Abstract:
A heat exchanger and method for defrosting a heat exchanger is disclosed and which includes a heat exchanger having a fluid receiving conduit, and at least one space which is defined, at least in part, by the fluid receiving conduit, an expandable and contractible heating element which is received within the space, and which is located in heat transmitting relation relative to the fluid receiving conduit, and a biasing member mounted on the heat exchanger and the heating element and which longitudinally, and resiliently restrains the movement of the heating element relative to the heat exchanger during the expansion and contraction of the heating element relative to the heat exchanger.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a heat exchanger and method for defrosting a heat exchanger, and more specifically to a novel mounting arrangement for electric resistance heating elements which are employed to defrost low temperature air-cooling heat exchangers. 
       BACKGROUND OF THE INVENTION 
       [0002]    Air-cooling heat exchangers are used in a variety of residential, commercial and industrial refrigeration applications where temperatures of a space are maintained below the freezing point of water (32° F.). When operating at these lower temperatures and in many environments, frost or ice will accumulate on the fins and tube surfaces of the heat exchangers. The frost or ice must be periodically removed from these surfaces in order to maintain the efficiency of the cooling system. 
         [0003]    One common method of defrosting heat exchangers involves inserting electric resistance heating elements into vacant spaces which are adjacent to a heat exchanger fin bundle. Thereafter, these heating elements are occasionally and periodically energized to warm the fin and tube surfaces to a temperature which is sufficient to melt the accumulated frost or ice. The resulting water is then captured and removed from the space which is being refrigerated. After all the fin and tube surfaces have been freed of the accumulated frost and ice, the heating elements are deenergized, and the heat exchanger is again used to reduce the refrigerated space to the desired temperature. This periodic heating and cooling of the fin and tube surfaces to render the frost and ice free is sometimes referred to as a “defrost cycle.” 
         [0004]    During a defrost cycle, melted frost or ice, in the form of liquid water, can sometimes make its way into the vacant tube spaces occupied by the heating element. As the heat exchanger begins to cool the refrigerated space after the defrost cycle, this liquid water conformally freezes and attaches, as ice, to the heating elements and to the sides of the vacant tube spaces in which the heating elements were placed. It should be understood that this same ice which forms around the heating element will temporarily anchor the heating element to the vacant tube spaces. Still further, and due to its coefficient of linear expansion, the metal sheath which typically encloses such heating elements will contract as the temperature of the heat exchanger drops. In the case of commercial and industrial heat exchangers, these heating elements can be as long as twenty feet or more. Consequently, the contraction which is experienced by these heating elements, when cooled, can be as much as one-half inch or more. When the heat exchanger is warmed during a subsequent defrost cycle, the same metal sheath of the heating element expands due the same coefficient of linear expansion. However, the ice that is anchoring the heating element to the vacant tube spaces does not immediately melt. Consequently, the resulting expansion of the heating element will cause it to move or creep outwardly from the heat exchanger tube bundle. Once the ice is dissipated, the heating element is left in an orientation where it is displaced outwardly relative to the heat exchanger by an amount which is equal to its linear expansion. 
         [0005]    This movement of the heating element relative to the heat exchanger occurs, to some degree, during each defrost cycle. After repeated heating and cooling cycles, the heating element will essentially “creep” or “walk” out of the heat exchanger due to this repeated contraction and expansion. If this movement of the heating element remains unchecked, this relative movement of the heating elements may cause damage to the heating elements themselves, to the electrical wiring and circuits that feed the heating elements, or to neighboring equipment. To address this problem, a rigid mounting system was designed to restrain the heating element within the heat exchanger. It was discovered, however, that these mounting arrangements were often insufficient to counter the very strong forces resulting from the thermal expansion of the metal sheaths. More specifically, even if the chosen attachment device or method was strong enough, the repeated thermal expansion and contraction of the heating elements usually resulted in some internal damage to the heat exchanger tubes, fins, or casings. 
         [0006]    A number of inventions have been disclosed which address the myriad of issues associated with the uneven expansion and contraction of components in heat exchanging devices, and which is caused by differences in temperatures of the component parts thereof. In U.S. Pat. No. 3,643,733 to Hall, for example, a spring is used to accommodate differences in expansion rates between tubes used to carry the different fluids in a fluid-to-fluid heat exchanger. Similar approaches have been used in cryogenic devices (U.S. Pat. No. 4,194,119 to MacKenzie) and fluid heaters (U.S. Pat. No. 5,117,482 to Hauber). None of these inventions, however, provide a solution to the problems associated with the expansion of an intermittently used heating element that is not directly involved with the normal heat exchange function. 
         [0007]    Therefore, it has long been known that it would be desirable to provide a means of restraining electric resistance heating elements in such a way so as to accommodate limited movement of the heating elements during multiple defrost cycles while simultaneously preventing damage to the heating element and the associated heat exchanger. Further, it would be desirable to provide a means whereby the heating element could be returned to its proper position within the heat exchanger after each defrost cycle without causing damage to either the heating element itself, the heat exchanger, or associated equipment during their normal expected lifetime. 
         [0008]    A novel mounting arrangement for electric resistance heating elements which avoids the shortcomings attendant with the prior art devices and practices utilized heretofore is the subject matter of the present application. 
       SUMMARY OF THE INVENTION 
       [0009]    A first aspect of the present invention relates to a heat exchanger with a heating element which is positioned within a vacant space thereof, and which is further mounted in a resilient, longitudinally restrained orientation relative to the main body of the heat exchanger during the expansion or contraction of the heating element. 
         [0010]    Another aspect of the present invention relates to a heat exchanger with a heating element and which further has a biasing member having a first end which is affixed to the first end of the heating element, and a second end which is affixed to a casing which encloses the heat exchanger. 
         [0011]    Another aspect of the present invention relates to a heat exchanger which includes a casing which defines, at least in part, a vacant space; a fluid receiving conduit mounted on the casing and which defines, at least in part, the vacant space; a heat radiating fin mounted on the fluid receiving conduit, and extending outwardly relative thereto and into the vacant space; a heating element having a main body with opposite first and second ends, and wherein the main body is received within the vacant space, and disposed in juxtaposed, thermal transmitting relation relative to the fluid receiving conduit and heat radiating fin; and a biasing member having a first end which is affixed to the first end of the heating element, and a second end which is affixed to the casing. 
         [0012]    Yet another aspect of the present invention relates to a heat exchanger with a casing defining at least one vacant space, and further including at least one aperture corresponding with the at least one vacant space; a plurality of fluid receiving conduits mounted on the casing; a plurality of heat radiating fins affixed to the plurality of fluid receiving conduits and extending substantially radially outwardly therefrom; a heating element having a main body with opposite first and second ends, and wherein the main body is received within the vacant space, and wherein the first end protrudes from the casing through the aperture, and wherein the heating element is disposed in juxtaposed, thermal transmitting relation relative to the fluid receiving conduit; and a flexing member with a first end, and an opposite second end; and wherein the first end of the flexing member is fixedly attached to the first end of the heating element, and wherein the second end of the flexing member is fixedly attached to the casing; and wherein the heating element is movable longitudinally relative to the vacant space to accommodate expansion and contraction of the heating element relative to the vacant space. 
         [0013]    Still another aspect of the present invention relates to a method for defrosting an air cooling heat exchanger, and wherein the method includes the steps of providing a heating element; energizing the heating element to a temperature over 200° F., deenergizing the heating element; cooling the heat exchanger to a temperature below about 32° F.; and resiliently restraining the heating element relative to the casing so as to substantially oppose longitudinal movement of the heating element during the energizing and deenergizing of the heating element. 
         [0014]    These and other aspects of the present invention will be described in greater detail hereinafter. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    Preferred embodiments of the invention are described below with reference to the following accompanying drawings. 
           [0016]      FIG. 1  is a perspective view of an air-cooling heat exchanger. 
           [0017]      FIG. 2  is a fragmentary, longitudinally, cross-sectional view of a heat exchanger and which illustrates a vacant space which receives a heating element and which is taken from a position along line  2 - 2  of  FIG. 1 . 
           [0018]      FIG. 3  is a fragmentary, longitudinal, vertical, cross-sectional view of a heating element for a heat exchanger of the present invention and which is taken from a position along line  2 - 2  of  FIG. 2 . 
           [0019]      FIG. 4  is a fragmentary, side elevation view of a first embodiment of the present invention. 
           [0020]      FIG. 5  is a fragmentary, side elevation view of an alternative embodiment of the present invention. 
           [0021]      FIG. 6  is a fragmentary, side elevation view of an alternative embodiment of the present invention. 
           [0022]      FIG. 7  is a perspective view of one form of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8). 
         [0024]    Referring now to  FIG. 1 , a typical air-cooling heat exchanger which is generally designated by the numeral  1  consists of a plurality of fluid receiving and thermally conductive conduits or tubes  10 , and heat radiating fins  11 , and which are mounted in a given arrangement within a main body or casing  12 . The fins  11  extend typically radially, outwardly from the tubes  10  and are affixed to or otherwise made integral with the tubes  10  in such a way so that heat is efficiently transferred from the tubes  10  to the fins. A cooling fluid or refrigerant (not shown) is pumped through the tubes  10  thus cooling them and the affixed radiant fins  11 . Thereafter, air from a space to be refrigerated is typically forced over the cooled fins  11  to remove heat from the air. This cooled air is then returned to a refrigerated space (not shown). The heated cooling fluid then releases the heat energy to ambient and then returns to absorb more heat from the air of the refrigerated space until the temperature of the refrigerated space reaches the desired temperature. 
         [0025]    The plurality of tubes  10  are arranged in spaced relation one relative to the others. As presently illustrated, a multiplicity of tubes  10  extend through the heat exchanger. In some arrangements, the tubes may be interconnected or continuous as seen in  FIG. 2 , and wherein the same conduit may pass through the heat exchanger, more than once. Further, the plurality of radiant fins  11  are shaped to define within the casing  12  a plurality of vacant spaces  13  ( FIG. 2 ) which are located between the respective tubes  10 . In one embodiment, the casing  12  will include an aperture  15 , that will allow access to a vacant space  13  between the tubes and fins. In other embodiments of the invention, the vacant space may also include a vacant space tube  14  that does not normally conduct a cooling fluid. The vacant space tube  14  which is mounted within the vacant space  13  is typically mounted within the casing  12  such that it may conduct heat energy between it, and the adjacent radiant fins  11 . One of ordinarily skill in the art of heat exchanger design will recognize that numerous other configurations of tubes, fins, and vacant spaces are possible, beyond that which is illustrated in the figures. 
         [0026]    Referring now to  FIG. 2 , an electric resistance heating element  20  in accordance with the teachings of the present invention is shown inserted into at least one of the vacant spaces  13  in order to periodically supply heat energy which would be useful in conducting a defrost cycle for the heat exchanger. In this regard, heat from the heating element  20  is supplied to the heat exchanger  1  by way of the thermally conductive fins  11  and tubes  10  to facilitate the melting of frost or ice that has accumulated in unnatural amounts upon those components. The heating element  20  is energized by way of an electrical conduit  21  which is coupled to an AC or DC power source (not shown). A control circuit (not shown) selectively energizes or deenergizes the heating element  20  during predetermined defrost cycles, as described later in this application. 
         [0027]    Referring now to  FIG. 3 , the novel electric resistance heating element  20  which forms a feature of the present invention includes a high-resistance filament wire  22 , which may be surrounded by a ceramic filler material  23 . The ceramic filler material is further surrounded by a metallic sheath  24 . The filament wire is electrically connected to the electrical conduit  21 , and receives the AC or DC electricity from the external power source (not shown). The electrical connection made between the filament wire  22  and the electrical conduit  21  may be covered by or enclosed within an electrically insulative boot  25  made of a synthetic; flexible membrane; or other flexible, electrically insulating material. In one possible embodiment of the present invention, the heating element  20  provides electrical power from but one end. However, in another form of the invention, the heating element  20  may also be energized from the opposite distal end thereof (not shown). As best illustrated in  FIG. 2 , one end  26  of the heating element  20  is inserted into the vacant space tube  14  of the heat exchanger  1  such that the electrical conduit  21  and the protective electrical insulating boot  25  protrude outwardly from the vacant space  13 , and are otherwise located on the outside of the casing  12  of the heat exchanger  1 . The heating element  20  may extend along the entire length of the heat exchanger or along only a portion thereof. 
         [0028]    Referring now to  FIG. 4 , it will be seen that a biasing member which is generally indicated by the numeral  30  is provided, and which permits limited movement of the heating element  20  relative to the heat exchanger casing  12  during periodic defrost cycles, as explained below. The biasing member  30  is oriented so as to bias the heat element  20  in the direction of the heat exchanger casing  12 . In one possible embodiment of the present invention, as shown in  FIG. 4 , the biasing member  30  comprises a coil spring  31 . The coil spring  31  is attached near one end  26  of the heating element  20 , in a manner whereby it does not interfere with the electrical connection which is made between the heating element  20  and the electrical conduit  21 . In this embodiment, the coil spring  31  is attached to the metal sheath  24  of the heating element  20  by means of a releasable clamp  40  that will be discussed in greater detail, below. In another possible embodiment of the present invention, the biasing member  30  may be affixed to the sheath of the heating element with a ring clamp, a weld, an adhesive, or any other releasable or non-releasable fastener means which has sufficient strength to withstand the forces which are exerted on same. When the coil spring  31  is employed in the present invention, the heating element  20  is telescopingly received, at least in part, within the coil spring. The remaining portion of the heating element  20  may then be inserted into a vacant space tube  14  of the heat exchanger  1  while the coil spring  31  remains outside of the vacant space. 
         [0029]    In other embodiments of the present invention, the biasing member  30  may comprise at least one Belleville washer which is generally indicated by the numeral  32  ( FIG. 5 ); a leaf spring  33  ( FIG. 6 ); or any other type of mechanically flexing or biasing member. In all embodiments of the invention, one end of the biasing member  30  is affixed to one end  26  of the heating element  20 , and the opposite second end of the biasing member is affixed to the heat exchanger  1 , and preferably to either the casing  12 , or the outside surface which defines, at least in part, vacant space  13  ( FIG. 2A ). Still further, it should be understood that the biasing member  30  may be installed such that it may be mounted, in whole or in part, within the casing  12 , or as in one embodiment as shown in  FIG. 4 , it may be mounted entirely outside of the casing. As seen in  FIGS. 4 and 7 , the coil spring  31  is attached to the heat exchanger casing  12  by a fastener  35 . This fastener could include a bolt with a corresponding nut; a machine screw (as illustrated); a cam lock mechanism; an adhesive; or any other conventional fastener or fastening agent. 
         [0030]    In the event that the biasing member  30  is fabricated from an electrically conductive material, such as when a metal coil spring  31  is employed, the biasing member  30  will also act as a means to provide an electrical grounding path between the heat exchanger casing  12 , and the metal sheath  24  of the heating element  20  ( FIG. 3 ). As should be understood, an electrically continuous ground between the heating element  20  and the heat exchanger is required for safety reasons. Further, if the biasing member  30  is not fabricated from an electrically conductive material, or if any of the means for affixing the biasing member  30  to the heat exchanger casing  12  or the heating element will electrically isolate the casing  12  from the metal sheath  24  of the heating element, then a grounding strap (not shown) must be installed between the casing  12  and the metal sheath  24  to provide an appropriate grounding path. 
         [0031]    Referring now to  FIG. 7 , a means of affixing the coil spring  30  to the heating element  20  is shown. As illustrated therein, a releasable clamp which is generally indicated by the numeral  40  is provided and which consists of first and second members  41  and  42 , respectively. As will be appreciated from the drawings, these two members are substantially mirror images of each other. Typically, they are fabricated from metal. The respective members are shaped to receive or otherwise matingly cooperate with the outside surface of the metal sheath  24  of the heating element  20 . A close approximation of the shape of the heating element  20  by the releasable clamp  40  is required to insure a secure attachment, and to further facilitate a low-resistance electrical grounding path assuming that the biasing member is electrically conductive. The first and second members  41  and  42  are held together by one or more fasteners  43  of conventional design. As noted earlier, and in other embodiments of the invention, a non-releasable means to affix the coil spring  31  to the heating element  20  may be used. These means may include welds; formed or blind (pop) rivets; adhesive; or other non-releasable fastener means. 
       Operation 
       [0032]    The operation of the described embodiments of the present invention are believed to be readily apparent and are briefly summarized at this point. 
         [0033]    During normal operation of the air-cooling heat exchanger  1 , refrigerant (not shown) is pumped through the heat exchanger tubes  10  while fans (not shown) blow air across the radiant fins  11  so that the refrigerant may extract heat from same. In the operation of the heat exchanger  1 , the heating element  20  is normally deenergized. During a subsequent defrost cycle, the following sequence of events typically occurs. As a first matter, the flow of refrigerant to the heat exchanger tubes  10  is stopped. Secondly, the air-cooling fans are turned off once most of the refrigerant has boiled off. Thirdly, the heating elements  20  are energized to a temperature which is normally above 200° F. The heat from the heating elements  20  is then thermally conducted or otherwise transmitted to the heat exchanger&#39;s refrigerant tubes  11  and radiating fins  12 . During this stage, any frost or ice that has accumulated on these components is melted, and the liquid water is drained from the heat exchanger. Some water, however, inevitably finds its way into some of the regions adjacent to the vacant space tubes  14  in which the heating elements are placed. Fourthly, once all the frost and ice has melted, the heating elements  20  are deenergized. Fifthly, the flow of refrigerant through the heat exchanger tubes  10  is restored and the heat exchanger cools the refrigerant space down to the appropriate temperatures. Finally, in a sixth step, the air-cooling fans are reenergized. 
         [0034]    When the heat exchanger begins to cool after the end of a defrost cycle, the water that accumulates, for example, in the vicinity of the vacant space tubes  14  where the heating elements  20  are located will freeze. The resulting ice will conformally and substantially rigidly affix at least a portion of the individual heating elements to the vacant space tube where they rest or are otherwise positioned. During a subsequently conducted defrost cycle, the heating element  20  will heat rapidly, and the metallic sheath  24  will expand as a function of its coefficient of linear expansion. This heating and expansion will typically occur before all the ice that has formed in the vacant spaces  13  and tubes  14  have melted. Since part of the heating element  20  is still anchored to the vacant space tube  14  by the remaining accumulating ice, the heating element will expand outwardly with respect to the heat exchanger casing  12 . This outward expansion pressure will then be absorbed by the biasing member  30  without putting undue pressure on the clamp  40  or first and second members  41  and  42 , respectively. More importantly, since the biasing member  30  is absorbing the linear expansion forces of the heating element, the heating element itself will not typically be damaged. Further, internal damage which might be caused to the heat exchanger tubes or fins by the expanding heat element  20  is substantially impeded. 
         [0035]    Once the defrost cycle nears completion, the ice that has anchored the heating element  20  to the vacant space tube  14  eventually melts as well. As this anchoring ice melts, the biasing element  30  then returns the heating element  20  back to its original position, thus preventing the heating element from “creeping” or “walking” out of the heat exchanger  1 . This, of course, further prevents damage to the heating element wiring and any neighboring equipment. 
         [0036]    In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however; that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.