阅读说明：本技术 热交换器设备 (Heat exchanger device ) 是由 赵旭东 徐鹏 马小丽 K.芬西 李俊明 于 2017-10-11 设计创作，主要内容包括：本发明涉及一种热交换器设备,其包括至少一个金属薄片(10)(例如铝),并且优选地包括呈堆叠形式的多个金属薄片。每个金属薄片(10)具有波纹表面,其中织物覆盖金属薄片的一个表面的至少一部段以促进蒸发。润湿剂(例如,LiCl/聚乙烯醇(PVA)溶液)被提供在织物中以促进织物的润湿,并且还用作抗微生物剂。织物优选地覆盖全部波纹表面,并且两个平面部段被分别提供在波纹表面的上方和下方。在使用中,热交换器设备以长侧竖直的方式设置并且波纹表面设置在中间部段上,上平面部段与空气出口邻接,和/或下平面部段与空气入口邻接。在优选实施例中,波纹表面的横截面具有周期性波形轮廓,其中,峰-到-峰距离为11.6 mm,振幅为2.5 mm,并且波纹与热交换器设备的平面以与该平面成50度的角度相交。还公开了包括热交换器设备的冷却系统和操作冷却系统的方法,所述方法涉及间歇地操作供水系统以向织物施加水,和/或使用供水系统来使水从水储槽再循环。(The invention relates to a heat exchanger device comprising at least one foil (10), for example aluminium, and preferably a plurality of foils in a stack. Each foil (10) has a corrugated surface, wherein the fabric covers at least a section of one surface of the foil to promote evaporation. Wetting agents (e.g., LiCl/polyvinyl alcohol (PVA) solutions) are provided in the fabric to facilitate wetting of the fabric, and also serve as antimicrobial agents. The fabric preferably covers the entire corrugated surface and the two planar sections are provided above and below the corrugated surface, respectively. In use, the heat exchanger device is arranged with the long sides vertical and the corrugated surface is arranged on the middle section, the upper planar section adjoining the air outlet and/or the lower planar section adjoining the air inlet. In a preferred embodiment, the cross-section of the corrugated surface has a periodic waveform profile with a peak-to-peak distance of 11.6 mm, an amplitude of 2.5 mm, and the corrugations intersect the plane of the heat exchanger apparatus at an angle of 50 degrees to the plane. Also disclosed are cooling systems including the heat exchanger apparatus and methods of operating cooling systems involving intermittently operating a water supply to apply water to the fabric and/or using the water supply to recirculate water from a water reservoir.)

1. A heat exchanger apparatus, comprising: at least one metal sheet having a corrugated surface; a fabric covering at least a portion of one surface of the at least one metallic foil to facilitate evaporation; the method is characterized in that: a wetting agent in the fabric to facilitate wetting of the fabric, and the wetting agent also acts as an antimicrobial agent.

2. A heat exchanger apparatus as claimed in claim 1, wherein the heat exchanger apparatus has an elongate axis which, in use, is arranged vertically.

3. The heat exchanger apparatus of claim 1, wherein the corrugated surface comprises corrugations on a first section of the one surface of the heat exchanger apparatus.

4. The heat exchanger apparatus of claim 3, wherein the fabric covers a second section of the one surface, the second section overlapping the first section.

5. The heat exchanger apparatus of claim 3, wherein the fabric covers a second section of the one surface, the first section being completely contained within the second section.

6. The heat exchanger apparatus of claim 3, wherein the one surface of the heat exchanger apparatus comprises a third section outside the first section, the third section being flat.

7. The heat exchanger apparatus according to claim 6, wherein, in use, (i) the first section is provided on an upper section of the heat exchanger apparatus and/or adjacent to an air outlet, and/or (ii) the third section is provided on a lower section thereof and/or adjacent to an air inlet.

8. The heat exchanger apparatus of claim 3, wherein the one surface of the heat exchanger apparatus comprises a fourth section outside the first section, the fourth section being flat.

9. The heat exchanger apparatus according to claim 8, wherein, in use, the fourth section is disposed on an uppermost section of the heat exchanger apparatus and/or adjacent an air outlet.

10. The heat exchanger apparatus of claim 1, wherein a cross-section of the corrugated surface has a periodic waveform profile.

11. The heat exchanger apparatus of claim 10, wherein the periodic waveform has a peak-to-peak distance of (i) 10-13 mm, (ii) 11-12 mm, or (iii) 11.6 mm.

12. The heat exchanger apparatus of claim 10, wherein the periodic waveform has an amplitude of (i) 2-3 mm, (ii) 2.2-2.8 mm, or (iii) 2.5 mm.

13. The heat exchanger apparatus of claim 10, wherein corrugations intersect the plane of the heat exchanger apparatus at an angle of (i) 46-54 degrees, (ii) 48-52 degrees, or (iii) 50 degrees to the plane.

14. The heat exchanger apparatus as claimed in claim 1, wherein the corrugated surface has dimensions of (i) 300-.

15. The heat exchanger apparatus of claim 1, wherein the fabric is a synthetic wicking fabric.

16. The heat exchanger apparatus of claim 1, wherein the fabric is formed from (i) polyester or (ii) a woven fabric.

17. The heat exchanger apparatus of claim 1, wherein the wetting agent comprises a halogen and a polyvinyl surfactant.

18. The heat exchanger apparatus of claim 17, wherein the wetting agent comprises polyvinyl pyrrolidone (PVP) or polyvinyl alcohol (PVA).

19. The heat exchanger apparatus of claim 17, wherein the wetting agent comprises a salt compound.

20. The heat exchanger apparatus of claim 19, wherein the wetting agent is a LiCl/polyvinyl alcohol (PVA) solution.

21. The heat exchanger apparatus of claim 1, wherein the foil is formed of aluminum.

22. The heat exchanger apparatus according to claim 1, wherein some or all of the corrugations in the corrugated surface have one or more through holes at or near one end thereof.

23. The heat exchanger apparatus according to claim 22, wherein, in use, the through-hole is provided at or near an uppermost end of the heat exchanger apparatus.

24. The heat exchanger apparatus of claim 1, wherein the fabric is secured to the foil by an adhesive.

25. The heat exchanger apparatus of claim 1, comprising a plurality of metal sheets, wherein the corrugated surfaces of adjacent metal sheets define channels to promote air flow when two or more heat exchangers are placed together.

26. The heat exchanger apparatus of claim 1, comprising: a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; and a controller coupled to the water supply, the controller configured for intermittently operating the water supply for applying water to the fabric so as to maintain the fabric in a wet state.

27. The heat exchanger apparatus of claim 1, comprising a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling, wherein the water supply system is configured to recirculate water from a water sump to the heat exchanger apparatus.

28. A method of operating a cooling system, the method comprising:

providing a heat exchanger apparatus according to claim 1;

providing a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; and is characterized in that:

a wetting agent in the fabric to facilitate wetting of the fabric, and the wetting agent also serves as the antimicrobial agent; and

providing a controller coupled to the water supply system; and

intermittently operating the water supply system using the controller for applying water to the fabric so as to maintain the fabric in a wet state while preventing the formation of a film of water.

29. A method of operating a cooling system, the method comprising:

providing a heat exchanger apparatus according to claim 1;

providing a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; the method is characterized in that:

a wetting agent in the fabric (12) to facilitate wetting of the fabric (12), and which also serves as the antimicrobial agent; and

recirculating water from the water sump using the water supply.

Technical Field

The present invention relates to cooling systems relying on evaporative cooling, and more particularly to heat exchanger apparatus, cooling systems and methods of operating the same.

Background

It is known to provide a dew point air conditioner comprising a plate heat exchanger with complex heat exchanger lamellae, fans, pumps, a housing and control means. The known heat exchanger surfaces are usually not treated in any way, resulting in poor water distribution and insufficient wetting, especially in the horizontal direction, due to the influence of gravity on the water. This results in poor heat and mass transfer between the dry and wet channel air streams of the heat exchanger. In addition, the amount of circulating water in the air conditioner causes a pump of the air conditioner to consume a large amount of electric power due to poor water distribution and insufficient humidification.

Known plate heat exchangers do not make full use of the heat exchange space, resulting in less heat transfer capacity. Known heat exchangers use air guides between adjacent heat exchanger fins, which increases the air flow resistance between the fins, resulting in higher fan power consumption.

Problems with known arrangements include excessive power consumption, excessive water consumption, and fouling of the heat exchanger due to the presence of bacteria and the like, in addition to increased health risks. Known plate heat exchangers also have reduced life due to fouling and corrosion. Some wetting agents are known to be useful as antimicrobial agents. Furthermore, it is known to use wetting agents for evaporative cooling. For example, LiCl is a known hygroscopic agent and surfactant that may also have antimicrobial properties, and polyvinyl alcohol (PVA) is known for its use with contact lenses and in dehumidifiers. However, known techniques for operating air cooling devices do not involve the addition of LiCl to PVA for use in evaporative cooling to enhance antimicrobial properties.

US2005/0218535a1 discloses a method and a device for indirect evaporative air cooling, wherein each plate of the device is made of a laminate with one sheet of wicking material for the wet zone(s) and another sheet of waterproof plastic material for the dry zone(s). The wicking layer may be made of cellulose, polyester, polypropylene, or glass fibers. One embodiment uses corrugated sheets, the corrugations forming guides for the air flow and thus the channels. The channels are maintained by orienting the corrugations of adjoining plates such that they are not parallel (e.g., they are at right angles) and do not nest with adjoining plates. The plastic layer and cross-flow arrangement do not help to optimize heat transfer and the use of the preferred wicking material does not optimize moisture retention.

US2013/0233005a1 discloses a method of controlling the operation of an evaporative air cooler, wherein the pad of the cooler (i.e., corrugated paper media) is intermittently wetted by an amount of water to absorb and retain during each wetting operation. Any free water within the evaporative medium (pad) is allowed to flow back into the reservoir below the pad. The static pressure transducers on either side of the pad enable the speed of the air flow passing therethrough to be measured. The air flow is limited to a velocity so as not to entrain water in the air flow during the moistening operation, and the velocity of the air flow is increased after each intermittent moistening operation so as to increase the cooling output level of the cooler between each intermittent moistening operation. The wetting sequence may account for 10% to 20% of the operating time. Corrugated paper media does not help optimize heat transfer and the disclosed wetting techniques do not optimize moisture retention while reducing water or electricity usage.

Known materials commonly used for heat exchanger sheets in dew point air cooler installations are non-metallic materials (e.g., kraft paper, plastic, etc.). Such non-metallic materials have poor thermal conductivity.

A general object of the present invention is to address one or more of the above-mentioned disadvantages of previously known heat exchanger devices.

Disclosure of Invention

What is needed is a heat exchanger apparatus that can reduce or minimize at least some of the above-mentioned problems.

According to a first aspect of the present invention, there is provided a heat exchanger apparatus comprising: at least one metal sheet having a corrugated surface; a fabric covering at least a portion of one surface of the at least one metallic foil to facilitate evaporation; a wetting agent in the fabric to facilitate wetting of the fabric and also to act as an antimicrobial agent.

Such an arrangement provides the advantage that the corrugations can reduce flow resistance due to the unobstructed internal support, the fabric and wetting agent can increase the evaporation rate, and the wetting agent can prevent negative effects such as fouling, corrosion and bacterial growth, and all synergistically increase or optimize the flow rate and cooling efficiency of the heat exchanger apparatus. In addition, such irregular/corrugated heat exchange sheets can increase the heat and mass transfer area by about 35%, resulting in the same percentage increase in heat transfer rate.

Preferably, the heat exchanger apparatus has an elongate axis which, in use, is arranged vertically (i.e. substantially vertically).

Preferably, the corrugated surface comprises corrugations on the first section of the one surface of the heat exchanger apparatus. In one embodiment, the fabric covers a second section of the one surface, the second section overlapping the first section. In another embodiment, the fabric covers a second section of the one surface, the first section being completely contained within the second section. Advantageously, the fabric thus covers the entire corrugation, so that the fabric increases the evaporation rate over the entire corrugated surface.

Preferably, the one surface of the heat exchanger apparatus comprises a third section outside the first section, the third section being flat. The third section is a section or a portion of a flat or planar surface of the one surface. This can improve the flow efficiency near the third section (i.e., near the air inlet and outlet, respectively). Preferably, in use, (i) the first section is provided on an upper section of the heat exchanger apparatus and/or adjacent to the air outlet, and/or (ii) the third section is provided on a lower section thereof and/or adjacent to the air inlet. In this regard, abutting means that the edge of the first section or the edge of the third section shares an edge or boundary with the air inlet or outlet as desired.

Preferably, the one surface of the heat exchanger device comprises a fourth section outside the first section, the fourth section being flat. Preferably, in use, the fourth section is provided on an uppermost section of the heat exchanger apparatus and/or adjacent the air outlet.

Preferably, the cross-section of the corrugated surface has a periodic wave-shaped profile. The waveform may be quasi-sinusoidal or triangular. This configuration enables adjacent sheets to abut at or near the edges (peaks) formed by the corrugations to form effective airflow channels. This configuration advantageously omits the channel support (or so-called "air guide") from the heat exchanger stack, resulting in an air flow resistance reduction of about 55%, and in the same percentage of fan power savings.

Preferably, the periodic waveform has a peak-to-peak distance of (i) 10-13 mm, (ii) 11-12 mm, or (iii) 11.6 mm. Preferably, the periodic waveform has an amplitude of (i) 2-3 mm, (ii) 2.2-2.8 mm, or (iii) 2.5 mm. Preferably, the corrugations intersect the plane of the heat exchanger apparatus at an angle of (i) 46-54 degrees, (ii) 48-52 degrees or (iii)) 50 degrees to the plane. Preferably, the corrugated surface has dimensions of (i) 300-.

Preferably, the fabric is a synthetic wicking fabric. Preferably, the fabric is formed from polyester. Preferably, the fabric is formed of a woven fabric. The inventors have found that the use of a fabric made of a material such as polyester fibres can significantly improve the wettability and water diffusivity across the fabric surface, thereby improving its heat transfer performance.

Preferably, the wetting agent is a halogen and polyvinyl surfactant. Preferably, the wetting agent comprises polyvinylpyrrolidone (PVP) or polyvinyl alcohol (PVA). Preferably, the wetting agent comprises a salt compound.

Preferably, the wetting agent is a LiCl/polyvinyl alcohol (PVA) solution. The inventors have found that the use of a LiCl/polyvinyl alcohol coating solution on the wetted surfaces of heat exchange sheets can improve the water adsorption capacity of the heat exchange sheets and prevent negative effects on the surfaces (e.g., fouling, corrosion, and bacterial growth). This improves the operating efficiency and can prevent adverse health effects.

Preferably, the metal foil is formed of aluminum. This helps to improve/maximize heat transfer from the dry channels to the wet channels. Preferably, marine adhesives are used to bond the fabric to the aluminum heat exchanger sheet, advantageously resulting in a strong bond and long life for the heat exchanger sheet.

Preferably, some or all of the corrugations in the corrugated surface have one or more through holes at or near one end of the corrugated surface. This helps to separate the flow into exit air and return/exhaust air. Preferably, in use, the through-hole is provided at or near an uppermost end of the heat exchanger apparatus. This further helps to split the flow into leaving air and return/exhaust air, i.e. shortly before the outlet of the cooled working air.

Preferably, there is provided a heat exchanger apparatus according to any one of claims 1 to 27 of the accompanying claims, comprising a plurality of metal sheets, wherein the corrugated surfaces of adjacent metal sheets define channels to promote air flow when two or more heat exchangers are placed together.

Preferably, a water supply system is included, configured for supplying water to the fabric of the heat exchanger device for evaporative cooling. Preferably, a controller is included that is coupled to the water supply, the controller being configured for intermittently operating the water supply for applying water to the fabric so as to maintain the fabric in a wet condition. Preferably, the water supply is configured to recirculate water from the water sump to the heat exchanger apparatus.

According to a second aspect of the present invention, there is provided a cooling system comprising: a heat exchanger apparatus according to any one of claims 1 to 27 of the accompanying claims; a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; a controller coupled to the water supply, the controller configured for intermittently operating the water supply for applying water to the fabric so as to maintain the fabric in a wet condition.

According to a third aspect of the present invention, there is provided a cooling system comprising: a heat exchanger apparatus according to any one of claims 1 to 27 of the accompanying claims; a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; wherein the water supply is configured to recirculate water from the water sump to the heat exchanger apparatus.

According to a fourth aspect of the present invention, there is provided a method of operating a cooling system, the method comprising: providing a heat exchanger apparatus according to any one of claims 1 to 27 of the accompanying claims; providing a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; providing a controller coupled to a water supply; and intermittently operating the water supply using the controller for applying water to the fabric so as to maintain the fabric in a wet condition.

This aspect has the advantage that the intermittent operation of the water circulation keeps the wetted surfaces of the heat exchange sheet in a saturated state, while preventing the formation of a water film on the surfaces, which would reduce the evaporation of water.

According to a fifth aspect of the present invention, there is provided a method of operating a cooling system, the method comprising: providing a heat exchanger apparatus according to any one of claims 1 to 27 of the accompanying claims; providing a water supply system configured for supplying water to the fabric of the heat exchanger apparatus for evaporative cooling; water is recirculated from the water reservoir using a water supply system.

The advantage of this aspect is that although the water supply is mainly delivered by tap water, the circulation pump is only activated when the bottom tank is full; this therefore minimizes the pump operation time and its power consumption.

According to an alternative feature of the present invention, there is provided a heat exchanger apparatus comprising: at least one metal sheet with a first portion having a corrugated surface, a second portion having a flat surface, and a third portion having a flat surface, the second and third portions being located on either side of the first portion; a fabric covering at least a section of one surface of the foil to promote evaporation; a wetting/antimicrobial agent in the fabric to promote wetting of the fabric and inhibit microbial growth, wherein the fabric covers at least a section of the first portion and one or both of the second portion and the third portion of the one surface.

In use, the heat exchanger apparatus is provided with vertical foils such that the second portion is adjacent the air outlet and the third portion is adjacent the air inlet.

Any preferred or optional feature of one aspect or feature of the invention may be a preferred or optional feature of another aspect or feature of the invention.

Drawings

Further features of the invention will become apparent from the following description of preferred embodiments, which is given by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a perspective side view of a heat exchanger sheet according to an embodiment of the invention;

FIG. 2 shows a perspective side view of the stack of heat exchanger sheets shown in FIG. 1;

FIG. 3 is a schematic perspective view of four sheets of the apparatus of FIG. 2;

FIG. 4 is a cross-section across a heat exchanger sheet shown in FIG. 1; and

fig. 5 shows the steps of a method according to an embodiment of the invention.

Detailed Description

FIG. 1 shows a perspective side view of a heat exchanger sheet, generally designated 10, according to an embodiment of the present invention. In fig. 1, the heat exchanger sheet is shown in its normal orientation in use. The heat exchanger foil 10 is 5005 series aluminium. The heat exchanger foil 10 is corrugated in the upper region 14. The 5005 series aluminum used to form the heat exchanger sheet 10 provides suitable ductility to form the corrugations and also provides the required thermal conductivity. The upper region 15 of the heat exchanger foil 10 is planar. The lower region 16 of the heat exchanger foil 10 is planar. It is also shown that the transition 17 from each of the upper region 15 and the lower region 16 to the corrugations is smooth. The heat exchanger sheet 10 is 360 mm wide and 1000 mm long. The length of the corrugated area of the heat exchanger sheet 10 is 860 mm. The length of the planar area 16 is 115 mm and the length of the planar area 15 is 20 mm. As shown in fig. 1, the heat exchanger sheet 10 is elongated and its elongation axis 19, which is the direction in which the heat exchanger sheet 10 has the largest dimension, is indicated. In use, the elongate axis 19 is arranged vertically (i.e. substantially vertically). The axis of elongation 19 is also the direction along which the channel extends, and is also the direction along which fluid flows as discussed below.

The fabric is glued to one side of the heat exchanger sheet 10, as indicated by the dashed outline 12. When the material is suspended in water at its lower end, the fabric is preferably formed of a material that exhibits the following or substantially similar properties in the test for capillary wicking effect (i.e., height of water absorption):

more preferably, the fabric is formed from Coolmax-2 (above (b)) available from Invista. Line (a) above represents kraft paper and is included as a control to show the advantage of using Coolmax-2.

The fabric is preferably formed from a material that exhibits the following or substantially similar properties in the water diffusivity and evaporation rate tests: when the material is glued to the aluminium foil, water droplets are applied to the material and observed from above:

more preferably, the fabric is formed from Coolmax-2 (above (b)) available from Invista. Line (a) above represents kraft paper and is included as a control to show the advantage of using Coolmax-2. It will be appreciated that Coolmax fabric is a polyester material, Coolmax is synthetic and generally resistant to degradation, which may be referred to as a synthetic wicking fabric, such as a synthetic and wicking knitted fabric.

The operation of applying the fabric to the aluminum foil involved grinding the aluminum surface to grind it, applying specific Sikaflex-291 i marine adhesive on a rough surface, and spreading the fabric (preferably Coolmax-2 fibers) over the glued surface. The inventors have found that an excellent bonding effect is thus produced, resulting in an increased heat transfer between the dry side and the wet side of the sheet 10 and an increased water evaporation on the wet surface of the sheet 10. Such an adhesive provides suitable heat transfer between the aluminum heat exchanger sheet 10 and the fabric 12. In one arrangement for manufacturing the heat exchanger sheet 10, a hot plate (not shown) is preheated to a specified temperature and allowed to stabilize for about 30 minutes, then the heat exchanger sheet 10 is placed on the hot plate for about 5 minutes, then an adhesive is spread over the heat exchanger sheet 10, and then a fabric 12 is placed over the adhesive on top of the heat exchanger sheet 10. Pressure is then applied on top of the fabric 12 (e.g., by placing a suitably contoured block onto the fabric 12), and the hot plate is then allowed to cool until the adhesive solidifies. This manner of applying the fabric 12 to the heat exchanger sheet 10 may be referred to as a hot pressing process.

To complete the preparation of the fabric, a wetting agent (preferably a halogen polyvinyl surfactant solution, e.g., a LiCl/polyvinyl alcohol hydrophilic solution) is applied to the fabric. The inventors have found that an increased water diffusivity effect is achieved and that the surface is free of scaling, corrosion and bacterial growth over long term operation. LiCl/polyvinyl alcohol solutions are used as hydrophilic solutions (i.e., wetting agents) and also as antimicrobial agents. Alternatively, polyvinyl pyrrolidone (PVP) may be used instead of polyvinyl alcohol (PVA) wetting agent. In addition, the halogen and polyvinyl surfactant solutions may alternatively be referred to as polymeric wetting agents, which also serve as antimicrobial agents. Generally, the wetting agent/antimicrobial agent is a mixture of a salt and a wetting agent, e.g., a combination of a lithium salt and a wetting agent.

Returning to fig. 1, in each heat exchanger sheet 10, two rows of through holes 18 are provided at the upper ends of the corrugations. In one arrangement, up to four rows of vias 18 may be provided. A through hole 18 is located in one side of each raised section of each corrugation. As will be described in more detail below, during operation, inlet air is drawn into a heat exchanger apparatus comprising a stack of heat exchanger sheets 10. This air travels along the drying tunnel formed by the stack. At the end of the drying tunnel, the air is divided into two parts: one part is transported to the indoor space (room space) for space cooling, while the other part is transferred to the adjacent wet channel via the through hole 18.

Fig. 2 shows a perspective side view of the stack of heat exchanger sheets 10 shown in fig. 1, generally designated 20. In fig. 2, features common to the arrangement of fig. 1 are shown with the same reference numerals. In fig. 2, the heat exchanger foils 10 are placed next to each other such that the aluminium sides of adjacent heat exchanger foils 10 face each other and such that the fabric sides of adjacent heat exchanger foils 10 face each other. The corrugations of adjacent sheets provide vertical channels such that there are "wet channels" with a fabric side and "dry channels" with an aluminum side. In this embodiment the gap between two heat exchanger sheets 10 to form the wet or dry channel is at its maximum 5 mm. Vertical channels include trapezoidal or rhomboidal flow channels for "wet" and "dry" air. The surfaces of adjacent sheets 10 do not require support to form these trapezoidal or rhomboidal flow channels, which avoids restriction to air flow. This arrangement of adjacent sheets 10 prevents moisture transfer between adjacent channels and means that only heat transfer can occur between adjacent "wet" or "dry" air channels, which also provides for overall improved operation of the heat exchanger sheet 10.

In fig. 2, ambient inlet air (either received via an inlet air filter or a mixture of outside and inside from the room's outside or room air) is shown at 22, cooled product outlet air is shown at 24, and working air and drain water are shown at 26. Water is input at the top of each "wetted path". It will be appreciated that in view of the stack of heat exchanger sheets shown at 28, in practice the sides will be closed so that air or water does not escape. In practice, there may be as many as 100 heat exchanger sheets 10 in the stack.

It will be appreciated that the flat regions 15 and 16 of each heat exchanger foil 10 comprise an inlet region and an outlet region respectively. The above-mentioned flat portions of the heat exchanger sheet 10 permit the distribution of air and water to be prepared within the channels of the stack of heat exchanger sheets 20.

Fig. 3 is a schematic perspective view of four sheets, generally designated 30, of the apparatus 20 of fig. 2. In fig. 3, features common to the arrangement of fig. 2 are shown with the same reference numerals. In fig. 3, four heat exchanger foils 10 are shown, wherein the corrugations are omitted for clarity. The surfaces of the two heat exchanger sheets 10 having the fabric thereon are shown at 32 (i.e., the fabric 32 is on one side of each sheet 10). The aluminum surfaces of the two heat exchanger foils 10 are shown at 34 (i.e., the aluminum surface 34 is one side of each foil 10). With this arrangement, the fabric 32 of the surface of one sheet 10 faces the fabric 32 of the surface of the other sheet 10. Similarly, the aluminum surface 34 of one foil 10 faces the aluminum surface 34 of the other foil 10. A water reservoir 36 having a water level 38 is also shown. The water reservoir is filled by a water supply 40, which may be tap water. The pump 42 transfers water from the water reservoir 36 along a conduit 44 to two water transport tubes 46 at the top of the two wetting channels. The water 46 from the water duct 46 wets the fabric 32 on each heat exchanger sheet 10 and the fabric fibers with wetting agent help spread the water over the fabric 32 and enlarge the wetted area, which promotes evaporation. A valve arrangement (not shown) may be provided such that the water supply 30 is shut off when the reservoir water is at a certain level.

Ambient inlet air 22 is drawn into the drying tunnel by a fan (not shown). The incoming air then splits into two streams, with one stream 50 entering the through-hole 18 and the other exiting as cooled product outlet air 24. The flow 50 then enters two wet channels (as shown at 52) where the flow 50 causes water to evaporate from the fabric. The flow 50 also absorbs heat transported from the drying tunnel and receives moisture evaporated from the wet tunnel surface (i.e., fabric 32). It will be appreciated that the fabric 32, due to its fibers and wetting agent, promotes a high degree of evaporation. It will be appreciated that the top of each humidification chamber is closed so that air cannot escape from the top of each humidification channel and is forced downwardly, as shown at 52. The working air and drain are shown at 26. This arrangement may be referred to as a counter-flow heat exchanger, where inlet ambient air 22 passes in one direction (i.e., upward) on one side of the sheet 10, and working air and water 26 pass in the other direction (i.e., downward) on the other side of the sheet 10. It will be appreciated that the inlet ambient air 22 passes upwardly in the "dry pass" and the working air and water 26 pass downwardly in the "wet pass". With this arrangement, each of the four corrugated heat exchanger sheets 10 operates as a heat transfer plate with an increased heat transfer area. The air exhausted at 26 is hot and humid. It will be appreciated that the air 22 travels along a stacked drying tunnel where the air 22 loses heat and becomes cooler due to a temperature difference established between the dry and wet sides of the sheet 10, caused by water evaporation on the wet surface. In effect, the corrugated region provides increased heat and mass transfer area between air 22 and air 26.

The four foils 10 are only part of the heat exchanger foil 10 and the four foils of fig. 3 are small working units of the apparatus. In practice, four foil units will be repeated several times in the stack of heat exchanger foils 10. It will also be appreciated that a controller (not shown) is coupled to the water supply and configured for intermittently operating the water supply for applying water to the fabric in order to maintain the fabric in a wet condition. The controller is also configured to recirculate water from the water reservoir 36 to the heat exchanger apparatus, the reservoir 36 also being referred to as a water reservoir.

Fig. 4 is a cross-section across the heat exchanger sheet shown in fig. 1. As seen in fig. 4, the cross-section of the corrugated surface has a periodic wave-shaped profile. Such a waveform may be quasi-sinusoidal, triangular, or other waveform. Irregular or regular corrugated surfaces may be used.

The corrugated surface has a horizontal dimension W of 300-. In any case, the heat exchanger sheet 10 may have 6 mm wide side bands 59, i.e. at the edges of the sheet 10, thereby facilitating mounting/fixing of the sheets in the stack.

The corrugations are selected to have specific dimensions to promote air flow. Thus, with the periodic waveform described above, it may have a peak-to-peak distance T (i.e., wavelength) of 10-13 mm, 11-12 mm, or, in a preferred embodiment, 11.6 mm. In addition, the periodic waveform may have an amplitude 2A of 4-6 mm, 4.5-5.5 mm, or in a preferred embodiment 5 mm. Thus, in this embodiment, the corrugations are 2.5 mm deep and 5.8 mm wide from the plane of the sheet 10. The inventors have found that these sizes of corrugations result in channels that are particularly effective in increasing the efficiency of the heat exchanger. Figure 4 also shows that the corrugations intersect the plane of the heat exchanger apparatus at an angle of 50 degrees to the plane, and this angle may be between 46-54 degrees, or in a preferred embodiment between 48-52 degrees.

It will be understood from fig. 4 that the plane of the heat exchanger sheet 10 is shown at 57, and that the flat regions 15, 16 are coplanar with the plane 57. This arrangement facilitates the inlet/outlet of the water distributor and the air flow through the stack of heat exchanger sheets 10.

Fig. 5 illustrates the steps of a method, generally designated 60, according to an embodiment of the present invention. It will be appreciated that these steps may be performed in a different order, and may not necessarily be performed in the order shown in fig. 5.

Initially, at step 62, a plurality of heat exchanger sheets 10 are provided; this may involve tens or hundreds of heat exchanger foils 10. The heat exchanger sheet 10 is then formed into a stack or heat exchanger device at step 64. As part of the cooling system as described hereinabove, a water supply system (including tanks, pipes, etc.) is provided at step 66. Thereafter, the cooling system is operated at 68.

As part of the latter step, method 60 may include step 70 and/or step 72. Step 70 includes receiving water from the stack into a water reservoir and recirculating the water from the water reservoir back into the stack. The inventors have found that with such a small supply of water, water can be supplied directly from the tap, while the circulation pump needs to be activated only when the bottom tank is full. This can significantly reduce the operating time of the pump and thus minimize its power consumption.

Step 72 includes intermittently operating a water supply for applying water to the fabric. The present inventors have further found that the water supply to the wetted surface of the heat exchange sheet 10 should not be run continuously; instead, it should be run intermittently, for example, for 20 seconds during every ten minutes of operation. The method is capable of producing a saturated wetted surface over a period of operation while preventing the formation of a water film above the wetted surface, which can lead to negative effects on water evaporation.

The combination of the above features has resulted in an increase in the energy efficiency (COP) of the cooling system of about 80% to 100%, which means that the new heat exchanger device is capable of achieving about 40% to 50% savings in energy usage compared to existing best performing dew point (evaporative) cooling techniques, with the same amount of cooling output. This will contribute to global energy saving and carbon abatement goals.

The above description describes the heat exchanger sheet 10 corrugated over its upper region 14, the substantially flat lower section 16 and the section 15 above the upper region 14 which is also substantially flat. In an alternative arrangement, the heat exchanger sheet 10 may be corrugated over substantially its entire surface. It will be appreciated that the area of the corrugated regions 14 relative to the area of the heat exchanger sheet 10 or the area of the flat regions 15, 16 may depend on the configuration of the heat exchanger apparatus, and the skilled person will know the requirements for determining the area of the corrugated regions 14 and/or the flat regions 15, 16.

In the foregoing description, various sections of the heat exchanger sheet 10 are shown, for example, a section 14 with corrugations, a section 12 with weave, a flat lower section 16, and a flat upper section 15. It will be understood that the area of the sections 12, 14, 15, 16 relative to each other and/or to the area of the heat exchanger sheet 10 may depend on the configuration of the heat exchanger apparatus, and the skilled person will know the requirements for determining the area of the sections 12, 14, 15, 16. In one arrangement, the corrugated surface comprises corrugations on the first section 14 of the one surface of the heat exchanger sheet 10, and the fabric covers at least a second section 21 (see fig. 1) of the one surface such that the second section 21 overlaps at least the first section 14. It will be appreciated that the second section 21 shown in fig. 2 is for illustrative purposes only, and that the amount of overlap between the first section 14 and the second section 21 may be greater than that shown. In another arrangement, the corrugated surface comprises corrugations on a first section 14 of the one surface of the heat exchanger sheet 10 and the fabric covers at least a second section 12 of the one surface, the first section 14 being completely contained within the second section 12 (see fig. 1).