Hybrid heat exchanger

Patent metadata

Field	Value
Publication number	US-2022196330-A1
Application number	US-202117558203-A
Country	US
Kind code	A1
Filing date	Dec 21, 2021
Priority date	Dec 23, 2020
Publication date	Jun 23, 2022
Grant date	—

Abstract

In one aspect, a hybrid heat exchanger that includes a metallic serpentine tube having an inlet end portion to receive a process fluid, an outlet end portion, and a series of runs and return bends directing the process fluid from the inlet end portion to the outlet end portion of the metallic serpentine tube. The hybrid heat exchanger further includes a thermally conductive polymer body thermally integrated with the serpentine tube. The thermally conductive polymer body has an outer surface to be contacted by a fluid, such as air and/or water. The thermally conductive polymer body is configured to transfer heat between the metallic serpentine tube and the fluid contacting the outer surface of the thermally conductive polymer body. The outer surface of the thermally conductive polymer body includes surface enhancement features that affect flow of the fluid across the outer surface of the thermally conductive polymer body.

First claim

What is claimed is:

1 . A hybrid heat exchanger comprising:
a metallic serpentine tube having an inlet end portion to receive a process fluid, an outlet end portion, and a series of runs and return bends directing the process fluid from the inlet end portion toward the outlet end portion; a thermally conductive polymer body thermally integrated with the serpentine tube and having an outer surface to be contacted by a fluid, the thermally conductive polymer body configured to transfer heat between the metallic serpentine tube and the fluid contacting the outer surface of the thermally conductive polymer body; and surface enhancement features of the outer surface of the thermally conductive polymer body that affect flow of the fluid at the outer surface of the thermally conductive polymer body.

2 . The hybrid heat exchanger of claim 1 wherein the runs of the metallic serpentine tube have a total outer surface area; and
wherein the outer surface of the thermally conductive polymer body has a surface area larger than the total outer surface area of the runs of the metallic serpentine tube.

3 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body includes sheath portions;
wherein the runs extend in the sheath portions; and
wherein the thermally conductive polymer body includes wall portions extending between adjacent sheath portions that include the surface enhancement features.

4 . The hybrid heat exchanger of claim 1 wherein the runs of the metallic serpentine tube each have a length; and
wherein the thermally conductive polymer body is in thermal contact with the runs of the metallic serpentine tube for at least a majority of the lengths of the runs.

5 . The hybrid heat exchanger of claim 4 wherein the runs each have an outer surface and cross-section normal to the length; and
wherein the thermally conductive polymer body is in thermal contact with the outer surfaces of the runs about at least a majority of the cross-sections of the runs.

6 . The hybrid heat exchanger of claim 1 further comprising a thermally conductive paste thermally connecting the thermally conductive polymer body and the metallic serpentine tube.

7 . The hybrid heat exchanger of claim 1 wherein at least one of the runs of the serpentine tube has a length and a cross-section normal to the length; and
wherein the thermally conductive polymer body has a sheath portion extending about the entire cross-section of the serpentine tube for at least a portion of the length of the run.

8 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body has a thermal conductivity of at least two Watts per meter-Kelvin.

9 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body comprises:
a matrix phase of a polymer material; and
a particulate phase of at least one of metal and graphite.

10 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body comprises a polymer material and metallic wire.

11 . The hybrid heat exchanger of claim 1 wherein the runs of the metallic serpentine tube are received in the thermally conductive polymer body; and
wherein the inlet end portion and outlet end portion of the metallic serpentine tube are outside of the thermally conductive polymer body.

12 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body is a plate.

13 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body includes portions of the thermally conductive polymer body assembled with the metallic serpentine tube.

14 . The hybrid heat exchanger of claim 13 wherein the portions of the thermally conductive polymer body include collars that compliment outer surfaces of the runs of the metallic serpentine tube.

15 . The hybrid heat exchanger of claim 1 wherein the metallic serpentine tube has a unitary construction.

16 . The hybrid heat exchanger of claim 1 wherein the metallic serpentine coil comprises at least one of:
a stainless steel tube;
an aluminum tube;
a copper tube; and
a carbon steel tube.

17 . The hybrid heat exchanger of claim 1 wherein the metallic serpentine tube is configured to withstand an operating pressure of the process fluid of at least 150 psig.

18 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body includes a fill portion extending away from the metallic serpentine tube.

19 . The hybrid heat exchanger of claim 1 wherein the thermally conductive polymer body comprises thermally conductive material and a phase change material encapsulated in the thermally conductive material; and
wherein the phase change material is configured to change phase in response to heat transfer between the thermally conductive material and the phase change material.

20 . A heat exchanger system comprising:
an inlet header to receive a process fluid; an outlet header; a plurality of fluid conduits of a first thermally conductive material, the fluid conduits each having an inlet end portion connected to the inlet header, an outlet end portion connected to the outlet header, and an intermediate portion between the inlet and outlet end portions along the fluid conduits, the fluid conduits configured to permit process fluid to flow from the inlet header to the outlet header; a body of a thermally conductive polymer different than the first thermally conductive material and having an outer surface; and the thermally conductive polymer body in thermal contact with the intermediate portions of the fluid conduits and configured to facilitate heat transfer between the process fluid as the process fluid travels through the intermediate portions of the fluid conduits and a fluid at the outer surface of the thermally conductive polymer body.

21 . The heat exchanger system of claim 20 wherein the thermally conductive polymer body is secured to the intermediate portions of the fluid conduit and is spaced from the inlet and outlet header.

22 . The heat exchanger system of claim 20 wherein the fluid conduits each have a length; and
at least one of the fluid conduits is embedded in the thermally conductive polymer body for at least a portion of the length of the at least one fluid conduit.

23 . The heat exchanger system of claim 20 wherein the fluid conduits each have a length; and
wherein the thermally conductive polymer body is in thermal contact with the fluid conduits for at least a majority of the lengths of the fluid conduits.

24 . The heat exchanger system of claim 23 wherein the fluid conduits each have an outer surface and a cross-section normal to the length thereof; and
wherein the thermally conductive polymer body is in thermal contact with the outer surfaces of the fluid conduits about at least a majority of the cross-sections of the fluid conduits.

25 . The hybrid heat exchanger of claim 20 further comprising a thermally conductive paste thermally connecting the thermally conductive polymer body and the fluid conduits.

26 . The hybrid heat exchanger of claim 20 wherein the thermally conductive polymer body has a thermal conductivity of at least two Watts per meter-Kelvin.

27 . The hybrid heat exchanger of claim 20 further comprising:
a fan operable to generate airflow relative to the thermally conductive polymer body;
an ev

Assignees

• Baltimore Aircoil Co Inc

Inventors

• Guy Eric
• Rousselet Yohann Lilian
• Egolf Kevin Ellsworth

Classifications

• F28F25/087

  Vertical or inclined sheets; Supports or spacers · CPC title

• F28F2260/02

  having microchannels · CPC title

• F28F1/22

  the means having portions engaging further tubular elements · CPC title

• F28F1/20

  the means being attachable to the element (F28F1/22 takes precedence) · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title