Counterflow helical heat exchanger

1. A helical heat exchanger assembly, comprising:

a plurality of helical heat exchangers, each helical heat exchanger comprising a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter; a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis, the tube insert sealed within the tube by sealing an outer edge of the helix to an inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube; and a plurality of inlet and outlet fluid ports for passage of a first and second fluid into and out of the tube;

a first manifold connecting each of the first ends of the helical heat exchanger tubes, the first manifold including a fluid inlet port for passage of the first fluid into the heat exchanger assembly; and

a second manifold connecting each of the second ends of the helical heat exchanger tubes, the second manifold including a fluid inlet port for passage of the second fluid into the heat exchanger assembly,

wherein the first and second manifolds are each sealed to prevent fluid mixing inside the heat exchanger assembly.

2. The heat exchanger assembly of claim 1 wherein at least two of the plurality of helical heat exchangers are arranged in parallel.

3. The heat exchanger assembly of claim 1 wherein at least two of the plurality of helical heat exchangers are arranged in series.

4. The heat exchanger assembly of claim 1 wherein at least one of the first or second manifolds includes baffles to direct fluid flow within the manifold.

5. The heat exchanger assembly of claim 1 wherein each helix has a predetermined pitch, the pitch of the helix defining a length of the first and second fluid flow paths within each helical heat exchanger.

6. The heat exchanger assembly of claim 5 wherein the pitch of each helix is constant along the length of the tube insert.

7. The heat exchanger assembly of claim 5 wherein the pitch of at least one of the helices is not constant along the length of the tube insert.

8. The heat exchanger assembly of claim 1 wherein the first manifold further comprises a fluid outlet port for passage of the second fluid out of the heat exchanger assembly and the second manifold further comprises a fluid outlet port for passage of the first fluid out of the heat exchanger assembly, and wherein the first and second manifold inlet and outlet fluid ports are arranged for counterflow operation.

9. The heat exchanger assembly of claim 1 wherein the first and second ends of each helix sealingly contact inner surfaces of the first and second tube ends, respectively, such that the first fluid flow path is defined between a first side of the helix and the inner surface of the tube, and the second fluid flow path is defined between a second side of the helix and the inner surface of the tube.

10. The heat exchanger assembly of claim 1 wherein each pair of tube and tube insert are comprised of braze-clad aluminum and are brazed together to create fluid-tight first and second fluid flow paths within the tube.

11. The heat exchanger assembly of claim 10 wherein the tube is mechanically swaged or compressed onto the outer edge of the helix prior to brazing.

12. A method of assembling a heat exchanger, comprising the steps of:

providing a plurality of helical heat exchangers, each helical heat exchanger comprising: a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter; a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis, the tube insert sealed within the tube by sealing an outer edge of the helix to an inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube; and a plurality of inlet and outlet fluid ports for passage of a first and second fluid into and out of the tube;

providing first and second manifolds for attachment to opposing ends of the plurality of heat exchangers, at least one of the first or second manifolds comprising baffles to direct fluid flow within the manifold;

connecting each of the first ends of the helical heat exchanger tubes to the first manifold, the first manifold including a fluid inlet port for passage of the first fluid into the heat exchanger assembly;

connecting each of the second ends of the helical heat exchanger tubes to the second manifold, the second manifold including a fluid inlet port for passage of the second fluid into heat exchanger assembly; and

sealing the first and second manifolds to the first and second ends of the heat exchanger tubes, respectively, to prevent fluid mixing inside the heat exchanger assembly.

13. The method of claim 12 further including the step of:

prior to connecting opposing ends of the plurality of heat exchangers to each of the first and second manifolds, respectively, arranging at least two of the plurality of helical heat exchangers in parallel via the baffles in one or both of the first and second manifolds.

14. The method of claim 12 further including the step of:

prior to connecting opposing ends of the plurality of heat exchangers to each of the first and second manifolds, respectively, arranging at least two of the plurality of helical heat exchangers in series via the baffles in one or both of the first and second manifolds.

15. The method of claim 12 wherein each helix has a predetermined pitch, the pitch of the helix defining a length of the first and second fluid flow paths within each helical heat exchanger.

16. The method of claim 15 wherein the pitch of each helix is constant along the length of the tube insert.

17. The method of claim 15 further including the step of:

varying the pitch of at least one helix along the length of the tube insert, wherein decreasing the pitch along at least a portion of the length of the tube insert increases the length of the first and second fluid flow paths within the helical heat exchanger, and wherein increasing the pitch along at least a portion of the length of the tube insert increases the flow path area of the first and second fluids within the helical heat exchanger.

18. The method of claim 12 wherein the first manifold further comprises a fluid outlet port for passage of the second fluid out of the heat exchanger assembly and the second manifold further comprises a fluid outlet port for passage of the first fluid out of the heat exchanger assembly, and wherein the first and second manifold inlet and outlet fluid ports are arranged for counterflow operation.

19. The method of claim 12 wherein sealing each tube insert within the tube to form the helical heat exchanger comprises:

sealing the first and second ends of the tube insert to inner surfaces of the first and second tube ends, respectively, such that the first fluid flow path is defined between a first side of the helix and the inner surface of the tube, and the second fluid flow path is defined between a second side of the helix and the inner surface of the tube.

20. The method of claim 12 wherein each pair of tube and tube insert are comprised of braze-clad aluminum, and further including the step of:

brazing each helical heat exchanger in a controlled atmosphere brazing furnace to create fluid-tight first and second fluid flow paths within each tube.

21. The method of claim 20 further including mechanically swaging or compressing the tube onto the outer edge of the helix prior to brazing the heat exchanger.

22. A method of operating a heat exchanger assembly, comprising:

providing a plurality of helical heat exchangers, each helical heat exchanger comprising: a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter; a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis, the tube insert sealed within the tube by sealing an outer edge of the helix to an inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube; and a plurality of inlet and outlet fluid ports for passage of a first and second fluid into and out of the tube;

providing first and second manifolds for attachment to opposing ends of the plurality of heat exchangers, at least one of the first or second manifolds comprising baffles to direct fluid flow within the manifold;

connecting each of the first ends of the helical heat exchanger tubes to the first manifold, the first manifold including a fluid inlet port for passage of the first fluid into the heat exchanger assembly and a fluid outlet port for passage of the second fluid out of the heat exchanger assembly;

connecting each of the second ends of the helical heat exchanger tubes to the second manifold, the second manifold including a fluid inlet port for passage of the second fluid into heat exchanger assembly and a fluid outlet port for passage of the first fluid out of the heat exchanger assembly;

sealing the first and second manifolds to the first and second ends of the heat exchanger tubes, respectively, to prevent fluid mixing inside the heat exchanger assembly;

connecting inlet and outlet fluid lines for the first fluid to the first fluid inlet and outlet ports of the first and second manifolds, respectively;

connecting inlet and outlet fluid lines for the second fluid to the second fluid inlet and outlet ports of first and second manifolds, respectively; and

flowing the first and second fluids through the heat exchanger assembly to transfer heat from one fluid to the other.

23. The method of claim 22 wherein the first and second manifold inlet and outlet fluid ports are arranged for counterflow operation.

24. The method of claim 22 wherein at least two of the plurality of helical heat exchangers are arranged in parallel via the baffles in one or both of the first and second manifolds.

25. The method of claim 22 wherein at least two of the plurality of helical heat exchangers are arranged in series via the baffles in one or both of the first and second manifolds.

26. The method of claim 22 wherein each helix has a predetermined pitch defining a length of the first and second fluid flow paths within each helical heat exchanger, and further including the step of:

varying the pitch of at least one helix along the length of the tube insert, wherein decreasing the pitch along at least a portion of the length of the tube insert increases the length of the first and second fluid flow paths within the helical heat exchanger, and wherein increasing the pitch along at least a portion of the length of the tube insert increases the flow path area of the first and second fluids within the helical heat exchanger.