FIELD OF THE PRESENT INVENTION The present invention relates to a heat exchanger for bathing shower with features in good heat exchanging efficiency, simple structure and easy fabrication so that manufacturing cost is decreased and energy saving efficiency is increased. Thereby, the purchasing intention of the consumers is spurred and energy saving and carbon reducing effects is promoted.
BACKGROUND OF THE INVENTION For the purpose of reducing carbon product, many heat exchangers for bathing shower used in household have been introducing in the market. The design concept is that the incoming cold tap water running through in the heat exchanger is heated up by the bathed hot waste water, which is served as thermal source, so that the temperature of output tap water from heat exchanger becomes warmer than that of incoming tap water for being redirected into an inlet pipe for the water heater of bathing shower. Thereby, the temperature of the inlet water for the water heater of bathing shower is increased to result in saving energy source for heating water. Taking China Patent for title “Water heater of energy saving type” in Number of CN201016505 at New Model invention publicized on Feb. 6, 2008 as an example, as shown in FIGS. 1 through 3, the “Water heater of energy saving type” comprises a water heater 10, which includes a water outlet pipe 12 and a shower sprayer 13, and a metal heat absorbing slab 20, which comprises a hollow chamber 21 with a top surface 24, a water inlet pipe 23 and a water outlet pipe 22 such that said hollow chamber 21, which allows cold tap water W1 flows therein, has one end thereof with water outlet pipe 22 connected to a water intake 11 of the water heater 10 and the other end thereof with water inlet pipe 23 connected to a source of cold tap water W1 (as shown in FIGS. 1 and 2). Upon a shower user M standing on the metal heat absorbing slab 20 for starting shower, certain hot shower water W, which comes from the water heater 10 and flow through a water outlet pipe 12, will spray out of the shower sprayer 13. The hot shower water W will drop on the flat top surface 24 of the metal heat absorbing slab 20 after showering on the body of the shower user M, meanwhile certain cold tap water W1 will flow into the hollow chamber 21 of the metal heat absorbing slab 20 via the water inlet pipe 23 and circulate among all hollow chamber 21 to absorb thermal energy of the dropped hot shower water W on the top surface 24 of the metal heat absorbing slab 20 so that the cold tap water W1 becomes warm heat-exchanged water W2. The warm heat-exchanged water W2 then flows out of the water outlet pipe 22 of the metal heat absorbing slab 20 to flow into the water heater 10 orderly via the water outlet pipe 22 and the water intake 11 thereof for serving as warm feeding water (as shown in FIG. 2). Thereby, the energy saving effect for electricity of gas consumption of the water heater 10 is achieved.
Please refer to FIGS. 4 and 5 that show another exemplary embodiment for the water heater 10 of a metal heat absorbing slab 200. The metal heat absorbing slab 200 comprises a spiral metal tube 201, which is configured into planar serpent disk through multiple metal working process. The spiral metal tube 201 has multiple continual coils with a gap S for each pair of adjacent coils, one end thereof with water outlet pipe 22 connected to a water intake 11 of the water heater 10 and the other end thereof with water inlet pipe 23 connected to a source of cold tap water W1. By heat exchanging means of the spiral metal tube 201 between (hot shower water W) dropped on the top surface of the metal heat absorbing slab 200 and cold tap water W1 will flow into the spiral metal tube 201 of the metal heat absorbing slab 200, the cold tap water W1 flowed in the spiral metal tube 201 becomes warm heat-exchanged water W2. The warm heat-exchanged water W2 then flows out of the water outlet pipe 22 of the metal heat absorbing slab 200 to flow into the water heater 10 orderly via the water outlet pipe 22 and the water intake 11 thereof for serving as warm feeding water. Thereby, the energy saving effect for electricity of gas consumption of the water heater 10 is achieved.
However, some drawbacks still exist in the China Patent for title “Water heater of energy saving type” in Number of CN201016505 at New Model invention as following:
1. Please refer to FIGS. 1 through 3 for metal heat absorbing slab 20. In order to keep the hot shower water W drop on the top surface 24 of the metal heat absorbing slab 20, the shower user M must stand on the top surface 24 of the metal heat absorbing slab 20. Consequently, the metal top surface 24 with hollow chamber 21 beneath will be indented deformation owing to body weight strain of the shower user M for long term use (as hypothetical line shown in FIG. 3). Because metal heat absorbing slab 20 is fabricated by metal welding process, water leakage is incurred from certain metal welding seams on the metal heat absorbing slab 20 being fractured due to indented deformation thereon so that not only the heat exchanging effect will be lost but also certain fractured metal welding seams may cause accidental hurt to the shower user M inadvertently. Moreover, because no circulation directing means is designed in the hollow chamber 21, water turbulences will happen in the chamber 21 after cold tap water W1 flows into therein via the water inlet pipe 23 (as indicting arrow heads shown in FIG. 2) so that the energy saving effect will be considerably decreased in consequence of lowering heat exchanging efficiency.
2. Please refer to FIGS. 4 and 5 for metal heat absorbing slab 200. Likewise, in order to keep the hot shower water W drop on the top surface of the metal heat absorbing slab 200, the shower user M must stand on the top surface of the metal heat absorbing slab 200. Because metal heat absorbing slab 200 is formed by spiral metal tube 201 having multiple continual coils with a gap S for each pair of adjacent coils, the round top surface thereof becomes slippery once hot shower water W drops thereon so that the shower user M stands thereon often suffered from injure inadvertently incurred by falling down due to such round slippery surface (as shown in FIG. 4). That is a menace to the safety of the shower user M. Moreover, all the gaps S between each pair of adjacent coils in the spiral metal tube 201 cause no heat exchanging function as the hot shower water W passes therein without contacting to the spiral metal tube 201 (as shown in FIG. 5) so that the energy saving effect will be considerably decreased in consequence of lowering heat exchanging efficiency.
3. The key process for the manufacturing of metal heat absorbing slab 20 in FIG. 1 and metal heat absorbing slab 200 in FIG. 4 is metal welding process, which cause relative high labor cost in manufacturing expense as metal welding process is often worked by high-skilled technician with high salary to maintain high yield. Moreover, the multiple continual coils with a gap S for each pair of adjacent coils for fabricating the spiral metal tube 201 must processed by a tube-bending machine of high accuracy together with metal welding process for welding connection with water inlet pipe 23 and water outlet pipe 22 respectively so that overall manufacturing cost keep soaring high without possibility of lowering down. Thus, the ex-factory price and retail price for the product of metal heat absorbing slab 20 and 200 become particular high with difficulty for lowering down so that not only the purchasing intention of the consumer is retarded but also the product itself becomes unpopular.
Therefore, how to contrive an improved product of heat exchanger for bathing shower with simplified structure and relative low manufacturing cost to satisfy with the purchasing ability and intention of customers seem very critical.
SUMMARY OF THE INVENTION The primary object of the present invention is to provide a heat exchanger for bathing shower with following features: (1) integral propping strength is good enough to support maximal body weight of a bathing user; (2) the circulation of internal water passages is configured into continual zigzag duct to considerably increase energy saving effect in consequence of improvement in heat exchanging efficiency of the bathing water heater; (3) simple structure and easy fabrication by traditional extruding method without involving welding process and related high-salary welding technician. Thereby, selling price can be substantially reduced with strong marketing competitiveness because overall manufacturing cost is decreased without sacrifice quality so that the purchasing intention of the consumers is spurred. Thus, the present invention is not only favorable to promote and penetrate marketing range and depth but also valuable to expedite in achieving the eco-friend effect of energy saving and carbon reducing requirement.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is the first structural schematic view for the conventional heat exchanger of China Patent in No. CN201016505.
FIG. 2 is a sectional view taken along line 2-2 as indicated in FIG. 1.
FIG. 3 is an operational schematic view for the conventional heat exchanger of China Patent in No. CN201016505.
FIG. 4 is the second structural schematic view for the conventional heat exchanger of China Patent in No. CN201016505.
FIG. 5 is the third structural schematic view for the conventional heat exchanger of China Patent in No. CN201016505.
FIG. 6 is an exploded perspective view of a heat exchanger for bathing shower according to a first preferred embodiment of the present invention.
FIG. 7 is a perspective schematic view showing an upper deck under drilling bores process by a drilling tool for the above first preferred embodiment of the present invention.
FIG. 8 is a perspective schematic view showing an upper deck for the above first preferred embodiment of the present invention.
FIG. 9 is the first perspective schematic view showing assembling process for the above first preferred embodiment of the present invention.
FIG. 10 is the second perspective schematic view showing assembling process for the above first preferred embodiment of the present invention.
FIG. 11 is the third perspective schematic view showing assembling process for the above first preferred embodiment of the present invention.
FIG. 12 is a sectional view taken along line 12-12 as indicated in FIG. 11.
FIG. 13 is a sectional view taken along line 13-13 as indicated in FIG. 11.
FIG. 14 is an installed schematic view showing practical usage for the above first preferred embodiment of the present invention.
FIG. 15 is a sectional view taken along line 15-15 as indicated in FIG. 14.
FIG. 16 is a illustrative schematic view showing extruding process for the above first preferred embodiment of the present invention.
FIG. 17 is a perspective schematic view showing an upper deck under fraise process by milling cutter for the above first preferred embodiment of the present invention.
FIG. 18 is a perspective schematic view showing an upper deck after deck fraise process by milling cutter for the above first preferred embodiment of the present invention.
FIG. 19 is an exploded perspective view for the second preferred embodiment of the present invention.
FIG. 20 is an assembly schematic view for the second preferred embodiment of the present invention.
FIG. 21 is an exploded perspective view for the third preferred embodiment of the present invention.
FIG. 22 is an assembly schematic view for the third preferred embodiment of the present invention.
FIG. 23 is an exploded schematic view for the fourth preferred embodiment of the present invention.
FIG. 24 is an assembly schematic view for the fourth preferred embodiment of the present invention.
FIG. 25 is an assembly schematic view for the fifth preferred embodiment of the present invention.
FIG. 26 is an operational schematic view for the fifth preferred embodiment of the present invention.
FIG. 27 is an exploded perspective view for the sixth preferred embodiment of the present invention.
FIG. 28 is an assembly perspective view for the sixth preferred embodiment of the present invention.
FIG. 29 is a sectional view taken along line 29-29 as indicated in FIG. 28. FIG. 30 is a sectional view taken along line 30-30 as indicated in FIG. 28.
FIG. 31 is a sectional view taken along line 31-31 as indicated in FIG. 28.
FIG. 32 is a perspective schematic view for the seventh preferred embodiment of the present invention.
FIG. 33 is an exploded sectional view for the seventh preferred embodiment of the present invention.
FIG. 34 is an assembly sectional view for the seventh preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 6 through 13, a heat exchanger for bathing shower according to a first preferred embodiment of the present invention comprises a stacked upper deck 30, a founded lower chassis 40 and two hatches 50.
Referring to FIGS. 6 through 13, the upper deck 30 is a planiform cuboid extruded by metal material and encompassed by a top surface 31, a bottom surface 32, a front side 33, a rear side 34, a pair of parallel flanks 35, includes a plurality of screw bores 36 created in the front side 33 and rear side 34 respectively, several parallel septa 37 downwardly disposed on the bottom surface 32 such that a water passage 303 is created between each pair of adjacent septa 37, an upper docking latch bar 38 in male dovetail cross section being downwardly formed on the terminal of one septum 37, a circulating bore 39 being created on each septum 37 in interlaced stagger manner, which means a circulating bore 39 in upper section of one septum 37 and another circulating bore 39 in lower section of the other septum 37 for each pair of adjacent septa 37, so that all the adjacent water passages 303 can be mutually communicable as a continual zigzag circulating duct even being separated by a septum 37 between them, a water intake 301 is created in one flank 35 while a water outtake 302 is created in the other opposed flank 35 respectively;
The lower chassis 40 is a planiform slab extruded by metal material and encompassed by a top surface 41, a sole surface 42, a front side 43, a rear side 44, a pair of parallel flanks 45 with same planar shape and area with corresponding upper deck 30, includes a plurality of screw bores 47 created in the front side 43 and rear side 44 respectively, and a lower docking latch bar 46 in female dovetail cross section, which is upwardly formed on the top surface 41 in a suitable position corresponding to the upper docking latch bar 38 of the specific septum 37 on the upper deck 30 so that the male dovetailed upper docking latch bar 38 and the corresponding female dovetailed lower docking latch bar 46 can be securely engaged in mutual latch manner; and
The each hatch 50 is a planiform slab with suitable planar shape and area to properly cover an interim integral assembly of the upper deck 30 and lower chassis 40 in flush manner, has a plurality of punched holes 51 disposed thereon in corresponding to the screw bores 36 on the upper deck 30 or screw bores 47 on the lower chassis 40 so that both of front and rear hatches 50 can hermetically seal both front sides 43 and 44 as well as both rear sides 34 and 44 of the interim integral assembly of the upper deck 30 and lower chassis 40 in plenum manner including all water passages 303 of continual zigzag circulating duct with septa 37 therein (as shown in FIG. 12).
Referring to FIGS. 9 through 11, the assembling process is described as below.
Firstly, align and insert the male dovetailed upper docking latch bar 38 on the upper deck 30 into the female dovetailed lower docking latch bar 46 on the lower chassis 40 (as shown in FIG. 9);
Secondly, simultaneously apply forces on both of the rear side 34 on the upper deck 30 and the front side 43 on the lower chassis 40 in opposed inward manner to dock both of the upper deck 30 and lower chassis 40 up to flush manner so that a interim integral assembly of the upper deck 30 and lower chassis 40 is assembled (as shown in FIG. 10); and
Finally, cover both of front and rear hatches 50 on both front sides 43 and 44 as well as both rear sides 34 and 44 of the interim integral assembly of the upper deck 30 and lower chassis 40, then drive (screws N) in the punched holes 51 on the upper deck 30 through the punched holes 51 on the lower chassis 40 to securely fix the interim integral assembly of the upper deck 30 and lower chassis 40 into a final plenum (as shown in FIG. 11).
For all foregoing assembling process, only few three simple steps are required without involving any welding process and related welding technician so that manufacturing cost is substantially reduced owing to low human labor and labor hour.
Please refer to FIGS. 14 and 15. The installation and operation methods for a heat exchanger for bathing shower of the present invention are described as below. By means of proper pipe fittings, connect a water inlet pipe 23 of tap water to the water intake 301 on the upper deck 30 while connect a water outlet pipe 22 in water intake 11 of a water heater 10 to the water outtake 302 on the same upper deck 30 to finish the installation before operation (as shown in FIG. 14). For shower, firstly, upon a shower user M starting shower, certain hot shower water W, which comes from the water heater 10 and flow through a water outlet pipe 12, will spray out of the shower sprayer 13; secondly, the hot shower water W will drop on the flat top surface 31 of the upper deck 30 after shower on the body of the shower user M, meanwhile certain cold tap water W1 will flow into the water passages 303 of the upper deck 30 orderly via the water inlet pipe 23 and the water intake 301 of the upper deck 30, then circulate among all water passages 303 by means of every circulating bore 39 on each septum 37 (as indicated by arrowhead shown in FIG. 15) to absorb thermal energy of the dropped hot shower water W on the top surface 31 of the upper deck 30 so that the cold tap water W1 becomes warm heat-exchanged water W2; and finally, the warm heat-exchanged water W2 then flows out of the water outtake 302 on the upper deck 30; and then flows into the water heater 10 orderly via the water outlet pipe 22 and the water intake 11 thereof for serving as warm feeding water (as shown in FIG. 14). Thereby, the energy saving effect for electricity of gas consumption of the water heater 10 is achieved.
It is known from FIGS. 14 and 15 that the plural septa 37 in each pair adjacent water passages 303 formed between the bottom surface 32 of the upper deck 30 and the upper surface 41 of the lower chassis 40 also serve as props (as indicated by enlarged view shown in FIG. 14), which is strong enough to completely support normal body weight of a shower user M so that not only the service life span of the integral plenum of the upper deck 30 and lower chassis 40 can be extended due to no indented deformation being able to happen thereon, but also the shower user M suffered from injure inadvertently incurred by falling down can be avoided because the flat top surface 31 on the upper deck 30 offers stable platform for shower user M to stand thereon (as shown in FIG. 14 and indicated by enlarged view associated). Moreover, the circulating bore 39, which is created on each septum 37 to make every pair adjacent water passages 303 become water communicable mutually, serves as a circulation directing means in the heat exchanging slab 30 (as indicated by arrowhead shown in FIG. 15) for directing the cold tap water W1 to become a smoothly regular path-oriented stable flow in the water passages 303 between the upper deck 30 and lower chassis 40 so that the heat exchanging efficiency of the present invention is improved and the energy saving effect of the water heater 10 is substantially increased.
All the foregoing upper deck 30 and lower chassis 40 of the present invention are produced by traditional extruding method. Referring to FIG. 16, take fabrication of the upper deck 30 as an example. Firstly, melt raw material of aluminum alloy by an extruder A, then extrude it out as a continual upper deck slab 300 via an extruding die B; secondly, cut the continual upper deck slab 300 into piece form of desired length by a cutting tool C, and finally, drill all circulating bores 39 by a drilling tool D (as indicated by hypothetical lines shown in FIG. 7), and then a finished upper deck 30 is produced. The fabrication of the lower chassis 40 can be done in the same way as well. For all foregoing fabricating process, only few traditional techniques and related tools are required without involving any complicated process and related expensive machinery so that manufacturing cost is substantially reduced because fabricating process can be done in mass production of continuous production line with low human labor and labor hour.
Please refer to FIGS. 17 and 18, which show an upper deck under fraise process by milling cutter for the first exemplary embodiment of the present invention. The foregoing drilling process in creating circulating bores 39 by a drilling tool D can be adapted by replacing a milling cutter G for the drilling tool to cut out equivalent circulating notches 391 in indented manner, which still function as circulating bores 39 (as shown in FIG. 17).
Comparing to conventional fabricating process, which involves welding process and related welding technician, the fabricating process of the present invention only with drilling tool D in creating circulating bores 39 or milling cutter G in creating circulating notches 391 eliminating welding process is apparently much simpler. Thereby, the marketing competitiveness of the present invention can be considerably enhanced in consequence of the manufacturing cost being substantially reduced from low human labor and labor hour. Thus, to promote energy saving campaign in recycling hot shower water W for the water heater 10, the present invention can play an important role for immediate effectiveness.
Referring to FIGS. 19 and 20, they show the second exemplary embodiment of the present invention. Wherein, the upper deck 30 is further modified to dispose a male dovetailed inward flank latch bar 351 on each flank 35 thereof while the lower chassis 40 is further modified to dispose a corresponding female dovetailed outward flank latch bar 451 on each suitable marginal position of upper surface 41 thereof (as shown in FIG. 19). By means of additional engagement from the pair of male dovetailed inward flank latch bar 351 and the corresponding female dovetailed outward flank latch bar 451, the interim integral assembly of the upper deck 30 and lower chassis 40 can be securely docked in much better manner (as shown in FIG. 20).
Referring to FIGS. 21 and 22, they show the third exemplary embodiment of the present invention. Wherein, the upper deck 30 is further modified to dispose a male dovetailed upper docking latch bar 38 on every septa 37 on the bottom surface 32 thereof while the lower chassis 40 is further modified to dispose a corresponding equivalent number of female dovetailed lower docking latch bars 46 on each suitable marginal position of upper surface 41 thereof such that each lower docking latch bars 46 is in corresponding to a matched upper docking latch bar 38 (as shown in FIG. 21). By means of additional engagement from all male dovetailed upper docking latch bars 38 and the corresponding female dovetailed lower docking latch bars 46, the interim integral assembly of the upper deck 30 and lower chassis 40 can be securely docked in much better manner (as shown in FIG. 22).
Referring to FIGS. 23 and 24, they show the fourth exemplary embodiment of the present invention. Wherein, the original male dovetailed upper docking latch bar 38 on the upper deck 30 is modified into a female dovetailed upper docking latch bar 38 while original female dovetailed lower docking latch bar 46 on the lower chassis 40 is modified into a corresponding male dovetailed lower docking latch bar 46 (as shown in FIG. 23). By means of engagement from the new pair of female dovetailed upper docking latch bar 38 and the corresponding male dovetailed lower docking latch bar 46, the interim integral assembly of the upper deck 30 and lower chassis 40 can be securely docked in same effect as that engagement from the original pair of male dovetailed upper docking latch bar 38 and the corresponding female dovetailed lower docking latch bar 46 (as indicated by enlarged view shown in FIG. 24).
Referring to FIGS. 25 and 26, they show the fifth exemplary embodiment of the present invention. Wherein, the top surface 31 on the upper deck 30 is modified into a cambered top surface 31 (as shown in FIG. 25) to facilitate the sprinkled hot shower water W to easily drain out without and accumulation on the cambered top surface 31 of the upper deck 30 so that heat exchanging effect is not reduced due to cooling effect of the accumulated hot shower water W thereon (as shown in FIG. 26).
Referring to FIGS. 27 through 31, they show the sixth exemplary embodiment of the present invention. Wherein, each internal hatch face 501 of the front hatch and rear hatch 500 is modified to inwardly create an array of terminal linking passages 502 of zigzag end therein to replace the function of the circulating bores 39 or circulating notches 391 (as shown in FIG. 27). The assembling process for this sixth exemplary embodiment is shown in FIGS. 27 through 31, which is almost the same as that shown in FIGS. 9 through 11. After having securely engaged the integral assembly of the upper deck 30 and lower chassis 40 as well as modified hatches 500 by screws N, a configuration of zigzag circulation from combination of water passages 303 and terminal linking passages 502 is finished (as shown in FIG. 29). By means of the terminal linking passages 502, the fabricating process of the circulating bores 39 or circulating notches 391 can be obliterated to reduce manufacturing cost.
Referring to FIGS. 32 through 34, they show the seventh exemplary embodiment of the present invention. Wherein, the upper deck 30 is modified to split into a primary upper deck 30a and an annexed subordinate upper deck 30b while the lower chassis 40 is also split into a corresponding primary one and a subordinate one (as shown in FIG. 32) such that an additional recessed linking elbow bar 352 is disposed on a flank 35a of the primary upper deck 30a while an additional corresponding projected linking elbow bar 353 is disposed on a flank 35b of the annexed subordinate upper deck 30b. Moreover, a plurality of screw bores 354 are formed in the recessed linking elbow bar 352 while a plurality of punched holes 355 are perforated in the projected linking elbow bar 353 (as shown in FIG. 33). By driving a screw N through each punched hole 355 and screwing with each corresponding screw bore 354, the primary upper deck 30a and annexed subordinate upper deck 30b can be mutually engaged securely so that the covering area of the present invention can be enhanced with more flexibility to meet some specific requirement of irregularly expanded floor layout of the bathing room (as shown in FIGS. 32 and 34). Preferably but not necessarily, the primary upper deck 30a is identical to the upper deck 30 while the width of the annexed subordinate upper deck 30b is less than that of the upper deck 30.
The metal material used in the upper deck 30 of the present invention can be replaced by a non-metal synthetic material with good heat conductivity such as carbon fiber, which also has the same heat exchanging effect for hot shower water W in energy-saving function of the water heater 10 as that of the metal material. In conclusion all the disclosure heretofore, the simple structure with less fabricating process of the present can definitely reduce the manufacturing cost other than considerably energy-saving effect for the bathing water heater. Thus, it meets the basic criterion of patentability.
