Coiled tube heat exchanger deformable support system and method

Abstract

A coiled tube heat exchanger using a deformable support system and a method for manufacturing a tube bundle for the coiled tube heat exchanger. The coiled tube heat exchanger includes: a mandrel; a first pipe layer formed by winding one or more pipes around the mandrel; and a plurality of supports and spacers circumferentially arranged on an outer surface of the first pipe layer in an alternating pattern. A second tube layer is formed by winding one or more tubes around the mandrel, whereby the second tube layer contacts opposite sides of the support. A deformation force is applied to the second tube layer in a direction normal to the outer surface of each support, which causes the one or more tubes forming the second tube layer to deform the outer support surface of each support.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Nonprovisional Application No. 18 / 477,644, filed on September 29, 2023, which is incorporated herein by reference. Background Technology

[0002] This application relates to coiled tube heat exchangers (CWHE), and more specifically to methods and systems for supporting the individual tube layers of a CWHE tube bundle.

[0003] CWHE (Chemical Wave Heater) is frequently used in processing industries where large heat transfer areas are required for heating or cooling fluid flows at high heat transfer rates. A CWHE utilizes a bundle of tubes constructed from multiple long tubes spirally wound around an axial central core called a mandrel. The bundle is enclosed within a shroud. The bundle and mandrel are sealed within a housing that provides a pressure boundary. The mandrel, housing, and shroud provide the structure of the CWHE and allow for connectivity with other operating components. Multiple long tubes are wound to form one or more helical structures with different diameters. This forms a bundle of tubes comprising multiple layers of tubes formed in the radial direction, where the diameter of each outwardly positioned layer increases relative to the preceding inner layer. Adjacent layers of tubes are typically maintained at a desired separation distance (also called layer spacing) from each other by axial spacers. Such spacers are typically solid rods or wires. Spacers typically have a circular cross-sectional shape but can have different cross-sectional geometries (e.g., oval, square, rectangular, etc.). Each tube can be supported by supports that are circumferentially spaced between each layer of tubes and can be positioned parallel to the mandrel. In other embodiments, the spacers may be arranged spirally for positioning and / or have uneven spacing. Each support may include a pre-formed recess or other structure that holds or supports the tubes, thereby holding the tubes in the desired position.

[0004] One drawback of preformed supports is that each preformed support can only be used with tube bundles that have a specific tube bundle geometry, including the number and size (diameter) of tubes, the desired tube-to-tube spacing, and the tube-to-tube winding angle. This means that different preformed supports must be provided for each CWHE with different tube bundle geometries, which may result in higher production time and costs.

[0005] Therefore, there is a need for an improved system and method for spacing and supporting the tube layers of a CWHE, wherein each support is not limited to use with a specific tube geometry. Summary of the Invention

[0006] The disclosed embodiments meet the needs of the art by providing a deformable support structure that is formed into the final desired configuration during the tube winding step of CWHE construction and assembly. The structure of the deformable support is not limited to use in a particular CWHE configuration and can have a common starting structure regardless of the final CWHE configuration, as the final structure of the deformable support is formed during CWHE construction. A deformable support structure with a single design can be manufactured to support individual tube layers in a manner that achieves the radial and axial stiffness required and used throughout the CWHE tube bundle. This deformable support can be used to support the tube bundle system under non-operating or operating conditions. In some configurations, the deformable support may optionally have a non-deformable portion that can serve as a spacer, thus replacing the need for individual spacers. During the tube winding operation, the deformable support is positioned between the individual tube layers. During the initial construction of the CWHE, before winding the first tube layer, a first deformable support structure is positioned to contact and attach to a mandrel. Then, a first tube layer is wound around a mandrel, such that a first deformable support is positioned between the mandrel and the first tube layer. The first deformable support structure may include a non-deformable portion that can be used as a spacer, such that the winding operation of the first tube layer around the mandrel deforms a portion of the deformable support while leaving the non-deformable portion unchanged, thereby providing a desired spacing between the first tube layer and the mandrel. Alternatively, if the deformable support structure does not include a non-deformable portion, one or more individual non-deformable spacers may also be positioned between the mandrel and the first tube layer to provide a desired spacing between the first tube layer and the mandrel. After the winding of the first tube layer is completed, a series of additional deformable supports are positioned on the completed first tube layer. When subsequent tube layers are wound, the winding operation deforms the deformable support and shapes it to follow a winding angle defined for each tube layer. The deformable support is configured to have desired radial compressive strength and axial shear strength characteristics along the longitudinal length of the housing.

[0007] The following outlines several aspects of the system and methodology.

[0008] Aspect 1: A method for forming a tube bundle for a wound-tube heat exchanger, wherein the tube bundle comprises a plurality of tube layers, each layer comprising at least one tube, and the method comprises:

[0009] (a) Provide a mandrel extending along the longitudinal axis of the mandrel;

[0010] (b) A first tube layer is formed by winding at least one of the at least one tubes having a tube height H around the mandrel;

[0011] (c) A plurality of first-layer supports and a plurality of first-layer spacers are placed on the outer tube surface of the first tube layer, each of the first-layer supports having a longitudinal axis of the support, an inner support surface in contact with the outer tube surface and an outer surface away from the inner support surface, and each of the plurality of first-layer spacers having a spacer height S;

[0012] (d) Forming a second tube layer by winding at least one of the at least one tube around the mandrel, the first tube layer, and the plurality of first-layer supports; and

[0013] (e) Apply at least one deformation force to the second tube layer in a direction normal to the outer support surface of each of the plurality of first layer supports, the at least one deformation force being sufficient to deform the at least one tube forming the second tube layer to at least one of the outer support surface and the inner support surface of each of the plurality of first layer supports, without deforming the at least one tube forming the second tube layer.

[0014] Aspect 2: According to the method of aspect 1, the radial interlayer spacing between the first tube layer and the second tube layer is greater than the spacer height S before performing step (e), and equal to the spacer height S after performing step (e).

[0015] Aspect 3: The method according to any one of aspects 1 to 2, the method further comprising:

[0016] (f) Before performing step (b), a plurality of mandrel layer supports are placed on the mandrel such that the mandrel layer supports are positioned between the mandrel and the first tube layer.

[0017] Aspect 4: The method according to any one of Aspects 1 to 3, wherein the application of the deformation force causes at least one of the outer support surface or the inner support surface of at least one of the plurality of first layer supports to move from an initial contact position to a recessed position, and wherein the distance E between the initial contact position and the recessed position is at least 5% of the tube height H.

[0018] Aspect 5: According to the method of aspect 4, wherein the distance E is less than 50% of the pipe height H.

[0019] Aspect 6: The method according to any one of Aspects 1 to 5, wherein the deformation force in step (e) is the result of applying tension to the second tube layer during step (d).

[0020] Aspect 7: The method according to any one of Aspects 1 to 6, wherein at least a portion of the deformation force in step (e) is applied by an external device passing over the second tube layer during or after the execution of step (d).

[0021] Aspect 8: The method according to any one of Aspects 1 to 7, wherein step (b) further comprises winding the at least one first layer tube around the mandrel at a winding angle α relative to the longitudinal axis of the mandrel, and step (d) further comprises winding the at least one second layer tube at a winding angle -α relative to the longitudinal axis of the mandrel.

[0022] Aspect 9: The method according to any one of Aspects 1 to 8, wherein each of the at least one tube has a tube radial compressive strength, and each of the plurality of first layer supports has a support outer layer, the radial compressive strength of the support outer layer being less than the tube radial compressive strength.

[0023] Aspect 10: According to the method of aspect 8, the outer support surface of each of the plurality of first layer supports is adapted to be deformed by the deformation force during the execution of step (b) to form a tube seat oriented at an angle corresponding to either the winding angle α or the winding angle -α.

[0024] Aspect 11: The method according to any one of aspects 1 to 10, wherein each of the plurality of first layer supports includes a non-deformable spacer portion that is substantially non-deformable during the execution of step (e).

[0025] Aspect 12: The method according to any one of aspects 1 to 11, wherein step (b) further comprises arranging the plurality of first layer supports and the plurality of first layer spacers on the outer tube surface of the first tube layer in a circumferentially alternating arrangement.

[0026] Aspect 13: The method according to any one of aspects 1 to 12, the method further comprising:

[0027] (g) Before performing step (d), a pre-winding force is applied to each of the plurality of first layer supports, the pre-winding force causing each of the plurality of first layer supports to deform only on the inner support surface.

[0028] Aspect 14: The method according to any one of aspects 1 to 13, the method further comprising forming one or more additional tube layers in the tube bundle by repeating steps (c) to (e) for each additional tube layer in the tube bundle.

[0029] Aspect 15: The method according to any one of aspects 1 to 14, wherein each of the plurality of first layer supports placed in step (c) is also a first layer spacer among the plurality of first layer spacers.

[0030] Aspect 16: According to the method of aspect 15, each of the plurality of first layer supports includes an inner layer and at least one outer layer, wherein the maximum inner radial compressive strength of the inner layer is greater than the maximum outer radial compressive strength of each of the at least one outer layer.

[0031] Aspect 17: A method of forming a tube bundle for a wound-tube heat exchanger, wherein the tube bundle comprises a plurality of tube layers, each layer comprising at least one tube, and the method comprises:

[0032] (a) Provide a mandrel extending along the longitudinal axis of the mandrel;

[0033] (b) Provide a plurality of first-layer supports, each of the plurality of first-layer supports comprising a hollow unit material, each of the plurality of first-layer supports having a longitudinal axis of the support and an outer support surface;

[0034] (c) Forming a first tube layer by winding at least one of the at least one tubes around the mandrel in a first circumferential direction; and

[0035] (d) Place the plurality of first layer supports on the outer tube surface of the first tube layer.

[0036] Aspect 18: The method according to aspect 17 further includes placing a plurality of mandrel layer supports on the mandrel before performing step (c), such that the mandrel layer supports are positioned between the mandrel and the first tube layer.

[0037] Aspect 19: The method according to any one of Aspects 17 to 18, wherein the hollow unit material of each of the plurality of first layer supports comprises at least one perforated unit.

[0038] Aspect 20: The method according to any one of aspects 17 to 19, wherein the hollow unit material of each of the plurality of first layer supports comprises at least one open-cell unit and at least one closed-cell unit.

[0039] Aspect 21: The method according to any one of aspects 17 to 20, wherein each of the plurality of first layer supports comprises at least one outer layer having a first outer layer radial compressive strength and at least one inner layer having an inner layer radial compressive strength greater than the at least one outer layer radial compressive strength.

[0040] Aspect 22: A wound-tube heat exchanger, said wound-tube heat exchanger comprising:

[0041] An outer casing that defines an internal volume;

[0042] At least one tube bundle, located within the housing, comprising multiple layers wound around a mandrel, each layer comprising at least one tube, each tube having radial compressive strength, and each layer having a winding angle; and

[0043] Multiple support members are located between each of the multiple layers, and each of the multiple support members includes a functionally guiding material and extends substantially transversely to the winding angle or the mandrel.

[0044] Aspect 23: According to aspect 22, the wound-tube heat exchanger further includes an initial support layer, the initial support layer including one or more supports positioned between the mandrel and a first layer of the multilayer.

[0045] Aspect 24: The coiled tube heat exchanger according to any one of aspects 22 to 23, wherein each of the plurality of supports comprises a hollow unit material.

[0046] Aspect 25: According to aspect 24, the hollow unit material of each of the plurality of supports includes at least one perforated unit.

[0047] Aspect 26: According to aspect 24, the hollow unit material of each of the plurality of supports comprises at least one open-cell unit and at least one closed-cell unit.

[0048] Aspect 27: A coiled tube heat exchanger according to any one of aspects 22 to 26, wherein each of the plurality of supports further comprises a maximum radial compressive strength less than the radial compressive strength of the at least one tube.

[0049] Aspect 28: According to the coiled tube heat exchanger of aspect 27, each of the plurality of supports further includes an outer layer, each of the outer layers having a maximum outer layer radial compressive strength less than the maximum inner layer radial compressive strength of the inner layer, wherein the inner layer is located between the outer layers.

[0050] Aspect 29: A coiled tube heat exchanger according to any one of aspects 22 to 28, wherein each of the plurality of supports includes a first side outer surface and a second side outer surface, wherein the first side outer surface includes a partially defined recess extending inward toward the second side outer surface, whereby the partially defined recess is configured to receive at least a portion of the at least one tube.

[0051] Aspect 30: A coiled heat exchanger according to any one of Aspects 22 to 29, wherein the multilayer comprises at least a first layer and a second layer, wherein the distance between the first layer and the second layer is between 0.5 mm and 100 mm.

[0052] Aspect 31: A method of forming a tube bundle for a wound-tube heat exchanger, wherein the tube bundle comprises a plurality of tube layers, each layer comprising at least one tube, and the method comprises:

[0053] (a) Provide a mandrel extending along the longitudinal axis of the mandrel;

[0054] (b) A first tube layer is formed by winding at least one of the at least one tubes having a tube height H around the mandrel;

[0055] (c) A plurality of first-layer supports are placed on the outer tube surface of the first tube layer, each of the first-layer supports having a support longitudinal axis and an outer support surface;

[0056] (d) Forming a second tube layer by winding at least one of the at least one tube around the mandrel, thereby defining a first distance between the outer tube surface of the first tube layer and the outer tube surface of the second tube layer; and

[0057] (e) Apply a deformation force to the second tube layer in a direction normal to the outer surface of each of the plurality of first layer supports, the deformation force being sufficient to deform the outer support surface of each of the plurality of first layer supports by the at least one tube forming the second tube layer, thereby creating a second distance between the outer tube surface of the first tube layer and the outer tube surface of the second tube layer, wherein the second distance is less than the first distance.

[0058] Aspect 32: According to the method of aspect 29, the method further includes placing a plurality of mandrel layer supports on the mandrel before performing step (b), such that the mandrel layer supports are positioned between the mandrel and the first tube layer.

[0059] Aspect 33: The method according to aspect 29, wherein the second distance is between 0.5 mm and 100 mm.

[0060] Aspect 34: A method for forming a tube bundle for a wound-tube heat exchanger, wherein the tube bundle comprises a plurality of tube layers, each layer comprising at least one tube, and the method comprises:

[0061] (a) Provide a mandrel extending along the longitudinal axis of the mandrel;

[0062] (b) A first tube layer is formed by winding at least one of the at least one tubes having a tube height H around the mandrel;

[0063] (c) A plurality of first-layer supports and a plurality of first-layer spacers are placed on the outer tube surface of the first tube layer in an alternating circumferential arrangement, each of the plurality of first-layer supports having an undeformed support height H2, and each of the plurality of first-layer spacers having a spacer height H1.

[0064] (d) Forming a second tube layer by winding at least one of the at least one tube around the mandrel, the first tube layer, and the plurality of first-layer supports; and

[0065] (e) Apply at least one deformation force to the second tube layer, the at least one deformation force being sufficient to deform each of the plurality of first layer supports without deforming the at least one tube forming the second tube layer;

[0066] The first tube layer and the second tube layer have an initial layer spacing at each of the plurality of first layer supports before performing step 17(e), and have a final layer spacing at each of the plurality of first layer supports after performing step 17(e), the final layer spacing being smaller than the initial layer spacing.

[0067] Aspect 35: The method according to any one of aspects 1 to 34, wherein each of the plurality of first layer supports comprises a plurality of separate support structures such that each of the plurality of first layer supports is discontinuous along the axial direction of the tube bundle.

[0068] Aspect 36: The method according to any one of Aspects 34 to 35, wherein the final interlayer spacing is substantially equal to the spacer height H1.

[0069] Aspect 37: The method according to any one of Aspects 34 to 36, wherein the initial interlayer spacing is substantially equal to the height H2 of the undeformed support. Attached Figure Description

[0070] The invention will be described below with reference to the accompanying drawings, wherein similar reference numerals denote similar elements.

[0071] Figure 1 This is a cross-sectional perspective view of an exemplary prior art CWHE.

[0072] Figure 2 It is along Figure 1 The cross-sectional view taken from line 2-2.

[0073] Figure 3 This is a side elevation sectional view of an exemplary prior art CWHE, illustrating an illustrative example of a prior art support system.

[0074] Figure 4 This is a schematic side view of a prior art spacer located between two layers of a tube bundle.

[0075] Figure 5 This is a schematic side view of a preformed support component in the prior art.

[0076] Figure 6 It is located between the two layers of the tube bundle. Figure 5 A schematic side view of the preformed support.

[0077] Figure 7 This is a schematic side view of an exemplary deformable support of the present invention, showing two layers of tubing before the deformable support is deformed.

[0078] Figure 8 This is shown after the support has been deformed. Figure 7 A schematic side view of the two layers of the tube bundle and the deformable support.

[0079] Figure 9 yes Figure 7 A magnified partial view of area 9-9.

[0080] Figure 10 yes Figure 8 A magnified partial view of region 10-10.

[0081] Figure 11 This is a schematic side view of two layers of the tube bundle and another exemplary deformable support, illustrating an alternative method of providing a normal force for deforming the support.

[0082] Figure 12 This is a schematic side view of the two layers of the tube bundle after the deformable support has been deformed, and another exemplary deformable support.

[0083] Figure 13 This is a schematic side view of another exemplary deformable support with a partially defined recess that is configured to receive two layers of tubular bundles before the deformable support deforms.

[0084] Figure 14 This is a schematic side view of the two layers of the tubular bundle after one part of the deformable support has been deformed, and another exemplary deformable support.

[0085] Figure 15 The diagram shows a schematic side view of two layers of tubular bundle after one portion of a deformable support has been deformed, and another exemplary deformable support, wherein the deformable support includes a statically non-deformable portion configured to receive two layers of tubular bundle before the deformable support is deformed.

[0086] Figure 16 This is a flowchart illustrating the steps of a first exemplary method for forming a tube bundle for CWHE using an exemplary support system. Detailed Implementation

[0087] The following detailed description provides only preferred exemplary embodiments of the invention and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the subsequent detailed description of preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments of the invention, and it should be understood that various changes to the function and arrangement of elements may be made without departing from the spirit and scope of the invention.

[0088] To aid in the description of the invention, directional terms (e.g., up, down, left, right, etc.) may be used to describe parts of the invention in this specification and claims. These directional terms are intended only to aid in the description and claim of the invention and are not intended to limit the invention in any way. Furthermore, reference numerals introduced in connection with the drawings in this specification may be repeated in one or more subsequent drawings without further description in the specification, in order to provide context for other features.

[0089] Unless otherwise specified, the articles “a” and “an” as used herein, when applied to any feature of the embodiments of the invention as described in this specification and claims, mean one or more (kinds). The use of “a” or “an” does not limit the meaning to a single feature unless such a limitation is specifically stated. The article “the” preceding a singular or plural noun or noun phrase indicates one or more specified features and may have a singular or plural connotation depending on the context in which it is used.

[0090] In the claims, letters are used to identify steps protected by the claims (e.g., (a), (b), and (c)). These letters are used to help designate method steps and are not intended to indicate the order in which the steps protected by the claims are performed, unless and only if such an order is specifically stated in the claims.

[0091] As used in the specification and claims, the term "hollow unit material" means a material comprising at least one hollow unit or an array of hollow units. A "hollow unit" is defined as a volumetric void within a material. Hollow unit materials may include: "open-cell units" having at least one volumetric void visible through or open to the outside of the hollow unit material; and / or "closed-cell units" having at least one volumetric void completely surrounded by the outside of the hollow unit material. The volumetric void of a "closed-cell unit" may also be filled with material. Hollow unit materials may include any combination of open-cell and closed-cell units.

[0092] As used in the specification and claims, the term "compressive strength" means the amount of force required to deform the outer surface of a material by one millimeter.

[0093] As used in the specification and claims, the term "functionally oriented material" means a deformable material formed to satisfy desired radial compressive strength properties. Examples of functionally oriented materials include hollow cells, open-cell cells, closed-cell cells, honeycomb cells, finned tubes, and knitted mesh forms. The term "functionally graded structural material" refers to a functionally oriented material formed to provide radial compressive strength properties that increase continuously or gradually from one side to the other.

[0094] As used in the specification and claims, the term "radial compressive strength" refers to the amount of force required to deform the outer surface of a material by one millimeter, whereby the force is applied in a direction normal to the outer surface and orthogonal to the longitudinal axis of the material being tested. It should be noted that the deforming force (force vector) may include a component normal to the outer surface and another component not normal to the outer surface.

[0095] As used in the specification and claims, the term "preformed" when applied to articles such as supports means that the article is manufactured with a specific static structure and shape before it is used to assemble a larger integral system, such that the assembly process of the larger integral system does not change the static structure and shape of the article, and the article retains its initial structure and shape after the larger integral system is assembled.

[0096] As used in the specification and claims, the term "deformable" when applied to articles such as supports means that at least a portion of the article includes material or structural properties suitable for allowing at least a portion of the outer surface of the article to change shape during the assembly process, thereby allowing the article to be installed as part of a larger integral system.

[0097] As used in the specification and claims, the term "non-deformable" when applied to articles such as supports means that at least a portion of the article includes material or structural properties suitable for maintaining at least a portion of the article's outer surface in an initial shape during assembly, whereby the article is installed as part of a larger integral system. Articles may include any combination of both "deformable" and "non-deformable" portions.

[0098] As used in the specification and claims, the term "compression zone" when applied to articles such as supports defines at least a portion of the article that is "deformable" as defined above.

[0099] Figures 1 to 6 Existing CWHE technology and supporting systems are illustrated. (Reference) Figure 1 CWHE 100 includes a pressure boundary or housing 102. At least one tube 106 is wound around a central mandrel 108 in the circumferential direction C to form tube layers in a multilayer tube bundle 109, which may be enclosed within a shield 104. Each tube layer in the vertically stacked structure is supported by preformed supports 118, and preformed spacers (not visible) are used to maintain the desired spacing between the tube layers of the multilayer tube bundle 109, which allows fluid within the housing 102 to flow between the tube layers. Figure 2 The diagram illustrates how at least one tube 106 is wound around a mandrel to form various tube layers extending radially outward from the mandrel 108 of a multilayer tube bundle 109. Each individual tube layer includes at least one tube 106, and each tube layer may include tubes 106 that are the same as or different from those of adjacent layers. Thus, a single tube can be used to form at least a portion of multiple tube layers, or each tube layer may alternatively be formed by one or more tubes that are different from the tubes forming adjacent tube layers.

[0100] Figure 3This is a side elevation sectional view of a CWHE illustrating an exemplary example of a prior art support system. A mandrel 108 is shown extending along a longitudinal axis Z. At least one tube 106 is wound around the mandrel 108 in the circumferential direction C and at a desired winding angle α relative to the longitudinal axis Z of the mandrel to form a first tube layer 112. At least one tube 106 is further wound in the circumferential direction C at a winding angle -α relative to the longitudinal axis Z of the mandrel to form a second tube layer 114. The first tube layer 112 and the second tube layer 114 constitute a tube bundle 109, which may also include additional tube layers in addition to the first tube layer 112 and the second tube layer 114. Each of the first tube layer 112 and the second tube layer 114 is supported in a desired vertical position via a support member 118, which extends parallel to the mandrel 108 and substantially transverse to the winding angle. In this context, "substantially transverse" means that the support member extends along an axis forming an angle between 70 degrees and 110 degrees with respect to the winding angle α. Support member 118 is adapted to provide a load-bearing structure for tube bundle 109 during non-operational and / or operational load periods. At least one spacer 119 (which also extends parallel to mandrel 108) provides and maintains a desired separation distance between the respective tube layers 112, 114. In an exemplary example, the separation distance between the first tube layer 112 and the second tube layer 114 is between 0.5 mm and 100 mm. Although Figure 3 It is not shown in the figure, but the support layer may also be provided between the mandrel 108 and the first tube layer 112.

[0101] Figure 4 An example of a prior art spacer system is shown. The individual tubes 206a to 206f of the tube bundle 209 are separated by a desired center-to-center distance Dt, where Dt is equal to the distance between the axial midpoints of any two adjacent individual tubes, such as the distance between tubes 206a and 206b. Each of the first tube layer 212 and the second tube layer 214 is separated by spacer 219 by a desired distance Ds, where Ds is equal to the distance between the axial midpoints of any two of the individual tubes 206a to 206f across each of the first tube layer 212 and the second tube layer 214, such as the distance between tubes 206a and 206d. A support structure, not visible in the figure, provides structural support for the individual tubes 206a to 206f, while spacer 219 provides the desired spacing between the first tube layer 212 and the second tube layer 214.

[0102] Figure 5 An example of a prior art support system is shown. In the illustrated example, support 318 includes preformed tube seats 316a to 316f. Each of tube seats 316a to 316f is configured to receive and support at least a portion of a tube. Figure 6 Showing from Figure 5The support member 318 is used to support the tubes 306a to 306f of the tube bundle 309. Preformed tube seats 316a to 316f are manufactured to receive and support tubes 306a to 306f with specific diameters and with specific distances between adjacent tubes 306a to 306f in the first tube layer 312 and the second tube layer 314 (e.g., between tubes 306a and 306b). As described above, the preformed support member (such as support member 318) can only be used with a specific tube bundle 309 having tube diameters and spacings that match the tube seats 316a to 316f. This means that for each tube bundle with different tube diameters and / or tube spacings, different supports with tube seats constructed in different ways need to be manufactured and stocked.

[0103] Figures 7 to 11 A portion of a tube bundle 409 is shown utilizing a deformable support 418 having an outer support surface 422 adapted to deform during assembly of the tube bundle 409, such that each tube 406a to 406f is supported within a recess 425 formed in the outer support surface 422 of the support 418, thereby forming the recess 425 due to deformation of the outer support surface 422. This allows the support 418 to provide a desired spacing between the first tube layer 412 and the second tube layer 414, and to provide a load-bearing structure for the tubes 406a to 406f when the CWHE is fully assembled. As described herein, the support 418 is desired to have physical properties including radial compressive strength, which allows the outer support surface 422 to deform during the mounting of the first tube layer 412 and the second tube layer 414. This allows tubes 406a to 406f to be recessed into the support 418 at a controllable and predictable distance without deforming the outer tube surface 423 of any of tubes 406a to 406f. At least a portion of the support 418 is configured to undergo deformation; this portion is defined as a “compression zone”.

[0104] In an exemplary example, deformable supports 418 and spacers (not shown) can be arranged circumferentially alternately, meaning that each support 418 is positioned between two spacers along the direction of tube winding. This allows the non-deformable spacers to provide a "stop" for the deformation of the deformable supports 418. This arrangement allows the supports 418 to deform and perform their support function while precisely controlling the amount of deformation of the deformable supports 418 to provide uniform and accurate interlayer spacing. The deformable supports 418 can be staggered in both radial and axial directions. In one exemplary example, the deformable support 418 may comprise a single continuous structure extending along the axial direction Y of the tube bundle. In another exemplary example, the deformable support 418 may comprise multiple separate structures such that the deformable supports 418 are discontinuous along the axial direction of the tube bundle. In other specific embodiments, the supports and spacers can be arranged / patterned in other ways to effectively provide the desired end result.

[0105] Before any deformation of the deformable support 418 (see...) Figure 7 The radial spacing R between the tube layers is greater than the height of the spacer (not shown). After the support deforms (see...), Figure 8 The radial spacing R decreases and is substantially equal to the height of the spacer. In this context, "substantially equal" can mean, for example, within 10% of the spacer height, within 5% of the spacer height, or within 1% of the spacer height.

[0106] Figure 7 The support 418 and tubes 406a to 406f are shown before deformation of the outer support surface 422 of the support 418. Figure 8 The same support 418 is shown after the outer support surface 418 has been deformed. The deformation of the outer support surface 422 forms a recess 425 in the outer support surface 422. The recess 425 serves as a tube seat that receives and supports the individual tubes 406a to 406f of each of the first tube layer 412 and the second tube layer 414 constituting the tube bundle 409. Figure 7 In an exemplary example, the support 418 may be formed of a hollow unit material, which may include a plurality of perforated units 420a, 420b forming at least a portion of the support 418. In the exemplary example, the perforated units 420a, 420b provide a hollow unit structure that also allows fluid to move in a circumferential direction relative to the first tube layer 412 and the second tube layer 414 wound around the mandrel (e.g., see...). Figure 6 It passes through the support member 418 in the circumferential direction C).

[0107] exist Figures 7 to 11In the exemplary example shown, support 418 may include a hollow unit material comprising a combination of one or more open-cell units 420 and one or more closed-cell units 421. Closed-cell units 421 may include open-cell units 420 that are selectively closed after the support 418 is manufactured. As an example, closed-cell units 421 may be formed by filling open-cell units 420 with a material different from the material forming the remainder of support 418, whereby the compressive strength of the material filling closed-cell units 421 is greater than that of the material forming the remainder of support 418. Closed-cell units 421 may also be formed initially with the original construction of support 418. Each closed-cell unit 421 prevents circumferential fluid flow across its corresponding portion of support 418. When made of hollow unit material, support 418 may include a desired number and arrangement or pattern of closed-cell units 421 and open-cell units 420, and may be filled or otherwise closed to prevent fluid from flowing through it, thereby forming a desired flow pattern for circumferential fluid flow. The support member 418 may be composed entirely of hollow unit material, or may include a combination of hollow unit material and other types of materials. In other embodiments, the support member 418 may be deformable, but may not include hollow unit material.

[0108] To deform the support 418 to achieve the desired configuration of the tube bundle 409, after the first tube layer 412 has been wound around the mandrel, the support 418 is placed on the outer tube surface 423 of the first tube layer 412. Then, a second tube layer 414 is wound around the mandrel such that the second tube layer contacts the opposite side of the support 418, which is opposite to the side of the support 418 that contacts the first tube layer 412. Figure 7 As shown, a deformation force is applied to the outer tube surface 423 of the second tube layer 414 in direction N, which is normal to the outer support surface 422 of the support member 418. In this example, the support member 418 has a radial compressive strength ranging from 10 N / mm to 400 N / mm.

[0109] In some examples, support 418 may comprise a material with a non-constant radial compressive strength. For example, the radial compressive strength of the material may increase with deformation of the outer surface of the material. In this example, the amount of force required to deform the outer surface of a material that has already deformed by one millimeter by another millimeter is greater than the amount of force required to deform the previously undeformed outer surface of the material by one millimeter. Furthermore, the amount of force required to deform the outer surface of a material that has already deformed by two millimeters by another millimeter is greater than the amount of force required to deform the outer surface material that has already deformed by one millimeter by another millimeter, and so on. This functional relationship between the radial compressive strength of the material and the amount of deformation already performed on the outer surface of the material can be linear, exponential, stepwise, or any other type of functional relationship. In the context of such materials, the desired deformation of the outer surface of the material is achieved when a constant force is applied to the material.

[0110] For the purposes of this specification and claims, the term "maximum radial compressive strength" refers to the maximum radial compressive strength occurring in the deformed portion of the support member throughout the deformation process. Preferably, the maximum radial compressive strength of the portion of the support member 418 deformed by tubes 406a to 406f is less than the radial compressive strength of tubes 406a to 406b. In this way, the normal force required to deform the support member 418 can be applied to tube 406 without causing deformation of the outer tube surface 423 of tube 406.

[0111] In an illustrative example, the normal force can be applied via the tension caused by the winding operation of the second tube layer 414. In another illustrative example, such as Figure 11 As shown, a normal force can be applied via a roller 428 rotatable about axis 430. The normal force applied via the roller 428 is applied when the second tube layer 414 is wound around the mandrel, causing the second tube layer 414 to contact one side of the support member 418, opposite the side that contacts the first tube layer 412. The pressure applied by the roller 428 as it passes over the tube 406 is configured to apply a normal force to the outer tube surface 423 of the tube 406, causing the outer support surface 422 of the support member 418 to undergo desired deformation. The pressure applied by the roller 428 can alternatively be provided by another external device, such as a pressure shoe or slider that pushes the tube 406 into the support member 418.

[0112] In the previously discussed illustrative examples (such as...) Figure 8 In the illustrated example and in other illustrative examples, the applied normal force is sufficient to compress and deform the inner support surface 422 and outer support surface 427 of the support member 418, causing the first tube layer 412 and the second tube layer 414 to compress and deform them. The deformation of the support surfaces 422, 427 forms a recess 425, which serves as a seat for receiving, supporting, and stabilizing the tube 406. This results in the tubes 406a to 406f of the first tube layer 412 and the second tube layer 414 being in a recessed position relative to the support member 418, whereby the recess 425 defines a seat oriented at an angle corresponding to either the winding angle α or the winding angle -α, depending on which tube layer 412, 414 the recess 425 receives. The radial compressive strength of the tubes 406a to 406f is greater than the radial compressive strength of the support surfaces 422, 427 of the support member 418. This prevents unwanted deformation of tubes 406a to 406f during the deformation of the support surfaces 422, 427 of the support member 418.

[0113] In another exemplary embodiment, a normal force (“pre-winding force”) may be applied to the support 418 prior to winding the second tube layer 414. This will result in deformation only of the inner support surface 427.

[0114] Figure 9 A portion of the tube bundle 409 is shown before the support 418 deforms, with the tube 406 in contact with the outer support surface 422 of the support 418. The dashed line T illustrates the initial contact position in which the tube 406 first contacts the outer support surface 422 of the support 418. Figure 10 A portion of the tube bundle 409 is shown after the deformation of the support 418 has been completed, with the tube 406 contacting the support 418 such that the newly formed recess 425 serves as a seat to receive, support, and stabilize the tube 406. The material properties of the support 418 (e.g., radial compressive strength) may vary to achieve the desired final recessed position of the tube 406. In the exemplary example, the recessed position of the tube 406 is spaced from the initial contact position T by a distance E, which is at least 5% of the tube height H. In other exemplary examples, the distance E may be at least 25% of the tube height H. It should be noted that in this exemplary embodiment, the tube 406 is shown as having a circular cross-section, and therefore, the tube height H is the outer diameter of the tube. In other embodiments, the tube 406 may have a non-circular cross-section (oval, elliptical, etc.), and in such embodiments, the tube height H will be a measurement of the height of the tube in a direction perpendicular to the surface of the outer support surface 422.

[0115] Figures 12 to 15 Various exemplary examples of supports with different materials and / or physical properties are shown. Figure 12An exemplary example of a support member 518 is shown, having an inner layer 532 sandwiched between outer layers 534a, 534b. The maximum radial compressive strength of the inner layer 532 is greater than that of the outer layers 534a, 534b, meaning that when the outer layers 534a, 534b of the support member 518 deform, the inner layer 532 will maintain its shape and will not undergo deformation. This allows the deformation depth of the outer layers 534a, 534b of the support member 509 to be consistent even if the normal forces applied to the tubes 506a to 506f vary and / or the radial compressive strength of the outer layers 534a, 534b varies. In some examples, the outer layers 534a, 534b and the inner layer 532 are made of different materials, whereby the maximum radial compressive strength of the material of the inner layer 532 is greater than that of the material of the outer layers 534a, 534b. In another example where the inner layer 532 and the outer layers 534a, 534b are made of the same material (particularly hollow unit material), the outer layers 534a, 534b may include open-cell units, while the inner layer 532 includes closed-cell units. In yet another example, the inner layer 532 and the outer layers 534a, 534b may all comprise a combination of closed-cell and open-cell units, thereby the inner layer 532 includes a greater number of closed-cell units than the outer layers 534a, 534b, to ensure that the maximum radial compressive strength of the inner layer 532 is greater than that of the outer layers 534a, 534b. In this embodiment, the inner layer 532 may serve as a spacer element, such that the spacer is integral with the support 518. This allows the support 518 to perform a spacer function, which in other examples would be provided by separate spacers. In other words, each support 518 is also a spacer.

[0116] Figure 13 An exemplary example of a support member 518 including partially defined recesses 636a to 636f is shown. The partially defined recesses 636a to 636f are configured to receive at least a portion of the tubes 606a to 606f of each of the tube layers 612, 614 before deformation of the outer support surface 622 of the support member 618. The dimensions of the partially defined recesses 636a to 636f are smaller than the resulting tube seat recess formed after deformation of the outer support surface 622 of the support member 618. The partially defined recesses 606a to 606f are adapted to assist in aligning the tubes 606a to 606f to a desired position and vertical spacing before the deformation step forming the tube seat recess. In the exemplary example, the partially defined recesses 636a to 636f are provided on opposing first sides 636 and second sides 638 of the support member 618. In other examples, the partially defined recesses 636a to 636f may be provided only on one of the first side 636 or the second side 638 of the support member 618. After the outer support surface 622 of the support member 618 is deformed, the dimensions of the partially defined recesses 636a to 636f are increased to form the tube seat recess.

[0117] Figure 14 An exemplary example of a support member 718 is shown, wherein the outer support surface 722a along the first side 736 of the support member 718 is configured to be deformed. In this exemplary example, the support member 718 is configured such that the maximum radial compressive strength of the outer support surface 722a along the first side 736 of the support member 718 is less than the maximum radial compressive strength of the outer support surface 722b along the second side 738 of the support member 718. Similar to... Figure 13 The example support shows the inner and outer support layers. Figure 14 A first side 736 and a second side 738 of a support member 718 are shown, the first side and the second side comprising different materials with different maximum radial compressive strengths. In another example, the first side 736 and the second side 738 of the support member 718 may comprise the same material with different combinations of open-cell and closed-cell units to achieve a desired difference in maximum radial compressive strength between the outer support surface 722a of the first side 736 and the outer support surface 722b of the second side 738 of the support member 718. In this illustrative example, the outer support surface 722a along the first side 736 of the support member 718 is configured to be deformable, while the outer support surface 722b along the second side 738 of the support member 718 retains its original shape and profile during and after the deformation of the outer surface 722a of the first side 736 of the support member 718. In this example, the non-deformable second side 738 of the support member 718 can be used as a spacer element, such that the spacer element is integral with the support member 718. Similar to... Figure 12 The example shown allows support 718 to perform a spacing function, which in other examples would be provided by a separate spacer.

[0118] Figure 15 An exemplary example of a support member 818 is shown, wherein the outer support surface 822a along the first side 836 of the support member 818 is configured to be deformed. In this exemplary example, the support member 818 is configured such that the maximum radial compressive strength of the outer support surface 822a along the first side 836 of the support member 818 is less than the maximum radial compressive strength of the outer support surface 822b along the second side 838 of the support member 818. Similar to... Figure 14 , Figure 15A first side 836 and a second side 838 of a support member 818 are shown, the first side and the second side comprising different materials with different maximum radial compressive strengths. In another example, the first side 836 and the second side 838 of the support member 818 may comprise the same material with different combinations of open-cell and closed-cell units to achieve a desired difference in maximum radial compressive strength between the outer support surface 822a of the first side 836 and the outer support surface 822b of the second side 838 of the support member 818. In this illustrative example, the outer support surface 822a along the first side 836 of the support member 818 is configured to be deformable, while the outer support surface 822b along the second side 838 of the support member 818 retains its original shape and profile during and after the deformation of the outer surface 822a of the first side 836 of the support member 818. In this example, the non-deformable second side 838 of the support member 818 can be used as a spacer element, such that the spacer element is integral with the support member 818. Similar to... Figure 12 and Figure 14 The example shown allows support 818 to perform a spacing function, which in other examples would be provided by separate spacers. In this exemplary example, the non-deformable second side 838 of support 818 includes tube seats 846a to 846c, which are configured to receive at least a portion of tubes 806a to 806f of at least one of tube layers 812, 814 before deformation along the outer support surface 822b of the second side 838 of support 818. Tube seats 846a to 846c facilitate securing at least one of tube layers 812, 814 in place and allow for different spacing configurations.

[0119] Figure 16 An exemplary method is shown for forming a tubular bundle for a CWHE using deformable supports (such as those described above and shown in the previous figures). The exemplary method includes providing a mandrel extending along the longitudinal axis of the mandrel, an illustrative example of which is shown in... Figures 1 to 3The diagram shows (step 1050). A support layer is formed by placing a plurality of spacers and supports against a mandrel (step 1051). A first tube layer is then formed by winding at least one tube around the mandrel (step 1052). Supports and spacers are then placed on the outer surface of the first tube layer (step 1054), and a second tube layer is formed by winding at least one tube around the mandrel and onto the spacers and supports (step 1056). A deformation force having a component normal to the outer surface of each of the plurality of first-layer supports is applied to the second tube layer (step 1058). The deformation force may include tension on the tube due to the winding process and / or additional forces (such as rollers that closely follow the winding of the tube). The application of the deformation force is sufficient to deform the tube against the support, such that each tube in the first and second tube layers is in a concave position relative to the initial position of the outer surface of the support. Steps 1052 to 1058 may be repeated for each additional layer added to the tube bundle.

[0120] Therefore, the present invention has been disclosed according to preferred embodiments and alternative embodiments thereof. Of course, those skilled in the art can make various changes, modifications, and alterations based on the teachings of the present invention without departing from the spirit and scope thereof. The present invention is intended to be limited only by the terms of the appended claims.

Claims

1. A method for forming a tube bundle for a wound-tube heat exchanger, wherein the tube bundle comprises a plurality of tube layers, each layer comprising at least one tube, and the method comprising: (a) Provide a mandrel extending along the longitudinal axis of the mandrel; (b) A first tube layer is formed by winding at least one of the at least one tubes having a tube height H around the mandrel; (c) A plurality of first-layer supports and a plurality of first-layer spacers are placed on the outer tube surface of the first tube layer, each of the first-layer supports having a longitudinal axis of the support, an inner support surface in contact with the outer tube surface and an outer surface away from the inner support surface, and each of the plurality of first-layer spacers having a spacer height S; (d) A second tube layer is formed by winding at least one of the at least one tubes around the mandrel, the first tube layer and the plurality of first layer supports; as well as (e) Apply at least one deformation force to the second tube layer in a direction normal to the outer support surface of each of the plurality of first layer supports, the at least one deformation force being sufficient to deform the at least one tube forming the second tube layer to at least one of the outer support surface and the inner support surface of each of the plurality of first layer supports, without deforming the at least one tube forming the second tube layer.

2. The method according to claim 1, wherein the radial interlayer spacing between the first tube layer and the second tube layer is greater than the spacer height S before performing step (e), and equal to the spacer height S after performing step (e).

3. The method according to claim 1, further comprising: (f) Before performing step (b), a plurality of mandrel layer supports are placed on the mandrel such that the mandrel layer supports are positioned between the mandrel and the first tube layer.

4. The method of claim 1, wherein the application of the deformation force causes at least one of the outer support surface or the inner support surface of at least one of the plurality of first layer supports to move from an initial contact position to a recessed position, and wherein the distance E between the initial contact position and the recessed position is at least 5% of the tube height H.

5. The method according to claim 4, wherein the distance E is less than 50% of the pipe height H.

6. The method according to claim 1, wherein the deformation force in step (e) is the result of applying tension to the second tube layer during step (d).

7. The method of claim 1, wherein at least a portion of the deformation force in step (e) is applied by an external device passing over the second tube layer during or after the execution of step (d).

8. The method of claim 1, wherein step (b) further comprises winding the at least one first layer tube around the mandrel at a winding angle α relative to the longitudinal axis of the mandrel, and step (d) further comprises winding the at least one second layer tube at a winding angle -α relative to the longitudinal axis of the mandrel.

9. The method according to claim 1, wherein each of the at least one tube has a tube radial compressive strength, and each of the plurality of first layer supports has a support outer layer, the radial compressive strength of the support outer layer being less than the tube radial compressive strength.

10. The method of claim 8, wherein the outer support surface of each of the plurality of first layer supports is adapted to be deformed by the deformation force during step (b) to form a tube seat oriented at an angle corresponding to either the winding angle α or the winding angle -α.

11. The method of claim 1, wherein each of the plurality of first layer supports includes a non-deformable spacer portion that is substantially non-deformable during the execution of step (e).

12. The method of claim 1, wherein step (b) further comprises arranging the plurality of first layer supports and the plurality of first layer spacers on the outer tube surface of the first tube layer in a circumferentially alternating arrangement.

13. The method according to claim 1, further comprising: (g) Before performing step (d), a pre-winding force is applied to each of the plurality of first layer supports, the pre-winding force causing each of the plurality of first layer supports to deform only on the inner support surface.

14. The method of claim 1, further comprising forming one or more additional tube layers in the tube bundle by repeating steps (c) to (e) for each additional tube layer in the tube bundle.

15. The method of claim 1, wherein each of the plurality of first-layer supports placed in step (c) is also a first-layer spacer among the plurality of first-layer spacers.

16. The method of claim 15, wherein each of the plurality of first layer supports comprises an inner layer and at least one outer layer, the maximum inner radial compressive strength of the inner layer being greater than the maximum outer radial compressive strength of each of the at least one outer layer.

17. A method of forming a tube bundle for a wound-tube heat exchanger, wherein the tube bundle comprises a plurality of tube layers, each layer comprising at least one tube, and the method comprising: (a) Provide a mandrel extending along the longitudinal axis of the mandrel; (b) A first tube layer is formed by winding at least one of the at least one tubes having a tube height H around the mandrel; (c) A plurality of first-layer supports and a plurality of first-layer spacers are placed on the outer tube surface of the first tube layer in an alternating circumferential arrangement, each of the plurality of first-layer supports having an undeformed support height H2, and each of the plurality of first-layer spacers having a spacer height H1. (d) A second tube layer is formed by winding at least one of the at least one tubes around the mandrel, the first tube layer and the plurality of first layer supports; as well as (e) Apply at least one deformation force to the second tube layer, the at least one deformation force being sufficient to deform each of the plurality of first layer supports without deforming the at least one tube forming the second tube layer; The first tube layer and the second tube layer have an initial layer spacing at each of the plurality of first layer supports before performing step (e), and have a final layer spacing at each of the plurality of first layer supports after performing step (e), the final layer spacing being smaller than the initial layer spacing.

18. The method of claim 17, wherein each of the plurality of first-layer supports comprises a plurality of separate support structures such that each of the plurality of first-layer supports is discontinuous along the axial direction of the tube bundle.

19. The method of claim 17, wherein the final interlayer spacing is substantially equal to the spacer height H1.

20. The method of claim 17, wherein the initial interlayer spacing is substantially equal to the height H2 of the undeformed support.

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