3-D dimpled heat exchanger

Abstract

A heat exchanger apparatus comprising a frame, a tube coupled to the frame, and turbulating structure disposed within the tube and extending into an inner hollow space thereof for promoting turbulent fluid flow within the tube. The turbulating structure comprises elements located arcuately around an inner periphery of the tube at approximately 120° increments. A method of manufacturing and a heating system is also provided.

1 . A heat exchanger apparatus, comprising: 
 a frame;    a tube coupled to said frame; and    turbulating structure disposed within said tube and extending into an inner hollow space thereof for promoting turbulent fluid flow within said tube, said turbulating structure comprising elements located arcuately around an inner periphery of said tube at approximately 120° increments.    
   
   
       2 . The apparatus of  claim 1  wherein said elements comprise dimples formed in said tube.  
   
   
       3 . The apparatus of  claim 1  wherein said tube has a longitudinal axis and wherein said turbulating structure comprises a first dimple trio formed in said tube and having a first trio of centers, said first trio of centers substantially coplanar with a plane normal to said longitudinal axis.  
   
   
       4 . The apparatus of  claim 3  wherein said turbulating structure comprises a second dimple trio spaced apart from said first dimple trio along said longitudinal axis, and wherein said tube has: 
 a first reference radius from said longitudinal axis and through a center of one of said elements of said first dimple trio; and    a second reference radius from said longitudinal axis and through a center of one of said elements of said second dimple trio; and wherein said first and second reference radii are coplanar.    
   
   
       5 . The apparatus of  claim 4  wherein said first dimple trio has a first dimple depth and said second dimple trio has a second dimple depth not equal to said first dimple depth.  
   
   
       6 . The apparatus of  claim 3  wherein said turbulating structure comprises a second dimple trio spaced apart from said first dimple trio along said longitudinal axis, and wherein said tube has: 
 a first reference radius from said longitudinal axis and through a center of one of said elements of said first dimple trio;    a second reference radius from said longitudinal axis and through a center of one of said elements of said second dimple trio; and wherein said first and second reference radii are non-coplanar.    
   
   
       7 . The apparatus of  claim 6  wherein said second reference radius arcuately differs from said first reference radius by an angle between about ±5° and about ±30°.  
   
   
       8 . The apparatus of  claim 7  wherein said turbulating structure comprises a third dimple trio spaced apart from said second dimple trio along said longitudinal axis, and wherein said tube has a third reference radius from said longitudinal axis and through a one of said elements of said third dimple trio wherein said third reference radius arcuately differs from said second reference radius by an angle between about ±5° and about ±30°.  
   
   
       9 . The apparatus of  claim 1  wherein said turbulating structure comprise said dimples including smoothly curving surfaces in said tube.  
   
   
       10 . The apparatus of  claim 1  wherein said tube has a weld parallel said longitudinal axis.  
   
   
       11 . The apparatus of  claim 10  wherein a one of said elements is diametrically opposed said weld.  
   
   
       12 . The apparatus of  claim 1  wherein said tube has a path for off-cycle or off-season condensate.  
   
   
       13 . A method of manufacturing a heat exchanger apparatus, comprising: 
 providing a frame;    coupling a tube to said frame; and    disposing turbulating structure within said tube and extending into an inner hollow space thereof for promoting turbulent fluid flow within said tube, said turbulating structure comprising elements located arcuately around an inner periphery of said tube at approximately 120° increments.    
   
   
       14 . The method of  claim 13  wherein disposing includes forming dimples in said tube.  
   
   
       15 . The method of  claim 13  wherein said tube has a longitudinal axis and wherein disposing includes forming a first dimple trio in said tube, said first dimple trio substantially coplanar with a plane normal to said longitudinal axis.  
   
   
       16 . The method of  claim 15  wherein disposing includes forming a second dimple trio spaced apart from said first dimple trio along said longitudinal axis, and wherein said tube has: 
 a first reference radius from said longitudinal axis and through a one of said elements of said first dimple trio; and    a second reference radius from said longitudinal axis and through a one of said elements of said second dimple trio; and wherein said first and second reference radii are coplanar.    
   
   
       17 . The method of  claim 16  wherein disposing includes forming said first dimple trio having a first dimple depth and forming said second dimple trio having a second dimple depth not equal to said first dimple depth.  
   
   
       18 . The method of  claim 15  wherein disposing includes forming a second dimple trio spaced apart from said first dimple trio along said longitudinal axis, and wherein said tube has: 
 a first reference radius from said longitudinal axis and through a one of said elements of said first dimple trio; and    a second reference radius from said longitudinal axis and through a one of said elements of said second dimple trio; and wherein said first and second reference radii are non-coplanar.    
   
   
       19 . The method of  claim 16  wherein disposing includes forming said second dimple such that said second reference radius arcuately differs from said first reference radius by an angle between about ±5° and about ±30°.  
   
   
       20 . The method of  claim 19  wherein disposing includes forming a third dimple trio spaced apart from said second dimple trio along said longitudinal axis, and wherein said tube has a third reference radius from said longitudinal axis and through a one of said elements of said third dimple trio wherein said third reference radius arcuately differs from said second reference radius by an angle between about ±5° and about ±30°.  
   
   
       21 . The method of  claim 13  wherein disposing includes forming said dimples including smoothly curving surfaces in said tube.  
   
   
       22 . The method of  claim 13  wherein coupling includes coupling a tube having a weld parallel said longitudinal axis.  
   
   
       23 . The method of  claim 22  wherein coupling includes coupling wherein a one of said elements is diametrically opposed said weld.  
   
   
       24 . A heating system, comprising: 
 a cabinet;    a frame coupled to said cabinet;    a heat exchanger having at least one tube coupled to said frame; and    turbulating structure disposed within said tube and extending into an inner hollow space thereof for promoting turbulent fluid flow within said tube, said turbulating structure comprising elements located arcuately around an inner periphery of said tube at approximately 120° increments.    
   
   
       25 . The heating system of  claim 24  wherein said elements comprise dimples formed in said tube.  
   
   
       26 . The heating system of  claim 24  wherein said tube has a longitudinal axis and wherein said turbulating structure comprises a first dimple trio formed in said tube, said first dimple trio substantially coplanar with a plane normal to said longitudinal axis.  
   
   
       27 . The heating system of  claim 26  wherein said turbulating structure comprises a second dimple trio spaced apart from said first dimple trio along said longitudinal axis, and wherein said tube has: 
 a first reference radius from said longitudinal axis and through a one of said elements of said first dimple trio;    a second reference radius from said longitudinal axis and through a one of said elements of said second dimple trio; and wherein said first and second reference radii are coplanar.    
   
   
       28 . The heating system of  claim 27  wherein said first dimple trio has a first dimple depth and said second dimple trio has a second dimple depth not equal to said first dimple depth.  
   
   
       29 . The heating system of  claim 26  wherein said turbulating structure comprises a second dimple trio spaced apart from said first dimple trio along said longitudinal axis, and wherein said tube has: 
 a first reference radius from said longitudinal axis and through a one of said elements of said first dimple trio;    a second reference radius from said longitudinal axis and through a one of said elements of said second dimple trio; and wherein said first and second reference radii are non-coplanar.    
   
   
       30 . The heating system of  claim 29  wherein said second reference radius arcuately differs from said first reference radius by about +30°.  
   
   
       31 . The heating system of  claim 30  wherein said turbulating structure comprises a third dimple trio spaced apart from said second dimple trio along said longitudinal axis, and wherein said tube has a third reference radius from said longitudinal axis and through a one of said elements of said third dimple trio wherein said third reference radius arcuately differs from said second reference radius by about −30°.  
   
   
       32 . The heating system of  claim 24  wherein said turbulating structure comprises said dimples including curving surfaces in said tube.  
   
   
       33 . The heating system of  claim 24  wherein said tube has a weld parallel said longitudinal axis.  
   
   
       34 . The heating system of  claim 33  wherein a one of said elements is diametrically opposed said weld.