U.S. patent application number 15/821741 was filed with the patent office on 2018-05-24 for tube sheet apparatus and heat exchanger.
The applicant listed for this patent is General Electric Company. Invention is credited to John Patrick DOWELL, Hafiz Hassan EISA, Deepak N, Eric David PETERS.
Application Number | 20180142966 15/821741 |
Document ID | / |
Family ID | 62147553 |
Filed Date | 2018-05-24 |
United States Patent
Application |
20180142966 |
Kind Code |
A1 |
DOWELL; John Patrick ; et
al. |
May 24, 2018 |
TUBE SHEET APPARATUS AND HEAT EXCHANGER
Abstract
An apparatus (e.g., tube sheet) includes a plate piece, a sleeve
piece, and a tube piece. The plate piece defines a hole. The sleeve
piece has first and second ends; the second end is shaped to fit
through the hole for attachment of the sleeve piece to the plate
piece. The tube piece also has first and second ends. Inner and
outer cross-sectional geometries of the tube piece and the sleeve
piece (e.g., in the case of round tubes, inner and outer diameters)
are shaped for the first end of the tube piece to fit in the first
end of the sleeve piece and to form a continuous interior fluid
flow path from the second end of the tube piece through the plate
piece when the sleeve piece is disposed in the hole and attached to
the plate piece and the tube piece is disposed in the sleeve
piece.
Inventors: |
DOWELL; John Patrick; (Grove
City, PA) ; PETERS; Eric David; (Lawrence Park,
PA) ; EISA; Hafiz Hassan; (Lawrence Park, PA)
; N; Deepak; (Bangalore, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
62147553 |
Appl. No.: |
15/821741 |
Filed: |
November 22, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62425187 |
Nov 22, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28F 9/165 20130101;
F28F 9/185 20130101 |
International
Class: |
F28F 9/18 20060101
F28F009/18 |
Claims
1. An apparatus comprising: a plate piece defining a hole; and a
tube assembly comprising: a sleeve piece having first and second
ends, wherein the second end of the sleeve piece is shaped to fit
through the hole for attachment of the sleeve piece to the plate
piece; and a tube piece having a first end and a second end,
wherein inner and outer cross-sectional geometries of the tube
piece and the sleeve piece are shaped for the first end of the tube
piece to fit in at least the first end of the sleeve piece and to
form a continuous interior fluid flow path from the second end of
the tube piece through the plate piece when the sleeve piece is
disposed in the hole and attached to the plate piece and the tube
piece is disposed in the sleeve piece.
2. The apparatus of claim 1, wherein: the first and second ends of
the sleeve piece have different first and second inner
cross-sectional geometries, respectively, such that a transition
between the first and second ends of the sleeve piece defines an
interior shoulder; and an outer cross-sectional geometry of the
first end of the tube piece matches the inner cross-sectional
geometry of the first end of the sleeve piece, and an inner
cross-sectional geometry of the first end of the tube piece
corresponds to the inner cross-sectional geometry of the second end
of the sleeve piece, for the first end of the tube piece to abut
the shoulder and to establish a continuous geometry from the tube
piece to the sleeve piece for the continuous interior fluid flow
path.
3. The apparatus of claim 1, wherein: the sleeve piece has a
uniform inner cross-sectional geometry; and the first end of the
tube piece has an outer cross-sectional geometry that corresponds
to the uniform inner cross-sectional geometry of the sleeve piece,
wherein the first end of the tube piece is configured to extend
entirely through the sleeve piece, for the continuous interior
fluid flow path to be established by the interior of the tube
piece.
4. The apparatus of claim 1, wherein the sleeve piece and the tube
piece are round tubes and the inner and outer cross-sectional
geometries of the tube piece and the sleeve piece are inner and
outer diameters of the tube piece and the sleeve piece,
respectively.
5. A heat exchanger comprising the apparatus of claim 1, wherein
the sleeve piece is attached to the plate piece, the first end of
the tube piece is fit into the first end of the sleeve piece, and
the tube piece is attached to the sleeve piece, and wherein the
plate piece defines the hole and plural additional holes, and
further comprising plural additional tube assemblies respectively
associated with the plural additional holes and attached to the
plate.
6. The heat exchanger of claim 5, wherein the plate piece and the
tube assemblies are a monolithic structure formed using an additive
manufacturing process, with the plate piece, sleeve pieces, and
tube pieces being composed of different materials and defined by
boundaries between the different materials.
7. An apparatus comprising: a plate piece defining a hole; and a
tube assembly comprising: a sleeve piece having first and second
ends, wherein the second end of the sleeve piece is shaped to fit
through the hole for attachment of the sleeve piece to the plate
piece; and a tube piece having a first end shaped to fit in the
first end of the sleeve piece, wherein when the first end of the
tube piece is disposed in the first end of the sleeve piece, an
inner cross-sectional geometry of the second end of the sleeve
piece conforms to an inner cross-sectional geometry of the first
end of the tube piece, forming a continuous geometry across an
interior transition between the sleeve and the tube piece.
8. The apparatus of claim 7, wherein: the inner cross-sectional
geometry of the second end of the sleeve piece is different from an
inner cross-section geometry of the first end of the sleeve piece,
respectively, such that a transition between the first and second
ends of the sleeve piece defines an interior shoulder; an outer
cross-sectional geometry of the first end of the tube piece matches
the inner cross-sectional geometry of the first end of the sleeve
piece, and the inner cross-sectional geometry of the first end of
the tube piece corresponds to the inner cross-sectional geometry of
the second end of the sleeve piece, for the first end of the tube
piece to abut the shoulder and to establish the continuous geometry
across the interior transition between the sleeve and the tube
piece.
9. The apparatus of claim 7, wherein the sleeve piece and the tube
piece are round tubes, the inner cross-sectional geometry of the
second end of the sleeve piece is an inner diameter of the second
end of the sleeve piece, and the inner cross-sectional geometry of
the first end of the tube piece is an inner diameter of the first
end of the tube piece that is equal to the inner diameter of the
second end of the sleeve piece.
10. A heat exchanger comprising the apparatus of claim 7, wherein
the sleeve piece is attached to the plate piece, the first end of
the tube piece is fit into the first end of the sleeve piece, and
the tube piece is attached to the sleeve piece, and wherein the
plate piece defines the hole and plural additional holes, and
further comprising plural additional tube assemblies respectively
associated with the plural additional holes.
11. The heat exchanger of claim 10, wherein the plate piece and the
tube assemblies are a monolithic structure formed using an additive
manufacturing process, with the plate piece, sleeve pieces, and
tube pieces being composed of different materials and defined by
boundaries between the different materials.
12. An apparatus comprising: a tube piece having a first end; a
plate piece defining a hole; and a sleeve piece having first and
second ends; wherein the first end of the tube piece is disposed in
and attached to the first end of the sleeve piece with an outer
cross-sectional geometry of the first end of the tube piece
conforming to an inner cross-sectional geometry of the first end of
the sleeve piece and forming a first joint; wherein the second end
of the sleeve piece is disposed through the hole of the plate piece
and attached to plate piece forming a second joint; and wherein an
inner cross-sectional geometry of the second end of the sleeve
piece conforms to an inner cross-sectional geometry of the first
end of the tube piece, forming a continuous geometry across a
third, interior joint between the first end of the tube piece and
the second end of the sleeve piece.
13. The apparatus of claim 12, wherein: the first end of the tube
piece, defined by the outer cross-sectional geometry of the first
end of the tube piece, is at least one of brazed, welded, or
mechanically coupled to the first end of the sleeve piece, defined
by the inner cross-sectional geometry of the first end of the
sleeve piece; and the sleeve piece is at least one of welded,
mechanically coupled, or brazed to the plate piece.
14. The apparatus of claim 12, wherein the sleeve piece is
removably attached to the plate piece.
15. The apparatus of claim 12, wherein the sleeve and plate pieces
are constructed as a single unit with a material gradient marking
the boundary of the sleeve and plate pieces.
16. The apparatus of claim 12, wherein the tube, plate and sleeve
pieces are each made of different materials, a thermal coefficient
of the material composing the sleeve piece selected to act as a
thermal buffer between the tube and plate pieces.
17. The apparatus of claim 12, wherein: the inner cross-sectional
geometry of the first end of the sleeve piece defines a first
interior opening of the sleeve piece that is wider than a second
interior opening of the sleeve piece defined by the inner
cross-sectional geometry of the second end of the sleeve piece,
such that a transition between the first and second ends of the
sleeve piece defines an interior shoulder; the first end of the
tube piece is sized to abut the interior shoulder, with the inner
cross-sectional geometry of the first end of the tube piece
defining an interior opening of the tube piece that matches the
second interior opening of the sleeve piece, to establish the
continuous geometry across the third joint.
18. The apparatus of claim 17, wherein: the sleeve piece and the
tube piece are round tubes, with the inner cross-sectional geometry
of the first end of the sleeve piece defining a first inner
diameter of the sleeve piece that is wider than a second inner
diameter of the sleeve piece defined by the inner cross-sectional
geometry of the second end of the sleeve piece, such that a
transition between the first and second ends of the sleeve piece
defines an annular interior shoulder; the first end of the tube
piece is sized to abut the annular interior shoulder, with the
inner cross-sectional geometry of the first end of the tube piece
defining an inner diameter of the tube piece that matches the
second inner diameter of the sleeve piece, to establish the
continuous geometry across the third joint.
19. A heat exchanger comprising the apparatus of claim 12, wherein
the tube piece is fluidly coupled to a first fluid source and a
volume outside the tube piece is fluidly coupled to a second fluid
source, for the tube piece to transfer heat between the first fluid
and the second fluid.
20. The heat exchanger of claim 19, wherein the plate piece, tube
piece, and sleeve piece are a monolithic structure formed using an
additive manufacturing process, with the plate piece, sleeve piece,
and tube piece being composed of different materials and defined by
boundaries between the different materials.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 62/425,187 filed 22 Nov. 2016, which is
incorporated herein by reference.
FIELD
[0002] Embodiments of the subject matter disclosed herein relate to
systems and methods for the joining of tubes to plates or sheets in
general. Other embodiments relate to heat exchangers.
BACKGROUND
[0003] Tubes are frequently joined to plates during the
construction of shell-and-tube heat exchangers. In such exchangers,
it is common for thermal stress to occur at the joint where a tube
joins a plate often due to differences in material composition and
mass. Tubes are commonly joined by pneumatic or hydraulic pressure,
or by roller expansion.
[0004] In another method, sidewalls of holes drilled in plates to
accommodate tubes have a series of grooves reamed into the walls;
the tube wall is then mechanically or explosively expanded into the
grooves for forming a mechanical joint and seal. This often creates
a deformation in the interior-wall of the tube where undesired
materials can accumulate and flow through the tube is disrupted. In
instances where the tube and plate materials are weldable, the
tube-plate joint can be strengthened by applying a seal weld or
strength weld to the joint. A strength weld has a tube slightly
recessed inside a tube hole or slightly extended beyond the plate;
this weld adds material to the resulting lip. In a seal weld, no
material is added. Instead, the tube and plate materials are fused
together.
[0005] In the often-harsh environment of a heat exchange system,
thermal gradients and materials with differing coefficients of
thermal expansion often result in differential thermal expansion of
tube and plate pieces. When temperature gradients are increased,
stress at the site of the tube-to-plate joint is also increased.
Increased stress often results in deformation or early failure of
the joint.
BRIEF DESCRIPTION
[0006] In an embodiment, an apparatus (e.g., a tube-to-sheet joint,
a tube sheet, or parts that can be assembled to form a
tube-to-sheet joint or tube sheet) includes a plate piece, a sleeve
piece, and a tube piece. The plate piece defines a hole, that is, a
hole extends through the plate piece. The sleeve piece has first
and second ends; the second end is shaped to fit through the hole
for attachment of the sleeve piece to the plate piece. The tube
piece also has first and second ends. Inner and outer
cross-sectional geometries of the tube piece and the sleeve piece
(e.g., in the case of round tubes, inner and outer diameters) are
shaped for the first end of the tube piece to fit in the first end
of the sleeve piece and to form a continuous interior fluid flow
path from the second end of the tube piece through the plate piece
when the sleeve piece is disposed in the hole and attached to the
plate piece and the tube piece is disposed in the sleeve piece.
[0007] Thus, according to one aspect, the sleeve piece is attached
to the plate piece, and the tube piece is attached to the sleeve
piece, thereby forming a tube-to-sheet joint where the sleeve piece
may act as a thermal and/or mechanical buffer between the tube
piece and the plate piece. The sleeve piece and tube piece are
shaped to establish the continuous interior fluid flow path, such
that even though the tube piece is attached to the plate piece by
way of the sleeve piece, a flow of fluid through the tube piece and
sleeve piece is not impeded by the sleeve piece or the interface
between it and tube piece.
[0008] In an embodiment, the tube piece, sleeve piece, and plate
piece are part of a heat exchanger. The heat exchanger includes
additional sleeve pieces and tube pieces, which are associated, as
mated pairs, with additional holes in the plate piece.
[0009] In an embodiment, the tube sheet, sleeve piece, and/or plate
piece are a monolithic structure made using an additive
manufacturing process, with each of the pieces made from a
different material (e.g., for thermal buffering).
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The subject matter described herein will be better
understood from reading the following description of non-limiting
embodiments, with reference to the attached drawings, wherein
below:
[0011] FIG. 1 is a side elevation (longitudinal), cross-sectional
view of an apparatus in an assembled form, according to an
embodiment;
[0012] FIG. 2 is a top plan (transverse), cross-sectional view of
another embodiment of the apparatus of FIG. 1, taken along line 2-2
in FIG. 1;
[0013] FIG. 3 is a top plan, cross-sectional view of the embodiment
of the apparatus of FIG. 2, taken along line 3-3 in FIG. 1;
[0014] FIG. 4 is a side elevational, cross-sectional view of the
apparatus of FIG. 1, shown in an exploded, pre-assembled state;
[0015] FIG. 5 is a side elevational, cross-sectional view of
another embodiment of an apparatus, shown in an exploded,
pre-assembled state;
[0016] FIG. 6 is a transverse cross-sectional view of an embodiment
of a heat exchanger;
[0017] FIG. 7 is a side elevation, cross-sectional view of an
apparatus in an assembled form, according to another
embodiment;
[0018] FIG. 8 is a side elevation, cross-sectional view of an
apparatus in an assembled form, according to another
embodiment;
[0019] FIG. 9 is a side elevation, cross-sectional view of another
embodiment of an apparatus;
[0020] FIG. 10 is a side elevation, cross-sectional view of another
embodiment of an apparatus; and
[0021] FIG. 11 is a side elevation, cross-sectional view of another
embodiment of an apparatus.
DETAILED DESCRIPTION
[0022] Embodiments described herein relate to systems and methods
for joining a tube to a sheet. Other embodiments relate to
shell-and-tube heat exchangers or other heat exchangers. According
to one aspect, tubes are connected to a plate or sheet by
intermediary sleeve pieces, for example, the sleeve pieces are
disposed in holes formed in the plate or sheet, and the tubes are
received in the sleeve pieces. The sleeve pieces thereby act as a
mechanical and/or thermal buffer between the tubes and the plate or
sheet. To avoid impeding the flow of fluid through the tubes, the
tubes and sleeve pieces are configured/shaped, as described herein,
for a continuous fluid flow path through the tubes and sleeve
pieces. For example, the tubes and sleeve pieces may be configured
to establish a constant diameter flow path in the interior
transition region between the tubes and sleeves pieces, thereby
avoiding any internal ridges, creases, steps, etc. that would
impede fluid flow or trap contaminants.
[0023] According to one aspect, "thermal expansion coefficient"
refers to, and/or is a measure of, how the size of an object
changes with a change in temperature. Thus, an "intermediate
thermal expansion coefficient" refers to a thermal expansion
coefficient value anywhere between higher and lower thermal
expansion coefficient values. According to one aspect, "continuous
geometry" refers to the location of the joining or blending of one
element to another wherein the joining or blending of the two
elements results in a contiguous piece. For example, in the joining
of two pieces containing an interior passageway between the two
elements, there is no intrusion into or disruption of the interior
passage that results from the joining of the elements, exclusive of
a seam. According to one aspect, the term "tube" refers to any
hollow geometry where a perimeter wall defines an interior passage
space from an exterior environment. By way of non-limiting
examples, tubes may include hollow cylinders (i.e., round tubes),
hollow rectangles (i.e., square or rectangular tubes), and members
where there are differing cross-sectional areas between one end and
another end. According to one aspect, the term "cross-sectional
geometry" refers to the shape of the part if it was cut at a given
point, usually perpendicular to the long axis of the part. By way
of non-limiting example, the cross-sectional geometry of a
cylindrical tube (i.e., round tube) would comprise the inner and
outer diameters of the tube in addition to the overall shape. In
like fashion, a cross-sectional geometry for the end of a tube
could have an inner circular diameter and an outer edge, of a
different shape. For example, a round passage of inner diameter "d"
could be embedded in a rectangular block with an outer length and
width.
[0024] According to another aspect, the terms "sheet," "plate" (or
"plate piece"), and "tube sheet" are synonymous in referring to a
base material to which one or more tubes are attached. Sheets and
tube sheets may extend the interior passages of tubes when
connected, may form a cap over a tube when attached, or may
introduce elements into the interior passage of the tube when
attached. Sheets and tube sheets may be made out of any material
similar or dissimilar to tubes. According to another aspect, the
terms "tube sleeve," "sleeve," and "sleeve piece" are refer to an
intermediary element (e.g., tubular element) placed between tubes
and sheets. Sleeves may have their own interior or exterior
geometries independent of any individual sheets and tubes.
[0025] FIGS. 1 and 4 show cross-sectional views (assembled and
exploded, respectively) of an embodiment of an apparatus 100, e.g.,
a tube-to-sheet joint, which may be part of a heat exchanger. A
plate piece 102 (also referred to as a tube sheet) is interfaced
with a sleeve 104 (also referred to as a sleeve piece) which is
interfaced with a tube 106, also referred to as a tube piece. (The
sleeve and tube in combination are occasionally referred to herein
as a tube assembly, simply to recognize that there may be plural
such assemblies, i.e., sleeve and tube mated pairs, associated with
a single plate piece having plural holes, such as in a heat
exchanger.) An interior joint 110 is formed by an abutment of the
tube 106 against the interior of the sleeve 104 and does not
protrude into the passageway formed across the interface. An
exterior tube and sleeve joint 108 can be formed by brazing,
welding, friction fitting, etc. The sleeve 104 interfaces with the
plate piece 102 and may be secured, for example, by a sealing weld
112. A sleeve-plate joint or interface 114 may be formed through
tight-tolerance fitting of the sleeve 104 within a hole 116 defined
by the plate piece.
[0026] To explain further, in embodiments, the plate piece 102
defines a hole 116, e.g., the hole is formed in or otherwise
extends through the plate piece. The sleeve piece 104 has first and
second ends 118, 120; the second end 120 is shaped to fit through
the hole for attachment of the sleeve piece to the plate piece. The
tube piece 106 also has first and second ends 122, 124. Inner and
outer cross-sectional geometries of the tube piece and the sleeve
piece (e.g., in the case of round tubes, inner and outer
diameters--see FIGS. 2 and 3), discussed in more detail below, are
shaped for the first end 122 of the tube piece to fit in the first
end 118 of the sleeve piece and to form a continuous interior fluid
flow path 126 from the second end of the tube piece through the
plate piece when the sleeve piece is disposed in the hole and
attached to the plate piece and the tube piece is disposed in the
sleeve piece.
[0027] In another aspect, when the first end 122 of the tube piece
106 is disposed in the first end 118 of the sleeve piece 104, an
inner cross-sectional geometry 128 of the second end 120 of the
sleeve piece 104 conforms to an inner cross-sectional geometry 130
of the first end 122 of the tube piece 106, forming a continuous
geometry across the interior transition (joint 110) between the
sleeve and the tube piece.
[0028] In another aspect, when assembled (such as shown in FIG. 1),
the first end 122 of the tube piece 106 is disposed in and attached
to the first end 118 of the sleeve piece 106, with an outer
cross-sectional geometry 132 of the first end of the tube piece
conforming to an inner cross-sectional geometry 134 of the first
end 118 of the sleeve piece 106 and forming joint 108. The second
end 120 of the sleeve piece 106 is disposed through the hole 116 of
the plate piece 102 and attached to plate piece forming the joint
114. The inner cross-sectional geometry 128 of the second end 120
of the sleeve piece 106 conforms to the inner cross-sectional
geometry 130 of the first end 122 of the tube piece 106, forming
the continuous geometry across the joint 110.
[0029] As mentioned, the tube 106 (or, more specifically, the first
end of the tube that fits in the sleeve) may be a round tube, a
square tube, a shape other than square or round, or it may have a
mix of shapes, i.e., different inner and outer cross-sectional
geometries, such as a square outer cross-sectional geometry and a
round inner cross-sectional geometry, from the perspective of a
plane normal to the long axis of the tube. (The inner cross-section
geometry of the first end of the sleeve piece, into which the tube
fits, may be shaped to correspond to the outer cross-sectional
geometry of the first end of the tube.) Thus, the embodiment of
FIGS. 1 and 4 is broadly directed to any shape, whereas the
apparatus 136 of FIGS. 2 and 3 is directed to the more specific
embodiment of a round tube and round tubular sleeve having circular
inner and outer cross-sectional geometries defined by inner and
outer diameters of the tube and sleeve, as an example.
[0030] In an embodiment, the first and second ends of the sleeve
piece have different inner cross-sectional geometries, respectively
(134, 128), such that a transition between the first and second
ends of the sleeve piece defines an interior shoulder 138. The
outer cross-sectional geometry 132 of the first end of the tube
piece matches the inner cross-sectional geometry 134 of the first
end of the sleeve piece, and the inner cross-sectional geometry 130
of the first end of the tube piece corresponds to the inner
cross-sectional geometry 128 of the second end of the sleeve piece,
for the first end 122 of the tube piece to abut the shoulder 138
and to establish the continuous geometry at the interior junction
of the tube and sleeve.
[0031] In another embodiment, with reference to FIG. 5, the sleeve
piece 104 has a uniform inner cross-sectional geometry 140 (e.g.,
the same diameter from the first end through the second end). The
outer cross-sectional geometry 132 of the first end of the tube
piece corresponds to the uniform inner cross-sectional geometry of
the sleeve piece. The first end of the tube piece is configured to
extend entirely through the sleeve piece, for the continuous
interior fluid flow path to be established by the interior of the
tube piece. That is, the fluid flow path is defined solely by the
interior of the tube piece, and the fluid (liquid or gas) does not
come into contact with the interior of the sleeve.
[0032] In an embodiment, with reference to FIG. 6, a heat exchanger
142 includes a plate piece 102 with plural holes, and plural mated
sleeve and tube pairs, each including a respective tube 106 and
sleeve 104, disposed in the holes and attached to the plate piece.
The tubes may extend between two sides of the heat exchanger, with
each such tube being held in place attached between two
plates/walls of the heat exchanger by two sleeves, one at either
end of the tube. The plates/walls of the heat exchanger may be part
of, and/or define, a housing of the heat exchanger. Additional
ports may be provided for ingress and egress of a first fluid (from
a first fluid source) into the interior (inner volume) of the
housing around the exterior of the tubes, for heat exchange with a
second fluid (from a second fluid source) passing through the
tubes. (FIG. 6 does not show the additional lines, tubes, ducts,
etc. that would be connected to, and/or part of, the heat
exchanger, for routing fluids through fluid circuits that include
the heat exchanger and fluid sources.) In terms of the tubes,
sleeves, and sleeve-plate interface, the heat exchanger may be
alternatively configured as per any of the other embodiments set
forth herein. For example, the heat exchanger could be provided
with sleeves as shown in FIG. 5, such that the tubes extend all the
way through the plate/wall.
[0033] The tube, sleeve, and/or plate piece or sheet may be made of
metal, either the same metal or different metals. Different grey
shading in the figures represents individual parts in cross
section, but does not mean the parts are necessarily made of
different materials. Further, one or more of the parts may be made
from non-metal materials, such as polymers, ceramics, or
composites. In one embodiment, the tube, plate, and sleeve pieces
are each made of different materials, with a thermal coefficient of
the material of the sleeve piece selected to act as a thermal
buffer between the tube and plate pieces.
[0034] In an embodiment, the first end of the tube piece, defined
by the outer cross-sectional geometry of the first end of the tube
piece, is at least one of brazed, welded, or mechanically coupled
to the first end of the sleeve piece, defined by the inner
cross-sectional geometry of the first end of the sleeve piece.
Alternatively or additionally, the sleeve piece may be welded,
mechanically coupled, and/or brazed to the plate piece.
[0035] In an embodiment, the sleeve piece is removably attached to
the plate piece, for example, by way of a press fit (tight friction
fit), de-couplable adhesive, removable weld, etc., so that sleeves
and/or tubes can easily be removed and replaced for repair or
cleaning.
[0036] FIG. 7 shows a cross-sectional diagram of an assembled joint
according to an embodiment. The plate piece 102 is interfaced with
the sleeve 104, which is interfaced with the tube 106.
Sleeve-plate/sheet joint 144 is a mechanical interface, e.g., screw
threads. Interior joint 110 is formed by an abutment of the tube
106 against the interior of the sleeve 104 and does not protrude
into the passageway formed across the interface. Exterior tube and
sleeve joint 108 can be formed by brazing, welding, friction
fitting, etc.
[0037] FIG. 8 shows a cross-sectional diagram of an assembled joint
according to an embodiment. The plate piece 102 is interfaced with
a sleeve 146, which is interfaced with tube 106. Sleeve-plate/sheet
joints 148, 150 may be singularly or dually secured by at least one
of welding, mechanical fitting, friction fitting, and/or brazing.
Interior joint 110 is formed by an abutment of the tube 106 against
the interior of the sleeve 104 and does not protrude into the
passageway formed across the interface. Exterior tube and sleeve
joint 108 can be formed by brazing, welding, friction fitting,
etc.
[0038] FIG. 9 shows a cross-sectional view of an assembled joint
according to an embodiment. Plate piece 102 is fitted with an
integrated tube-and-sleeve member 152 formed by additive
manufacturing or other techniques. Interior joint 154 is marked as
a transition point where the material of 152a blends with the
material of 152b, forming integrated tube-and-sleeve member 152.
Exterior joint 156 may be further shaped to more fully secure
integrated piece 152 to plate 102. A plate and integrated piece
joint 158 may be formed by any technique.
[0039] FIG. 10 shows a cross-sectional view of an assembled joint
according to an embodiment. Plate piece 160, comprised of materials
160a comprising the base stock of the tube sheet and 160b
comprising the tube-to-plate/sheet interface material, is
interfaced with tube 106. Materials 160a and 160b are interfaced at
joint 162 defined as a transitional gradient zone of materials
formed by additive manufacturing techniques and the like. Interior
joint 110 is formed by abutment of tube 106 against material 160b.
Exterior joint 108 can be formed by brazing, welding, friction
fitting, etc.
[0040] FIG. 11 shows a cross-sectional view of a unified interface
structure 164 according to an embodiment. The integrated
tube-and-sleeve zone 166 includes an interior joint 168 with
continuous geometry and no seam, as marked as a transition point
where the material of 166a blends with the material of 166b, and is
further interfaced at joint 170 represented as the zone where
material 166b blends with sheet stock material 166a.
[0041] In any of the embodiments herein, the plate piece and the
tube assemblies may be a monolithic structure formed using an
additive manufacturing process, with the plate piece, sleeve
pieces, and/or tube pieces being composed of different materials
and defined by boundaries between the different materials.
Reference is made to U.S. application Ser. No. 15/821,729, filed 22
Nov. 2017 and incorporated herein by reference in its entirety, for
further detail regarding additive manufacturing processes and
monolithic structures. Further, in any of the embodiments herein,
the sleeve and plate pieces may be constructed as a single unit
with a material gradient marking the boundary of the sleeve and
plate pieces, e.g., using additive manufacturing processes.
[0042] In an embodiment, the sleeve piece includes two or more
lateral halves or other lateral sections, which are configured to
be mated together around the tube piece and fastened together using
fasteners, welding or brazing, adhesives, or otherwise, to form the
sleeve piece as illustrated in the drawings.
[0043] In an embodiment, an apparatus includes a tube piece made of
a first material with inner and outer cross-sections and a first
end with first outer and inner geometries. The apparatus also
includes a plate piece made of a second material of a first
thickness and having a hole with at least first and second
cross-sections. The apparatus also includes a sleeve piece with
first and second ends with first and second inner and outer
cross-sectional geometries, made of a third material with a thermal
coefficient intermediate of thermal coefficients of the first and
second materials of the tube and sheet pieces. The first end of the
tube piece is attached and fitted into the first end of the sleeve
piece, with the first outer cross-section geometry of the tube
piece complementary to the first inner cross-section geometry of
the sleeve piece, forming a first joint. The first joint is sealed
by at least one of a weld or braze. The second end of the sleeve
piece is disposed through the hole of the plate piece and attached
to the plate piece forming a second joint. The sleeve piece, at the
second joint, is at least one of removably attached to the plate
piece, welded, brazed, and/or mechanically coupled into place with
the plate piece. The second inner cross-sectional geometry of the
first end of the sleeve piece conforms with the first inner
geometry of first end of the tube piece forming a continuous
geometry across the length of the first joint free of distortions
in the inner geometries of both the sleeve piece and the tube piece
caused by the action of joining the pieces together.
[0044] In another embodiment, a mechanical coupling of the sleeve
piece at the second joint is at least one of: threading, mechanical
expansion, or bolting to the plate piece.
[0045] In another embodiment, at least one of brazing and welding
at the first joint utilizes fill material with a compatible thermal
expansion coefficient.
[0046] In another embodiment, the first joint is sealed using
mechanical means.
[0047] In another embodiment, the second cross-section of the hole
in the plate piece forms a positive stop for seating the second end
of the sleeve piece.
[0048] In another embodiment, the inner and outer cross-sectional
geometries of the tube and sleeve pieces are tailored to minimize
anticipated stress levels at the first and second joints.
[0049] In another embodiment, the tube, plate, and sleeve pieces
are components of a tube-and-sheet heat exchanger.
[0050] Another embodiment relates to an apparatus that includes a
sleeve comprising a sleeve body with a first end and a second end.
The sleeve body defines a througbore extending along a center axis
of the sleeve body from a first opening in the first end to a
second opening in the second end. The sleeve further includes an
interior perimeter step attached to the first end of the sleeve
body, the step defining the first opening. A major inner cross
dimension of the first opening is smaller than a major inner cross
dimension of the throughbore, such that the sleeve body and the
step form a shoulder in an interior of the sleeve. The major inner
cross dimension of the throughbore corresponds to an outer
dimension of a tube to be received in and attached to the sleeve
such that when the tube is received in the sleeve the tube engages
an inner wall of the sleeve body and the shoulder. An outer
dimension of the sleeve corresponds to an opening that extends
through a sheet to which the sleeve and tube are to be attached,
such that when the sleeve is received in the opening in the sheet
the sleeve engages an inner sidewall of the opening in the sheet. A
length of the sleeve along the center axis is longer than a
thickness of the sheet such that when the sleeve is received in the
opening with the first end of the sleeve body lying flush to a flat
surface of the sheet the second end of the sleeve lies spaced apart
from an opposite, second surface of the sheet.
[0051] In another embodiment, the materials comprising sleeve,
tube, and sheet have differing thermal coefficients.
[0052] In another embodiment, the tube, sheet and sleeve pieces are
joined by at least one of welding, brazing, or mechanical
coupling.
[0053] In another embodiment, the geometry of the throughbore is
consistent across all piece joints and does not follow outer
geometry.
[0054] In another embodiment, the tube, sheet, and sleeve pieces
are part of a tube-sheet heat exchanger.
[0055] Another embodiment relates to an apparatus that includes a
tube piece, a sleeve piece, and a plate piece. The tube piece and
the sleeve piece are manufactured as a unitary body with a material
gradient demarcating the boundary between the tube piece and the
sleeve piece. The unitary body is joined to the plate piece.
[0056] Another embodiment relates to an apparatus that includes a
tube piece, a sleeve piece, and a plate piece. The sleeve piece and
the tube piece are manufactured as a unitary body with a material
gradient demarcating the boundary between the plate piece and the
sleeve piece. The tube piece is joined to the unified plate-sleeve
piece.
[0057] Another embodiment relates to an apparatus that includes a
tube piece, a sleeve piece, and a plate piece. The pieces are
manufactured as a unitary body with a material gradient demarcating
the boundaries between the pieces.
[0058] In another embodiment, a method includes inserting a first
end of a tube piece, having the first end and at least a second
end, a throughbore, and at least first inner and outer
cross-sections, into a first end of a sleeve piece having a first
end and a second end, a throughbore, a first inner cross-section at
the first end and a first outer cross-section at the first end, and
a second inner cross-section and a second outer cross-section at
the second end; and inserting the second end of the sleeve piece
into a hole in a plate piece with at least a first thickness. The
first inner cross-section of the first end of the sleeve piece
corresponds to the first outer cross-section of the first end of
the tube piece. The second inner cross section of the second end of
the sleeve piece is the same as the inner cross-section of the
first end of the tube piece, forming a continuous cross-section
across the joint of the tube piece and the sleeve piece.
[0059] In another embodiment of the method, the hole in the plate
piece is defined by at least two different cross-sectional
geometries.
[0060] In another embodiment of the method, at least one of the at
least two cross-sectional geometries is shaped to accommodate
attachment of the sleeve piece to the plate piece.
[0061] In another embodiment of the method, the tube piece, sleeve
piece, and plate piece are each made of different materials.
[0062] In another embodiment of the method, the sleeve piece is
made of a material whose coefficient of thermal expansion is an
intermediate between thermal coefficients of the materials forming
the tube piece and plate piece.
[0063] In another embodiment of the method, the first end of the
tube piece is inserted into the first end of the sleeve piece and
the change in cross-section from the first to second inner
cross-sections of the sleeve piece creates a positive stop for
abutment of the first end of the tube piece against the sleeve
piece.
[0064] In another embodiment of the method, the tube piece is
joined to the sleeve piece by at least one of brazing, welding, and
mechanical coupling.
[0065] In another embodiment of the method, the sleeve piece is
welded to the plate piece.
[0066] In another embodiment of the method, the sleeve piece is
removably attached to the plate piece.
[0067] In another embodiment of the method, the first outer
cross-section of the first end of the sleeve piece is different
from the second outer cross-section of the second end of the sleeve
piece.
[0068] In another embodiment of the method, the first outer
cross-section of the first end of the sleeve piece is configured to
minimize thermal stress between the sleeve piece and tube piece
while maximizing attachment surface area between the two
pieces.
[0069] In another embodiment of the method, the second outer
cross-section of the second end of the sleeve piece is configured
to minimize thermal stress between the sleeve piece and plate piece
while maximizing attachment surface area between the two
pieces.
[0070] The foregoing description of certain embodiments of the
inventive subject matter will be better understood when read in
conjunction with the appended drawings. To the extent that the
figures illustrate diagrams of the functional blocks of various
embodiments, the functional blocks are not necessarily indicative
of the division between hardware circuitry. Thus, for example, one
or more of the functional blocks (for example, processors or
memories) may be implemented in a single piece of hardware (for
example, a general purpose signal processor, microcontroller,
random access memory, hard disk, and the like). Similarly, the
programs may be stand-alone programs, may be incorporated as
subroutines in an operating system, may be functions in an
installed software package, and the like. The various embodiments
are not limited to the arrangements and instrumentality shown in
the drawings.
[0071] The above description is illustrative and not restrictive.
For example, the above-described embodiments (and/or aspects
thereof) may be used in combination with each other. In addition,
many modifications may be made to adapt a particular situation or
material to the teachings of the inventive subject matter without
departing from its scope. While the dimensions and types of
materials described herein are intended to define the parameters of
the inventive subject matter, they are by no means limiting and are
exemplary embodiments. Other embodiments may be apparent to one of
ordinary skill in the art upon reviewing the above description. The
scope of the inventive subject matter should, therefore, be
determined with reference to the appended claims, along with the
full scope of equivalents to which such claims are entitled.
[0072] In the appended claims, the terms "including" and "in which"
are used as the plain-English equivalents of the respective terms
"comprising" and "wherein." Moreover, in the following claims, the
terms "first," "second," and "third," etc. are used merely as
labels, and are not intended to impose numerical requirements on
their objects. Further, the limitations of the following claims are
not written in means-plus-function format and are not intended to
be interpreted based on 35 U.S.C. .sctn. 112(f), unless and until
such claim limitations expressly use the phrase "means for"
followed by a statement of function void of further structure. And,
as used herein, an element or step recited in the singular and
proceeded with the word "a" or "an" should be understood as not
excluding plural of said elements or steps, unless such exclusion
is explicitly stated. Furthermore, references to "one embodiment"
of the inventive subject matter are not intended to be interpreted
as excluding the existence of additional embodiments that also
incorporate the recited features. Moreover, unless explicitly
stated to the contrary, embodiments "comprising," "including," or
"having" an element or a plurality of elements having a particular
property may include additional such elements not having that
property.
[0073] This written description uses examples to disclose several
embodiments of the inventive subject matter and also to enable a
person of ordinary skill in the art to practice the embodiments of
the inventive subject matter, including making and using any
devices or systems and performing any incorporated methods. The
patentable scope of the inventive subject matter is defined by the
claims, and may include other examples that occur to those of
ordinary skill in the art. Such other examples are intended to be
within the scope of the claims if they have structural elements
that do not differ from the literal language of the claims, or if
they include equivalent structural elements with insubstantial
differences from the literal languages of the claims.
* * * * *