber 67 of pump 41 in place of heat exchanger 16. Heat exchanger 64 may reside within discharge channel 55 with tubing coils 70, 74 extending around impeller rotation axis 51.
FIG. 5 shows a heat exchanger 80, which is similar to heat exchanger 64, illustrated in FIG. 4, with the addition of fins 56 and spacers 46. In heat exchanger 80, a first section 91 of tube assembly 39, which includes a section of tube 54 and fins 56, may extend helically along central axis 66 and may include first set of helical tubing coils 70. A second section 93 of tube assembly 39 may extend helically around central axis 66 and include second set of helical tubing coils 74. Fins 56 may extend from each helical tubing coil 70 toward adjacent helical tubing coils 74. Similarly, fins 56 may extend from each helical tubing coil 74 toward adjacent helical tubing coils 70. A portion of spacer 46 may extend substantially parallel to each helical tubing coil 70 between it and an adjacent helical tubing coil 74. The portion of spacer 46 between each helical tubing coil 70 and an adjacent helical tubing coil 74 may attach to fins 56 extending from helical tubing coil 70 and fins 56 extending from adjacent helical tubing coil 74, thereby attaching helical tubing coil 70 to adjacent helical tubing coil 74.
Consistent with certain disclosed embodiments, pump 10 or pump 41 may include heat exchanger 80. For example, heat exchanger 80 may reside within annular chamber 32 of pump 10 in place of heat exchanger 16. Heat exchanger 80 may reside within discharge channel 22 with tubing coils 70, 74 extending around impeller rotation axis 18. Additionally, heat exchanger 80 may reside within annular chamber 67 of pump 41 in place of heat exchanger 16. Heat exchanger 80 may reside within discharge channel 55 with tubing coils 70, 74 extending around impeller rotation axis 51.
FIGS. 6A and 6B show a configuration of tube assembly 39 and spacers 46 consistent with certain embodiments. FIG. 6A is a perspective view of tube assembly 39 with spacers 46 mounted to fins 56. FIG. 6B is a sectional view of the assembly shown in FIG. 6A, through a cross-section of tube 54. Fins 56 may be joined to tube 54 along a length thereof to form tube assembly 39. Fins 56 may extend completely or partially around tube 54. Alternatively, fins 56 may extend from only one side of tube 54. Fins 56 may have parallel straight edges 82 on opposite sides of tube 54.
One or more spacers 46 may attach to fins 56 and extend substantially parallel to tube 54. Spacers 46 may attach to edges 82 on opposite sides of tube 54. Spacers 46 may have rectangular cross-sections, as is shown in FIGS. 6A and 6B. Spacers 46 may be constructed of a malleable material, such as aluminum, copper, another metal, or a metallic alloy. Furthermore, spacers 46 may be constructed of a material with relatively high thermal conductivity.
Tube 54, fins 56, and spacers 46 are not limited to the configuration shown in FIGS. 6A and 6B. For example, while FIGS. 6A and 6B show spacers 46 attached to every fin 56, spacers 46 may attach to only a subset of fins 56 joined to tube 54. Additionally, fins 56 may extend through openings in spacers 46 and/or spacers 46 may extend through openings in fins 56. Furthermore, while FIGS. 6A and 6B show spacers 46 as having rectangular cross-sections, spacers 46 may have cross-sections of other shapes.
INDUSTRIAL APPLICABILITY
Pump 10 and pump 41 have potential application in any system requiring movement of fluid where heating or cooling of the fluid discharged from the pump is desired.
Pump 10 may be operated by rotating impeller 14 about impeller rotation axis 18. When impeller 14 is rotated, impeller blades 38 pump fluid into discharge channel 22. Discharge channel 22 routes the pumped fluid along flow paths 31 to connection ports 26, 28. As the fluid flows through pump housing 12, the pumped fluid flows across tubing coils 58 or 70 and 74 of any heat exchangers 16, 42, 64, or 80 residing within discharge channel 22. Consistent with certain embodiments, such as the embodiment shown in FIGS. 1A and 1B, the pumped fluid may flow from radially outside tubing coils 58, or 70 and 74 to radially inside tubing coils 58 or 70 and 74. Heat-transfer fluid may flow through any tubing coils 58 or 70 and 74 disposed within discharge channel 22. The heat-transfer fluid accepts heat from or conveys heat to the pumped fluid, dependant upon the respective temperatures of the heat-transfer fluid and the pumped fluid.
Pump 41 may be operated by rotating first impeller 45 about impeller rotation axis 51. When first impeller 45 is rotated, impeller blades 75 pump fluid into discharge channel 55. Discharge channel 55 routes the pumped fluid along flow paths 63 to connection ports 59, 61. If second impeller 47 is rotated around impeller rotation axis 51, it may accelerate the pumped fluid out of second-impeller chamber 69 through portions of discharge channel 55 between second-impeller chamber 69 and connection port 59. As the pumped fluid flows through pump housing 43, the pumped fluid flows across tubing coils 58 or 70 and 74 of any heat exchangers 16, 42, 64, or 80 residing within discharge channel 55. Consistent with certain embodiments, such as the embodiment shown in FIGS. 2A and 2B, the pumped fluid may flow from radially outside tubing coils 58 or 70 and 74 to radially inside tubing coils 58 or 70 and 74. Heat-transfer fluid may flow through any tubing coils 58 or 70 and 74 disposed within discharge channel 55. The heat-transfer fluid accepts heat from or conveys heat to the pumped fluid, dependant upon the respective temperatures of the heat-transfer fluid and the pumped fluid.
The disclosed embodiments of heat exchangers 16, 42, 64, and 80 provide a high surface area to cooler volume ratio, while presenting low risk of developing fluid leaks. By extending continuously around a respective axis 18, 48, 51, or 66, each tubing coil 58, 70, or 74 of heat exchangers 16, 42, 64, or 80 provides a long cooling surface without leak-prone connections. Moreover, consistent with certain embodiments, tube 54 may extend multiple times around a respective axis 18, 48, 51, or 66, forming multiple tubing coils 58, 70, or 74 without leak prone connections therebetween. Because heat exchangers 16, 42, 64, and 80 present low risks of developing fluid leaks, they may be mounted in pump housing 12 or pump housing 43 without causing a need to frequently disassemble pump housing 12 or pump housing 43 to repair leaks.
Additionally, the configurations of heat exchangers 16, 42, 64, and 80 enable cost-effective methods of manufacturing them. FIGS. 7A and 7B illustrate a method that may be utilized in joining fins 56 to tube 54 to form tube assembly 39. A ribbon 84 may be bent parallel to its major surfaces 86 around a fixture multiple times to form multiple fins 56. A major surface 86 of a ribbon, as the term is used herein, refers to one of the two surfaces that compose the majority of the surface area of the ribbon. Ribbon 84 may be constructed of a malleable material such as a metal or a metal alloy. Consistent with certain embodiments, tube 54 may be the fixture around which ribbon 84 is bent. As shown in FIGS. 7A and 7B, tube 54 may be clamped in a chuck 88 along with an end 90 of ribbon 84. Chuck 88 may then rotate tube 54 and end 90 around an axis 92 of tube 54, while a guide 94 stops an outer portion 96 of ribbon 84 from rotating with tube 54. While holding outer portion 96 of ribbon 84 against rotation, guide 94 may allow outer portion 96 of ribbon 84 to advance toward tube 54. As chuck 88 and tube 54 rotate, they may draw outer portion 96 of ribbon 84 toward tube 54 and bend successive portions of ribbon 84 around tube 54. As chuck 88 and tube 54 bend successive portions of ribbon 84 around tube 54, guide 94 may move outer portion 96 of ribbon 84 along axis 92, so as to form ribbon 84 into coils that advance along axis 92, forming fins 56. Chuck 88 and tube 54 may rotate at a constant rate, and guide 94 may advance at a constant rate along axis 92, so as to form ribbon 84 into a helix around tube 54. Tube 54 and ribbon 84 may be constructed of material with relatively high thermal conductivity.
A method of bending ribbon 84 multiple times around a fixture to form ribbon 84 into fins 56, is not limited to the embodiments described above in connection with FIGS. 7A and 7B. For example, a fixture other than tube 54 may be employed. Additionally, in addition to, or in place of, chuck 88 and guide 94, other components and/or a person may apply force to ribbon 84 to bend it around the fixture. Furthermore, the fixture may have shapes other than that shown in FIGS. 7A and 7B. Moreover, instead of the fixture rotating to bend ribbon 84, the fixture may be held stationary and ribbon 84 bent around it.
After ribbon 84 is bent multiple times around a fixture to form ribbon 84 into fins 56, ribbon 84 may be joined to tube 54 to form tube assembly 39. When ribbon 84 has been bent around a fixture other than tube 54, ribbon 84 may be removed from the fixture and slid over tube 54. When ribbon 84 has been bent around tube 54, ribbon 84 is positioned around tube 54 following bending of ribbon 84. Once ribbon 84 has been bent into fins 56 and positioned around tube 54, ribbon 84 may be joined to tube 54 by adhesive bonding, metallic bonding, or by expanding tube 54 to create an interference fit with ribbon 84.
Tube 54 may be expanded to create an interference fit with ribbon 84 by drawing a mandrel (not shown) through an interior of tube 54.
A method of joining fins 56 to tube 54 is not limited to the embodiments described above in connection with FIGS. 7A and 7B. For example, fins 56 may be formed and joined to tube 54 individually.
As is shown in FIGS. 8A and 8B, after ribbon 84 is bent to form fins 56, a cutting tool 98 may be used to shape fins 56 by cutting portions of them off. Consistent with certain embodiments, cutting tool 98 may be run parallel to a center axis 100 around which ribbon 84 extends to cut a first series 102 of straight edges 82, aligned with one another in the direction of center axis 100, on fins 56. Subsequently, cutting tool 98 may be run parallel to center axis 100 on an opposite side thereof to cut a second series 104 of straight edges 82, aligned with one another in the direction of center axis 100, on fins 56. As is best seen in FIG. 8B, while cutting second series 104 of straight edges 82, cutting tool 98 may also run parallel to first series 102 of straight edges 82, to produce second series 104 of straight edges 82 parallel to first series 102 of straight edges 82. Cutting tool 98 may be a mechanical cutting tool, such as a saw blade, as is shown in FIGS. 8A and 8B. Alternatively, cutting tool 98 may be a laser, a torch, a plasma cutter, a hydraulic jet, or any other type of device suited for cutting fins 56. Additionally, cutting tool 98 may be used to form straight edges 82 on fins 56 before or after fins 56 are joined to tube 54.
As is shown in FIGS. 9A and 9B, a ram 106 may also be used to shape fins 56 by bending them. For example, instead of cutting tool 98, ram 106 may be run parallel to center axis 100 to bend outer portions of fins 56 over and form straight edges 82 on fins 56. Ram 106 may be used to form straight edges 82 on fins 56 before or after fins 56 are secured to tube 54.
Methods other than those described above in connection with FIGS. 8A, 8B, 9A, and 9B may be employed to provide straight edges 82 on fins 56. Before using cutting tool 98 or ram 106 to form straight edges 82 on fins 56, one may join fins 56 to tube 54 to form tube assembly 39 and bend tube tube assembly 39, as is described in greater detail below. Additionally, individual fins 56 with parallel, straight edges 82 may be constructed and attached to tube 54 one at a time to form tube assembly 39.
FIG. 10 illustrates one embodiment of a method that may be employed in the manufacture of a heat exchanger, such as heat exchangers 42 and 80, with tube assembly 39. This method may include forming tube assembly 39 by joining fins 56 to tube 54. Tube assembly 39 may then be bent into coils including tubing coils 58 or 70 and 74 by employing the method described hereinafter. After tube assembly 39 is constructed, an end 108 of tube assembly 39 may be temporarily anchored adjacent a fixture 110 by a chuck 112. Fixture 110 and chuck 112 may rotate together while a guide 114 stops an outer portion 116 of tube assembly 39 from rotating with fixture 110. While holding outer portion 116 of tube assembly 39 against rotation, guide 114 may allow outer portion 116 of tube assembly 39 to advance toward fixture 110. As fixture 110 and chuck 112 rotate, they may draw outer portion 116 of tube assembly 39 toward fixture 110 and bend successive portions of tube assembly 39 against fixture 110 into coils 118. Tube assembly 39 may be bent to yielding, such that they take on a new shape in their free states. Tube assembly 39 may be bent directly against fixture 110. In other words, tube assembly 39 may bear directly against fixture 110 during bending, as is shown in FIG. 10. Additionally, tube assembly 39 may be bent indirectly against fixture 110. In other words, tube assembly 39 may bear against another component supported by fixture 110. For example, as is shown in FIG. 11, which is discussed in greater detail below, tube assembly 39 may be bent multiple times around fixture 110 within a plane. In such cases, the first time tube assembly 39 is bent around fixture 110, tube assembly 39 would bear directly against fixture 110. The second time tube assembly 39 is bent around fixture 110 within the same plane, tube assembly 39 would bear against the portion of tube assembly 39 bent around fixture 110 the first time. Thus, the second time tube assembly 39 is bent around fixture 110 within a plane, tube assembly 39 is bent indirectly against fixture 110.
As fixture 110 and chuck 112 rotate, guide 114 may also control the position of outer portion 116 of tube assembly 39 with respect to an axis 120 of fixture 110 to control the shape of coils 118. For example, while fixture 110 rotates, guide 114 may hold outer portion 116 of tube assembly 39 in one position with respect to axis 120 to form coils 118 in radially outwardly extending spirals. Alternatively, while fixture 110 rotates, guide 114 may move outer portion 116 of tube assembly 39 with respect to axis 120 to form coil 118 in an axially-extending helix.
A method of bending tube assembly 39 is not limited to the embodiments described above in connection with FIG. 10. For example, fixture 110 may have different shapes, depending on what shape coil 118 is desired. Additionally, instead of fixture 110 rotating to bend tube assembly 39, fixture 110 may be held stationary and tube assembly 39 bent against fixture 110. Moreover, in addition to, or in place of, fixture 110, chuck 112, and guide 114, other components and/or a person may apply force to tube assembly 39 to bend it.
The methods described above in connection with FIGS. 9, 10, and 11 may be implemented to manufacturer heat exchanger 42, shown in FIGS. 3A-3C. Tube assembly 39 may be constructed by constructing fins 56 and joining them to tube 54 with each fin 56 having straight edges 82 parallel to one another on opposite sides of tube 54. Subsequently, as is shown in FIG. 11, each tube assembly may be bent around a fixture 124 multiple times within a plane. This forms at least a portion of tube 54 into tubing coils 58 spiraling radially outwardly. An outer perimeter 126 of a cross-section of fixture 124 may have the form of one rotation of a spiral in order to facilitate forming tube 54 into tubing coils 58 that spiral radially outwardly.
During bending of tube 54 and fins 56 multiple times within a plane, a sheet 128 of material, such as cardboard, stiff paper, plastic, or metal, may be temporarily disposed between fins 56 of radially-adjacent spiral coils of tube assembly 39 to prevent radial overlap of fins 56 of radially-adjacent spiral coils of tube assembly 39. As can be seen in FIG. 11, sheet 128 may support fins 56 of each spiral coil of tube assembly 39 in spaced relationship with fins 56 of the spiral coil of tube assembly 39 radially inward thereof. Following bending of tube assembly 39 multiple times within a plane to form radially-outwardly extending spiral coils, any sheets 128 temporarily disposed between adjacent spiral coils may be removed from between fins 56 of radially-adjacent coils of tube assembly 39.
Using the process described above, additional tube assemblies 39 may be bent into radially-outwardly extending spirals including tubing coils 58 that spiral radially outwardly. Spacers 46 may be formed in spirals of substantially the same shape as tubing coils 58 of each tube assembly 39 so bent. As FIG. 12 illustrates, spacers 46 and coiled tube assemblies 39 may then be stacked in alternation on a fixture 122. Each spacer 46 may be attached to straight edges 82 of fins 56 such as by adhesive or metallic bond. By attaching coiled tube assemblies 39 between spacers 46, heat exchanger sections 44 are formed.
A method of manufacturing heat exchanger 42 is not limited to the embodiments described above. For example, tube assembly 39 may be bent into spiral coils prior to forming straight edges 82 on fins 56, such as by cutting fins 56 with cutting tool 98, or bending fins 56 with ram 106. Additionally, instead of perimeter 126 of the cross-section of fixture 110 having the shape of one rotation of a spiral, fixture 110 may have cross-sections of other shapes, such as circular. Additionally, heat exchanger 42 may be constructed using tools and/or fixtures other than those mentioned above.
Additionally, the methods described above in connection with FIG. 10 may be implemented to manufacture heat exchanger 80, shown in FIG. 5. Fins 56 may be constructed and joined to one or more tubes 54 to form one or more tube assemblies 39. Each fin 56 may have straight edges 82 parallel to one another on opposite sides of tube 54. First section 91 of tube assembly 39 may then be bent parallel to straight edges 82 of fins 56 around fixture 110 into a helix extending in a first direction along axis 120 to form first set of helical tubing coils 70. Additionally, second section 93 of tube assembly 39 may be bent parallel to straight edges 82 of fins 56 around fixture 110 into a helix extending in first direction 68 to form second set of helical tubing coils 74. In some embodiments, first section 91 of tube assembly 39 and second section 93 of tube assembly 39 may be simultaneously bent parallel to one another helically around fixture 110, to simultaneously form first set of helical tubing coils 70 and second set of helical tubing coils 74 in alternating positions along axis 120 of fixture 110. After first set of helical tubing coils 70 and second set of helical tubing coils 74 are formed, first end 79 of first set of helical tubing coils 70 and first end 81 of second set of helical tubing coils 74 may be fluidly connected, such as by fluidly connecting connector 72 therebetween. Additionally, spacers 46 may be formed into helixes of substantially the same shape as first set of helical tubing coils 70 and second set of tubing coils 74. These spacers 46 may then be slid between fins 56 extending from first set of tubing coils 70 and fins 56 extending from second set of tubing coils 74. These spacers 46 may then be attached to these fins 56 such as by adhesive or metallic bond.
Methods of manufacturing heat exchangers 64 and 80 are not limited to the embodiments described above. For example, the components of heat exchangers 64 and 80 may be formed and attached to one another in different manners and orders than is described above. Additionally, heat exchangers 64 and 80 may be constructed using tools and/or fixtures other than those mentioned above.
Once a heat exchanger, such as heat exchanger 16, heat exchanger 42, heat exchanger 64, or heat exchanger 80 is constructed, it may be installed in pump housing 12 between inlet opening 20 and connection port 26 or in pump housing 43 between inlet opening 53 and connection port 59. For example, a manufacturer may install heat exchanger 16 or 42 in pump housing 12 with tubing coils 58 extending around impeller rotation axis 18. Consistent with certain embodiments a manufacturer may install heat exchanger 64 or heat exchanger 80 in pump housing 12 with first set of helical tubing coils 70 and second set of helical tubing coils 74 extending around impeller rotation axis 18. Furthermore, a manufacturer may install heat exchanger 16 or 42 in pump housing 43 with tubing coils 58 extending around impeller rotation axis 51. Consistent with certain embodiments a manufacturer may install heat exchanger 64 or heat exchanger 80 in pump housing 43 with first set of helical tubing coils 70 and second set of helical tubing coils 74 extending around impeller rotation axis 51.
It will be apparent to those skilled in the art that various modifications and variations can be made in the pump, heat exchanger and manufacturing methods without departing from the scope of the disclosure. Other embodiments of the pump, heat exchanger and manufacturing methods will be apparent to those skilled in the art from consideration of the specification and practice of the pump, heat exchanger and manufacturing methods disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
Patent Application
20060275151
