U.S. patent application number 16/509752 was filed with the patent office on 2020-01-23 for fin-plate heat exchanger.
The applicant listed for this patent is HS Marston Aerospace Limited. Invention is credited to Stuart ASTLEY, Aditya DESHPANDE.
Application Number | 20200025454 16/509752 |
Document ID | / |
Family ID | 63014469 |
Filed Date | 2020-01-23 |
United States Patent
Application |
20200025454 |
Kind Code |
A1 |
DESHPANDE; Aditya ; et
al. |
January 23, 2020 |
FIN-PLATE HEAT EXCHANGER
Abstract
A fin-plate heat exchanger is arranged to allow heat to be
exchanged between a first fluid and a second fluid. The fin-plate
heat exchanger comprises: a core with first flow paths for the
first fluid and second flow paths for the second fluid; a plurality
of separating plates; a plurality of fin components; a plurality of
first enclosure bars; and a plurality of second enclosure bars. The
heat exchanger further comprises a manifold arranged in fluid
communication with each of the first flow paths of the core. The
manifold and the core are formed as one integral piece, said
integral piece comprising a stack of laminate members and said fin
components. The plurality of laminate members comprise: first fluid
enclosure structures each including a first manifold section.
Inventors: |
DESHPANDE; Aditya;
(Birmingham, GB) ; ASTLEY; Stuart; (Wolverhampton,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HS Marston Aerospace Limited |
Wolverhampton |
|
GB |
|
|
Family ID: |
63014469 |
Appl. No.: |
16/509752 |
Filed: |
July 12, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28F 3/10 20130101; F28F
2250/102 20130101; F28F 3/025 20130101; F28D 9/0075 20130101; F28D
9/0062 20130101; F28F 9/0221 20130101 |
International
Class: |
F28D 9/00 20060101
F28D009/00; F28F 3/10 20060101 F28F003/10; F28F 9/02 20060101
F28F009/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 19, 2018 |
EP |
18275099.2 |
Claims
1. A fin-plate heat exchanger for allowing heat to be exchanged
between a first fluid and a second fluid, the fin-plate heat
exchanger comprising: a core comprising: a plurality of first flow
paths for the first fluid and a plurality of second flow paths for
the second fluid; a plurality of separating plates, adjacent first
and second flow paths being separated by respective separating
plates; a plurality of fin components extending through respective
first and second flow paths and extending between adjacent
separating plates; a plurality of first enclosure bars extending
between adjacent separating plates, the first enclosure bars being
arranged to at least partially define the first flow path; and a
plurality of second enclosure bars extending between adjacent
separating plates, the second enclosure bars being arranged to at
least partially define the second flow path; and a manifold
arranged in fluid communication with each of the first flow paths
of the core; wherein: the manifold and the core are formed as one
integral piece; said integral piece comprising a stack of laminate
members and said fin components; and the plurality of laminate
members comprise: a plurality of first fluid enclosure structures
for enclosing the first flow path, each first fluid enclosure
structure comprising a first manifold section and said first
enclosure bars; a plurality of second fluid enclosure structures
for enclosing the second flow path, each second fluid enclosure
structure comprising at least one second enclosure bar, and at
least some of the of the second fluid enclosure structures
comprising a second manifold section; and the plurality of
separating plates, each separating plate comprising a third
manifold section, and each separating plate separating each first
enclosure structure from adjacent second enclosure structures,
wherein the first, second and third manifold sections are shaped to
form the manifold when the plurality of laminate members are
stacked.
2. The fin-plate heat exchanger as claimed in claim 1, further
comprising: at least one flange for mounting the heat exchanger to
other components; wherein the manifold, the core and the at least
one flange are formed as one integral piece; wherein each of the
first enclosure structures, each of the separating plates and at
least some of the second enclosure structures comprise respective
flange portions; and wherein the flange portions are shaped to form
the at least one flange when the plurality of laminate members are
stacked.
3. The fin-plate heat exchanger as claimed in claim 1, wherein the
integral piece comprises the laminate members and the fin
components brazed together.
4. The fin-plate heat exchanger as claimed in claim 1, wherein the
manifold is not welded to the core.
5. The fin-plate heat exchanger as claimed in claim 1, wherein the
laminate members do not comprise fins.
6. The fin-plate heat exchanger as claimed in claim 1, wherein the
manifold comprises manifold features for allowing the first fluid
to be supplied to and/or received from the first flow paths; and
wherein the first, second and third manifold sections each comprise
respective features that form the manifold features when the
plurality of laminate members are stacked.
7. The fin-plate heat exchanger as claimed in claim 1, further
comprising: a base plate; and a top plate; wherein the laminate
members comprise the base plate and the top plate, wherein the base
plate forms the lower-most layer of the stack and the top plate
forms the upper-most layer of the stack, wherein the base plate and
the top plate each comprise a fourth manifold portion and a core
portion, wherein the base plate and the top plate are each shaped
such that the core portion encloses the core and the fourth
manifold portion encloses the manifold.
8. A fin-plate heat exchanger as claimed in any preceding claim,
wherein the laminate members are produced by additive manufacturing
and/or subtractive manufacturing.
9. The fin-plate heat exchanger as claimed in claim 1, wherein the
fin components are not made by additive manufacturing or
subtractive manufacturing.
10. A method of manufacturing a fin-plate heat exchanger as claimed
in claim 1, the method comprising: stacking the laminate members
and the fin components (103); and joining the laminate members and
the fin components together to form the integral piece.
11. The method as claimed in claim 10, wherein the method does not
include joining the manifold and the core together.
12. The method as claimed in claim 10, comprising producing at
least some of the laminate members by additive manufacturing.
13. The method as claimed in claim 10, comprising producing at
least some of the laminate members by subtractive
manufacturing.
14. A method as claimed in claim 13, comprising producing the
separating plates by subtractive manufacturing.
15. The method as claimed in claim 10, comprising removing excess
material from the integral piece after the joining process.
Description
FOREIGN PRIORITY
[0001] This application claims priority to European Patent
Application No. 18275099.2 filed Jul. 19, 2018, the entire contents
of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a fin-plate heat exchanger
and a method of manufacturing a fin-plate heat exchanger,
particularly for use in aerospace applications.
BACKGROUND
[0003] A fin-plate heat exchanger is a known type of heat
exchanger.
[0004] It typically comprises a core that has a plurality of first
flow paths and a plurality of second flow paths. The first flow
paths are in communication with a manifold that communicates a
first fluid (such as oil) through the first flow paths. The second
flow paths are arranged to allow a second fluid (such as air) to
pass. The first and second flow paths are generally planar and are
arranged in a stacked arrangement, where second flow paths are
located above and below a given first flow path, and first flow
paths are located above and below a given second flow path.
Separating the flow paths are separating plates that allow heat to
transfer between the first and second flow paths.
[0005] To assist the transfer of heat, fins are provided in the
first and second flow paths. The fins extend between adjacent
separating plates. The fins are orientated in a direction to assist
or guide fluid flow.
[0006] Adjacent separating plates are separated by enclosure bars.
The enclosure bars act to enclose respective first and second flow
paths. Together with the separating plates, the enclosure bars act
to define the first and second flow paths in the core.
[0007] The fin-plate heat exchanger also comprises a manifold that
is in fluid communication with the first flow paths, but is not in
fluid communication with the second flow paths. The manifold can
supply and/or receive the first fluid to and/or from the core.
[0008] Such a typical fin-plate heat exchanger is conventionally
made in the following way.
[0009] The core is made by forming a stack of components. This is
achieved by first providing a base plate. On top of the base plate,
enclosure bars for the first fluid path are placed, and a fin
component (such as a corrugated sheet) is placed. On top of these,
a separating plate is placed. On top of this, enclosure bars for
the second fluid path are placed, and a fin component (such as a
corrugated sheet) is placed. On top of this, a separating plate is
placed. This is repeated until the stack of a desired size is
formed. To finish the stack, on top of the upper-most enclosure
bars and the upper-most fin component, a top plate is placed.
[0010] The stack is then brazed together to form the core.
[0011] The manifold is made by a separate process, such as by
casting, machining or fabrication.
[0012] The heat exchanger is then formed by welding the manifold
and/or interface flanges to the core together.
[0013] However, the present inventors have identified a desire to
provide a more reliable and light-weight heat exchanger that is
quicker and cheaper to produce due to the elimination of welding
process.
SUMMARY
[0014] Viewed from a first aspect, the invention provides a
fin-plate heat exchanger for allowing heat to be exchanged between
a first fluid and a second fluid. The fin-plate heat exchanger
includes a core comprising: a plurality of first flow paths for the
first fluid and a plurality of second flow paths for the second
fluid; a plurality of separating plates, adjacent first and second
flow paths being separated by respective separating plates; a
plurality of fin components extending through respective first and
second flow paths and extending between adjacent separating plates;
a plurality of first enclosure bars extending between adjacent
separating plates, the first enclosure bars being arranged to at
least partially define the first flow path; and a plurality of
second enclosure bars extending between adjacent separating plates,
the second enclosure bars being arranged to at least partially
define the second flow path. The heat exchanger also includes a
manifold arranged in fluid communication with each of the first
flow paths of the core. The manifold and the core are formed as one
integral piece, said integral piece comprising a stack of laminate
members and said fin components. The plurality of laminate members
comprise: a plurality of first fluid enclosure structures for
enclosing the first flow path, each first fluid enclosure structure
comprising a first manifold section and said first enclosure bars;
a plurality of second fluid enclosure structures for enclosing the
second flow path, each second fluid enclosure structure comprising
at least one second enclosure bar, and at least some of the of the
second fluid enclosure structures comprising a second manifold
section; the plurality of separating plates. Each separating plate
comprises a third manifold section, and each separating plate
separates each first enclosure structure from adjacent second
enclosure structures. The first, second and third manifold sections
are shaped to form the manifold when the plurality of laminate
members are stacked.
[0015] The first manifold section may be on a first laminate
member, the second manifold section may be on a second laminate
member, and the third manifold section may be on a third laminate
member, with the first, second and third laminate members being
stacked in sequence. This sequence may be repeated to build up a
heat exchanger with multiple parallel flow paths formed via
multiple sets of first, second and third laminate members.
[0016] The fin-plate heat exchanger may comprise at least one
flange for mounting the heat exchanger to other components, wherein
the manifold, the core and the at least one flange are formed as
one integral piece, wherein each of the first enclosure structures,
each of the separating plates and at least some of the second
enclosure structures comprise respective flange portions, wherein
the flange portions are shaped to form the at least one flange when
the plurality of laminate members are stacked.
[0017] The integral piece may comprise the laminate members and the
fin components brazed together.
[0018] Optionally, the manifold is not welded to the core.
[0019] Optionally the laminate members do not comprise fins.
[0020] The manifold may comprise manifold features for allowing the
first fluid to be supplied to and/or received from the first flow
paths, wherein the first, second and third manifold sections each
comprise respective features that form the manifold features when
the plurality of laminate members are stacked.
[0021] The fin-plate heat exchanger may comprise a base plate and a
top plate, wherein the laminate members comprise the base plate and
the top plate, wherein the base plate forms the lower-most layer of
the stack and the top plate forms the upper-most layer of the
stack, wherein the base plate and the top plate each comprise a
fourth manifold portion and a core portion, wherein the base plate
and the top plate are each shaped such that the core portion
encloses the core and the fourth manifold portion encloses the
manifold.
[0022] The laminate members may be produced by additive
manufacturing and/or subtractive manufacturing.
[0023] The fin components are optionally not made by either
additive manufacturing or subtractive manufacturing.
[0024] The invention further extends to a method of manufacturing a
fin-plate heat exchanger, wherein the heat exchanger is as
discussed above and the method comprises: stacking the laminate
members and the fin components; and joining the laminate members
and the fin components together to form the integral piece.
[0025] Optionally the method does not include joining the manifold
and the core together.
[0026] At least some of the laminate members may be produced by
additive manufacturing.
[0027] At least some of the laminate members may be produced by
subtractive manufacturing.
[0028] In one example at least some of the laminate members are
produced by subtractive manufacturing and the separating plates are
produced by subtractive manufacturing.
[0029] The method may comprise removing excess material from the
integral piece after the joining process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Certain embodiments of the disclosure will now be described
by way of example only and with reference to the accompanying
drawings in which:
[0031] FIG. 1 shows an exemplary embodiment of the fin-plate heat
exchanger;
[0032] FIG. 2 shows details of the components of the fin-plate heat
exchanger of FIG. 1;
[0033] FIGS. 3A and 3B show details of the components of the
fin-plate heat exchanger of FIG. 1;
[0034] FIG. 4 shows details of the components of the fin-plate heat
exchanger of FIG. 1;
[0035] FIG. 5 shows another view of the of the fin-plate heat
exchanger of FIG. 1;
[0036] FIG. 6 shows an exemplary embodiment of a method of
manufacturing a fin-plate heat exchanger; and
[0037] FIG. 7 shows an example of a flow path in an exemplary
embodiment of the fin-plate heat exchanger.
DETAILED DESCRIPTION
[0038] As mentioned above, in a first aspect, disclosed is a
fin-plate heat exchanger for allowing heat to be exchanged between
a first fluid and a second fluid. The fin-plate heat exchanger
comprises a core comprising: a plurality of first flow paths for
the first fluid and a plurality of second flow paths for the second
fluid; a plurality of separating plates, adjacent first and second
flow paths being separated by respective separating plates; a
plurality of fin components extending through respective first and
second flow paths and extending between adjacent separating plates;
a plurality of first enclosure bars extending between adjacent
separating plates, the first enclosure bars being arranged to at
least partially define the first flow path; and a plurality of
second enclosure bars extending between adjacent separating plates,
the second enclosure bars being arranged to at least partially
define the second flow path. The fin-plate heat exchanger also
comprises a manifold arranged in fluid communication with each of
the first flow paths of the core. The fin-plate heat exchanger is
characterised in that the manifold and the core are formed as one
integral piece, said integral piece comprising a stack of laminate
members and said fin components. The plurality of laminate members
comprise: a plurality of first fluid enclosure structures for
enclosing the first flow path, each first fluid enclosure structure
comprising a first manifold section and said first enclosure bars;
a plurality of second fluid enclosure structures for enclosing the
second flow path, each second fluid enclosure structure comprising
a second enclosure bar, and at least some of the of the second
fluid enclosure structures comprising a second manifold section;
the plurality of separating plates, each separating plate
comprising a third manifold section, and each separating plate
separating each first enclosure structure from adjacent second
enclosure structures. The first, second and third manifold sections
are shaped to form the manifold when the plurality of laminate
members are stacked. Thus, first manifold section may be on a first
laminate member, the second manifold section may be on a second
laminate member, and the third manifold section may be on a third
laminate member, with the first, second and third laminate members
being stacked in sequence. This sequence may be repeated to build
up a heat exchanger with multiple parallel flow paths formed via
multiple sets of first, second and third laminate members. This
fin-plate heat exchanger should be more reliable than conventional
fin-plate heat exchangers due to the elimination of welding
process. In conventional fin-plate heat exchangers, the manifold
and core are formed separately, and are then joined together, for
example by a welding process. However, the inventors have
identified that such welding joints are susceptible to
thermo-mechanical fatigue cracking. The present heat exchanger does
require any such weld, and therefore does suffer such reliability
issues.
[0039] Further, the present fin-plate heat exchanger may be lighter
in weight than conventional fin-plate heat exchangers, which is of
particular relevance in industries such as aerospace. Due to the
presence of the weld (which is a potential weakness, as mentioned
above) conventional fin-plate heat exchangers may be built heavier
than the present heat exchanger.
[0040] Further still, the present fin-plate heat exchanger may be
built more rapidly and cheaply than conventional fin-plate heat
exchangers. Since both the manifold and the core are made as one
integral piece from the laminate members, there is no need to
manufacture the manifold and the core separately and then join them
together, which reduces construction time. Further, the laminate
members can be manufactured very quickly (for example from additive
or subtractive manufacturing processes) and the fin components can
be provided as standard components. Thus, all of the components
that make up the heat exchanger can be made or provided very
quickly. In addition, the form of the laminate members can be
varied quickly, which allows great flexibility and quick changing
of the overall heat exchanger design, especially in comparison to
when a conventional manifold is made from a cast in a mould or
machined from solid or fabricated joining individual
components.
[0041] As mentioned above, the present heat exchanger is a
fin-plate heat exchanger. This is a specific type of heat exchanger
and is different to other types of heat exchanger, such as
microchannel heat exchangers or heat exchangers where pins (or
other heat conducting elements) are used in the flow paths.
[0042] The heat exchanger may be arranged to exchange heat only
between the first and second fluids, i.e. there may be no
additional fluids present.
[0043] As can be understood from the description of the core above,
the core of the present heat exchanger may be similar to or
identical to the cores of conventional heat exchangers. The
inventors have not intended to alter the design of the core.
Indeed, one of the purposes of the present invention is to produce
a fin-plate heat exchanger that has the same (or a similar) form to
conventional fin-plate heat exchangers, but also has the advantages
listed above. The inventors have achieved this by the innovative
design of the laminate members discussed herein.
[0044] Thus, the core may comprise a plurality of first flow paths
arranged in a layered fashion. Between said first flow paths may be
second flow paths. The first and second flow paths may be separated
by separating plates. The first and second flow paths may be
generally planar and the first and second fluids may move in
parallel to said planes.
[0045] The core may comprise a first end and a second end, the
first end being the end to which the manifold is attached and the
second end being opposite said first end. The core may comprise a
bottom and a top. The top and the bottom being the extremes of the
core in the direction generally normal to the direction of the
stack (i.e. generally parallel to the normal of the plane defined
by the separating plates, see below). The core may comprise a first
side and a second side, the first and second sides extending
between the top and bottom and the first and second ends, and being
opposite each other. The core may be shaped in a general
cuboid-shape.
[0046] Adjacent first and second flow paths may be in thermal
communication with each other (e.g. via the fins and the separating
plates). For example, one first flow path may be in communication
with two second flow paths (the second flow paths above and below
the first flow path); and one second flow path may be in
communication with two first flow paths (the first flow paths above
and below the first flow path).
[0047] The separating plates may be generally planar (herein
"planar" may mean totally flat, or may be a curved plane). The
first and second flow paths may be correspondingly planar. The
separating plates (and hence the flow paths) may be stacked in a
way such that they are separated from each other in a direction
generally normal to said plane. The separating plates may have a
rectangular area.
[0048] Each fin component may be an integral piece comprising
multiple fins (such as a corrugated sheet). There may be only one
integral piece per flow path. However, there may be more than one.
Alternatively, each fin component can comprise only one fin, and a
plurality of such components are provided separately within each
flow path.
[0049] The fin components may be placed between adjacent separating
plates and hence in said flow paths. The fins may guide the fluid
in said flow paths.
[0050] As is known, fins are generally planar heat transfer
elements that extend between adjacent separating plates and extend
generally in the direction of fluid flow. They are different from
pins and other heat transfer elements.
[0051] The first enclosure bars may be located at the first and
second sides of the core. The first enclosure bars may be located
between separating plates at the periphery of the separating
plates. There may be one first enclosure bar between two adjacent
separating plates at the first side and another first enclosure
between the same two adjacent separating plates at the second side.
There may not be any second enclosure bars present between said
separating plates. There may be second enclosure bars present on
the other side of both said separating plates. The first enclosure
bars and the separating plates define a first flow path where at
least one end of the core is open.
[0052] The second enclosure bars may be located at the first and
second ends of the core. The second enclosure bars may be located
between separating plates at the periphery of the separating
plates. There may be one second enclosure bar between two adjacent
separating plates at the first end and another second enclosure
between the same two adjacent separating plates at the second end.
There may not be any first enclosure bars present between said
separating plates. There may be first enclosure bars present on the
other side of both said separating plates. The second enclosure
bars and the separating plates define a first flow path where at
least one side of the core is open.
[0053] Stated differently, a given separating plate will be
separated from an adjacent separating plate above/below by first
enclosure bars and by an adjacent separating plate below/above by
second enclosure bars.
[0054] The manifold is for supplying the first fluid to and/or
receiving the first fluid from the first fluid paths. It is not in
communication with the second fluid paths.
[0055] The manifold may be located at the first end of core.
[0056] There may be only one manifold. In this case, the second end
of the core of the first flow paths may be enclosed by another
first enclosure bar. The manifold may comprise a supply and a
return path for the first fluid. There may be a guiding structure
present in the core to guide the fluid through the first flow paths
from the supply to the return path.
[0057] There may be two manifolds. In this case, the manifolds may
be present at either end of the core.
[0058] As mentioned above, in the present fin-plate heat exchanger,
the manifold and the core are formed as one integral piece. This
means that they are not two separate pieces that have been joined
together, for example by welding. Rather, they are formed in the
same formation process (such as the brazing process mentioned
below).
[0059] There may also be flanges formed in the same integral piece,
with the flanges acting as interface flanges. These interface
flanges may be formed by interface flange sections provided on some
or all of the laminate members.
[0060] The stack of laminate members are laminated together.
Lamination is known term in the art and is not discussed herein.
The stack may be referred to as a laminated stack.
[0061] Each laminate member may be an integral piece, i.e. they are
formed in one process and do not comprise any joints, such as
welds.
[0062] The stack may be arranged by having separating plates
separated by alternating first and second enclosure structures.
[0063] The first manifold sections of respective first enclosure
structures may be the same as or different to each other. The
second manifold sections of respective second enclosure structures
may be the same as or different to each other (and the same as or
different to the first manifold sections). The third manifold
sections of respective separating plates may be the same as or
different to each other (and the same as or different to the first
and second manifold sections). The form of the respective first,
second and third manifold sections can be such that, when the
laminate members are stacked appropriately, a manifold with the
correct form/features results. The first, second and third manifold
sections are effectively cross-section slices of the overall
manifold, such that when they are placed together the manifold is
formed. Thus, first manifold section may be on a first laminate
member, the second manifold section may be on a second laminate
member, and third manifold section may be on a third laminate
member, with the first, second and third laminate member being
stacked in sequence. This sequence may be repeated to build up a
heat exchanger with multiple parallel flow paths formed via
multiple sets of first, second and third laminate members.
[0064] Having the laminate members comprise such manifold sections
is advantageous, not only because the manifold and the core can be
formed as an integral piece, but also because it means the features
of the manifold (e.g. the pipes/openings/etc.) do not need to be
machined into the manifold after the stack is laminated. Further it
allows the form of the manifold to be varied easily from one heat
exchanger to the next.
[0065] The fin-plate heat exchanger may comprise at least one
flange for mounting the heat exchanger to other components. Such
other components may be nearby supporting structures, such as an
airframe, or other components such as ducts and pipes.
[0066] The manifold, the core and the at least one flange may be
formed as one integral piece. This may be achieved by having each
of the first enclosure structures, each of the separating plates
and at least some of the second enclosure structures (and
preferably each of the second enclosure structures) comprise
respective flange portions, wherein the flange portions are shaped
to form the at least one flange when the plurality of laminate
members are stacked.
[0067] Conventionally, such flanges are welded onto the
core/manifold after the core is formed. However, by providing
flange portions in the laminated members, the flanges can be formed
at the same time as the core and can be integral with the core.
This can improve reliability, reduce construction time and reduce
weight. Thus, the flange may not be joined (e.g. welded) to the
remainder of the heat exchanger.
[0068] There may be a plurality of flanges each formed by a
respective plurality of flange portions in the laminate members.
There may be (exactly) four flanges, one located proximate each
corner of the core.
[0069] The integral piece may comprise (or consist of) the laminate
members and the fin components adhered (e.g. brazed) together.
There may of course be some adhering (e.g. brazing or bonding)
material present too.
[0070] As mentioned above, the manifold may not be joined (e.g.
welded) to the core. Said flange(s) may not be joined (e.g. welded)
to the remainder of the heat exchanger. There may be no flange or
manifold joined (e.g. welded) to the remainder of the heat
exchanger. There may be no weld present in the heat exchanger.
[0071] The laminate members may not comprise any fins (or any other
secondary assisting heat transfer surfaces, such as pins). Rather,
the fins may only be provided in the fin components, which may not
be laminated members. The fins may be provided in a conventional
way, such as by a corrugated sheet. The fins may be placed in the
stack (between separating plates) and adhered (e.g. brazed)
together with the laminated members.
[0072] As mentioned above, the manifold may comprise manifold
features for allowing the first fluid to be supplied to and/or
received from the first flow paths. The first, second and third
manifold sections may each comprise respective features that form
the manifold features when the plurality of laminate members are
stacked.
[0073] The manifold features may comprise fluid paths, pipes,
openings, etc. for the first fluid.
[0074] If only one manifold is present in the heat exchanger, the
manifold features may comprise a supply fluid path and a return
fluid path, each being open to the first fluid paths.
[0075] If two manifolds are present (e.g. one at each end of the
core), then a first manifold may comprise a supply fluid path and a
second manifold may comprise a return fluid path, the supply and
the return paths being open to the first fluid paths.
[0076] The fin-plate heat exchanger may comprise a base plate and a
top plate. These may also be referred to as "side plates" in the
art. The base plate may be located at the bottom of the stack and
the top plate may be located at the top of stack.
[0077] The laminate members may comprise the base plate and the top
plate. The base plate and the top plate may each comprise a fourth
manifold portion and a core portion. The base plate and the top
plate may be each shaped such that the core portion encloses the
core and the manifold portion encloses the manifold.
[0078] The top and the base plates may effectively provide some
external structure to the heat exchanger and may seal the manifold
and/or the core.
[0079] The laminate members may consist of the first enclosure
structures, the second enclosure structure, the separating plates,
the base plate and the top plate. Thus, the integral member may be
formed solely of the first enclosure structures, the second
enclosure structure, the separating plates, the base plate, the top
plate and the fin components (and some adhering material, such as
brazing material).
[0080] The laminate members may be produced by additive
manufacturing (such as laser powder bed fusion or energy metal
deposition) and/or subtractive manufacturing (such as etching,
laser cutting, water jet cutting, wire eroding or high-speed
machining). Different laminated members can be made by the same or
different methods. The top plate, the base plate, the first
enclosure structures or the second enclosure structures may be made
by either additive manufacturing or subtractive manufacturing.
However, the separating plates are preferably made by subtractive
manufacturing.
[0081] The present heat exchanger allows a large proportion of its
constituent components to be made by these methods. Conventional
methods do not allow this. This is advantageous since it allows a
great deal of flexibility in design of heat exchanger, and the heat
exchanger's form can be varied very quickly. Further, it can
increase the speed of the manufacture.
[0082] The fin components may be manufactured by a different
technique to the laminate members. Thus, they may be made during a
separate process. In some examples fin components are not made by
additive manufacturing or by subtractive manufacturing. Rather, the
fins may be made (or supplied) in a conventional way for heat
exchanger finstock (for example by pressing/bending a sheet to form
a corrugated and/or perforated sheet).
[0083] The present heat exchanger allows the use of conventional
fin components as one of its constituent components. This is
advantageous since it allows the structure of the heat exchanger to
be made quickly and strongly (as mentioned above), but can still
use the conventional fin components, which are cheap and easy to
make/supply.
[0084] As can be appreciated, the inventors have devised a sort of
"hybrid" technology, that is somewhere between producing a
fin-plate heat exchanger purely from a rapid manufacture process
(such as additive manufacturing), producing a fin-plate heat
exchanger by a pure laminated process (such as in EP 2474803,
discussed below) and by producing a fin-plate heat exchanger by
conventional means (as discussed in the background section).
[0085] The present method is advantageous over these alternatives
since it is quicker and more reliable than conventional means, but
is more straightforward than using pure rapid manufacture (which
may struggle to produce such a complex fin-plate heat exchanger) or
by using a pure laminated process (where the fins would be required
to be part of each laminate member making up a given layer). Thus,
the inventors have found an improved way of manufacturing a
fin-plate heat exchanger.
[0086] For instance, it may be known (for example from US
2015/260459 or EP 2474803) to manufacture a core and a manifold as
one integral piece from laminate members.
[0087] However, in the prior art there is no teaching or suggestion
of using fin components in both the first and second flow paths in
such a laminated core structure. Rather, in the prior art, whenever
a laminated integral core and manifold are produced, the heat
transfer elements used are pins or the like.
[0088] Further, these prior art heat exchangers are made from a
pure laminated process, where the heat transfer elements (the pins)
are integral parts of each laminated member. Pins are used as the
heat transfer elements because they lend themselves to being formed
in this laminated way. However, it is much more difficult to
produce fins in a laminated way (which is why it has not been done
in the prior art).
[0089] In contrast to these prior art examples, in the present heat
exchanger the fins are provided as separate to the laminate members
(e.g. the fins are provided as conventional fin components (e.g.
corrugated sheets) whereas the laminate members are provided as
rapidly-produced (e.g. subtractive or additive manufactured)
components). Thus, the present inventors have developed a "hybrid"
type technology that is that is somewhere between producing a
fin-plate heat exchanger purely from a rapid manufacture process,
producing a fin-plate heat exchanger by a pure laminated process,
and producing a fin-plate heat exchanger by conventional means.
[0090] The fin-plate heat exchanger may be for use in an aircraft.
For instance, it may be for use in an aircraft engine, or possibly
in an air management system in an aircraft.
[0091] The fin-plate heat exchanger may be for use with a first
fluid that can vary between -40.degree. C. to 210.degree. C. The
fin-plate heat exchanger may be for use with a second fluid that
can very between -50.degree. C. to 100.degree. C. The fin-plate
heat exchanger may be for use with a first fluid that can vary
between 3 kPa to 150 kPa. The fin-plate heat exchanger may be able
to function over both of these ranges, and possibly beyond. The
fin-plate heat exchanger may comprise the first and second
fluids.
[0092] The first fluid may be a liquid, such as oil and the second
fluid may be a gas, such as air or any combinations thereof.
[0093] In a second aspect, provided is a method of manufacturing a
fin-plate heat exchanger. The heat exchanger may be the heat
exchanger of the first aspect. The method may comprise stacking the
laminate members and the fin components; and adhering (e.g.
brazing) the laminate members and the fin components together to
form the integral piece.
[0094] The stacking may be as set out above, i.e. a first enclosure
structure, then a separating plate, then a second enclosure
structure, then a separating plate, then a first enclosure,
etc.
[0095] Stacking the laminate members may comprise placing a first
(or second) enclosure structure on top of the base plate; placing a
separating plate on top of the first (or second) enclosure
structure; placing a second (or first) enclosure structure on top
of the separating plate; placing a separating plate on top of the
second (or first) enclosure structure; and then repeating the first
enclosure structure, separating plate, second enclosure structure
pattern until the core is complete. Then the top plate is placed on
the upper most enclosure structure (which may be a first or a
second enclosure structure).
[0096] In addition to these components, adhering (e.g. brazing)
material may also be added during the stacking. For instance,
adhering material may be added between the base plate and the lower
most enclosure structure. Adhering material may be added between
the top plate and the upper most enclosure structure.
[0097] Adhering material may be added between each layer of the
stack. However, preferably it is only added in the positions
mentioned in the paragraph above.
[0098] To bond the remainder of the structure, adhering material
may be provided on both sides of the separating plates (i.e. the
separating plates may be formed from a sheet of material that
already has adhering material cladded onto both of its upper and
lower surfaces).
[0099] The method may not include joining (e.g. welding) the
manifold and the core together. As mentioned above, conventionally
the manifold and the core of a fin-plate heat exchanger are
manufactured separately, and then welded together. The inventors
have devised a method where this step may not be necessary.
[0100] The method may comprise producing at least some of the
laminate members by additive manufacturing. The first enclosure
structures may be produced by additive manufacturing. The second
enclosure structures may be produced by additive manufacturing. The
top and base plates may be produced by additive manufacturing.
[0101] Additionally/alternatively, the method may comprise
producing at least some of the laminate members by subtractive
manufacturing. The first enclosure structures may be produced by
subtractive manufacturing. The second enclosure structures may be
produced by subtractive manufacturing. The top and base plates may
be produced by subtractive manufacturing.
[0102] The method may comprise producing the separating plates by
subtractive manufacturing. This is preferable (instead of additive
manufacturing), since the separating plates may be made from sheets
where adhering material is already present. Such a material would
be difficult to produce by additive manufacture.
[0103] The method may comprise removing excess material from the
integral piece after the adhering process. There may be excess
material present near the manifold and in other places, so as to
provide enough structural integrity in the stack during adhering
(where the stack may be held under pressure). Further, there may be
excess material in the flange(s), which may be too big for their
intended purpose. Further, holes can be drilled into the flange(s)
so that they can be attached (e.g. bolted) to other components.
[0104] The method may not comprise machining the manifold or the
core after the integral piece is formed. There is no need to do
so.
[0105] The method may comprise producing a first laminated heat
exchanger using any of the methods above, and then producing a
second laminated heat exchanger using any of the methods above. The
first and the second laminated heat exchanger may differ in form,
e.g. they be of different sizes, have different dimensions, have
different manifold features, have different areas and thicknesses
of flow paths, etc.
[0106] Due to the flexibility of the present method, the time taken
to produce two such different heat exchangers may be dramatically
reduced in comparison to conventional methods.
[0107] Turning now to FIG. 1, shown is a fin-plate heat exchanger 1
in accordance with an embodiment of the present fin-plate heat
exchanger.
[0108] The heat exchanger 1 comprises a core 100. The core 100
comprises a plurality of first flow paths 200 for a first fluid and
a plurality of second flow paths 300 for the second fluid. The
first 200 and second 300 flow paths are arranged in an alternating
stack and are separated by a plurality of separating plates 101. A
plurality of fin components 103 extend through respective first 200
and second 300 flow paths and extend between adjacent separating
plates 101. In FIG. 1, only the fin components 103 in the second
flow path 300 are shown, since the fin components 103 in the first
flow path 200 cannot be seen.
[0109] First enclosure structures 201 act in cooperation with the
separating plates 101 to define the first flow paths 200.
[0110] Second enclosure structures 301 act in cooperation with the
separating plates 101 to define the second flow paths 300.
[0111] The core 100 comprises a first end 151 and a second end 152;
a bottom 153 and a top 154; and a first side 155 and a second side
156.
[0112] The fin-plate heat exchanger 1 also comprises a manifold 400
arranged in fluid communication with each of the first flow paths
200 of the core 100.
[0113] The manifold 400 comprises manifold features, such as supply
line 401 and a return line 402 for supplying the first fluid to the
first fluid paths 200 and receiving fluid from the first fluid
paths 200 respectively.
[0114] The fin-plate heat exchanger 1 comprises flanges 600. The
flanges 600 are for attaching the heat exchanger 1 to other
adjacent components.
[0115] The manifold 400, the flanges 600 and the core 100 are
formed as one integral piece.
[0116] The integral piece comprises a stack of laminate members
101, 501, 502, 201, 301 and said fin components 103.
[0117] The plurality of laminate members 101, 501, 502, 201, 301
comprise: the first fluid enclosure structures 201; the second
fluid enclosure structures 301; the plurality of separating plates
101; a base plate 501 and a top plate 502 (not shown in FIG.
1).
[0118] The stack is formed by placing a first enclosure structure
201 and at least one fin component (not shown) on top of the base
plate 501. On top of the first enclosure 201 and the at least one
fin component, a separating plate 101 is placed. On top of the
separating plate 101, a second enclosure structure 301 and a fin
component 103 is placed. On top of these, another separating plate
101 is placed. This pattern is then repeated until the top 154 of
the heat exchanger is reached, when a top plate 502 is placed on
top of the uppermost enclosure structure(s) and fin
component(s).
[0119] As mentioned above, the stack may be brazed together to form
the integral piece.
[0120] Regarding FIG. 2, an exemplary first enclosure structure 201
is shown in more detail.
[0121] The first enclosure structure 201 comprises a manifold
section 202.
[0122] The manifold section comprises manifold feature cut outs
208, 209. The manifold section 202 is shaped such that, when the
first enclosure structure 201 is placed in the stack, the manifold
400 with the correct features 401, 402 is formed.
[0123] The first enclosure structure 201 also comprises a first
enclosure bar 203 arranged to close off the first side 155 of the
first fluid path 200 when placed between two separating plates
101.
[0124] The first enclosure structure 201 also comprises a second
enclosure bar 204 arranged to close off the second side 156 of the
first fluid path 200 when placed between two separating plates
101.
[0125] The first enclosure structure 201 may also comprise a third
enclosure bar 206 arranged to close off the second end 152 of the
first fluid path 200 when placed between two separating plates
101.
[0126] The first enclosure structure 201 may also comprise a
guiding structure 207 arranged to guide the flow of the first fluid
through the first flow path 200 from the supply 401 to the return
402 of the manifold.
[0127] The first enclosure structures 201 leave the first end 151
of the first flow path 200 open.
[0128] Other guides may be present, or no guides may be present.
For instance, it may be that there are two manifolds present, one
at either end 151, 153.
[0129] The first enclosure structure 201 also comprises a plurality
of flange portions 210 arranged such that, when the first enclosure
structure 201 is placed in the stack, the flanges 600 are
formed.
[0130] Each first enclosure structure 201 may be the same as one
another, or may be different. The precise form of each first
enclosure structure will depend on the desired shape and features
of the heat exchanger 1.
[0131] Regarding FIGS. 3a and 3b, shown are exemplary second
enclosure structures 301. The enclosure structures of FIGS. 3a and
3b work in combination with each other to close respective ends
151, 152 of the core 100 between two separating plates 101 so as to
define a given second flow path. In the example shown here, the
second enclosure structure 301 shown in FIG. 3a closes the second
end 152 and the second enclosure structure 301 shown in FIG. 3b
closes the first end 151 of the same second flow path 300.
[0132] Regarding FIG. 3a, the first enclosure structure 301
comprises a second enclosure bar 306 arranged to close off the
second end 152 of the second fluid path 300 when placed between two
separating plates 101.
[0133] Regarding FIG. 3b, the second enclosure structure 301
comprises a manifold section 302. The manifold section comprises
manifold feature cut outs 308, 309. The manifold section 302 is
shaped such that, when the first enclosure structure 301 is placed
in the stack, the manifold 400 with the correct features 401, 402
is formed.
[0134] The second enclosure structure 302 also comprises a first
enclosure bar 305 arranged to close off the first end 151 of the
second fluid path 300 when placed between two separating plates
101.
[0135] The second enclosure structures 301 leave the first and
second sides 155, 156 of the second flow path 300 open.
[0136] The second enclosure structures 301 also comprise a
plurality of flange portions 310 arranged such that, when the
second enclosure structures 301 are placed in the stack, the
flanges 600 are formed.
[0137] Each second enclosure structure 301 of FIG. 3a may be the
same as one another, or may be different to each other. Each first
enclosure structure 301 of FIG. 3b may be the same as one another,
or may be different. The precise form of each first enclosure
structure will depend on the desired shape and features of the heat
exchanger 1.
[0138] Regarding FIG. 4, an exemplary separating plate 101 is shown
in more detail.
[0139] The separating plate 101 comprises a manifold section 102.
The manifold section comprises manifold feature cut outs 108, 109.
The manifold section 102 is shaped such that, when the separating
plate 101 is placed in the stack, the manifold 400 with the correct
features 401, 402 is formed.
[0140] The separating plate 101 has a core portion 104 that is
solid (unbroken) and extends from the first end 151 to the second
end 152 and from the first side 155 to the second side 156.
[0141] The separating plate 101 also comprises a plurality of
flange portions 110 arranged such that, when the separating plate
101 is placed in the stack, the flanges 600 are formed.
[0142] Each separating plate 101 may be the same as one another, or
may be different. The precise form of each separating plate 101
will depend on the desired shape and features of the heat exchanger
1.
[0143] The top and base plates 501, 502 are not shown in detail,
but may be similar to the separating plate 101, but without the
manifold features 108, 109 (i.e. the top and base plates 501, 502
may be solid (unbroken) so as to close the manifold 400 and the
core 100).
[0144] FIG. 5 shows a completed fin-plate heat exchanger 1. This is
largely identical to the fin-plate heat exchanger 1 shown in FIG.
1, except the top plate 502 is also shown. Further, excess material
(such as the honey-comb material in the manifold sections 102, 202,
402) have been removed, and holes have been drilled in the
flange.
[0145] The fin-plate heat exchanger 1 of the above embodiment
comprises only one manifold 400. However, it may be possible for
two manifolds 400 to be present, one at each end 151, 152 of the
core. In this case, one manifold may be for supply and one may be
for return of the first fluid. To achieve this, additional manifold
sections will be needed in the laminated members, and the manifold
features of each will differ from what is shown in the Figures. For
instance, third enclosure bar 206 may need to be replaced with a
manifold section; a manifold section may be needed to be added to
the enclosure bar 306; and a manifold section may need to be added
at the second end 152 of the separating plate 101. In this case,
there may be no need for guide 207.
[0146] Regarding FIG. 7, it shows in more detail an exemplary first
flow path 200 defined by an exemplary first enclosure structure
201. The first flow path comprises three fin components 103a, 106b,
103c.
[0147] The first fin component 103a extends from the manifold
section 202 in a direction from the first end 151 toward the second
end 152. The fins of the first fin component 103a are orientated in
this direction, thus guiding fluid away from the supply line 401 of
the manifold 400 between the second enclosure bar 204 and the
guiding structure 207.
[0148] The second fin component 103b extends from the manifold
section 202 in a direction from the first end 151 toward the second
end 152. The fins of the second fin component 103b are orientated
in this direction, thus guiding fluid toward the return line 402 of
the manifold 400 between the first enclosure bar 203 and the
guiding structure 207. The guiding structure fluidly separates the
first and second fin structures 103a, 103b.
[0149] The third fin component 103c extends between the first and
second fin components 103a, 103b in a direction generally
perpendicular to the direction of the first and second fin
components 103a, 103b (i.e. the fins of the third fin component
103c are generally parallel to and proximate to the second end 152
of the heat exchanger). The third fin component 103c guides the
fluid from the first fin component 103a to the second fin component
103b between the third enclosure bar 206 and the guiding structure
207.
[0150] Each of the first flow paths may comprise similar or
identical fin components 103a, 103b, 103c.
[0151] The fin component 103 of the second flow paths may be a
single component. It may simply extend, and guide the second fluid,
from the first side 155 to the second side 156 between the first
and second enclosure bars 305, 306 of the second enclosure
structure 301.
[0152] Regarding FIG. 6, a method of manufacturing the fin-plate
heat exchanger is schematically shown.
[0153] In a first step 901, the laminate members 101, 201, 301,
501, 502 are produced. This may occur by additive or subtractive
manufacturing.
[0154] In a second step 902, the fin components 103 are formed.
This may be achieved by cutting a corrugated sheet to size, and/or
by punching a flat sheet such that corrugated fins are
produced.
[0155] In a third step 903, the laminate members 101, 201, 301,
501, 502 and the fin components 103 are stacked. Possibly some
brazing material is also placed in appropriate places in the
stack.
[0156] In a fourth step 904, the stack is brazed to from the
integral piece.
[0157] In a fifth step 905, excess material is cut off the integral
piece.
[0158] In a sixth step 906, ancillary components such as relief
valves are fitted.
[0159] This process can be repeated for a similarly-shaped or a
differently-shaped fin-plate heat exchanger.
* * * * *