US20130081794A1 - Layered core heat exchanger - Google Patents
Layered core heat exchanger Download PDFInfo
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- US20130081794A1 US20130081794A1 US13/628,213 US201213628213A US2013081794A1 US 20130081794 A1 US20130081794 A1 US 20130081794A1 US 201213628213 A US201213628213 A US 201213628213A US 2013081794 A1 US2013081794 A1 US 2013081794A1
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- Prior art keywords
- heat exchanger
- fluid
- flow passage
- fluid flow
- plates
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B29/00—Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
- F02B29/04—Cooling of air intake supply
- F02B29/045—Constructional details of the heat exchangers, e.g. pipes, plates, ribs, insulation, materials, or manufacturing and assembly
- F02B29/0475—Constructional details of the heat exchangers, e.g. pipes, plates, ribs, insulation, materials, or manufacturing and assembly the intake air cooler being combined with another device, e.g. heater, valve, compressor, filter or EGR cooler, or being assembled on a special engine location
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
- F02M26/13—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories
- F02M26/22—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories with coolers in the recirculation passage
- F02M26/29—Constructional details of the coolers, e.g. pipes, plates, ribs, insulation or materials
- F02M26/30—Connections of coolers to other devices, e.g. to valves, heaters, compressors or filters; Coolers characterised by their location on the engine
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
- F02M26/13—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories
- F02M26/22—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories with coolers in the recirculation passage
- F02M26/29—Constructional details of the coolers, e.g. pipes, plates, ribs, insulation or materials
- F02M26/32—Liquid-cooled heat exchangers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M31/00—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture
- F02M31/02—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture for heating
- F02M31/04—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture for heating combustion-air or fuel-air mixture
- F02M31/06—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture for heating combustion-air or fuel-air mixture by hot gases, e.g. by mixing cold and hot air
- F02M31/08—Apparatus for thermally treating combustion-air, fuel, or fuel-air mixture for heating combustion-air or fuel-air mixture by hot gases, e.g. by mixing cold and hot air the gases being exhaust gases
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
- F28D9/0043—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another
- F28D9/005—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another the plates having openings therein for both heat-exchange media
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0093—Multi-circuit heat-exchangers, e.g. integrating different heat exchange sections in the same unit or heat-exchangers for more than two fluids
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0043—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for fuel cells
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
- H01M8/04007—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids related to heat exchange
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
Definitions
- the present invention relates to a layered core heat exchanger for exchanging heat between fluids.
- a layered core heat exchanger is typically formed from a plurality of heat exchanger plates stacked one above the other. Two fluidly separate flow passages are formed between the plates. Each flow passage includes an inlet and an outlet to the heat exchanger for the respective fluid.
- the heat exchanger functions to exchange heat between the two fluids such that a first of the fluids is heated and a second of the fluids is cooled.
- the invention provides a layered core heat exchanger having a first fluid flow passage for receiving a first fluid and a second fluid flow passage for receiving a second fluid.
- the second fluid flow passage is fluidly separate from the first fluid flow passage and in thermal communication with the first fluid flow passage to exchange heat between the first and second fluids.
- the first fluid flow passage comprises two or more flow paths arranged to be fluidly in parallel with one another.
- the second fluid flow passage comprises two or more flow paths arranged to be fluidly in parallel with one another.
- the heat exchanger also includes a third flow passage adjacent a single one of the flow paths of the first fluid flow passage.
- the third flow passage has a lower fluid capacity than the first and second flow passages such that heat is transferred to or from the third flow passage with minimal effect on the total heat transfer between the first and second flow passages.
- the invention provides a layered core heat exchanger formed of a plurality of plates stacked with respect to one another.
- a first flow passage and a second flow passage are formed between the plurality of plates.
- the heat exchanger includes a first inlet and a first outlet for the first flow passage and a second inlet and a second outlet for the second flow passage.
- One of the plurality of plates includes an embossment providing a space between the one of the plurality of plates and another of the plurality of plates.
- a third inlet and a third outlet are formed in fluid communication with the space to provide a third flow passage in thermal communication with one of the first and second flow passages.
- the invention provides a method of manufacturing a heat exchanger including forming a plurality of heat exchanger plates, embossing one of the plurality of heat exchanger plates to form a space, forming an inlet and an outlet in fluid communication with the space, and stacking the plurality of heat exchanger plates to form a heat exchanger.
- FIG. 1 is a perspective view of a layered core heat exchanger according to the invention.
- FIG. 2 is a cross section of the layered core heat exchanger of FIG. 1 illustrating a counterflow arrangement.
- FIG. 3 is a cross section of the layered core heat exchanger of FIG. 1 illustrating a concurrent flow arrangement.
- FIG. 4 is an enlarged view of a portion of the cross section of FIG. 2 .
- FIG. 5 is another enlarged view of a portion of the cross section of FIG. 4 .
- FIG. 1 illustrates a layered core heat exchanger 10 having a mounting plate 12 , an end plate 14 and a plurality of heat exchanger plates 16 forming a primary heat exchanger core 17 .
- the heat exchanger plates 16 are stacked with respect to one another in between the mounting plate 12 and the end plate 14 .
- the edges of the heat exchanger plates 16 overlap adjacent edges of the heat exchanger plates 16 and are connected in the overlapping region, for example by brazing in a fluid-tight manner.
- Formed in each case between two of the adjacent heat exchanger plates 16 are flow paths including a first flow passage 18 for receiving a first fluid and a second flow passage 20 for receiving a second fluid.
- the first and second fluids are different fluids, and in other embodiments, the first and second fluids are the same fluid (e.g., a recuperative preheater).
- FIGS. 2-5 illustrate a cross section of the heat exchanger 10 including the first and second flow passages 18 , 20 .
- the first and second flow passages 18 , 20 are arranged in a counterflow manner and in an alternating fashion.
- the first and second flow passages 18 , 20 are fluidly separate and in thermal communication with each other for exchanging heat between the first fluid and the second fluid.
- the first and second fluids are primary fluids and the heat exchange therebetween is referred to herein as primary heat exchange.
- other arrangements of the first and second flow passages for exchanging heat between the first and second fluids may be employed, such as but not limited to concurrent flow and non-alternating flow passages.
- the heat exchanger 10 includes a first inlet 22 and a first outlet 24 in fluid communication with the first flow passage 18 and a second inlet 26 and a second outlet 28 in fluid communication with the second flow passage 20 .
- the first and second inlets 22 , 26 and first and second outlets 24 , 28 are openings or ports mounted to the end plate 14 for facilitating connection to fluid conduits carrying the first and second fluids to and from the heat exchanger 10 .
- the inlets 22 , 26 and outlets 24 , 28 may be positioned elsewhere on the heat exchanger 10 .
- the end plate 14 includes an embossment 30 projecting away from the heat exchanger plates 16 to form a space 32 between the end plate 14 and an outermost heat exchanger plate 44 of the stacked heat exchanger plates 16 .
- the embossment 30 may encase a secondary heat exchange fin 46 in the space 32 .
- the embossment 30 is formed by embossing the end plate 14 , for example using roller dies or patterned rolls. In other embodiments, the embossment 30 may be formed in the mounting plate 12 , in either or both sides of the primary heat exchanger core 17 , or in multiple such locations.
- a third inlet 34 and a third outlet 36 are formed in the embossment 30 and are in fluid communication with the space 32 .
- First and second ports 38 , 40 are coupled to the embossment 30 at the third inlet 34 and the third outlet 36 , respectively, for facilitating connection to fluid conduits carrying a third fluid to and from the space 32 , thereby forming a third flow passage 42 in the heat exchanger 10 .
- the third fluid is referred to herein as a secondary fluid.
- multiple secondary fluids may be employed, one for each embossment 30 , or a single secondary fluid may be passed through all of the embossments 30 in series.
- the third fluid may be directed through the third flow passage 42 in either direction, i.e., counterflow or concurrent flow with respect to the first fluid in the first flow passage 18 .
- the third fluid flows in a counterflow direction with respect to the first fluid in the first flow passage 18 , i.e., opposite directions.
- FIG. 3 illustrates the third fluid flowing in a concurrent flow direction with respect to the first fluid in the first flow passage 18 , i.e., parallel flow in the same direction.
- the space 32 or third flow passage 42 , is adjacent to and in thermal communication with an outermost flow path of the first flow passage 18 .
- Heat exchange between the third flow passage 42 and the top layer, or outermost heat exchanger plate 44 , of the primary heat exchanger core 17 is referred to herein as secondary heat exchange. Secondary heat exchange occurs between the primary fluids and the secondary fluid(s).
- the heat exchanger core 17 In order to promote high effectiveness heat exchange between the primary fluids, it can be advantageous for the heat exchanger core 17 to include a large number of plates 16 , so that the surface area available for heat transfer is maximized.
- the effectiveness can be defined as the temperature change experienced by that one of the primary fluids having the lowest heat capacity, divided by the difference between the entering temperatures of the two primary fluids.
- the amount of heat gained or lost by the primary fluids to the secondary fluid(s) is small compared to the total heat transferred between the primary fluids.
- This effect is achieved because the flow rates of the primary fluids are substantially higher than the flow rate of the secondary fluid(s), preferably by as much as ten times, and even more preferably by as much as twenty times.
- this effect is achieved because the mass flow of the primary fluids is substantially higher than the mass flow of the secondary fluid(s), preferably by as much as ten times, and even more prefererably by as much as twenty times.
- this effect is achieved because the heat capacity of the primary fluids is substantially higher than the heat capacity of the secondary fluid(s), preferably by as much as five times, and even more prefererably by as much as ten times. In other embodiments, this effect is achieved because the volume of the primary fluids contained in the primary heat exchanger core 17 is substantially higher than the volume of the secondary fluid(s) in the third flow passage 42 , preferably by as much as ten times, and even more prefererably by as much as twenty times.
- the disparity between the secondary fluid(s) and the first primary fluid can allow for suitably effective heat exchange therebetween even though heat is transferred only between the secondary fluid(s) and that portion of the first primary fluid passing through the outermost flow path of the first flow passage 18 .
- the number of plates 16 used to construct the heat exchanger core 17 can be selected in order to achieve a certain heat capacity ratio between the secondary fluid(s) and that portion of the first primary fluid passing through the outermost flow path of the first flow passage 18 .
- the primary fluids are directed through the primary heat exchanger core 17 at flow rates that are significantly higher than a flow rate of the secondary fluid(s).
- the first fluid may include air
- the second fluid may include exhaust, such as a fuel cell exhaust
- the third fluid may include a fuel flow to be supplied to the fuel cell.
- the fuel flow may be a reformate stream from a high-temperature reformer, and the temperature of the fuel flow may be reduced to a suitable fuel cell operating temperature concurrent with the recuperative preheating of the air (to be supplied to the fuel cell cathode).
- the invention eliminates the need for a separate heat exchanger to accomplish a temperature change in the secondary fluid and does not significantly affect the temperatures of the primary fluids, reducing part count and total material weight of the system.
- the invention can be used in other applications as well.
- the invention can function as an exhaust gas recirculation (EGR) cooler, whereby the first fluid includes recirculated exhaust gas from an internal combustion engine and the second fluid includes engine coolant.
- EGR exhaust gas recirculation
- Fuel for the combustion engine can be advantageously preheated by passing through the heat exchanger as the third fluid, thereby being placed into heat transfer relationship with a portion of the recirculated exhaust gas.
- the number of plates 16 can be selected so that the heat capacity ratio of the fuel and said portion of the recirculated exhaust gas limits the achievable effectiveness of the heat exchange therebetween.
- the heat exchanger 10 is formed by providing a plurality of heat exchanger plates stacked on top of one another to form fluid passages between adjacent heat exchanger plates, embossing one of the plurality of heat exchanger plates to form a space, forming an inlet and an outlet in fluid communication with the space, and connecting the heat exchanger plates to form the heat exchanger.
- the heat exchanger 10 is used by passing primary fluids through the primary heat exchanger core 17 at a first set of flow rates to exchange heat with one another, and passing a secondary fluid through the embossment 30 at a second flow rate to exchange heat with the primary fluids.
- the second flow rate is significantly lower than the first set of flow rates.
- the invention provides, among other things, a layered core heat exchanger having primary and secondary heat exchange functions, where the secondary heat exchange function is accomplished with an insignificant effect on the primary heat exchange function.
Abstract
A layered core heat exchanger is provided, and includes first and second fluid flow passages defined by heat exchanger plates stacked one above the other. Fluids passing through the first and second fluid flow passages are in thermal communication with each other through the plates, in order to provide for the exchange of heat between the fluids. A third fluid flow passage is provided adjacent one of the flow paths, and has a lower fluid capacity than the first and second flow passages.
Description
- This application claims priority to U.S. Provisional Application No. 61/541,570, filed Sep. 30, 2011, the entire contents of which are hereby incorporated by reference herein.
- The present invention relates to a layered core heat exchanger for exchanging heat between fluids.
- A layered core heat exchanger is typically formed from a plurality of heat exchanger plates stacked one above the other. Two fluidly separate flow passages are formed between the plates. Each flow passage includes an inlet and an outlet to the heat exchanger for the respective fluid. The heat exchanger functions to exchange heat between the two fluids such that a first of the fluids is heated and a second of the fluids is cooled.
- In some embodiments, the invention provides a layered core heat exchanger having a first fluid flow passage for receiving a first fluid and a second fluid flow passage for receiving a second fluid. The second fluid flow passage is fluidly separate from the first fluid flow passage and in thermal communication with the first fluid flow passage to exchange heat between the first and second fluids. The first fluid flow passage comprises two or more flow paths arranged to be fluidly in parallel with one another. Similarly, the second fluid flow passage comprises two or more flow paths arranged to be fluidly in parallel with one another. The heat exchanger also includes a third flow passage adjacent a single one of the flow paths of the first fluid flow passage. The third flow passage has a lower fluid capacity than the first and second flow passages such that heat is transferred to or from the third flow passage with minimal effect on the total heat transfer between the first and second flow passages.
- In some embodiments, the invention provides a layered core heat exchanger formed of a plurality of plates stacked with respect to one another. A first flow passage and a second flow passage are formed between the plurality of plates. The heat exchanger includes a first inlet and a first outlet for the first flow passage and a second inlet and a second outlet for the second flow passage. One of the plurality of plates includes an embossment providing a space between the one of the plurality of plates and another of the plurality of plates. A third inlet and a third outlet are formed in fluid communication with the space to provide a third flow passage in thermal communication with one of the first and second flow passages.
- In yet another aspect, the invention provides a method of manufacturing a heat exchanger including forming a plurality of heat exchanger plates, embossing one of the plurality of heat exchanger plates to form a space, forming an inlet and an outlet in fluid communication with the space, and stacking the plurality of heat exchanger plates to form a heat exchanger.
- Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
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FIG. 1 is a perspective view of a layered core heat exchanger according to the invention. -
FIG. 2 is a cross section of the layered core heat exchanger ofFIG. 1 illustrating a counterflow arrangement. -
FIG. 3 is a cross section of the layered core heat exchanger ofFIG. 1 illustrating a concurrent flow arrangement. -
FIG. 4 is an enlarged view of a portion of the cross section ofFIG. 2 . -
FIG. 5 is another enlarged view of a portion of the cross section ofFIG. 4 . - Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
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FIG. 1 illustrates a layeredcore heat exchanger 10 having amounting plate 12, anend plate 14 and a plurality ofheat exchanger plates 16 forming a primaryheat exchanger core 17. Theheat exchanger plates 16 are stacked with respect to one another in between themounting plate 12 and theend plate 14. The edges of theheat exchanger plates 16 overlap adjacent edges of theheat exchanger plates 16 and are connected in the overlapping region, for example by brazing in a fluid-tight manner. Formed in each case between two of the adjacentheat exchanger plates 16 are flow paths including afirst flow passage 18 for receiving a first fluid and asecond flow passage 20 for receiving a second fluid. In some embodiments, the first and second fluids are different fluids, and in other embodiments, the first and second fluids are the same fluid (e.g., a recuperative preheater). -
FIGS. 2-5 illustrate a cross section of theheat exchanger 10 including the first andsecond flow passages second flow passages second flow passages - The
heat exchanger 10 includes afirst inlet 22 and afirst outlet 24 in fluid communication with thefirst flow passage 18 and asecond inlet 26 and asecond outlet 28 in fluid communication with thesecond flow passage 20. In the illustrated embodiment, the first andsecond inlets second outlets end plate 14 for facilitating connection to fluid conduits carrying the first and second fluids to and from theheat exchanger 10. In other embodiments, theinlets outlets heat exchanger 10. - The
end plate 14 includes anembossment 30 projecting away from theheat exchanger plates 16 to form aspace 32 between theend plate 14 and an outermostheat exchanger plate 44 of the stackedheat exchanger plates 16. Theembossment 30 may encase a secondaryheat exchange fin 46 in thespace 32. Theembossment 30 is formed by embossing theend plate 14, for example using roller dies or patterned rolls. In other embodiments, theembossment 30 may be formed in themounting plate 12, in either or both sides of the primaryheat exchanger core 17, or in multiple such locations. - A
third inlet 34 and athird outlet 36 are formed in theembossment 30 and are in fluid communication with thespace 32. First andsecond ports embossment 30 at thethird inlet 34 and thethird outlet 36, respectively, for facilitating connection to fluid conduits carrying a third fluid to and from thespace 32, thereby forming athird flow passage 42 in theheat exchanger 10. The third fluid is referred to herein as a secondary fluid. In the embodiment where theembossment 30 is formed in multiple locations (described above), multiple secondary fluids may be employed, one for eachembossment 30, or a single secondary fluid may be passed through all of theembossments 30 in series. - The third fluid may be directed through the
third flow passage 42 in either direction, i.e., counterflow or concurrent flow with respect to the first fluid in thefirst flow passage 18. As illustrated inFIG. 2 , the third fluid flows in a counterflow direction with respect to the first fluid in thefirst flow passage 18, i.e., opposite directions.FIG. 3 illustrates the third fluid flowing in a concurrent flow direction with respect to the first fluid in thefirst flow passage 18, i.e., parallel flow in the same direction. - The
space 32, orthird flow passage 42, is adjacent to and in thermal communication with an outermost flow path of thefirst flow passage 18. Heat exchange between thethird flow passage 42 and the top layer, or outermostheat exchanger plate 44, of the primaryheat exchanger core 17 is referred to herein as secondary heat exchange. Secondary heat exchange occurs between the primary fluids and the secondary fluid(s). - In order to promote high effectiveness heat exchange between the primary fluids, it can be advantageous for the
heat exchanger core 17 to include a large number ofplates 16, so that the surface area available for heat transfer is maximized. The effectiveness can be defined as the temperature change experienced by that one of the primary fluids having the lowest heat capacity, divided by the difference between the entering temperatures of the two primary fluids. - The amount of heat gained or lost by the primary fluids to the secondary fluid(s) is small compared to the total heat transferred between the primary fluids. This effect is achieved because the flow rates of the primary fluids are substantially higher than the flow rate of the secondary fluid(s), preferably by as much as ten times, and even more preferably by as much as twenty times. In other embodiments, this effect is achieved because the mass flow of the primary fluids is substantially higher than the mass flow of the secondary fluid(s), preferably by as much as ten times, and even more prefererably by as much as twenty times. In other embodiments, this effect is achieved because the heat capacity of the primary fluids is substantially higher than the heat capacity of the secondary fluid(s), preferably by as much as five times, and even more prefererably by as much as ten times. In other embodiments, this effect is achieved because the volume of the primary fluids contained in the primary
heat exchanger core 17 is substantially higher than the volume of the secondary fluid(s) in thethird flow passage 42, preferably by as much as ten times, and even more prefererably by as much as twenty times. - In some embodiments, the disparity between the secondary fluid(s) and the first primary fluid can allow for suitably effective heat exchange therebetween even though heat is transferred only between the secondary fluid(s) and that portion of the first primary fluid passing through the outermost flow path of the
first flow passage 18. In order to prevent that heat exchange effectiveness from exceeding a desired level (and consequently undesirably overheating or undercooling the secondary fluids), the number ofplates 16 used to construct theheat exchanger core 17 can be selected in order to achieve a certain heat capacity ratio between the secondary fluid(s) and that portion of the first primary fluid passing through the outermost flow path of thefirst flow passage 18. - In operation, the primary fluids are directed through the primary
heat exchanger core 17 at flow rates that are significantly higher than a flow rate of the secondary fluid(s). This enables a useful temperature change in the secondary fluid(s) while causing only a small or insignificant temperature change in the primary fluids. For example, the first fluid may include air, the second fluid may include exhaust, such as a fuel cell exhaust, and the third fluid may include a fuel flow to be supplied to the fuel cell. In some embodiments the fuel flow may be a reformate stream from a high-temperature reformer, and the temperature of the fuel flow may be reduced to a suitable fuel cell operating temperature concurrent with the recuperative preheating of the air (to be supplied to the fuel cell cathode). Thus, the invention eliminates the need for a separate heat exchanger to accomplish a temperature change in the secondary fluid and does not significantly affect the temperatures of the primary fluids, reducing part count and total material weight of the system. - The invention can be used in other applications as well. By way of example, the invention can function as an exhaust gas recirculation (EGR) cooler, whereby the first fluid includes recirculated exhaust gas from an internal combustion engine and the second fluid includes engine coolant. Fuel for the combustion engine can be advantageously preheated by passing through the heat exchanger as the third fluid, thereby being placed into heat transfer relationship with a portion of the recirculated exhaust gas. The number of
plates 16 can be selected so that the heat capacity ratio of the fuel and said portion of the recirculated exhaust gas limits the achievable effectiveness of the heat exchange therebetween. - The
heat exchanger 10 is formed by providing a plurality of heat exchanger plates stacked on top of one another to form fluid passages between adjacent heat exchanger plates, embossing one of the plurality of heat exchanger plates to form a space, forming an inlet and an outlet in fluid communication with the space, and connecting the heat exchanger plates to form the heat exchanger. Theheat exchanger 10 is used by passing primary fluids through the primaryheat exchanger core 17 at a first set of flow rates to exchange heat with one another, and passing a secondary fluid through theembossment 30 at a second flow rate to exchange heat with the primary fluids. The second flow rate is significantly lower than the first set of flow rates. - Thus, the invention provides, among other things, a layered core heat exchanger having primary and secondary heat exchange functions, where the secondary heat exchange function is accomplished with an insignificant effect on the primary heat exchange function.
Claims (8)
1. A layered core heat exchanger comprising:
a first fluid flow passage comprising two or more parallel arranged flow paths;
a second fluid flow passage fluidly separate from the first fluid flow passage and in thermal communication therewith; and
a third fluid flow passage arranged adjacent to a single one of said flow paths.
2. The layered core heat exchanger of claim 1 , wherein the first fluid flow passage has a first fluid capacity defined by the internal volume of the first fluid flow passage, the second fluid flow passage has a second fluid capacity defined by the internal volume of the second fluid flow passage, the third fluid flow passage has a third fluid capacity defined by the internal volume of the third fluid flow passage, and the third fluid capacity is substantially smaller than both the first and the second fluid capacities.
3. The layered core heat exchanger of claim 1 , wherein the second flow passage comprises two or more parallel arranged flow paths interleaved with the parallel arranged flow paths of the first fluid flow passage.
4. The layered core heat exchanger of claim 1 , further comprising a plurality of plates stacked with respect to one another, the first and second fluid flow passages being arranged between the plurality of plates.
5. The layered core heat exchanger of claim 4 , wherein the third fluid flow passage is provided in an embossment of one of the plurality of plates.
6. A method of manufacturing a heat exchanger, comprising:
forming a plurality of heat exchanger plates;
embossing one of the plurality of heat exchanger plates to form a space;
forming an inlet and an outlet in fluid communication with the space; and
stacking the plurality of plates to form a heat exchanger.
7. The method of claim 6 , further comprising joining the plates to one another through brazing.
8. The method of claim 6 , further comprising encasing a fin into the space.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US13/628,213 US20130081794A1 (en) | 2011-09-30 | 2012-09-27 | Layered core heat exchanger |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201161541570P | 2011-09-30 | 2011-09-30 | |
US13/628,213 US20130081794A1 (en) | 2011-09-30 | 2012-09-27 | Layered core heat exchanger |
Publications (1)
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US20130081794A1 true US20130081794A1 (en) | 2013-04-04 |
Family
ID=47991526
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/628,213 Abandoned US20130081794A1 (en) | 2011-09-30 | 2012-09-27 | Layered core heat exchanger |
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US (1) | US20130081794A1 (en) |
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US20170016679A1 (en) * | 2012-12-10 | 2017-01-19 | Mahle International Gmbh | Heat exchanger |
US10054373B2 (en) | 2014-10-21 | 2018-08-21 | Bright Energy Storage Technolgies, LLP | Concrete and tube hot thermal exchange and energy store (TXES) including temperature gradient control techniques |
US10234211B2 (en) * | 2015-07-30 | 2019-03-19 | Mahle Filter Systems Japan Corporation | Heat exchanger |
CN110461704A (en) * | 2017-01-25 | 2019-11-15 | 大宇造船海洋株式会社 | Boil-off gas for liquefied natural gas (LNG) ship liquifying method again |
US10900716B2 (en) | 2015-12-28 | 2021-01-26 | Mahle Filter Systems Japan Corporation | Heat exchanger |
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