Abstract:
A plate heat exchanger that is provided with an internal insert located between plates that form a channel. The insert takes the form of an additional plate that has guide channels with at least one inlet and one outlet which lead from one flow channel of one medium to another flow channel of the same medium. Sections of the additional plate that are free of guide channels are metallically connected to an adjacent heat exchanger plate. The guide channels are metallically connected to the other adjacent heat exchanger plate of the same channel.

Description:
RELATED APPLICATIONS 
     This application claims priority to German Patent Application No. 100 21 481.9 filed May 3, 2000. 
     FIELD OF THE INVENTION 
     The present invention relates to an improved plate heat exchanger for heat exchanging media in separate loops of the heat exchanger wherein heat exchanger plates are stacked one upon the other and are metallically connected. The stacked plates each have openings disposed in a vertical manner to form flow channels for other medium/media. These flow channels are separate from each other and each is in fluid communication with channels between individual heat exchanger plates to thereby define separate loops each of which consists of flow channels interconnected by channels between the heat exchanger plates. At lease some of the channels between the plates are equipped with an internal insert. 
     BACKGROUND OF THE INVENTION 
     Plate type heat exchanger technology is a well developed field where the basic structure of stacked heat exchange plates with multiple vertical medium/media flow channels into and out of the heat exchanger are common. It appears that many improvements in this technology involve the manner in which the heat exchanger plates are constructed to provide horizontal channels between the plates that interconnect the various vertical flow channels. An example of this is found in some plate heat exchangers where knobs or similar protrusions are embossed in the heat exchanger plates that form the horizontal channels for heating or cooling medium. These knobs of adjacent heat exchanger plates are in contact and soldered to each other in order to increase the strength of the plate heat exchanger. Such knobs have proven themselves in general and are therefore employed frequently because they cause almost no detectable pressure loss. However, it appears that the useful life of heat exchangers embodying such knobs where extreme loads, both from temperature shock and extreme vibrations related to operation, is not always adequate. In other heat exchangers of the plate type in order to increase the strength and useful life relative to load, temperature shock and vibration, the heat exchanger is provided with thicker outer support plates which serve as an upper and lower cover plate between which there is situated corrugated heat exchanger plates. An increased useful life for the heat exchanger is derived from this structure, but only between the aforementioned plates and the corrugated heat exchanger plates. A similar problem is found in another such heat exchanger in which a reinforcement plate is provided with an edge inserted between a base plate and a lower most heat exchanger plate. In this heat exchanger environment, loads which also act in the interior of the plate heat exchanger cannot be countered by simply employing heat exchanger plates with knobs or using a reinforcement plate. 
     It is against this background that the instant invention effectively overcomes the problems just described, in a manner that is readily fabricated and significantly improves the state of the art. 
     SUMMARY OF THE INVENTION 
     The plate heat exchanger embodying the invention provides a greatly increased structural strength in the interior of the heat exchanger but above all the internal structure produces turbulence in the medium brought about by securing inserts in channels between the exchanger plates which are soldered to the heat exchanger plates. The turbulence enhancing inserts of the invention, which also minimize pressure loss of medium flowing through the channels, take a structural form of an additional plate that cooperates with adjacent heat exchanger plates to create guide channels with at least one inlet and one outlet which lead from a flow channel of one medium to another flow channel of the same medium, in which sections of the additional plate that are free of guide channels are metallically connected to an adjacent heat exchanger plate and the guide channels are metallically connected to the other adjacent heat exchanger plate of the same channel. 
     A primary object of the invention consists of improving the useful life of the interiors of plate heat exchangers without significantly increasing pressure loss of medium flowing through channels between heat exchanger plates. This is accomplished by an additional plate that has guide channels with at least one inlet and one outlet, which lead from one flow channel of one medium to the other flow channel of the same medium. 
     Another object of the invention is to provide increased turbulence in the medium as the medium flows through a channel between adjacent heat exchanger plates, by the provision of a guide channel between the plates wherein the addition plate that includes the guide channel includes sections of the additional plate and guide channels that are metallically connected to an adjacent heat exchanger plate and the guide channels are additional metallically connected to the other adjacent heat exchanger plate of the same channel. 
     Yet another object of the invention is to provide a plate heat exchanger that produces very limited pressure loss by means of the inclusion of guide channels that have at least one inlet and one outlet wherein there is an alignment of a number of guide channels from one flow channel to the other. 
     Still yet another object of the invention is to provide a plate heat exchanger that has a significantly improved useful life relative to temperature shock and extreme alternating temperature loads, as well as mechanical stress because the additional plate is connected on both sides to adjacent heat exchanger plates wherein connection surfaces are very large. 
     A still further object of the invention is to provide a plate type heat exchanger that is nearly cubic in shape which has pairs of flow channels for different mediums in opposing covers wherein guide channels between flow channels in heat exchanger plates can run arc like and into and around flow channels in corners of the heat exchanger. 
     Another object of the invention is to create a highly efficient plate heat exchanger wherein additional plates that include guide channels are located in all of its channels. 
     A major object of the invention which dramatically diminishes pressure loss resides in the provision of two irregular shaped openings in the additional plate which are adapted to the arrangement of guide channels that interconnect flow channels wherein the openings are larger than corresponding flow channel openings in the heat exchanger plates. 
     Another object of the invention is to provide the irregular openings in additional plates wherein the irregular openings include indentations in a direction toward inlet or outlets of selected guide channels thereby greatly increasing heat exchanger efficiency. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is further described in the detailed description which follows in reference to the noted plurality of drawings by way of non-limiting examples of embodiments of the present invention in which like reference numerals represent similar parts throughout the several views of the drawing wherein: 
     FIG. 1 is an exploded view of heat exchanger plates and an additional insert plate that when assembled establish a channel between the plates; 
     FIG. 2 is a top view of an assembly of the additional plate and a heat exchanger plate of FIG. 1 in which the additional plate is superimposed upon the heat exchanger plate; 
     FIG. 3 is a cross-section along line  3 — 3  in FIG. 2; 
     FIG. 3 a  is a cross-section similar to that shown in FIG. 3 in which an additional plate has a slightly modified configuration; 
     FIG. 4 is a cross-section of heat exchanger plates with an additional plate shown schematically therebetween and illustrates the nature of an assembly of plates and additional plate of the nature set forth in FIG. 1; 
     FIG. 5 depicts a cross-section of a portion of a heat exchanger channel that shows the relationship of heat exchanger plates to an additional plate interposed between the plates; 
     FIG. 6 depicts a cross-section taken along line  6 — 6  of FIG. 2 that has been modified to include a showing of a top heat exchanger plate and an additional plate of the type depicted in FIG. 3 a;    
     FIG. 7 is a cross-section of a plate heat exchanger that is provided with additional plates; and 
     FIG. 8 is similar to FIG. 7 in that it depicts another embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference is now made to FIG. 1 which illustrates the three major components of each channel of a plate type heat exchanger embodying the invention. In the description that follows and in the balance of this specification and appended claims the following terms will be employed to explain various basic components involved in the invention. Accordingly, the phrase “flow channel” will be employed to describe the pathway for either heating or cooling medium in the heat exchanger whereas the term channel will refer to a space between adjacent plates of the heat exchanger. It will be noted that FIG. 1 is an exploded view that is divided into an upper, middle and bottom portions of a heat exchanger plate assembly embodying the invention. In the bottom portion of FIG. 1 there is depicted a heat exchanger plate  2  of the general configuration shown. The plate  2  is provided with flow channel openings  15 ,  16 ,  17 , and  18 . The flow channel openings  15  and  16  are shown diagonally across from each other in opposite corners of the plate  2  as are flow channels  17  and  18 . The perimeter of the plate  2  is provided with a raised edge  13  the detailed nature and function of which will become apparent as a description of subsequent figures unfolds. In the top portion of FIG. 1 an adjacent heat exchanger plate  2   a  is shown with flow channel openings  15 ′,  16 ′ and  17 ′,  18 ′ positioned as shown. The outer edge of the plate  2   a  also includes a raised edge  13 ′. The physical cooperation of the plates  2  and  2   a  will best be appreciated in an explanation that follows. 
     The middle portion of FIG. 1 shows an additional plate  6  which has an edge  7  that is smooth. The overall dimensions of additional plate  6  are such that it fits precisely between the two heat exchange plates  2 ,  2   a  in the manner shown in FIG.  5 . 
     The additional plate  6  has openings  32 ,  34  which align with the plate openings  15 ,  16  and  15 ′,  16 ′ and create, when assembled, flow channels  4  that pass vertically through a heat exchanger  1  as shown in FIGS. 7 and 8. The additional plate openings  33 ,  35  align with plate openings  17 ,  17 ′ when assembled to provide a flow channel through all three plates to accommodate another medium in heat exchange of heating or cooling medium K of the nature shown in FIGS. 7 and 8. 
     The openings  32  and  34  are irregular in shape and include indentations  40   a,    40   b  and  40   c,    40   d.  The role and function of the openings  32 ,  34  and the indentations  40   a,    40   b  and  40   c,    40   d  will be explained in detail hereinafter. 
     FIG. 3 is a cross-section taken along line  3 — 3  in FIG. 2 whereas FIG. 3 a  is a cross-section similar to that shown in FIG. 3 in which an additional plate  6 ′ has a slightly modified configuration. 
     FIG. 4 illustrates in a cross-sectional manner the nature in which the plates  2 ,  2   b  and additional plate  6 ′ of the nature just noted in FIG. 3 a  depicted and generally described in FIG. 1 as they would be arranged prior to final assembly. FIG. 5 illustrates a completed assembly of plates  2   a,    2   b  with additional plate  6 ′ inserted in between the plates. A channel  5  is present between the plates  2  and  2   a.  The additional plate  6 ′ has been embossed to create the overall cross-sectional structure of guide channels  8   a,    8   b,    8   c  shown in this figure as well as FIG.  2 . It should be understood that the invention is intended to include a variety of guide channel configurations each designed to accommodate the nature of the medium flowing in the channel/guide channel. The guide channels  8   a,    8   b,    8   c  take the form of elongated beads as is best appreciated by a study of FIG.  2 . Accordingly, it will be observed that the embossed additional plate  6 ′ structurally cooperates with the plates  2  and  2   a  to establish between the plates  2 ,  2   a  the channel  5  and guide channels  8   a,    8   b  and  8   c.  Although not identified by reference numerals it is to be understood that wherever the embossed additional plate  6 ′ comes into contact with the plates  2  and  2   a,  the plate is securely soldered to the plates. 
     Attention is now directed to FIG. 2 which is a top view of an assembly of the additional plate  6  and a heat exchanger plate  2 , absent the plate  2   a  depicted in FIG. 1. A heating or cooling medium will enter channel as noted above between the plates  2 ,  2   a  from an opening  15  of a flow channel in corner region  22 . The medium will then flow through all of the guide channels  8   a  through  8   k  as well as the space between the guide channels and heat exchanger plates and leave the channel  5  (see FIG. 5) again via the opening  16 , i.e., the corresponding flow channel which is arranged in the diagonal corner region  24 . The medium continues its flow through other channels in the heat exchangers as shown in FIGS. 7 and 8. Openings  17  and  18  of plate  2  which cooperate with openings  35  and  33  of the additional plate  6  have rings  20 ,  20   a  positioned as shown so that channel  5  from different media are separated from each other. The physical relationship of ring  20  and plates  2  and  2   a  can best be observed in FIG.  6 . Instead of rings  20  collars (not shown) could also be formed in the opening at  17  and  18 . 
     Turning again specifically to FIG. 2 it is apparent that there are a significant array of guide channels  8   a,    8   b,    8   c,    8   d,    8   e,    8   f,    8   g,    8   j,    8   k,    8   l  and  8   m  disposed as shown in this figure. Typically a guide channel such as  8   c  have an inlet  9  and an outlet  19 . The inlet  9  and outlet  10  are optimized with respect to flow and are roughly egg shaped, that is oblong in nature, so that a limited pressure loss is supported for corner region  22 . In corner region  22  in the lower left hand corner of FIG. 2 the arrows  21  and  21  a show the path the heating or cooling medium takes as it exits a flow channel and flows through guide channel  8   d  and guide channel  8   c.  Note also in the upper right hand corner of FIG. 2 in the corner region  24  that flow arrows  21   b,    21   c,    21   d  show the flow of the medium into the flow channel at opening  16 . Most guide channels are provided with a slight curvature. Some guide channels such as  8   k  and  8   m  connect openings  15  and  16  directly. Others are shorter and begin and end as can be seen in FIG. 2 with a certain spacing from openings  15  and  16 . Note also that guide channels  8   d,    8   e,    8   f  and  8   g  are provided in each of the corner regions  23 ,  24 ,  25  and  22 . A branch  30  is also provided between guide channels  8   d  and  8   a.  Free sections such as  11   a  and  11   b  between guide channels are soldered, as noted earlier, to plate  2  and the guide channels are soldered to the plate  2   a  not shown in the figure. This design ensures that the corner regions  22 ,  23 ,  24  and  25  participate intensely in heat exchange and establish excellent strength in the heat exchanger as a whole. In corner region  23  note also in the region of the branch  30 , additional inlets and outlets  9 ,  10   a  which are provided in order to make the flow in this region more uniform. In corner regions  22  and  24  the irregular shaped openings  32  and  34  most easily seen in the center region of FIG. 1 include the indentations such as  40   a,    40   b,    40   c  and  40   d  which lead to inlets and outlets such as  9  and  10  of the longer guide channel  8   m.    
     In the lower right hand corner of FIG. 2 a set of three knobs  14   a,    14   b,    14   c,  one of which  14   a  is shown in section in FIG. 6, are shown arranged in the vicinity of corner region  23  and adjacent a flow channel defined by ring  20 . The knobs  14   a,    14   b,    14   c  are soldered to the adjacent plate  2   a  as shown in FIG.  6 . The undeformed region in the additional plate  6  around the flow channel openings in corner regions  23 ,  25  are strengthened by the knobs. 
     The configuration of the guide channels  8   a,    8   b,    8   c  which are illustrated in FIG. 5 are designed to be bead like in nature. 
     FIG.  7  and FIG. 8 are cross-sections of plate type heat exchangers  1  and  1 ′ that embody the invention. A number of structural details inherent in the pair of heat exchanger plates having an additional plate between them and fully described herein before can be identified in these embodiments. In FIG. 7, the edge  13  of the plate heat exchanger  1  is shown directed upward. In FIG. 8 the heat exchanger  1 ′ shows the edges  13 ′ directed downward. The heat exchanger plates  2  in FIG. 8 and 2 a  in FIG. 7 are the only plates that are referenced. Typical of plate heat exchangers these two heat exchangers are comprised of heat exchanger plates stacked one upon the other. Both the heat exchangers of FIG.  7  and FIG. 8 represent practical examples of different variants of a retarder-oil-cooler, which are intended for use in trucks. These heat exchangers cool the truck&#39;s brake fluid. Extremely high oil temperatures of more than 200° C. occur in such oil coolers. An extensive series of experiments have demonstrated that operating conditions in such trucks create high temperature shock loads which prior art plate heat exchanger oil coolers are not able to handle. 
     In FIG. 8 the cross-section through the plate heat exchanger  1 ′ depict a total of four separate loops. The flow channel  4  for the cooling or heating medium K is situated on the left side in both FIG.  7  and FIG.  8 . On the right side, the flow channel  4 ′ for oil  1 , oil  2 , and oil  3  are apparent. There are another two flow channels not shown for emergence of the media. The flow channels  4  and  5 ′ have connection flanges  3  and  3 ′. The connection flange  3 ′ for oil  1  has a connection channel (not shown) so that the oil  1  enters through this connection channel and is in heat exchange in upper channels such as  5  and  5   a  with the coolant K. All channels for oil  1 , oil  2  and oil  3  have convention lamellae  53 . The oil  2  also enters at connection flange  3 ′ of the plate heat exchanger  1  through the tube piece  50  with a flange that is rigidly soldered between two heat exchanger plates  2  and  2   a.  The oil  3 , on the other hand, is supplied or taken from the bottom of the plate heat exchanger  1 . A baffle  51  is provided to keep oil  2  separate from oil  3  which is present in flow channel  4 ′. 
     In practice the heat plate exchanger of FIG. 7 includes in all the channels for the coolant K an additional plate  6  only one of which is referenced in FIG.  7 . In another practical example (not shown), only the channels for coolant K, which are adjacent to the sections “a” for oil  1 , “b” for oil  2  and “c” for oil  3  were equipped with additional plates of the type previously described. 
     FIG. 8 is another cross-section of a plate heat exchanger  1 ′ with a loop for coolant K and an oil loop shown. Only the two upper and two lower channels  5 ′,  5   a ′ for the coolant K were provided with an additional plates  6   a,    6   b,    6   c,  because it turned out that the outer channels are exposed to the strongest temperature differences. The heat exchange plates referenced in other channels for coolant K were equipped as usual with knobs such as knobs  52 ,  52 ′ which are in contact and soldered to each other. 
     Though the invention has been described with respect to preferred embodiments thereof; many variations and modifications will immediately become apparent to those skilled in the art. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include such variations and modifications.