Desiccant rotor and method for constructing a desiccant rotor

Abstract

The present disclosure relates to a desiccant rotor (200). The desiccant rotor comprises a set of pieces (220a-d), each piece (220a-d) of the set of pieces having a shape determined by a set of straight lines, each piece of the set of pieces comprising a desiccant material. The set of pieces (220a-d) is arranged such that the set of pieces are packed to optimally fill a circle having a radius (r) matching the intended radius of the desiccant rotor. The arranged set of pieces defines a remaining space (130, 230) between the set of pieces and the circle circumference. The remaining space (120, 230) is filled with a mixture of the desiccant material and a binder.

Description

[0001] DESICCANT ROTOR AND METHOD FOR CONSTRUCTING A DESICCANT ROTOR

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to desiccant rotors, in particular to desiccant rotors that can be manufactured with minimal waste of the desiccant material.

[0004] BACKGROUND ART

[0005] Waste of desiccant material is a problem when manufacturing desiccant rotors. The desiccant material is typically provided in rectangular blocks from which the rotors need to be manufactured. A common process is to cut pie-shapes, e.g. a circular disc cut into for equal pieces, and later assembled. While smaller pie pieces can better approximate the area of a rectangular block, more cuts are needed, which introduces more spill and potentially more misalignment issues relating to as misalignments of the sheets that cause left overs along the edges of the block. A further problem is that the thin and sharp edge of a narrow pie-cut piece is more susceptible to damage, which limits how small pieces can be cut. The remaining desiccant material, either pieces not suitable for rotor assembly or dust and fragments from the cutting process, is often difficult or impossible to recycle and therefore ends up in landfills. There is thus a need in the art for manufacturing processes of desiccant rotors that make better use of the available desiccant material.

[0006] SUMMARY OF THE INVENTION

[0007] The present disclosure relates to a method for constructing a desiccant rotor. The method comprises dividing a set of rectangular bricks along a set of straight lines into a first set of pieces. The first set of pieces comprises a second and a third set of pieces. The bricks comprise a desiccant material. The method further comprises arranging the second set of pieces such that the second set of pieces are packed to optimally fill a circle having a radius, r, matching the intended radius of the desiccant rotor, the arranged second set of pieces defining a remaining space between the second set of pieces and the circle circumference. The method also comprises filling the remaining space with a mixture of desiccant material from the third set of pieces and a binder.

[0008] The method thereby enables manufacturing of desiccant rotors with minimal waste of desiccant material, since pieces of the desiccant material not arranged to fill the circle can be used, e.g. by grinding them, to fill the remaining space. Additionally, desiccant material given off during the cutting process when the set of rectangular bricks are divided can also be collected and used to fill the remaining space. The method can thereby effectively use all desiccant material in the construction of the desiccant rotor, practically eliminating spill of desiccant material.

[0009] According to some aspects, the second set of pieces comprises at least one piece of a triangular, square, rectangular, and / or convex polygonal shape.

[0010] Cutting the first set of pieces into sets of triangular, square, rectangular and / or convex polygonal shapes greatly simplifies the procedure for dividing the set of rectangular bricks, and further limits the types of shapes that are used to optimally fill the circle, thereby reducing optimization algorithm complexity and optimization time when determining how the second set of pieces are packed to optimally fill the circle.

[0011] According to some aspects, arranging the second set of pieces further comprises arranging the second set of pieces to utilize a support structure configured to provide stability to the second set of pieces when packed to optimally fill the circle.

[0012] In addition to providing structural support by facilitating the second set of pieces to maintain their relative positions when the desiccant rotor is rotating, the structural support may also facilitate the transfer of torque to the desiccant rotor without the need to connect a shaft to the second set of pieces directly.

[0013] According to some aspects, arranging the second set of pieces further comprises applying an adhesive such that the pieces are secured to each other and / or a support structure.

[0014] The adhesive prevents movement of the pieces relative to each other during operational use, thereby significantly reducing wear and tear.

[0015] According to some aspects, filling the remaining space further comprises grinding the third set of pieces, and wherein the desiccant material of the mixture comprises the desiccant material of the ground third set of pieces.

[0016] By grinding the third set of pieces and adding the ground material to the mixture, the desiccant material can easily be made to fit the often-complex shape of the remaining space between the second set of pieces and the circle circumference.

[0017] According to some aspects, filling the remaining space further comprises collecting desiccant material released during the dividing of the set of rectangular blocks, and wherein the desiccant material of the mixture comprises the desiccant material of the collected desiccant material.

[0018] More of the desiccant material that would otherwise be wasted is thereby put to use when constructing the desiccant rotor. According to some aspects, filling the remaining space comprises using a coating and / or casting process.

[0019] The use of a coating and / or casting process are ideal to shape the mixture to fit the of the remaining space between the second set of pieces and the circle circumference.

[0020] According to some aspects, the method further comprises covering the edge of the desiccant rotor with a protective metal sheet.

[0021] In addition to protect the desiccant rotor against collisions, e.g. during transport, it also serves as a structure helping to keep the desiccant rotor together when it rotates. The protective metal sheet can alleviate much of the shearing forces due to inertia that the second set of pieces may experience during rotation if they are glued together and / or to a support structure, thereby prolonging the lifetime of the desiccant rotor.

[0022] The present disclosure further relates to a desiccant rotor. The desiccant rotor comprises a set of pieces. Each piece of the set of pieces has a shape determined by a set of straight lines. Each piece of the set of pieces comprises a desiccant material. The set of pieces is arranged such that the set of pieces are packed to optimally fill a circle having a radius, r, matching the intended radius of the desiccant rotor. The arranged set of pieces define a remaining space between the set of pieces and the circle circumference. The remaining space is filled with a mixture of the desiccant material and a binder.

[0023] According to some aspects, the set of pieces comprises at least one piece of a triangular, square, rectangular, and / or convex polygonal shape.

[0024] According to some aspects, the desiccant rotor further comprises a support structure configured to provide stability to the set of pieces when packed to optimally fill the circle. The set of pieces are further arranged to utilize the support structure.

[0025] According to some aspects, each piece of the set of pieces are secured to each other and / or a support structure by an adhesive.

[0026] According to some aspects, the desiccant material of the mixture comprises ground desiccant material.

[0027] According to some aspects, the desiccant rotor further comprises a protective metal sheet covering the edge of the desiccant rotor.

[0028] All aspects of the desiccant rotor share the same technical effects and advantages as the corresponding technical features of the method for constructing a desiccant rotor. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1a illustrates aspects of the method for constructing a desiccant rotor;

[0030] Figures 1 b-e further illustrate visually the aspects of figure 1a; and

[0031] Figure 2 illustrates a desiccant rotor.

[0032] DETAILED DESCRIPTION

[0033] Figure 1a illustrates aspects of the method 100 for constructing a desiccant rotor 1000 and associated figures 1b-1e illustrate visually the aspects of the disclosed method. The main idea behind the disclosed method is to remove the use of pie-cuts and instead divide the rectangular blocks of desiccant material typically used, see Figure 1 b, into pieces that better match the shape of the rectangular blocks, i.e. mostly rectangles and triangles, that better utilize the area of the blocks of desiccant material, see Figure 1c. The resulting pieces that are cut from the are assembled to approximate the circular shape of the desiccant rotor, see Figure 1d. Since the pieces are cut along straight lines, there will be a gap between the desired perfect circular shape of the rotor and the resulting shape of the assembled pieces. This gap is filled with spill from the cutting process and, preferably ground, leftover material from the cut blocks, with a binder holding the spill and ground leftover material together and enabling the leftover desiccant material to fill the gap needed to form the circular shape of the desiccant rotor. Figure 1e illustrates the final rotor, here illustrated with the option of a support structure and a protective metal sheet. Thus, the method comprises dividing S100 a set of rectangular bricks 110a-e along a set of straight lines into a first set of pieces. The bricks comprise a desiccant material. According to some aspects, the first set of pieces comprises at least one piece of a triangular 120c-d, square 120a, rectangular 120b, and / or convex polygonal shape. According to some aspects, the second set of pieces comprises at least one piece of a triangular 120c-d, square 120a, rectangular 120b, and / or convex polygonal shape.

[0034] The first set of pieces comprise a second 150 and a third 160 set of pieces. The second set of pieces 150 will be used as the building blocks of the desiccant rotor 1000, while the third set of pieces 160 represent leftover desiccant material, which will be used to fill the remaining space 130 between the shape formed by the arranged second pieces and the desired circular shape. Depending on the size of the bricks and the desired radius of the rotor, it may be more resource cut the pieces for several rotors across the set of bricks. For instance, when constructing the rotor, the set of bricks may have more leftover desiccant material than needed for to fill the gap, i.e. remaining space 130. The leftover desiccant material may therefore be cut such that pieces from the third set of pieces may be used for another desiccant rotor. Thus, according to some aspects, the third set of pieces also comprise pieces intended for another desiccant rotor.

[0035] The method 100 further comprises arranging S200 the second set of pieces 150 such that the second set of pieces are packed to optimally fill a circle having a radius, r, matching the intended radius of the desiccant rotor. The arranged second set of pieces define a remaining space 130 between the second set of pieces and the circle circumference.

[0036] In order to provide structural stability and provide a means for transferring torque from a shaft to the desiccant rotor, the desiccant rotor is preferably provided with a support structure 140. The support structure further provides something that the second set of pieces can be adhered to, e.g. using an adhesive.

[0037] Thus, according to some aspects, arranging S200 the second set of pieces further comprises arranging S210 the second set of pieces to utilize a support structure configured to provide stability to the second set of pieces when packed to optimally fill the circle. According to some aspects, arranging S200 the second set of pieces further comprises applying S220 an adhesive such that the pieces are secured to each other and / or a support structure.

[0038] In case of a support structure 140 that also takes up space within the circle area of the desiccant rotor, here illustrated as a cross 140, the dividing S100 of the set of rectangular bricks preferably considers the change in the available space within the circle and adjusts the size and shape of the pieces resulting from the dividing S100 of the set of rectangular bricks accordingly. Thus, according to some aspects, dividing S100 the set of rectangular bricks 110a-e along a set of straight lines into a first set of pieces is further based on the shape of the support structure 140.

[0039] The method 100 also comprises filling S300 the remaining space with a mixture of desiccant material from the third set of pieces and a binder.

[0040] In order to be able to better fit the third set of pieces to fill the remaining space, it if often preferable to have them broken up, e.g. by crushing and / or grinding the third set of pieces, or a subset of the third set of pieces.

[0041] Thus, according to some aspects, filling S300 the remaining space further comprises grinding S310 the third set of pieces, and wherein the desiccant material of the mixture comprises the desiccant material of the ground third set of pieces.

[0042] Certain technologies used for dividing the blocks of desiccant material, such as cutting, also chip away material from the blocks. In order to further improve the desiccant material utilization, this desiccant material can be collected and used in the mixture. Thus, according to some aspects, filling S300 the remaining space further comprises collecting S320 desiccant material released during the dividing S100 of the set of rectangular blocks, and wherein the desiccant material of the mixture comprises the desiccant material of the collected desiccant material.

[0043] According to some aspects, filling S300 the remaining space comprises using a coating and / or casting process. Coating and casting can easily adapt the mixture to fit remaining spaces of any shape, and are therefore particularly suited to deal with the sharp edges resulting from cutting with a set of straight lines.

[0044] According to some aspects, the method 100 further comprises covering S400 the edge of the desiccant rotor with a protective metal sheet. Covering S400 the edge with a metal sheet protects the desiccant rotor during storage and transportation, while also serving as an additional support structure keeping the desiccant rotor together. When the desiccant rotor rotates, the pieces of desiccant material will experience inertial pull. By providing the protective metal sheet, the stress on the desiccant rotor is reduced, which in turn increases the expected lifetime of the desiccant rotor.

[0045] Figure 2 a desiccant rotor 2000 according to the present disclosure.

[0046] The desiccant rotor 2000 comprises a set of pieces. Each piece 220a-d of the set of pieces comprises a desiccant material. Each piece 220a-d of the set of pieces has a shape determined by a set of straight lines. According to some aspects, the set of pieces comprises at least one piece of a triangular 220c-d, square 220a, rectangular 220b, and / or convex polygonal shape.

[0047] As described above in relation to figures 1a-e, by having the rotor constructed from a set of pieces with straight edges, a manufacturing process that reduces waste of desiccant material can be used to produce the disclosed desiccant rotor 2000.

[0048] The set of pieces is arranged such that the set of pieces are packed to optimally fill a circle having a radius, r, matching the intended radius of the desiccant rotor. According to some aspects, the desiccant rotor 200 further comprises a support structure 240 configured to provide stability to the set of pieces when packed to optimally fill the circle. The set of pieces are further arranged to utilize the support structure 240.

[0049] In order to provide additional stability, an adhesive can be used to keep the pieces together when the desiccant rotor is in motion. Thus, according to some aspects, each piece 220a-d of the set of pieces are secured to each other and / or a support structure by an adhesive.

[0050] The arranged set of pieces defines a remaining space 230 between the set of pieces and the circle circumference. The remaining space 230 being filled with a mixture of the desiccant material and a binder. According to some aspects, the desiccant material of the mixture comprises ground desiccant material. By filling the remaining space 230 with the mixture of (preferably ground) desiccant material, the desiccant rotor 2000 enables a manufacturing process, as described in relation to figures 1a-e, that enable a very efficient use of available desiccant material while allowing the use of standard rectangular bricks of desiccant material.

[0051] According to some aspects, the desiccant rotor 200 further comprises a protective metal sheet 260 covering the edge of the desiccant rotor. The protective metal sheet reduces wear and tear by directly protecting the edge, but also indirectly by assisting in holding the pieces of the desiccant rotor together during operational use. Inertial pull affecting adhesives and / or brittle desiccant material can thereby be greatly reduced, thereby increasing desiccant rotor longevity.

Claims

CLAIMS1 . A method (100) for constructing a desiccant rotor, the method comprising dividing (S100) a set of rectangular bricks (110a-e) along a set of straight lines into a first set of pieces, the first set of pieces comprising a second (150) and a third set of pieces (160), the bricks (110a-e) comprising a desiccant material, arranging (S200) the second set of pieces (150) such that the second set of pieces are packed to optimally fill a circle having a radius (r) matching the intended radius of the desiccant rotor, the arranged second set of pieces defining a remaining space (130, 230) between the second set of pieces and the circle circumference, and filling (S300) the remaining space with a mixture of desiccant material from the third set of pieces and a binder.

2. The method (100) according to claim 1 , wherein the second set of pieces (150) comprises at least one piece of a triangular (120c, 220c, 120d, 220d), square (120a, 220a), rectangular (120b, 220b), and / or convex polygonal shape.

3. The method (100) according to claim 1 or 2, wherein arranging (S200) the second set of pieces further comprises arranging (S210) the second set of pieces to utilize a support structure (140, 240) configured to provide stability to the second set of pieces when packed to optimally fill the circle.

4. The method according to any of the preceding claims, wherein arranging (S200) the second set of pieces further comprises applying (S220) an adhesive such that the pieces are secured to each other and / or a support structure.

5. The method (100) according to any of the preceding claims, wherein filling (S300) the remaining space further comprises grinding (S310) the third set of pieces, and wherein the desiccant material of the mixture comprises the desiccant material of the ground third set of pieces.

6. The method (100) according to any of the preceding claims, wherein filling (S300) the remaining space further comprises collecting (S320) desiccant material released during the dividing (S100) of the set of rectangular blocks, and wherein the desiccant material of the mixture comprises the desiccant material of the collected desiccant material.

7. The method (100) according to any of the preceding claims, wherein filling (S300) the remaining space comprises using a coating and / or casting process.

8. The method (100) according to any of the preceding claims, further comprising covering (S400) the edge of the desiccant rotor with a protective metal sheet (170, 270).

9. A desiccant rotor (1000, 2000) comprising a set of pieces (120a-d, 220a-d), each piece (120a-d, 220a-d) of the set of pieces having a shape determined by a set of straight lines, each piece of the set of pieces comprising a desiccant material,- wherein the set of pieces (120a-d, 220a-d) is arranged such that the set of pieces are packed to optimally fill a circle having a radius (r) matching the intended radius of the desiccant rotor, the arranged set of pieces defining a remaining space (130, 230) between the set of pieces and the circle circumference, and the remaining space (130, 230) being filled with a mixture of the desiccant material and a binder.

10. The desiccant rotor (1000, 2000) according to claim 9, wherein the set of pieces (120a- d, 220a-d) comprises at least one piece of a triangular (120c, 120d, 220c, 220d), square (120a, 220a), rectangular (120b, 220b), and / or convex polygonal shape.11 . The desiccant rotor (1000, 2000) according to claim 10, further comprising a support structure (140, 240) configured to provide stability to the set of pieces (220a-d) when packed to optimally fill the circle, and- wherein the set of pieces are further arranged to utilize the support structure (140, 240).

12. The desiccant rotor (1000, 2000) according to any of the preceding claims, wherein each piece of the set of pieces (120a-d, 220a-d) are secured to each other and / or a support structure (140, 240) by an adhesive.

13. The desiccant rotor (1000, 2000) according to of the preceding claims, wherein the desiccant material of the mixture comprises ground desiccant material.

14. The desiccant rotor (1000, 2000) according to any of the preceding claims, further comprising a protective metal sheet (170, 270) covering the edge of the desiccant rotor.

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