U.S. patent application number 14/048446 was filed with the patent office on 2014-03-06 for heat exchanger and method of operating the same.
This patent application is currently assigned to Modine Manufacturing Company. The applicant listed for this patent is Modine Manufacturing Company. Invention is credited to Tony Paul Rousseau.
Application Number | 20140060789 14/048446 |
Document ID | / |
Family ID | 50185807 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140060789 |
Kind Code |
A1 |
Rousseau; Tony Paul |
March 6, 2014 |
HEAT EXCHANGER AND METHOD OF OPERATING THE SAME
Abstract
An evaporative heat exchanger includes first and second stacked
plates forming a first fluid flow path between a first end and a
second end. The first stacked plate defines a plane. Third and
fourth stacked plates define a second fluid flow path. A fluid flow
plate is positioned between the first and second stacked plates,
and has a plurality of flow channels extending substantially
parallel to the plane between the first end and the second end. At
least one of the first and second stacked plates defines slots that
form a portion of the first fluid flow path so that fluid flowing
along the first fluid flow path flows along the flow channels in
the first direction, then flows along at least one of the slots,
then flows into adjacent flow channels and then along the adjacent
flow channels in a second direction parallel to the first
direction.
Inventors: |
Rousseau; Tony Paul;
(Racine, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Modine Manufacturing Company |
Racine |
WI |
US |
|
|
Assignee: |
Modine Manufacturing
Company
Racine
WI
|
Family ID: |
50185807 |
Appl. No.: |
14/048446 |
Filed: |
October 8, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12572310 |
Oct 2, 2009 |
8550153 |
|
|
14048446 |
|
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61102458 |
Oct 3, 2008 |
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Current U.S.
Class: |
165/166 |
Current CPC
Class: |
F28D 21/0003 20130101;
F28D 9/005 20130101; F22B 29/06 20130101; Y02E 20/30 20130101; Y02E
20/363 20130101; F01K 25/08 20130101; F28F 3/046 20130101; F01K
23/065 20130101; F22B 1/1807 20130101; F28F 9/026 20130101; F28D
9/0068 20130101; F28F 3/086 20130101; F28F 3/025 20130101; F01K
23/10 20130101; F28D 9/0075 20130101; F28D 2021/0071 20130101; F28D
2021/0064 20130101 |
Class at
Publication: |
165/166 |
International
Class: |
F28F 3/08 20060101
F28F003/08 |
Claims
1. An evaporative heat exchanger operable to at least partially
vaporize fluid, the heat exchanger comprising: first and second
stacked plates defining a first fluid flow path between the first
and second stacked plates, the first and second stacked plates each
having a first end and a second end, and the first stacked plate
defines a plane; third and fourth stacked plates defining a second
fluid flow path between the third and fourth stacked plates,
wherein the third stacked plate is positioned adjacent the second
stacked plate; and a fluid flow plate positioned between the first
and second stacked plates, the fluid flow plate having a plurality
of flow channels extending in a first direction between the first
end and the second end, wherein the first direction is
substantially parallel to the plane; wherein at least one of the
first and second stacked plates and the fluid flow plate defines a
plurality of slots, wherein the plurality of slots form a portion
of the first fluid flow path such that fluid flowing along the
first fluid flow path flows along at least one of the flow channels
in the first direction and then flows in a second direction into at
least one of the plurality of slots, wherein the second direction
is non-parallel to the plane, and then flows in a third direction
toward an adjacent one of the flow channels, wherein the third
direction is substantially parallel to the plane, and then in a
fourth direction into the adjacent one of the flow channels,
wherein the fourth direction is substantially non-parallel to the
plane, and then in a fifth direction along the adjacent one of the
flow channels, wherein the fifth direction is substantially
parallel to the plane.
2. The heat exchanger of claim 1, wherein at least one of the slots
is an elongate slot extending along the third direction.
3. The heat exchanger of claim 1, wherein the second direction is
substantially perpendicular to the plane.
4. The heat exchanger of claim 1, wherein the first direction is
substantially perpendicular to the third direction.
5. The heat exchanger of claim 1, wherein the first direction is
substantially parallel to the fifth direction.
6. The heat exchanger of claim 1, wherein at least one of the
plurality of slots is formed in the first plate.
7. The heat exchanger of claim 1, wherein at least one of the
plurality of slots is formed in the second plate.
8. The heat exchanger of claim 1, wherein the plurality of slots
include at least one slot formed in the first plate and at least
one slot formed in the second plate.
9. The heat exchanger of claim 1, wherein the plurality of slots
includes a first group of slots and a second group of slots,
wherein the first group of slots is formed in the first plate and
wherein the second group of slots is formed in the second
plate.
10. The heat exchanger of claim 1, wherein the fluid flow plate has
convolutions that form adjacent the peaks and valleys, and wherein
the plurality of flow channels are defined by peaks and
valleys.
11. The heat exchanger of claim 1, wherein the plurality of slots
include at least one group of elongate slots each extending in the
third direction, substantially perpendicular to the first
direction.
12. The heat exchanger of claim 1, further comprising a convoluted
fin positioned between the third and fourth plates.
13. An evaporative heat exchanger operable to at least partially
vaporize fluid, the heat exchanger comprising: first and second
stacked plates defining a first fluid flow path between the first
and second stacked plates, the first and second stacked plates each
having a first end and a second end, and the first stacked plate
defines a plane; third and fourth stacked plates defining a second
fluid flow path between the third and fourth stacked plates,
wherein the third stacked plate is positioned adjacent the second
stacked plate; and a fluid flow plate positioned between the first
and second stacked plates, the fluid flow plate having a plurality
of flow channels extending in a first direction between the first
end and the second end, wherein the first direction is
substantially parallel to the plane; wherein at least one of the
first and second stacked plates defines a plurality of slots,
wherein the plurality of slots form a portion of the first fluid
flow path such that fluid flowing along the first fluid flow path
flows along at least one of the flow channels in the first
direction, then flows along at least one of the plurality of slots,
then flows into an adjacent one of the flow channels and then along
the adjacent flow channel in a second direction, substantially
parallel to the first direction.
14. The heat exchanger of claim 13, wherein the plurality of slots
are elongate and extend in a third direction, wherein the third
direction is non-parallel to the plane.
15. The heat exchanger of claim 14, wherein the third direction is
substantially perpendicular to the first direction.
16. The heat exchanger of claim 13, wherein at least one of the
plurality of slots is an elongate slot.
17. The heat exchanger of claim 13, wherein the plurality of slots
includes a first plurality of slots formed in the first plate and a
second plurality of slots formed in the second plate.
18. The heat exchanger of claim 17, wherein each the first
plurality of slots are substantially aligned with a corresponding
one of the second plurality of slots in a direction substantially
perpendicular to the plane.
19. The heat exchanger of claim 13, wherein the fluid flow plate
has convolutions that form adjacent peaks and valleys, and wherein
the plurality of flow channels are defined by the peaks and
valleys.
20. The heat exchanger of claim 13, further comprising a convoluted
fin positioned between the third and fourth plates.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S.
application Ser. No. 12/572,310, filed Oct. 2, 2009 which claims
priority to U.S. Provisional Patent Application Ser. No.
61/102,458, filed Oct. 3, 2008, the entire contents of both of
which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to heat exchangers, and more
particularly to evaporative heat exchangers having a number of
stacked plates at least partially defining two separate and
substantially adjacent fluid flow paths
SUMMARY OF THE INVENTION
[0003] Attempts to use stacked plate style heat exchangers in
applications where one of the fluids experiences a change of phase
from a liquid to a vapor have been problematic. In such
applications the fluid that is evaporating exists, over at least a
portion of its flow path through the heat exchanger, as a two-phase
fluid having both vapor and liquid fractions. The vapor fraction
tends to separate from the liquid fraction due to the substantial
differences in densities between the phases, making it difficult to
achieve a uniform distribution of the fluid over the multiple
parallel passages. This maldistribution effect can be especially
pronounced when the flow path through the heat exchanger is
circuitous, requiring the fluid to make multiple changes in flow
direction. When the distribution is not uniform, the performance of
the heat exchanger tends to suffer. Separation of the phases of the
evaporating fluid can result in liquid flooding of certain regions,
with slugs of the liquid forced through the heat exchanger at a
non-constant rate. For this reason, evaporative heat exchangers
have often been of a construction wherein the evaporating fluid
does not require redistribution along its flow path.
[0004] In certain evaporative heat exchanger applications, it may
be especially beneficial to arrange the flow passages so that the
hot fluid and the evaporating fluid pass through the heat exchanger
in a counter-flow or in a concurrent flow orientation to one
another. A counter-flow orientation may be desirable when the hot
fluid is to be cooled to as low a temperature as possible, or when
the evaporating fluid is to be superheated to as high a temperature
as possible. A concurrent flow orientation may be desirable when
the hot fluid and the evaporating fluid are to exit the heat
exchanger at one common temperature. Examples of such applications
include, but are not limited to, air-conditioning and refrigeration
chillers, Rankine cycle evaporators, and water and/or fuel
vaporizers for fuel processing and fuel cell applications. A
disadvantage of using a tube and fin evaporator construction in
such applications is the difficulties that it poses in arranging
the hot and cold fluid flows in a circuiting arrangement other than
cross-flow.
[0005] According to one embodiment of the invention, a stacked
plate evaporative heat exchanger for the transfer of heat from a
first fluid to a second fluid to vaporize the second fluid includes
a plurality of separate parallel flow passages to direct the first
fluid through the heat exchanger, and a plurality of parallel
arranged fluid flow plates for the second fluid interleaved with
the parallel flow passages for the first fluid. The fluid flow
plates have a first and second set of flow channels extending from
a first end of the fluid flow plate to a second end of the fluid
flow plate to define a first flow pass for the second fluid. The
fluid flow plates further have a third set of flow channels to
define a second flow pass for the second fluid parallel to the
first pass. A first collection manifold is located at the second
end to receive at least a portion of the second fluid flow from the
first pass and transfer it to the second pass. A second collection
manifold is located between the first and second ends and
intersects the second set of flow channels and at least some of the
third set of flow channels, but not the first set of flow channels,
to receive at least a portion of the second fluid from the first
pass and transfer it to the second pass.
[0006] In some embodiments, the fluid flow plate is constructed by
corrugating a thin sheet of material. The second collection
manifold may be defined by slots passing through the corrugations
of the fluid flow plate.
[0007] In some embodiments, the plurality of separate parallel flow
passages are arranged to direct the first fluid through the heat
exchanger in a direction approximately perpendicular to the first
and second flow passes for the second fluid. In some embodiments
the plurality of separate parallel flow passages are arranged to
direct the first fluid in two or more sequential passes through the
heat exchanger.
[0008] In some embodiments, the pressure resistance and heat
transfer performance of the heat exchanger may be improved by
having a uniformly narrow channel width for the flow channels of
the fluid flow plates. In some embodiments the second collection
manifold can consist of one or more slots extending through the
fluid flow plate. In some embodiments the one or more slots can
each have a slot width that is approximately equal to the channel
width.
[0009] In some embodiments, the fluid flow plates include a fourth
set of flow channels to additionally define the second flow pass,
and a fifth set of flow channels to define a third pass downstream
of the first and second passes A third collection manifold is
located at the first end of the fluid flow plate to receive at
least a portion of the second fluid from the second pass and
transfer it to the third pass. A fourth collection manifold is
located between the first and second ends and intersects the fourth
set of flow channels and at least some of the fifth set of flow
channels, but not the third set of flow channels, to receive at
least a portion of the second fluid from the second pass and
transfer it to the third pass. In some such embodiments the fluid
flow plates include additional flow passes downstream of the third
pass.
[0010] In some embodiments, the plurality of separate parallel flow
passages are at least partially defined by a plurality of stamped
plates. Each of the stamped plates can include a recessed area to
receive one of the fluid flow plates.
[0011] In some embodiments, the present invention provides an
evaporative heat exchanger operable to at least partially vaporize
fluid. The heat exchanger can include a number of parallel flow
passages extending through the heat exchanger, together the flow
passages define a first fluid flow path, and a number of
substantially parallel stacked plates interleaved with the parallel
flow passages. Each plate can have a first end and a second end
spaced apart from the first end and at least partially define a
first set of flow channels extending from the first end to the
second end and a second set of flow channels extending from the
first end to the second end parallel to the first set of flow
channels. The first and second sets of flow channels together can
comprise a first flow pass of a second fluid flow path. Each plate
can also include a third set of flow channels extending from the
first end to the second end and comprising a second flow pass of
the second fluid flow path substantially parallel to the first flow
pass of the second fluid flow path, a first collection manifold
adjacent to the second end and connecting the first and second
passes, and a second collection manifold between the first end and
the second end, the second collection manifold intersecting the
second set of flow channels and at least some of the third set of
flow channels. The can plate separate the first set of flow
channels from the second collection manifold.
[0012] In some embodiments, the present invention provides an
evaporative heat exchanger that is operable to at least partially
vaporize fluid. The heat exchanger includes first and second
stacked plates that define a first fluid flow path between the
first and second stacked plates. The first and second stacked
plates each have a first end and a second end, and the first
stacked plate defines a plane. Third and fourth stacked plates
define a second fluid flow path between the third and fourth
stacked plates. The third stacked plate is positioned adjacent the
second stacked plate. A fluid flow plate is positioned between the
first and second stacked plates. The fluid flow plate has flow
channels extending in a first direction between the first end and
the second end. The first direction is substantially parallel to
the plane. At least one of the first and second stacked plates and
the fluid flow plate includes slots that form a portion of the
first fluid flow path so that fluid flowing along the first fluid
flow path flows along at least one of the flow channels in the
first direction and then flows in a second direction into at least
one of the slots. The second direction is non-parallel to the
plane. The fluid then flows in a third direction toward an adjacent
one of the flow channels. The third direction is substantially
parallel to the plane. The fluid then flows in a fourth direction
into the adjacent one of the flow channels. The fourth direction is
substantially non-parallel to the plane. Finally, the fluid flows
in a fifth direction along the adjacent one of the flow channels.
The fifth direction is substantially parallel to the plane.
[0013] In some embodiments, the present invention provides an
evaporative heat exchanger that is operable to at least partially
vaporize fluid. The heat exchanger includes first and second
stacked plates that define a first fluid flow path between the
first and second stacked plates. The first and second stacked
plates each have a first end and a second end, and the first
stacked plate defines a plane. Third and fourth stacked plates
define a second fluid flow path between the third and fourth
stacked plates. The third stacked plate is positioned adjacent the
second stacked plate. A fluid flow plate is positioned between the
first and second stacked plates. The fluid flow plate has flow
channels that extend in a first direction between the first end and
the second end. The first direction is substantially parallel to
the plane. At least one of the first and second stacked plates
includes slots that form a portion of the first fluid flow path so
that fluid flowing along the first fluid flow path flows along at
least one of the flow channels in the first direction, then flows
along at least one of the slots, then flows into an adjacent one of
the flow channels and then along the adjacent flow channel in a
second direction, substantially parallel to the first
direction.
[0014] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an isometric view of a heat exchanger according to
some embodiments of the present invention.
[0016] FIG. 2 is a partially exploded isometric view of the heat
exchanger of FIG. 1.
[0017] FIG. 3 is an isometric view of certain portions of the heat
exchanger of FIGS. 1 and 2.
[0018] FIG. 4 is similar to FIG. 3 but with certain details removed
to more clearly show fluid flow paths.
[0019] FIGS. 5a-c are diagrammatic illustrations of possible fluid
flow paths through a heat exchanger according to embodiments of the
present invention.
[0020] FIG. 6 is an isometric view of a heat exchanger according to
another embodiment of the present invention.
[0021] FIG. 7 is an isometric view of certain portions of the heat
exchanger of FIG. 6.
[0022] FIG. 8 is an isometric view of a heat exchanger according to
another embodiment of the present invention.
[0023] FIG. 9 is an isometric view of certain portions of the heat
exchanger of FIG. 8.
[0024] FIG. 10 is an exploded view of FIG. 9.
[0025] FIG. 11 is a cross-sectional view taken along line 11-11 of
FIG. 8.
[0026] FIG. 12 is a close-up view of a portion of FIG. 11.
[0027] FIGS. 13-16 illustrate alternative embodiments of stacked
plate assemblies of heat exchangers according to some embodiments
of the present invention.
[0028] FIG. 17 illustrates an alternative embodiment of a plate for
use in any of the heat exchangers described here.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise,
the terms "mounted," "connected," "supported," and "coupled" and
variations thereof are used broadly and encompass both direct and
indirect mountings, connections, supports, and couplings. Further,
"connected" and "coupled" are not restricted to physical or
mechanical connections or couplings.
[0030] FIGS. 1 and 2 illustrate a heat exchanger 1 according to
some embodiments of the present invention. The heat exchanger 1 is
adapted to receive a first fluid flow 2 and a second fluid flow 3
and to place them in heat exchange relation with one another so as
to transfer heat from one of the fluid flows to the other of the
fluid flows. The heat exchanger 1 is especially well suited for use
when the fluid flow 2 is a hot gas flow and the fluid flow 3 is a
liquid or partially liquid flow having a boiling point or bubble
point temperature that is lower than the entering temperature of
the fluid flow 2, so that heat can be transferred from the first
fluid flow 2 to the second fluid flow 3 in order to substantially
vaporize the second fluid flow 3.
[0031] In some such applications, the heat that is so transferred
may be sufficient to fully vaporize the second fluid flow 3,
whereas in other applications the heat may be sufficient to
vaporize only a portion of the first fluid flow 3. Furthermore, in
some applications, the heat that is transferred from the first
fluid flow 2 to the second fluid flow 3 may exceed the amount of
latent heat required to fully vaporize the second fluid flow 3, so
that the second fluid flow 3 exits the heat exchanger 1 as a
superheated vapor.
[0032] The heat exchanger 1 shown in FIGS. 1 and 2 may be
especially useful as an evaporator in a Rankine cycle waste heat
recovery system for an internal combustion engine. In such a
system, the first fluid flow 2 can be a flow of exhaust gas from
the internal combustion engine, and the second fluid flow 3 can be
a Rankine cycle working fluid such as water, ammonia, ethanol,
methanol, R245fa or similar refrigerants, or a combination thereof.
The utility of the heat exchanger 1 is not limited to such
applications, however, and no limitations to the use of a heat
exchanger according to the present invention are implied unless
expressly recited in the claims.
[0033] As best seen in FIG. 2, the heat exchanger 1 includes a
plurality of parallel arranged stamped shells 5, each of which is
adapted to house a fluid flow plate 4 for the second fluid flow 3.
The heat exchanger 1 further includes a plurality of convoluted fin
structures 6 for the first fluid flow 2 interleaved with the
stamped shells 5, and a plurality of stamped shells 7 located
between the convoluted fin structures 6 and the fluid flow plates 4
in order to maintain separation between the first and second fluid
flows 2 and 3 traveling through the heat exchanger 1. While
reference is made herein to stamped shells 5, 7, in some
embodiments, the shells 5, 7 can be formed in manners other than
stamping. Alternatively or in addition, the shells 5, 7 can be
positioned along or form less than the entire first and second
fluid flows 2, 3.
[0034] In the illustrated embodiment of FIGS. 1 and 2, the stamped
plates 5 and 7 are adapted to form sealed edges along the length of
the heat exchanger 1. The heat exchanger 1 further includes a top
plate 8 and a bottom plate 9, as well as header plates 10 to define
an inlet and outlet for the first fluid flow 2. The components of
the heat exchanger 1 may be joined to one another by brazing,
soldering, welding, or other methods known in the art.
[0035] Features of the fluid flow plates 4 and stamped shells 5
will now be further described with reference to FIGS. 3 and 4. The
stamped shells 5 include a fluid inlet port 11 to receive the
second fluid flow 3 and a fluid outlet port 12 through which the
second fluid flow 3 can exit the heat exchanger 1. Between the
inlet port 11 and the outlet port 12 the second fluid flow 3 is
routed through multiple flow passes defined by the stamped shell 5
and the fluid flow plate 4, with the flow passes extending between
parallel ends 40, 41 of the fluid flow plate 4. In the exemplary
embodiment shown in FIGS. 3 and 4, a fluid flow would encounter
eight passes as it travels from inlet port 11 to outlet port 12.
The eight passes are depicted using dashed lines in FIG. 4, with
arrows indicating the direction of flow through each pass. It
should be recognized that the desirable number of passes would vary
with the application, and that heat exchangers having fewer than or
more than eight passes are possible.
[0036] In the depicted embodiment, the fluid flow plate 4 is a
corrugated thin metal sheet. Each of the eight fluid passes 14-21
comprise a plurality of flow channels 13 defined by corrugations of
the fluid flow plate 4. The crests of the corrugations may be
rounded as shown, or they may be some other shape such as, for
example, flat or peaked. During fabrication of the heat exchanger
1, the crests of the corrugations can be bonded to the adjacent
surfaces of the stamped plates 5 and 7 in order to define the flow
channels 13. Alternatively or in addition, the crest of the
corrugations can engage correspondingly shaped recesses or
protrusions on the adjacent surfaces of the stamped plates 5 and 7
to seal the flow channels 13. Adjacent ones of the channels 13 are
generally non-communicative with each other, except in the manifold
regions to be described later on.
[0037] The inlet port 11 is directly connected to the channels 13
comprising the fluid pass 14 at the end 40, so that a portion of
the second fluid flow 3 can enter the space between the stamped
shell 5 and an adjacent stamped shell 7 or top plate 8 and can flow
through the fluid pass 14. After traveling through the pass 14, the
fluid can transfer to the pass 15 by way of the collection manifold
22 located at the end 41, and additionally by way of the collection
manifold 23 located between the ends 40 and 41. It should be
observed that the collection manifold 23 does not intersect some of
the channels 13 comprising the pass 14, so that any fluid traveling
through these channels is forced to travel the entire length of the
channels and through the manifold 20. Additionally, the collection
manifold 23 as shown does not intersect some of the channels 13
comprising the pass 15, and any fluid traveling through those
channels must come from the collection manifold 22.
[0038] After flowing through the pass 15, the fluid can transfer to
the pass 16 by way of the collection manifold 24 located at the end
40, and additionally by way of the collection manifold 25 located
between the ends 40 and 41. Again, the collection manifold 25 as
shown does not intersect some of the channels comprising the pass
15 and does not intersect some of the channels comprising the pass
16.
[0039] As can be inferred from inspection of FIGS. 3 and 4, the
number of channels comprising any one pass need not be equal to the
number of channels comprising any other pass. In fact, it may be
preferable in some embodiments for the number of channels per pass
to increase from the first pass to the second pass and so forth, as
is the case for the embodiment of FIGS. 3 and 4. The reduced number
of channels in the upstream passes can aid in achieving a uniform
distribution of flow among the channels when the flow is all or
mostly liquid and consequently has a relatively high density. As
the flow moves downstream and the vapor quality increases, the mean
density of the flow decreases and a greater number of channels can
be used in order to accommodate the increased volumetric flow rate
without compromising flow distribution.
[0040] In the illustrated embodiment, the collection manifold 25
consists of three approximately parallel slots 25a, 25b and 25c
extending through the fluid flow plate 4. In different embodiments,
the collection manifold can consist of more or fewer slots, so that
the flow area in the collection manifold can be adjusted. Some
advantages can be found, however, in having multiple slots to
comprise the manifold rather than one larger slot. A smaller slot
width will result in a smaller hydraulic diameter than a larger
slot width, and this will reduce the negative impact on heat
transfer performance caused by removal of the corrugations in the
slot area. Additionally, a smaller slot width will provide greater
structural support to resist deformation of the shells 5, 7 when
the second fluid flow 3 is at a substantially higher pressure than
the first fluid flow 2, as is frequently the case in evaporative
systems. It should be understood by those having skill in the art
that the proper slot width and number of slots may vary depending
on the application.
[0041] In a manner similar to that described above, the fluid flows
through the pass 16, then by way of the manifolds 26 and 27 through
the pass 17, then by way of the manifolds 28 and 29 through the
pass 18, then by way of the manifolds 30 and 31 through the pass
19, then by way of the manifolds 32 and 33 through the pass 20,
then by way of the manifolds 34 and 35 through the pass 21, after
which the fluid exits the heat exchanger 1 through outlet port
12.
[0042] The manifolds 24, 28 and 32 at the end 40 are separated from
each other by protrusions 36 that extend from the wall of the
recess in the plate 5 that houses the fluid flow plate 4. These
protrusions extend approximately to the end 40 of the fluid flow
plate 4 in order to provide a highly tortuous flow path for the
fluid to flow directly from one of the manifolds 24, 28 and 32 to
an adjacent one of the manifolds 24, 28 and 32 without passing
through two of the flow passes in the plate 4. Similar protrusions
36 prevent or substantially inhibit bypass flow from the inlet port
11 to the manifold 24, and between the manifolds 22, 26, 30 and 34
located at the end 41.
[0043] In some embodiments, the bypass prevention may be improved
by providing notches in the fluid flow plate 4 to receive portions
of the protrusions 36 therein in order to provide an even more
tortuous flow path. In some embodiments the protrusions 36 may be
joined to one or more of the corrugations comprising the channels
13 of the fluid flow plate 4 to completely block such bypass flow.
In some such embodiments, the joining can be accomplished by
creating a brazed joint. In such embodiments, the protrusions 36
can block off one end of one or more of the channels 13 located
between adjacent passes in the fluid flow plate 4 in order to
direct substantially all of the fluid flow through the passes. In
some embodiments, the flow blocking protrusions 36 may
alternatively extend from the fluid flow plate 4 to engage the wall
of the plate 5.
[0044] The flow manifolds 26, 28, 30, 32 and 34 also can be seen to
include a flow area constriction region defined by features 37 that
extend partially into the manifolds from the wall of the plate 5,
the purpose of which will be described later.
[0045] Turning now to FIGS. 5a-c, some of the aspects of the
present invention will be described. FIG. 5a illustrates a portion
of the fluid flow path for the second fluid flow 3 as it passes
through a heat exchanger 1 according to some embodiments of the
present invention. The arrows represent the overall flow direction
of the fluid in the various depicted sections of the fluid flow
path.
[0046] The portion of the fluid flow path shown in FIG. 5a includes
a pass A and a pass B located adjacent to and immediately
downstream from the pass A, each of the passes A, B comprising a
plurality of parallel flow channels such as the channels 13 of the
embodiment of FIG. 3. The passes A and B may be any two adjacent
passes along the fluid flow path. For example, they could represent
any adjacent pair of the passes 14-21 in the embodiment of FIGS. 3
and 4.
[0047] The passes A and B extend from an end 38 of the fluid flow
plate 4 to an end 39 of the fluid flow plate 4. Additional (not
shown) flow passes may be located upstream and/or downstream of the
passes A and B. The ends 38 and 39 can correspond to the ends 40
and 41, respectively, in the embodiment of FIGS. 3 and 4 if the
pass A corresponds to one of the even-numbered passes 14, 16, 18 or
20. Likewise, the ends 38 and 39 can correspond to the ends 41 and
40, respectively, in the embodiment of FIGS. 3 and 4 if the pass A
corresponds to one of the odd-numbered passes 15, 17 or 19.
[0048] The passes A and B are fluidly connected to one another by
way of manifolds C and D, where manifold C is located at the end 39
and manifold D is located between the ends 38 and 39. The pass A
comprises a set of channels Al that directly connect to the
manifold C, and another set of channels A2 that directly connect to
both manifolds C and D.
[0049] The channels comprising the pass B are each connected to at
least one of the manifolds C and D. As shown in FIG. 5a, in some
embodiments, some of the channels comprising the pass B are
connected to the manifold C but are not connected to the manifold
D, while the other of the channels comprising the pass B are
connected to both manifolds C and D. In other embodiments, such as
the one shown in FIG. 5b, some of the channels comprising the pass
B are connected to the manifold D but are not connected to the
manifold C. In still other embodiments, all of the channels
comprising the pass B may be connected to both manifolds C and
D.
[0050] When a heat exchanger including a flow plate 4 according to
the embodiment of FIG. 5a is operated as an evaporative heat
exchanger, with the evaporating fluid flowing as a two-phase fluid
through pass A, the liquid and vapor phases of the portion of the
fluid in the set of channels A2 will tend to separate from one
another when the fluid encounters the manifold D. Due to its lower
density, the vapor phase will experience a much greater pressure
drop than the liquid phase will in passing from the manifold D back
into the channel region between manifolds D and C. As a result, the
vapor phase portion of the fluid traveling in the channels of
section A2 will tend to flow in greater proportion through the
manifold D. The liquid phase portion, in contrast, is more likely
to continue straight through into the manifold C.
[0051] As a result of having the set of channels Al only connect to
the manifold C, the entirety of the fluid traveling in the set of
channels A1 will be directed into manifold C. This can prevent the
accumulation of liquid in manifold C, as any vapor present in the
set of channels A1 will "push" the liquid through into the pass B.
In the embodiment of
[0052] FIG. 5a, in some embodiments, it is preferable to include a
local constriction of the manifold C, such as by the presence of
the partial flow blocking feature 37. Including such a local
constriction can prevent the entirety of the flow in manifold C
from flowing all the way to the end of that manifold and into only
the last few channels of the pass B. When the fluid reaches the
local constriction, a substantial portion of the fluid will be
directed into the manifold D, from where it can then be distributed
into the channels of pass B that are directly connected to manifold
D.
[0053] In the alternative embodiment of FIG. 5b, the manifold C
does not extend to all of the channels of pass B, and all of the
fluid in the manifold C is directed into the manifold D, from where
it can then be distributed to the channels of pass B.
[0054] In the embodiment of FIG. 5c, an additional flow pass E
immediately adjacent to pass B is shown. The passes B and E are
fluidly connected to one another by a manifold F located at the end
38 of the flow plate 4, and by a manifold G located between the
ends 38 and 39. One set B1 of the channels of pass B are connected
only to the manifold F, while a separate set B2 of the channels are
connected to both manifolds F and G, so that the manifolds F and G
can provide similar benefits as was described with reference to the
manifolds C and D. It should be readily apparent that this pattern
can be repeated as necessary in order to provide the desirable
number of flow passes for a particular application.
[0055] FIG. 6 illustrates another embodiment of a heat exchanger
101 of the present invention. A hot fluid flow 102 and an
evaporating fluid flow 103 are directed into and out of the heat
exchanger 101 through ports in the top plate 108 of the heat
exchanger 101. Such an embodiment can operate as a liquid chiller
in a refrigeration or climate control system, wherein the hot fluid
flow 102 is a liquid that is chilled by evaporation of a
refrigerant flow 103. As seen in FIG. 7, in such an application,
the fluid flow plate 104 can include openings 111, 112
corresponding to the port locations for the fluid flow 103. The
flow 103 is distributed by way of the openings 111 to the plurality
of layers 105 containing the flow plates 104. Within the fluid flow
plate 104, the fluid flow 103 is directed though multiple passes of
the parallel arranged flow channels 113, as indicated by the arrows
in FIG. 7.
[0056] The flow 113 is distributed into the first pass by way of
the manifolds 115 and 116. From the first pass, the flow 113 is
distributed into the second pass by way of the manifolds 117 and
118, which serve the purpose of the manifolds C and D of FIGS.
5a-c. Specifically, it can be seen that some of the channels 113
belonging to the first pass are connected to the manifold 117 but
not to the manifold 118, whereas others of the channels are
connected to both manifolds 117 and 118.
[0057] Some of the flow channels 113 may be blocked by a ring 115
surrounding a port 110 through which the flow 102 is collected from
the plurality of flow layers 107 interleaved with the flow layers
105. A portion 118a of the manifold 118 is located so as to
intersect those channels and allow for the fluid passing through
those channels to bypass around the ring 115.
[0058] The flow 103 is directed into the second pass from the
manifolds 117 and 118, and is directed from the second pass into
the third pass through the manifolds 119 and 120. The fluid is
directed from the third pass to the fourth pass through the
manifolds 121 and 122, and from the fourth pass to the fifth pass
through the manifolds 123 and 124. The manifolds 125 and 126
redirect the fluid from the fifth pass into the port 112, through
which the fluid 103 is removed from the heat exchanger 101.
[0059] Similar to the first pass, some of the channels in the fifth
flow pass are blocked by a ring 114 surrounding the inlet
distribution port 106 for the fluid 102. A portion 124c of the
manifold 124 is located such that a portion of the fluid 103 can be
directed into those channels despite the flow blockage due to the
ring 114.
[0060] The manifolds 117, 119, 121 and 123 have local constrictions
caused by protrusions or extensions 128 protruding from the fluid
flow plate 104 into the manifold areas. These extensions 128 serve
a similar function as the previously described protrusions 37.
[0061] The manifolds 117, 121 and 125 are separated from one
another by protrusions 136 extending from the wall of the plate
105, said protrusions being received into notches 127 in the fluid
flow plate 104. The manifolds 115, 119 and 123 are similarly
separated from one another.
[0062] FIGS. 8-12 illustrate another embodiment of a heat exchanger
201 of the present invention. The illustrated embodiment of FIGS.
8-12 incorporates many of the features described and illustrated
with respect to the embodiments of FIGS. 1-7. The discussion of the
embodiments of FIGS. 8-12 will primarily focus on the features that
are not disclosed in the description or figures of the embodiments
of FIGS. 1-7. As shown in FIGS. 8-12, the heat exchanger 201
includes a hot fluid flow 202 and an evaporating fluid flow 203.
The hot fluid flow 202 is shown flowing generally from left to
right, but can flow generally right to left in other embodiments.
The evaporating fluid flow 203 flows generally from right to left,
but can flow generally left to right in other embodiments. The
illustrated heat exchanger 201 is a counter flow heat exchanger.
However, in other embodiments, the heat exchanger 201 can have one
or more portions of the heat exchanger arranged as parallel flow,
cross flow, counter-cross flow or other type of heat exchanging
flow relationship.
[0063] The illustrated heat exchanger 201 includes a plurality of
stacked plate assemblies. One of the stacked plate assemblies is
shown in FIGS. 9 and 10. Each of the stacked plate assemblies
includes a fluid flow plate 204, first and second stamped shells
205a, 205b, a convoluted fin 206 and first and second stamped
shells 207a, 207b. The plurality of stacked plate assemblies are
positioned between a top plate 208 and a bottom plate 209 (shown in
FIG. 11).
[0064] The hot fluid flow 202 flows into the heat exchanger 201 at
a first collection region 210a and exits the heat exchanger 201 at
a second collection region 210b. The hot fluid flow 202 flows from
the first collection region 210a between the first and second
stamped shells 207a, 207b and along convolutions defined by the
convoluted fin 206 prior to flowing into the second collection
region 210b.
[0065] The evaporating fluid flow 203 flows into the heat exchanger
201 at a fluid inlet 211 and flows out of the heat exchanger 201 at
a fluid outlet 212. The evaporating fluid flow 203 travels along a
circuitous flow path between the fluid inlet 211 and the fluid
outlet 212. The circuitous flow path extends between first and
second parallel ends 240, 241 of the heat exchanger 201. The
circuitous flow path includes a plurality of fluid passes 214, 215,
216, 217, 218 and 219 (see stamped shell 205a of FIG. 10). The
circuitous flow path is defined by a plurality of flow channels 213
formed in the fin 204 and a plurality of slots formed in the
stamped shells 205a, 205b. The plurality of slots include a
plurality of groups of substantially parallel slots. In the
illustrated embodiment, the first and second stamped shells 205a,
205b have corresponding slots. However, in other embodiments, the
first and second stamped shells 205a, 205b can have offset slots or
differing numbers and/or configurations of slots.
[0066] A first group of the plurality of slots includes slots 225a,
225b, 225c and 225d which are positioned adjacent to the fluid
inlet port 211 and adjacent the first parallel end 240. A second
group of the plurality of slots includes slots 227a, 227b and 227c
spaced from the fluid inlet port 211 and positioned adjacent the
second parallel end 241. A coordinate axis is included on FIG. 9
for clarity. The evaporating fluid flow 203 in the fluid pass 214
travels along the flow channels 213 of the fluid flow plate 204
(along the Y axis) between the first group of slots 225a-225d and
the second group of slots 227a-227c. The first group of slots
225a-225d allows the fluid to move between adjacent flow channels
213 in the fluid flow plate 204. Specifically, the fluid can flow
along the Z axis into the slots 225a-225d, then along the X axis in
the slots 225a-225d, then finally along the Z axis into one or more
of the adjacent flow channels 213. The first group of slots
225a-225d and the fluid pass 214 are relatively narrow (when
measured along the X axis) when compared to the second group of
slots 227a-227c and the fluid pass 215. Each of the slots in the
first group of slots 225a-225d is spaced apart a greater distance
(when measured along the Y axis) than each of the slots in the
second group of slots 227a-227c.
[0067] The second group of slots 227a-227c functions as a
turn-around so that the fluid flow reverses direction and flows
back toward the parallel end 240 along the fluid pass 215.
Specifically, the fluid flows in the Y direction along some of the
flow channels 213 from the first parallel end 240 toward the second
parallel end 241, then into any of the slots 227a-227c which allows
the fluid to flow along the X direction into adjacent flow channels
213. When the fluid is in the adjacent flow channels 213, the fluid
can flow in the Y direction along the fluid pass 215 from the
second parallel end 241 toward the first parallel end 240. Because
the second group of slots 227a-227c and the fluid pass 215 are
wider (when measured along the X axis) than the first group of
slots 225a-225d and the fluid pass 214, the second group of slots
227a-227c is in fluid connection with a greater number of flow
channels 213 than the first group of slots 225a-225d. The flow
channels 213 that are fluidly connected to the first group of slots
225a-225d form fluid pass 214 and permit fluid to flow from the
first parallel end 240 to the second parallel end. The flow
channels 213 that are fluidly connected to the second group of
slots 227a-227c but are fluidly separated from the first group of
slots 225a-225d form fluid pass 215 and permit fluid to flow from
the second parallel end 241 to the first parallel end 240.
[0068] After the fluid is allowed to turn around in the second
group of slots 227a-227c, the fluid flows along the Y axis in the
fluid pass 215 toward a third group of slots 229a, 229b, 229c, 229d
and 229e positioned adjacent the first parallel end 240 and the
first group of slots 225a-225d. Similar to the discussion above,
the third group of slots 229a-229e allows the fluid to move between
adjacent flow channels 213 in the fluid flow plate 204.
Specifically, the fluid can flow along the Z axis into the slots
229a-229e, then along the X axis in the slots 229a-229e, then
finally along the Z axis into one or more of the adjacent flow
channels 213. The slots 227a-227c of the second group are narrower
(when measured along the X axis) and fewer in number than the slots
229a-229e of the third group. Because the third group of slots
229a-229e are wider (when measured along the X axis) than the
second group of slots 227a-227c, the third group of slots 229a-229e
is in fluid connection with a greater number of flow channels 213
than the second group of slots 227a-227c. The flow channels 213
that are fluidly connected to the third group of slots 229a-229e
but are fluidly separated from the second group of slots 227a-227c
form fluid pass 216 and permit fluid to flow from the first
parallel end 240 to the second parallel end 241. Therefore, the
fluid is allowed to turn around in the third group of slots
229a-229e and move from fluid pass 215 to fluid pass 216.
[0069] After the fluid turns around in the third group of slots
229a-229e, the fluid flows along the flow channels 213 of the fluid
pass 216 from the first parallel end 240 toward a fourth group of
slots 231a, 231b, 231c, 231d, 231e, 231f and 231g adjacent the
second parallel end 241. The fourth group of slots 231a-231g, like
the second and third groups of slots 227a-227c and 229a-229e
discussed above, functions as a turn-around for fluid flowing along
the flow channels 213. Specifically, fluid that flows along the
fluid pass 216 toward the fourth group of slots 231a-231g can flow
along the Z axis into the slots 231a-231g, then along the X axis in
the slots 231a-231g, then finally along the Z axis into one or more
of the adjacent flow channels 213. The slots 229a-229e of the third
group are narrower (when measured along the X axis) and fewer in
number than the slots 231a-231g of the fourth group. Because the
fourth group of slots 231a-231g are wider (when measured along the
X axis) than the third group of slots 229a-229e, the fourth group
of slots 231a-231g is in fluid connection with a greater number of
flow channels 213 than the third group of slots 229a-229e. The flow
channels 213 that are fluidly connected to the fourth group of
slots 231a-231g but are fluidly separated from the third group of
slots 229a-229e form fluid pass 217 and permit fluid to flow from
the second parallel end 241 to the first parallel end 240. Thus,
the fourth group of slots 231a-231g permits the fluid to turn
around and move from the fluid pass 216 to the fluid pass 217.
Fluid pass 217 is wider (when measured along the X axis) than fluid
pass 216.
[0070] After the fluid turns around in the fourth group of slots
231a-231g, the fluid flows along the flow channels 213 of the fluid
pass 217 from the second parallel end 241 toward a fifth group of
slots 233a, 233b, 233c, 233d, 233e, 233f, 233g, 233h and 233i
adjacent the first parallel end 240. The fifth group of slots
233a-233i, like the second, third and fourth groups of slots
227a-227c, 229a-229e and 231a-231g discussed above, functions as a
turn-around for fluid flowing along the flow channels 213.
Specifically, fluid that flows along the fluid pass 217 toward the
fifth group of slots 233a-233i can flow along the Z axis into the
slots 233a-233i, then along the X axis in the slots 233a-233i, then
finally along the Z axis into one or more of the adjacent flow
channels 213. The slots 233a-233i of the fifth group are wider
(when measured along the X axis) and greater in number than the
slots 231a-231g of the fourth group. Because the fifth group of
slots 233a-233i are wider (when measured along the X axis) than the
fourth group of slots 231a-231g, the fifth group of slots 233a-233i
is in fluid connection with a greater number of flow channels 213
than the fourth group of slots 231a-231g. The flow channels 213
that are fluidly connected to the fifth group of slots 233a-233i
but are fluidly separated from the fourth group of slots 231a-231g
form fluid pass 218 and permit fluid to flow from the first
parallel end 240 to the second parallel end 241. Thus, the fifth
group of slots 233a-233i permits the fluid to turn around and move
from the fluid pass 217 to the fluid pass 218.
[0071] After the fluid turns around in the fifth group of slots
233a-233i, the fluid flows along the flow channels 213 of the fluid
pass 218 from the first parallel end 240 toward a sixth group of
slots 235a, 235b, 235c, 235d, 235e, 235f, 235g, 235h, 235i, 235j
and 235k adjacent the second parallel end 241. The sixth group of
slots 235a-235k, like the second, third, fourth and fifth groups of
slots 227a-227c, 229a-229e, 231a-231g and 233a-233i discussed
above, functions as a turn-around for fluid flowing along the flow
channels 213. Specifically, fluid that flows along the fluid pass
218 toward the sixth group of slots 235a-235k can flow along the Z
axis into the slots 235a-235k, then along the X axis in the slots
235a-235k, then finally along the Z axis into one or more of the
adjacent flow channels 213. The slots 235a-235k of the sixth group
are wider (when measured along the X axis) and greater in number
than the slots 233a-233i of the fifth group. Because the sixth
group of slots 235a-235k are wider (when measured along the X axis)
than the fifth group of slots 233a-233i, the sixth group of slots
235a-235k is in fluid connection with a greater number of flow
channels 213 than the fifth group of slots 233a-233i. The flow
channels 213 that are fluidly connected to the sixth group of slots
235a-235k but are fluidly separated from the fifth group of slots
233a-233i form fluid pass 219 and permit fluid to flow from the
second parallel end 241 to the first parallel end 240. Thus, the
sixth group of slots 235a-235k permits the fluid to turn around and
move from the fluid pass 218 to the fluid pass 219. Fluid pass 219
is wider (when measured along the X axis) than fluid pass 218.
[0072] With continued reference to FIG. 10, the illustrated first
and second stamped shells 207a and 207b are substantially mirror
images and define a first collection opening 245a that forms a
portion of the first collection region 210a and a second collection
opening 245b that forms a portion of the second collection region
210b. In the illustrated embodiment, the first and second
collection openings 245a, 245b are substantially triangular.
However, in other embodiments, the first and/or section collection
openings 245a, 245b can have differing shapes and
configurations.
[0073] The illustrated first and second stamped shells 205a and
205b are substantially mirror images and define first collection
openings 247a, 247b that form a portion of the first collecting
region 210a and second collection openings 249a, 249b that form a
portion of the second collecting region 210b. In the illustrated
embodiment, the first and second collection openings 247a, 247b,
249a, 249b are substantially triangular. However, in other
embodiments, the first and/or section collection openings 247a,
247b, 249a, 249b can have differing shapes and configurations. In
the illustrated embodiment, the first and second collection
openings 247a, 247b, 249a, 249b each have dimples 251a, 251b, 253a,
253b that provide points at which the first and second stamped
plates 205a, 205b can be connected (for example, by brazing). In
other embodiments, other arrangements of dimples or other shapes
can be utilized to connect the first and second stamped plates
205a, 205b adjacent the first and second collection openings 247a,
247b, 249a, 249b.
[0074] Turning now to FIGS. 11 and 12, the plurality of stacked
plate assemblies are shown in cross-section. FIG. 12 is a close up
of the portion of FIG. 11 surrounded by the circle 12. The fluid
flow plates 204 are omitted from FIG. 12 for clarity. In the
illustrated embodiment, each of the stacked plate assemblies has a
substantially identical configuration and has corresponding
positions and quantities of slots. While only slots 231e, 231f and
231g are illustrated in each of the first and second stamped shells
205a, 205b, each of the first, second, third, fourth, fifth and
sixth groups of slots 225a-225d, 227a-227c, 229a-229e, 231a-231g,
233a-233i and 235a-235k are present in each of the first and second
stamped shells 205a, 205b. However, in non-illustrated
configurations, one or more of the stacked plate assemblies can
have a different configuration and/or different locations and
quantities of slots than the remaining stacked plate
assemblies.
[0075] Turning now to FIG. 13, a portion of an alternate embodiment
of a stacked plate assembly is illustrated. Similar to the
embodiment of FIGS. 8-12, the illustrated stacked plate assembly
includes a fluid flow plate 304 positioned between first and second
stamped shells 305a, 305b. The embodiment of FIG. 13 further
includes a third stamped shell 305c positioned adjacent the first
stamped shell 305a and a fourth stamped shell 305d positioned
adjacent the second stamped shell 305b. The fluid flow plate 304
and the first, second, third and fourth stamped shells 305a, 305b,
305c and 305d are sandwiched between first and second stamped
shells 307a, 307b. While the first and second stamped shells 307a,
307b are illustrated at opposite ends of the fluid flow plate 304,
the first and second stamped shells 307a, 307b are positioned in
pairs adjacent both the third stamped shell 305c and the fourth
stamped shell 305d. Similar to the embodiments described above, the
assemblies formed by the fluid flow plate 304 and the stamped
shells 305a, 305b, 305c and 305d are interleaved with the pairs of
stamped shells 307a, 307b. Although not illustrated, a convoluted
fin can be provided between the first stamped shell 307a and the
second stamped shell 307b.
[0076] The first, second, third and fourth stamped shells 305a,
305b, 305c, 305d each include a plurality of groups of slots. The
slots are substantially identical in each of the first, second,
third and fourth stamped shells 305a, 305b, 305c, 305d. The slots
illustrated in FIG. 13 substantially correspond to the slots in the
first and second stamped shells 205a, 205b shown in FIGS. 8-12 and
described in detail above. Specifically, the groups of slots form
substantially rectangular shapes. In other, non-illustrated
embodiments, the slots in one or more of the stamped shells can
differ in quantity and/or location across the respective stamped
shell.
[0077] Turning now to FIG. 14, a portion of an alternate embodiment
of a stacked plate assembly is illustrated. Similar to the
embodiment of FIG. 13, the illustrated stacked plate assembly
includes a fluid flow plate 404 positioned between first and second
stamped shells 405a, 405b, as well as a third stamped shell 405c
positioned adjacent the first stamped shell 405a and a fourth
stamped shell 405d positioned adjacent the second stamped shell
405b. The fluid flow plate 404 and the first, second, third and
fourth stamped shells 405a, 405b, 405c and 405d are sandwiched
between first and second stamped shells 407a, 407b. Like the
embodiments of FIGS. 1-13, the first, second, third and fourth
stamped shells 405a, 405b, 405c and 405d have identical slots. In
contrast to the embodiments of FIGS. 1-13, many of the slots in
each group of slots have different widths. Specifically, many of
the slots positioned adjacent outer edges of the first, second,
third and fourth stamped shells 405a, 405b, 405c and 405d are wider
than the slots positioned inward from the outer edges. In the
illustrated embodiments, many of the groups of slots form a
substantially trapezoidal shape. In other embodiments, one or more
of the groups can include slots that form substantially trapezoidal
shapes whereas one or more of the groups can include other,
non-trapezoidal shapes and configurations.
[0078] Turning now to FIG. 15, a portion of an alternate embodiment
of a stacked plate assembly is illustrated. Similar to the
embodiments of FIGS. 13 and 14, the illustrated stacked plate
assembly includes a fluid flow plate 504 positioned between first
and second stamped shells 505a, 505b, as well as a third stamped
shell 505c positioned adjacent the first stamped shell 505a and a
fourth stamped shell 505d positioned adjacent the second stamped
shell 505b. The fluid flow plate 504 and the first, second, third
and fourth stamped shells 505a, 505b, 505c and 505d are sandwiched
between first and second stamped shells 507a, 507b. Like the
embodiments of FIGS. 1-14, the first, second, third and fourth
stamped shells 505a, 505b, 505c and 505d have identical slots. In
contrast to the embodiments of FIGS. 1-14, the groups of slots each
form a substantially parallelogram shape. Specifically, the slots
adjacent an outer edge of the stamped shells 505a, 505b, 505c and
505d are positioned closer to a second parallel end 541 than the
slots spaced from the outer edge. However, the slots in each group
of slots have a substantially uniform length. In other embodiments,
at least one of the groups of slots can have the slots adjacent the
outer edge positioned closer to a first parallel end 540 than the
slots spaced from the outer edge.
[0079] Turning now to FIG. 16, a portion of an alternate embodiment
of a stacked plate assembly is illustrated. Similar to the
embodiments of FIGS. 13-15, the illustrated stacked plate assembly
includes a fluid flow plate 604 positioned between first and second
stamped shells 605a, 605b, as well as a third stamped shell 605c
positioned adjacent the first stamped shell 605a and a fourth
stamped shell 605d positioned adjacent the second stamped shell
605b. The fluid flow plate 604 and the first, second, third and
fourth stamped shells 605a, 605b, 605c and 605d are sandwiched
between first and second stamped shells 607a, 607b. Like the
embodiments of FIGS. 1-15, the first and second stamped shells 605a
and 605b have identical slots. However, the third and fourth
stamped shells 605c and 605d do not have any slots. Similar to the
embodiments of FIGS. 1-13, the groups of slots each form a
substantially rectangular shape.
[0080] FIG. 17 illustrates a stamped shell 705 that can be utilized
with any of the heat exchangers described and illustrated herein.
Like the stamped shells 205a and 205b, the illustrated stamped
shell 705 includes first, second, third, fourth, fifth and sixth
fluid passes 714, 715, 716, 717, 718 and 719 that extend between
first and second parallel ends 740, 741. The illustrated stamped
shell 705 also includes a first group of slots 725, a second group
of slots 727, a third group of slots 729, a fourth group of slots
731, a fifth group of slots 733 and a sixth group of slots 735. The
third, fourth, fifth and sixth groups of slots 729, 731, 733 and
735 substantially correspond to the slots described above and
illustrated in FIGS. 8-12. In contrast to the slots of the
embodiment of FIGS. 8-12, each of the slots of the first group of
slots 725 form a bypass between the first flow pass 714 and the
second flow pass 715. Specifically, the first group of slots 725
include a first portion that extends across at least a portion of
the first flow pass 714 and a second portion that extends across at
least a portion of the second flow pass 715. The first portion of
the first group of slots 725 is narrower than the second portion
when measured in the direction extending between first and second
parallel ends 740, 741. Additionally, the first group of slots 725
extend at a non-parallel angle with respect to the other groups of
slots 727, 729, 731, 733 and 735. In particular, the first portion
of the first group of slots 725 extend at a non-parallel angle with
respect to the second portion of the first group of slots. Further
in contrast to the embodiment of FIGS. 8-12, each of the slots of
the second group of slots 727 is thinner in the direction extending
between the first and second parallel ends 240, 241.
[0081] Other configurations of plates and slots can be utilized
with the heat exchangers of the present invention and the
illustrated embodiments are given by way of example only.
[0082] Various alternatives to the certain features and elements of
the present invention are described with reference to specific
embodiments of the present invention. With the exception of
features, elements, and manners of operation that are mutually
exclusive of or are inconsistent with each embodiment described
above, it should be noted that the alternative features, elements,
and manners of operation described with reference to one particular
embodiment are applicable to the other embodiments.
[0083] The embodiments described above and illustrated in the
figures are presented by way of example only and are not intended
as a limitation upon the concepts and principles of the present
invention. As such, it will be appreciated by one having ordinary
skill in the art that various changes in the elements and their
configuration and arrangement are possible without departing from
the spirit and scope of the present invention.
* * * * *