U.S. patent application number 11/280917 was filed with the patent office on 2007-05-17 for heat exchanger with embedded heater.
This patent application is currently assigned to Honeywell International Inc.. Invention is credited to Gus W. Cutting, Nicholas A. Hartney, Winston S. Webb.
Application Number | 20070107453 11/280917 |
Document ID | / |
Family ID | 38039349 |
Filed Date | 2007-05-17 |
United States Patent
Application |
20070107453 |
Kind Code |
A1 |
Cutting; Gus W. ; et
al. |
May 17, 2007 |
Heat exchanger with embedded heater
Abstract
A heat exchanger having both heating and cooling functions
includes a first container, a second container and at least one
heater. The first container is adapted to hold a first fluid. The
second container is adapted to hold a second fluid. Moreover, the
second container is thermally coupled to the first container such
that thermal energy transfer between the first and second container
occurs. The at least one heater is embedded with the first and
second container.
Inventors: |
Cutting; Gus W.; (Palm
Harbor, FL) ; Hartney; Nicholas A.; (St. Petersburg,
FL) ; Webb; Winston S.; (Key Largo, FL) |
Correspondence
Address: |
HONEYWELL INTERNATIONAL INC.
101 COLUMBIA ROAD
P O BOX 2245
MORRISTOWN
NJ
07962-2245
US
|
Assignee: |
Honeywell International
Inc.
Morristown
NJ
07962
|
Family ID: |
38039349 |
Appl. No.: |
11/280917 |
Filed: |
November 16, 2005 |
Current U.S.
Class: |
62/276 |
Current CPC
Class: |
F28D 7/106 20130101;
F25D 21/08 20130101 |
Class at
Publication: |
062/276 |
International
Class: |
F25D 21/06 20060101
F25D021/06 |
Claims
1. A heat exchange system comprising: a first container adapted to
hold a first fluid; a second container adapted to hold a second
fluid, the second container thermally coupled to the first
container such thermal energy transfer between the first and second
container occurs; and at least one heater embedded with the first
and second container.
2. The heat exchange system of claim 1, wherein the at least one
heater is one of a solid plate heater, a rope heater, a wire heater
and an immersion heater.
3. The heat exchange system of claim 1, wherein the first container
is a thermally conductive tube having one or more coils and the
second container is also a thermally conductive tube having one or
more coils.
4. The heat exchange system of claim 3, wherein the at least one
heater is at least one wire heater positioned adjacent the one or
more coils of the first and second containers.
5. The heat exchange system of claim 3, wherein the at least one
heater is at least one wire heater wrapped around the one or more
coils.
6. The heat exchange system of claim 3, further comprising:
conductive material encasing the one or more coils of the first and
second containers and the wire heater.
7. The heat exchange system of claim 6, further comprising:
insulation material encasing the conductive material.
8. A method of manufacturing a heat exchanger, the method
comprising: forming a first thermal container adapted to contain a
first liquid; forming a second thermal container adapted to contain
a second liquid, the second thermal container being thermally
coupled to the first thermal container; and embedding at least one
heater with the first and second thermal containers.
9. The method of claim 8, wherein forming the first thermal
container further comprises: forming one or more coils with the
first thermal container; and wherein forming the second thermal
container further comprises; forming one of more coils with the
first thermal container, wherein the one or more coils of the first
and second thermal containers are in thermal contact with each
other.
10. The method of claim 9, wherein embedding the at least one
heater with the first and second thermal containers further
comprises: placing the at least one heater with the one or more
coils of the first and second thermal containers.
11. The method of claim 9, further comprising: forming a layer of
conductive material around the one or more coils of the first and
second thermal conductors and the heater.
12. A method of operating a heat exchange, the method comprising:
generating a flow of a first fluid in a first container; generating
a flow of a second fluid in a second container, wherein the second
container is thermally coupled to the first container; and
adjusting the thermal energy in the first and second fluids with at
least one heater that is integrated with the first and second
container.
13. The method of claim 12, further comprising: thawing frozen
first and second fluids in the first and second containers in a
relatively rapid fashion with the at least one heater.
14. A heat exchange system comprising: a first means for containing
a first fluid; a second means for containing a second fluid, the
first and second means being in thermal contact with each other;
and a means for heating the first and second fluids with a heater
embedded with the first and second means for containing the first
and second fluid.
15. The heat exchange system of claim 14, further comprising: a
means for enhancing thermal transfer between the first fluid,
second fluid and the means for heating.
16. The heat exchange system of claim 14, further comprising: a
means for insulting the heat exchange system from the environment
it is located in.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to heat exchangers
and in particular to heat exchangers having both heating and
cooling functions.
BACKGROUND
[0002] Fluids are used in various industries for certain heating or
cooling applications. For example, fluids (liquid or gas) are used
in heat exchangers. A heat exchanger is a device used to transfer
thermal energy from one fluid to another fluid. The two fluids are
held in separate containers that are thermally coupled to each
other so that the transfer of thermal energy occurs. In some
applications the heat exchangers are designed for both heat
exchange and cold exchange. For heat exchange, a heater is
typically submerged in an associated fluid which is then activated
to heat the fluid as it flows over the heater. The heated fluid is
then pumped through the heat exchanger (i.e. through the containers
thermally coupled to each other to transfer the heat from the
heated fluid to the other fluid). This type of arrangement,
however, presents a problem with the separation of control of the
energy entering and exiting the system. In particular, this type of
arrangement, can cause oscillation at set points and unreliable
operation during ramps (i.e. the transition period it takes from
going from an initial temperature to a desired temperature). In
addition, in very cold dwells or rapid ramps, the cold exchanger
can actually freeze the working fluid in the exchanger, stopping
all flow. If this happens, no matter how much heat the heating
system adds, the cold exchanger will not thaw since there is no
flow of the fluids. This forces the system to stop operation until
the cold exchanger thaws out on its own. This can take days in
large systems causing loss of production and time. Another
disadvantage to this type of system is the bulkiness of the total
system (i.e. the separate heater and heat exchanger takes up a lot
of space). Where space is limited, this type of heat exchanger
system is not a viable option.
[0003] For the reasons stated above and for other reasons stated
below which will become apparent to those skilled in the art upon
reading and understanding the present specification, there is a
need in the art for a heat exchange system that is efficient, not
as susceptible to the freezing of the working fluid and is
relatively small in size.
SUMMARY OF INVENTION
[0004] The above-mentioned problems of current systems are
addressed by embodiments of the present invention and will be
understood by reading and studying the following specification.
[0005] In one embodiment, a heat exchange system is provided. The
heat exchange system includes a first container, a second container
and at least one heater. The first container is adapted to hold a
first fluid. The second container is adapted to hold a second
fluid. Moreover, the second container is thermally coupled to the
first container such that thermal energy transfer between the first
and second container occurs. The at least one heater is embedded
with the first and second container.
[0006] In another embodiment, a method of manufacturing a heat
exchanger is provided. The method comprises forming a first thermal
container adapted to contain a first liquid. Forming a second
thermal container adapted to contain a second liquid. The second
thermal container is thermally coupled to the first thermal
container. Finally, embedding at least one heater with the first
and second thermal containers.
[0007] In yet another embodiment, a method of operating a heat
exchange is provided. The method comprises generating a flow of a
first fluid in a first container. Generating a flow of a second
fluid in a second container, wherein the second container is
thermally coupled to the first container and adjusting the thermal
energy in the first and second fluids with at least one heater that
is integrated with the first and second container.
[0008] In still another embodiment, a heat exchange system
comprises a first means for containing a first fluid and a second
means for containing a second fluid. The first and second means
being in thermal contact with each other. The heat exchange system
also includes a means for heating the first and second fluids with
a heater embedded with the first and second means for containing
the first and second fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention can be more easily understood and
further advantages and uses thereof more readily apparent, when
considered in view of the description of the preferred embodiments
and the following figures in which:
[0010] FIG. 1 is a cross-sectional side view of a heat exchanger
system of one embodiment of the present invention;
[0011] FIG. 2 is a side view of a heat exchanger system of another
embodiment of the present invention;
[0012] FIG. 3 is an illustration of a heat exchanger system of one
embodiment of the present invention;
[0013] FIG. 4 is an illustration of a heat exchanger system of FIG.
3 including a layer of thermally conductive material.
[0014] In accordance with common practice, the various described
features are not drawn to scale but are drawn to emphasize specific
features relevant to the present invention. Reference characters
denote like elements throughout Figures and text.
DETAILED DESCRIPTION
[0015] In the following detailed description, reference is made to
the accompanying drawings, which form a part hereof, and in which
is shown by way of illustration specific embodiments in which the
inventions may be practiced. These embodiments are described in
sufficient detail to enable those skilled in the art to practice
the invention, and it is to be understood that other embodiments
may be utilized and that logical, mechanical and electrical changes
may be made without departing from the spirit and scope of the
present invention. The following detailed description is,
therefore, not to be taken in a limiting sense, and the scope of
the present invention is defined only by the claims and equivalents
thereof.
[0016] Embodiments of the present invention provide a heat
exchanger that has a heater embedded therein. By embedding the
heater in the heat exchanger, greater temperature control of the
heat exchanger is achieved since the thermal capacitance stored in
the cold exchanger is driven away by one or heaters embedded in the
heat exchanger rather then simply being transferred to the working
fluid. Moreover, a controller of the heat exchanger of embodiments
of the present invention does not have to try and compensate for
residual cooling potential left in the cold heat exchanger after it
is no longer needed. In addition, in embodiments of the present
invention, you do not have to wait for the working fluid to pass
through the entire system and return before heating the cold
exchanger, thus reducing feedback time. This helps to minimize
overshoot while ramping to set point as well as oscillation at set
point. Embodiments of the present invention also help to prevent
the cold heat exchanger from freezing during cold dwells and rapid
ramps. Moreover, if the exchanger does freeze and the flow of
working fluid is stopped, the heater or heaters can rapidly thaw
the exchanger and restore the fluid flow. Finally, embodiments of
the present invention provide a heat exchange system that is
relatively small in size.
[0017] Referring to FIG. 1, a cross-sectional view of a heat
exchange system 100 of one embodiment of the present invention is
illustrated. As illustrated, the heat exchange system includes a
first thermally conductive container 102 adapted to hold a first
fluid 106 (gas or liquid) and a second thermally conductive
container 104 to hold a second fluid (gas or liquid) (108). In this
example of the embodiment of the present invention, the first
container 102 is in the form of an annulus that surrounds the
second container 104 which is in the form of a pipe. Fluid 106
exchanges thermal energy with fluid 108 in performing the heat
exchange function.
[0018] FIG. 1, also illustrates heaters 110-1 through 110-N which
are embedded in the heat exchange system 100. In one embodiment the
heaters 110-1 through 110-N are electrical heaters. Also
illustrated in FIG. 1 is controller 112 that is designed to control
the electric heaters 110-1 through 110-N. Under control of the
controller 112, the thermal capacitance stored in the cold
exchanger is selectively driven away by the heaters 110-1 through
110-N embedded in the heat exchanger rather then simply being
transferred to the working fluid. The present invention is not
limited to the type of heat exchanger 100 illustrated in FIG. 1
since other types of heat exchange systems would benefit from
having one or more heaters embedded in the system. Moreover,
embodiments of the present invention use different types of heaters
which include but are not limited to solid plate heaters, rope
heaters, wire heaters and immersion heaters and the like.
Accordingly, the present invention is not limited to a specific
type of heater.
[0019] An example of a different type of heat exchange system 200
incorporating an embodiment of the present invention is illustrated
in FIG. 2. As illustrated, the heat exchange system 200 of FIG. 2
includes a first and second container 202 and 204 respectively. The
first and second containers 202 and 204 in this embodiment are
tubes that are formed into coils. The tubes are made from a
material that has relative high thermal conductivity such as
copper. The coils of the first and second containers 202 and 204
are positioned next to each other so that thermal energy can be
transferred between them. Also positioned next to the coils of the
first and second containers 202 and 204 is a heater 206. In
particular, in this embodiment, the heater 206 is a wire (or cable)
heater that is wrapped around the coils of the first and second
containers 202 and 204.
[0020] The embodiment of FIG. 2 also includes a thermally
conductive material 208 that encases the coils of the first and
second container 202 and 204 as well as the heater 206 wrapped
around the coils of the first and second containers 202 and 204.
The thermally conductive material 208 enhances thermal conduction
between the fluids in the coils of the first and second containers
and the heater 206. This embodiment further includes a layer of
insulation 210 that encases the thermally conductive material 208.
The layer of insulation 210 provides further efficiency to the heat
exchanger system 200 of FIG. 2, by inhibiting unwanted thermal
energy exchange between the heat exchange system 200 and the
environment surrounding the system 200.
[0021] Referring to FIG. 3, an illustration of a heat exchange
system 300 similar to the heat exchange system of FIG. 2 of one
embodiment of the present invention is provided. This heat exchange
system 300 also includes a first and second container 302 and 304
respectively. The first and second container 302 and 304 are tubes
that are formed into coils that are positioned next to each other
to achieve thermal transfer. Embedded in the coils is an electric
wire heater 306. The connections to the electric wire heater are
indicated at 308 and 310. FIG. 4 illustrates the heat exchange
system 300 of FIG. 3 including conductive material 408 embedding
the coils of the first and second containers 302 and 304 and the
embedded wire heater 306. In one embodiment, the conductive
material is made from conductive clay that hardens after it is
placed around the coils of the first and second containers 302 and
304 and the embedded wire heater 306.
[0022] A flow diagram 500 illustrating the operation of a heat
exchange system of one embodiment of the present invention is
illustrated in FIG. 5. As illustrated, the operation begins by
generating a flow of first and second fluids through a respective
first and second containers (502 and 504). In embodiments of the
present invention the thermal energy in the first and second fluids
is adjusted using an embedded heater (506). As discussed above, the
embedded heater provides greater temperature control of the heat
exchanger since the thermal capacitance stored in the cold
exchanger is driven away by the rather then simply being
transferred to the working fluid. As a result, you do not have to
wait for the working fluid to pass through the entire system and
return before heating the cold exchanger, thus reducing feedback
time. This helps to minimize overshoot while ramping to set point
as well as oscillation at set point. Moreover, the adjusting of the
temperature at (506) also helps to prevent the cold heat exchanger
from freezing during cold dwells and rapid ramps. In addition, even
if the exchanger does freeze and the flow of working fluid is
stopped, the adjustment of the temperature at (506) can rapidly
thaw the exchanger and restore the fluid flow.
[0023] Although specific embodiments have been illustrated and
described herein, it will be appreciated by those of ordinary skill
in the art that any arrangement, which is calculated to achieve the
same purpose, may be substituted for the specific embodiment shown.
This application is intended to cover any adaptations or variations
of the present invention. Therefore, it is manifestly intended that
this invention be limited only by the claims and the equivalents
thereof.
* * * * *