Continuous spiral baffle heat exchanger

Abstract

The utility model relates to a continuous spiral baffle heat exchanger. The heater includes a fluid director and a plurality of resistive heating elements. The deflector defines a continuous geometric helix disposed about a longitudinal direction axis of the continuous helical baffle heat exchanger. The deflector defines a predetermined pattern of perforations extending in a longitudinal direction through a first longitudinal length of the geometric helicoid, the longitudinal direction being parallel to the longitudinal direction axis. The plurality of resistive heating elements extends through the perforations. At least one resistive heating element of the plurality of resistive heating elements has a first region of a first power density and a second region of a second power density. The second region is located in the longitudinal direction farther than the first region. The second power density is less than the first power density.

Description

Technical Field

[0001] This utility model generally relates to heating equipment.

[0002] More specifically, this utility model relates to a continuous spiral baffle heat exchanger for heating fluids. Background Technology

[0003] This section provides background information related to the present invention and does not constitute prior art.

[0004] A heat exchanger typically comprises a tubular container and multiple heating elements disposed within the tubular container. The working fluid enters the tubular container at one longitudinal end and exits at the other longitudinal end. As the working fluid flows within the tubular container, it is heated by the multiple heating elements. In a fluid-to-fluid heat exchanger, the heating elements are the tubes through which the heated fluid flows. Heat is transferred from the heated fluid to the working fluid through the tube walls. In an electric heat exchanger, the heating elements are electric heating elements (e.g., resistance heating elements).

[0005] To heat the working fluid more quickly and efficiently, typical heat exchangers increase the total heat exchange area or the heat flux of the heating element to increase heat output. However, the typical approach of increasing the total heat exchange area requires more space in the heat exchanger, which is available for accommodating the working fluid, and the typical approach of increasing the heat flux of the heating element may be limited by the materials and design of the heating element, as well as other application-specific requirements. Utility Model Content

[0006] This utility model provides a continuous spiral baffle heat exchanger, comprising: a flow guide defining a continuous geometric spiral body disposed around a longitudinal axis of the continuous spiral baffle heat exchanger, the flow guide defining a predetermined pattern of perforations extending through the geometric spiral body for a first longitudinal length, the longitudinal direction being parallel to the longitudinal axis; and a plurality of resistance heating elements extending through the perforations, wherein each resistance heating element includes a resistance element having a first region of a first power density and a second region of a second power density, the second region being positioned further in the longitudinal direction than the first region, the second power density being less than the first power density.

[0007] In one embodiment, a continuous spiral baffle heat exchanger is provided, comprising a series of continuous spiral members and a plurality of heating elements. Each spiral member defines opposing edges and perforations of a predetermined pattern extending through each spiral member and parallel to the longitudinal axis of the continuous spiral baffle heat exchanger. A plurality of heating elements extend through the perforations of the continuous series of spiral members (and in one form, extend through all the perforations). The series of continuous spiral members defines a geometric spiral.

[0008] In another embodiment, the heat exchanger includes a body defining a cavity, a continuous spiral baffle heat exchanger disposed within the cavity, and a proximal flange configured to secure the continuous spiral baffle heat exchanger to the body. The continuous spiral baffle heat exchanger defines a longitudinal axis and includes a series of continuous spiral members and a plurality of heating elements. Each spiral member defines opposing edges and perforations of a predetermined pattern extending through each spiral member and parallel to the longitudinal axis. The plurality of heating elements extend through the perforations of the continuous series of spiral members. The series of continuous spiral members defines a geometric spiral.

[0009] In yet another embodiment, in the heat exchanger, the device provides a uniform linear temperature rise along the length of the heat exchanger. The device comprises a series of continuous helical members. Each helical member defines opposing edges and perforations of a predetermined pattern extending through each helical member and parallel to the longitudinal axis of the heat exchanger. The continuous series of helical members defines a geometric helix, and the perforations are configured to receive heating elements.

[0010] In one embodiment, the continuous spiral baffle heat exchanger includes a series of continuous perforated spiral members and a plurality of heating elements. The perforated spiral members cooperate to define a geometric spiral body arranged around the longitudinal axis of the continuous spiral baffle heat exchanger. Each perforated spiral member defines opposing edges and a predetermined perforation pattern. Perforations extend parallel to the longitudinal axis through each perforated spiral member. Heating elements extend through the perforations.

[0011] In another embodiment, each heating element includes a first segment, a second segment, and a bend connecting the first and second segments. The first segment extends through a first set of perforations. The second segment extends through a second set of perforations. The second set of perforations is parallel to and offset from the first set of perforations.

[0012] In a further configuration, multiple heating elements are arranged in a concentric pattern.

[0013] In another embodiment, the continuous spiral baffle heat exchanger also includes a central support member. Each perforated spiral member defines a central aperture, and the central support member extends through the central aperture.

[0014] According to another embodiment, the continuous spiral baffle heat exchanger also includes a temperature sensor extending through the interior of the central support member, which includes a probe outside the central support member.

[0015] According to another embodiment, the continuous spiral baffle heat exchanger also includes a proximal flange configured to secure the continuous spiral baffle heat exchanger to the heat exchanger body. The flange defines a plurality of flange holes and a central recess. The flange holes are aligned with perforations in the perforated spiral member. A heating element extends through the flange holes. A central support is received in the central recess.

[0016] According to another embodiment, the continuous spiral baffle heat exchanger also includes a vent that provides fluid communication between the exterior of the central support member and the interior of the central support member near the flange.

[0017] In another form, the central support member includes at least one additional heater.

[0018] According to another embodiment, the continuous spiral baffle heat exchanger also includes an unperforated spiral member disposed at the distal end of a continuous series of perforated spiral members, the unperforated spiral member forming an extension of a geometric spiral.

[0019] In another embodiment, each heating element is fixed to at least a portion of each perforation through which each heating element extends.

[0020] In another form, the opposite edges of a helical member overlap with the opposite edges of an adjacent helical member.

[0021] In another form, the opposite edges of a helical member are spaced apart from the opposite edges of an adjacent helical member and are connected to it by a bridging member.

[0022] According to another embodiment, the continuous spiral baffle heat exchanger also includes a plurality of rods extending parallel to the longitudinal axis. The periphery of each perforated spiral member defines a plurality of grooves, and the rods are at least partially disposed within the respective sets of grooves.

[0023] In another configuration, the rod extends outward from the groove beyond the periphery of each perforated helical member. The continuous helical baffle heat exchanger is configured to be housed within a cylindrical cavity of the body, and the rod is configured to provide sliding contact with the wall of the body defining the cylindrical cavity.

[0024] According to another embodiment, the continuous spiral baffle heat exchanger also includes a shroud arranged around at least one perforated spiral member and connected to the rod.

[0025] In another form, the rod does not extend outward beyond the perimeter of each perforated helical component.

[0026] In another form, the shield is a heat shield that is constructed to reflect radiant energy radially inward relative to the longitudinal axis.

[0027] According to another form, the shield includes at least one skirt that defines a plurality of deformable flaps that extend radially outward relative to a longitudinal axis.

[0028] In another embodiment, the at least one skirt is positioned near the proximal or distal end of the continuous spiral baffle heat exchanger.

[0029] According to another embodiment, at least one skirt includes a first skirt and a second skirt. The first skirt is disposed at the proximal end of the continuous spiral baffle heat exchanger, and the second skirt is disposed at the distal end of the continuous spiral baffle heat exchanger.

[0030] In another form, a continuous series of perforated helical members defines a variable pitch.

[0031] In another form, the perforated spiral components in a continuous series have a longer pitch near the inlet end of the continuous spiral baffle heat exchanger than near the outlet end.

[0032] In another form, the heating element is a resistance heating element.

[0033] According to another form, the resistance heating element is one of the following groups: tube heater, cylinder heater, or multi-unit heater.

[0034] According to another form, the plurality of heating elements includes a first heating element and a second heating element, wherein the first heating element has a different length than the second heating element.

[0035] In another embodiment, the continuous spiral baffle heat exchanger further includes an alignment plate coaxially arranged around the longitudinal axis. The alignment plate defines a plurality of plate holes aligned with the perforations of the perforated spiral member.

[0036] In another embodiment, the heat exchanger includes a body, a continuous spiral baffle heat exchanger, and a proximal flange. The body defines a cylindrical cavity. The continuous spiral baffle heat exchanger defines a longitudinal axis. The continuous spiral baffle heat exchanger includes a series of continuous perforated spiral members and a plurality of heating elements. The perforated spiral members are disposed within the cylindrical cavity and define a geometric spiral. Each perforated spiral member defines opposing edges and a predetermined perforation pattern extending through each perforated spiral member and parallel to the longitudinal axis. Heating elements extend through the perforations of the perforated spiral members. The proximal flange secures the continuous spiral baffle heat exchanger to the body.

[0037] According to another embodiment, the heat exchanger also includes a plurality of rods extending longitudinally parallel to the longitudinal axis. The periphery of each perforated helical member defines a plurality of grooves, and the rods are partially disposed within a corresponding set of grooves and have a thickness extending radially outward from the periphery of the perforated helical member, such that the rods slide in contact with the inner wall of a body defining a cylindrical cavity.

[0038] According to another embodiment, the heat exchanger also includes a skirt comprising elastically deformable fins extending radially between a perforated helical member and the inner wall of a body defining a cylindrical cavity.

[0039] According to another embodiment, the body includes an inlet at the proximal end of a cylindrical cavity and an outlet at the distal end of the cylindrical cavity. The continuous spiral baffle heat exchanger also includes an unperforated spiral member coupled to the last of a continuous series of perforated spiral members. The unperforated spiral member forms an extension of the geometric spiral and begins at or before the outlet along the geometric spiral.

[0040] In another form, the pitch of the non-perforated helical component is equal to the diameter of the outlet.

[0041] In another embodiment, the continuous spiral baffle heat exchanger includes continuous perforated spiral baffles and a plurality of heating elements. The baffles define a geometric spiral about a longitudinal axis. The perforated spiral baffles define a predetermined perforation pattern extending through the perforations and parallel to the longitudinal axis. The heating elements extend through the perforations.

[0042] In a further form, the geometric helix has a pitch that varies along the longitudinal axis.

[0043] According to another form, the pitch is continuously variable.

[0044] According to another embodiment, the plurality of said resistance heating elements includes a first group of resistance heating elements and a second group of resistance heating elements, each of the first group of resistance heating elements having an end that is further in the longitudinal direction than the end of each of the second group of resistance heating elements; wherein the end of the second group of resistance heating elements is positioned further than the end of the first group of resistance heating elements along a spiral flow path defined by the geometric helix.

[0045] Further applicability will become apparent from the description provided herein. It should be understood that these descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this invention. Attached Figure Description

[0046] The present invention will be more fully understood from the detailed embodiments and accompanying drawings, wherein:

[0047] Figure 1 This is a perspective view of a continuous spiral baffle heat exchanger constructed according to the teachings of this utility model;

[0048] Figure 2 yes Figure 1 A three-dimensional view of a series of continuous spiral components in a continuous spiral baffle heat exchanger;

[0049] Figure 3 yes Figure 2 A three-dimensional view of the spiral component;

[0050] Figure 4 yes Figure 3 Front view of the spiral component;

[0051] Figure 5 yes Figure 1 A three-dimensional view of a series of continuous spiral components and a central support component;

[0052] Figure 6 yes Figure 5 A partial perspective view of the spiral component and heating element;

[0053] Figure 7 The connection between the heating element and the spiral component is shown;

[0054] Figure 8 yes Figure 1 A partial perspective view of the spiral component and heating element;

[0055] Figure 9 This is a front view of the heating element installed on the spiral component;

[0056] Figure 10 This is a front view of the heating element mounted on the spiral component, showing different arrangements of the heating element;

[0057] Figure 11 yes Figure 1 A partial perspective view of a continuous spiral baffle heat exchanger, in which the shroud has been removed to show the unperforated spiral components and support rods;

[0058] Figure 12 yes Figure 1 A partial perspective view of a continuous spiral baffle heat exchanger, in which the protective cover and unperforated spiral components have been removed;

[0059] Figure 13 yes Figure 1 An enlarged view of part A;

[0060] Figure 14 yes Figure 1 An enlarged view of part B;

[0061] Figure 15 yes Figure 1 A perspective view of the near-end mounting flange;

[0062] Figure 16 This is a cross-sectional perspective view of an electric heat exchanger constructed according to the teachings of this utility model;

[0063] Figure 17 yes Figure 16 A cross-sectional front view of an electric heat exchanger;

[0064] Figure 18 It shows along Figure 1 A diagram showing the temperature distribution of a continuous spiral baffle heat exchanger;

[0065] Figure 19 It shows a conventional heat exchanger and has Figure 18 A graph showing the surface temperature of the heating element of a continuous spiral baffle heat exchanger relative to the distance from the near-end mounting flange.

[0066] Figure 20 This is a left perspective view of a continuous spiral baffle heat exchanger with a second construction according to the teachings of this utility model, showing the case with an optional shroud installed.

[0067] Figure 21 yes Figure 20 The right-side perspective view of the continuous spiral baffle heat exchanger shows the case without the optional shroud installed;

[0068] Figure 22 yes Figure 20 A three-dimensional view of a part of the protective shield;

[0069] Figure 23 yes Figure 22 A three-dimensional view of the far end of a continuous spiral baffle heat exchanger;

[0070] Figure 24 yes Figure 20 A three-dimensional view of the central tube and mounting flange of a continuous spiral baffle heat exchanger;

[0071] Figure 25 yes Figure 24 An exploded perspective view of the center pipe and mounting flange;

[0072] Figure 26 This is a perspective view of a heat exchanger according to the teachings of this utility model, which includes... Figure 20 Continuous spiral baffle heat exchanger;

[0073] Figure 27 yes Figure 26 A cross-sectional view of the proximal end of the heat exchanger;

[0074] Figure 28 yes Figure 26 A cross-sectional view of the distal end of the heat exchanger;

[0075] Figure 29 This is a perspective view of a continuous spiral baffle heat exchanger with a third construction according to the teachings of this utility model, showing a straight heating element;

[0076] Figure 30 This is a top view of a continuous spiral baffle heat exchanger with a fourth construction according to the teachings of this utility model;

[0077] Figure 31 It is based on the teachings of this utility model. Figure 30 A partial cross-sectional view of a portion of the resistance heating element of a continuous spiral baffle heat exchanger;

[0078] Figure 32 It is similar to Figure 31 A partial cross-sectional view shows a resistance heating element with a second structure according to the teachings of this utility model;

[0079] Figure 33 It is similar to Figure 31 A partial cross-sectional view shows a resistance heating element with a third structure according to the teachings of this utility model;

[0080] Figure 34 It is similar to Figure 31 A partial cross-sectional view shows a resistance heating element with a fourth structure according to the teachings of this utility model;

[0081] Figure 35 It is similar to Figure 31 A partial cross-sectional view shows a resistance heating element with a fifth structure according to the teachings of this utility model;

[0082] Figure 36 It is similar to Figure 31 A partial cross-sectional view shows a resistance heating element with a sixth structure according to the teachings of this utility model;

[0083] Figure 37 This is a perspective view of the terminal pins at the end of a heating element having a single straight section, in accordance with the teachings of this utility model.

[0084] Figure 38 This is a perspective view of the terminal pins at the ends of a heating element having two straight sections, in accordance with the teachings of this utility model.

[0085] Figure 39 This is a top view of a portion of a heater with an alternative structure according to the teachings of this utility model;

[0086] Figure 40 yes Figure 39 Side view of the heater section;

[0087] Figure 41 This is a top view of a portion of a heater with another structure according to the teachings of this utility model; and

[0088] Figure 42 yes Figure 41 Side view of the heater section.

[0089] In the several views in the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0090] The following description is merely exemplary in nature and is not intended to limit the invention, application, or use.

[0091] Reference Figure 1 The continuous spiral baffle heat exchanger 10 constructed according to the teachings of this utility model is configured to be installed in the heat exchanger 80 ( Figure 16 and 17 The continuous spiral baffle heat exchanger 10 is housed within a tubular body 82 or shell (as shown in the diagram) to heat the working fluid flowing through the heat exchanger 80. The continuous spiral baffle heat exchanger 10 can be mounted to the tubular body 82 of the heat exchanger 80 via a proximal end plate or mounting flange 12. The continuous spiral baffle heat exchanger 10 includes a flow guide 14 and a plurality of extending heating elements 16. The continuous spiral baffle heat exchanger 10 defines a proximal end 20 and a distal end 21, which define the longitudinal axis X of the continuous spiral baffle heat exchanger 10. The mounting flange 12 is disposed at the proximal end 20 of the continuous spiral baffle heat exchanger 10. The plurality of heating elements 16 extend along the longitudinal axis X of the continuous spiral baffle heat exchanger 10.

[0092] Reference Figure 2 The flow guide 14 includes a plurality of perforated helical members 18 or helical baffles connected in a linear array along the longitudinal axis X of the continuous helical baffle heat exchanger 10 to define a continuous geometric helix. The continuous geometric helix results in each perforated helical member 18 defining a surface following a helical path around the longitudinal axis X. Optionally, the flow guide 14 also includes helical end baffles or unperforated helical members 23 configured adjacent to the distal end 21 of the continuous helical baffle heat exchanger 10 and connected to adjacent perforated helical members 18 to form an extension of the continuous geometric helix. The plurality of perforated helical members 18 and unperforated helical members 23 define a continuous helical flow channel 22 to guide the working fluid through it and generate a helical flow within the tubular body 82 of the heat exchanger 80. Figure 16 and 17 ).

[0093] refer to Figure 3 and Figure 4 Each perforated spiral member 18 is in the form of a sheet of metal that is bent to form a complete spiral coil. Although not shown in the figures, it should be understood that the sheet of metal may be bent to form only a portion of a spiral coil of one or more turns. Each perforated spiral member 18 defines opposing edges 26 and 28 and a perforation 30 extending through a predetermined pattern of each perforated spiral member 18. Opposing edges 26 or 28 from one perforated spiral member 18 may be welded to opposing edges 28 or 26 of adjacent perforated spiral members 18. In one embodiment, as... Figure 8 As shown, the opposite edges 26 or 28 of a perforated spiral member 18 may overlap with the opposite edges 28 or 26 of adjacent perforated spiral members 18. Figure 8As shown, this overlap is approximately equal to 1.01 rotations to provide additional coverage. In another implementation, as... Figure 6 As shown, opposite edges 26 or 28 of a perforated helical member 18 may abut or be welded to opposite edges 28 or 26 of adjacent perforated helical members 18, such that the surfaces of adjacent perforated helical members 18 form a continuous surface. In another example not specifically shown, opposite edges 26 or 28 of a perforated helical member 18 may be connected to opposite edges 28 or 26 of adjacent perforated helical members 18 by means of a bridging member (not shown). The bridging member may be helical in shape or may be another shape, such as extending a short distance in a circular manner.

[0094] Therefore, the perforated helical members 18 are connected along the longitudinal axis X of the continuous helical baffle heat exchanger 10 to form a linear array (continuous series) of perforated helical members 18. The perforations 30 in the plurality of perforated helical members 18 are aligned either parallel to the longitudinal axis X of the continuous helical baffle heat exchanger 10 or perpendicular to the radial direction, resulting in an angle relative to each face of the perforated helical member 18. Unperforated helical members 23 are connected to the distal ends of the series of continuous perforated helical members 18. The unperforated helical members 23 are structurally similar to the perforated helical members 18, but without perforations.

[0095] Each of the perforated helical member 18 and the unperforated helical member 23 has an inner peripheral edge 32, the profile of which defines a circular aperture 34 coaxial with the longitudinal axis X when viewed along a direction parallel to the longitudinal axis X of the continuous helical baffle heat exchanger 10. In the provided example, each of the perforated helical members 18 defines a plurality of circumferential grooves 36 along its outer periphery. Similarly, the unperforated helical member 23 defines a plurality of circumferential grooves 36 along its outer periphery. The circumferential grooves 36 of the plurality of perforated helical members 18 (and unperforated helical members 23) are also aligned along a direction parallel to the longitudinal axis X of the continuous helical baffle heat exchanger 10.

[0096] The pitch, outer diameter of the perforated helical member 18, diameter of the central hole 34 of the perforated helical member 18, and thickness of the perforated helical member 18 can be appropriately selected according to the desired flow rate and flow rate of the working fluid. The number of heating elements 16 and the number of perforations 30 in the perforated helical member 18 can be appropriately selected according to the desired heat output and thermal efficiency.

[0097] Reference Figure 5The continuous spiral baffle heat exchanger 10 also includes a central support member 40 extending through a central bore 34 of the perforated spiral member 18 and the unperforated spiral member 23 to connect a plurality of perforated spiral members 18 and unperforated spiral members 32 together, providing structural support for the continuous spiral baffle heat exchanger 10. The central support member 40 and the unperforated spiral member 23 may also be configured to provide additional heating to the working fluid. In one embodiment, the central support member 40 is an additional heating element (e.g., an electric heating element). When also used as an additional heating element, the central support member 40 may include one or more resistance heating elements, such as a cylindrical heater, a tubular heater, or any conventional heater with an elongated configuration, to provide both heating and structural support.

[0098] Reference Figure 6 and 7 Multiple heating elements 16 are inserted through the perforations 30. For clarity, in Figure 6 and 7 Only one pair of heating elements 16 is shown, but when fully assembled, all perforations 30 receive heating elements 16 passing through them, allowing fluid to travel along the helical flow channel 22 without passing through the perforations 30. In the provided example, each of the multiple heating elements 16 has a clamp-like configuration and includes a pair of straight portions 42 extending through the perforations 30 of the perforated helical member 18 and a curved portion 44 connecting the pair of straight portions 42. The heating elements 16 can be any suitable type of heating element, such as a resistance heating element.

[0099] For example, an electric tube heater, a flashlight heater, or a multi-unit heater can be used. When the heating element 16 is an electric heating element, it may include a resistance heating element (e.g., a heating coil, not specifically shown), which may be disposed within the straight portion 42 and the curved portion 44 (when included). In the provided example, the resistance heating coil may extend through the straight portion 42 and the curved portion 44 and has opposing leads (not specifically shown) extending from the proximal end of the respective straight portion 42. (See reference...) Figure 29 An example of a cylindrical heater is shown. In this example, the heating element comprises only straight sections 42. Each straight section 42 terminates at a distal end, and the heating element 16 is not bent to connect to two of the straight sections 42. Instead, a resistance heating element (not shown) is disposed in each straight section 42, and an electrical lead extends from the proximal end of each straight section 42.

[0100] Return to Figure 6 and Figure 7Each heating element 16 is fixed to at least a portion of each perforation 30 through which it extends. In the provided example, the heating element 16 is fixed to approximately half of the periphery of each perforation 30 by welding, such that a weld joint 46 is formed along half of the periphery of the perforation 30.

[0101] Reference Figure 8 The working fluid is guided by the perforated spiral member 18 in the flow channel 22 to flow in the spiral direction F and is continuously heated by the heating element 16. By using the flow channel 22, the working fluid can be guided to flow laterally across the heating surface of the heating element 16. Therefore, the working fluid can be heated more effectively by the heating element 16 within a predetermined length of the heat exchanger 80, unlike a typical heat exchanger (not shown, in which the working fluid flows in a direction parallel to the longitudinal axis X of the heat exchanger). Since the working fluid is properly guided to flow laterally across the heating surface of the heating element 16, dead zones where the working fluid is not heated can be avoided. In conventional heat exchangers (not specifically shown), dead zones can lead to fouling, where the working fluid decomposes and causes material to accumulate and deposit on the heating element. Therefore, the heat exchanger of this teaching can improve flow uniformity and reduce the impact on the shell or container (e.g., Figure 16 and 17 The main body 82 shown in the figure reduces radiative heat loss to reduce fouling and increase heat transfer efficiency.

[0102] Reference Figure 9 and Figure 10 The heating element 16 can be inserted into the perforation 30 in such a way that the bent portion 44 of the heating element 16 forms a concentric pattern around the central support member 40. Figure 9 ), or form a pattern symmetrical with respect to the diameter of the perforated spiral member 18 ( Figure 10 ).exist Figure 9 and Figure 10 The configurations shown allow for the use of concentric patterns to mount higher-density heating elements 16 within the same space, but other configurations and patterns can also be used. Figure 9 and Figure 10 Between the structures shown, concentric patterns typically have a closer bend radius connecting the straight sections 42. Therefore, patterns can also be selected based on design criteria such as component density or bend radius. Figure 12As shown, the heating elements 16 may have different lengths, such that some heating elements 16 extend further along the longitudinal axis X than others. The lengths of the heating elements 16 may be based on their positions relative to the unperforated helical member 23. In one configuration, one or more heating elements 16 may be a first group of heating elements all having a first length, while one or more different heating elements 16 may be a second group of heating elements all having a second length different from the first length. In this example, the heating elements 16 are not limited to two groups having only two lengths, and may include additional groups and lengths.

[0103] refer to Figure 11 and Figure 12 The continuous spiral baffle heat exchanger 10 may further include a plurality of support rods 50, which extend through the peripheral grooves 36 of the perforated spiral member 18 and the unperforated spiral member 23 and are parallel to the longitudinal axis X of the continuous spiral baffle heat exchanger 10. The support rods 50 may extend outward (i.e., radially relative to the longitudinal axis X) beyond the periphery of the peripheral grooves 36 and may be configured as sliding rods for mounting the continuous spiral baffle heat exchanger 10 into the cylindrical chamber 84 of the tubular body 82 of the heat exchanger 80. Figure 16 and 17 In other words, the support rod 50 can reduce the direct surface contact between the continuous spiral baffle heat exchanger 10 and the inner wall of the tubular body 82. Figure 16 and Figure 17 This reduces friction, thereby reducing the force required to slide the continuous spiral baffle heat exchanger 10 into the tubular body 82. Alternatively, the support rod 50 may be configured not to extend beyond the periphery of the peripheral groove 36 and serve only as a structural support for supporting the continuous spiral baffle heat exchanger 10. In the provided example, the support rod 50 is welded to the perforated spiral member 18 and the unperforated spiral member 23.

[0104] Return to Figure 1 The continuous spiral baffle heat exchanger 10 may also include a pair of shields 52 disposed at a proximal end 20 and a distal end 21, for surrounding the perforated spiral member 18, the unperforated spiral member 23, the heating element 16, and the support rod 50. At the proximal end, the shields 52 are typically located between the unheated portion 54 and the heated portion 56. Although Figure 1 Two shields 52 are shown, but any number of shields 52 (including one) can be provided to surround the perforated helical member 18, the heating element 16, and the support rod 50. When a shield 52 is provided, it can be located at the distal portion 21 or the proximal portion 20.

[0105] See Figure 13 and Figure 14Each of the shields 52 may define a cylindrical shield member 51 and a plurality of deformable vanes 53, the deformable vanes 53 forming a skirt surrounding the cylindrical shield member 51. The cylindrical shield member 51 may enclose a portion of perforated and / or unperforated helical members 18, 23. In the provided example, each cylindrical shield member 51 extends along a longitudinal axis X by a length equal to at least one complete helical pitch of the corresponding perforated or unperforated helical member 18, 23 around which it is enclosed. The deformable vanes 53 are typically formed by cutting radially outward flange portions of the shield 52 such that the vanes 53 extend radially outward from the cylindrical shield member 51. Contact with the inner wall of the tubular body 82 allows the vanes 53 to elastically deform, such that the vanes 53 are biased to contact the inner wall of the tubular body 82 to prevent fluid from escaping between the tubular bodies 82 of the heat exchanger 80, thereby reducing blow-by. In the provided example, Figure 13 The fins 53 of the distal shroud 52 shown may be axially positioned near the distal end of the continuous spiral baffle heat exchanger 10, for example, just before the outlet 88 of the tubular body 82 of the heat exchanger 80. For example, the fins 53 of the distal shroud 52 may be positioned approximately before the outlet 88 of the tubular body 82. Figure 17 The dotted line at point 92 is shown. In the example provided, Figure 14 The fins 53 of the proximal shield 52 shown may be axially positioned near the starting point of the perforated helical member 18, for example, after the inlet 86 of the tubular body 82. For example, the fins 53 of the proximal shield 52 may be positioned approximately after the inlet 86 of the tubular body 82. Figure 17 The dotted line at point 94 is shown in the diagram.

[0106] Reference Figure 15 As shown, the proximal mounting flange 12 is configured to secure the continuous spiral baffle heat exchanger 10 to the tubular body 82 of the heat exchanger 80. The proximal mounting flange 12 includes a plate body 58, a plurality of holes 60, and a plurality of bolt holes 62 passing through the heat exchanger 80. The plurality of holes 60 are aligned with the perforations 30 of a continuous series of perforated spiral members 18 and are configured to guide a plurality of heating elements 16 through the proximal mounting flange 12. Although not specifically shown, the heating elements 16 can be sealed to the holes 60 to prevent fluid flow through them. The plurality of bolt holes 62 are defined along the periphery of the plate body 58. The proximal mounting flange 12 can be secured by inserting bolts (not shown) into the bolt holes 62 and through a mating flange (e.g., a flange in the tubular body 82) into the bolt holes 62. Figure 26 The tubular body 82 of the heat exchanger is installed using bolt holes in the mating flange 83 shown. Gaskets (not shown) or other sealing materials can be used in the mounting flange 12 and the mating flange (e.g., Figure 26A fluid-free seal is formed between the flanges 83 shown. In another configuration not shown, the end plate or mounting flange 12 may be mechanically attached to the mating flange in various ways, such as welding, latching, clamping, etc.

[0107] The proximal mounting flange 12 may also define a circular central recess or groove 64, which is configured to align with the central support member 40. The central groove 64 is coaxial with the longitudinal axis X, and the proximal end of the central support member 40 is configured such that the central support member 40 is received in the central groove 64. In the provided example, the central support member 40 is welded to the proximal mounting flange 12.

[0108] refer to Figure 16 and Figure 17 As shown, the heat exchanger 80 according to the present invention comprises a tubular body or shell 82 defining a cylindrical cavity 84, an inlet 86, an outlet 88, and a continuous spiral baffle heat exchanger 90 disposed within the tubular body 82. The continuous spiral baffle heat exchanger 90 defines a proximal end 20 and a distal end 21. A proximal mounting flange 12 is configured to secure the continuous spiral baffle heat exchanger 90 to the body 82.

[0109] The continuous spiral baffle heat exchanger 90 is structurally similar to Figure 1 The continuous spiral baffle heat exchanger is characterized by a series of continuous perforated spiral members 18 and unperforated spiral members 23 connected in such a manner that the spiral body defined by the perforated spiral members 18 and the unperforated spiral members 23 has a variable pitch. Therefore, similar elements are indicated by similar reference numerals, and their detailed descriptions are omitted herein for clarity. In the provided example, outlet 88 is a radial outlet, such that it opens radially into the flow path 22. In alternative configurations not specifically shown, outlet 88 may be an axial end outlet opening through the axial end 96 of the body 82.

[0110] Returning to the provided example, the pitch of the helix defined by the perforated helical member 18 and the unperforated helical member 23 is largest at the proximal end 20 (near the inlet 86 of the heat exchanger 80) and smallest at the distal end 21 (near the outlet 88 of the heat exchanger 80). In one embodiment, the pitch is a continuously varying pitch that gradually decreases from the proximal end 20 to the distal end 21. Figure 17As shown, a continuous spiral baffle heat exchanger 90 can define multiple regions along its longitudinal axis X. The pitch can be fixed within a specific region, while different regions can have different pitches. For example, the continuous spiral baffle heat exchanger 90 can define three heating regions, wherein a first region has a first fixed pitch P1, a second region has a second fixed pitch P2, and a third region has a third fixed pitch P3. The second fixed pitch P2 is greater than the third fixed pitch P3 and less than the first fixed pitch P1. The first pitch P1 is located at the proximal end 20. The third pitch P3 is located at the distal end 21. The second pitch P2 is located between the first pitch P1 and the third pitch P3. Although three regions are shown, more or fewer regions can be used. In one embodiment, each perforated spiral member 18 or a group of perforated spiral members 18 can have a constant pitch along its specific length, while different perforated spiral members 18 or different groups thereof can have different pitches to form a variable pitch geometric spiral.

[0111] In alternative constructions not specifically shown, the perforated helix may not be formed from individual components joined together, but rather from a single continuous helical member spanning from the proximal to the distal end of the continuous helical baffle heat exchanger. For example, the single helical member may be extruded, formed, or 3D printed by feeding strip metal sheets with opposing conical dies.

[0112] Reference Figure 18 The figure illustrates the temperature distribution along the longitudinal axis X of the heating element 16 for a specific configuration of the continuous spiral baffle heat exchangers 10, 90. In this particular example, a portion of the heating element 16 (adjacent to the proximal portion of the continuous spiral baffle heat exchanger) has a temperature of approximately 33.94°C. As the working fluid is guided by the flow channels 22 of the perforated spiral member 18 and flows to the distal end of the continuous spiral baffle heat exchangers 10, 90, the temperature gradually increases to approximately 534.92°C in the provided example. Although Figure 18 The diagram illustrates a specific inlet temperature, electrical power load of heating element 16, and temperature distribution of the fluid's mass flow rate; however, other temperatures and distributions can also be produced by different conditions or configurations. Generally, a continuous spiral baffle heat exchanger constructed according to the teachings of this invention will have a reduced heating element temperature, with no dead zones where the working fluid is not heated along its flow path.

[0113] Reference Figure 19The figure illustrates the relationship between the distance from the near-end mounting flange 12 and the temperature of the heating element 16. The near-end mounting flange 12 is located near the inlet 86 of the heat exchanger 80. As the working fluid enters the inlet 86 and flows away from the near-end mounting flange 12, the temperature of the outer surface of the heating element 16 remains stable and gradually increases, as shown by line 97. In contrast, the outer surface of the heating element in a typical heat exchanger (not shown) has a higher temperature, which also increases and decreases as the fluid flows away from the near-end flange (i.e., from the inlet to the outlet), as shown by line 98. Accordingly, the teachings of this invention provide a continuous spiral baffle heat exchanger and heat exchanger that provides a consistent and low linear temperature rise of the heating element along the length of the heat exchanger.

[0114] The continuous spiral baffle heat exchanger of this invention can be applied to any heating device (e.g., an electric heating device) to heat the working fluid. A series of continuous perforated spiral members 18 guide the fluid to produce a uniform spiral crossflow pattern. The spiral channels 22 of the continuous spiral baffle heat exchangers 10, 90 can change and increase the flow path of the working fluid without increasing the length of the continuous spiral baffle heat exchangers 10, 90. Therefore, the continuous spiral baffle heat exchangers 10, 90 can improve the heat transfer from the continuous spiral baffle heat exchangers 10, 90 to the working fluid. With the improvement of heat transfer efficiency, the temperature of the jacket of the heating element 16 and the temperature of the heat exchanger shell (e.g., the tubular body 82) can be reduced, and the physical footprint of the heat exchanger can be reduced.

[0115] Furthermore, the perforated spiral member 18 can be formed of a thermally conductive material. Since the perforated spiral member 18 can be connected to the heating element 16 (e.g., via...) Figure 7 The welds 46 shown in the diagram can therefore be considered as extensions of the heating element 16 to serve as extended heating surfaces or radiators or fins to distribute heat to the working fluid, thereby increasing heat transfer from the heating element 16 to the working fluid. The central support member 40 may take the form of a cylindrical electric heating device to provide additional heating to the working fluid in the electric heat exchanger.

[0116] Furthermore, due to the use of a continuous series of perforated spiral members 18 and a central support member 40, the continuous spiral baffle heat exchangers 10 and 90 are more rigid than those in conventional heat exchangers. The central support member 40 is connected to a proximal mounting flange 12, which in turn is connected to the body of the heat exchanger. This continuous structure improves the vibration characteristics of the heat exchanger, thereby increasing the rigidity and damping characteristics of the continuous spiral baffle heat exchanger. The support rod 50 can further increase the rigidity and damping characteristics.

[0117] See also Figure 20-25 As shown, a continuous spiral baffle heat exchanger 210 is illustrated, and reference is made to... Figure 26-28The figure shows a heat exchanger 80 with a continuous spiral baffle heat exchanger 210. Heat exchanger 80 and continuous spiral baffle heat exchanger 210 are similar to heat exchanger 80 and continuous spiral baffle heat exchangers 10, 90, unless otherwise shown or described herein. Therefore, similar elements are indicated by similar reference numerals, and detailed descriptions thereof are omitted herein for clarity.

[0118] Refer to 20 and Figure 21 As shown, the continuous spiral baffle heat exchanger 210 may include a first lifting member 214 and a second lifting member 218. The first lifting member 214 is fixedly coupled to the periphery of the mounting flange 12. In the provided example, the first lifting member 214 extends from the top of the mounting flange 12 and defines an orifice 222 through which a hook (not shown) or other lifting device can support the proximal end of the continuous spiral baffle heat exchanger 210. The second lifting member 218 is fixedly coupled to the distal end of the central support member 40. In the provided example, the second lifting member 218 extends from the top of the central support member 40 and is aligned with the first lifting member 214. The second lifting member 218 defines an orifice 226 through which a hook (not shown) or other lifting device can support the distal end of the continuous spiral baffle heat exchanger 210. In the provided example, the second lifting member 218 is positioned within the axial length of the unperforated spiral member 23, although the second lifting member 218 may extend beyond the unperforated spiral member 23. The first lifting member 214 and the second lifting member 218 can be used to lift the continuous spiral baffle heat exchanger 210 and position the continuous spiral baffle heat exchanger 210 in the tubular body 82 of the heat exchanger 80.

[0119] The continuous spiral baffle heat exchanger 210 may also include a shroud 230. The shroud 230 is wound around a perforated spiral member 18, a heating element 16, and a support rod 50. The axial length of the shroud 230 may extend along the entire length of the heated portion of the continuous spiral baffle heat exchanger 210 (e.g., including...). Figure 1 The shield 52 shown may be smaller than the length of the entire heated portion. See also... Figure 22 As shown, the shield 230 may include a plurality of thin-walled cylindrical shield members 234. The shield members 234 may suppress air leakage between the perforated helical member 18 and the tubular body 82. The shield members 234 may also be formed of or coated with a heat-reflective material to form a heat shield that reflects heat radially inward toward the longitudinal axis X. Such a heat shield may further reduce heat loss from the body 82 and lower the temperature of the body 82. Adjacent cylindrical shield members 234 may be adjacent to each other along the longitudinal axis X. In one embodiment, any cylindrical shield member 234 of the shield 230 may optionally include deformable fins 53. Figure 13 and Figure 14 This allows shield 230 to function similarly to shield 52. Figure 1 , 13 and 14).

[0120] In the provided example, the support rod 50 has a generally rectangular or cross-sectional shape, and the outer surface 238 of each support rod 50 is flush with the outer periphery of the perforated and unperforated helical members 18, 23. In one embodiment, the outer surface 238 of each support rod 50 may have a curvature matching the outer periphery curvature of the perforated helical member 18 and the unperforated helical member 23. A shield 230 is attached to the support rod 50. In the provided example, the support rod 50 includes a plurality of holes 242, and each cylindrical shield member 234 includes a plurality of holes 246 aligned with the holes 242 of the support rod 50. Fasteners 250 (e.g., rivets, screws, etc.) or plug welds are received through the holes 242, 246 and attach the cylindrical shield member 234 to the support rod 50.

[0121] For further reference Figure 23 As shown, the continuous spiral baffle heat exchanger 210 may further include an alignment plate 254. The alignment plate 254 is a flat disk comprising a plurality of holes 256 and a peripheral groove 260. The holes 256 are the same size as and aligned with the perforations 30 of the perforated spiral member 18. The peripheral groove 260 is the same size as and aligned with the peripheral groove 36. A support rod 50, similar to the peripheral groove 36, is received in the peripheral groove 260. In the provided example, the alignment plate 254 defines a keyed central hole 262 with a diameter similar to that of the central support member 40 and a radially inwardly extending key 264. In the provided example, the central support member 40 includes a keyway 266 passing through a distal opening of the central support member 40. The keyway 266 extends through the wall of the central support member 40 and extends longitudinally parallel to the longitudinal axis X. The keyway 266 has a width in the circumferential direction of the central support member 40 corresponding to the width of the key 264. The central support member 40 is received through a central hole 262, and a key 264 is received in a keyway 266 to prevent the alignment plate 254 from rotating relative to the central support member 40. In one embodiment, the central hole 262 may include more than one key 264 circumferentially spaced around the central hole 262, and the central support member 40 may include a matching number of keyways 266.

[0122] Continue to refer to Figure 23 As shown, the continuous spiral baffle heat exchanger 210 may also include one or more sensors (e.g., sensor 300). In the provided example, sensor 300 is a thermocouple or other temperature sensor, but other types of sensors may also be used. Sensor 300 includes a probe end 306 disposed within the flow channel 22. In the provided example, probe end 306 is positioned near outlet 88 (…). Figure 26 and 28The probe tip 306 may be attached (e.g., welded or clamped) to one of the heating element clusters 16. Similarly, an additional sensor (not shown) may be attached to other heating elements 16 to detect their temperatures. In an alternative configuration not shown, the probe tip 306 may be detached from the heating element 16 and configured to detect the temperature of the working fluid at the probe tip 306.

[0123] Sensor 300 extends longitudinally from probe tip 306 toward the distal end of central support member 40 generally along the longitudinal axis X on the outer side of central support member 40. In the provided example, the distal end of central support member 40 includes a sensor groove 308 that passes through the outer wall of central support member 40 and is separated from keyway 266. Sensor 300 has a bend to extend through sensor groove 308 and into the internal cavity of central support member 40. Sensor 300 then extends within central support member 40 toward the proximal end of central support member 40. Figure 25 As shown, sensor 300 extends through a hole 318 in mounting flange 12. Hole 318 seals around sensor 300 to prevent fluid from flowing through it. Hole 318 is radially inward of recess 64. Thus, the electronic connection for sensor 300 can be located on the back side of mounting flange 12, together with the electrical connection of heating element 16 when an electric heating element is used.

[0124] In an alternative configuration (not shown), a set of aligned perforations 30 may not have heating elements 16, and a temperature sensor 300 may extend through the set of perforations 30 and the corresponding flange holes 60. In this configuration, a probe can be positioned at any desired location along the set of perforations 30. In an alternative configuration, one or more heating elements 16 may be used as dummy sensors to detect temperature.

[0125] For further reference Figure 24 and Figure 25 As shown, the vent 410 allows for a small amount of fluid communication between the exterior and interior of the proximal end of the central support member 40. In the provided example, the central support member has a slot extending through the proximal end, which mates with the mounting flange 12 to define the vent 410 when the central support member 40 is received in the recess 64 of the mounting flange 12. Unlike Figure 15 Groove 64, Figure 25The groove 64 is an incomplete circle (i.e., it does not extend a complete circumference around the longitudinal axis X). Instead, the groove 64 has a starting point 414 and an ending point 418 aligned with a slot in the proximal end of the central support member 40. In the provided example, the groove 64 has a flat bottom adjacent to the flat bottom surface of the central support member 40. The starting end 414 and the ending point 418 also form a key that ensures the correct rotational alignment of the central support member 40. In the provided example, the key between the central support member 40 and the mounting flange 12, as well as the alignment plate 254, cooperate to position the continuous helix in the correct rotational position, such that the perforation 30 is aligned with the holes 60 and 256. In the provided example, the key at both ends of the central support member 40 is parallel to the longitudinal axis X, but other configurations may be used. In the provided example, the groove 64 also extends radially outward a short distance at the starting point 414 and the ending point 418 of the groove 64. In the provided example, the central support member 40 is welded to the mounting flange 12 from the starting point 414 to the ending point 418 of the groove 64. In other words, the central support member 40 is welded circumferentially around the vent 410, except that the groove defines the circumferential area of ​​the vent 410. In another embodiment, the vent 410 may be an opening entirely defined by the central support member 40 near the proximal end, which may be aligned with the top of the mounting flange 12.

[0126] For details, please refer to the following: Figure 27 As shown, the edge 28 (i.e., near the proximal end) of the first perforated spiral member 18 may be positioned along the longitudinal axis X at or before the inlet 86, allowing the flow from the inlet to enter the flow path 22. See details. Figure 28 As shown, the opposite edge 26 (i.e., near the distal end) of the last perforated spiral member 18 can be positioned along the longitudinal axis X at or before the outlet 88. In the provided example, the longest heating element of the heating elements 16 extends along the longitudinal axis X to a position partially located within the area aligned with the outlet 88, but other configurations may also be used. In the provided example, the last cylindrical shroud member 234 can extend along the longitudinal axis X to axially overlap the end of the longest heating element of the heating elements 16, forcing fluid to flow from the last heating element 16 to the unperforated spiral member 23 before exiting from outlet 88, but other configurations may also be used.

[0127] See also Figure 29A portion of a third-structure continuous spiral baffle heat exchanger 310 is shown. The continuous spiral baffle heat exchanger 310 is similar to continuous spiral baffle heat exchangers 10, 90, or 210, unless otherwise shown and described herein. Therefore, the same elements are indicated by the same reference numerals, and their detailed descriptions are not repeated here. In the provided embodiment, the heating element 16 is a straight element terminating at the closed end 314. In other words, the straight portion 42 is not connected by a bend. In the provided example, the heating element 16 is a resistance heating element, such as a cylindrical heater, whose leads or terminal pins 6010, 6014 ( Figure 37 All from the mounting flange 12 ( Figure 26 The same straight portion 42 extends from the opposite side (as shown).

[0128] See also Figure 30 The figure shows a portion of a fourth type of continuous spiral baffle heat exchanger 510. The continuous spiral baffle heat exchanger 510 is similar to continuous spiral baffle heat exchangers 10, 90, and 210, unless otherwise shown or described herein. Therefore, the same elements are indicated by the same reference numerals, and their detailed description is not repeated herein.

[0129] In the continuous spiral baffle heat exchanger 510, at least some of the heating elements 16 do not extend far enough in the longitudinal direction 514 to completely span the spiral guide channel 22 defined between the last perforated baffle 18 and the non-perforated baffle 23.

[0130] In the provided example, the heating element 16 includes a first group 518 of heating elements 16 having a first length and a second group 522 of heating elements 16 having a second longer length, although more groups with different lengths may be used. The longer heating elements 16 of the second group 522 terminate further downstream along the helical flow guide channel 22 compared to the shorter heating elements 16 of the first group 518. The ends of the second group of resistance heating elements are positioned further downstream than the ends of the first group of resistance heating elements along the helical flow channel defined by the geometric helix.

[0131] In the provided embodiment, the heating element 16 has a pair of straight portions 42 that terminate at the curved portion 44 along the longitudinal direction 514. Similar to... Figure 29 In an optional configuration, the heating element 16 may have a single straight section 42 and terminate at an end 314. Figure 29 ).

[0132] In the example provided, however, other configurations may be used, but the bent portions 44 of some heating elements 16 are aligned with the inlet / outlet 88 in the longitudinal direction 514. In an alternative configuration not specifically shown, all heating elements 16 may terminate in the longitudinal direction 514 prior to the inlet / outlet 88.

[0133] In other alternative constructions, the non-perforated baffle 23 can be omitted. Figure 39 and 40 This illustrates one such structure excluding the non-perforated baffle 23. In this example, some heating elements extend further in the longitudinal direction 514 than others, similar to... Figure 30 Due to the position of the inlet / outlet 88 relative to the end of the final perforated baffle 18 and the end of the heating element 16, a low-pressure or low-flow region can be formed, schematically represented by the area outlined in dashed circles, indicated by reference numeral 3910. In this configuration, the heating element 16 has a lower power density region in the low-pressure or low-flow region 3910 (e.g., see reference 3910). Figures 31-36 Detailed description of areas 626 and 650).

[0134] Figure 41 and 42 Another such structure is shown, in which the unperforated baffle 23 is omitted. In this example, all heating elements 16 terminate at the same position in the longitudinal direction 514. In this structure, the heating elements 16 have a lower power density region in the low pressure or flow region 3910 (e.g., see reference). Figures 31-36 Detailed description of areas 626 and 650).

[0135] In another configuration not specifically shown, the non-perforated baffle 23 may be omitted, and some or all of the heating elements 16 may terminate in the longitudinal direction 514 after the inlet / outlet 88.

[0136] Back Figure 30 While the pitch of the unperforated baffle 23 is approximately half the diameter of the inlet / outlet 88, other configurations may be used. In one embodiment, the pitch of the unperforated baffle 23 may be equal to or approximately equal to the diameter of the inlet / outlet 88. In another embodiment, the pitch of the unperforated baffle 23 may be greater than or less than half the diameter of the inlet / outlet 88. The pitch of the perforated baffle 18 may be the same as or different from the pitch of the unperforated baffle 23. The pitch of the perforated baffle 18 may be constant along the length of the heater 510 or may vary along the length (e.g., as referred to above). Figure 17 (as described).

[0137] In the provided example, the heating element 16 has a non-uniform heating curve along its longitudinal length. Specifically, at least some of the ends 526 of the heating element 16 have a lower power density than the rest of the heating element 16. The ends 526 include bends 44, and optionally, some of each straight portion 42 approximates a bend 44.

[0138] Specifically, if the heating element 16 does not extend sufficiently in the longitudinal direction 514 to completely span the spiral guide channel 22 defined between the final perforated baffle 18 and the non-perforated baffle 23, more fluid flowing along the spiral guide channel 22 will tend to flow in the space unobstructed by the heating element 16. Therefore, less heat can be removed from the heating element 16 at the end 526, where it does not completely fill the spiral guide channel 22. The lower power density at the end 526 can suppress overheating, although overheating can occur due to the reduced flow rate at the end 526.

[0139] In one embodiment, the longitudinal length 514 of the lower power density end 526 may be the same for all heating elements 16. In another embodiment, the longitudinal length 514 of the lower power density end 526 may vary depending on the position of the heating element 16 in the helical flow channel 22. For example, each heating element 16 may be configured such that the lower power density end 526 is only the same length as the portion of that heating element 16 extending beyond the final perforated baffle 18.

[0140] In the example shown, however, other configurations can be used, but some of the lower power density ends 526 of the heating element 16 are aligned with the inlet / outlet 88 in the longitudinal direction.

[0141] Reference Figure 31 , showed Figure 30 A partial cross-sectional view of one of the heating elements 16. The heating element 16 includes a resistive element 610, an insulating material 614, and a sheath 618. The sheath 618 surrounds the resistive element 610, and the insulating material 614 is disposed between the resistive element 610 and the sheath 618 to insulate the sheath 618 from the resistive element 610. The insulating material 614 is a heat-conducting material that allows heat to be transferred from the resistive element 610 to the sheath 618, such as magnesium oxide (MgO).

[0142] In the provided embodiment, the resistive element 610 includes a high-resistance region 622 and a low-resistance region 626. The low-resistance region 626 corresponds to the end 526 of the resistive heating element 16. In the provided example, the final perforated baffle 18 is schematically indicated by dashed lines. In the provided example, the low-resistance region 626 is primarily located downstream of the final perforated baffle 18; however, other configurations may be used.

[0143] In the provided example, the high-resistance region 622 includes the resistance wire coil 630 in each straight section 42, and the low-resistance region 626 is a metal pin 634 with high conductivity (i.e., low resistance), such that the current flowing through the pin 634 heats the low-resistance region 626 significantly less than the current flowing through the coil 630 in the high-resistance region 622. For example, the heat generated in the low-resistance region 626 is negligible compared to the heat generated in the high-resistance region 622. In another embodiment, the heat generated in the low-resistance region 626 may not be negligible, but it is still less than the heat generated in the high-resistance region 622.

[0144] In one embodiment, pin 634 is a solid conductive material (e.g., metal) bent around bend 44 to connect to resistor coil 630 in straight section 42. In one embodiment, pin 634 may be a solid wire with a diameter larger than that of resistor coil 630. In another embodiment, pin 634 may be a flat metal plate with low resistance. Low-resistance region 626 may be made of the same material as high-resistance region 622.

[0145] In another embodiment, the low-resistance region 626 may be made of a different material than the high-resistance region 622, such that the low-resistance region 626 is formed of a material having lower resistance (i.e., higher conductivity) than the high-resistance region 622. In a construction using different materials, the low-resistance region 626 may also optionally have a coil shape similar to the high-resistance region 622, but generate less heat due to the low-resistance material.

[0146] refer to Figure 32 An alternative configuration for the heating element 1016 is shown for use in a continuous spiral baffle heat exchanger 510. Figure 30 In ), heating element 1016 is similar to heating element 16 ( Figure 31Unless otherwise shown and described herein, the resistive element 610 of the heating element 1016 includes an intermediate resistance region 650 in addition to the high-resistance region 622 (first region) and the low-resistance region 626 (second region). The intermediate resistance region 650 is located between the low-resistance region 626 and the high-resistance region 622. The intermediate resistance region 650 may have a power density between a first power density of the high-resistance region 622 and a second power density of the low-resistance region 626. In the provided example, the intermediate resistance region 650 is a coil 654, which is a continuation of the resistance wire coil 630 of the high-resistance region 622, except that the pitch of the coil 654 in the intermediate resistance region 650 is longer than the pitch in the high-resistance region 622; however, other configurations can be used to achieve the intermediate power density. In the provided example, the pitch of the coil 654 is constant in the intermediate resistance region 650. In another configuration, the pitch of the coil 654 in the intermediate resistance region 650 may be varied. In one example, not specifically shown, the pitch of coil 654 and / or coil 630 may increase as they approach the low-resistance region 626. In the provided example, the low-resistance region 626 is located downstream of the final perforated baffle 18, and the intermediate resistance region 650 is also primarily located downstream of the final perforated baffle 18; however, other configurations may be used.

[0147] refer to Figure 33 An alternative structure for the heating element 2016 is shown for the continuous spiral baffle heat exchanger 510. Figure 30 Heating element 2016 is similar to heating element 16. Figure 31 ) and 1016 ( Figure 32 Unless otherwise stated and described. In the provided example, the low-resistance region 626 is coil 660, which is a continuation of the resistance wire coil 630 of the high-resistance region 622, except that the pitch of coil 660 in the low-resistance region 626 is longer than the pitch of coil 630 in the high-resistance region 622. In one embodiment, the pitch of coil 660 is constant in the low-resistance region 626. In another configuration, the pitch of coil 660 in the low-resistance region 626 can be varied. In one example, the pitch may increase with approach to the bend 44. In the provided example, the low-resistance region 626 is primarily located downstream of the final perforated baffle 18; however, other configurations may be used.

[0148] In the form described above, each heating element has two straight portions 42 (e.g., Figures 31-33 ), the end of each straight portion 42 relative to the elbow 44 includes the flange 12 ( Figure 26 The leads or terminal pins 6010 and 6014 on the opposite side of the ) Figure 38 (to receive electricity.)

[0149] refer to Figure 34 An alternative configuration for heating element 3016 is shown for continuous spiral baffle heat exchanger 510. Figure 30 Heating element 3016 and heating element 16 ( Figure 31 ) and 16 ( Figure 31 Similar to, unless otherwise stated and described herein. In the provided embodiment, the heating element 3016 includes a single straight portion 42 and lacks a curved portion 44. Figure 31 The low-resistance region 626 includes... Figure 31 The pin shown is similar to pin 634, but the pin is straight instead of going around the bend 44. In the example provided, the low-resistance region 626 is mainly located downstream of the final perforated baffle 18; however, other constructions can be used.

[0150] refer to Figure 35 An alternative configuration for heating element 4016 is shown for use in a continuous spiral baffle heat exchanger 510. Heating element 4016 is different from heating element 16 ( Figure 31 ) and 1016 ( Figure 32 Similar to, unless otherwise stated and described herein. In the provided embodiment, the heating element 4016 includes a single straight portion 42 and lacks a bent portion 44. The low-resistance region 626 includes, similar to, Figure 32 The pin 634 shown is similar to pin 634, but the pin is straight instead of going around the bend 44, and the intermediate resistance region 650 connects the low resistance region 626 to the pin 634. Figure 32 The high-resistance region 622 is similar. In the provided embodiment, the low-resistance region 626 is located downstream of the final perforated baffle 18, while the intermediate-resistance region 650 is mainly located downstream of the final perforated baffle 18; however, other configurations may be used.

[0151] Reference Figure 36 An alternative configuration for heating element 5016 is shown for continuous spiral baffle heat exchanger 510. Figure 30 Heating element 5016 and heating element 16 ( Figure 31 ) and 2016 ( Figure 33 Similar to, unless otherwise stated and described herein. In the provided embodiment, the heating element 5016 includes a single straight portion 42 and lacks a bent portion 44. The low-resistance region 626 includes, similar to, Figure 33 A similar longer-pitch coil 660 is shown, but this coil is straight instead of winding around the bend 44. In the example provided, the low-resistance region 626 is primarily located downstream of the final perforated baffle 18; however, other constructions can be used.

[0152] In combination Figures 34-36In the table above, a single straight section 42 ends at terminal 314 instead of at bend 44, and one or more coils (not shown) or straight wires (not shown) of additional length can be drawn from pin 634 (or Figure 36 The end of the coil 660 shown is in the longitudinal direction 514 ( Figure 30 The circuit extends back into the sheath in the opposite direction to complete the circuit, such that each heating element 3016, 4016, 5016 has a pair of terminal pins 6010, 6014 (e.g., ...). Figure 37 (As shown) near flange 12 ( Figure 1 To receive power. For example, coil 630 may terminate at a second coil (not shown), or may be parallel to coil 630 (and...). Figure 35 Coil 654 in the form shown, or Figure 36 The coil 660 shown is of the form indicated.

[0153] In another configuration not specifically shown, the third coil may be parallel to the first two coils and have a corresponding third terminal pin extending from the straight section 42, allowing the use of a three-phase power supply.

[0154] The low-resistance region 626 and / or intermediate-resistance region 650 described above are located at the ends 526 of the heating elements 16, 1016, 2016, 3016, 4016, and 5016, while the low-resistance region 626 and / or intermediate-resistance region 650 may be located at other locations along the length of the heating elements 16, 1016, 2016, 3016, 4016, and 5016. For example, the low-resistance region 626 and / or intermediate-resistance region 650 may be aligned with the inlet / outlet 86 in the longitudinal direction 514. Figure 26 and 27 Or align at different locations between import / export 86 and import / export 88.

[0155] It should be understood that the heating elements described herein can be constructed using generally known techniques and structures, unless otherwise described or shown herein. As a non-limiting example, the teachings of the following U.S. patents may be used and are incorporated herein by reference in their entirety: U.S. Patent 4,346,287; U.S. Patent 6,124,579; U.S. Patent 6,147,335; U.S. Patent 6,300,607; U.S. Patent 6,414,281; U.S. Patent 6,337,470; U.S. Patent 10,247,445; and U.S. Patent 10,728,956.

[0156] It should be noted that this utility model is not limited to the embodiments described and illustrated as implementations. Various modifications have been described, and more are part of the knowledge of those skilled in the art. These and further modifications, as well as any substitutions by technical equivalents, can be added to the specification and drawings without departing from the protection scope of this utility model and this patent.

Claims

1. A continuous spiral baffle heat exchanger (80), characterized in that, include: A flow guide (14) defining a continuous geometric helix arranged around the longitudinal axis of the continuous helical baffle heat exchanger (80), the flow guide (14) defining a predetermined pattern of perforations extending longitudinally through the geometric helix for a first longitudinal length, the longitudinal direction being parallel to the longitudinal axis; and Multiple resistance heating elements (16) extending through the perforation, wherein each resistance heating element (16) includes a resistance element (610) having a high resistance region (622) and a low resistance region (626), the pitch of the low resistance region (626) being longer than the pitch of the high resistance region (622), and the power density of the low resistance region (626) being less than the power density of the high resistance region (622).

2. The continuous spiral baffle heat exchanger (80) according to claim 1, wherein, The low-resistance region (626) is located at the end of the resistance heating element (16).

3. The continuous spiral baffle heat exchanger (80) according to claim 1, wherein, Each resistance heating element (16) further includes: a sheath (618) surrounding the resistance element (610), and an insulating material between the resistance element (610) and the sheath (618) and electrically insulating the resistance element (610) from the sheath (618), wherein the resistance element (610) has a lower resistance in the low resistance region (626).

4. The continuous spiral baffle heat exchanger (80) according to claim 3, wherein, The resistive element (610) includes a resistive coil (630) located in the high-resistance region (622) and a pin (634) located in the low-resistance region (626).

5. The continuous spiral baffle heat exchanger (80) according to claim 3, wherein, The resistive element (610) includes a resistive coil (630) in the high-resistance region (622) and a resistive coil (660) in the low-resistance region (626), wherein the pitch of the resistive coil (660) in the low-resistance region (626) is longer than the pitch of the resistive coil (630) in the high-resistance region (622).

6. The continuous spiral baffle heat exchanger (80) according to claim 3, wherein, The resistive element (610) includes an intermediate resistive region (650) between the high-resistance region (622) and the low-resistance region (626) having a resistive coil (654), wherein the pitch of the resistive coil (654) is longer than the pitch of the resistive coil (630) in the high-resistance region (622).

7. The continuous spiral baffle heat exchanger (80) according to claim 1, wherein, Each resistance heating element (16) includes a pair of straight portions (42) connected by a curved portion (44).

8. The continuous spiral baffle heat exchanger (80) according to claim 7, wherein, The low-resistance region (626) is located downstream of the last perforated baffle of the geometric helix.

9. The continuous spiral baffle heat exchanger (80) according to claim 1, wherein, Each resistance heating element (16) includes a single straight section (42) terminating at one end.

10. The continuous spiral baffle heat exchanger (80) according to claim 1, wherein, At least one resistance heating element (16) includes a resistance coil (660) at the low resistance region (626) and a resistance coil (630) at the high resistance region (622), wherein the resistance coil (660) at the low resistance region (626) is a continuation of the resistance coil (630) at the high resistance region (622).

11. The continuous spiral baffle heat exchanger (80) according to claim 1, wherein, The plurality of said resistance heating elements (16) include a first group of resistance heating elements and a second group of resistance heating elements, each of the first group of resistance heating elements having an end that is further away in the longitudinal direction than the end of each of the second group of resistance heating elements; wherein the end of the second group of resistance heating elements is positioned further away than the end of the first group of resistance heating elements along a spiral flow path defined by the geometric helix.

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