Plastic heat exchanger and core thereof

Abstract

A heat exchanger and a heat exchanger core are disclosed. The heat exchanger core is formed from a strip of synthetic resin molded into multiple panels which are accordion folded to form the heat exchanger core. One embodiment is a counterflow core in which sides of each panel parallel to the longitudinal axis of the strip are divided to form a closed portion and an open portion. The opposite longitudinal sides are similarly formed but the portions are reversed. The sides of each panel perpendicular to the longitudinal axis of the strip are closed either by a hinge formed in the strip or by panel borders abutting each other. A second embodiment discloses a strip also formed into multiple panels and accordion folded. However, every second hinge has an opening so that when folded, a cross flow core is created. Both cores are mated with appropriately designed molded plastic housings to form effective but simple and economical heat exchangers.

1 . A heat exchanger core comprising: 
 an elongated strip of synthetic resin material, said strip having a longitudinal axis;    said elongated strip being divided into a plurality of panels and having longitudinal sides and latitudinal sides;    a plurality of hinges formed in said elongated strip, each of said plurality of hinges extends generally perpendicular to said longitudinal axis and connects latitudinal sides of adjacent panels;    said plurality of hinges being alternately bendable in opposite directions whereby said elongated strip assumes an accordion folded disposition;    when folded, each panel of said plurality of panels is aligned generally parallel to and spaced from adjacent panels, said plurality of panels forming first and second fluid flow passages between adjacent pairs of panels where one panel of each adjacent pair is common to both adjacent pairs; and    said latitudinal sides of a pair of adjacent panels opposite the hinge connecting said pair of adjacent panels form a closure.    
     
     
         2 . An apparatus as claimed in  claim 1  wherein: 
 longitudinal sides of every second pair of panels abut each other.  
 
     
     
         3 . An apparatus as claimed in  claim 1  wherein: 
 the entire length of said longitudinal sides of every second pair of adjacent panels abut each other.  
 
     
     
         4 . An apparatus as claimed in  claim 2  wherein: 
 a portion of the length of said longitudinal sides of every pair of adjacent panels are closed.  
 
     
     
         5 . An apparatus as claimed in  claim 1  including: 
 portions of latitudinal and longitudinal sides of each of said plurality of panels include projections for spacing one panel away from an adjacent panel.  
 
     
     
         6 . An apparatus as claimed in  claim 5  wherein: 
 every second hinge includes an opening extending along a portion of said hinge.  
 
     
     
         7 . An apparatus as claimed in  claim 5  wherein: 
 a portion of each longitudinal side of each panel of said plurality of panels abuts a portion of a longitudinal side of an adjacent panel.  
 
     
     
         8 . An apparatus as claimed in  claim 7  wherein: 
 said portion of each longitudinal side of each panel of said plurality of panels that abuts a portion of a longitudinal side of an adjacent panel alternates with another portion of each longitudinal side of each panel of said plurality of panels that abuts another portion of a longitudinal side of an adjacent panel.  
 
     
     
         9 . An apparatus as claimed in  claim 1  including: 
 a plurality of first passages alternating with a plurality of second passages; wherein  
 said plurality of first passages forms a first fluid flow path;  
 said plurality of second passages forms a second fluid flow path; and  
 each portion of the first flow path being separated from an adjacent second flow path by a panel whereby heat from a flowing higher temperature fluid is transferred to a flowing lower temperature fluid through said panel.  
 
     
     
         10 . An apparatus as claimed in  claim 4  wherein: 
 portions of latitudinal and longitudinal sides of each of said plurality of panels include projections for spacing one panel away from an adjacent panel; and including  
 a plurality of first passages alternating with a plurality of second passages; wherein  
 said plurality of first passages forms a first fluid flow path and said plurality of second passages forms a second fluid flow path, each portion of said flow paths being separated from an adjacent flow path by a panel whereby heat from a flowing higher temperature fluid is transferred to a flowing lower temperature fluid through said panel.  
 
     
     
         11 . An apparatus as claimed in  claim 10  wherein: 
 a portion of each longitudinal side of each panel of said plurality of panels abuts against a portion of a longitudinal side of an adjacent panel; and  
 each portion of said longitudinal side of each panel of said plurality of panels that abuts a portion of a longitudinal side of an adjacent panel alternates with another portion of each longitudinal side of each panel of said plurality of panels that abuts another portion of a longitudinal side of an adjacent panel.  
 
     
     
         12 . An apparatus as claimed in  claim 3  wherein: 
 portions of latitudinal and longitudinal sides of each of said plurality of panels include projections for spacing one panel away from adjacent panel; and including  
 a plurality of first passages alternating with a plurality of second passages; and  
 said plurality of first passages forms a first fluid flow path and said plurality of second passages forms a second fluid flow path, each portion of said fluid flow paths being separated from an adjacent flow path by a panel whereby heat from a flowing higher temperature fluid is transferred to a flowing lower temperature fluid through said panel.  
 
     
     
         13 . An apparatus as claimed in  claim 12  wherein: 
 every second hinge includes an opening extending along a portion of said hinge.  
 
     
     
         14 . A heat exchanger comprising: 
 an outer housing;    an elongated strip of synthetic resin material located in said outer housing, said strip having a longitudinal axis;    said elongated strip having longitudinal sides and latitudinal sides and being divided into a plurality of panels;    a plurality of hinges formed in said elongated strip, each of said plurality of hinges extending generally perpendicular to said longitudinal axis and connecting latitudinal sides of adjacent panels;    said plurality of hinges being alternately bendable in opposite directions whereby said elongated strip assumes an accordion folded disposition;    when folded, each panel of said plurality of panels is aligned generally parallel to and spaced from adjacent panels of said plurality of panels, said plurality of panels forming first and second fluid flow passages between adjacent pairs of panels where one panel of each adjacent pair is common to both adjacent pairs; and    said latitudinal sides of a pair of adjacent panels opposite the hinge connecting said pair of adjacent panels form a closure.    
     
     
         15 . An apparatus as claimed in  claim 14  wherein: 
 longitudinal sides of every pair of adjacent panels abut each other.  
 
     
     
         16 . An apparatus as claimed in  claim 14  wherein: 
 the entire length of said longitudinal sides of every second pair of panels abuts each other.  
 
     
     
         17 . An apparatus as claimed in  claim 15  wherein: 
 a portion of the length of said longitudinal sides of every pair of adjacent panels abut each other.  
 
     
     
         18 . An apparatus as claimed in  claim 14  including: 
 portions of latitudinal and longitudinal sides of each panel of said plurality of panels include projections for spacing one panel away from an adjacent panel.  
 
     
     
         19 . An apparatus as claimed in  claim 18  wherein: 
 every second hinge includes an opening.  
 
     
     
         20 . An apparatus as claimed in  claim 18  wherein: 
 a portion of each longitudinal side of each panel of said plurality of panels abuts a portion of a longitudinal side of an adjacent panel.  
 
     
     
         21 . An apparatus as claimed in  claim 20  wherein: 
 said portion of each longitudinal side of each panel of said plurality of panels that abuts a portion of a longitudinal side of an adjacent panel alternates with another portion of each longitudinal side of each panel of said plurality of panels that abuts another portion of a longitudinal side of an adjacent panel.  
 
     
     
         22 . An apparatus as claimed in  claim 14  including: 
 a plurality of first passages alternating with a plurality of second passages; and wherein  
 said plurality of first passages forming a first fluid flow path and said plurality of second passages forming a second fluid flow path, each portion of said flow paths being separated from an adjacent flow path by a panel whereby heat from a flowing higher temperature fluid is transferred to a flowing lower temperature fluid through said panel.  
 
     
     
         23 . An apparatus as claimed in  claim 17  wherein: 
 portions of latitudinal and longitudinal sides of each of said plurality of panels include projections for spacing one panel away from an adjacent panel; and including  
 a plurality of first passages alternating with a plurality of second passages; and wherein  
 said plurality of first passages forming a first fluid flow path and said plurality of second passages forming a second fluid flow path, each portion of said fluid flow paths being separated from an adjacent flow path by a panel whereby heat from a flowing higher temperature fluid is transferred to a flowing lower temperature fluid through said panel.  
 
     
     
         24 . An apparatus as claimed in  claim 23  wherein: 
 a portion of each longitudinal side of each panel of said plurality of panels abuts a portion of a longitudinal side of an adjacent panel; and  
 said portion of each longitudinal side of each panel of said plurality of panels that abuts a portion of a longitudinal side of an adjacent panel alternates with another portion of each longitudinal side of each panel of said plurality of panels that is sealed to another portion of a longitudinal side of an adjacent panel.  
 
     
     
         25 . An apparatus as claimed in  claim 16  wherein: 
 portions of latitudinal and longitudinal sides of each of said plurality of panels include projections for spacing one panel away from an adjacent panel; and including  
 a plurality of first passages alternating with a plurality of second passages; and wherein  
 said plurality of first passages forming a first fluid flow path and said plurality of second passages forming a second fluid flow path, each portion of said flow paths being separated from an adjacent flow path by a panel whereby heat from a flowing higher temperature fluid is transferred to a flowing lower temperature fluid through said panel.  
 
     
     
         26 . An apparatus as claimed in  claim 25  wherein: 
 every second hinge includes an opening.  
 
     
     
         27 . A heat exchanger core comprising: 
 an elongated strip of synthetic resin material, said strip having a longitudinal axis;    a plurality of panels formed in said strip of material;    a plurality of integral hinges formed in said strip of material, each of said plurality of hinges formed between two adjacent panels, said strip of material being folded in an accordion style;    first fluid flow passages formed between a first group of pairs of panels; and    second fluid flow passages formed between a second group of pairs of panels, said first group of pairs of panels alternating with said second group of pairs of panels.    
     
     
         28 . An apparatus as claimed in  claim 27  wherein: 
 each of said panels includes sides generally parallel to and generally perpendicular to said longitudinal axis; and  
 at least portions of said sides parallel to said longitudinal axis of each panel abut at least portions of said sides parallel to said longitudinal axis of adjacent panels.  
 
     
     
         29 . An apparatus as claimed in  claim 28  wherein: 
 a side perpendicular to said longitudinal axis of each panel abuts a side perpendicular to said longitudinal axis of an adjacent panel at a location opposite the hinge connecting said first mentioned panel and said adjacent panel.  
 
     
     
         30 . An apparatus as claimed in  claim 27  wherein: 
 every second hinge includes an opening.  
 
     
     
         31 . An apparatus as claimed in  claim 27  wherein: 
 each of said panels includes sides generally parallel to and generally perpendicular to said longitudinal axis; and  
 every second pair of panels includes borders along said sides parallel to said longitudinal axis that abuts one another.  
 
     
     
         32 . An apparatus as claimed in  claim 31  wherein: 
 every second hinge includes an opening.  
 
     
     
         33 . A heat exchanger comprising: 
 an outer housing;    an elongated strip of synthetic resin material placed in said housing, said strip having a longitudinal axis;    a plurality of panels formed in said strip of material;    a plurality of integral hinges formed in said strip of material, each of said plurality of hinges formed between two adjacent panels, said strip of material being folded in an accordion style;    first fluid flow passages formed between a first group of pairs of panels; and    second fluid flow passages formed between a second group of pairs of panels, said first group of pairs of panels alternating with said second group of pairs of panels.    
     
     
         34 . An apparatus as claimed in  claim 33  wherein: 
 each of said panels includes sides generally parallel to and generally perpendicular to said longitudinal axis; and  
 at least portions of said sides parallel to said longitudinal axis of each panel abut at least portions of said sides parallel to said longitudinal axis of adjacent panels.  
 
     
     
         35 . An apparatus as claimed in  claim 34  wherein: 
 a side perpendicular to said longitudinal axis of each panel abuts a side perpendicular to said longitudinal axis of an adjacent panel at a location opposite the hinge connecting said first mentioned panel and said adjacent panel.  
 
     
     
         36 . An apparatus as claimed in  claim 33  wherein: 
 every second hinge includes an opening.  
 
     
     
         37 . An apparatus as claimed in  claim 33  wherein: 
 each of said panels includes sides generally parallel to and generally perpendicular to said longitudinal axis; and  
 every second pair of panels includes borders along said sides parallel to said longitudinal axis that abuts one another.  
 
     
     
         38 . An apparatus as claimed in  claim 37  wherein: 
 every second hinge includes an opening.