Planar plate core and method of assembly

Abstract

An apparatus includes a core configured for use in an energy exchanger. The core includes a plurality of stacked and spaced planar plate pairs including a top plate and a bottom plate to support fluid flow of a first fluid flow and a second fluid flow. A plurality of dimples is provided by instances of the plate pairs. The plurality of dimples are arranged to generate substantially counter current flow between the first fluid flow and the second fluid flow.

1 . An apparatus, comprising:
 a core being configured for use in an energy exchanger, the core including a plurality of stacked and spaced planar plate pairs including a top plate and a bottom plate to support fluid flow of a first fluid flow and a second fluid flow; and   a plurality of dimples being provided by instances of the plurality of stacked and spaced planar plate pairs, and the plurality of dimples being arranged to generate substantially counter current flow between the first fluid flow and the second fluid flow.   
     
     
         2 . The apparatus of  claim 1 , wherein:
 the plurality of dimples are further arranged to draw condensation from any one of the first fluid flow and the second fluid flow in any plate orientation.   
     
     
         3 . The apparatus of  claim 1 , wherein:
 the energy exchanger includes:
 a warm-flow outlet being configured to facilitate a warm-fluid flow; 
 a cold-flow outlet being configured to facilitate a cool-fluid flow; and 
 a divider being configured to separate the warm-fluid flow and the cool-fluid flow in such a way that a temperature gradient established across sides of the divider promotes heat exchange between the warm-fluid flow and the cool-fluid flow. 
   
     
     
         4 . The apparatus of  claim 1 , wherein:
 the core includes:
 fluid directing rails being arranged in the core, and the fluid directing rails being configured to provide counter current energy exchange in the core in such a way that the fluid flow is opposite to each other in areas proximate to the fluid directing rails. 
   
     
     
         5 . The apparatus of  claim 1 , wherein:
 symmetrically arranged instances of the plurality of dimples are arranged to establish gaps between the instances of the plurality of stacked and spaced planar plate pairs, and the gaps operative for directing the fluid flow and operative for leaving spaces allowing for condensate drainage.   
     
     
         6 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 instances of the plurality of dimples of the top plate are configured to protrude into the fluid flow, which rests against instances of the plurality of dimples protruding into the bottom plate, to establish gaps, and the gaps are operative for providing spacing between the bottom plate and the top plate. 
   
     
     
         7 . The apparatus of  claim 6 , wherein:
 the plurality of dimples includes:
 symmetrically arranged instances of the plurality of dimples alternating between and protruding into and away from the fluid flow, for spacing instances of the plurality of stacked and spaced planar plate pairs for operative distribution of the fluid flow. 
   
     
     
         8 . The apparatus of  claim 1 , wherein:
 instances of the plurality of dimples are arranged at:
 a top side of instances of the plurality of stacked and spaced planar plate pairs; and 
 a bottom side of instances of the plurality of stacked and spaced planar plate pairs. 
   
     
     
         9 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 a plurality of spaced extended-length dimples being oriented substantially parallel to a side of instances of the plurality of stacked and spaced planar plate pairs; and 
 a plurality of elliptical dimples being configured to surround instances of the plurality of spaced extended-length dimples on either side. 
   
     
     
         10 . The apparatus of  claim 9 , wherein:
 instances of the plurality of spaced extended-length dimples are configured to protrude into a supply side;   instances of the plurality of spaced extended-length dimples are configured to protrude into the supply side;   instances of the plurality of elliptical dimples are configured to protrude into an exhaust side; and   instances of the plurality of elliptical dimples extend into the exhaust side.   
     
     
         11 . The apparatus of  claim 9 , wherein:
 the plurality of dimples, the plurality of spaced extended-length dimples, and the plurality of elliptical dimples are configured to form an asymmetrical pattern.   
     
     
         12 . The apparatus of  claim 9 , wherein:
 a warm side has the plurality of elliptical dimples, the plurality of elliptical dimples configured to leave gaps, and the gaps operative for draining condensation and water from defrost.   
     
     
         13 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 a plurality of elliptical dimples including:
 a first set of dimples; and 
 a second set of dimples protruding into a warm side and meeting with respective instances of the second set of dimples. 
 
   
     
     
         14 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 warm-side dimples protruding into a warm side of the core being operative for forcing a flow direction to be more parallel with sides of the core; and 
 cold-side dimples protruding into a cold side of the core being operative for forcing the flow direction to be more parallel with the sides of the core. 
   
     
     
         15 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 warm-side dimples for a warm side flow, the warm-side dimples being about half of a width of a side of the core, the warm-side dimples operative for leaving additional room for a fluid to move within the core; and 
 cold-side dimples for a cold side flow, the cold-side dimples being on a top portion of the core and extending to about the middle of the core. 
   
     
     
         16 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 a plurality of slanted dimples having:
 cold-side dimples; and 
 warm-side dimples; 
 
 the cold-side dimples being located downstream of warm-side dimples; 
 the plurality of slanted dimples configured to operatively force the fluid flow towards sides of the core more than the instances of the plurality of slanted dimples that are parallel to the sides to permit the plurality of slanted dimples to be spaced further apart. 
   
     
     
         17 . The apparatus of  claim 1 , wherein:
 the plurality of dimples includes:
 warm-side dimples alternating between and protruding into a warm side, and the warm-side dimples leaving a cold-side recess in a cold side; and 
 cold-side dimples alternating between and protruding into the cold side, and the cold-side dimples leaving a warm-side recess in the warm side. 
   
     
     
         18 . The apparatus of  claim 1 , wherein:
 the plurality of dimples is spaced apart and do not meet between the instances of the plurality of stacked and spaced planar plate pairs, the plurality of dimples includes:
 cold-side dimples; and 
 warm-side dimples alternating with the cold-side dimples. 
   
     
     
         19 . The apparatus of  claim 1 , wherein:
 a wetted perimeter of each of the plurality of dimples is minimized to reduce pressure drop of a counter current flow.   
     
     
         20 . The apparatus of  claim 1 , wherein:
 instances of the plurality of spaced and stacked planar plate pairs are hexagonal shaped.   
     
     
         21 . The apparatus of  claim 1 , wherein:
 the core is effectively counter flow near an outside edge while the flow near a center of the core essentially goes straight from an inlet to an outlet.   
     
     
         22 . The apparatus of  claim 1 , wherein:
 a hot fluid flow and a cold fluid flow being directed at angles that approach each other at about 120 degrees.   
     
     
         23 . An apparatus, comprising:
 an energy recovery system, including:
 an energy exchanger; 
 a core being configured for use in the energy exchanger, the core including a plurality of stacked and spaced planar plate pairs including a top plate and a bottom plate to support fluid flow of a first fluid flow and a second fluid flow; and 
 a plurality of dimples being provided by instances of the plurality of stacked and spaced planar plate pairs, and the plurality of dimples being arranged (i) to generate substantially counter current flow between the first fluid flow and the second fluid flow and (ii) to draw condensation from any one of the first fluid flow and the second fluid flow in any plate orientation. 
   
     
     
         24 . The apparatus of  claim 23 , wherein:
 the energy exchanger includes:
 a warm-flow outlet being configured to facilitate a warm-fluid flow; 
 a cold-flow outlet being configured to facilitate a cool-fluid flow; and 
 a divider being configured to separate the warm-fluid flow and the cool-fluid flow in such a way that a temperature gradient established across sides of the divider promotes heat exchange between the warm-fluid flow and the cool-fluid flow; and 
   the core includes:
 fluid directing rails being arranged in the core, and the fluid directing rails being configured to provide counter current energy exchange in the core in such a way that the fluid flow is opposite to each other in areas proximate to the fluid directing rails. 
   
     
     
         25 . The apparatus of  claim 23 , wherein:
 symmetrically arranged instances of the plurality of dimples are arranged to establish gaps between the instances of the plurality of stacked and spaced planar plate pairs, and the gaps operative for directing the fluid flow and operative for leaving spaces allowing for condensate drainage.   
     
     
         26 . The apparatus of  claim 23 , wherein:
 the plurality of dimples includes:
 instances of the plurality of dimples of the top plate are configured to protrude into the fluid flow, which rests against instances of the plurality of dimples protruding into the bottom plate, to establish gaps, and the gaps are operative for providing spacing between the bottom plate and the top plate and wherein the plurality of dimples further include: 
 symmetrically arranged instances of the plurality of dimples alternating between and protruding into and away from the fluid flow, for spacing instances of the plurality of stacked and spaced planar plate pairs for operative distribution of the fluid flow. 
   
     
     
         27 . The apparatus of  claim 23 , wherein:
 instances of the plurality of dimples are arranged at:
 a top side of instances of the plurality of stacked and spaced planar plate pairs; and 
 a bottom side of instances of the plurality of stacked and spaced planar plate pairs. 
   
     
     
         28 . The apparatus of  claim 23 , wherein:
 the plurality of dimples includes:
 a plurality of spaced extended-length dimples being oriented substantially parallel to a side of instances of the plurality of stacked and spaced planar plate pairs; and 
 a plurality of elliptical dimples being configured to surround instances of the plurality of spaced extended-length dimples on either side; and wherein 
 instances of the plurality of spaced extended-length dimples are configured to protrude into a supply side; 
 instances of the plurality of spaced extended-length dimples are configured to protrude into the supply side; 
 instances of the plurality of elliptical dimples are configured to protrude into an exhaust side; and 
 instances of the plurality of elliptical dimples extend into the exhaust side. 
   
     
     
         29 . The apparatus of  claim 23 , wherein:
 the plurality of dimples includes one of:
 (i) a plurality of elliptical dimples including:
 a first set of dimples; and 
 a second set of dimples protruding into a warm side and meeting with respective instances of the second set of dimples; 
 
 (ii) warm-side dimples protruding into a warm side of the core being operative for forcing a flow direction to be more parallel with sides of the core; and
 cold-side dimples protruding into a cold side of the core being operative for forcing the flow direction to be more parallel with the sides of the core; 
 
 (iii) warm-side dimples for a warm side flow, the warm-side dimples being about half of a width of a side of the core, the warm-side dimples operative for leaving additional room for a fluid to move within the core; and
 cold-side dimples for a cold side flow, the cold-side dimples being on a top portion of the core and extending to about the middle of the core; 
 
 (iv) a plurality of slanted dimples having:
 cold-side dimples; and 
 warm-side dimples; 
 the cold-side dimples being located downstream of warm-side dimples; 
 the plurality of slanted dimples configured to operatively force the fluid flow towards sides of the core more than the instances of the plurality of slanted dimples that are parallel to the sides to permit the plurality of slanted dimples to be spaced further apart; and 
 
 (v) warm-side dimples alternating between and protruding into a warm side, and the warm-side dimples leaving a cold-side recess in a cold side; and
 cold-side dimples alternating between and protruding into the cold side, and the cold-side dimples leaving a warm-side recess in the warm side. 
 
   
     
     
         30 . The apparatus of  claim 23 , wherein:
 the energy recovery system includes:
 any one of an air exchange system and a heat recovery ventilator system. 
   
     
     
         31 . A method of joining a plurality of stacked and spaced planar plate pairs used in a core, the method comprising:
 folding seams of the plurality of stacked and spaced planar plate pairs to operatively lock the plurality of stacked and spaced planar plate pairs together; and   applying an adhesive at the seams being folded to operatively attach and space the plurality of stacked and spaced planar plate pairs.