U.S. patent application number 12/221703 was filed with the patent office on 2010-02-11 for cross-counterflow heat exchanger assembly.
Invention is credited to Don C. Corser, Frederick V. Oddi, Gregory R. Smith.
Application Number | 20100031505 12/221703 |
Document ID | / |
Family ID | 41278377 |
Filed Date | 2010-02-11 |
United States Patent
Application |
20100031505 |
Kind Code |
A1 |
Oddi; Frederick V. ; et
al. |
February 11, 2010 |
Cross-counterflow heat exchanger assembly
Abstract
A manifold for use in a heat exchanger assembly and a method of
forming the manifold is disclosed herein. The method starts with
the step of separately forming a first member at least partially
defining an interior and having a spaced set of first tube slots
and a second member having a wall positioned against the first tube
slots and dividing the interior into a plurality of chambers. The
method is finalized with the step of permanently fixing the first
member to the second member to define an first manifold after the
separately forming step.
Inventors: |
Oddi; Frederick V.; (Orchard
Park, NY) ; Corser; Don C.; (Lockport, NY) ;
Smith; Gregory R.; (Lockport, NY) |
Correspondence
Address: |
Delphi Technologies, Inc.
M/C 480-410-202, PO BOX 5052
Troy
MI
48007
US
|
Family ID: |
41278377 |
Appl. No.: |
12/221703 |
Filed: |
August 6, 2008 |
Current U.S.
Class: |
29/890.03 |
Current CPC
Class: |
F28D 1/0391 20130101;
Y10T 29/4935 20150115; F28F 9/0214 20130101; F28D 1/05391 20130101;
F28F 9/0224 20130101 |
Class at
Publication: |
29/890.03 |
International
Class: |
B21D 53/02 20060101
B21D053/02 |
Claims
1. A method of forming a manifold for use in a heat exchanger
assembly including the steps of: separately forming a first member
at least partially defining an interior and having a spaced set of
first tube slots and a second member having a wall positioned
against the first tube slots and dividing the interior into a
plurality of chambers; and permanently fixing the first member to
the second member to define an first manifold after the separately
forming step.
2. The method as set forth in claim 1 wherein the forming the first
member is further defined as rolling a flat sheet of material into
a channel having a cross-section presenting a U-shape presenting a
base and arms extending forwardly to arm ends.
3. The method as set forth in claim 1 further including the step
of: forming a plurality of tubes extending between first and second
tube ends.
4. The method as set forth in claim 3 wherein the forming each tube
is further defined by rolling a flat sheet of material into a tube
defining a tube divider.
5. The method as set forth in claim 3 further including the step
of: forming a tube divider extending between the first and second
tube ends in each of the tubes to separate each tube into a first
passage and a second passage.
6. The method as set forth in claim 5 further including the step
of: inserting the first tube end of each tube into one of the first
tube slots of the first manifold and abutting the tube divider of
each tube against the wall to establish fluid communication between
the first passage of the tubes and one of the chambers of the first
manifold and to establish fluid communication between the second
passage of the tubes and the other of the chambers of the first
manifold.
7. The method as set forth in claim 6 further including the step
of: forming a second manifold having a set of spaced second tube
slots to correspond with the set up first tube slots of the first
manifold.
8. The method as set forth in claim 7 further including the step
of: inserting the second tube end of each of the tubes into the
corresponding second tube slot of the second manifold to establish
fluid communication between the first and second passages of each
tube and the second manifold.
9. The method as set forth in claim 8 further including the step
of: forming a plurality of air fins.
10. The method as set forth in claim 9 further including the step
of: inserting an air fin between adjacent tubes to dissipate heat
from the tubes.
11. An assembly manufactured according to the method of claim
1.
12. The assembly as set forth in claim 11 wherein said first member
extends longitudinally and said first tube slots are longitudinally
spaced from each other.
13. The assembly as set forth in claim 11 wherein said first member
is a channel having a cross-section defining a U-shape and
presenting arms integrally connected to a base and extending
forwardly to arm ends.
14. The assembly as set forth in claim 13 wherein said second
member includes a plate extending between said arm ends of said
channel and said wall extends transversely from said plate to said
tube slots of said channel.
15. The assembly as set forth in claim 11 further comprising: an
input disposed on one of said chambers to receive a fluid and to
define an input chamber and an output disposed on the other of said
chambers to dispense the fluid and to define an output chamber.
16. The assembly as set forth in claim 11 further comprising: a
plurality of tubes extending between first and second tube ends;
and said first tube end of each of said tubes is disposed in one of
said first tube slots of said first manifold.
17. The assembly as set forth in claim 16 wherein each of said
defines a tube divider extending between said first and second tube
to define a first passage in fluid communication with one of said
chambers of said first manifold and a second passage in fluid
communication with the other of said chambers; and said tube
divider at said first tube end abuts said wall of said second
member.
18. The assembly as set forth in claim 17 further comprising: a
second manifold extending in spaced and parallel relationship with
said first manifold and end engaging said second tube ends of said
plurality of tubes to establish fluid communication between said
first and second passages of said tubes and said second
manifold.
19. The assembly as set forth in claim 18 wherein said second
manifold defines a plurality of second tube slots spaced from each
other to correspond with said first tube slots of said first
manifold, and said second end of each of said tubes extends into
said corresponding second tube slot.
20. The assembly as set forth in claim 19 wherein each of said
tubes has a cross-section defining flat sides and round ends.
21. The assembly as set forth in claim 20 wherein said flat sides
of adjacent tubes are spaced from one another to define a plurality
of air passages for the flow of air between said adjacent
tubes.
22. The assembly as set forth in claim 21 further comprising: an
air fin disposed between and brazed to said parallel flat sides of
said tubes and extending between said first and second manifolds
for dissipating heat from said tubes.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to manifolds having multiple passages.
More specifically, the invention relates to extruded manifolds with
multiple passages and cross-counterflow heat exchangers
incorporating such manifolds.
[0003] 2. Description of the Prior Art
[0004] Air-cooling (or heating) cross-counterflow heat exchangers
are often used in applications where space limitations restrict the
surface area of the heat exchanger. Cross-counterflow heat
exchangers typically include a plurality of stacked, assembled
modules, with each module including a pair of spaced manifolds
interconnected by a plurality of spaced and parallel tubes. The
modules are stacked such that air flows in a direction
perpendicular to the face of the heat exchanger, and air fins are
disposed between adjacent pairs of tubes for transferring heat from
the tubes to the passing air.
[0005] Another type of cross-counterflow heat exchanger assembly is
shown in U.S. Pat. No. 5,941,303, issued to James D. Gowan on Aug.
24, 1998 and hereinafter referred to as Gowan '303. Gowan '303
discloses a cross-counterflow heat exchanger comprising a pair of
spaced and continually extruded manifolds. Each of the manifolds
includes an interior, and each of the manifolds includes at least
one dividing wall to divide the interior into a plurality of flow
paths. A plurality of tubes extends and establishes fluid
communication between the pair of manifolds. Each of the tubes
includes at least one tube divider to separate it into a plurality
of passages.
SUMMARY OF THE INVENTION
[0006] In summary, the invention provides a manifold for use in a
heat exchanger assembly and a method of forming the manifold. The
method starts with the step of separately forming a first member at
least partially defining an interior and having a spaced set of
first tube slots and a second member having a wall positioned
against the first tube slots and dividing the interior into a
plurality of chambers. The method is finalized with the step of
permanently fixing the first member to the second member to define
a first manifold after the separately forming step.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Advantages of the present invention will be readily
appreciated, as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0008] FIG. 1 is a perspective and exploded view of the exemplary
embodiment of the invention;
[0009] FIG. 2 is a cross-sectional view of the first and second
manifolds and the tubes taken along line 2-2 of FIG. 1;
[0010] FIG. 3 is a front view of the first member of the exemplary
embodiment of the invention;
[0011] FIG. 4 is a front view of the second member of the exemplary
embodiment of the invention; and
[0012] FIG. 5 is a cross-sectional view of one of the tubes taken
along line 5-5 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring to FIG. 1, a heat exchanger assembly 20 is
generally shown and includes a first member 22 at least partially
defining an interior. Referring to FIG. 3, in the exemplary
embodiment, the first member 22 is a channel having a cross-section
defining a U-shape and presenting arms 24 integrally connected to a
base 26 and extending forwardly to arm ends 28. Referring again to
FIG. 1, the base 26 of the first member 22 presents a plurality of
first tube slots 30 longitudinally spaced from one another. The
first tube slots 30 can be formed by conventional machining methods
including stamping, grinding, or milling.
[0014] Referring to FIG. 2, the assembly 20 includes a second
member 32 comprising a plate 34 and a wall 36 extending transversly
to the plate 34. The plate 34 extends between and engages the arm
ends 28 of the first member 22 and the wall 36 engages the base 26
of the first member 22 to divide the interior into a plurality of
chambers 38, 40. Referring again to FIG. 1, the second member 32
includes a plurality of notches being spaced to correspond with the
first tube slots 30 of the first member 22. The second member 32 is
permanently fixed to the first member 22 to define an first
manifold 42, which is generally indicated. In the exemplary
embodiment, the second member 32 is brazed to the first member 22,
but any other method of permanently fixing the first and second
members 22, 32 may also be used.
[0015] Other geometries for the first and second members 22, 32 may
be used and are meant to be included in the scope of the invention.
For example, the first member may be a flat shield presenting a
plurality of first tube slots, and the second member may include a
flat plate extending in spaced and parallel relationship with the
first member and having a plurality of arms extending transversely
therebetween to define an interior divided into a plurality of
chambers. The first member may also be cylindrically shaped and
present a unified interior defining a plurality of first tube
slots. The second member would then be inserted into the first
member to divide the unified interior into a plurality of
chambers.
[0016] The assembly 20 also includes a plurality of tubes 44
extending between first and second tube ends 46, 48. The first tube
end 46 of each tube 44 is disposed in one of the first tube slots
30 of the first manifold 42. Referring to FIG. 5, each tube 44
defines at least one tube divider 50 disposed in the tube 44 and
extending between the first and second tube ends 46, 48 to define a
first passage 52 in fluid communication with one of the chambers
38, 40 and a second passage 54 in fluid communication with the
other of the chambers 38, 40. The tube divider 50 at the first tube
end 46 abuts and is permanently fixed to the wall 36 of the second
member 32.
[0017] The assembly 20 further includes a second manifold 56
extending in spaced and parallel relationship with the first
manifold 42. The second manifold 56 presents a plurality of second
tube slots 58 spaced from each other to correspond with the spacing
of the first tube slots 30 of the first manifold 42. The second
tube end 48 of each tube 44 extends into and engages the
corresponding second tube slot 58 to establish fluid communication
between the tubes 44 and the second manifold 56. The second
manifold 56 directs the flow of coolant from one of the passages
52, 54 of the tubes 44 to the other to define a two-pass
cross-counterflow heat exchanger assembly 20.
[0018] In the exemplary embodiment, the tubes 44 and the first and
second tube slots 30, 58 each have a cross-section presenting flat
sides 60 and round ends. However, the tubes 44 may be have any
shape capable of transmitting a fluid between the first and second
manifolds 42, 56. The flat sides 60 of adjacent tubes 44 are spaced
from one another to define a plurality of air passages for the flow
of air therebetween. A corrugated air fin 62 is disposed between
and brazed to the parallel flat sides 60 of adjacent tubes 44 and
extends between the first and second manifolds 42, 56.
[0019] One of the chambers 38, 40 of the first manifold 42 includes
an input 64 to define an input chamber 38 for receiving a fluid,
and the other of the chambers 38, 40 includes an output 66 to
define an output chamber 40 for dispensing the coolant after it has
passed through the heat exchanger assembly 20. In the preferred
embodiment, the input 64 is disposed on the chamber that is
downstream of the direction of the flow of air and the output 66 is
disposed on the chamber upstream of the input chamber 38. The input
64 and output 66 may have any shape capable of delivering a fluid
to the input and output chambers 38, 40 of the first manifold
42.
[0020] The embodiment shown in the drawings is for a two-pass
counter cross-flow heat exchanger assembly. However, the manifolds
and tubes may be designed to allow for more than two passes by
inserting walls in either or both of the first and second manifolds
and including a plurality of tube dividers in each tube. For
example, in a three-pass heat exchanger assembly, the second member
has one wall to divide the first manifold into two chambers, the
second manifold has one wall, and each tube has two tube
dividers.
[0021] The invention also includes a method of forming a first
manifold 42 for use in a heat exchanger assembly 20. The method
starts with the step of separately forming a first member 22 at
least partially defining an interior and a second member 32. The
first member 22 has a spaced set of first tube slots 30 and the
second member 32 has a wall 36 that is positioned against the first
tube slots 30 to divide the interior into a plurality of chambers
38, 40. The method continues with the step of permanently fixing
the first member 22 to the second member 32 to define a first
manifold 42 after the separately forming step. The second member 32
is preferably extruded and then cut to size, but may also be formed
by other methods including casting and machining. In one
embodiment, the forming the first member 22 is further defined as
rolling a flat sheet of material into a channel having a
cross-section presenting a U-shape and having a base 26 and arms 24
extending forwardly to arm ends 28. Rolling the first member 22
from a flat sheet provides advantages because the flat sheet can be
a stock sheet of metal with a brazing material pre-disposed on
either side of it. The brazing material then may be used for the
step of permanently fixing the first member 22 to the second member
32.
[0022] The method proceeds with the step of forming a plurality of
tubes 44 extending between first and second tube ends 46, 48. The
method then continues with the step of forming a tube divider 50
extending between the first and second tube ends 46, 48 in each of
the tubes 44 to separate each tube 44 into a first passage 52 and a
second passage 54. Referring to FIG. 5, in one embodiment, the
forming each tube 44 is further defined by rolling a flat sheet of
material into a tube 44 defining a tube divider 50. Rolling each
tube 44 from a flat sheet provides advantages because the flat
sheet can be a stock sheet of metal having a pre-disposed brazing
material on either side of it. The bazing material may then later
be used for the step of fixing and sealing the tube ends 46, 48 to
the first and second tube slots 30, 58 of the manifolds 42, 56.
However, any other method of forming the tube divider 50 may also
be used.
[0023] The method continues with the step of inserting the first
tube end 46 of each tube 44 into one of the first tube slots 30 of
the first manifold 42 and abutting the divider of each tube 44
against the wall 36 of the second member 32 to establish fluid
communication between the first passage 52 of the tubes 44 and one
of the chambers 38, 40 of the first manifold 42 and to establish
fluid communication between the second passage 54 of the tubes 44
and the other of the chambers 38, 40 of the first manifold 42. The
first tube end 46 of each tube 44 is then permanently fixed to the
associated first tube slot 30 first manifold 42.
[0024] The method further continues with the step of forming a
second manifold 56 having a set of second tube slots 58 being
spaced from each other to correspond with the set of first tube
slots 30 of the first manifold 42. The method proceeds with the
step of inserting the second tube end 48 of each of the tubes 44
into the corresponding second tube slot 58 of the second manifold
56 to establish fluid communication between the first and second
passages 52, 54 of each tube 44 and the second manifold 56.
[0025] The method is finished with the steps of forming a plurality
of air fins 62 and inserting one of the air fins 62 between
adjacent tubes 44 to dissipate heat from the tubes 44. In the
exemplary embodiment, the tubes 44, manifold, and air fins 62 are
all brazed together to define a unified heat exchanger assembly
20.
[0026] The subject invention provides for a manifold and a
cross-counterflow heat exchanger assembly 20 that is both cheaper
and quicker to manufacture than those of the prior art. Many of the
traditional methods for forming the tube slots in the first
manifold of the Gowan '303 patent must be abandoned in order to
avoid interfering with the dividing wall of the first manifold. The
first tube slots of the Gowan '303 patent must be milled or
grinded, either of which is a very time consuming and costly
process. The first tube slots 30 of the present invention may be
formed in the first member 22 using a variety of manufacturing
methods including stamping before the step of permanently fixing
the first and second members 22, 32 together. This leads to
significantly greater manufacturing efficiency, thereby reducing
the cost and time to assemble the first manifold 42 and of the heat
exchanger assembly 20.
[0027] While the invention has been described with reference to an
exemplary embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *