LAMINATED HEAT EXCHANGERS

Abstract

A heat exchanger for allowing heat to be exchanged between a first fluid and at least one other fluid comprises: a core comprising: at least one flow path; a manifold in communication with the at least one flow path; wherein the manifold comprises a void formed in the core; and the manifold comprises end caps, wherein at least one of the end caps is a non-flat end cap.

Claims

1. A heat exchanger for the exchange of heat between a first fluid and at least one other fluid, the heat exchanger comprising: a core comprising: at least one flow path; a manifold in communication with the at least one flow path, wherein the manifold comprises: void formed in the core; and end caps, wherein at least one of the end caps is a non-flat end cap.

2. The heat exchanger of claim 1, wherein the heat exchanger is for allowing the exchange of heat between two fluids, the core comprising: a first flow path and a second flow path.

3. The heat exchanger of claim 1, wherein the heat exchanger is a laminate heat exchanger, wherein the core comprises a plurality of laminate members, and wherein the void extends through the plurality of laminate members.

4. The heat exchanger of claim 3, wherein the plurality of laminate members comprises: a plurality of fluid enclosures arranged to at least partially define the at least one flow path; at least one separating plate for separating each of the plurality of fluid enclosures; a base plate; and a top plate.

5. The heat exchanger of claim 4, wherein at least one of the base plate or the top plate integrally comprises at least one non-flat end cap.

6. The heat exchanger of claim 1, wherein the at least one non-flat end cap is ellipsoidal, torispherical, hemispherical, or any other curved shape.

7. The heat exchanger of claim 1, wherein the heat exchanger comprises at least one flange for mounting the heat exchanger to other components, optionally wherein the at least one non-flat end cap does not protrude above the extent of the flange.

8. The heat exchanger of claim 1, wherein the manifold comprises: an inlet; an outlet; a supply plenum in fluid communication with the inlet; and a return plenum in fluid communication with the outlet.

9. The heat exchanger of claim 9, wherein the lengthways cross-section of one or both of the supply plenum and the return plenum is elliptical, rounded rectangular, or stadium-shaped.

10. The heat exchanger of claim 9, wherein the widthways cross-section of one or both of the supply plenum and the return plenum is spherical, elliptical, rounded rectangular, stadium-shaped, or any other suitable shape.

11. The heat exchanger of claim 9, wherein the supply plenum and the return plenum are separated by a plenum wall.

12. The heat exchanger of claim 1, wherein the non-flat configuration of the end cap allows stresses in the end cap to be more uniformly distributed than if the end cap were flat.

13. A method of forming a heat exchanger, the method comprising: forming a core; providing a void within the core; using end caps to seal the void, wherein the void and the end caps together form a manifold, and wherein at least one of the end caps is a non-flat end cap.

14. The method of claim 13, wherein the heat exchanger is a laminate heat exchanger, wherein forming the core includes stacking a plurality of laminate members, and wherein the void extends through the plurality of laminate members, and wherein the plurality of laminate members comprises: a plurality of fluid enclosures arranged to at least partially define at least one flow path; at least one separating plate for separating each of the plurality of fluid enclosures; a base plate; and a top plate.

15. The method of claim 13, wherein the at least one non-flat end cap is ellipsoidal, torispherical, hemispherical, or any other curved shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Certain embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings in which:

[0042] FIG. 1 shows a the heat exchanger;

[0043] FIG. 2 shows end plates having integral end caps;

[0044] FIG. 3A shows a cross-section of the integral manifold in a heat exchanger;

[0045] FIG. 3B shows a different cross-section of the integral manifold; and

[0046] FIG. 4 shows an intermediate step in a method of forming the heat exchanger.

DETAILED DESCRIPTION

[0047] Although the end plates are referred to as a base plate and a top plate below, the particular orientation alluded to by the naming of these plates is in relation only to the orientation shown in the figures and has no bearing on the final orientation of the completed product either before or after installation. The skilled person would understand that a heat exchanger 1 may be oriented as shown in the figures or may be rotated through any angle in any direction. The skilled person would then understand that the base plate 110 and top plate 120 as shown in FIG. 2 are simply end plates of the heat exchanger 1 and are not restricted to the orientation depicted in the figure.

[0048] Turning to FIG. 1, a heat exchanger 1 comprises a core 100. The core 100 comprises end plates 110, 120 and a stack 130, where the stack 130 is between the end plates 110, 120. The stack 130 is formed from a plurality of separating plates 132, a plurality of first enclosure structures 134, and a plurality of second enclosure structures 136. First enclosure structures 134 act in cooperation with the separating plates 132 to define a plurality of first flow paths 138 for a first fluid. Second enclosure structures 136 act in cooperation with the separating plates 132 to define a plurality of second flow paths 139 for a second fluid.

[0049] The plurality of first enclosure structures 134 comprise a plurality of first fluid transfer elements (not shown) and the plurality of second enclosure structures 136 comprise a plurality of second fluid transfer elements 137. The first and second fluid transfer elements may be pins or fins or any other suitable structure for facilitating heat transfer.

[0050] The core 100 of the heat exchanger 1 also comprises a manifold 140, the manifold 140 being formed from a void 141 within the stack 130 and from end caps 150.

[0051] The manifold 140 comprises manifold features, such an inlet 143 and an outlet 145 for supplying and returning, respectively, the first fluid from the first fluid flowpaths. The manifold is supplied with the first fluid via the inlet 143. The first fluid exits the manifold via the outlet 145. In this example the inlet 143 and outlet 145 are on the same end of the heat exchanger 1.

[0052] The heat exchanger 1 also comprises flanges 200. The flanges 200 are for facilitating the interfacing of the heat exchanger 1 with adjacent components. The flanges 200 may comprise holes 201. The holes 201 may be formed by drilling, water cutting, or any other suitable method. Typically the holes 201 are formed after the formation of the core 100. The holes 201 allow the heat exchanger 1 to be attached, using bolts, for example, to other components such as air ducts.

[0053] The core 100, manifold 140, and flanges 200 are formed as one integral piece. The end plates 110, 120 may also provide end caps 150 for the manifold 140. Alternatively, the end plates 110, 120 may be formed without end caps 150. In the latter case, end caps 150 may be formed separately and joined to the integral piece.

[0054] The integral piece comprises a plurality of laminate members 110, 120, 132, 134, 136. The integral piece has a first end 102, a second end 104, a first side 106, and a second side 108.

[0055] The plurality of laminate members 110, 120, 132, 134, 136 includes end plates 110, 120, the plurality of separating plates 132, the plurality of first enclosure structures 134, and the plurality of second enclosure structures 136.

[0056] The manifold is formed towards the first end 102 of the integral piece. The manifold 140 has end caps 150, wherein at least one of the end caps 150 forms a curved manifold end 152. In this example each of the end caps 150 is a curved manifold end 152, i.e. all of the end caps 150 are non-flat end caps. The curved manifold end 152 may be made as a separate end cap 150 and then joined to one of the end plates 110, 120. Alternatively, as shown in the Figures, the curved manifold ends 152 may be formed as parts of the end plates 110, 120.

[0057] FIG. 2 shows end plates 110, 120 having curved manifold ends 152 formed integrally therein. End plates 110, 120 may also be known as a base plate 110 and a top plate 120. Both of the base plate 110 or the top plate 120 may have a curved manifold end 152 formed integrally therein. Therefore, the complete core 100 has a base plate 110 having a curved manifold end 152 and a top plate 120 having a curved manifold end 152.

[0058] The curved manifold end 152 can be formed as a protrusion from an otherwise flat end plate 110, 120, as shown in the Figures.

[0059] The end plates 110, 120 are formed with flange portions 202, 204. The flange portions 202, 204 form part of a complete flange 200 when the end plates 110, 120 are joined to the stack of laminate members to complete the core 100. The flanges 200 are proximate the first and second sides 106, 108 of the core 100.

[0060] The curved manifold ends 152 shown in the figures are generally torispherical. However, the curved manifold end 152 may be shaped to be ellipsoidal, hemispherical, or any other suitable curved shape enabling enhanced pressure and/or stress distribution over the non-flat end caps 150 compared to a flat end cap (e.g. as provided by a flat end plate). The skilled person would appreciate that the shape of the curved manifold end 152 may differ to suit differences in the shape of the manifold 140. Thus, the shape depicted in the figures is intended to be exemplary and non-limiting to any particular curved shape.

[0061] An extension 206 may be formed during the manufacturing stage of an end plate 110, 120. The extension 206 lies in the plane of the end plate 110, 120. The purpose of the extension 206 will be elaborated on below.

[0062] The end plates 110, 120 may be formed by cold forming, hydroforming, additive manufacturing, subtractive manufacturing, or any other suitable forming method. Depending on the forming method used, the curved manifold ends 152 may require additional machining to remove excess material.

[0063] FIGS. 3A and 3B show cross-sections of a heat exchanger manifold 140 as viewed from the first end 102 and the first side 106, respectively, of the integral piece. The heat exchangers shown in FIGS. 3A and 3B have a core 100 comprising end plates 110, 120 that both integrally contain curved manifold ends 152.

[0064] The manifold 140 comprises two plena: a supply plenum 146 and a return plenum 148. The supply plenum 146 is in fluid communication with the first fluid paths and is for supplying the first fluid to the fluid paths. The return plenum 148 is in fluid communication with the first fluid paths and is for returning the first fluid from the first fluid paths. The plena 146, 148 are separated by a plenum wall 149. The supply plenum 146 is in fluid communication with inlet 143. The return plenum is in fluid communication with outlet 145.

[0065] The supply plenum 146 has supply end caps 150. The supply plenum end caps 150 may be formed as part of the end plates 110, 120. At least one of the supply plenum end caps 150 may be part of a curved manifold end 152. The supply plenum end cap 150 that is part of the at least one curved manifold end 152 may be shaped to be ellipsoidal, torispherical, hemispherical, or any other suitable curved shape enabling enhanced pressure and/or stress distribution over the supply plenum end cap 150.

[0066] Similarly, the return plenum 148 has return plenum end caps 150. The return plenum end caps 150 may be formed as part of the end plates 110, 120. At least one of the return plenum end caps 150 may be part of a curved manifold end 152. The return plenum end cap 150 that is part of the at least one curved manifold end 152 may be shaped to be ellipsoidal, torispherical, hemispherical, or any other suitable curved shape enabling enhanced pressure and/or stress distribution over the return plenum end cap 150.

[0067] The lengthways cross-section of at least one of the manifold plena 146, 148 may be elliptical, rounded rectangular, or stadium-shaped. By a lengthways cross-section, it is meant that the cross-section is formed in a plane orthogonal to the plane of a laminate member.

[0068] The widthways cross-section of at least one of the manifold plena 146, 148 may be spherical, elliptical, rounded rectangular, stadium-shaped, or any other suitable shape. By a widthways cross-section, it is meant that the cross-section is formed in the same plane as the plane of a laminate member.

[0069] Turning now to FIG. 4, FIG. 4 illustrates an intermediate step in a method of manufacture of the heat exchanger 1. A method of forming the heat exchanger 1 comprises: forming a core 100; forming a void 141 in the core 100; providing end caps 150 to seal the void 141, wherein the void 141 and the end caps 150 together form a manifold 140, and wherein at least one of the end caps 150 is a non-flat end cap 152. The core 100 is formed by stacking together laminate members and then brazing them together.

[0070] The laminate members 110, 120, 132, 134, 136 may be formed by cold forming, hydroforming, additive manufacturing, subtractive manufacturing, or any other suitable forming method. Laminate members 110, 120, 132, 134, 136 may be formed with extensions 206, as shown on the end plates 110, 120 in FIG. 2. When laminate members 110, 120, 132, 134, 136 are stacked in the desired configuration, the extensions line up to form an extension block 208. The laminate members 110, 120, 132, 134, 136 are formed such that, when they are stacked, the manifold 140 is formed as a void 141 within the stack 130.

[0071] The laminate members 132, 134, 136 also comprise flange portions which align to form parts of the flange 200 on the first side 106 and the second side 108 of the stack 130. The flange 200 is completed by flange sections 202, 204 on the end plates 110, 120.

[0072] The end caps 150 are formed as protrusions on the end plates 110, 120 such that the end caps 150 protrude above a main plane of the end plate 110, 120. The flange sections 202, 204 also protrude above the main plane of the end plate 110, 120.

[0073] After the laminate members 110, 120, 132, 134, 136 have been stacked in the desired configuration, they are joined together. The joining process may use vacuum brazing or any other suitable method.

[0074] Once the laminate members 110, 120, 132, 134, 136 have been joined together, the extension block 208 may be machined to form interface features such as the inlet 143 and the outlet 145. Depending on the machining or forming method used, additional machining may be required to remove excess material.

[0075] The void 141 can be formed by stacking laminate members 110, 120, 132, 134, 136 having a void portion, the void portion being formed during the formation of the laminate members 110, 120, 132, 134, 136. Alternatively, the laminate members 110, 120, 132, 134, 136 can be formed without a void portion with the void portion then being formed by a subtractive manufacturing step, such as by machining the stack of laminate members 132, 134, 136. In another alternative, the laminate members 132, 134, 136 are formed by additive manufacturing and have a void portion requiring additional machining to remove undesired material. The void 141 extends fully through the stack 130 and is then sealed using end caps 150 to form the manifold 140.