U.S. patent number 3,601,878 [Application Number 04/877,601] was granted by the patent office on 1971-08-31 for method for fabricating a heat exchanger.
Invention is credited to John Karmazin.
United States Patent |
3,601,878 |
Karmazin |
August 31, 1971 |
**Please see images for:
( Certificate of Correction ) ** |
METHOD FOR FABRICATING A HEAT EXCHANGER
Abstract
A heat exchanger and method for making a heat exchanger
consisting of a rectangular framework, within which a plurality of
spaced parallel sheets of material are disposed having spaced-apart
integral tapered tubular projections positioned in aligned nested
relationship defining a plurality of conduits extending and clamped
between opposed sides of the framework. The assembly is brazed in a
furnace, effecting a bonding and sealing of the joints formed by
the projections and the connections of the framework forming an
integral structure of accurate dimension and of increased
durability and ruggedness.
Inventors: |
Karmazin; John (Wyandotte,
MI) |
Family
ID: |
27095353 |
Appl.
No.: |
04/877,601 |
Filed: |
November 24, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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648314 |
Jun 23, 1967 |
3515208 |
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Current U.S.
Class: |
29/890.039;
29/469; 165/149; 29/890.043; 165/151 |
Current CPC
Class: |
B21D
53/08 (20130101); F28F 1/28 (20130101); B23K
1/008 (20130101); F28F 1/32 (20130101); Y10T
29/49366 (20150115); Y10T 29/49373 (20150115); Y10T
29/49904 (20150115) |
Current International
Class: |
F28F
1/28 (20060101); F28F 1/24 (20060101); B23K
1/008 (20060101); B21D 53/02 (20060101); B21D
53/08 (20060101); F28F 1/32 (20060101); B21d
053/02 () |
Field of
Search: |
;165/151,149
;29/175.3B,157.3D,469 ;113/118B |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Campbell; John F.
Assistant Examiner: Reiley; D. C.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of copending
application Ser. No. 648,314, filed June 23, 1967, for "Heat
Exchanger Construction," now U.S. Pat. No. 3,515,208 which is
assigned to the same assignee as the present invention.
Claims
I claim:
1. A method of making a heat exchanger which comprises the steps of
forming a plurality of sheets of material with a series of spaced
tapered integral tubular projections therealong, stacking said
sheets in substantially parallel relationship with said projections
disposed in aligned nested relationship defining therewith a
plurality of conduits, clamping the assembly of the nested sheets
within a rectangular framework comprising a pair of side members,
said framework forming an integral part of the heat exchanger and a
pair of end members, applying a metallic bonding and sealing
material to the joints of said projections, heating the assembly to
effect a melting of said bonding material and a wetting of said
joints, and thereafter cooling the assembly forming the integral
heat exchanger.
2. The method as defined in claim 1 further characterized by
forming said end members as header conduits and positioning said
header conduits in communication with the adjacent ends of said
conduits and in end clamping relationship relative to said
sheets.
3. The method as defined in claim 1 further characterized in that
said metallic bonding and sealing material is a brazing compound
and said heating is accomplished in a brazing furnace.
4. The method as defined in claim 1 further characterized by the
step of applying bonding material at the connections of said
framework and concurrently bonding said framework during the
heating of said assembly.
Description
BACKGROUND OF THE INVENTION
The present invention is directed to heat exchangers of the fin and
tube type which are formed by a stack of sheets disposed in
substantially parallel relationship and which sheets are formed
with integral tapered tubular projections that are disposed in
mutual aligned nested relationship defining therewith a plurality
of conduits. The sheet portion serves as a heat radiating or
receiving fin for transferring the heat from and to the conduits
through which a fluid is adapted to be transmitted.
It has been conventional in a manufacture of heat exhangers of the
aforementioned type to form the individual sheets by passing them
incrementally through a progressive die, whereafter they are nested
and placed in a suitable clamping fixture. The clamping fixture
maintains the nested stack of sheets in appropriate assembled
relationship and the resultant assembly is thereafter placed in a
brazing furnace with a brazing material positioned adjacent to the
joints formed between the tubular projections whereby a concurrent
bonding and sealing of the joints occurs. After removal of the
assembly from the brazing furnace and a cooling of the stacked
sheets, the heat exchanger core, comprising the integrally brazed
fin and tubes, are removed from the fixture and subjected to
further final assembly operations.
The foregoing manufacturing technique has been found to be
cumbersome in many respects necessitating a large inventory and
capital investment in jigs and fixtures for accommodating nested
stacks of the deformed sheets to produce heat exchanger cores of
various sizes and surface areas to provide heat exchanging
capacities and/or configurations consistent with their intended end
use. The loading of such stacked nested assemblies in the fixtures
prior to brazing and subsequent removal of the brazed core from the
fixture constitutes a tedious and time consuming operation. It has
also been noted that the subjection of such jigs and clamping
fixtures to repeated cycling between elevated temperatures as
encountered in the brazing furnace and room temperature occasions a
progressive warping and distortion of the fixture, whereby
variations occur in the dimensions of the heat exchanger cores
produced. Such warping and distortion of the clamping fixtures has,
in some instances, also resulted in inadequate clamping forces in
localized areas of the nested sheet assembly, whereupon leakage of
the heat exchanger core in certain localized areas is caused due to
excessive gaps which are not adequately sealed by the bonding or
brazing material employed.
A further problem associated in the manufacture of fin and tube
heat exchangers is the fragile nature of the brazed or soldered
assembly after removal from the clamping fixture, necessitating
care in the handling of such assemblies during further processing
and work operations to be performed thereon to avoid physical
damage thereto.
The present invention overcomes the foregoing disadvantages in the
manufacture and construction of fin and tube-type heat exchangers
by employing a framework which becomes an integral part of the
resultant heat exchangers dispensing with the need of separate
clamping fixtures and further substantially enhancing the
dimensional accuracy and ruggedness of the heat exchanger apparatus
produced.
SUMMARY OF THE INVENTION
The foregoing and other advantages and benefits of the present
invention are achieved by a fin and tube-type heat exchanger
construction employing a rectangular framework including a pair of
end members and a pair of side members, between which a plurality
of parallel spaced sheets of a heat conductive material are
disposed and are formed with spaced integral tapered tubular
projections which are positioned in aligned nested relationship and
are retained in appropriate clamped relationship between the end
members of the framework. The resultant assembly is brazed as a
unit employing a suitable solder or brazing compound forming a
unitary assembly having the protective framework extending around
the core, which prevents physical damage to the side edges of the
heat exchanger, while concurrently assuring consecutive accuracy in
the dimensions in the heat exchanger produced. The construction and
method of making the heat exchanger apparatus, as hereinafter
described in detail, dispenses with the need of a large inventory
and capital investment in special jigs and fixtures which
themselves must be periodically replaced due to wear and warpage.
Substantial increases in the efficiency of manufacture and in the
economy and durability of the heat exchangers produced is also
attained.
Additional benefits and advantages of the present invention will
become apparent upon a reading of the preferred embodiments of the
invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a fin and tube-type heat exchanger
constructed in accordance with one of the embodiments comprising
the present invention;
FIG. 2 is a transverse sectional view through one end of the heat
exchanger as shown in FIG. 1 and taken substantially along the line
2--2 thereof;
FIG. 3 is a transverse sectional view through the other end of the
heat exchanger shown in FIG. 1 and taken substantially along the
line 3--3 thereof;
FIG. 4 is a side elevational view of the heat exchanger shown in
FIG. 1;
FIG. 5 is a plan view, partly in section, of a fin and tube-type
heat exchanger constructed in accordance with an alternative
satisfactory embodiment of the present invention;
FIG. 6 is a side elevational view of the heat exchanger shown in
FIG. 5; and
FIG. 7 is a fragmentary magnified sectional view illustrating the
nested aligned relationship of the tubular projections integrally
formed on the stacked sheets.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings, and as may be best seen in
FIGS. 1 to 4, a heat exchanger constructed in accordance with the
practice of the present invention comprises a framework 10
consisting of a pair of L-shaped end panels or members 12,
interconnected at their end portions by a pair of parallel spaced
side panels or members 14. As best seen in FIG. 4, the oppositely
extending flanges of the end panels 12 are provided with nuts 18
affixed at laterally spaced increments therealong for threadably
securing the heat exchanger to a suitable mounting platform or
base.
A plurality of conduits 18 extend in paired laterally spaced
parallel relationship between the end panels 12 and are formed by
means of a plurality of spaced parallel sheets 20 extending between
the side panels 14. As best seen in FIG. 7, each of the sheets 20
are formed with a series of tapered tubular projections 22, which
are disposed in aligned nested relationship with corresponding
tubular projections on adjacent sheets forming a telescopic tubular
wall defining the conduits 18. The sheets 20 serve as heat
radiating or transfer fins for conducting heat to or from a fluid
adapted to be circulated through the conduits of the heat
exchanger.
As shown in FIGS. 1-4, one of the ends of the conduits 18 are
connected in pairs and slidably received in a U-shaped manifold 24
formed with an outlet 26 projecting from the bight portion thereof,
which in turn is connected by means of a nipple 28 to a header
conduit 30 disposed outwardly of and substantially parallel to the
end panel 12. The other ends of the conduits 18 slidably overlie
and are connected to U-shaped manifolds 25 similarly having an
outlet 26 connected by a nipple 28 to the header conduit 32. As
will be noted, each of the end panels 12 is formed with a plurality
of spaced apertures 34 for receiving the outlet 26 of the U-shaped
manifolds 24, 25, such that the bight portion of the manifolds is
disposed in firm seated relationship against the surface of the end
panel. In accordance with this arrangement, the clamping thrust of
the end panels is transmitted by the manifolds 24, 25 to the
stacked sheets, maintaining the tubular projections in appropriate
nested relationship.
The header conduit 30 is of a circular cross section and is
provided with end caps 36 and a centrally disposed plug 38 defining
two noncommunicating chambers. An inlet 40 is mounted in
communication with one of the chambers for delivering a suitable
fluid thereto for circulation through the conduits 18 connected
thereto to the opposite header conduit 32. The header conduit 32
similarly is provided with end plugs 42 and may be further provided
with suitable baffles for directionally guiding the fluid passing
therethrough. The other chamber of the header conduit 30 is
provided with an outlet 44 through which the fluid is transmitted
to the system containing the heat exchanger.
In the manufacture of the heat exchanger, as shown in FIGS. 1-4,
the framework 10 is first assembled by securing the ends of the
side panels 14 to one of the end panels 12 and thereafter a
plurality of the sheets 20 are positioned in appropriate stacked
relationship such that the tubular projections are in nested
alignment as shown in FIG. 7. The U-shaped manifolds 24, 25 are
placed in appropriate position with the outlets 26 extending
through the apertures 34 in the end panels and with the outlet ends
of the U-shaped portion in communication with the conduits defined
by the tubular projections. The opposite end panel thereafter is
secured to the side panels whereby the stacked sheets are placed in
appropriate clamped relationship assuring uniform nested
relationship between the tubular projections on the spaced sheets.
A suitable sealing and bonding material, such as a metallic solder
or brazing metal, is placed in the interior of the tubular
projections, such as a brazing rod 46 as shown in FIG. 7, and the
assembly as such is placed in a brazing furnace in which it is
heated to an elevated temperature at which the brazing compound
melts and flows by capillary action around the joints formed
between the nested tubular projections, effecting a sealing and
bonding thereof into an integral unit. In accordance with a
preferred embodiment, the side edges of the sheets 20 are also
supplied with a brazing compound whereby the edges of the sheets
are at least partially affixed to the side panels further enhancing
the structural integrity and strength of the heat exchanger unit.
It will be appreciated, depending on the specific composition of
the materials employed in making the framework and the stacked
sheets, that suitable fluxing compounds can also be used to
advantage for assuring appropriate wetting of the surfaces by a
solder or brazing compound employed. It is also contemplated that
the headers, including the nipples, can be concurrently united with
the conduits preliminarily to placing the assembled unit in the
brazing furnace, whereby the entire unit is integrally united in
one brazing operation. The header components can be added as
subassemblies, if desired, to the stacked assembly prior to
brazing.
In accordance with an alternative satisfactory construction
comprising the present invention, the end members of the framework
are defined by headers, further enhancing the simplicity and
economy of the manufacture and cost of the heat exchanger
apparatus. As shown in FIGS. 5 and 6, the framework consists of a
pair of spaced, substantially parallel side member 48 which are
formed with openings 50 adjacent to the ends thereof for encircling
and engaging the projecting end portions of header conduits 52 and
54, disposed in parallel spaced relationship. Extending between the
header conduits are a plurality of pairs of conduits 56, which are
formed by the nesting of a plurality of transversely extending
parallel spaced sheets 58 having integrally formed tubular
projections thereon disposed in aligned telescopic relationship in
a manner as previously described and as best seen in FIG. 7. The
ends of the conduits 56 are connected to and flow in communication
with U-shaped manifolds 60 and 62. In the specific embodiment as
illustrated in FIGS. 5 and 6, the manifolds 60 are formed with
tapered projections which are adapted to be slidably received by
the tubular projections integrally formed in the adjacent sheet,
while the manifolds 62 connected to the header 52 are formed with
enlarged projections 64 for receiving the integrally formed tubular
projection on the adjacent sheet 58. Each of the manifolds 60, 62
is formed with an outlet 66 at the center portion of the bight
section thereof, which is adapted to extend through appropriate
ports 68 formed at spaced intervals in the walls of the header
conduits 52 and 54.
As shown in FIGS. 5 and 6, the header conduit 52 is provided with
end caps 70 and a central plug 72 dividing the header conduit into
two noncommunicating compartments. One of the compartments is
provided with an inlet tube 74 for delivering a fluid thereto for
transmittal through the conduits 56 and into the header conduit 54.
The header conduit 54 similarly is provided with end caps 78
disposed in sealing engagement therewith. The fluid upon entering
the header conduit 54 passes to the left, as viewed in FIG. 5, and
back into the conduits 56, and thence into the other compartment of
the header conduit 52 and is removed through the outlet tube 76.
The inlet tube and outlet tube are illustrated with appropriate
fittings for removably connecting the heat exchanger to the fluid
system.
In order to facilitate installation of the heat exchanger, four
mounting straps 80 formed with mounting holes 82 are securely fixed
in paired relationship, such as by means of welding, to the
underside of the headers 52 and 54.
During the manufacture and assembly of the heat exchanger, as shown
in FIGS. 5 and 6, the side members 48 are first positioned in
overlying engaging relationship with the ends of a preliminarily
formed header 52 and the manifolds 62 are placed in appropriate
assembled relationship thereon. Thereafter, the appropriate number
of sheets 58 are stacked in aligned nested relationship to define
the conduits 56 and a suitable bonding and sealing material is
placed in the interior thereof, after which the manifolds 60 are
placed over the ends thereof and the preliminarily assembled header
conduit 54 is placed in overlying relationship with the ports 68
thereof disposed in receiving relationship relative to the outlets
66 of the manifolds 60. The openings 50 and the side members 48 are
thereafter placed in overlying engaging relationship around the end
portion of the header conduit 54, effecting a clamping of the
stacked sheets and tubular projections thereon in appropriate
parallel spaced relationship. Appropriate fluxing agents and solder
or brazing materials are thereafter placed at positions contiguous
to the joints to be sealed and bonded, and the assembly is placed
in a brazing furnace and heated to an elevated temperature,
effecting a flow of the material by capillary action, forming a
rigid fluidtight bond upon subsequent cooling of the assembly.
It will be appreciated that in the heat exchanger construction as
shown in FIGS. 1-4 and in FIGS. 5 and 6, the securing of the
framework can be achieved concurrently with the brazing operation
of the stacked sheets, or alternatively, to prevent inadvertent
movement or disengagement of the frame members, the individual
components can be preliminarily tack welded or brazed prior to
transfer of the assembly to the brazing furnace. In the
construction of the framework shown in FIGS. 1-4, it is usually
necessary to preliminarily braze or tack weld the framework in
order to retain the sheets in appropriate clamped position. In the
construction shown in FIGS. 5 and 6, on the other hand, the
encircling engagement of the side members around the end portions
of the header conduits enables concurrent fastening of the
framework and tubular projections. It will be appreciated also that
when brazed subassemblies, such as the header conduits, are
employed, the bonding of the subassembly is achieved with bonding
materials having a remelt temperature above that to which the
assembly is subjected during the final brazing operation.
While it will be apparent that the invention disclosed herein is
well calculated to fulfill the objects above stated, it will be
appreciated that the invention is susceptible to modification,
variation and change without departing from the proper scope or
fair meaning of the subjoined claims.
* * * * *