U.S. patent application number 16/003620 was filed with the patent office on 2018-10-11 for heat exchangers.
The applicant listed for this patent is Laird Technologies, Inc.. Invention is credited to Christoph BAUCKHAGE.
Application Number | 20180292137 16/003620 |
Document ID | / |
Family ID | 59013596 |
Filed Date | 2018-10-11 |
United States Patent
Application |
20180292137 |
Kind Code |
A1 |
BAUCKHAGE; Christoph |
October 11, 2018 |
HEAT EXCHANGERS
Abstract
Disclosed are exemplary embodiments of heat exchangers that may
be capable of cooling multiple process loops with a single primary
or shell-side fluid and/or have combined liquid-to-liquid and
liquid-to-air heat exchange capability.
Inventors: |
BAUCKHAGE; Christoph; (North
Andover, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Laird Technologies, Inc. |
Chesterfield |
MO |
US |
|
|
Family ID: |
59013596 |
Appl. No.: |
16/003620 |
Filed: |
June 8, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2016/065745 |
Dec 9, 2016 |
|
|
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16003620 |
|
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62265872 |
Dec 10, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28D 7/1615 20130101;
F28D 2021/0028 20130101; F28D 2021/0068 20130101; F28F 2009/0287
20130101; F28D 1/05308 20130101; F28D 7/0066 20130101; F28F 9/02
20130101; F28D 2021/005 20130101; F28D 1/05333 20130101; F28D
1/0443 20130101; F28D 2021/004 20130101; F28D 1/0461 20130101; F28D
2021/0059 20130101 |
International
Class: |
F28D 1/053 20060101
F28D001/053; F28F 9/02 20060101 F28F009/02 |
Claims
1. A heat exchanger comprising: a shell defining an interior; one
or more tubes extending through the interior of the shell; at least
one shell-side fluid inlet; at least one shell-side fluid outlet;
at least one shell-side gas inlet; and at least one shell-side gas
outlet; at least one tube-side fluid inlet for allowing at least
one tube-side fluid to enter the heat exchanger and flow into the
one or more tubes; at least one tube-side fluid outlet for allowing
the at least one tube-side fluid to exit the heat exchanger after
flowing through the one or more tubes; wherein: the at least one
shell-side fluid inlet and the at least one shell-side fluid outlet
are configured to allow a shell-side fluid to respectively enter
and exit an area of the heat exchanger such that the shell-side
fluid flows around portions of the tubes within the area thereby
allowing heat transfer between the at least one tube-side fluid
within the one or more tubes and the shell-side fluid within the
area; and the at least one shell-side gas inlet and the at least
one shell-side gas outlet are configured to allow a shell-side gas
to respectively enter and exit the interior of the shell such that
the shell-side gas flows around portions of the one or more tubes
within the interior thereby allowing heat transfer between the
shell-side gas and the at least one tube-side fluid within the one
or more tubes within the interior of the shell.
2. The heat exchanger of claim 1, further comprising first and
second headers at opposite end portions of the shell, and wherein:
the one or more tubes extend between the first and second headers
through the interior of the shell; the first header includes the at
least one tube-side fluid inlet; and the second header includes the
at least one tube-side fluid outlet.
3. The heat exchanger of claim 2, wherein: the first header
includes one or more first tube sheets having one or more openings
in which are positioned corresponding inlet end portions of the one
or more tubes; and the second header includes one or more second
tube sheets having one or more openings in which are positioned
corresponding outlet end portions of the one or more tubes; whereby
the first and second tube sheets are operable for helping retain
the positioning of the one or more tubes.
4. The heat exchanger of claim 1, wherein: the at least one
tube-side fluid is at least one tube-side liquid; the shell-side
fluid is a shell-side liquid; the shell-side gas is air; and the
heat exchanger is selectively operable for providing either or both
of: liquid-to-liquid heat exchange between the at least one
tube-side liquid and the shell-side liquid within the area; and
liquid-to-air heat exchange between the air within the interior of
the shell and the at least one tube-side liquid.
5. The heat exchanger of claim 1, further comprising one or more
divider plates that separate the shell into separate sections such
that the heat exchanger is operable for cooling multiple process
loops with a single shell-side fluid.
6. The heat exchanger of claim 5, wherein the heat exchanger is
operable for cooling at least three process loops with a single
shell-side fluid.
7. The heat exchanger of claim 5, wherein the heat exchanger is
operable for cooling three process loops of a medical imaging
system with facility water flow as the single shell-side fluid.
8. The heat exchanger of claim 5, wherein: the one or more tubes
comprise at least two sets of tubes separated by the one or more
divider plates; and each set of tubes is configured to receive a
different tube-side fluid than the other sets of tubes.
9. The heat exchanger of claim 1, wherein the heat exchanger is
selectively operable for providing either or both of
liquid-to-liquid heat exchange and/or liquid-to-air heat
exchange.
10. A heat exchanger comprising: a shell defining an interior; one
or more divider plates that separate the shell into separate
sections; at least two sets of one or more tubes extending through
the interior of the shell and separated by the one or more divider
plates, each set of one or more tubes configured to receive a
different tube-side fluid than each other set of tubes; whereby the
heat exchanger is operable for cooling multiple process loops with
a single shell-side fluid.
11. The heat exchanger of claim 10, wherein the heat exchanger is
operable for cooling at least three process loops with a single
shell-side fluid.
12. The heat exchanger of claim 10, wherein the heat exchanger is
operable for cooling three process loops of a medical imaging
system with facility water flow as the single shell-side fluid.
13. The heat exchanger of claim 10, wherein the heat exchanger
includes at least one shell-side fluid inlet and at least one
shell-side fluid outlet configured to allow a shell-side fluid to
respectively enter and exit an area of the heat exchanger such that
the shell-side fluid flows around portions of the at least two sets
of one or more tubes within the area.
14. The heat exchanger of claim 13, wherein the heat exchanger
includes at least one tube-side fluid inlet and at least one
tube-side fluid outlet configured to allow at least one tube-side
fluid to respectively enter and exit the heat exchanger.
15. The heat exchanger of claim 10, wherein the heat exchanger
includes at least one shell-side gas inlet and at least one
shell-side gas outlet configured to allow a shell-side gas to
respectively enter and exit the interior of the shell such that the
shell-side gas flows around portions of the at least two sets of
one or more tubes within the interior of the shell.
16. The heat exchanger of claim 10, further comprising first and
second headers at opposite end portions of the shell, and wherein:
the at least two sets of one or more tubes extend between the first
and second headers through the interior of the shell; the first
header includes at least one tube-side fluid inlet configured to
allow at least one tube-side fluid to enter the heat exchanger; and
the second header includes at least one tube-side fluid outlet
configured to allow the at least one tube-side fluid to exit the
heat exchanger.
17. The heat exchanger of claim 16, wherein: the first header
includes one or more first tube sheets having one or more openings
in which are positioned corresponding inlet end portions of the at
least two sets of one or more tubes; and the second header includes
one or more second tube sheets having one or more openings in which
are positioned corresponding outlet end portions of the at least
two sets of one or more tubes; whereby the first and second tube
sheets are operable for helping retain the positioning of the at
least two sets of one or more tubes.
18. The heat exchanger of claim 10, wherein the heat exchanger is
selectively operable for providing either or both of
liquid-to-liquid heat exchange and/or liquid-to-air heat exchange.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT International
Application No. PCT/US2016/065745 filed Dec. 9, 2016 (published as
WO 2017/100521 on Jun. 15, 2017) which, in turn, claims priority to
and the benefit of U.S. Provisional Patent Application No.
62/265,872 filed Dec. 10, 2016. The entire disclosures of the above
applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to heat exchangers.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Heat exchangers operate by facilitating the transfer of heat
from one fluid to a second fluid by various means. One type of heat
exchanger design is a shell and tube heat exchanger which includes
a shell (a large pressure vessel) and multiple tubes. The tubes
extend through an interior of the shell. The set of tubes may also
be referred to as a tube bundle, and may be composed of several
types of tubes, e.g., straight, bent, U-shaped, plain,
longitudinally finned, etc. The tubes may be held in place within
the shell by tube sheets.
[0005] During operation of the heat exchanger, one fluid (the
tube-side fluid) runs through the tubes. Another separate fluid
(the shell-side fluid) flows over the tubes but inside the shell.
Heat is transferred from one fluid to the other through the tube
walls, either from the tube-side fluid to the shell-side fluid or
vice versa. For example, liquid-to-liquid heat exchange would occur
when both the tube-side fluid and the shell-side fluid are liquids
such that heat is transferred from one liquid to the other liquid
via the tube walls. Or, for example, liquid-to-air (or
liquid-to-gas) heat exchange would occur when one of the tube-side
and shell-side fluid is a liquid and the other one is a gas (e.g.,
air, etc.) such that heat may be transferred between the liquid and
the gas.
DRAWINGS
[0006] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0007] FIG. 1 illustrates a heat exchanger according to an
exemplary embodiment in which the heat exchanger is being used to
cool three different process loops (e.g., OCU, GCU, and CCU of a
medical imaging system, etc.) with a single primary side cooling
fluid (e.g., facility water flow, etc.); and
[0008] FIG. 2 illustrates a heat exchanger according to another
exemplary embodiment in which the heat exchanger is configured to
be operable with liquid-to-liquid and liquid-to-air heat exchange
capability.
DETAILED DESCRIPTION
[0009] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0010] The inventor hereof has recognized a need for a heat
exchanger that is capable of cooling multiple process loops (e.g.,
multiple tube-side fluids from different sources, etc.) with a
single primary side cooling fluid or single shell-side fluid. The
inventor hereof has also recognized a need for a heat exchanger
having versatility such that either or both liquid-to-liquid heat
exchange and/or liquid-to-air heat exchange may be used. After
recognizing the above, the inventor hereof developed and discloses
herein exemplary embodiments of heat exchangers capable of cooling
multiple process loops with a single primary or shell-side fluid
and/or having combined liquid-to-liquid and liquid-to-air heat
exchange capability.
[0011] In exemplary embodiments, a heat exchanger includes a
multi-core design having a liquid-to-air heat exchange section and
a liquid-to-liquid heat exchange section. The liquid-to-air and
liquid-to-liquid heat exchange sections are incorporated in the
construction of the heat exchanger by the addition of one or more
divider plates. The combined liquid-to-air and liquid-to-liquid
heat exchanger may comprise a tube and fin heat exchanger, a shell
and tube heat exchanger, or other suitable types of heat
exchangers, etc.
[0012] The combined liquid-to-air and liquid-to-liquid heat
exchanger may be useful when it is uncertain as to whether facility
water will be available to cool the process fluid. If facility
water is not available, the cooling system including the combined
liquid-to-air and liquid-to-liquid heat exchanger may still operate
completely under air cooled conditions. The combined liquid-to-air
and liquid-to-liquid heat exchanger may thus allow for a versatile
common platform that reduces the number of cooling system types
that might otherwise be needed, such as air cooled or liquid
cooled. The combined liquid-to-air and liquid-to-liquid heat
exchanger may be useful in emergency cooling situations (e.g.,
power outages which could trigger city water or facility water
valves to open and maintain the necessary cooling of the process
fluid, etc.). The combined liquid-to-air and liquid-to-liquid heat
exchanger may also be used in multi-loop applications in which
process water may heat and/or cool a secondary cooling loop inside
or within the end user's system.
[0013] In exemplary embodiments, a multi-core heat exchanger may be
based on or have a shell and tube heat exchanger design. The heat
exchanger includes one or more divider plates that allow for
cooling different process loops with a single primary side or
shell-side cooling fluid (e.g., facility water or refrigerant,
etc.). For example, the heat exchanger may be used to cool three
different process loops of a medical imaging system (e.g., OCU
(Optional Cooling Unit), GCU (Gradient Coil Unit), and CCU (Cabinet
Cooling Unit), etc.) with facility water flow as the single primary
side or shell-side cooling fluid.
[0014] In operations in which multiple process fluids will be
cooled (e.g., at different flow rates, at different temperatures,
and/or for different consumers, etc.), exemplary embodiments of the
heat exchangers disclosed herein may not require the use of
additional manifolds when cooling multiple process fluids. Thus,
exemplary embodiments may eliminate the need to use additional
manifolds and reduce the total number of heat exchangers that would
otherwise be used. Hence, these exemplary embodiments may allow for
reduced package size and reduced number of fittings and joints,
which, in turn, may increase reliability, reduce part count, and
reduce complexity. By using a single high performance heat
exchanger on the primary side (in contrast to splitting the flow
into three different heat exchangers), the pressure drop on the
primary side may be greatly reduced. This, in return, reduces the
amount of energy consumption on the system level within the
installation (e.g. less hydraulic pressure required from the HVAC
system or cooling tower, etc.). Some exemplary embodiments have a
shell and tube multi-loop heat exchanger design that allows the
performance element (e.g., tube bundle removable from the housing,
etc.) to be removed from the assembly and cleaned for reuse. In
contrast, conventional braze plate type heat exchangers cannot be
opened and/or cleaned easily.
[0015] In exemplary embodiments, a heat exchanger is based in part
on a shell and tube heat exchanger design. In such exemplary
embodiments, the heat exchanger generally includes tubes extending
within and through a shell. First and second headers may be
positioned at opposite ends of the shell. The first and second
headers may respectively include first and second tube sheets. The
first and second headers may respectively include or define inlet
and outlet plenums that are fluidically connected to or in fluid
communication with the respective inlet and outlet ends of the
tubes through holes in first and second tube sheets. One or more
divider plates may be oriented generally parallel to the first and
second tube sheets and extend generally between the first and
second headers in order to divide the heat exchanger and shell into
multiple sections. The shell may include one or more inlets (e.g.,
openings, holes, etc.) for allowing the shell-side fluid (e.g.,
liquid, air, etc.) to flow into the shell between the first and
second headers to thereby allow exchange between the tube-side
fluid and the shell-side fluid.
[0016] In some exemplary embodiments where there are inlets for
allowing air to flow into the shell between the first and second
headers, the heat exchanger may be configured to be operable with a
shell-side liquid so as to allow both liquid-to-liquid heat
exchange and liquid-to-air heat exchange. Alternatively, the heat
exchanger may be configured to be operable without a shell-side
liquid such that the heat exchanger relies only on liquid-to-air
heat exchange.
[0017] With reference to the drawings, FIG. 1 illustrates an
exemplary embodiment of a heat exchanger 100 embodying one or more
aspects of the present disclosure. As shown, the heat exchanger 100
includes divider plates 104 that separate the shell 106 into
separate sections. This allows the heat exchanger 100 to be used
for cooling three different process loops with a single primary
side or shell-side cooling fluid (e.g., facility water flow, etc.)
as represented by arrow 108. In this example, the heat exchanger
100 is shown in use with an OCU (Optional Cooling Unit) cooling
loop, a GCU (Gradient Coil Unit) cooling loop, and a CCU (Cabinet
Cooling Unit) of a medical imaging system. The heat exchanger 100
may also be used in other applications for cooling more or less
than three process loops, different process loops, and/or in
different systems besides medical imaging systems.
[0018] With continued reference to FIG. 1, arrows 112 and 116
represent a secondary or tube-side fluid of the OCU cooling loop
respectively flowing into and out of the heat exchanger 100. Arrows
120 and 124 represent a secondary or tube-side fluid of the GCU
cooling loop respectively flowing into and out of the heat
exchanger system 100. Arrows 128 and 132 represent a secondary or
tube-side fluid of the CCU cooling loop respectively flowing into
and out of the heat exchanger 100. Arrow 108 represents the single
primary side or shell-side fluid entering the heat exchanger 100
generally perpendicularly to the flow of the secondary or tube-side
fluids represented by arrows 112, 116, 120, 124, 128, 132. In the
heat exchanger 100, the primary side or shell-side fluid exchanges
heat with secondary or tube-side fluids of the OCU, GCU, and CCU
cooling loops. The primary side fluid then egresses or exits the
heat exchanger 100 as represented by arrow 136. The result is the
cooling of all three loops (OCU, GCU, and CCU) with a single
primary side fluid with a single heat exchanger 100. In this
exemplary embodiment, the heat exchanger 100 may be configured such
that the single primary side fluid is one continuous, straight flow
through a continuous, seamless tube.
[0019] In exemplary embodiments, the shell 106 includes one or more
inlets (e.g., openings, holes, gaps, etc.) in the shell's outer
portion between a first header and a second header. The one or more
inlets are configured to allow gas (e.g., ambient air, heated air,
cooled air, other gas, etc.) to flow (pressurized or unpressurized)
into the shell's interior region between the first and second
headers. For example, the one or more inlets may be configured
(e.g., positioned, etc.) such that they do not allow air into the
first and second headers. The air that flows into the shell via the
one or more inlets may function or act as a shell-side fluid for
liquid-to-air heat exchange. More specifically, heat may be
transferred from the liquid within the tubes (tube-side fluid) to
the air (shell-side fluid) within the shell that flows over the
tubes, or vice versa. In some exemplary embodiments, the one or
more inlets of the shell may be expansive, effectively acting as a
single gap allowing air to flow unimpeded through the shell. The
shell-side gas may be ambient temperature or heated or cooled to a
desired temperature.
[0020] In exemplary embodiments, the heat exchanger includes
divider plates separating the shell into separate sections. This
allows the heat exchanger to be used for cooling multiple different
process loops with a single primary side or shell-side cooling
fluid (e.g., facility water, refrigerant flow, etc.). For example,
the heat exchanger may be used with an OCU (Optional Cooling Unit)
cooling loop, a GCU (Gradient Coil Unit) cooling loop, and a CCU
(Cabinet Cooling Unit) of a medical imaging system. But the heat
exchanger may also be used in other applications for cooling more
or less than three process loops, different process loops, and/or
in different systems besides medical imaging systems. For example,
the heat exchanger may be used with industrial drives and frequency
converters that use several cooling loops for different heat
sources or a common cooling system cooling two or more drives. Or,
for example, the heat exchanger may be used with semiconductor
fabrication tools that use several cooling loops for temperature
controlling different heat sources or using a common cooling system
to cool multiple tools. As yet another example, the heat exchanger
may be used with data infrastructure for cooling several heat
sources in serves and or cooling several server racks with a common
cooling system.
[0021] First and second headers are at opposite ends of the shell.
The first header may include or be fluidically connected to or in
fluid communication with one or more first tube sheets. In this
example, the heat exchanger may include four divider plates having
end portions respectively disposed between corresponding pairs of
the five first tube sheets. The first header may also include or
define an inlet plenum that is fluidically connected to or in fluid
communication with the inlet ends of the tubes through openings
(e.g., holes, perforations, etc.) in the first tube sheets.
Similarly, the second header may include or be fluidically
connected to or in fluid communication with one or more second tube
sheets. The divider plates may have end portions also respectively
disposed between corresponding pairs of the second tube sheets. The
second header may also include or define an outlet plenum that is
fluidically connected to or in fluid communication with the outlet
ends of the tubes through openings (e.g., holes, perforations,
etc.) in the second tube sheets. The divider plates may be oriented
generally parallel to the first tube sheets and the second tube
sheets. The divider plates may extend generally between the first
and second headers in order to divide the heat exchanger and shell
into five sections in this example. The divider plates may be used
to separate and completely seal the five sections, and the fluid
may turn several times within one body. Alternatively, the heat
exchanger may be configured differently in other embodiments, such
as with more or less than four divider plates, more or less than
five first and second tube sheets, and/or more or less than five
sections.
[0022] In addition to the first tube sheets and the second tube
sheets at the opposite end portions of the shell, the heat
exchanger may include additional tube sheets. The tube sheets may
be spaced apart the opposite end portions of the shell to help hold
the tubes in place within the shell. If the tubes are microtubes,
stiffener plates may also be used to increase stability.
[0023] The heat exchanger may include one or more baffles
positioned between (e.g., about midway, etc.) between the first and
second headers. A baffle may be configured to direct the flow of
the primary side or shell-side fluid through the shell so that the
primary side or shell-side fluid does not take a short cut through
the shell leaving ineffective low flow volumes. The baffle may be
configured to increase turbulence of the shell-side fluid in order
to achieve more effective heat transfer. The baffle may be attached
to the tube bundle so that the tube bundle is more readily
removable for cleaning and/or maintenance. Alternatively, the heat
exchanger may be configured differently in other embodiments, such
as with more or less than one baffle and/or a baffle configured
differently (e.g., positioned elsewhere, attached to the shell
instead of the tube bundle, etc.).
[0024] The heat exchanger may be configured such that the primary
side or shell-side fluid passes through the shell in a single pass.
For example, the heat exchanger may include a seamless single tube
through which the fluid flows from one end to the other end. Or,
for example, two loops may be created such as by completely welding
the body to a baffle so that there is no fluid bypass between the
chambers.
[0025] The first and second headers are configured to allow
tube-side fluid to respectively flow into and out of the tubes
without contacting the shell-side fluid. The heat exchanger may be
configured such that a different tube-side fluid enters the tubes
of each of the corresponding sections or process loops of the heat
exchanger. Thus, the set of tubes of one section or process loop
may contain a tube-side fluid different than the tube-side fluids
within the sets of tubes of the other sections or process
loops.
[0026] FIG. 2 illustrates another exemplary embodiment of a heat
exchanger 300 embodying one or more aspects of the present
disclosure. The heat exchanger 300 is configured to be selectively
operable with either or both liquid-to-liquid heat exchange and
liquid-to-air heat exchange.
[0027] The heat exchanger 300 includes a first or top header 340
and a second or bottom header 344. The first and second headers
340, 344 are along or at opposite top and bottom (or upper and
lower) portions of a shell 306 of the heat exchanger 300.
[0028] The first header 340 may include or be fluidically connected
to or in fluid communication with a first tube sheet 348. The first
tube sheet 348 may include openings (e.g., holes, perforations,
etc.) defining or fluidically connected to or in fluid
communication with inlet ends of the process fluid tubes 354. In an
example embodiment, end portions of the tubes 354 may be coupled
(e.g., welded, brazed, epoxied, other suitable "leak free"
connection, etc.) to the first tube sheet 348. The first header 340
includes a tube-side fluid inlet 356 (e.g., process fluid fitting,
etc.) by which a tube-side fluid may enter the heat exchanger 300.
The tube-side fluid inlet 356 may allow the tube-side fluid to
enter the tubes 354 without contacting the shell-side fluid.
[0029] The second header 344 may include or be fluidically
connected to or in fluid communication with a second tube sheet
350. The second tube sheet 350 may include openings (e.g., holes,
perforations, etc.) defining or fluidically connected to or in
fluid communication with outlet ends of the tubes 354. In an
example embodiment, end portions of the tubes 354 may be coupled
(e.g., welded, brazed, epoxied, other suitable "leak free"
connection, etc.) to the second tube sheet 350. The second header
344 includes a tube-side fluid outlet 360 (e.g., process fluid
fitting, etc.) through which the tube-side fluid may exit or be
discharged from the heat exchanger 300 without contacting the
shell-side fluid.
[0030] The tubes 354 generally extend downwardly from the top
header 340 through the first tube sheet 348, additional tube sheet
352, shell 306, and the second tube sheet 350 to the bottom header
344. In this example, the tubes 354 are generally parallel to each
other and held in position by the tube sheets 348, 352, and 350.
Each tube sheet 348, 352, 350 may include openings in which are
positioned (e.g., friction or interference fit, etc.) portions of
the tubes 354. Alternatively, the tubes 354 may be configured
differently, such as nonlinearly, curved, U-shaped, etc.
[0031] The heat exchanger 300 also includes an area 372, which may
also be referred to as a liquid-to-liquid heat exchange area 372.
More specifically, the heat exchanger 300 includes a shell-side
fluid inlet 364 (e.g., facility fluid fitting, etc.) and a
shell-side fluid outlet 368 (e.g., facility fluid fitting, etc.) by
which a shell-side fluid may respectively enter and exit the area
372. The area 372 may be defined generally below and sealed off
from the portion of the first header 340 that receives the
tube-side fluid via the tube-side fluid inlet 356. Accordingly, a
shell-side fluid (e.g., facility water, etc.) may enter the heat
exchanger 300 via the inlet 364, flow through the area 372 and
around portions of the tubes 354 within the area 372, and exit the
heat exchanger 300 via outlet 368. As the shell-side fluid flows
through and around portions of the tubes 354, heat may be
transferred between the tube-side fluid and the shell-side fluid
via the tube walls. When the shell-side fluid and tube-side fluid
are both liquids, the area 372 may also be referred to as a
liquid-to-liquid heat exchange area. The shell-side fluid may be
generally contained within the area 372. The tubes 354 are "leak
free" coupled to the tube sheet 352 such that liquid within area
372 cannot leak into area 376.
[0032] The heat exchanger 300 may also be configured to allow air
(or other suitable gas) to flow around portions of the tubes 354
within the area 376 between and sealed off from the area 372, tube
sheets 350, 352, and first and second headers 340, 344. This may
allow heat exchange between the tube-side fluid and the air within
area 376 via the tube walls. The area 376 may also be referred to
as a liquid-to-air heat exchange area when the tube-side fluid is a
liquid and the fluid within area 376 is air. The area 376 may also
be referred to as a liquid-to-gas heat exchange area when the
tube-side fluid is a liquid and the fluid within area 376 is a
gas.
[0033] In exemplary embodiments, one or more tube-side fluid inlets
may allow flow of multiple different tube-side fluids (also known
as "process fluids" or "secondary side fluids") into the tubes. A
tube-side fluid inlet may be constructed so as to allow a tube-side
fluid to enter the tubes and flow through the shell without
contacting the shell-side fluid. Further, each tube-side fluid
inlet may be constructed so as to allow a different tube-side fluid
to flow into a distinct set of tubes among the plurality of tubes.
For example, each tube-side fluid inlet may permit flow of one
tube-side fluid into only one set of tubes from among the plurality
of sets of tubes. Each tube-side inlet may thus allow for fluid
flow for a different cooling loop through the heat exchanger.
[0034] In some embodiments, each separate cooling loop may include
a different tube-side fluid into a different tube-side inlet to
form a system involving a single heat exchanger and multiple
different cooling loops. In some exemplary embodiments, there are
two or more cooling loops and two or more corresponding tube-side
inlets. This functionally allows for cooling multiple cooling loops
(e.g., cooling tube-side fluids from different sources, etc.) in a
single system. By way of example only, a system of three different
cooling loops (e.g., for use in a medical imaging device, etc.) may
be cooled using a heat exchanger of the present disclosure. Each
cooling loop may have its own tube-side fluid and distinct
tube-side inlet. In which case, each cooling loop may include fluid
flow through its own distinct set of tubes. Accordingly, the
tube-side fluid within each of the multiple loops may be cooled as
each passes through the heat exchanger by a single shell-side (or
"primary side") fluid without the tube-side fluids contacting each
other or contacting the shell-side fluid. Thus, this example allows
cooling of multiple separate cooling loops with a single heat
exchanger using a single shell-side (or "primary side") fluid.
[0035] In exemplary embodiments that include one or more divider
plates, the divider plates may be operable to separate or segregate
different sets of tubes carrying different tube-side fluids, e.g.,
OCU, GCU, and CCU tube side-side fluids, etc. The divider plates
may be made of various materials, such as metals, metal alloys,
plastics, etc.
[0036] As disclosed herein, exemplary embodiments may include a
shell and one or more divider plates. The divider plates may extend
through the shell parallel to the tubes and perpendicular the first
and second headers. In this exemplary manner, the divider plates
may divide the shell into two or more separate sections, wherein
each section has a tube-side fluid inlet separate from the other.
In exemplary embodiments, the shell-side fluid may be free to flow
through the first header and second header unimpeded.
[0037] In some exemplary embodiments, the tubes may include one or
more surfaces (e.g., fins, etc.) extending outwardly from the
exterior surface of the tube walls to thereby increase the heat
transfer surface area. In other exemplary embodiments, the tubes
may not include any such outwardly extending fins or other
surfaces. In some exemplary embodiments, the tubes may have
enhanced surfaces (e.g., metal coatings on the inside and/or
outside of the tube walls, etc.) to facilitate heat transfer and/or
prevent corrosion.
[0038] The tube wall thickness may vary depending, for example, on
the fluid pressures used in the heat exchanger system, materials
used, and/or other factors. The length of the tubes and overall
size of the shell and heat exchanger may depend, for example, on
the space available for the heat exchanger, the level of cooling
needed, and/or other factors.
[0039] In exemplary embodiments, the tubes may be made of various
materials including metal, metal alloys, and other non-metal
materials. For example, the tubes may be made of carbon steel, low
carbon steel, stainless steel, copper, copper-nickel stainless
steel, nickel-chromium iron alloys, titanium, and other alloys
thereof. The tube may be made of an alloy including, for example,
cobalt, chromium, iron, nickel, tungsten, manganese, molybdenum,
copper, titanium, zirconium, aluminum, carbon, silicon, sulfur,
phosphorus, boron, etc. In some exemplary embodiments, the tubes
may be conventionally-sized tubes with diameters of, for example,
greater than 1 millimeter. In other exemplary embodiments, the
tubes may be microtubes having a diameter smaller than conventional
tubes, e.g., a diameter less than 1 millimeter, etc. Such
microtubes may be made of metals, metal alloys, plastic, ceramic
materials, etc., depending on the intended application or end use,
fluid properties, operation temperature of the heat exchanger
system, potential for fouling, and other factors.
[0040] The tubes may be attached (e.g., welded, mechanically
fastened, brazed, glued, etc.) to the shell and/or the first or
second headers. In exemplary embodiments, machined grooves in tube
sheets and corresponding nodules at the appropriate location on the
tubes may allow for increased anchoring strength between the tube
sheet and tubes. In other exemplary embodiments, the tubes may be
secured to the tube sheets by welding, gaskets, or other forms of
hermetic sealing commonly known in the art.
[0041] Various fluids may be used for the shell-side and tube-side
fluids in exemplary embodiments. For example, exemplary embodiments
may include on or more of ethylene glycol water (EGW), water,
water-glycol mixtures, electronics cooling fluid (e.g., Fluorinert,
etc.), oil, inert fluorinated fluid (e.g., perfluoropolyether
(PFPE) fluorinated fluids, galden PFPE fluid, etc.), deionized
water, demineralized water, ultrapure water, fuel, etc.
[0042] The shell may be made from various materials, such as
metals, metal alloys (e.g., low carbon steel, etc.), and other
materials. For example, the shell may be made of a metal alloy
including one or more of cobalt, chromium, iron, nickel, tungsten,
manganese, molybdenum, copper, titanium, zirconium, aluminum,
carbon, silicon, sulfur, phosphorus, boron, etc.
[0043] The size of the first and second headers may vary depending
on the size of overall heat exchanger, ratio of liquid-to-liquid
heat exchange to liquid-to-air heat exchange desired in the heat
exchanger, and/or other factors. The first and second headers may
be made from various materials, such as metals, metal alloys (e.g.,
low carbon steel, etc.), and other materials. For example, the
headers may be made of a metal alloy including one or more of
cobalt, chromium, iron, nickel, tungsten, manganese, molybdenum,
copper, titanium, zirconium, aluminum, carbon, silicon, sulfur,
phosphorus, boron, etc.
[0044] In exemplary embodiments, a tube-side fluid may have a
higher temperature than the shell-side fluid such that heat is
transferred from the tube-side fluid to the shell-side fluid. When
configured in this exemplary manner, the heat exchanger may be used
to cool the tube-side fluid. In other exemplary embodiments, a
tube-side fluid may have a lower temperature than the shell-side
fluid such that heat is transferred from the shell-side fluid to
the tube-side fluid. When configured in this exemplary manner, the
heat exchanger may be used to warm the tube-side fluid.
[0045] In exemplary embodiments, ambient air is allowed to flow
into the shell between the first and second headers and around the
tubes. When the ambient air has a lower temperature than the
tube-side fluid, the tube-side fluid may be cooled by the ambient
air. In other exemplary embodiments, the ambient air may have a
higher temperature than the tube-side fluid, such that the
tube-side fluid may be warmed by the ambient air.
[0046] In exemplary embodiments, an intermediate region of the
shell between the first and second headers may include one or more
inlets (e.g., holes, gaps, etc.) in the shell outer surface to
allow a gas (e.g., pressurized, cooled, warmed, or ambient air,
etc.) to flow through the intermediate region. This allows the
ambient air or other gas to act as a second, additional, or
alternative shell-side fluid that may flow over and around the
portions of the tubes within the intermediate region. In which
case, heat may be exchanged between the tube-side fluid and the
ambient air or other gas within the intermediate region via the
walls of the tubes. The ambient air or other gas may then exit or
be discharged from the shell via one or more outlets (e.g., holes,
gaps, etc.). In exemplary embodiments, the intermediate region of
the shell is between the first and second headers and optionally
includes one or more divider plates separating groups of tubes
carrying different tube-side fluids.
[0047] Exemplary embodiments of the heat exchangers disclosed
herein may be used in a wide array of applications, such as heating
and air-conditioning (HVAC) systems, medical imaging systems, oil
refining processes, heat pumps, engines, and other systems where
cooling or heating of fluids is useful.
[0048] Example embodiments are provided so that this disclosure
will be thorough, and will fully convey the scope to those who are
skilled in the art. Numerous specific details are set forth such as
examples of specific components, devices, and methods, to provide a
thorough understanding of embodiments of the present disclosure. It
will be apparent to those skilled in the art that specific details
need not be employed, that example embodiments may be embodied in
many different forms, and that neither should be construed to limit
the scope of the disclosure. In some example embodiments,
well-known processes, well-known device structures, and well-known
technologies are not described in detail. In addition, advantages
and improvements that may be achieved with one or more exemplary
embodiments of the present disclosure are provided for purpose of
illustration only and do not limit the scope of the present
disclosure, as exemplary embodiments disclosed herein may provide
all or none of the above mentioned advantages and improvements and
still fall within the scope of the present disclosure.
[0049] Specific dimensions, specific materials, and/or specific
shapes disclosed herein are example in nature and do not limit the
scope of the present disclosure. The disclosure herein of
particular values and particular ranges of values for given
parameters are not exclusive of other values and ranges of values
that may be useful in one or more of the examples disclosed herein.
Moreover, it is envisioned that any two particular values for a
specific parameter stated herein may define the endpoints of a
range of values that may be suitable for the given parameter (i.e.,
the disclosure of a first value and a second value for a given
parameter can be interpreted as disclosing that any value between
the first and second values could also be employed for the given
parameter). For example, if Parameter X is exemplified herein to
have value A and also exemplified to have value Z, it is envisioned
that parameter X may have a range of values from about A to about
Z. Similarly, it is envisioned that disclosure of two or more
ranges of values for a parameter (whether such ranges are nested,
overlapping or distinct) subsume all possible combination of ranges
for the value that might be claimed using endpoints of the
disclosed ranges. For example, if parameter X is exemplified herein
to have values in the range of 1-10, or 2-9, or 3-8, it is also
envisioned that Parameter X may have other ranges of values
including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.
[0050] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a", "an" and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0051] When an element or layer is referred to as being "on",
"engaged to", "connected to" or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to", "directly connected to" or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0052] The term "about" when applied to values indicates that the
calculation or the measurement allows some slight imprecision in
the value (with some approach to exactness in the value;
approximately or reasonably close to the value; nearly). If, for
some reason, the imprecision provided by "about" is not otherwise
understood in the art with this ordinary meaning, then "about" as
used herein indicates at least variations that may arise from
ordinary methods of measuring or using such parameters. For
example, the terms "generally", "about", and "substantially" may be
used herein to mean within manufacturing tolerances. Whether or not
modified by the term "about", the claims include equivalents to the
quantities.
[0053] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
could be termed a second element, component, region, layer or
section without departing from the teachings of the example
embodiments.
[0054] Spatially relative terms, such as "inner," "outer,"
"beneath", "below", "lower", "above", "upper" and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
[0055] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements, intended or stated uses, or features of a particular
embodiment are generally not limited to that particular embodiment,
but, where applicable, are interchangeable and can be used in a
selected embodiment, even if not specifically shown or described.
The same may also be varied in many ways. Such variations are not
to be regarded as a departure from the disclosure, and all such
modifications are intended to be included within the scope of the
disclosure.
* * * * *