Continuous helical baffle heat exchanger

Patent metadata

Field	Value
Publication number	US-11486660-B2
Application number	US-202017064808-A
Country	US
Kind code	B2
Filing date	Oct 7, 2020
Priority date	Aug 28, 2017
Publication date	Nov 1, 2022
Grant date	Nov 1, 2022

Abstract

A heater assembly includes a continuous series of perforated helical members and a plurality of electrical resistance heating elements. The perforated helical members cooperate to define a geometric helicoid disposed about a longitudinal axis of the heater assembly. Each perforated helical member defines opposed edges and a predetermined pattern of perforations. The perforations extend through each perforated helical member parallel to the longitudinal axis. The heating elements extend through the perforations.

First claim

What is claimed is:

1. A heater assembly comprising:
a continuous series of perforated helical members that cooperate to define a geometric helicoid disposed about a longitudinal axis of the heater assembly, each perforated helical member defining opposed edges and a predetermined pattern of perforations, the perforations extending through each perforated helical member parallel to the longitudinal axis; and
a plurality of electrical resistance heating elements, each electrical resistance heating element extending through its own corresponding set of the perforations,
wherein the plurality of electrical resistance heating elements includes a first electrical resistance heating element and a second electrical resistance heating element, the first electrical resistance heating element having a different length than the second electrical resistance heating element.

2. The heater assembly according to claim 1 , wherein each heating element includes a first segment, a second segment, and a bend connecting the first and second segments, wherein the corresponding set of the perforations for each electrical resistance heating element includes a first set of the perforations and a second set of the perforations, the first segment extending through the first set of the perforations, the second segment extending through the second set of the perforations, the second set of the perforations being parallel to and offset from the first set of the perforations.

3. The heater assembly according to claim 1 , wherein the plurality of heating elements are arranged in a concentric pattern.

4. The heater assembly according to claim 1 , further comprising a central support member, wherein each of the perforated helical members defines a central aperture and the central support member extends through the central aperture.

5. The heater assembly according to claim 4 , further comprising a temperature sensor that extends through an interior of the central support member, the temperature sensor including a probe external of the central support member.

6. The heater assembly according to claim 4 further comprising a proximal flange configured to secure the heater assembly to a heat exchanger body, the flange defining a plurality of flange apertures and a central groove, the flange apertures being aligned with the perforations of the perforated helical members, the heating elements extending through the flange apertures, the central support member being received in the central groove.

7. The heater assembly according to claim 6 , further comprising a vent aperture providing fluid communication between an exterior of the central support member and an interior of the central support member proximate to the flange.

8. The heater assembly according to claim 4 , wherein the central support member includes at least one additional heater.

9. The heater assembly according to claim 1 , wherein each of the heating elements is secured to at least a portion of each perforation through which each heating element extends.

10. The heater assembly according to claim 1 , wherein the opposed edge from one helical member overlaps with the opposed edge from an adjacent helical member.

11. The heater assembly according to claim 1 , wherein the opposed edge from one helical member is spaced apart from the opposed edge from an adjacent helical member and connected thereto by a bridging member.

12. The heater assembly according to claim 1 , wherein the continuous series of perforated helical members defines a variable pitch.

13. The heater assembly according to claim 12 , wherein the continuous series of perforated helical members has a longer pitch proximate to an inlet end of the heater assembly than an outlet end of the heater assembly.

14. The heater assembly according to claim 1 , wherein the electrical resistance heating elements are one of the group of: a tubular heater, a cartridge heater, or a multi-cell heater.

15. The heater assembly according to claim 1 , further comprising an alignment plate disposed coaxially about the longitudinal axis, the alignment plate defining a plurality of plate apertures that align with perforations of the perforated helical members.

16. A heat exchanger comprising:
a body defining a cylindrical cavity;
a heater assembly defining a longitudinal axis, the heater assembly comprising:
a continuous series of perforated helical members disposed within the cylindrical cavity and defining a geometric helicoid, each perforated helical member defining opposed edges and a predetermined pattern of perforations extending through each perforated helical member and parallel to the longitudinal axis; and
a plurality of electrical resistance heating elements, each electrical resistance heating element extending through its own corresponding set of the perforations of the perforated helical members, wherein the plurality of electrical resistance heating elements includes a first electrical resistance heating element and a second electrical resistance heating element, the first electrical resistance heating element having a different length than the second electrical resistance heating element; and

a proximal flange securing the heater assembly to the body.

17. The heat exchanger according to claim 16 further comprising a plurality of rods extending longitudinally parallel to the longitudinal axis, wherein a periphery of each perforated helical member defines a plurality of grooves, and the rods are at least partially disposed within a corresponding set of the grooves.

18. The heat exchanger according to claim 17 , wherein each rod has a thickness that extends radially outward of the periphery of the perforated helical members so that the rods are in sliding contact with an interior wall of the body that defines the cylindrical cavity.

19. The heat exchanger according to claim 17 , wherein each rod does not extend radially outward beyond the periphery of each perforated helical member.

20. The heat exchanger according to claim 17 , wherein the heater assembly further comprises a shroud disposed about at least one of the perforated helical members and coupled to the rods.

21. The heat exchanger according to claim 20 , wherein the shroud includes a skirt that includes elastically deformable flaps that extend radially between the perforated helical members and an interior wall of the body that defines the cylindrical cavity.

22. The heat exchanger according to claim 21 , wherein the skirt is disposed proximate to a proximal end portion or a distal end portion of the heater assembly.

23. The heat exchanger according to claim 16 , wherein the body includes an inlet at a proximal end of the cylindrical cavity and an outlet at a distal end of the cylindrical cavity, wherein the heater assembly further includes a non-perforated helical member coupled to a last one of the continuous series of perforated helical members, the non-perforated helical member forming an extension of the geometric helicoid and beginning along the geometric helicoid at or before the outlet.

24. The heat exchanger according to claim 23 , wherein the non-perforated helical member has a pitch equal to a diameter of the outlet.

25. A heater assembly comprising:
a continuous series of perforated helical members that cooperate to define a geometric helicoid disposed about a longitudinal axis of the heater assembly, each perforated helical member defining opposed edges and a predetermined p

Assignees

• Watlow Electric Mfg

Inventors

• Tatavarthy Satya
• Dinauer Ethan
• Zhang Sanhong
• Boehmer Scott

Classifications

• F28F2009/228

  Oblique partitions · CPC title

• F28D7/1607

  with particular pattern of flow of the heat exchange media, e.g. change of flow direction (F28D7/1623, F28D7/1638, F28D7/1661, F28D7/1676, F28D7/1692 take precedence) · CPC title

• F28D7/06

  the conduits having a single U-bend (F28D7/10 takes precedence){(F28D7/0016 and F28D7/0033 take precedence)} · CPC title

• F28F2009/222

  Particular guide plates, baffles or deflectors, e.g. having particular orientation relative to an elongated casing or conduit · CPC title

• F24H9/2028

  Continuous-flow heaters · CPC title