Patent Description:
Heat exchangers are widely used to perform refrigeration or heating functions. Moreover, refrigeration systems may include heat exchangers as a condenser and/or as a vaporizer of a refrigerant liquid. A refrigeration cycle may include a condenser, a vaporizer, and a compressor, forming a closed circuit for the refrigerant. These components typically require a certain volume of refrigerant to achieve a certain performance. It may be advantageous to limit the amount of refrigerant necessary to obtaina certain cooling power. More genereally, there would be a need for an improved heat exchanger. <CIT> discloses a heat exchanger having the features of the preamble of claim <NUM>.

<CIT> discloses a vessel for containing a refrigerant comprising an inner wall and an outer wall arranged concentrically and having an inner space bounded by the inner wall and outer wall, an inlet and an outlet for transport of refrigerant into and out of the inner space; a tube inside the inner space arranged around the inner wall; an input tube fluidly connected to the inner space and arranged to allow flow of the refrigerant through the input tube into the inner space; an output tube connected to the inner space and arranged to allow flow of the refrigerant out of the inner space into the output tube; a compressor arranged to receive the refrigerant from the output tube and to compress the refrigerant; and a condenser arranged to receive the compressed refrigerant fluid from the compressor, to condense the refrigerant, and to forward the compressed refrigerant into the input tube.

Although the amount of refrigerant may be reduced by employing such a vessel, it would be advantageous to further reduce the amount of refrigerant, or to reduce the amount of refrigerant in another kind of vaporizer or compressor.

It would be advantageous to provide an improved heat exchanger. To address this need, a heat exchanger is provided for a heat pump, comprising the features of independent claim <NUM>.

The structure is made up of a plurality of grains. This provides such a random structure of filling material. Moreover, it is easy to manufacture because the grains adjust to any shape of chamber.

Preferably, the channels of the structure do not have dead ends. This may improve performance, because dead ends may prevent or slow down a portion of the working fluid from moving from inlet to outlet.

The material may comprise sand or quartz or grit. Such a material may have suitable characteristics in terms of durability, non-absorbence and the working fluid may not stick to the surface of the material. Moreover, these types of material have a certain heat capacity, allowing them to store the heat or coldness, which may improve the quality of the heat exchange.

The material may comprise a polymer, for example a thermoplastic polymer, such as a polyoxymethylene copolymer, POM-C, or a polyoxymethylene homopolymer, POM-H. Such a material may have suitable characteristics in terms of durability, non-absorbence, and the working fluid may not stick to the surface of the material. Moreover, this type of material may have a relatively low heat capacity, so that the heat exchange is more directly controlled by the temperature and the velocity of flow of the working fluid. The material may comprise polymer grains. Alternatively, a rigid open connected structure with the channels may be provided.

The material may be substantially non-absorbent with respect to oil. This may be advantageous, since the working fluid may be contaminated with some oil used for e.g. a compressor.

The grains may have an average diameter of preferably between <NUM> millimeter and <NUM> millimeter, preferably about <NUM> millimeter. The dimensions of the grains may depend on the specific application. The given ranges are suitable for a wide range of applications. The dimensions of the channels may depend on the specific application. The given ranges are suitable for a wide range of applications.

The filling material may fill up between <NUM>% and <NUM>% of the volume of the chamber, preferably <NUM> to <NUM>%. This way, the amount of working material is greatly reduced, while still providing sufficient space for the heat exchange and optional evaporation or condensation to take place inside the channels.

The heat exchanger may comprise an evaporator or a condenser. This allows phase change of the working fluid inside the heat exchanger without using much working fluid.

The heat exchanger may further comprise a compressor, an expansion valve, and the other of evaporator and condenser, to form a vapor-compression cycle. Optionally, both the evaporator and the condenser may be filled with the filling material. In that case, the filling material of the evaporator may be the same as that of the condenser, or they may both have a different filling material and/or a different structure. Alternatively, only the evaporator may have the filling and not the condensor. Alternatively, only the condensor may have the filling and not the evaporator. Independently from this decision, it is also possible to fill any channels for the working fluid, the channels fluidly connecting the components of the vapor-compression cycle, with the filling material in a similar way.

Said other of evaporator and condenser may comprise:.

According to another aspect of the invention, a method of heat exchange is provided. The method comprises:.

The person skilled in the art will understand that the features described above may be combined in any way deemed useful. Moreover, modifications and variations described in respect of the apparatus may likewise be applied to the method, and modifications and variations described in respect of the method may likewise be applied to the apparatus.

In the following, aspects of the invention will be elucidated by means of examples, with reference to the drawings. The drawings are diagrammatic and may not be drawn to scale. Throughout the drawings, similar items are identified with the same reference numerals.

Certain exemplary embodiments will be described in greater detail, with reference to the accompanying drawings.

The matters disclosed in the description, such as detailed construction and elements, are provided to assist in a comprehensive understanding of the exemplary embodiments. Accordingly, it is apparent that the exemplary embodiments can be carried out without those specifically defined matters. Also, well-known operations or structures are not described in detail, since they would obscure the description with unnecessary detail. In the following, example implementations will be described in more detail with reference to the drawings. However, it will be understood that the details described herein are only provided as examples to aid an understanding of the invention and not to limit the scope the disclosure. The skilled person will be able to find alternative embodiments which are within the scope and spirit of the present invention as defined by the appended claims and their equivalents.

<FIG> shows a diagram of a cooling system capable of circulating a working fluid in a heat pump, which may be based on a vapor-compression cycle, such as a refrigeration cycle. The cooling system comprises a compressor <NUM>, a condenser <NUM>, a valve <NUM>, an expansion device <NUM>, and an evaporator <NUM>. These components <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are fluidly connected to form the refrigeration cycle. Many different implementations of the compressor <NUM>, condenser <NUM>, valve <NUM>, expansion device <NUM>, and evaporator <NUM> are known in the art. For example, the valve <NUM> and the expansion device <NUM> may be combined by means of an expansion valve. Some aspects of the invention relate to the evaporator <NUM>, which may be included in such a refrigeration cycle of a cooling system. In the following, the evaporator <NUM> will be described in greater detail. However, features of the invention may also be applied to the condenser <NUM> and/or to fluid connections between the components of the heat pump.

<FIG> shows a perspective view of a heat exchanger <NUM>. The example shown in <FIG> is a plate heat exchanger. The plate heat exchanger <NUM> has an inlet <NUM> and an outlet <NUM> for a working fluid, and an inlet <NUM> and an outlet <NUM> for a fluid to be cooled. <FIG> shows a worked open perspective view of the plate heat exchanger <NUM>. As shown the plate evaporator <NUM> comprises a sequence of plates <NUM>. In between the plates <NUM> there is alternately a chamber for working fluid or a space for a fluid to be cooled or warmed up. In case the heat exchanger <NUM> is an evaporator <NUM>, the space is for a fluid to be cooled. In case the heat exchanger is a condenser <NUM>, the space is for a fluid to be warmed up.

<FIG> shows a diagram of a cross section of a heat exchanger <NUM>. Heat exchanger <NUM> is a simplified and diagrammatic representation of plate heat exchanger <NUM>. The cross section is taken through the central axes of the inlet <NUM> and outlet <NUM> for the working fluid. The heat exchanger has a chamber <NUM> for a working fluid, and a space <NUM> for a substance to be processed (e.g. heat is to be extracted from the substance or heat is to be delivered to the substance). The chamber <NUM> may be separated from the space <NUM> by one or more walls <NUM>. The chamber <NUM> may comprise a sequence of subchambers <NUM>, <NUM>, <NUM> that may be connected by fluid connections <NUM>, such as tubes. The wall <NUM> is designed to allow heat exchange between the working fluid in the chamber <NUM> and the substance in the space <NUM> on the opposite side of the wall <NUM>. For example the wall <NUM> may be made of a material, such as a metal, that allows easy transfer of heat. The chamber <NUM> for the working fluid comprises a structure <NUM> to fill up the chamber <NUM> partly with a filling material <NUM> that is substantially non-absorbent with respect to the working fluid.

<FIG> illustrates a diagrammatic illustration of a filling structure <NUM> providing randomly distributed filling material <NUM>, leaving open randomly distributed channels <NUM>. That is, the working fluid will flow through a plurality of channels <NUM> left open by the filling material <NUM>. The channels <NUM> allow the working fluid to interact with the wall <NUM> to exchange heat with the substance in the space <NUM> on the opposite side of the wall <NUM>. The channels <NUM> provide a passage for the working fluid from the inlet <NUM> of the chamber <NUM> to the outlet <NUM> of the chamber <NUM>.

Although <FIG> shows randomly distributed channels, it will be understood that the channels may also have a non-random distribution, such as e.g. straight channels with junctions in an orderly fashion. Any shape of structure may be created by means of, for example, 3D printing. Alternatively, the structure may consist of loose grains. Such loose grains may typically create randomly distributed channels. Preferably the channels <NUM> do not have any dead ends. Dead ends may reduce the efficiency of the heat exchanger, because dead ends may partly prevent the working fluid to flow quickly towards the outlet after having exchanged heat with the substance.

The filling material <NUM> contains grains, the grains may have an average diameter of between <NUM> millimeter and <NUM> millimeter, preferably between <NUM> millimeter and <NUM> millimeter, preferably about <NUM> millimeter. In any case, the maximum distance between adjacent channels may be between <NUM> millimeter and <NUM> millimeter, preferably between <NUM> millimeter and <NUM> millimeter, preferably about <NUM> millimeter.

For example, the channels (<NUM>) may have a diameter of generally less than <NUM> millimeter in cross section.

The filling material <NUM> may fill up between <NUM>% and <NUM>% of the volume of the structure <NUM>, preferably <NUM> to <NUM>, and the channels (<NUM>) take up substantially the remaining portion of the volume of the structure <NUM>. If the chamber <NUM> is filled entirely with the structure <NUM>, the filling material and the channels take up a corresponding portion of the chamber <NUM>.

Examples of the structure <NUM> and material <NUM> include any porous material, sponge, polymer grains, polymer structure with holes defining channels, crystal grains, sand, quartz. Suitable polymers include thermoplastic polymers, such as polyoxymethylene copolymer, POM-C, and polyoxymethylene homopolymer, POM-H. Preferably, the material <NUM> is substantially non-absorbent with respect to oil, because the working fluid may be mixed with some oil used to smear the compressor <NUM>.

<FIG> shows a photograph of microscopically enlarged grit <NUM>, with quartz grains <NUM> leaving open channels <NUM> between the grains <NUM>.

<FIG> shows an alternative construction of a heat exchanger <NUM> with a vessel <NUM> that provides a space <NUM> for a substance, and a tube <NUM> having inlet <NUM> and outlet <NUM>. The interior of the tube <NUM> is a chamber <NUM> for the working fluid. At least part of the chamber <NUM> is filled with a structure <NUM> with filling material <NUM> and channels <NUM> similar to the structure <NUM> shown in <FIG>. In operation the working fluid flows through the channels <NUM> of the structure <NUM> from the inlet <NUM> to the outlet <NUM> of the chamber <NUM>. As illustrated the structure <NUM> may also fill at least part of channels <NUM>, <NUM> for the working fluid outside of the heat exhanger <NUM>.

<FIG> shows a perspective view of a vessel <NUM> that can take the role of the evaporator <NUM> in a refrigeration cycle. The vessel <NUM> contains a chamber <NUM>, and the chamber <NUM> contains tubing <NUM>. In this example, the vessel has a toroid shape. The illustrated toroid is a toroid generated by revolving a planar hexagon <NUM> (see <FIG>) about an axis (loosely drawn at numeral <NUM>) external to that hexagon <NUM>, which axis is parallel to the plane of the hexagon <NUM> and does not intersect the hexagon. It will be understood that the hexagon may be replaced by other shapes. The hexagon <NUM> is illustrated in <FIG>. As shown in <FIG>, the hexagon may have rounded corners. The rounding of a corner of the hexagon <NUM> may follow the outline of a tube portion <NUM>.

Shown in <FIG> is the tube portion <NUM> connected to one end of tube portion <NUM> to enable fluid to flow through tube portion <NUM> into tube portion <NUM>. Also shown is tube portion <NUM>, which is connected to another end of tube portion <NUM> to enable fluid to flow from tube portion <NUM> into tube portion <NUM>. It is noted that the flow of fluid may be reversed, so that fluid flows from tube portion <NUM> into tube portion <NUM> and then into tube portion <NUM>.

<FIG> shows a partially worked open drawing of the same vessel <NUM> as shown in <FIG>. The chamber <NUM> of the shown vessel <NUM> has a toroid shape as described above. The drawing shows that the chamber <NUM> of the vessel <NUM> is densely packed with tubing <NUM>. The tubing <NUM> is winded inside the chamber <NUM> around the above-mentioned axis <NUM>.

<FIG> shows again the cross section corresponding to portion <NUM> of the vessel <NUM> as shown in <FIG>. Tubes <NUM> and <NUM> are for transport of refrigerant from the chamber <NUM> to the compressor <NUM> and for transport of refrigerant from the expansion valve <NUM>, <NUM> into the chamber <NUM>, respectively. As can be seen from the drawing, the chamber <NUM> of the heat exchanger is densely packed with tube windings <NUM>. These windings may all belong to the same tube. Alternatively, a plurality of tubes exists inside the chamber <NUM>, and each winding belongs to one of those tubes.

In a particular example, the dimensions of the arrangement of the chamber <NUM> and the tube windings <NUM> are as follows. The tube or tubes may have an inner diameter of <NUM>, an outer diameter of <NUM>, a wall thickness of <NUM>. A distance between any two adjacent tube windings may be <NUM>, measured from center axis to center axis of the tube. The distance from the tube to the vessel wall may be <NUM>. The number of windings may be <NUM>.

<FIG> illustrates a top view of the chamber, wherein the windings are not shown. <FIG> illustrates a side view of the chamber. An example of dimensions of the chamber is as follows. The smallest diameter <NUM> of the chamber may be <NUM>, and the largest diameter <NUM> of the chamber may be <NUM>. A measurement of this may be done with an accuracy of ± <NUM>. A height <NUM> of the chamber may be <NUM>.

For example, the tube enters and exits the chamber <NUM> through two orifices in the vessel wall. The orifices may enclose the tube such that no refrigerant can enter or leave the chamber through the orifice, and no fluids from exterior may enter through the orifice into the chamber. Further, the vessel wall has an inlet and an outlet connected to tubing <NUM>, <NUM> to transport the refrigerant from the expansion device into the chamber <NUM> and from the chamber <NUM> into the compressor <NUM>. The inlet is located at the bottom side of the chamber <NUM>, or at least below a level of liquid refrigerant inside the chamber. However, the inlet may also be located above the level of liquid refrigerant in other embodiments. The outlet is located at the top side of the chamber <NUM>, or at least above a level of liquid refrigerant inside the chamber. This way, no liquid refrigerant can reach the compressor.

As explained, the vessel can be used in a refrigeration cycle of a cooling system. The vessel in that state contains a refrigerant in the chamber, which refrigerant is circulated through the cooling cycle. Some of the refrigerant is in liquid state, another portion is in vapor state. The vessel has a chamber bounded by a surface of the vessel wall, the vessel comprising an inlet and an outlet for transport of refrigerant into and out of the chamber. The inlet can be anywhere; the outlet is preferably above the level of liquid refrigerant in certain embodiments. At least one tube is provided through which a liquid to be cooled is to flow in operation. At least one tube portion is inside the chamber, wherein a first end of the tube portion is fixed to a first orifice of the vessel and a second end of the tube portion is fixed to a second orifice of the vessel to enable fluid communication into and/or out of the tube portion through the first orifice and the second orifice. For example, the tube extends through the first orifice and/or second orifice. The first orifice and second orifice may be an orifice in the vessel wall and/or an orifice in a toroid shaped body which may enclose the vessel wall, as explained below. In the example shown in <FIG>, the chamber of the heat exchanger presents a hole <NUM>. The tube portion inside the vessel is arranged in a plurality of windings around a wall portion of said vessel wall, which wall portion defines said hole. The hole <NUM> extends all the way through the vessel <NUM> and is defined by a wall portion of the vessel wall, so that fluids do not leak through the hole. The windings are arranged in a hexagonal tiling and form a bundle, with a space between each pair of adjacent windings. This hexagonal tiling can be best appreciated with reference to e.g. <FIG> which shows a cross section of the vessel at one side of the hole, as indicated in <FIG> at numeral <NUM>. In other words, in a cross section perpendicular to the central axis of the tube windings or tube segments, the tubes are arranged on a hexagonal grid. The tubes may be fixed to one another to keep them in place. Also, the tubes may be supported by the structure that fills the portion of the vessel that is not taken up by the tube windings.

The surface <NUM> of the vessel wall is arranged with a space between the vessel wall and all of the windings <NUM> that are at an outside of the bundle. The windings which are at the outside of the bundle are those windings that are surrounded by less than six adjacent windings. For example, winding <NUM> is surrounded by six adjacent windings <NUM>-<NUM> and is not at the outside of the bundle. Winding <NUM> is surrounded by three adjacent windings <NUM>, <NUM>, <NUM>, and winding <NUM> is surrounded by four adjacent windings <NUM>, <NUM>, <NUM>, <NUM>.

In the example shown in <FIG>, the hexagonally tiled windings are arranged in rows, e.g. <NUM>, <NUM>, <NUM>, etc., each row <NUM> consisting of a number of windings <NUM>, <NUM>, <NUM>, etc., wherein the number of windings in any one row <NUM> differs with respect to each adjacent row <NUM> or <NUM> by one winding. When considering the successive rows <NUM>, <NUM>, <NUM>, etc. in turn, the number of windings first increases from three windings to six windings and then decreases to four windings.

In an alternative embodiment, the number of windings in each row monotonically increases or monotonically decreases. For example, the number of windings in a row can increase from e.g. three (bottom row) to seven (top row). In another example, the number of windings in a row can decrease from e.g. seven (bottom row) to three (top row). The rows in a hexagonal tiling can be identified in three different directions, and the increase/decrease of the number of windings in each row applies to at least one of those directions.

Returning to <FIG>, the pattern of increasing number of windings in each row is identical for all three directions in which the rows can be identified. This property is also helpful to keep the chamber small.

The chamber <NUM> and the surface of the vessel wall <NUM> has a shape of a toroid generated by a hexagon. This hexagon has rounded corners following a contour of the tube <NUM>, <NUM>. When the number of windings in each row is monotonic, the shape of the chamber and surface is the shape of a toroid generated by a quadrilateral, optionally with rounded corners.

The distance between a central axis of the tube in two adjacent windings <NUM>, <NUM> multiplied by one half of the square root of three is smaller than an outer diameter (indicated d in <FIG>) of the tube. Referring to <FIG>, the distance between the central axis of the tube in two adjacent windings is equal to the sum of the space (indicated s in <FIG>) in between a pair of adjacent tube segments and the outer diameter (indicated d in <FIG>) of the tube portion. In a specific example, the distance between a central axis of the tube in two adjacent windings is <NUM>, the inner diameter of the tube is <NUM>, and the outer diameter of the tube is <NUM>. The spacing of the rows <NUM>, <NUM>, <NUM> is <NUM> in the example, which is smaller than the distance of <NUM> between the central axes of adjacent windings, which makes the design compact.

The distance from the inner surface <NUM> to a circumference <NUM> of a first portion of the tube adjacent to the inner surface <NUM> can be about equal to a distance between that circumference and a circumference <NUM> of a second portion of a winding of the tube adjacent to the first portion of the tube.

In a particular example of the heat exchanger the tube of the heat exchanger has an inner diameter of <NUM>, and the distance between the outlines of each pair of adjacent windings is between <NUM> and <NUM>.

Depending, among other parameters, on the dimensions of the heat exchanger, the heat exchanger can be used in conjunction with a variety of refrigerant materials, including Freon. In a particular example, the chamber comprises propane as the refrigerant. The dimensions described above are well suited for a cooling system based on propane as a refrigerant. Although certain dimensions have been disclosed above, the present disclosure is not limited thereto. The heat exchanger may be made with different dimensions.

Referring also to <FIG>, any one, or both of the heat exchangers <NUM>, <NUM> of the heat pump cycle may be filled at least partly, or entirely, with the structure <NUM>. The structure used to fill the condenser <NUM> may be different from the structure used to fill the evaporator <NUM>. These structures may differ with respect to the filling material <NUM> and/or the shape and dimensions of the channels <NUM>. In a preferred embodiment, the evaporator <NUM> has the filling material, while the condensor <NUM> does not have the filling material.

Referring also to <FIG>, the heat exchanger <NUM>, comprising the structure <NUM>, may be an evaporator <NUM> or a condenser <NUM> of a heat pump cycle.

In a particular embodiment, a heat pump comprises an evaporator comprising a chamber for a working fluid; and a wall for heat exchange between the working fluid in the chamber and a substance in a space on the opposite side of the wall, said chamber comprising a structure of a filling material that is substantially non-absorbent with respect to the working fluid, said structure defining a plurality of channels for the working fluid, said channels at least partly being bound by the wall separating the chamber from the space, said channels providing passage for the working fluid from an inlet of the chamber to an outlet of the chamber. In this embodiment, the heat pump further comprises a condensor comprising a second chamber for the working fluid, a second wall for heat exchange between the working fluid in the second chamber and a second substance in a second space on the opposite side of the second wall; said second chamber comprising a second structure of a second filling material that is substantially non-absorbent with respect to the working fluid, said second structure defining a plurality of second channels for the working fluid, said second channels at least partly being bound by the second wall separating the second chamber from the second space, said second channels providing passage for the working fluid from an inlet of the second chamber to an outlet of the second chamber.

When the heat pump is in operation, the compressor <NUM> pumps a working fluid (such as a refrigerant) though the condensor <NUM>, then through the expansion valve <NUM>, <NUM>, and then though the evaporator <NUM> back to the compressor <NUM>. When a part of the path of the working fluid (i.e. a chamber) is filled with the structure, the working fluid flows through channels of the structure, while interacting thermodynamically with a wall for heat exchange between the working fluid in the chamber and a substance in a space on the opposite side of the wall.

An embodiment comprises a method of heat exchange. The method comprises pumping a working fluid through channels of a chamber, causing the working fluid to interact thermodynamically with a wall for heat exchange between the working fluid in the chamber and a substance in a space on the opposite side of the wall, said chamber comprising a structure of a filling material that is substantially non-absorbent with respect to the working fluid, said structure defining a plurality of channels for the working fluid, said channels at least partly being bound by the wall separating the chamber from the space, wherein the working fluid flows from an inlet of the chamber to an outlet of the chamber through the channels.

Claim 1:
A heat exchanger for a heat pump, comprising
a chamber (<NUM>) for a working fluid; and
a wall (<NUM>) for heat exchange between the working fluid in the chamber and a substance in a space (<NUM>) on the opposite side of the wall,
said chamber (<NUM>) comprising a structure (<NUM>) of a filling material (<NUM>) that is substantially non-absorbent with respect to the working fluid,
said structure (<NUM>) defining a plurality of channels (<NUM>) for the working fluid, said channels (<NUM>) at least partly being bounded by the wall (<NUM>) separating the chamber (<NUM>) from the space (<NUM>),
said channels (<NUM>) providing passage for the working fluid from an inlet (<NUM>) of the chamber (<NUM>) to an outlet (<NUM>) of the chamber,
characterised in that
the maximum distance between adjacent channels (<NUM>) of the structure (<NUM>) is between <NUM> millimeter and <NUM> millimeter, or the structure is made up of a plurality of grains, said grains have an average diameter of between <NUM> millimeter and <NUM> millimeter, or the channels (<NUM>) have a diameter of generally less than <NUM> millimeter in cross section.