U.S. patent application number 12/688297 was filed with the patent office on 2011-07-21 for heat exchanger with extruded multi-chamber manifold with machined bypass.
Invention is credited to James D. Gowan, Alexander N. Kurochkin.
Application Number | 20110174472 12/688297 |
Document ID | / |
Family ID | 43875290 |
Filed Date | 2011-07-21 |
United States Patent
Application |
20110174472 |
Kind Code |
A1 |
Kurochkin; Alexander N. ; et
al. |
July 21, 2011 |
HEAT EXCHANGER WITH EXTRUDED MULTI-CHAMBER MANIFOLD WITH MACHINED
BYPASS
Abstract
The present invention heat exchanger with extruded multi-chamber
manifolds includes at least two panels, with each panel having a
row of at least one channel which communicates fluid. The heat
exchanger includes a first manifold and a second manifold, the
first manifold and the second manifold each having at least two
manifold chambers. Each panel is attached to a manifold chamber of
the first manifold and a manifold chamber of the second manifold,
with each chamber having an inner wall and outer wall. The outer
wall has a surface exposed outside the manifold chambers. There is
also an opening through the outer wall including a bypass slot. The
bypass slot allows fluid communication between the chambers.
Inventors: |
Kurochkin; Alexander N.;
(Moscow, RU) ; Gowan; James D.; (Lillian,
AL) |
Family ID: |
43875290 |
Appl. No.: |
12/688297 |
Filed: |
January 15, 2010 |
Current U.S.
Class: |
165/174 ;
29/890.03 |
Current CPC
Class: |
F28F 2250/04 20130101;
F28F 9/0214 20130101; Y10T 29/4935 20150115; F28D 1/05391
20130101 |
Class at
Publication: |
165/174 ;
29/890.03 |
International
Class: |
F28F 9/02 20060101
F28F009/02; B21D 53/02 20060101 B21D053/02; F28F 9/22 20060101
F28F009/22 |
Claims
1. A heat exchanger comprising: at least two panels, each panel
comprising at least one channel; a first manifold and a second
manifold, the first manifold and second manifold each having at
least two manifold chambers, each panel attached to a manifold
chamber of the first manifold and of the second manifold, the first
manifold chambers and second manifold chambers including an inner
wall and outer wall, the outer wall having a surface exposed
outside the manifold chambers; and an opening in the outer wall,
the opening including a bypass slot, the bypass slot allowing fluid
communication between two manifold chambers.
2. The heat exchanger of claim 1, wherein panels connected to the
first manifold and the second manifold allow fluid flow in only one
direction.
3. The heat exchanger of claim 1, wherein the opening is filled
with a bypass plug.
4. The heat exchanger of claim 3, wherein the bypass plug is sealed
to the manifold by welding.
5. An extruded multi-chamber manifold comprising: a manifold having
at least two manifold chambers, each of the at least two manifold
chambers including an inner wall and outer wall; and an opening in
the outer wall which extends to a bypass slot, the opening filled
with a plug.
6. The extruded multi-chamber manifold of claim 5, wherein the
bypass slot allows fluid communication between at least two
manifold chambers.
7. The extruded multi-chamber manifold of claim 6, wherein the
manifold includes at least three manifold chambers, with at least
one manifold chamber lacking a bypass slot.
8. A method of forming an extruded multi-chamber manifold with
internal bypass comprising: creating an extruded manifold with at
least two manifold chambers; machining at least one opening in an
outer wall and an inner wall of the manifold chambers, the opening
including a bypass slot and a seat; and inserting a plug into the
bypass slot to seal the at least two manifold chambers, the plug
located in the seat.
9. The method of claim 8, wherein the method further comprises
welding the plug.
10. The method of claim 8, wherein an additional step is included
comprising machining the seat to be wider than the bypass slot.
11. The method of claim 8, wherein the bypass slot and the seat are
machined separately.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to heat exchangers,
and more particularly, to an extruded multi-chamber manifold with a
machined bypass.
[0002] Heat exchanger manifolds must be strong enough to withstand
elevated pressures exerted by fluids flowing through the manifold
during operation. Many heat exchangers require multiple panels to
be put together to allow increased fluid flow. These panels are
aligned adjacent to each other and connect to separate chambers.
Therefore, there are situations where it is necessary for adjacent
chambers of a manifold to be in fluid communication with one
another.
[0003] A heat exchanger with a D-shaped manifold has been proposed
which has a single chamber manifold typical of that used in
automotive and commercial air conditioning applications. The heat
exchanger consists of a single row of tubes and fins stacked
together to form a panel. The panel is capped with the D-shaped
manifold on either end.
[0004] Multi-chamber manifolds can pose a problem when extruded as
the manifolds made by the extrusion process do not allow fluid
bypass. Where multi-chamber manifolds are necessary, fluid
communication between chambers typically requires an external
bypass between two or more of the above mentioned D-shaped
manifolds. This results in increasing the distance the fluid must
travel as well as increasing the pressure to unacceptable levels at
the external bypass.
[0005] When heat exchangers have multiple panels, individual
headers will not suffice. It is necessary to have a manifold which
can accommodate each panel individually, thus requiring multiple
manifolds or a multi-chamber manifold.
SUMMARY OF THE INVENTION
[0006] An example heat exchanger with extruded multi-chamber
manifolds includes at least two panels, with each panel having a
row of at least one channel which communicates fluid. The heat
exchanger includes a first manifold and a second manifold, the
first manifold and the second manifold each having at least two
manifold chambers. Each panel is attached to a manifold chamber of
the first manifold and a manifold chamber of the second manifold,
with each chamber having an inner wall and outer wall. The outer
wall has a surface exposed outside the manifold chambers. There is
also an opening through the outer wall including a bypass slot. The
bypass slot allows fluid communication between the chambers.
[0007] An example extruded multi-chamber manifold with machined
bypass includes at least two manifold chambers. Each of the at
least two manifold chambers has a panel attached to it. The
manifold chamber further includes an inner wall and outer wall. The
manifold also has at least one bypass slot. There is an opening in
the outer wall of the manifold which reaches the bypass slot and is
filled with a plug.
[0008] An example method of forming an extruded multi-chamber
manifold with internal bypass includes extruding a manifold with at
least two manifold chambers. An opening with a seat and a bypass
slot is machined in an outer wall and an inner wall of the manifold
chamber. A plug is inserted into the seat to seal the manifold
chamber.
[0009] These and other features of the present invention can be
best understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of the heat exchanger with
extruded multi-chamber manifold.
[0011] FIG. 2 is a cross-section of the extruded multi-chamber
manifold.
[0012] FIG. 3 is a top view of the extruded multi-chamber manifold
with both plugged and unplugged openings.
[0013] FIG. 4 is a sectional, top view of the extruded
multi-chamber manifold showing the machined seat and bypass
slot.
[0014] FIG. 5 is a sectional, top view of the extruded
multi-chamber manifold showing the bypass slot and a plug filling
the seat.
[0015] FIG. 6A is a front view of the heat exchanger showing a
second example of fluid movement between a first extruded manifold
and a second extruded manifold.
[0016] FIG. 6B is a front view of the heat exchanger showing a
first example of fluid movement between a first extruded manifold
and a second extruded manifold.
[0017] FIG. 7A is a step in a first example method for forming an
extruded multi-chamber manifold with machined bypass.
[0018] FIG. 7B is another step in the first example method for
forming an extruded multi-chamber manifold with machined
bypass.
[0019] FIG. 7C is another step in the first example method for
forming an extruded multi-chamber manifold with machined
bypass.
[0020] FIG. 8A is a step in a second example method for forming an
extruded multi-chamber manifold with machined bypass.
[0021] FIG. 8B is another step in the second example method for
forming an extruded multi-chamber manifold with machined
bypass.
[0022] FIG. 8C is another step in the second example method for
forming an extruded multi-chamber manifold with machined
bypass.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1, a heat exchanger system 26 includes
panels 22, a first extruded multi-chamber manifold 16, a second
extruded multi-chamber manifold 18, an inlet chamber 12, an outlet
chamber 14, and a fluid source 10. The fluid source 10 provides
fluid to the inlet chamber 12. The fluid can be, but is not limited
to, water, coolant or refrigerant. The panels 22 connect to both
the first extruded multi-chamber manifold 16 and the second
extruded multi-chamber manifold, communicating fluid between them.
Fluid can be communicated through the panels in one direction, or
single pass, or in multiple directions, or multiple pass.
[0024] Referring to FIGS. 2-5, with continuing reference to FIG. 1,
an extruded multi-chamber manifold 16 (18 will be similar) is shown
having an inner wall 40 and an exposed, outer wall 42. At least two
chambers 20 are present in the manifold 16, with an inner wall 40
separating the chambers 20. The inner wall 40 is formed through
extrusion such that there is no fluid communication between
chambers 20 without further machining. Openings 62 are machined
into the outer surface 56 of the outer wall 42 and include seats 52
and bypass slots 54. The openings 62 can be spaced a predetermined
distance apart from each other down the length of the manifold 16.
The bypass slot 54 sits inward of the seat 52 in the manifold 16.
The bypass slot 54 is machined out of the inner wall 40 and extends
to the seat 52 in the outer wall 42. The bypass slot 54 allows for
fluid communication between chambers 20 of the manifold 16. The
bypass slot 54 can be a different size than the seat 52 to allow
for various configurations of chambers 20 and necessary levels of
fluid communication. After the bypass slot 54 is created, a plug 44
is inserted into each seat 52. The plug 44 can be welded, or
otherwise secured using brazing, epoxy adhesives, or other known
means, in place to seal the opening 62. Once in the seat 52, the
plug 44 seals the chamber 20. The plug 44 can be larger than the
bypass slot. The plug 44 may create an even surface with the outer
wall 42. Alternatively, the plug 44 may sit above or below the
outer wall 42, creating an uneven surface. FIGS. 3-5 show one
configuration of the seats 52, bypass slots 54, and plugs 44. Other
configurations are also possible.
[0025] Referring to FIGS. 6A and 6B, fluid flow between the
extruded multi-chamber manifolds 16,18 is shown. FIG. 6A shows a
single pass configuration, where fluid flows within the panels 22
in one direction, from the second extruded multi-chamber manifold
18 to the first extruded multi-chamber manifold 16. Fluid can be
communicated between the chambers 20 of each manifold through the
bypass slots 54. FIG. 6B shows a multi-pass configuration where
fluid flows within the panels 22 in multiple directions and is able
to communicate between chambers 20 through bypass slots 54. These
embodiments show manifolds 16 having three chambers 20 with slots
found as above.
[0026] Referring to FIG. 7A, a method of creating an extruded
multi-chamber manifold 16 with internal bypass is shown. An
extruded multi-chamber manifold 16 with chambers 20 is created with
a solid, inner wall 40. Referring to FIG. 7B, an opening 62
including a bypass slot 54 and seat 52 is cut out of the inner wall
40 by machining through the outer wall 42 and into the inner wall
40 using a cutting tool 80. The seat 52 can be machined again to be
a different size than the bypass slot 54. Referring to FIG. 7C, a
plug 44 is then inserted into the opening 62 to seal the manifold
chambers 20. The plug 44 can be welded, or attached by other means,
after insertion.
[0027] Alternatively, referring to FIG. 8A, the method of creating
an extruded multi-chamber manifold 16,18 with internal bypass is
shown. An extruded multi-chamber manifold 16,18 with chambers 20 is
created with a solid, inner wall 40. An opening 62 including is
machined into outer wall 42 using a cutting tool 80. The machined
opening 62 first includes a seat 52. Referring to FIG. 8B, a bypass
slot 54 is cut out of the inner wall 40 by machining into the inner
wall 40 inside each seat 52 using a cutting tool 80. The bypass
slot 54 extends to the seat 52. The bypass slot 54 can be a
different size than the seat 52. Referring to FIG. 8C, a plug 44 is
then inserted into the seat 52 to seal the manifold chambers 20.
The plug 44 can be welded into place after insertion.
[0028] Although a preferred embodiment of this invention has been
disclosed, a worker of ordinary skill in this art would recognize
that certain modifications would come within the scope of this
invention. For that reason, the following claims should be studied
to determine the true scope and content of this invention.
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