U.S. patent application number 15/923604 was filed with the patent office on 2019-09-19 for integral heat exchanger core reinforcement.
The applicant listed for this patent is Hamilton Sundstrand Corporation. Invention is credited to Ryan Matthew Kelley, Gabriel Ruiz, James Streeter, Michael Zager.
Application Number | 20190285363 15/923604 |
Document ID | / |
Family ID | 65818244 |
Filed Date | 2019-09-19 |
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United States Patent
Application |
20190285363 |
Kind Code |
A1 |
Ruiz; Gabriel ; et
al. |
September 19, 2019 |
INTEGRAL HEAT EXCHANGER CORE REINFORCEMENT
Abstract
An embodiment of a heat exchanger core includes a plurality of
walls defining a plurality of layers in at least one heat exchange
relationship. At least one of the layers of the core having a first
load-bearing portion aligned with and adjacent to a first mount
location on a perimeter of the core, and a first non-load-bearing
portion distal from the non-load-bearing portion. A topology of the
first load-bearing portion has a load bearing capacity greater than
a load bearing capacity of the non-load-bearing portion.
Inventors: |
Ruiz; Gabriel; (Granby,
CT) ; Streeter; James; (Torrington, CT) ;
Kelley; Ryan Matthew; (Bloomfield, CT) ; Zager;
Michael; (Windsor, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hamilton Sundstrand Corporation |
Charlotte |
NC |
US |
|
|
Family ID: |
65818244 |
Appl. No.: |
15/923604 |
Filed: |
March 16, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28F 3/025 20130101;
F28F 2260/02 20130101; B33Y 80/00 20141201; F28D 2021/0021
20130101; F28F 9/0075 20130101; B33Y 10/00 20141201; B23P 15/26
20130101; F28D 9/0062 20130101; F28F 2225/04 20130101 |
International
Class: |
F28F 9/007 20060101
F28F009/007; F28F 3/02 20060101 F28F003/02; F28D 9/00 20060101
F28D009/00 |
Claims
1. A heat exchanger core comprising: a plurality of walls defining
a plurality of layers in at least one heat exchange relationship,
at least one of the layers of the core having a first load-bearing
portion aligned with and adjacent to a first mount location on a
perimeter of the core, and a first non-load-bearing portion distal
from the non-load-bearing portion; wherein a topology of the first
load-bearing portion has a load bearing capacity greater than a
load bearing capacity of the non-load-bearing portion.
2. The core of claim 1, wherein the heat exchanger comprises a
plate-and-fin heat exchanger or a micro-channel heat exchanger.
3. The core of claim 2, wherein the heat exchanger includes a
plurality of corrugated fins.
4. The core of claim 3, wherein a pitch of the plurality of
corrugated fins in the first load-bearing portion is less than a
pitch of the plurality of corrugated fins in the same layer in the
non-load-bearing portion.
5. The core of claim 3, wherein a thickness of the plurality of
corrugated fins in the first load-bearing portion is greater than a
thickness of the plurality of corrugated fins in the same layer in
the non-load-bearing portion.
6. The core of claim 3, wherein a thickness of a plurality of
plates separating the plurality of corrugated fins in the first
load-bearing portion is greater than a thickness of the plurality
of plates in the same layer in the non-load-bearing portion.
7. The core of claim 1, wherein the at least one of the layers of
the core also includes a transition region between the load-bearing
portion and the non-load-bearing portion.
8. The core of claim 1, wherein a mount portion of the core is
integrally formed with at least one of a mount pad and an end plate
of the heat exchanger core.
9. A heat exchanger assembly comprising: a mount for supporting a
heat exchanger in a system; and a heat exchanger core comprising: a
plurality of walls defining a plurality of layers in at least one
heat exchange relationship, at least one of the layers of the core
having a first load-bearing portion aligned with and adjacent to a
first mount location on a perimeter of the core, and a first
non-load-bearing portion distal from the non-load-bearing portion;
wherein a topology of the first load-bearing portion has a load
bearing capacity greater than load bearing capacity of the
non-load-bearing portion.
10. The assembly of claim 9, wherein the heat exchanger assembly is
a plate-and-fin heat exchanger or a micro-channel heat
exchanger.
11. The assembly of claim 10, wherein the plate-and-fin heat
exchanger includes a plurality of fins, and wherein a pitch of the
plurality of fins in the first load-bearing portion of a first
layer is less than a pitch of the plurality of fins in the
non-load-bearing portion of the same first layer.
12. The assembly of claim 10, wherein the plate-and-fin heat
exchanger includes a plurality of fins, and wherein a thickness of
the plurality of fins in the first load-bearing portion of a first
layer is greater than a thickness of the plurality of fins in the
non-load-bearing portion of the same first layer.
13. The assembly of claim 10, wherein a thickness of a plurality of
plates separating a plurality of fins in the first load-bearing
portion is greater than a thickness of the plurality of plates in
the same layer in the non-load-bearing portion.
14. The assembly of claim 9, wherein the heat exchanger is a
shell-and-tube heat exchanger.
15. The assembly of claim 14, wherein the mount includes at least
one clevis leg or bar integrally supporting at least one tube of
the shell-and-tube heat exchanger.
16. A method of making a heat exchanger, the method comprising:
forming a housing for a heat exchanger core; forming a first mount
portion; additively manufacturing the heat exchanger core, the step
comprising: forming a first load-bearing region in connection with
the joint/mount; and forming a first non-load bearing region
outward of the non-load bearing region.
17. The method of claim 16, wherein the core includes a different
topology in the first load-bearing region than in the first
non-load-bearing region.
18. The method of claim 16, wherein the first load-bearing region
is aligned with the at least one integrally formed joint such that
a load path includes both the first load-bearing region and the at
least one integrally formed joint.
19. The method of claim 16, further comprising: forming a mount for
a heat exchanger assembly; and integrally forming the mount with at
least one core wall or at least one manifold wall of the heat
exchanger assembly via one or more of a casting process or an
additive manufacturing process.
20. The method of claim 19, wherein the mount is integrally formed
with at least one of a mount pad and an end plate of the heat
exchanger core.
Description
BACKGROUND
[0001] The disclosure is directed generally to heat exchangers, and
more specifically to cores and mounts for heat exchangers.
[0002] Mounts are used to connect the heat exchanger to other
components or the aircraft directly. There are loads applied from
the connecting body to the heat exchanger creating a stress at the
connection between the mount pad and the core. Typically, the mount
is brazed and/or welded to the core and the load is transmitted
through the joint and internal core components, at roughly a
45.degree. angle outward from the joint.
SUMMARY
[0003] An embodiment of a heat exchanger core includes a plurality
of walls defining a plurality of layers in at least one heat
exchange relationship. At least one of the layers of the core
having a first load-bearing portion aligned with and adjacent to a
first mount location on a perimeter of the core, and a first
non-load-bearing portion distal from the non-load-bearing portion.
A topology of the first load-bearing portion has a load bearing
capacity greater than load bearing capacity of the non-load-bearing
portion.
[0004] An embodiment of a heat exchanger assembly includes a mount
for supporting a heat exchanger in a system and a heat exchanger
core. The heat exchanger core includes a plurality of walls
defining a plurality of layers in at least one heat exchange
relationship. At least one of the layers of the core has a first
load-bearing portion aligned with and adjacent to a first mount
location on a perimeter of the core, and a first non-load-bearing
portion distal from the non-load-bearing portion. A topology of the
first load-bearing portion has a load bearing capacity greater than
a load bearing capacity of the non-load-bearing portion.
[0005] An embodiment of a method of making a heat exchanger
includes forming a housing for a heat exchanger core and additively
manufacturing a heat exchanger core. The housing including a first
mount portion. Additively manufacturing the heat exchanger core
includes forming a first load-bearing region in connection with the
joint/mount, and forming a first non-load bearing region outward of
the non-load bearing region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 includes multiple views of an example heat
exchanger.
[0007] FIG. 2A shows a conventional core geometry of a
plate-and-fin heat exchanger.
[0008] FIG. 2B is a magnified view of a portion of FIG. 2A.
[0009] FIG. 3A shows an updated example core geometry for a
plate-and-fin heat exchanger according to the disclosure.
[0010] FIG. 3B is a magnified view of a portion of FIG. 3A.
[0011] FIG. 4 is a conventional mounting arrangement for a
shell-and-tube core of a heat exchanger.
[0012] FIG. 5 shows an example mounting arrangement for a core of a
shell-and-tube heat exchanger according to the disclosure.
[0013] FIG. 6 shows a strengthened core topology and mounting
arrangement for a second heat exchanger embodiment.
[0014] FIGS. 7A and 7B depict a third heat exchanger embodiment
with mounts integrally formed with one or more manifolds.
DETAILED DESCRIPTION
[0015] Integrally building a mount with the core using additive
manufacturing or castings, removes the need to braze, machine,
and/or weld the mount to a pad. This can increase the effective
contact area between the mount and the core, allowing the load to
be distributed better through the core components. Additionally,
the structure can be optimized for weight without having to
maintain unnecessary material needed to connect the mount to the
heat exchanger. Assembly weight, installation time, installation
space, and component count may all be reduced.
[0016] FIG. 1 shows an example heat exchanger assembly 10, with
first and second views 10-1 and 10-2. At its most basic, assembly
10 includes core 12 and one or more manifolds 14A, 14B, 14C meeting
at respective manifold/core interfaces 16A, 16B, 16C. First
manifold 14A and second manifold 14B are connected to and in fluid
communication with core 12 at respective first and second
manifold/core interfaces 16A, 16B. Core 12 generally receives and
places a plurality of mediums (here 20, 22) in at least one heat
exchange relationship with one another. As is generally known in
the art, core 12 can include structures, walls, tubes, etc. to
facilitate a cross-flow, counter-flow, micro-channel, or other
hybrid heat exchange relationship. In this particular non-limiting
example, heat exchanger assembly 10 can include a plate-and-fin
heat exchanger or any other type of heat exchanger that, generally,
consists of alternating layers (e.g., micro-channel heat
exchangers). Assembly 10 can also include one or more mount areas
(not shown in FIG. 1) for supporting heat exchanger assembly 10 in
a larger system.
[0017] One or more manifolds (here, first manifold 14A) include a
first end 26A distal from core 12 with at least one port 24A
adapted to receive (or discharge) a first medium of the plurality
of mediums (e.g., medium 20 or 22). Second end 28A of first
manifold 14A is joined to core 12 at first manifold/core interface
16A, and is adapted to transfer first medium 20 or second medium
22, either to or from a plurality of first heat exchange passages
in core 12. Similarly, second manifold 14B includes a first end 26B
and a second end 28B, the first end distal from core 12 with at
least one port 24B adapted to discharge (or receive) the first
medium 20. Second end 28B of second manifold 14B is joined to core
12 at second manifold/core interface 16B, and is adapted to
transfer first medium 20 either to or from a plurality of first
heat exchange passages in core 12.
[0018] Third manifold 14C includes first end 26C and second end 28C
for medium 22 to exit core 12 via port 24C. Thus, via manifolds
14A, 14B, 14C, core 12 receives first medium 20 flowing in first
direction X and second medium 22 of the plurality of mediums
flowing in second direction Y at a zero or nonzero angle relative
to first direction X. These directions may vary from layer to layer
within the core, for example in a counterflow heat exchanger core,
versus the cross-flow arrangement shown in FIG. 1.
[0019] FIGS. 2A and 2B show a conventional geometry for a
plate-and-fin heat exchanger core 12'. Specifically, core 12'
includes walls defining a topology of alternating flow layers 30',
32' respectively for first medium 20 and second medium 22. Between
upper and lower end plates 34', parting plates 36' separate and
define alternating flow layers 30', 32'. In this example, first
fins 38' provide additional heat transfer area for first medium 20
in first flow layers 30'. Optionally, second fins (omitted for
clarity) can be provided in second flow layers 32' for providing
additional heat transfer area for second medium 22.
[0020] In a mount arrangement for a conventional heat exchanger
core, such as is shown in FIGS. 2A and 2B, certain parts of core
12', particularly load-bearing portion or portions of layers
immediately adjacent to the mount location or joint bear a
disproportionate amount of the weight, vibrational, and other loads
as compared to other parts more distal from the load-bearing
portion. This has traditionally been dealt with, due to
manufacturability and cost concerns, by uniformly using thicker
plate or fin material throughout individual layers in order to
absorb and transmit the loads as shown, while preventing damage to
the unit.
[0021] As can be seen in FIGS. 2A and 2B, each layer 30' of
conventional core 12' has generally uniform topology though
adjacent layers 30' likely differ. Each individual parting plate
36' has a uniform plate thickness T' across an individual heat
transfer layer 30', while each fin 38' has substantially uniform
fin thickness F' and pitch P' (e.g., spacing between corrugations)
across an individual heat transfer layer 30'. Thus conventionally,
plates 36' closer to the mount location(s) 18' and/or joint(s) 19'
may have a greater thickness than those below. Similarly,
conventional fins 38' in layers close to mount location(s) 18'
and/or joint(s) 19' may have a greater fin thickness F' and/or
lesser pitch P' (corrugations closer together) than those fins 38'
in layers below (i.e., distal from) mount location(s) 18'. But
again, thickness and pitch are conventionally uniform across each
individual layer.
[0022] Conventional layer strengthening thus includes areas of the
core outside of the parts nearest to the mount area and thus most
responsible for load bearing. These regions are identified outside
of dashed line 40' representing approximately a perimeter of the
expected or actual load path. In conventional welded mounts 18' and
joints 19', the load path extends approximately 45.degree. outward
through core 12', but the angle and exact path may vary depending
on the types and numbers of attachment points. Regardless of the
particular load path 40', arrangements like those in FIGS. 2A and
2B unnecessarily add weight, reduce available volume for throughput
of the mediums, and can impede conduction of thermal energy through
the heat transfer surfaces because non-load-bearing areas of the
core are unnecessarily oversized.
[0023] FIGS. 3A and 3B show an updated example core 112 which, like
conventional core 12' in FIGS. 2A and 2B, includes a plurality of
walls defining a plurality of alternating layers for placing first
and second mediums 120, 122 in at least one heat exchange
relationship. FIGS. 3A and 3B show first layers 130A, 130B, 130C
and second layers 132A, 132B of core 112, along with load path 140.
Each of first layers 130A, 130B, 130C has at least one
corresponding load-bearing portion 144A, 144B, 144C aligned with,
and adjacent to, at least a first mount location 118 and/or joint
119 on a perimeter 142 of core 112. Perimeter can be defined by,
for example, closure bars or end plates 134. One or more
non-load-bearing portions 146A, 146B, 146C of each layer 130A,
130B, 130C can be located distal from load-bearing portion(s) 144A,
144B, 144C. Load-bearing portions of second layers 132A, 132B can
also be strengthened in a similar manner, but these are omitted for
clarity.
[0024] To optimize aspects of the core design with minimal weight
addition and flow disruption, a topology of the first load-bearing
portion 144A has an overall load bearing capacity greater than a
load bearing capacity of the non-load-bearing portion 146A in the
same layer 130A. That is, at least one layer 130A of core 112 is
locally strengthened by varying one or more aspects of the walls
(e.g., plates, fins, tubes, etc.) defining the passages in the
load-bearing portion. To save weight and material costs, parts of
the layer remain sufficiently thin and/or well-spaced to manage
desired medium flows. For illustrative purposes, first layers 130A,
130B, 130C shows one or more variation or adaptation in the
respective load bearing portion 144A, 144B, 144C; however, it will
be recognized that multiple aspects can be modified in each
load-bearing portion(s) of one or more layers. In layer 130C, for
example, a pitch P.sub.2 of the plurality of corrugated fins 138 in
load-bearing portion 144C is greater than a pitch P.sub.1 of the
plurality of corrugated fins 138 in the same layer (130C) in the
non-load-bearing portion 146C. That is, the sheet(s) forming the
fins in layer 130C are further compressed in load-bearing portion
144C so that each wall or fin is closer to an adjacent one as
compared to the spacing in non-load-bearing portion 146C. This can
reduce available flow area locally, but by maintaining or even
expanding pitch in non-load-bearing portion 146C, overall heat
transfer and/or pressure drop can be substantially maintained
relative to conventional designs.
[0025] In first layers 130A, 130B, for medium 120, a fin thickness
F.sub.1 of the plurality of fins 138 in load-bearing portions 144A,
144B is greater than a fin thickness F.sub.2 of the plurality of
corrugated fins 138 in the same layer (here 130A, 130B) in the
respective non-load-bearing portions 146A, 146B. The locally
thicker material in the load-bearing portion again can absorb and
transmit forces, while allowing for thinner fin material elsewhere.
This again may reduce local flow to a lesser degree as compared to
a conventional approach
[0026] In addition to the fins, dimensions or other aspects of
parting plates can also be varied in the load-bearing portion(s) to
improve strength versus the corresponding non-load-bearing portion.
Here, in FIGS. 3A and 3B a thickness T.sub.1 of one or more parting
plates 136 separating the plurality of corrugated fins in the first
load-bearing portion 144B is less than a thickness T.sub.2 of the
plurality of parting plates in the same layer in non-load-bearing
portion 146B.
[0027] It will be recognized that load path 140, is merely
illustrated for simplicity as a dashed line, but should not be read
as a precise stepwise difference between the load-bearing and
non-load-bearing portions in all cases. Rather, depending on the
precise construction of the unit, the mount, and the loads applied
thereto, there is somewhat of a gradual transition region on either
side of dashed line 140 (and other load paths described herein).
The dashed line(s) are therefore merely intended to represent an
approximate midpoint of this transition region in order to more
clearly and simply delineate the load-bearing and non-load-bearing
portions without adding clutter to the figures.
[0028] Additionally or alternatively, a mount portion of the core
is integrally formed with at least one of a mount pad and an end
plate of the heat exchanger core. FIG. 4 shows a heat exchanger and
accompanying mount arrangement, while FIG. 5 shows the mount
includes at least one mount arm integrally supporting at least one
element, a tube in this case, of the heat exchanger core.
Additional embodiments show the heat exchanger assembly supportable
by several mounts integrally formed with one or more manifolds.
[0029] Beginning with FIG. 4, a conventional mounted heat exchanger
assembly 210 includes core 212, mount bar 215, mount pad 217, mount
location 218 on core 212, and joint(s) 219. Conventionally, mount
pad 217 is attached to core 212 at mount location 218, in
particular to multiple tubes 225 in a shell-and-tube arrangement
shown herein. Mount pad 217 can be conventionally formed, for
example, by machining, extrusion, and/or casting. Subsequently,
mount bar 215 is welded, brazed, or otherwise metallurgically
joined around joint 219 near a perimeter of mount pad 217, securing
core 212 to one or more support structures (via mount bar 215). In
this arrangement, loads from the aircraft or other mounting support
structures (not shown) create high stress loads at connections 221
between mount pad 217 and tubes 225 in core 212.
[0030] In contrast, FIG. 5 includes assembly 310 with core 312
directly metallurgically joined to the mount by at least one joint
319, with core 312 adapted for receiving and placing a plurality of
mediums in at least one heat exchange relationship. Joint 319
includes at least one passage wall (e.g., walls of at least one
tube 325) integrally formed with mount bar 315 at mount location
318. As in FIG. 4, the heat exchanger comprises a shell-and-tube
heat exchanger or a micro-channel heat exchanger.
[0031] Mount 321 includes at least one clevis leg or bar 323
integrally formed with and supported by at least one tube 325 of
heat exchanger core 312. This allows for a substantially uniform
connection between mount bar 315 and core 312, rather than merely
about edges of mount pad 217 in FIG. 4.
[0032] FIG. 6 shows an alternate embodiment of heat exchanger
assembly 410 for an example shell-and-tube heat exchanger core 412.
Core 412, adapted for receiving and placing a plurality of mediums
in at least one heat exchange relationship, includes one or more
tubes 425 directly metallurgically joined around mount location 421
by at least one joint such as clevis leg or bar 423. Joint 419
includes at least one passage wall (e.g., walls of at least one
tube 425) integrally formed with a mount bar (not shown in FIG. 6)
at mount location (s) 418.
[0033] Mount 421 includes at least one branch 423 integrally
supporting at least one tube 425 of shell-and-tube heat exchanger
core 412. Mount 421 is also integrally formed with at least one of
a mount pad and an end plate (not shown) of heat exchanger core
412. This allows for a substantially uniform connection between
mount bar 415 and core 412, rather than merely about edges of mount
pad (e.g., 217 in FIG. 4).
[0034] Core 412 also includes first load-bearing region 444 in
connection with the joint/mount and a first non-load bearing region
446 outward of the non-load bearing region. As in FIGS. 3A and 3B,
the heat exchanger core includes a different (stronger) topology in
at least one load-bearing region (444) versus than in a
corresponding at least one non-load-bearing region 446 in the same
layer.
[0035] In this example, first load-bearing region 444 can be
aligned with the at least one integrally formed joint 419 such that
load path 440 includes both first load-bearing region 444 and the
at least one integrally formed joint 419. Here, that includes
thicker walled tubes 425 in load-bearing region 444 as compared to
those outside (in the non-load-bearing region 446).
[0036] Embodiments of heat exchangers described herein can leverage
additive manufacturing or any other manufacturing method or methods
(e.g., casting) that allows one to construct continuous,
homogeneous transitions between one or more mounts and the core,
the manifold, or other assembly components. Continuous, homogeneous
transitions between elements within the core can closely tailor
load bearing capacity. Additive manufacturing is also useful in
reducing mass and/or weight of different elements of the assembly,
as well as reducing the number of details and associated assembly
time. Further, additive manufacturing allows the mount to be
optimized with less constraint on how to connect the mount to the
heat exchanger core. The entire connection between the mount and
heat exchanger is made by metallurgical bond instead of just welded
edges as in the conventional approaches. The need for brazing the
mount to achieve a uniform load distribution is eliminated, as is a
more complicated brazing fixture that is typically required for
brazed mounts. Quality of the resulting assembly is improved
because full (or even 80%) braze joint coverage and/or full
penetration welds are not consistently achievable, resulting in
rejection of some parts when manufactured by brazing and/or
welding. With additive manufacturing, material strength is not
degraded as a result of welding and brazing, and the result is
well-controlled joint topology.
[0037] FIGS. 7A and 7B show two different perspective views of an
alternate embodiment of heat exchanger assembly 510. Manifolds
514A, 514B, 514C meet core 512 at corresponding interfaces 516A,
516B, 516C. Assembly 510 has several mount locations 518 formed
integrally with at least one manifold (here manifolds 514A, 514B).
Like other embodiments, core 512 places first and second mediums
520, 522 in at least one heat exchange relationship.
[0038] With that, a method of making a heat exchanger includes
forming a housing for a heat exchanger core and additively
manufacturing the heat exchanger core. This can be done, for
example, by forming a first load-bearing region in connection with
the joint and/or mount, and forming a first non-load bearing region
outward of the non-load bearing region. In certain embodiments, the
core includes a different topology in the first load-bearing region
than in the first non-load-bearing region. In certain of these
embodiments, the core is formed such that the first load-bearing
region is aligned with the at least one integrally formed joint
such that a load path includes both the first load-bearing region
and the at least one integrally formed joint.
[0039] In certain embodiments, the mount is formed with at least
one core wall (e.g. one or more tube walls of a shell-and-tube heat
exchanger assembly) via one or more of a casting process or an
additive manufacturing process. In certain of these embodiments,
the mount is integrally formed with at least one of a mount pad and
an end plate of the heat exchanger core.
[0040] In each example, the important manufacturing aspect includes
integrally forming parts to have the desired local impact. For
example, one can integrally form the mount with at least one core
wall of the heat exchanger assembly via one or more of a casting
process or an additive manufacturing process. The mount includes at
least one clevis integrally supporting at least one tube of the
shell-and-tube heat exchanger. The mount can be integrally formed
with at least one of a mount pad and an end plate of the heat
exchanger core. The core can be formed with a first load-bearing
region in connection with the joint/mount and a first non-load
bearing region outward of the non-load bearing region. The core
includes a different topology in the first load-bearing region than
in the first non-load-bearing region. The first load-bearing region
is aligned with the at least one integrally formed joint such that
a load path includes both the first load-bearing region and the at
least one integrally formed joint.
DISCUSSION OF POSSIBLE EMBODIMENTS
[0041] The following are non-exclusive descriptions of possible
embodiments of the present invention.
[0042] An embodiment of a heat exchanger core includes a plurality
of walls defining a plurality of layers in at least one heat
exchange relationship. At least one of the layers of the core
having a first load-bearing portion aligned with and adjacent to a
first mount location on a perimeter of the core, and a first
non-load-bearing portion distal from the non-load-bearing portion.
A topology of the first load-bearing portion has a load bearing
capacity greater than load bearing capacity of the non-load-bearing
portion.
[0043] The heat exchanger core of the preceding paragraph can
optionally include, additionally and/or alternatively, any one or
more of the following features, configurations and/or additional
components:
[0044] A heat exchanger core according to an exemplary embodiment
of this disclosure, among other possible things includes a
plurality of walls defining a plurality of layers in at least one
heat exchange relationship, at least one of the layers of the core
having a first load-bearing portion aligned with and adjacent to a
first mount location on a perimeter of the core, and a first
non-load-bearing portion distal from the non-load-bearing portion;
wherein a topology of the first load-bearing portion has a load
bearing capacity greater than a load bearing capacity of the
non-load-bearing portion.
[0045] A further embodiment of the foregoing heat exchanger core,
wherein the heat exchanger comprises a plate-and-fin heat exchanger
or a micro-channel heat exchanger.
[0046] A further embodiment of any of the foregoing heat exchanger
cores, wherein the heat exchanger includes a plurality of
corrugated fins.
[0047] A further embodiment of any of the foregoing heat exchanger
cores, wherein a pitch of the plurality of corrugated fins in the
first load-bearing portion is less than a pitch of the plurality of
corrugated fins in the same layer in the non-load-bearing
portion.
[0048] A further embodiment of any of the foregoing heat exchanger
cores, wherein a thickness of the plurality of corrugated fins in
the first load-bearing portion is greater than a thickness of the
plurality of corrugated fins in the same layer in the
non-load-bearing portion.
[0049] A further embodiment of any of the foregoing heat exchanger
cores, wherein a thickness of a plurality of plates separating the
plurality of corrugated fins in the first load-bearing portion is
greater than a thickness of the plurality of plates in the same
layer in the non-load-bearing portion.
[0050] A further embodiment of any of the foregoing heat exchanger
cores, the at least one of the layers of the core also includes a
transition region between the load-bearing portion and the
non-load-bearing portion.
[0051] A further embodiment of any of the foregoing heat exchanger
cores, wherein a mount portion of the core is integrally formed
with at least one of a mount pad and an end plate of the heat
exchanger core.
[0052] An embodiment of a heat exchanger assembly includes a mount
for supporting a heat exchanger in a system and a heat exchanger
core. The heat exchanger core includes a plurality of walls
defining a plurality of layers in at least one heat exchange
relationship. At least one of the layers of the core has a first
load-bearing portion aligned with and adjacent to a first mount
location on a perimeter of the core, and a first non-load-bearing
portion distal from the non-load-bearing portion. A topology of the
first load-bearing portion has a load bearing capacity greater than
a load bearing capacity of the non-load-bearing portion.
[0053] The heat exchanger assembly of the preceding paragraph can
optionally include, additionally and/or alternatively, any one or
more of the following features, configurations and/or additional
components:
[0054] A heat exchanger assembly according to an exemplary
embodiment of this disclosure, among other possible things includes
a mount for supporting a heat exchanger in a system; and a heat
exchanger core comprising: a plurality of walls defining a
plurality of layers in at least one heat exchange relationship, at
least one of the layers of the core having a first load-bearing
portion aligned with and adjacent to a first mount location on a
perimeter of the core, and a first non-load-bearing portion distal
from the non-load-bearing portion; wherein a topology of the first
load-bearing portion has a load bearing capacity greater than load
bearing capacity of the non-load-bearing portion.
[0055] A further embodiment of the foregoing heat exchanger
assembly, wherein the heat exchanger assembly is a plate-and-fin
heat exchanger or a micro-channel heat exchanger.
[0056] A further embodiment of any of the foregoing heat exchanger
assemblies, wherein the plate-and-fin heat exchanger includes a
plurality of fins, and wherein a pitch of the plurality of fins in
the first load-bearing portion of a first layer is less than a
pitch of the plurality of fins in the non-load-bearing portion of
the same first layer.
[0057] A further embodiment of any of the foregoing heat exchanger
assemblies, wherein the plate-and-fin heat exchanger includes a
plurality of fins, and wherein a thickness of the plurality of fins
in the first load-bearing portion of a first layer is greater than
a thickness of the plurality of fins in the non-load-bearing
portion of the same first layer.
[0058] A further embodiment of any of the foregoing heat exchanger
assemblies, wherein a thickness of a plurality of plates separating
a plurality of fins in the first load-bearing portion is greater
than a thickness of the plurality of plates in the same layer in
the non-load-bearing portion.
[0059] A further embodiment of any of the foregoing heat exchanger
assemblies, wherein the heat exchanger is a shell-and-tube heat
exchanger.
[0060] A further embodiment of any of the foregoing heat exchanger
assemblies, wherein the mount includes at least one clevis leg or
bar integrally supporting at least one tube of the shell-and-tube
heat exchanger.
[0061] An embodiment of a method of making a heat exchanger
includes forming a housing for a heat exchanger core and additively
manufacturing a heat exchanger core. The housing including a first
mount portion. Additively manufacturing the heat exchanger core
includes forming a first load-bearing region in connection with the
joint/mount, and forming a first non-load bearing region outward of
the non-load bearing region.
[0062] The method of the preceding paragraph can optionally
include, additionally and/or alternatively, any one or more of the
following steps, features, configurations and/or additional
components:
[0063] A method according to an exemplary embodiment of this
disclosure, among other possible things includes forming a housing
for a heat exchanger core; forming a first mount portion;
additively manufacturing the heat exchanger core, the step
comprising: forming a first load-bearing region in connection with
the joint/mount; and forming a first non-load bearing region
outward of the non-load bearing region.
[0064] A further embodiment of the foregoing method, wherein the
core includes a different topology in the first load-bearing region
than in the first non-load-bearing region.
[0065] A further embodiment of any of the foregoing methods,
wherein the first load-bearing region is aligned with the at least
one integrally formed joint such that a load path includes both the
first load-bearing region and the at least one integrally formed
joint.
[0066] A further embodiment of any of the foregoing methods,
further comprising: forming a mount for a heat exchanger assembly;
and integrally forming the mount with at least one core wall or at
least one manifold wall of the heat exchanger assembly via one or
more of a casting process or an additive manufacturing process.
[0067] A further embodiment of any of the foregoing methods,
wherein the mount is integrally formed with at least one of a mount
pad and an end plate of the heat exchanger core.
[0068] While the invention has been described with reference to an
exemplary embodiment(s), 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(s) disclosed, but that the invention will
include all embodiments falling within the scope of the appended
claims.
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