Patent ID: 12241659

DETAILED DESCRIPTION OF THE INVENTION

Referring initially toFIG.2, geothermal heat exchange apparatus10has a tubular shaped overall structure defined by the combination of a central conduit12and a helical arrangement of a plurality of pipes14around the central conduit12. The geothermal heat exchange apparatus10includes the central conduit12, plurality of pipes14, at least one fitting16and at least one joint18. The plurality of pipes14is twisted onto central conduit12in the helical arrangement for the exchange of heat. The at least one first fitting16connects to the plurality of pipes14and to at least two primary pipes4A and4B. The at least two primary pipes4A and4B are connected to at least one fitting16for fluid communication with heat pump3. The at least one joint18connects the plurality of pipes14to form a continuous loop for geothermal heat exchange. Geothermal heat exchange apparatus10or apparatus10defines a first longitudinal axis-X aligned with the centerline of central conduit12. The elongate shape of the geothermal heat exchange apparatus defines a proximal direction as being from the at least one joint18to the at least one fitting16and the distal direction to be from the at least one fitting16to the at least one joint18.

As shown inFIGS.2and3, central conduit12is a standard tubular conduit. Central conduit12or conduit12has a flexible structure that includes a first end portion20and a second end portion22. The first end portion20and second end portion22are opposed. First end portion20defines a first terminal end24and second end portion22defines a second terminal end26. Central conduit12defines an aperture28that extends between the first terminal end24and second terminal end26. Aperture28is a through hole that extends the length of central conduit12. In one preferred embodiment, the dimensions of central conduit12include an inside diameter of approximately one and nine-tenths (1.9) inches, outside diameter of approximately two and four-tenths (2.4) inches and a tubular wall thickness of approximately six hundred twenty five thousandths ( 1/16th or 0.0625) inches.

Central conduit12preferably has corrugated tubular walls that enhance the ability of central conduit to flex and form a circular or coiled shape. It is understood that the dimensions of the central conduit can vary depending upon the intended geothermal heat exchange application. The tubular wall of central conduit12can be solid or include a plurality of apertures29. The shape of apertures29is shown as being circular, but it is understood that apertures29can have any shape and/or directional alignment suitable for facilitating the flow of a material such as grout92from conduit12through apertures29. The central conduit12is not in fluid communication with the plurality of pipes,

The plurality of pipes14includes a first end portion30, an opposed second end portion32and a central portion33. The first end portion30of the plurality of pipes when positioned in bore hole8is below grade5, the center portion includes the helical twisting arrangement and the second end portion32is in proximity to the terminal end of the bore hole8. In this preferred embodiment, the geothermal heat exchange apparatus10has a proximal end portion that includes at least one fitting16, the first end portion30of the plurality of pipes14, and the first end portion20of the central conduit12and a distal end portion that includes the at least one joint18, second end portion of the plurality of pipes32of the plurality of pipes14, and second end portion22of central conduit12.

Each pipe15of the plurality of pipes14has a flexible tubular structure that includes a first end portion30and an opposed second end portion32. First end portion30includes a first terminal end34and second end portion32includes a second terminal end36. The first terminal end34and second terminal end36define an aperture38that is a through hole that extends the length of each pipe15. The diameter of aperture38of pipe15can vary depending upon the intended heat exchange application. In one preferred embodiment, individual pipes15of the plurality pipes14are standard ¾ or 0.75 inch inside diameter pipes15with a standard wall thickness of approximately 0.078 inch. The inside diameter and wall thickness of each pipe15of the plurality of pipes14is varied to accommodate the liquid flow and/or heat exchange demand for a given application. Primary pipe4preferably has an interior diameter of one and one-quarter (1.25) inches, but it is understood that the diameters of pipes15and primary pipe4can vary depending upon the application of geothermal heat exchange apparatus10.

Geothermal heat exchange apparatus10is structured for positioning in a bore hole8. The diameter and length of bore hole8and apparatus10can vary depending upon its intended application for heat exchange. In this one preferred embodiment, bore hole8has a six (6) inch diameter and apparatus10includes eight (8) pipes15that are wound around conduit12in the helical arrangement. The function of the helical arrangement of the eight (8) pipes15can vary, but the plurality of pipes14typically includes four (4) supply pipes15and four (4) return pipes15. One common length of apparatus10is approximately 300 feet.

The materials of construction of the plurality of pipes14and fluid flow therein are controlled by local ordinances, building codes and environmental laws. In this preferred embodiment, the plurality of pipes14is made from a high-density polyethylene (HDPE) material. It is understood that the plurality of pipes14can be made from other materials that satisfy the local ordinances, building codes and environmental laws of the different legal jurisdictions.

Each pipe15of the plurality of pipes14is twisted onto and around the central conduit or conduit12in a parallel, spaced, and twisted arrangement. Twisted onto as defined herein includes positioning the plurality of pipes14in direct contact with central conduit12in a helical arrangement. In the preferred embodiment the plurality of pipes14is positioned in an approximately parallel helical arrangement around the central conduit12. Each pipe15of the plurality of pipes14is fixed in position in direct contact with central conduit12and has a space or a gap40between pipes15. Each pipe15of the plurality of pipes14is positioned in approximate fixed spaced separation on central conduit12relative to the adjacent pipe15of the plurality of pipes14. Individual pipes15of the plurality of pipes14can vary in their respective inside diameters, their length, the quantity of pipes15in the plurality of pipes14and the arrangement of pipes15on central conduit12depending upon the intended application of geothermal heat exchange apparatus10. For example, in one preferred embodiment, plurality of pipes14includes a total of eight (8) pipes15in a twisted arrangement around the conduit12. While this embodiment as shown includes four (4) pipes15that are supply pipes and four (4) pipes15that are return pipes, alternative embodiments of apparatus10can include two (2) pairs of pipes15with one (1) pair of pipes15being supply pipes15and the one (1) pair of pipes15being return pipes15or six (6) supply pipes15and six (6) return pipes15.

The first end portion30and the second end portion32of the plurality of pipes14on central conduit12include a transition from the helical arrangement to a straight alignment with the central conduit and axis-X. The length of the straight alignment of the plurality of pipes14in first end portion30and second end portion32can vary, but is preferably three (3) to four (4) feet due primarily to the stiffness of pipes15and due to the straight length of pipe required to properly fuse the fitting onto the pipes. A straight alignment with each pipe15into each fitting16and primary pipe4A or4B is required because of the dimensional, form and fit limitations necessitated by the positioning of fittings16on conduit12that will be located in the six (6) inch diameter bore hole8. The straight alignments of pipe15, fitting16, joint18and primary pipe4also make a less complex and more reliable connection.

Referring now toFIG.4, fitting16is a non-standard and unique manifold connector specifically dimensioned for positioning in bore hole8(SeeFIG.2). In this one preferred embodiment, fitting16is a four (4) to one (1) manifold connector. Fitting16includes a housing44, a first end portion46and a second end portion48that is opposed to the first end portion46. First end portion46has a first terminal end50and first terminal end50defines a first aperture52. Tubular wall54defines a center56of first aperture52. Second end portion48includes a plurality of second terminal ends58that define a plurality of second apertures60. Second end portion48preferably includes a plurality of short tubular extensions62that extend as cantilevered tubes from housing44to second terminal ends58. Each second apertures60defined in second terminal ends58extends through tubular extension62and is in fluid communication with first aperture52. Each second aperture60is circular and defines a center64.

As shown inFIG.5, first end portion46includes tubular wall54and that defines first aperture52. The center56of first aperture52defines a centerline of fitting16housing44and also defines an axis-W. An axis-Z is perpendicular to, intersects axis-W and is aligned with the plurality of second terminal ends58. Tubular extensions62have an abbreviated length beyond housing44. Centers64that are also centerlines of tubular extensions62are aligned with axis-W.

Referring now toFIGS.5and6, an axis-Y is aligned with the plurality of second terminal ends58and is perpendicular to axis-Z. A plane Y-Z is defined by the intersection of the axis-Y and axis-Z. Plane Y-Z is aligned with the plurality of second terminal ends58and is parallel to the first terminal end50. Axis-W extends through the first end portion46, center56of first aperture52, through housing44and an axial center66of second end portion48. Tubular extensions62, apertures60and centers64are aligned with axis-W. Plane Y-Z is perpendicular to axis-W.

Second end portion48tubular extensions62are connected to their respective adjacent tubular extensions62by structural walls67. In this preferred embodiment each tubular extension62is connected by two structural walls67that include outer structural walls67and the inner structural wall67. The outer structural walls67are contiguous with housing44and extend between adjacent tubular extensions62. The inner structural walls67connect adjacent tubular extensions62in a region in proximity to axial center66and/or axis-W.

As shown inFIGS.4-6in this one preferred embodiment, fitting16is a four (4) to one (1) manifold connector that includes four (4) pipes15to one (1) primary pipe4(SeeFIG.2). The four (4) second apertures60each have centers64that define the corners of a square arrangement of second apertures60and tubular extensions62. The width between the outer edges of two adjacent second tubular extensions62of the second end portion48is greater than the outside diameter of first tubular wall54of first end portion46.

Referring now toFIG.7and continuing with the above preferred embodiment of fitting16, crossed pair of support walls68are positioned centrally in housing44have tapered terminal edges70. Crossed pair of support walls68or support walls68form a part of the inner surface of second tubular walls72. The intersection of the support walls68is axial center66. The outer surface of each second tubular wall72second end portion48extends outside of the diameter of the outer surface of first tubular wall54first end portion46. As shown inFIGS.4-7, the preferred embodiment of fitting16includes second apertures60and the initial portions of tubular walls72in proximity to terminal end58are aligned with and/or parallel to axis-W. After the initial length of second tubular walls72, the angular alignment of second tubular walls72are directed within housing44from the centerline64of second aperture parallel to axis-W in inward directions towards axis-W at an angle of approximately eight and four tenths of a degree (8.4 degrees). This relatively shallow angle defines a point of convergence of the four (4) apertures60that extends beyond the first terminal end50of fitting16and into the interior tubular wall of the connecting primary pipe4. The interior of housing44is structured to provide smooth fluid flow in both directions aligned with axis-W. For example, the support walls68that diverge the fluid flow from or merge the fluid flow into first aperture52include tapered edges70that are directed towards first terminal end50and the intersection of the support walls68has an approximate conical surface. Similarly, pairs of thin ridges74are located in proximity to and on opposing sides of the connection of each support wall68to the inner surface of tubular walls72. The pairs of thin ridges74begin in proximity to the start of the approximately eight and four tenths degree (8.4 degrees) degree angling of second tubular walls72and extend past the intersection of each support wall68on the inner surface of each tubular wall72. Each pair of ridges74is aligned with the center64of their respective second apertures60and second tubular walls72. Ridges74assist in maintaining laminar fluid flow through the diverging and merging of fluid flow in housing44. Fitting16, in this preferred embodiment, is made from a high-density polyethylene (HDPE) material. It is understood that the fitting16can be made from other materials that satisfy the local ordinances, building codes and environmental laws of the different legal jurisdictions where apparatus10is installed.

It is understood that while fitting16is shown as four (4) to one (1) manifold connector, fitting16can vary the external shape of housing44and have increased numbers of second apertures60and first apertures52for different applications. For example, fitting16second end portion48can include at least four apertures60and first end portion46can include two (2) first apertures52for connection to two (2) primary pipes4A for supply and4B for return.

The connections between the plurality of pipes14first terminal ends24and second terminal ends26, fitting16, primary pipes4and joint18are preferably by a hot melt butt joint type connection that is widely considered to be stable in connection qualities. Other method of connection, such as socket-type electric hot melt connection, for example. The above described hot melt butt joint can be further augmented in poor geological environments with additional layers of heat shrink material such as a tape as a sealing layer to further strengthen the connection.

As shown inFIG.8, in one preferred embodiment, the plurality of pipes14include a plurality of supply pipes15A and a plurality of return pipes15B. As shown for this embodiment, the second end portion32of four (4) supply pipes15A and second end portion32of four (4) return pipes15B respectively connect to the four (4) second terminal ends58on identical supply fitting14A and return fitting14B. The first apertures52of first end portions46of supply fitting14A and return fitting14B are preferably connected directly with a joint18or indirectly through sub-assemblies of joint18such as lengths of primary pipes4E and4F and fittings16, for example. In this embodiment, fittings16A and16B are connected to lengths of primary pipes4E and4F, respectively. Standard U-bend76is sized for connection with primary pipes4E and4F. Primary pipe4E connects to the first aperture52of supply fitting16A and primary pipe4F connects to the first aperture52of return fitting16B. Primary pipes4E and4F then connect to the apertures defined in U-bend76. This embodiment provides an advantageous use of fittings16for connection with primary pipe4as part of first end portion30of plurality of pipes14(SeeFIG.2) as well as in joint18that connects to second end portion32of plurality of pipes14.

Referring now toFIGS.9-11, in an alternative embodiment, each fitting16uses two (2) second apertures60for supply and two (2) second apertures60for return. First end portion46includes a cap78that secures to first terminal end50and closes first aperture52(SeeFIG.7) turning fitting16into a variation of a U-bend connector. The two supply pipes15A and two return pipes15B per fitting16can be operationally employed to stagger fittings16along axis-X or alternatively in tandem or side by side on opposing sides of axis-X.

As shown inFIGS.12-14, in another alternative embodiment, each pipe15connects to a single joint18. This embodiment has the advantage that the second terminal ends36of pipes15cannot be connected to the wrong aperture38in fitting16or joint18or the wrong fitting16. Joint18includes a housing80, first end portion82and an opposed second end portion84. First end portion82includes a first terminal end86and first terminal end86defines a plurality of apertures88. The second terminal ends36of pipes15connect to the apertures88in terminal end86. Apertures88feed into a common reservoir90that can vary in capacity depending upon the intended application. Joint18in this embodiment can have any arrangement of apertures88as long as apertures88are all connected to reservoir90. Referring now toFIG.15, each component of the geothermal heat exchange apparatus10that includes central conduit12, plurality of pipes14, fitting16and joint18is structured, connected and inter-related for flexibility. Thus, the fully assembled apparatus10can be coiled into a stack of coils for efficient storage and/or transportation. Upon arrival at an installation site, apparatus10can also be readily uncoiled into a linear alignment for installation down borehole8. Apparatus10primary pipes4C and4D can be connected to the primary pipes4A and4B that connect to the heat pump3before or after installation in bore hole8(SeeFIG.2).

As shown inFIGS.2and16, geothermal heat exchange apparatus10is installed in bore hole8for operational use with primary pipes4C and4D connecting to primary pipe4A and4B, respectively. Central conduit12has been used as a tremie type pipe for the insertion of grout92or other related compounds to backfill bore hole8. Grout92permeates the bore hole8from the bottom up as well as through apertures29of central conduit12.

Referring now toFIG.17, the dimensions of the fittings16and central conduit12require a tight fit in bore hole8. Fittings16are preferably located between (2) and three (3) feet below trench6and within the length of the casing8A of bore hole8. In this one preferred embodiment of a four to one (4 to 1) fitting16manifold connector in a six (6) inch bore hole, the dimensions of the outside diameter J of central conduit12is approximately two and four tenths inches (2.4) and the width dimension of fitting16is approximately two and three tenths (2.3) inches and a length of approximately four and seventy-five one-hundredth (4.75) inches. In an ideal arrangement the sum of the diameter of central conduit12and width of fitting16is approximately 4.7 inches. In the worst case, the diagonal distance between diagonally opposed second apertures60is approximately two and seventy-five one hundredth (2.75) inches or a total of approximately five and fifteen hundredth (5.15) inches that readily fits in the six (6) inch diameter bore hole.

As shown inFIGS.2and16, geothermal heat exchange apparatus10has been extended from the coiled position to a linear position in an approximately vertical borehole8in ground6. It is understood that borehole8is not required to be vertical and can be angled from the vertical. Once positioned in borehole8, an external source of grout92is used to supply grout92into central conduit12first aperture25in first end portion20. Grout92is preferably pumped under pressure down conduit12and out through second aperture28in the second end portion18and apertures29in the tubular wall of conduit12. Grout92surrounds the geothermal heat exchange apparatus10in borehole6through the primary loading of the grout92at the bottom of the borehole8and filling the borehole6vertically upward as is common practice. In addition, grout92advantageously passes through apertures29in the tubular wall of conduit12in the direction transverse to the longitudinal axis to assist in the filling of gaps40between pipes15of the plurality of pipes14that are positioned in approximately fixed spaced separation. As required for a given application, bands34can be applied around the plurality of pipes14.

The relatively thin walled structure of central conduit12and each pipe15of the plurality of pipes14of geothermal heat exchange apparatus10that facilitates coiling also advantageously provides less thermal resistivity and correspondingly better heat transfer when the geothermal heat exchange apparatus10is installed in the earth or ground6.

Geothermal heating exchange apparatus10has an advantageous level of heat transfer due to the helical twist in the plurality of pipes14and the creation of secondary effects in the fluid flow in the plurality of pipes14. Secondary effects occur in curved pipes15as the laminate flow against the boundary layer on the inside of each pipe15becomes a cross flow between the inner and outer pressure gradients experienced by the heat exchange fluid in the plurality of pipes14. The secondary flow results in elevated levels of heat transfer at relatively low Reynolds numbers in the range of 1,000 or less without the high turbulence and greater pump pressure demands required by straight pipes to achieve the approximately same level of heat transfer at Reynolds number in the range of approximately 2,500 to approximately 3,000. Further, the combination of multiple relatively small diameter pipes15of the plurality of pipes14provides for increased surface area for heat transfer.

Referring now toFIGS.2and18, geothermal heat exchange apparatus10is shown in another preferred embodiment similar to that described previously in reference toFIG.2for the central conduit12, plurality of pipes14, and at least one fitting16. In this preferred embodiment the at least one joint18is a plurality of joints18and the geothermal heat exchange apparatus10further includes a sleeve112and a weight100. The geothermal heat exchange apparatus10has a proximal end portion that includes the at least one fitting16, the first end portion30of the plurality of pipes14, and the first end portion20of the central conduit12and a distal end portion that includes the at least one joint18, second end portion32of the plurality of pipes14, sleeve112, and weight100. The plurality of joints18connects to the second end portion32of the plurality of pipes14to provide a continuous flow of the plurality of pipes14from the primary supply pipe4A to the primary return pipe4B. The sleeve112is a tube and is connected to the second end portion32of the plurality of pipes14and plurality of joints18. Weight100is positioned in aperture28of the central conduit12and connected to the central conduit12.

As shown inFIGS.18and19, in this one preferred embodiment of apparatus10, sleeve112is shown separate from the second end portion32of the plurality of pipes14and plurality joints18. Each adjacent pair of pipes15in their helical and straight arrangements of the plurality of pipes14include one (1) supply pipe15and one (1) return pipe15that connect to a single (1) U-bend18or joint18of the plurality of joints18. The adjacent pairs of pipes15are preferably arranged with each pair of pipes15having a different length such that the second terminal end36of each pair of pipes15of the plurality of pipes14is connected to each joint18in a staggered arrangement in the distal direction that is approximately aligned with longitudinal axis-X. The difference in length between adjacent pairs of pipes15is preferably approximately six (6) inches, but the difference in length of the staggered pairs of pipes15can vary depending upon the intended application of apparatus10and can often range over one (1) foot in length. As shown, the combination of the plurality of pipes14extending in the distal direction beyond the second terminal end26of central conduit12and the staggering of the lengths of the pairs of pipes15provides a sequential reduction in remaining number of pipes15of the plurality of pipes14and joints18of the plurality of joints18. The outer dimension of the second end portion32of the plurality of pipes14and plurality of joints18have a distinct taper in the distal direction as the quantity of the remaining pairs of pipes15of the plurality of pipes14and joints18of the plurality of joints18is reduced to a single pair of pipes15and a single joint18.

Each U-bend18has a housing80that includes a first end portion82and a second end portion84. The first end portion82includes a first terminal end86. The first terminal end86defines a first aperture88and a second aperture89. The second end portion84includes a common pipe94that connects and provides fluid communication between first aperture88and second aperture89. It is understood that variations of the U-bend shape of this embodiment of at least one joint18are encompassed herein and include a straight line and angled corner “U” shape vice a rounded “U” shape and a “V” shape, for example.

Weight100has an elongate shape that includes a first end portion102and a second end portion104. First end portion102includes a first terminal end106and second end portion104includes a second terminal end108. As shown in this one preferred embodiment, weight100has the structure of a pipe that defines an aperture110in first terminal end106that is a through hole that extends to the aperture110defined in the second terminal end108of weight100.

Weight100is positioned in aperture28defined in the second terminal end26of central conduit12and connected and fixed in position in central conduit12. Weight100can be positioned exclusively in aperture28of central conduit12or weight100can extend in the distal direction from within aperture28beyond second terminal end26of second conduit12. As shown in this one preferred embodiment, weight100extends proximally in the direction of fittings16for a pre-determined distance from a location in aperture28of central conduit12and extends in the distal direction beyond the second terminal end26of central conduit12. The extension of weight100in the distal direction preferably includes extending beyond the plurality of pipes14, the plurality of joints18, and sleeve112for a predetermined distance. Weight100is preferably fixed in position in the aperture28of central conduit12and by the connection between second end portion32of the plurality of pipes14, plurality of joints18, and sleeve112. The dual connection of weight100in the central conduit12and the connection between weight100and second end portion32of the plurality of pipes14, plurality of joints18, and sleeve112advantageously keeps the distal end portion of the geothermal heat exchange apparatus10in a stiff straight alignment and with a concentrated force of weight100aligned with the longitudinal axis-x for penetration through bore hole8outcroppings, irregularities, and water to the bottom of the bore hole8.

In this one preferred embodiment weight100is connected to and fixed in position in the geothermal heat exchange apparatus10using one or more methods that include, but are not limited to using, (1) tape111, bands, clamps, and/or ties through apertures29and around weight100, and/or using adhesives to bond weight100against the interior of the tubular wall of central conduit12and fix weight100relative to central conduit12; (2) using tape, bands, ties and/or clamps around weight100and using tape, bands, clamps, and/or ties to strengthen the connection of a cap, plug, or cover to second terminal end26that closes aperture28of central conduit12and preferably still includes an opening for weight100to extend through and still fix weight100in position in aperture28and apertures for the passage of grout92; and/or (3) using sleeve112to compress and bind the second end portion32of the plurality of pipes14and joints18around weight100and fix the location of weight100and second end portion32of the plurality of pipes14and joints18relative to the central conduit12.

In the preferred embodiment weight100has the structure of one or more pieces of rebar that accommodates the flow of grout92around weight100in aperture28and out through aperture28in second terminal end26, apertures29in the tubular wall of central conduit12, and into the bore hole8. Similarly, weight100can have the structure of one or more pieces of pipe that accommodate the flow of grout92around and through weight100, and through apertures28and29in central conduit12. Alternatively, weight100can be a solid structure that blocks the flow of grout92from aperture28of second terminal end26of central conduit12. When weight100blocks the flow of grout92down central conduit12, the plurality of apertures29in the tubular wall provide an adequate path for the flow of grout92from central conduit12and into bore hole8.

The benefits of weight100with a pipe structure that extends beyond second terminal end26of central conduit12, the plurality of pipes14, plurality of joints18, and sleeve112include the stiffness or rigidity of elongate weight100that connect the central conduit12and the second end portion32of the plurality of pipes14and the plurality of joints18. It is understood that the length of the second end portion32of the plurality of pipes14between the second terminal end26of the central conduit and the joints18can vary from between a few feet to as much as twenty (20) or more feet. The combination of the positioning the majority of the weight100distal to the central conduit, approximate alignment of weight100with longitudinal axis, plurality of pipes14, and the bore hole8, and stiffness of weight100combine to make the geothermal heat exchange apparatus10down hole penetrations significantly easier by overcoming outcroppings and irregularities in bore hole8. In addition, the locating of aperture110of weight100at the bottom of bore hole8provides for the flow of grout92to build from the bottom of bore hole8upwards. This has the potential to lessen the likelihood of undesirable air pockets and to uniformly force any water that may exist at the bottom upwards due to the higher density of the grout92. As desired, the water can then be pumped from the borehole once the grout92has reached a desired height.

The preferred material or materials of weight100are denser than water. Examples of preferred materials include alone or in combination, materials such as but not limited to, metals such as steel, iron, or copper. Other materials include high-density composites, concrete or cement, and natural material such sand, rocks, stones, and/or gravel. Additional examples of the structure of weight100include, but are not limited to one or more of pipes, cylinders, wire, bars, rods, and tubes. Weight100can be a single solid cylindrical bar without aperture110that fills aperture28of central conduit12or a plurality of small diameter pipes or tubes that define apertures110, or a plurality of bars that have relatively small diameters such as rebar that only partially fill aperture28and provide gaps or apertures110between the plurality of bars for the passage of grout92.

The length and quantity of the one or more weights100can also vary depending upon the desired total weight of weight100and other factors that include the length of the second end portion32of the plurality of pipes14between the second terminal end26of the central conduit12and the plurality of joints18, and ability of the geothermal heat exchange apparatus10to be stored and/or transported in a coil with weight100installed. The other materials noted above can similarly be contained in elongate containers that fit into aperture28of the central conduit and can vary from being rigid elongate canisters to flexible containers for smaller pieces of metals, high density composites, rocks, stones, sand and/or gravel that readily fit into aperture28of the central conduit12and preferably accommodate the passage of grout92. The amount of weight100required for a given application of geothermal heat exchange apparatus10can vary depending upon factors such as the quantity of pipes in the plurality of pipes, type of joint or joints, depth of, and conditions in the bore hole8to include outcroppings, the stability of the bore hole8wall, and the presence of and depth of any water in bore hole8. One common amount of weight100in applications for the present disclosure of apparatus10is approximately fifty (50) pounds. It is understood that the amount of weight of weight100required for a given application of apparatus10can vary as described herein above.

Referring now toFIG.20, sleeve112has the shape of a tube or pipe that includes a first end portion114and a second end portion116. The first end portion114includes a first terminal end118and the second end portion116includes a second terminal end120. The first end portion114and second end portion116are opposed. Sleeve12has a preferred length X of approximately sixteen (16) inches and the preferred outside diameter of approximately four and one-half (4.5) inches.

The first end portion114includes cuts122in the tubular wall of sleeve112. In this preferred embodiment, first end portion114has eight (8) elongate cuts122that preferably extend a distance-Y from the first terminal end118towards the second end portion116. In this one preferred embodiment, distance-Y is approximately three and one-half inches (3.5) inches. Cuts122are located at approximately forty-five (45) degree angle increments around the circle defined by first terminal end118of first end portion114.

Second end portion116of sleeve112preferably defines two sets of cuts124that remove a section of the tubular wall of sleeve112. The two sets of cuts124are separated by approximately one hundred and twenty (120) degrees of angle around the circular shaped second terminal end120of tubular sleeve112and preferably diametrically oppose one another across terminal end120. Each of the two sets of cuts124includes two (2) elongate cuts and one transverse cut124. The elongate cuts124extend a distance-Z from the second terminal end120towards the first terminal end118and are separated by approximately sixty (60) degrees of angle of second terminal end120. In this one preferred embodiment, the distance-Z is approximately three (3) inches. The transverse cut124in each set is preferably parallel to the second terminal end120and extends the approximately sixty (60) degrees between the two elongate cuts124. The three (3) cuts124of each set of cuts124removes one rectangular shaped piece of the tubular wall of sleeve112. It is understood that the diameter of tubular sleeve112as well as the quantity, size, and location of cuts122and124can vary with the intended application of sleeve112.

Sleeve112is preferably fabricated of the same high-density polyethylene (HDPE) material as the plurality of pipes14, but it is understood that sleeve112can be fabricated out a variety of materials to include, but not limited to sheet metal, composites, and fabrics. The tubular structure of sleeve112can also be extended longitudinally and define a receptacle for a “built in” weight100for sleeve112that could be for example, in the form of concrete or cement to provide additional weight100to the distal end portion of apparatus10. Sleeve112preferably has a smaller inside diameter than the outer dimensions of the plurality of pipes14around central conduit12of pipes14and the inside diameter of sleeve112is larger than the outer dimensions of any pair of pipes15connected to one joint18. The structure of sleeve12in with cuts122and124accommodates the reduction and expansion, respectively, of the tubular structure of sleeve112of the tapering of the staggered second end portion32of the plurality of pipes14and the plurality of joints18. It is understood that the dimensions identified herein for the length, diameter, and cuts122and124of sleeve112can vary depending upon a variety of factors such as the quantity of individual pipes15in any application of the plurality of pipes14and the length of the second end portion32of the plurality of pipes14between the at least one joint18and central conduit12.

As shown inFIG.21, sleeve112is connected to the second end portion32of the plurality of pipes14and the plurality of joints18. The second end portion116of sleeve112is positioned over the staggered second end portion32of the plurality of pipes14and plurality of joints18. The removed portion from cuts124of the second end portion116of sleeve112accommodate sleeve112being positioned in the proximal direction as far as practical over the increasing outer dimensions of the staggered second end portion32of the plurality of pipes14and plurality of joints18. It is understood that the diameter and material of sleeve112can vary to include creating varying amounts of an inwardly directed compressive bias on the plurality of pipes14, plurality of joints18, and weight100. It is understood that the second end portion116of sleeve112can be distant from or in proximity to the second terminal end26of central conduit12.

The cuts122in the first end portion114of sleeve112define bendable flaps that are preferably pushed inwards and overlapped to define a tapered structure of the first end portion114of sleeve112. The tapered structure of first end portion114provides an adjustable and close-fitting connection with the diminishing outer dimensions in the distal direction of the staggered second end portion32of the plurality of pipes14, plurality of joints18and weight100.

In this one preferred embodiment tape111is preferably used to retain the taper in first end portion114of sleeve112around the second end portion32of the plurality of pipes14and the plurality of joints18and to assist in the connection between sleeve112and the plurality of pipes14and the plurality of joints18. Similarly, the second end portion116can also include tape111or a similar device such as a band42to retain the connection between the second end portion116of sleeve112and the plurality of pipes14and the plurality of joints18.

Weight100is an elongate tubular, cylindrical, or bar shaped structure that can be rigid, flexible, or include a series of shorter length segments107that are attached to one another by connections109along the elongate length of weight100. Weight100connection109preferably connects the two adjacent segments107such that each segment107can move independently relative to other segments107. Connection109can include joint type connections, such as for example, tape, wire, hinges, and/or ball and socket. Each segment107of weight100, or for example, every other segment107in the elongate weight100can be separately connected and/fixed to the inside of the tubular wall of central conduit12as described previously such that weight100can flex and coil with central conduit12.

The connections109of weight100can also include devices to stiffen weight100such as for example, each segment107can define an aperture110that can be aligned with the longitudinal axis of each segment107and the segments107connected by a single wire or string through their apertures110. The length of the single wire can be used to allow play for the individual directional alignment of each segment107when apparatus10is coiled, for example, and then when the length of apparatus10is stretched out, the length of wire in apertures110can be shortened to abut each segment107tightly to the adjacent segments107. The terminal ends of segments107can also include mating interfaces, such as for example concave and convex shapes, that help the transition of each segment107of weight100from a flexible alignment to a straight and stiff or rigid alignment that is aligned with longitudinal axis-X to aid in the installation of apparatus10in bore hole8.

Referring now toFIG.22, in this one preferred embodiment weight100is located exclusively in aperture28of central conduit12with the second terminal end108of weight100in proximity to the second terminal end26of central conduit12. Weight100is fixed in position in central conduit12using one or more methods such as, for example, but not limited to taping, bands, and ties through apertures29, and/or using adhesives to attach weight100against the interior of the tubular wall of central conduit12and fix weight100relative to central conduit12; strengthening the connection between a cover, plug, or cap to the second terminal end26of central conduit12using111. As described above, weight100is preferably structured to accommodate the flow of grout92through and/or around weight100and out through apertures29and/or aperture28of second terminal end26of central conduit12. For example, the terminal cover or cap or the tape111over second terminal end26can include apertures that accommodate the flow of grout92, but prevent weight100from passing through second terminal end26.

As shown inFIG.23, in another preferred embodiment of the geothermal heat exchange apparatus10, the at least one joint18of geothermal heat exchange apparatus10in this one preferred embodiment is a single joint. The second end portion32of the plurality of pipes14extend a predetermined distance distal the second terminal end26of the central conduit and connect to the single joint18that preferably has an overall annular shape. Joint18in this one preferred embodiment has a housing80that includes a first end portion82and a second end portion84. The first end portion82and the second end portion84are opposed. The first end portion82includes a first terminal end86and second end portion84includes a second terminal end87. The first terminal end86defines a plurality of apertures88that connect to the second terminal ends36and/or second end portion32of the plurality of pipes14.

Each aperture88extends from the second terminal end86into housing80and connects to a reservoir90and/or a single common pipe94. Common pipe94preferably has an annular shape. Common pipe94receives the flow from the supply pipes15A of the plurality of pipes14into apertures88and the flow in common pipe94is drawn through other apertures88to the return pipes15B of the plurality of pipes14. The supply pipes15A and return pipes15B of the plurality of pipes14can be advantageously connected to any aperture88in this one preferred embodiment. Joint18apertures88are preferably located in an approximately circular arrangement in proximity to the perimeter of the first terminal end86.

It is understood that the arrangement of apertures88on first terminal end86depends upon factors that include minimizing the diameter of joint18and ease of connectivity between apertures88and the second terminal ends36of the plurality of pipes14. Alternative arrangements of apertures88include, for example, a staggered circular arrangement in first terminal end86and/or variations in the height of apertures88relative to first terminal end86in the direction of longitudinal axis-X that adjust for the staggered lengths of pipes15of the plurality of pipes14.

In this preferred embodiment of joint18, housing80, and first terminal end86preferably define an aperture96that extends between first terminal end86of first end portion82and the second terminal end87of second end portion84. Aperture96is not in fluid communication with apertures88or common pipe94. Aperture96is preferably aligned with the aperture28of central conduit12, weight100and longitudinal axis-X as shown. Aperture96can also be omitted from joint18in this one preferred embodiment and the outside diameter of joint reduced further.

Referring now toFIGS.18,23, and24, in another preferred embodiment of the at least one joint18of the geothermal heat exchange apparatus10,FIG.18, at least one joint18is one joint18that includes housing80, first end portion82, first terminal end86, apertures88and aperture96as described previously inFIG.23, but housing80has an extended length between first terminal end86and second terminal end87in the distal direction along the longitudinal axis-X. While first terminal end86is shown as having a planar shape, first terminal end86can also include variations in elevation of first terminal end and the variations in the location of apertures88as described previously to accommodate variations and/or staggering in the lengths of pipes15of the plurality of pipes14. Housing80in this preferred embodiment provides an extended length of protection to the connection between the plurality of pipes14and joint18due to the elongate structure of joint18minimizes the likelihood of joint18be turned out of alignment with the longitudinal axis-X by outcroppings and/or irregularities in bore hole8. Aperture96is preferably aligned with aperture28of central conduit12and weight100.

As shown inFIGS.18,19,22, and25geothermal heat exchange apparatus10in one preferred embodiment is fabricated as an assembly that includes central conduit12, the plurality of pipes14, two fittings16, a plurality of joints18, sleeve112, and with weight100as a component of apparatus10that can be connected and fixed in the central conduit12in the fabrication of apparatus10in the factory as previously described herein or as a separate optional component of apparatus10that can be subsequently installed into central conduit12of apparatus10prior to installation in the bore hole8.

The fabrication of apparatus10without the installation of weight100provides the flexibility of not burdening apparatus10with weight100and additional handling requirements for the added weight100when the drilling conditions of the bore hole8are foreseen as favorable soil and water conditions. The fabrication of apparatus10with the installation of weight100accommodates the adding of weight100into the central conduit12without increasing the overall diameter of apparatus10and can optionally provide an elongate element of stiffness to the extended length of apparatus10when the condition of the bore hole8takes an unexpected turn that can include outcroppings and/or irregularities in the walls of bore hole8that can bind and hang up the down hole positioning of apparatus10. Similarly, the penetration of water in bore hole8at least requires the addition of weight100in the distal end portion of apparatus10or second end portion32of the plurality of pipes14and at least one joint18to penetrate through the water to position the distal end portion of apparatus10at the bottom of the bore hole8.

It is understood that while bore hole8conditions in certain geographic locales can be somewhat predictable, bore hole8conditions at any given location cannot be predicted with certainty. Thus, there are geographic locales where it is most likely that there will be outcroppings and/or irregularities in bore hole8and/or water and it warrants the use of weight100through on-site installation and/or fabrication of apparatus10with weight100connected and fixed in central conduit12. In other situations, flexibility as to the amount of weight100to be employed within central conduit12and knowledge of problems with prior installation attempts can be advantageous. For example, an additional amount of weight100and/or stiffness of weight100may be required to penetrate through deep water in bore hole8, but a lesser amount of weight100to overcome outcroppings and irregularities in bore hole8. Similarly, there are other geographic locales where the bore hole8conditions are known to have a high risk of outcroppings, irregularities and/or high-water levels and favor the installation of weight100at the site that is elongate, stiff, and denser than water and stiffly or rigidly connects the central conduit12with the plurality of joints18to overcome the above-identified problems and others.

When geothermal heat exchange apparatus10is initially received at the site of bore hole8in its coiled configuration for transportation with either weight100installed or weight100separated from apparatus10, apparatus10is unwound from its coiled state. When apparatus10includes a plurality of joints18, weight100is installed in apparatus10on site by removing tape111around the outside of sleeve112and sleeve112is withdrawn in the distal direction from the plurality of joints18and the second end portion32of the plurality of pipes14. As required, the pairs of pipes15and their respective joints18are arranged to provide access to the second end portion22of central conduit12. Weight100is moved in the proximal direction as shown in Arrow-A between the plurality of joints18connected to the pairs of pipes15of the plurality of pipes14and inserted into aperture28of central conduit12. As described previously weight100can be one or more individual pieces of weight100in this preferred embodiment such as pipe and/or rebar that are preferably rigid, elongate, denser than water, and provide flow around or through weight100in aperture28of central conduit12. The preferred weight100has a small cross-sectional area relative to a cross-sectional area of aperture28of central conduit12for flow around weight100and/or provides flow through weight100so as to not unduly restrict the flow of grout92through aperture28of central conduit12.

The required amount of weight100is selected for a given apparatus10and conditions in the bore hole8. The individual pieces of weight100, as required, have their respective first terminal end106and/or second terminal end108protected to prevent any gouging or ripping of central conduit12and are preferably connected using bands, ties, clamps, and/or tape. The protection of first terminal end106and/or second terminal end108of weight100can include the use of polymer caps, polymer packaging material and heavy-duty tape. Weight100first end portion102is inserted into aperture28of central conduit12and second terminal end26is positioned at a desired location relative to the second terminal end26of central conduit12.

Referring now toFIGS.18and19, in one preferred embodiment of geothermal heat exchange apparatus10, weight100has a position and length that includes weight100extending in the proximal direction a predetermined distance within aperture28of the central conduit12and extending in the distal direction for a predetermined distance beyond the terminal end26of the central conduit12, plurality of pipes14, plurality of joints18, and sleeve112.

Weight100is preferably connected to the central conduit12once the second terminal end108is located at the desired distance distal to the at least one joint18, second end portion32of the plurality of pipes14, and sleeve112. Weight100is preferably connected to and fixed relative the central conduit12using tape111, ties, and/or bands as described previously. The second end portion32of the plurality of pipes14and their respective joints18of the plurality of joints18are then as appropriate taped, tied or banded together in an alignment that can include a transition from the helical arrangement of the plurality of pipes to the approximately straight alignment with the longitudinal axis-X in the second end portion32.

The connection of sleeve112into a tight fitting, binding, and compressing relationship around the staggered plurality of pipes32and plurality of joints18preferably includes positioning the plurality of joints18and at least a portion of the second end portion32through aperture119of the second end portion116of sleeve112and/or pulling sleeve112over the plurality of pipes32and plurality of joints18. The tight fitting, binding, and compressing relationship with the preferably staggered plurality of pipes32and plurality of joints18also fixes weight100in position relative to the second end portion32and central conduit12.

Tape111, a heavy-duty tape, is then applied again to secure the position and reinforce the cuts122of first end portion114and cuts124of second end portion116of sleeve112. Tape111preferably secures and reinforces the overlapped positions of the flaps defined by cuts122to define a close-fitting taper around the staggered plurality of joints18. Tape111can reinforce and secure the overlapping position of the flaps defined by the cuts122to close aperture119in first end portion114or alternatively reinforce and secure the overlapping position of the flaps defined by cuts122to define a reduced sized diameter aperture119in first end portion114of sleeve112. Retaining aperture119in sleeve112provides for a free flow of fluids through sleeve112which is preferable for the flow of grout92and removal of air pockets and water from borehole8. Tape111is preferably used to secure the second end portion104of weight100to the first end portion114of sleeve112. Tape111also preferably secures and reinforces the connection between the second end portion116of sleeve112and the second end portion32of the plurality of pipes14.

Once weight100is installed into and connected to aperture28of central conduit12on site and geothermal heat exchange apparatus10is re-assembled, apparatus10can then complete its final connections, testing, inspections, and installation into bore hole8.

Referring now toFIGS.18and22, in one preferred embodiment of geothermal heat exchange apparatus10, weight100has a position and length that includes weight100extending in the proximal direction a predetermined distance within aperture28of the central conduit12and extending in the distal direction for a predetermined distance to a point within aperture28before reaching second terminal end26of the central conduit12. Weight100in this preferred embodiment if preferably located within aperture28and in proximity to second terminal end26. Weight100is connected to and fixed in position in aperture28, against the tubular wall of and relative to central conduit12as described previously above using, tape111, bands, ties, caps and/or terminal end connections to second terminal end26of central conduit12.

The position of weight100solely within aperture28of central conduit12has advantages in that the installation of weight100into aperture28does not require securing weight100within the extended length of the plurality of pipes14, plurality of joints18, and sleeve112. This one preferred embodiment combines a simpler connectivity between weight100and central conduit12and the advantage of adding weight100to the extended length and inherent stiffness of the second end portion32of the plurality of pipes14and plurality of joints18which is more than adequate under most circumstances to prevent geothermal heat exchange apparatus10from being hung up on outcroppings and irregularities within bore hole8.

As shown inFIGS.18,21, and25weight100can also be integrated into the fabrication of the geothermal heat exchange apparatus10as described above by making weight100suitable for being coiled with the central conduit12, plurality of pipes14, at least one fitting16, and at least one joint18for ease of storage and/or transportation. As shown, the elongate weight100is shown as having multiple individual segments107of a predetermined abbreviated length that are joined by connections109. In one preferred embodiment the lengths of segments107is between three (3) and (4) four feet, but it is understood that segments107and connections109of weight100can vary in length and extend from within aperture28of central conduit12to distal to the plurality of joints18. As described above, the segments107can be configured to have a single wire extend through all segments107that can be loosened to accommodate flexing at connections109and then drawn tight to secure segments107in a rigid straight linear alignment for insertion into bore hole8. The use of flexible connections109with rigid sections107of the various structural configurations described herein for weight100that can be coiled and uncoiled within central conduit12can be applied to any of the embodiments presented herein.

As shown inFIGS.18,24, and25geothermal heat exchange apparatus10in one preferred embodiment is fabricated as an assembly that includes central conduit12, the plurality of pipes14, at least one fitting16, a single joint18, sleeve112and weight100as a components of apparatus10that can be connected and fixed in the central conduit12in the fabrication of apparatus10as previously described herein or subsequently installed into the apparatus28of and connected to central conduit12prior to installation of apparatus10in the bore hole8.

In one additional preferred embodiment of sleeve112, the first end portion114of sleeve112connects to the second end portion84of joint18and sleeve112second end portion116extends proximally towards central conduit12and connects one or more pipes15of the plurality of pipes14. In this embodiment of sleeve112, cuts122in first end portion114of sleeve112can taper first end portion114with the tapering of joint18second end portion84. Second end portion116of sleeve112extends past first terminal end86of joint18, connects to the second end portion32of the plurality of pipes14and acts as a tubular flexible shield around the connections between the second end portion32of the plurality of pipes14and apertures88during the handling associated with the preparation for and the descent of apparatus10down

Sleeve112can be connected to and fixed in position around the second end portion32of the plurality of pipes14between central conduit12and joint18. This embodiment of sleeve112can have a larger diameter to accommodate the diameter of single joint18or alternatively have a smaller diameter such as inFIG.18with the plurality of joints18to limit the movement individual pipes15of, provide outcropping protection for, and add stiffness to the plurality of pipes14.

When weight100extends through aperture96of joint18, weight100is preferably connected to and fixed in position in aperture96of joint18. Methods for connecting weight100in aperture96of joint18include those described previously for central conduit12that include the use of tape111, bands, and/or ties. Further, the structure of housing80of joint18can include and/or adhesives.

Referring now toFIGS.18and24, single joint18has an elongate tubular first end portion82and a second end portion84. First end portion82and second end portion84are opposed. The elongate first end portion82includes apertures88that extend between first terminal end86and common pipe94. In this embodiment, common pipe94is in and/or in proximity to second end portion84of joint18. Sleeve112first end portion114preferably connects to first end portion82of joint18and the second end portion32of the plurality of pipes14to provide an additional layer of protection from bore hole8outcroppings and irregularities. The elongate joint18has advantages in that the combination of the elongate first end portion82and tapered second end portion84is more likely to stay aligned during the descent in the bore hole8. This combination reduced the likelihood of damage to the connections between the individual pipes15of the plurality of pipes14and joint18. The taper of second end portion84and added weight of the fluid in the elongate joint18can also beneficially add to the ability to overcome outcroppings and irregularities in bore hole8. The other advantages identified above in connection with the single joint embodiment inFIG.23are also applicable to the elongate single joint18.

In the preceding specification, the present disclosure has been described with reference to specific exemplary embodiments thereof. It will be evident, however, that various modifications, combinations, and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the claims that follow. While the present disclosure is described in terms of a series of embodiments, the present disclosure can combine one or more novel features of the different embodiments. The specification and drawings are accordingly to be regarded in an illustrative manner rather than a restrictive sense.