HEAT-RECOVERING TEMPERATURE-GRADIENT BASED OVEN SYSTEM

• US 20170184345A1
• Filed: 12/16/2016
• Published: 06/29/2017
• Est. Priority Date: 12/23/2015
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Van Dyke, Christopher Gandhi, Caldwell, Turner Boris
• Granted Patent: US 10,641,552 B2
• Time in Patent Office: Days
• CPC Class Codes: F27B 2009/305 Particular conformation of the furnace
• CPC Class Codes: F27B 9/3005 arrangements for circulating gases
• CPC Class Codes: F27B 9/3044 Furnace regenerators
• CPC Class Codes: F27D 17/004 Systems for reclaiming waste heat
• CPC Class Codes: F27D 2017/007 including regenerators
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y02P 20/10 Process efficiency

Abstract

A heat-recovering oven system based on temperature gradient comprises: multiple chambers arranged in a sequence, the chambers configured for operating at various temperatures according to a temperature gradient arrangement that spans the sequence; a conveyor configured for transporting product through the multiple chambers in the sequence for heat treatment according to the temperature gradient arrangement; and multiple temperature-segregated heat exchanger systems, each heat exchanger system including a heat exchanger, a conduit to at least one of the chambers based on its temperature in the temperature gradient arrangement, and a return conduit from the at least one chamber to the heat exchanger.

Claims

1. A heat-recovering oven system based on temperature gradient, the heat-recovering oven system comprising:

multiple chambers arranged in a sequence, the multiple chambers configured for operating at various temperatures according to a temperature gradient arrangement that spans the sequence;

a conveyor configured for transporting product through the multiple chambers in the sequence for heat treatment according to the temperature gradient arrangement; and

multiple temperature-segregated heat exchanger systems, each temperature-segregated heat exchanger system including a heat exchanger, a conduit to at least one of the chambers based on its temperature in the temperature gradient arrangement, and a return conduit from the at least one of the chambers to the heat exchanger.

2. The heat-recovering oven system of claim 1, wherein the temperature gradient arrangement comprises increasing temperatures from a beginning of the sequence, and decreasing temperatures toward an end of the sequence.

3. The heat-recovering oven system of claim 1, wherein the heat-recovering oven system is open so that at least some of the temperature-segregated heat exchangers receive ambient air.

4. The heat-recovering oven system of claim 1, wherein each of the temperature-segregated heat exchanger systems is configured so that any one of the chambers whose temperature is within a temperature range predefined for that temperature-segregated heat exchanger system is assigned to a corresponding heat exchanger.

5. The heat-recovering oven system of claim 4, wherein the temperature range is evenly spaced throughout the temperature gradient arrangement.

6. The heat-recovering oven system of claim 4, wherein a higher temperature range is narrower than at least one other lower temperature range.

7. The heat-recovering oven system of claim 1, wherein each of the temperature-segregated heat exchanger systems further includes a heater in the conduit.

8. The heat-recovering oven system of claim 7, further comprising a heat pump, wherein heaters of each of the temperature-segregated exchanger systems are driven by the heat pump.

9. The heat-recovering oven system of claim 7, further comprising multiple heat pumps, wherein heaters of some of the temperature-segregated exchanger systems are driven a first heat pump and heaters of other of the temperature-segregated exchanger systems are driven by a second heat pump.

10. The heat-recovering oven system of claim 9, wherein a temperature segregation of the heaters with regard to corresponding heat pumps is different from a temperature segregation of the chambers with regard to the temperature-segregated heat exchangers.

11. The heat-recovering oven system of claim 9, wherein the multiple heat pumps are of different types depending on the temperature gradient arrangement.

12. The heat-recovering oven system of claim 1, wherein:

a first heat exchanger is included in a first temperature-segregated heat exchanger system;

a second heat exchanger is included in a second temperature-segregated exchanger system;

ambient incoming air incoming to the first heat exchanger is heated to a higher temperature than is ambient air incoming to the second heat exchanger.

13. The heat-recovering oven system of claim 1, wherein the temperature-segregated heat exchangers are of different types depending on the temperature gradient arrangement.

14. A method of recovering heat in an oven system based on temperature gradient, the method comprising:

setting up multiple chambers in a sequence according to a temperature gradient arrangement that spans the sequence, wherein a conveyor is configured for transporting product through the multiple chambers in the sequence for heat treatment according to the temperature gradient arrangement;

arranging multiple heat exchangers for the oven system; and

grouping the chambers with regard to the heat exchangers based on the temperature gradient arrangement.

15. The method of claim 14, further comprising:

setting up multiple heat pumps to drive a plurality of heaters positioned in conduits leading from the heat exchangers to the respective chambers; and

grouping the heaters with regard to the heat pumps based on the temperature gradient arrangement.

16. The method of claim 14, wherein a grouping of the heaters is different from the grouping of the chambers.

17. The method of claim 14, wherein the temperature gradient arrangement comprises increasing temperatures from a beginning of the sequence, and decreasing temperatures toward an end of the sequence.

18. The method of claim 14, further comprising operating the oven system as an open system so that at least some of the heat exchangers receive ambient air.

19. The method of claim 14, further comprising assigning heat exchangers to chambers based upon temperature ranges.

20. The method of claim 19, wherein the temperature ranges are evenly spaced throughout the temperature gradient arrangement.