Heat exchanger with an integrated temperature manipulation element   

Abstract: A heat exchanger includes a plurality of plates in stacked relation forming a plurality of fluid channels therebetween. Ports formed in each of the plates are arranged and substantially align to form an inlet manifold and an outlet manifold for receiving a working fluid therein, wherein the inlet manifold is in fluid communication with an inlet conduit and the outlet manifold is in fluid communication with an outlet conduit. A temperature manipulation element is disposed in at least one of the inlet conduit and the outlet conduit to manipulate a temperature of the working fluid flowing therethrough.

FIELD OF THE INVENTION

The present invention relates to a heat exchanger. More particularly, the invention is directed to a chiller heat exchanger having at least one temperature manipulation element integrated into at least one of a fluid inlet conduit and a fluid outlet conduit.

BACKGROUND OF THE INVENTION

Plate-type heat exchangers are used to transfer thermal energy between heat exchange working fluids. At least two heat exchange working fluid streams flow through separate flow passages defined between heat exchanger plates in the plate-type heat exchanger. Usually, the heat exchanger plates are arranged in a stacked relation, forming a part of the plate-type heat exchanger. The separate flow passages are defined by ports formed in the heat exchanger plates and flow channels formed between the heat exchanger plates.

Heat transfer between the working fluid streams occurs in the area of a central heat transfer portion of the heat exchanger plates. To transfer thermal energy, a first working fluid stream flows through the ports on one side of the heat exchanger into a plurality of first flow channels formed by alternating heat exchanger plates. Simultaneously, a second working fluid stream flows through the ports on an opposite side of the heat exchanger into a plurality of second flow channels also formed by the alternating heat exchanger plates and separate from the first flow channels. Thus, heat is exchanged between the two working fluid streams counter flowing through the heat exchanger.

One such type of plate-type heat exchanger is a chiller heat exchanger. The chiller heat exchanger typically is used to cool the working fluids flowing through the chiller heat exchanger from a heat source such as an engine, a motor, or a battery of a vehicle, for example. However, in certain cold climates it is desirable to heat the working fluids flowing from the heat source as well. Currently, the working fluids are heated by either separate heating elements located in the fluid system architecture remote from the chiller heat exchanger or by heating elements disposed within a body of the heat exchanger.

It would be desirable to develop a heat exchanger having a temperature manipulation element integrated into a fluid conduit thereof, which manipulates a temperature of a working fluid while minimizing cost and maximizing manufacturability of the heat exchanger, regardless of the conduit orientation, working fluid flow circuitry, or heat exchanger size.

SUMMARY

In concordance and agreement with the present invention, a heat exchanger having a temperature manipulation element integrated into a fluid conduit thereof, which manipulates a temperature of a working fluid while minimizing cost and maximizing manufacturability, has surprisingly been discovered.

In one embodiment, the heat exchanger comprises: a plurality of plates in stacked relation forming a plurality of first fluid flow channels and a plurality of second fluid flow channels therebetween, the plates having at least one first port formed therein in fluid communication with the first fluid flow channels and at least one second port formed therein in fluid communication with the second fluid flow channels, wherein the at least one first port of one of the plates substantially aligns with the at least one first port of another of the plates to form a first manifold for receiving a first working fluid therein and the at least one second port of one of the plates substantially aligns with the at least one second port of another of the plates to form a second manifold for receiving a second working fluid therein; a first conduit in fluid communication with the first manifold for receiving the first working fluid therein; a second conduit in fluid communication with the second manifold for receiving the second working fluid therein; and a temperature manipulation element disposed in at least one of the first conduit and the second conduit to manipulate a temperature of the respective working fluid flowing through the at least one of the first conduit and the second conduit.

In another embodiment, the heat exchanger comprises: a plurality of end plates, wherein at least one of the end plates includes a plurality of first ports formed therein and a plurality of second ports formed therein; a plurality of interior plates disposed between the end plates in stacked relation forming a plurality of first fluid flow channels and a plurality of second fluid flow channels therebetween, the interior plates having a plurality of first ports formed therein in fluid communication with the first fluid flow channels and a plurality of second ports formed therein in fluid communication with the second fluid flow channels, wherein the first ports of each of the plates substantially align to form an inlet manifold and an outlet manifold for receiving the first working fluid therein, and wherein the second ports of each of the plates substantially align to form an inlet manifold and an outlet manifold for receiving the second working fluid therein; a first inlet conduit in fluid communication with the inlet manifold for receiving the first working fluid therein; a first outlet conduit in fluid communication with the outlet manifold for receiving the first working fluid therein; a second inlet conduit in fluid communication with the inlet manifold for receiving the second working fluid therein; a second outlet conduit in fluid communication with the outlet manifold for receiving the second working fluid therein; and a temperature manipulation element disposed in at least one of the first inlet conduit, the first outlet conduit, the second inlet conduit, and the second outlet conduit to manipulate a temperature of the respective working fluid flowing through the at least one of the first inlet conduit, the first outlet conduit, the second inlet conduit, and the second outlet conduit.

In another embodiment, the heat exchanger comprises: a plurality of first plates including a pair of first ports and a pair of second ports formed therein; a plurality of second plates disposed adjacent the first plates in an alternating pattern to form a plurality of first fluid flow channels and a plurality of second fluid flow channels therebetween, wherein each of the first fluid flow channels receives a first working fluid therein and each of the second fluid flow channels receives a second working fluid therein, and wherein each of the second plates includes a pair of first ports and a pair of second ports formed therein, and wherein the first ports of each of the plates substantially align to form an inlet manifold and an outlet manifold for receiving the first working fluid therein, and wherein the second ports of each of the plates substantially align to form an inlet manifold and an outlet manifold for receiving the second working fluid therein; a first inlet conduit in fluid communication with the inlet manifold for receiving the first working fluid therein; a first outlet conduit in fluid communication with the outlet manifold for receiving the first working fluid therein; a second inlet conduit in fluid communication with the inlet manifold for receiving the second working fluid therein; a second outlet conduit in fluid communication with the outlet manifold for receiving the second working fluid therein; and at least one temperature manipulation element disposed in the second inlet conduit and the second outlet conduit to manipulate a temperature of the second working fluid flowing through the conduits.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiment when considered in the light of the accompanying drawings in which:

FIG. 1 is a top perspective schematic view of a heat exchanger according to an embodiment of the invention; and

FIG. 2 is a cross-sectional side elevational view of the heat exchanger illustrated in FIG. 1 taken along line 2-2 thereof.

DETAILED DESCRIPTION

The following detailed description and appended drawings describe and illustrate an exemplary embodiment of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

FIGS. 1-2 show a heat exchanger 10 according to an embodiment of the present invention. The heat exchanger 10 shown is a chiller heat exchanger, however, it is understood that the heat exchanger 10 can be any type of heat exchanger used for any desired application such as automotive, commercial, residential, marine, aeronautical, and recreational vehicle applications, for example. The heat exchanger 10 includes a corner plate 16 and a plurality of interior plates 18a, 18b disposed between a pair of end plates 19, 20 in stacked relation. Additional or fewer plates than shown can be employed as desired such as spacer plates or transfer plates, for example.

As illustrated, the corner plate 16 and the end plates 19, 20 have a greater thickness than the interior plates 18a, 18b to provide structural rigidity to the heat exchanger 10. The plates 16, 18a, 18b, 19, 20 are affixed around outer peripheries thereof in a substantially fluid-tight manner. It is understood that the plates 16, 18a, 18b, 19, 20 can be affixed by any suitable means as desired such as by brazing, soldering, welding, use of gasket, and the like, for example. Each of the plates 18a, 18b, 19, 20 shown has an upwardly and outwardly extending peripheral skirt portion 21 to facilitate a nesting of adjacent plates 18a, 18b, 19, 20 in the stack and maximize a sealing therebetween.

In the embodiment shown, the plates 16, 18a, 18b, 19, 20 have a generally rectangular shape, although it is understood that the plates 16, 18a, 18b, 19, 20 can have any shape and size as desired. It is further understood that the plates 16, 18a, 18b, 19, 29 can be formed from any suitable material such as a metal material, for example. A width and a length of the heat exchanger 10 shown depends on the shape and size of the plates 18a, 18b, 19, 20 and a height of the heat exchanger 10 depends upon the number of plates 18a, 18b, 19, 20 in the stack. The number of interior plates 18a, 18b in the stack is determined based on a desired cooling, heating, and flow capacity of the heat exchanger 10. The heat exchanger 10 illustrated includes twenty-four (24) interior plates 18a, 18b. It is understood, however, additional or fewer interior plates 18a, 18b than shown can be employed if desired.

As illustrated in FIG. 2, the interior plates 18a are disposed adjacent the interior plates 18b in an alternating pattern. The corner plate 16 is disposed adjacent the end plate 20. It is understood that the corner plate 16 can be disposed adjacent one of the interior plates 18a, 18b or the end plate 19 if desired. A plurality of flow channels 22a, 22b is formed between the alternating interior plates 18a, 18b and between the end plate 20 and the interior plate 18b. A first working fluid (not shown) is received in the flow channels 22a. A second working fluid (not shown) is received in the flow channels 22b. The working fluids can be any working fluids as desired such as any fluid used in an automotive application, a refrigerant (e.g. R12, R134a, etc.), a coolant (e.g. ethyl glycol), an engine oil, a transmission oil, a power-steering fluid, and the like, for example. In a non-limiting example, the first working fluid is a refrigerant and the second working fluid is an engine or battery coolant.

Surface irregularities 24 formed in the interior plates 18a, 18b contact the adjacent interior plates 18a, 18b or at least one of the end plates 19, 20, creating a plurality of non-linear flow paths within the flow channels 22a, 22b to maximize heat transfer between the working fluids. It is understood that the surface irregularities 24 can have any shape and size as desired.

Each of the plates 18a, 18b, 20 further includes a pair of first working fluid ports 30, 32 and a pair of second working fluid ports 34, 36. It is understood that the end plate 19 can have working fluid ports formed therein, if desired. The first working fluid ports 30, 32 of each of the plates 18a, 18b, 20 are arranged and substantially aligned to form an inlet manifold 40 and an outlet manifold 42, respectively. The first working fluid inlet manifold 40 permits the first working fluid to flow into the flow channels 22a and the first working fluid outlet manifold 42 permits the first working fluid to flow from the flow channels 22a. An inlet conduit 50 is coupled to the heat exchanger 10 and in fluid communication with the first working fluid inlet manifold 40 to permit the first working fluid to flow into the heat exchanger 10. An outlet conduit 52 is coupled to the heat exchanger 10 and in fluid communication with the first working fluid outlet manifold 42 to permit the first working fluid to flow from the heat exchanger 10. As illustrated, the conduits 50, 52 are received in respective openings formed in the corner plate 16 to form a fluid-tight connection therebetween. It is understood that the conduits 50, 52 can be coupled to the corner plate 16 or one of the end plates 19, 20 by any means as desired such as by brazing, soldering, welding, use of gasket, and the like, for example.

The second working fluid ports 34 of each of the plates 18a, 18b, 20 are arranged and substantially aligned to form a second working fluid inlet manifold 54. The second working fluid inlet manifold 54 permits the second working fluid to flow into the flow channels 22b. The second working fluid ports 36 of each of the plates 16, 18a, 18b, 20 are arranged and substantially aligned to form a second working fluid outlet manifold 56. The second working fluid outlet manifold 56 permits the second working fluid to flow from the flow channels 22b. An inlet conduit 58 is coupled to the heat exchanger 10 and in fluid communication with the second working fluid inlet manifold 54 to permit the second working fluid to flow into the heat exchanger 10. An outlet conduit 60 is coupled to the heat exchanger 10 and in fluid communication with the second working fluid outlet manifold 56 to permit the second working fluid to flow from the heat exchanger 10. It is understood that the conduits 50, 52, 58, 60 can be coupled to the heat exchanger 10 by any suitable means such as brazing, soldering, welding, use of a gasket, and the like, for example. It is further understood that the conduits 50, 52, 58, 60 can be formed from any suitable material such as a metal material or a plastic material, for example. As illustrated, the conduits 50, 52, 58, 60 extend laterally outwardly from one side of the heat exchanger 10. It is understood, however, that each of the conduits 50, 52, 58, 60 can formed to extend from any side of the heat exchanger 10 in any direction and configuration as desired.

In the embodiment shown, a temperature manipulation element 70 is disposed in each of the inlet conduit 58 and the outlet conduit 60 for the second working fluid. Additional or fewer temperature manipulation elements 70 than shown can be employed if desired such as a temperature manipulation element 70 disposed in each of the conduits 50, 52, 58, 60, two or more temperature manipulation elements 70 disposed in at least one of the conduits 50, 52, 58, 60, or one temperature manipulation element 70 disposed in only one of the conduits 50, 52, 58, 60, for example. As illustrated, the temperature manipulation element 70 is disposed in the conduits 58, 60 at a position substantially perpendicular to a direction of flow of the second working fluid through the conduits 58, 60. It is understood, however, that the temperature manipulation element 70 can be disposed in the conduits 50, 52, 58, 60 at any position as desired such as at a position substantially perpendicular to a direction of flow of the first working fluid through the conduits 50, 52, a position substantially parallel to the direction of flow of the working fluids through the conduits 50, 52, 58, 60 or at an intermediate position between substantially perpendicular and substantially parallel to the direction of flow of the working fluids through the conduits 50, 52, 58, 60, for example.

The temperature manipulation element 70 shown is a heating element such as a positive thermal coefficient (PTC) or a glow plug, for example. It is understood that the temperature manipulation element 70 can be any temperature manipulation element 70 as desired such as other heating elements or a cooling element if desired. In the embodiment shown, the temperature manipulation elements 70 are coupled to the conduits 58, 60 by a threaded engagement 72 forming a substantially fluid-tight connection therebetween. It is understood, however, that the temperature manipulation elements 70 can be coupled to the conduits 50, 52, 58, 60 by any means to form a fluid-tight connection as desired such as by brazing, soldering, welding, use of fasteners, and the like, for example. Gaskets (not shown) may also be employed to facilitate the formation of the fluid-tight connection if desired.

In operation, the first working fluid flows to the heat exchanger 10 through the inlet conduit 50 and into the inlet manifold 40 for the first working fluid. The first working fluid then flows into the flow channels 22a formed between the alternating plates 18a, 18b. As the first working fluid travels through the flow paths of the flow channels 22a, the first working fluid flows around the surface irregularities 24 formed in the plates 18a, 18b, which cause the first working fluid to be turbulated. Thereafter, the first working fluid flows from the flow channels 22a through the outlet manifold 42 and into the outlet conduit 52 out of the heat exchanger 10.

Simultaneously, the second working fluid flows to the heat exchanger 10 through the inlet conduit 58 and into the inlet manifold 54 for the second working fluid. The second working fluid then flows into the flow channels 22b formed between the alternating plates 18a, 18b. As the second working fluid travels through the flow paths of the flow channels 22b, the second working fluid flows around the surface irregularities 24 formed in the plates 18a, 18b, which cause the second working fluid to be turbulated. Typically, heat is transferred from the second working fluid to the first working fluid. It is understood, however, that in certain applications of the heat exchanger 10 such as in use in cold climates, for example, heat can be transferred from the first working fluid to the second working fluid if desired. Thereafter, the second working fluid flows from the flow channels 22b through the outlet manifold 56 and into the outlet conduit 60 out of the heat exchanger 10.

When a temperature of the second working fluid flowing through the inlet conduit 58 into the heat exchanger 10 is above or below a desired temperature, the temperature manipulation element 70 disposed in the inlet conduit 58 is either activated or deactivated. In the embodiment shown, the temperature manipulation element 70 is a heating element and is activated when the temperature of the second working fluid flowing through the inlet conduit 58 is below the desired temperature. Accordingly, the temperature manipulation element 70 in the inlet conduit 58 operates to heat the second working fluid flowing through the inlet conduit 58 until the desired temperature is reached. Once the desired temperature is reached, the temperature manipulation element 70 is then deactivated. It is understood, however, that the temperature manipulation element 70 can be used to maintain the temperature of the second working fluid flowing through the inlet conduit 58 at the desired temperature if desired. Additional temperature manipulation elements 70 disposed in the inlet conduit 58 minimize a time required to reach the desired temperature. When the temperature manipulation element 70 is a heating element that has been activated and the temperature of the second working fluid flowing through the inlet conduit 58 is above the desired temperature, the temperature manipulation element 70 is deactivated.

When a temperature of the second working fluid flowing through the outlet conduit 60 from the heat exchanger 10 is above or below a desired temperature, the temperature manipulation element 70 disposed in the outlet conduit 60 is either activated or deactivated. In the embodiment shown, the temperature manipulation element 70 is a heating element and is activated when the temperature of the second working fluid flowing through the outlet conduit 60 is below the desired temperature. Accordingly, the temperature manipulation element 70 in the outlet conduit 60 operates to heat the second working fluid flowing through the outlet conduit 60 until the desired temperature is reached. Once the desired temperature is reached, the temperature manipulation element 70 is then deactivated. It is understood, however, that the temperature manipulation element 70 can be used to maintain the temperature of the second working fluid flowing through the outlet conduit 60 at the desired temperature if desired. Additional temperature manipulation elements 70 disposed in the outlet conduit 60 minimize a time required to reach the desired temperature. When the temperature manipulation element 70 is a heating element that has been activated and the temperature of the second working fluid flowing through the outlet conduit 60 is above the desired temperature, the temperature manipulation element 70 is deactivated.

In another embodiment of the invention, the temperature manipulation element 70 disposed in the inlet conduit 58 is a cooling element and is activated when the temperature of the second working fluid flowing through the inlet conduit 58 is above the desired temperature. Accordingly, the temperature manipulation element 70 in the inlet conduit 58 operates to cool the second working fluid flowing through the inlet conduit 58 until the desired temperature is reached. Once the desired temperature is reached, the temperature manipulation element 70 is then deactivated. It is understood, however, that the temperature manipulation element 70 can be used to maintain the temperature of the second working fluid flowing through the inlet conduit 58 at the desired temperature if desired. Additional temperature manipulation elements 70 disposed in the inlet conduit 58 minimize a time required to reach the desired temperature. When the temperature manipulation element 70 is a cooling element that has been activated and the temperature of the second working fluid flowing through the inlet conduit 58 is below the desired temperature, the temperature manipulation element 70 is deactivated.

In another embodiment of the invention, the temperature manipulation element 70 disposed in the outlet conduit 60 is a cooling element and is activated when the temperature of the second working fluid flowing through the outlet conduit 60 is above the desired temperature. Accordingly, the temperature manipulation element 70 in the outlet conduit 60 operates to cool the second working fluid flowing through the outlet conduit 60 until the desired temperature is reached. Once the desired temperature is reached, the temperature manipulation element 70 is then deactivated. It is understood, however, that the temperature manipulation element 70 can be used to maintain the temperature of the second working fluid flowing through the outlet conduit 60 at the desired temperature if desired. Additional temperature manipulation elements 70 disposed in the outlet conduit 60 minimize a time required to reach the desired temperature. When the temperature manipulation element 70 is a cooling element that has been activated and the temperature of the second working fluid flowing through the outlet conduit 60 is below the desired temperature, the temperature manipulation element 70 is deactivated.

It is understood that the inlet conduit 58 and the outlet conduit 60 can have any combination of temperature manipulation elements 70 disposed therein such as where the temperature manipulation element 70 disposed in the inlet conduit 58 is a heating element and the temperature manipulation element 70 disposed in the outlet conduit 60 is a cooling element, where the temperature manipulation element 70 disposed in the inlet conduit 58 is a cooling element and the temperature manipulation element 70 disposed in the outlet conduit 60 is a heating element, or where one of the temperature manipulation elements 70 disposed in the inlet conduit 58 is a heating element and another of the temperature manipulation elements 70 disposed in the inlet conduit 58 is a cooling element and one of the temperature manipulation elements 70 disposed in the outlet conduit 60 is a heating element and another of the temperature manipulation elements 70 disposed in the outlet conduit 60 is a cooling element, for example.

It is further understood that at least one of the conduits 50, 52 may include at least one temperature manipulation element 70 disposed therein for heating or cooling the first working fluid until a desired temperature thereof is reached.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, make various changes and modifications to the invention to adapt it to various usages and conditions.