Abstract: A system for providing cooled compressed air free of entrained moisture. A housing surrounds a heat exchanger and has an inlet for passage of hot compressed air into an input plenum of the housing and an outlet plenum having an outlet for the cooled and dried compressed air. The bottom of the output plenum extends below the bottom of the heat exchanger to form a trough which collects condensate that collects on the plates of the heat exchanger, flows to the bottom of the heat exchanger, and is pushed by the flow of the compressed air to the output plenum. A shield is placed between the outlet and the heat exchanger to prevent condensate spewed from the plates of the heat exchanger from passing directly across the outlet opening or directly into the outlet opening.

Abstract: A heat insulator for an intake manifold of an air-cooled charge air cooler is a rectangular box placed inside the intake manifold housing. The charge air coming into the intake manifold is passed to the inside of the box by a liner in the housing tube. One side of the box has a plurality of openings with outwardly extending walls for abutting directly with the tubes or plates of the heat exchanger section of the cooler. The box has outwardly extending protrusions for positioning the box inside the intake manifold housing, the protrusions being such that direct heat transfer between the box and the housing is minimal and the heat conduction through the housing wall is sufficient to keep the housing temperature significantly lower than the charge air temperature. The box is not air tight to allow relatively thin material to be used since there is no pressure differential between the outside and the inside of the box.

Abstract: A system for providing cooled compressed air free of entrained moisture. A housing surrounds a heat exchanger and has an inlet for passage of hot compressed air into an input plenum of the housing and an outlet plenum having an outlet for the cooled and dried compressed air. The bottom of the output plenum extends below the bottom of the heat exchanger to form a trough which collects condensate that collects on the plates of the heat exchanger, flows to the bottom of the heat exchanger, and is pushed by the flow of the compressed air to the output plenum. A shield is placed between the outlet and the heat exchanger to prevent condensate spewed from the plates of the heat exchanger from passing directly across the outlet opening or directly into the outlet opening.

Abstract: A precooler/chiller/reheater (PCR) system comprising a precooler/reheater counterflow heat exchanger and a chiller counterflow heat exchanger separated by a moisture removal section. Refrigerant is flashed through a perforated distribution manifold along the plates of the chiller. Warm, moist air is precooled in the precooler/reheater heat exchanger. A manifold conveys the precooled air to the chiller heat exchanger. Chilled air exits the chiller at a low point in the system. Moisture condensed in the precooler and chiller drains into a sump that also acts to convey air into the moisture removal section. Water droplets are stripped from the airflow and drain downwards into the sump. The chilled and dried air is conveyed to the second side of the precooler/reheater heat exchanger and passes downward in counterflow to the direction of air entering the system on the first side of the heat exchanger, then exits the system ready for use as reheated, dried air.

Abstract: A finned heat exchange tube includes a metal cylindrical central tube having an outer surface and a metal fin helically disposed on and in thermally conductive contact with the outer surface of the tube. The cross-section of the fin is trapezoidal in shape, with a longer and a shorter base, the longer base being in contact with the outer surface of the tube. Alternatively, the fin can have a cross-section substantially rectangular in shape, having rounded comers and sides of longer and shorter dimensions perpendicular to one another, a side of the shorter dimension being in contact with the outer surface of the tube. A process for forming a heat exchanger tube comprises helically winding and securing a metal fin on an outer surface of a metal cylindrical central tube. The fin, which is in thermally conductive contact with the central tube, has a cross-section that can be trapezoidal or substantially rectangular in shape.

Abstract: A heat exchanger comprising a precooler and reheater core adjacent a chiller core, first heat transfer passages extending through both cores through which incoming air passes in a first direction, second heat transfer passages extending through the chiller core through which coolant passes in heat exchange relationship with incoming air and perpendicular to the first direction, and third heat transfer passages extending through the precooler and reheater core through which cooled air from the chiller core passes in heat exchange relationship with the incoming air and perpendicular to the first direction. A manifold contiguous with both cores conducts chilled air from the chiller core to the third set of heat transfer passages.Incoming air is chilled in the chiller core and thereafter exchanges heat with the incoming air in the precooler and reheater core to precool the incoming air to form water droplets and to raise the temperature of the chilled air to a usable temperature.

Abstract: A heat exchanger comprising a precooler and reheater core adjacent a chiller core, first heat transfer passages extending through both cores through which incoming air passes in a first direction, second heat transfer passages extending through the chiller core through which coolant passes in heat exchange relationship with incoming air and perpendicular to the first direction, and third heat transfer passages extending through the precooler and reheater core through which cooled air from the chiller core passes in heat exchange relationship with the incoming air and perpendicular to the first direction. A conduit conducts chilled air from the chiller core to the third set of heat transfer passages.Incoming air is chilled in the chiller core and thereafter exchanges heat with the incoming air in the precooler and reheater core to precool the incoming air to form water droplets and to raise the temperature of the chilled air to a usable temperature.

Abstract: A stacked plate heat exchanger is disclosed which includes heat exchange plates arranged in stacked relation, each of the plates including a peripheral flange. Each plate includes two types of flow openings, one type being formed as part of a depression therein, the other being substantially coplanar with the plate surface. The flow openings within the depressions adjoin the coplanar flow openings of the plate positioned immediately therebelow. Additional projections and depressions are formed between the flow openings of each plate to support it against similar projections and depressions formed in adjacent plates. A turbulator is positioned between and helps support each adjoining pair of heat exchange plates. Fluid is introduced to the heat exchanger by means of a nozzle having a base portion locked between a top plate and one of the heat exchange plates.

Abstract: The present invention relates to an inner finned tube particularly suitable for use in a continuous plate-finned heat exchanger. The plate fins are spaced apart along the tube in heat exchange relation therewith. An elongated cylindrical tube is provided with a plurality of integrally formed and radially disposed inner fins projecting toward the axial center line of the tube. Each fin in cross section is formed having a truncated triangular base and a rectangular portion extending toward the axial center line of the tube. The number of equally spaced formed fins is equal to 2.pi./.theta., where .theta. is the angle subtended between the center lines of two adjacent fins and may vary between 0.45 and 0.345 radian. The radial height of each fin may vary between 14 to 20% of the internal diameter of the tube.