DE102006056807A1 - Compact high-temperature heat exchanger such as a recuperator - Google Patents

Abstract

A heat exchanger for transferring heat energy between a first working fluid and a second working fluid. The heat exchanger may include: a first sheet contoured to define a plurality of first ribs and having an upper end and a lower end; a second panel contoured to define a plurality of second ribs and disposed between the top and bottom of the first panel; and a housing formed of a third sheet and at least partially surrounding the first sheet and the second sheet.

Description

cross-reference on related applications

The This application claims priority under 35 U.S.C. §119 against the preliminary U.S. Patent Application Serial No. 60 / 741,537 of December 1, 2005, their contents here completely is incorporated by reference.

invention field

The The present invention relates to heat exchangers and in particular heat exchangers (e.g., recuperators, exhaust heat recovery systems, and the like), which are compact and / or operated at high temperatures can.

Summary

compact Recuperators can in various applications such as microturbines and High temperature fuel cells be used. In these and other applications, the system efficiency be optimized by an incoming airflow with lower Temperature through the transmission of heat energy from a high temperature exhaust / exhaust air stream to a temperature heated will be the one you want Process operating temperature closer is. The recuperator can be a heat exchanger be that efficient transmission of heat energy from the warm stream to the cold stream while allowing one Isolation of the two streams maintains.

During the Can operate compact recuperators have operating temperatures above 750 ° C at the hot end and near ambient temperatures (i.e. less than 100 ° C) be exposed at the cold end. The combination of high temperatures and big ones temperature gradients in the thin-walled materials requires the use of materials such as nickel-containing Alloys that have high temperature resistance and corrosion resistance at higher Have temperatures. Such materials are relatively expensive, why a need for drafts for recuperators is present, in which to achieve the desired heat transfer required amount of material can be minimized. simultaneously have to the designs for recuperators by temperature gradient minimize thermal stresses in the device.

In some embodiments the invention gives a heat exchanger to transfer of heat energy between a first working fluid and a second working fluid at. The heat exchanger can be a pair of first ribs, which are formed from a single sheet are and at least partially form a flow path for the first working fluid, and a second rib interposed between the pair of first Ribs is arranged and at least partially a flow path for the second Forms working fluid. The flow path of the first working fluid may be separated from the flow path of the second working fluid.

In other embodiments the present invention provides a heat exchanger comprising: a first corrugated sheet having a pair of tips and a river path for separates the first working fluid from a flow path for the second working fluid, and a second corrugated metal sheet between the pair of spikes the first corrugated sheet is arranged.

In further embodiments the invention gives a heat exchanger a first sheet that is contoured to a plurality of first ribs to define, and an upper end and a lower one End has; a second sheet that is contoured to a variety define from second ribs, and between the upper end and the lower end of the first sheet is arranged; and a case that is formed of a third sheet, and at least partially surrounding the first sheet and the second sheet.

The The present invention further provides a method of mounting a heat exchanger which includes the following steps: waves of a first sheet to define a pair of peaks and at least partially one River path for a first working fluid and a flow path for a second working fluid define; Waves of a second sheet; and inserting the second sheet in the first sheet between the pair of tips and along the river path for the second working fluid.

Other Aspects of the invention will become apparent from the following detailed Description and attached Drawings clarified.

Summary the drawings

1 FIG. 13 is a partial exploded perspective view of a portion of a heat exchanger according to some embodiments of the present invention. FIG.

2 is a partially broken perspective view of the heat exchanger of 1 ,

3 is a partial exploded perspective view of the heat exchanger of 2 and 2 including a housing.

4 is a perspective view of the heat exchanger of 1 - 3 ,

5 is an end view of the heat exchanger of 1 - 4 ,

Full description

Before in the following embodiments the invention explained in detail It should be noted that the invention in its Application not on the design details and the arrangement of the Limited components is described in the following description and in the Drawings are shown. The invention may be achieved by other embodiments realized and implemented in different ways. Farther It should be noted that the wording used here is descriptive and not restrictive is to be understood. By "containing", "comprising" and "having" is meant to be understood in each case that the related units or equivalent Units in addition can be provided to other units.

So far Unless otherwise specified, "mounted", "connected", "held" and "coupled" are each direct or indirect mounts, connections, brackets and couplings to understand. Furthermore, the terms "connected" and "coupled" are not physical or mechanical Restricted connections or couplings.

The for example, by terms such as "central", "top", "bottom", "front", "rear" and the like The information given should be the description of the present invention clarify, however, do not mean that in connection with it units must have a specific orientation. Farther terms such as "first", "second" and "third" are merely descriptive here and not as statements of relative importance or importance specific.

1 - 5 show a heat exchanger 10 (eg a recuperator) for use in a microturbine and / or a high temperature fuel cell. In other embodiments, the heat exchanger 10 be installed in a vehicle with an internal combustion engine and operated as an exhaust heat recovery system or alternatively as part of an exhaust heat recovery system. In further embodiments, the heat exchanger 10 in oxide fuel cell-based auxiliary power units in vehicles (eg, sports cars, work or industrial vehicles, and the like) and / or used. In further embodiments, the heat exchanger 10 in other applications (eg in non-vehicle applications) such as in electronic refrigerators, industrial equipment, building heating, air conditioning and the like.

In some embodiments, the heat exchanger 10 provide a high heat transfer efficiency with a minimum size and a minimum weight, with a low cost construction by minimizing waste materials, easily accessible joints and connection points for easier repair and localization of leaks or other defects during or after manufacture and / or design without thermal restrictions is made possible. In other embodiments, the heat exchanger 10 include one or more additional features or advantages that will not be described here.

In the embodiment shown of 1 - 5 transfers the heat exchanger 10 Thermal energy from a first working fluid having a high temperature (for example, exhaust gas, water, _CO2, an organic refrigerant, R12, R245fa, air, or the like) to a second working fluid having a low temperature (for example, exhaust gas, water, _CO2, an organic refrigerant, R12 , R245fa, air or similar).

As in 1 - 5 shown, the heat exchanger 10 a core 60 with a first sheet metal or separating plate 12 and a number of second sheets 16 include. In the embodiment of 2 includes the core 60 twenty-one second sheets 16 and a single first sheet 12 , In other embodiments, the core 60 two or more first sheets 12 and one, two, three or more second sheets 16 include.

In the embodiment shown of 1 - 5 is the first sheet 12 Contours and includes a number of ribs, points or waves 22 and a number of channels 14 that between the tips 22 are arranged. In addition, each of the second sheets 16 Contours and includes a number of ribs, points or waves 26 and a number of channels 28 ,

In the embodiment shown, each of the tips 22 of the first sheet 12 and each of the tips 26 the second sheets 16 a substantially rounded end during each of the channels 14 of the first sheet 12 and each of the channels 28 the second sheets 16 has a correspondingly rounded cross-section. In other embodiments, the tips may 22 and / or channels 14 of the first sheet 12 and / or the tips 26 and the channels 28 the second sheets 16 tapered, square or irregular shaped. In further embodiments, the first sheet may 12 and / or the second sheets 16 essentially have a sawtooth shape. In further embodiments, adjacent peaks may be used 22 and / or channels 14 of the first sheet 12 and / or adjacent peaks 26 and / or channels 28 the second sheets 16 have different shapes.

In some embodiments, the tips may 22 and the channels 14 be shaped by the first sheet 12 folded or curled, and can the tips 26 and the channels 28 be formed by the second sheets 16 folded or curled. In further embodiments, the first sheet may 12 and / or the second sheets 16 cast or molded into a desired shape.

The first sheet 12 and / or the second sheets 16 may be made of one or more materials suitable for operation in a high temperature heat exchanger. In some embodiments, the first sheet may 12 and the second sheets 16 made of an alloy with a high nickel content. In some embodiments, the first sheet may 12 and the second sheets 16 be formed of materials having substantially the same or substantially similar thermal expansion coefficient. In other embodiments, the first sheet may 12 and / or the second sheets 16 made of other materials (eg aluminum, iron and other metals, composites and the like).

As in 1 - 5 shown, the second sheets can 16 in the channels 14 of the first sheet 12 between the top and bottom ends of the tips 22 of the first sheet 12 be positioned. In some embodiments, the second sheets may 16 in the channels 14 between alternating pairs of peaks 22 of the first sheet 12 be positioned. In other embodiments, the second sheets may 16 with regular or irregular intervals between the pairs of peaks 22 of the first sheet 12 be positioned.

In the embodiment of 1 - 5 are the second sheets 16 thinner than the first sheet 12 , In other embodiments, each of the second sheets may 16 have a different thickness. Alternatively or additionally, one or more of the second sheets may be used 16 have a thickness greater than or substantially equal to the thickness of the first sheet 12 is the mass flow rate of the first working fluid through the heat exchanger, depending on the flow characteristics (eg, flow rate, temperature, pressure, etc.) of the first working fluid and / or the second working fluid, the selected first working fluid 10 , the selected second working fluid, the mass flow rate of the second working fluid through the heat exchanger 10 and the like.

In some embodiments, surface folds may be along the inner or outer surface of one or more of the second sheets 16 be formed. In some such embodiments, the surface folds may include slots, lances, humps, channels, pits, ribs, etc. In other embodiments, surface folds may be along the inner or outer surfaces of the first sheet 12 be formed. In these embodiments, the surface folds may increase the stiffness or strength of the core 60 increase, the heat transfer rate between the first working fluid and the second working fluid and / or improve the efficiency of the heat exchanger 10 improve. By increasing the efficiency of the heat exchanger 10 is improved, the inclusion of such surface folds may additionally or alternatively the effective operation of the heat exchanger 10 ensure and at the same time that for the manufacture of the heat exchanger 10 Minimize required amount of material.

As in 1 and 2 shown, the first sheet can 12 and the second sheets 16 be dimensioned such that the corrugation height h of the second sheets 16 essentially the distance d between adjacent peaks 22 of the first sheet 12 corresponds (ie the width of the channels 14 of the first sheet 12 ). In this way, the second sheets can 16 reliable between adjacent peaks 22 of the first sheet 12 be inserted.

In some embodiments, such as in the embodiment of FIG 1 - 5 can the width W of the first sheet 12 be greater than the width w of the second sheets 16 making a non-ribbed section 20 . 21 on both sides of the second sheet 16 within the channel 14 of the first sheet 12 is provided. In other embodiments, the width W of the first sheet may be 12 less than or substantially equal to the width w of one or more of the second sheets 16 so there are no un-ribbed sections along one or more of the channels 14 of the first sheet 12 are provided. In these embodiments, the second sheets may 16 a structural hold and rigidity for the core 60 provide. In embodiments in which the pressure of the first or second working fluid is substantially greater than the pressure of the other working fluid, the additional structural support and rigidity provided by the second laminations 16 be provided, wear or damage to the core 60 prevent or reduce. In other embodiments, the non-ribbed portions 20 . 21 at only one end of one or more of the channels 14 of the first sheet 12 arranged.

In some embodiments, one or more of the second sheets may 16 on the first sheet 12 between adjacent peaks 22 of the first sheet 12 be fastened in some such Embodiments are the tips 26 the second sheets 16 with the first sheet 12 connected (eg welded, soldered, brazed, etc.). In other embodiments, the second sheets may 16 in the channels 14 for a movement relative to the first sheet 12 can be held or alternatively, the second sheets 16 otherwise with the first sheet 12 be joined, for example by a press fit, by gluing, using fasteners, etc.

As in 1 - 5 shown, the heat exchanger 10 additionally or alternatively, a housing or, a shell 50 include. In some embodiments, the housing may 50 from a third sheet 30 be trained, that around two or three sides of the core 60 is bent. Alternatively or additionally, the third sheet 30 tabs 32 which may be curved or shaped to extend over one or more of the channels 14 (ie the upwardly opening channels 14 from 5 ) of the first sheet 12 can extend. As in 1 - 5 shown, the tabs can 32 over opposite ends of alternating channels 14 of the first sheet 12 extend. In other embodiments, the tabs may be 32 over one or both ends of adjacent channels 14 extend. In some embodiments with tabs 32 can the tabs 32 on the first sheet 12 fastened (ie welded, brazed, brazed, etc.) to the ends of the channels 14 to dense or substantially to seal. In other embodiments, the tabs 32 otherwise with the first sheet 12 be connected, for example by a press fit, by gluing, using fasteners, etc.

In some embodiments, such as the embodiment of FIG 1 - 5 can be an area 36 of the third sheet 30 at the tips 22 of the first sheet 12 be attached. Alternatively or additionally, ends of the third sheet 30 flanges 40 Define outward over sidewalls 42 of the core 60 can extend. In the embodiment of 1 - 5 the flanges extend 40 over front and rear tips 22 of the first sheet 12 so the third sheet 30 at least partially the core 60 includes.

In some embodiments, such as the embodiment of FIG 1 - 5 can the heat exchanger 10 a first flow path (indicated by the arrows 62 in 4 reproduced) for the first working fluid and a second flow path (by the arrows 64 in 3 reproduced) for the second working fluid. In the embodiment of 1 - 5 is the heat exchanger 10 configured as a heat exchanger with a single pass, wherein the first working fluid along the first flow path 62 by at least one of a plurality of channels 14 (ie through the downwardly opening channels 14 from 1 - 5 ) in the first sheet 12 and wherein the second working fluid is along the second flow path 64 by at least one of a plurality of channels 14 (ie through the channels opening upwards 14 from 1 - 5 ) in the first sheet 12 passes. In these embodiments, the first sheet may 12 the first and second flow paths 62 . 64 separate from each other and prevent mixing of the first and second working fluids.

In other embodiments, the heat exchanger 10 be configured as a heat exchanger with multiple passages, wherein the first working fluid in a first passage through one or more of the channels 14 passes through and then in a second pass through one or more other channels 14 in a direction opposite to the flow direction of the first working fluid in the first passage. In these embodiments, the second working fluid may flow along the second flow path 64 by at least one of a plurality of other channels 14 pass.

In further embodiments, the heat exchanger 10 be configured as a heat exchanger with multiple passages wherein the second working fluid in a first passage through one or more of the channels 14 passes through and then in a second pass through one or more other channels 14 in a direction opposite to the direction of flow of the second working fluid in the first passage. In these embodiments, the first working fluid may be along the first flowpath 62 by at least one of a plurality of other channels 14 pass.

In further embodiments, the heat exchanger 10 be configured as a heat exchanger with multiple passages, wherein the first working fluid more than two consecutive passes through the heat exchanger 10 power. In other embodiments, the heat exchanger 10 be configured as a heat exchanger with multiple passages, wherein the second working fluid more than two consecutive passes through the heat exchanger 10 power.

As in 1 - 5 shown, the first and the second flow path 62 . 64 be in opposite directions. In other embodiments, the first and second flow paths 62 . 64 to be essentially parallel.

In embodiments such as those of 1 - 5 with a first river path 62 and egg a second flow path 64 can the case 50 a first inlet 41 and a first outlet 43 for the first river path 62 define. As in 1 - 5 shown, the housing can 50 Alternatively, also a second inlet 44 for the second river path 64 and a second outlet 45 for the second river path 64 define.

In the embodiment shown of 1 - 5 are connecting parts 56 . 58 on the housing 50 around the second inlet 44 and the second outlet 45 attached around. In some embodiments, the housing may 50 Include connecting parts adjacent to the first inlet 41 and / or the first outlet 43 are arranged to prevent the first or the second working fluid from the core 60 or part of the core 60 bypass. In some embodiments, the connectors see 56 . 58 the only contact points between the core 60 and the housing 50 to minimize or prevent unwanted heat transfer and to ensure that the core 60 remains thermally relaxed. Additionally, in some embodiments, the housing may 50 and / or the core 60 comprise an insulating and / or refractive material to further minimize and / or prevent unwanted heat transfer.

As in 1 - 5 shown during the operation of the heat exchanger 10 the first working fluid along the first flow path 62 through the first inlet 41 into an inlet of one or more channels 14 (ie from one or more of the downwardly opening channels 14 from 1 - 5 ) in the neighborhood of the first page 52 of the first sheet 12 , through the second sheet 16 in the channel (s) 14 and through the first outlet 43 in the neighborhood of the second page 54 of the first sheet 12 going out.

As continues in 1 - 5 shown, the working fluid along the second flow path 64 through the second inlet 44 and in one or more of the channels 14 (ie one or more of the upwardly opening channels 14 from 1 - 5 ), through a first non-ribbed section 20 of the channel (s) 14 , along the second sheet 16 in the channel (s) 14 through the second non-ribbed section 21 of the channel (s) 14 and from the second outlet 45 going out.

In the embodiment of 1 - 5 is the temperature of the first working fluid at the first inlet 41 greater than the temperature of the second working fluid at the second inlet 44 wherein heat energy is transferred from the first working fluid to the second working fluid. Because the first river path 62 is substantially linear, the impact of the flow of the first working fluid through the core 60 be minimized.

During assembly, the first sheet 12 and one or more of the second sheets 16 contoured. The second sheets 16 then be in the channels 14 between through the first sheet 12 formed tips 22 introduced. The third sheet 30 will then be the first sheet 12 fitted to the first sheet 12 and the second sheets 16 at least partially enclose. In some embodiments, the second sheets may 16 and the third sheet 30 in a single operation on the first sheet 12 be fixed (eg welded, soldered, brazed, etc.). In some such embodiments, the tabs may 32 in the same operation additionally or alternatively at the ends 52 . 54 of the first sheet 12 be attached.

In some embodiments, as in the embodiment shown, in which the core 60 from a single first sheet 12 and one or more second sheets 16 is formed and in which the housing 50 from a third sheet 30 is formed, the cost of materials can be minimized. In such embodiments, little or no waste material is generated during the manufacture of the heat exchanger 10 generated.

In the embodiment shown of 1 - 5 are the only connection points used to prevent cross leakage between the first flow path 62 and the second flow path 64 are required, between the edges of the tabs 32 and the contoured surface of the first sheet 12 intended. In some such embodiments, during manufacture of the heat exchanger 10 Simply access these connection points, thereby identifying and maintaining leaks in the heat exchanger 10 is simplified.

Further Features and advantages of the invention will become apparent from the following claims.

Claims (34)

A heat exchanger for transferring heat energy between a first working fluid and a second working fluid, the heat exchanger comprising: a pair of first fins formed from a single sheet and at least partially defining a flow path for the first working fluid, and a second fin interposed between is disposed on the pair of first fins and at least partially defines a flow path for the second working fluid, wherein the flow path of the first working fluid of the Flow path of the second working fluid is separated. heat exchangers according to claim 1, wherein the flow direction of the first working fluid through the heat exchanger essentially counter to the flow direction of the second working fluid is set. heat exchangers according to claim 1, wherein the second rib of a corrugated sheet is trained. heat exchangers according to claim 3, wherein the pair of first ribs through along the sheet formed waves is provided. heat exchangers according to claim 1, wherein an end of the second rib on one of the Pair of first ribs is attached and the other end of the second Rib attached to another of the pair of first ribs is. heat exchangers according to claim 1, wherein a pair of second ribs along the flow path the second working fluid is positioned, wherein the second rib one is from the pair of second ribs. heat exchangers according to claim 6, wherein the pair of second ribs consists of a single Sheet metal is formed. heat exchangers according to claim 7, wherein the pair of second ribs through along the sheet formed waves is provided. heat exchangers according to claim 7, wherein the pair of first ribs has an upper and has a lower end and wherein the second plate between the upper end and the lower end of the pair of first ribs arranged is. heat exchangers according to claim 1, wherein the pair of first ribs of a first corrugated metal sheet is formed, wherein the second rib of a second corrugated sheet is formed and wherein a housing a third plate is formed, wherein the housing at least partially surrounds the first sheet and the second sheet. heat exchangers according to claim 10, wherein the first sheet and the third sheet the River path for substantially enclose the first working fluid and wherein the first sheet, the second plate and the third plate together at least partially River path for enclose the second working fluid. heat exchangers according to claim 10, wherein the second sheet in the first sheet between is inserted in the pair of first ribs. heat exchangers to transfer of heat energy between a first working fluid and a second working fluid, the heat exchanger includes: a first corrugated sheet having a pair of tips and a river path for separates the first working fluid from a flow path for the second working fluid, and a second corrugated metal sheet between the pair of Tips of the first corrugated sheet is arranged. heat exchangers according to claim 13, wherein the flow direction of the first working fluid along the flow path substantially the flow direction of the second Working fluid along the river path is set against. heat exchangers according to claim 13, wherein the second plate has a pair of tips and wherein the pair of tips of the second sheet at one of the Pair of tips of the first sheet is fastened. heat exchangers according to claim 13, wherein a side of the second sheet at one of The pair of tips of the first sheet is attached and another one Side of the second sheet at the other from the pair of spikes the first sheet is attached. heat exchangers according to claim 13, wherein the first layer has a lower end, wherein the pair of tips of the first layer provide an upper end and wherein the second plate between the upper end and the lower End of the first sheet is arranged. heat exchangers according to claim 13, wherein a housing is formed of a third plate, wherein the housing at least partially surrounds the first sheet and the second sheet. heat exchangers according to claim 18, wherein the first sheet and the third sheet in the essentially the river path for enclose the first working fluid and wherein the first sheet, the second sheet and the third sheet are common at least partially enclose the flow path for the second working fluid. heat exchangers according to claim 13, wherein the second sheet in the first sheet between is inserted in the pair of tips of the first sheet. A method of mounting a heat exchanger, the method comprising the steps of: shafts of a first sheet to define a pair of tips and at least partially define a flow path for a first working fluid and a flow path for a second working fluid; Shafts of a second sheet, and inserting the second sheet into the first sheet between the pair of tips and along the flow path for the second working fluid. The method of claim 21, wherein inserting the attaching a second sheet between the pair of tips End of the second sheet at one of the pair of tips of the first sheet and the other end of the second sheet at the other of the Pair of tips of the first sheet covers. The method of claim 21, further comprising attaching a third sheet at the tips of the first sheet to to at least partially enclose the first flow path. The method of claim 23, wherein attaching the third sheet at the tips of the first sheet at least partially enclosing of the second flow path between the tips of the first sheet and of the third sheet. The method of claim 21, wherein the waves of the first sheet defining a second pair of tips and Continue to wave a third sheet and insert the third sheet in the first sheet between the second pair of Includes peaks. The method of claim 21, wherein inserting the second sheet between the pair of tips positioning the second sheet between an upper end and a lower end of the first sheet comprises. heat exchangers to transfer of heat energy between a first working fluid and a second working fluid, the heat exchanger includes: a first sheet that is contoured to a variety of to define first ribs, and upper and lower ends having, a second sheet that is contoured to a variety of define second ribs, and between the upper end and the lower end of the first sheet is arranged, and a case that is formed from a third sheet and at least partially surrounding the first sheet and the second sheet. heat exchangers according to claim 27, wherein the housing an inlet and an outlet for a flow path for the first Working fluid and an inlet and an outlet for one River path for defines the second working fluid. heat exchangers according to claim 28, wherein the second sheet along the flow path of the second working fluid is arranged. heat exchangers according to claim 28, wherein the flow direction of the first working fluid the flow direction of the second working fluid substantially opposite is set. heat exchangers according to claim 27, wherein the second sheet in the first plate between two of the plurality of first sheets is inserted. heat exchangers according to claim 27, wherein the plurality of first ribs through along Shafts formed of the first sheet are provided. heat exchangers according to claim 27, wherein a side of the first sheet at one of The variety of first ribs is attached and another side of the second sheet at another of the plurality of first Ribs is attached. heat exchangers according to claim 27, wherein the plurality of second ribs through along the second sheet formed waves are provided.