Heat Exchanger with heat exchange chambers and plate members utilizing respective medium directing members and method of making same

Abstract

A heat exchange unit having a plurality of chamber assembly coupled to a plate member, said chamber assembly including an inlet flow tube, an outlet flow tube, and a plurality of walls defining a chamber interior. Disposed within the chamber interior is a medium-directing member, having an inclined surface, diverting the heat exchange medium from the initial flow direction so that it disperses within the chamber interior, in to at least two distinct flow patterns. The heat exchange medium exits the chamber, via the outlet, in the initial line of flow. The chambers are interconnected by tubes to form assemblies. A plurality of plate member having plurality of chamber assembly is arranged on a spaced relation between manifolds to complete the medium flow.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to heat exchangers and, more specifically, to a heat exchanger having plurality of disk assemblies coupled to a plate member, each disk assemblies having a tube and a chamber apparatus, said chamber apparatus having a medium directing member within for transporting heat exchange medium.

2. Discussion of the Related Art

Heat exchangers are commonly utilized in systems where it is desired for heat to be removed. Typical basic heat exchangers are made of pipes, which channel heat exchanging medium. Headers or manifolds are attached to each end of the pipes. These headers and manifolds act as receptacles for the heat exchanging medium. The efficiency of the pipe heat exchangers is limited by the amount of surface area available for the transfer of heat. In a tube and chamber heat exchanger, plurality of tube and chamber extend in spaced relation between a pair of header or manifold, forming a core of a heat exchanger. The present invention provides an effective and efficient means to increase surface area to a core of a tube and chamber heat exchanger, which in turn greatly enhances the performance of a heat exchanger performance with a simple solution. The present invention achieves these enhancements without adversely affecting the overall size of the core, while simplifying the manufacturing process, thereby providing a heat exchanger with vastly improved heat exchanging characteristics without adverse cost impact.

To increase surface area, typical heat exchangers, such as condensers, incorporate a flat-tube design, usually of extruded tubular material, with extended surfaces provided by corrugated fin material. This type of heat exchanger typically includes flattened tubes having a fluid passing therethrough and a plurality of corrugated fins extending between the tubes. The fins are attached to the tubes to effectively increase the surface area of the tubes, thereby enhancing heat transfer capability of the tubes. A number of tubes and fins may be stacked on top of each other, which leaves a small opening to allow passage of air in between them. To further improve heat transfer efficiency, the tube thickness is made thinner. As a result, the parts are lighter in weight, which in turn makes the overall heat exchanger lighter in weight. However, the pressure resistance is reduced, and the thinner tubes are more prone to damage. Also, the assembly process is complicated because of the fragile nature of the parts. In addition, the extruded tubes are prone to plugging during the manufacturing process, particularly if a brazing process is utilized. The complexity of the extruding process potentially results in higher costs and higher defect rates.

The overall cost for the flat tube heat exchanging system will be higher because a higher powered compressor may be necessary to move the heat exchanging medium through the smaller openings of the tubes. Conversely, if a higher powered compressor is not utilized, then additional tubes will be necessary to obtain the desired heat exchanging performance because the smaller tubes reduce the flow of the heat exchange medium significantly. The additional tubes will increase the overall cost for the heat exchanging system. Currently, this type of heat exchanger is used in applications requiring high heat exchanging capabilities, such as automotive air conditioner condensers.

In another tube-and-fin design, the tube can be of a serpentine design, therefore eliminating the need for headers or manifolds, as the tube is bent back and forth in an “S” shape to create a similar effect. Typical applications of this type of heat exchanger, besides condensers, are evaporators, oil coolers, and heater cores. This tube-and-fin design is also utilized in radiators for automobiles. Outside of the automotive field, the tube and fin design is implemented by industrial oil coolers, compressor oil coolers, and in other similar applications requiring a higher efficiency heat exchanger.

A variation on the tube-based heat exchanger involves stacking flat ribbed plates. When stacked upon each other, these ribbed plates create chambers for transferring heat exchanging medium. In essence, this type of heat exchanger performs substantially the same function as tube-and-fin type heat exchangers, but is fabricated differently. This type of heat exchanger is commonly implemented by contemporary evaporators.

In a typical manufacturing method of tube and fin heat exchangers, plurality of fins are first stacked to a desired quantity. Once fins are bound and stacked together, tubes are inserted into plurality of holes pre-formed on each fin. Holes pre-formed on fins are arranged so that once the fins are bound together, the holes align with each other from the first fin material to the second fin material, allowing a generally straight tube to be inserted through the holes. In order to enhance the heat transfer characteristics, once tubes and fins are assembled together, individual tubes go through an expansion process whereby tubes are expanded from within by mechanical means to increase the diameter of tubes, enhancing the tube to fin surface contact. To facilitate the tube expansion process, at least one free end of tubes is left open to allow the tube expansion device to be inserted, once the tube and fin structure are assembled together. Upon completion of the tube expansion process, open end of tubes are sealed, usually by means of a manifold.

In a manufacturing process of flat tube heat exchangers, tubes are first cut to a desired length. In a separate line, fins are corrugated and fabricated to a desired shape, then cut to a desired length. Once tubes and fins are ready for assembly, plurality of tube and fin material is stacked together, with fin material coupled between two tubes aligned parallel to each other. Once tube and fin material is stacked together to a desired height, manifolds are assembled onto the free ends of the tubes. In assembling all the components together, a precision assembly fixture is generally required, as tube and fin material are prone to come apart during the assembly process, until the entire assembly is processed through a brazing process, a process which bonds all components together. Especially during the assembly of manifolds onto the free ends of the tubes, tubes need to be held in position firmly by an assembly fixture for a proper assembly. Due to the nature of the flat tube heat exchanger assembly, if the assembly fixture is even slightly off tolerances, the entire heat exchanger assembly may not braze properly. For this type of heat exchanger assembly, significant investment must be made in precision assembly machines and fixtures, in addition to having components made to a very high-precision tolerances, causing the assembly cost of a heat exchanger to rise significantly, in addition to having to pay more for precision made components.

SUMMARY OF THE INVENTION

The present invention is an enhanced tube for heat exchanging applications including flow tube and a chamber coupled to a generally planar plate member. The flow tube connects to the chamber. One end of the flow tube may connect to a header or a manifold. Heat exchange medium flows from the header or the manifold into the flow tube. The heat exchange medium then flows into the chamber. The chamber is coupled to a plate member. The heat exchange medium then flows from the chamber into another flow tube, which is connected to another header or manifold. The heat contained within the heat exchange medium is dispersed by a surface area of the flow tube, the chamber, and the plate member.

In an embodiment of the present invention, the flow tube, the chamber, and the plate member for a heat exchanger are provided, for example, for a condenser, evaporator, radiator, etc. The heat exchanger may also be a heater core, intercooler, or an oil cooler for an automotive application (i.e., steering, transmission, engine, etc.) as well as for non-automotive applications. An advantage of the present invention is that the heat exchanger has larger surface area for radiating heat over a shorter distance than that of a conventional heat exchanger, with the surface area provided by the flow tube and the chamber, along with extended heat exchanging surfaces provided by the plate member. With a provision of a large surface area for heat exchanging purposes, the efficiency of a heat exchanger is greatly increased. Another advantage of the present invention is that the overall length and weight of the enhanced tube for heat exchanging applications may be less compared to a conventional heat exchanger, which in turn provides for a lower overall cost as less raw material and less packaging is necessary. Additionally, the flow tube and the chamber may be made from a thicker gage material, while the plate member may be made of thinner gage material. This allows the flow tube and the chamber to handle heat exchanging medium requiring higher internal pressure, which may be common in applications such as a condenser for an air conditioner, for example. Usage of thin gage material for the plate member improves heat conductivity of the plate member, while significantly increasing the surface area for heat exchanging purposes, without adversely affecting cost or the weight. Furthermore, the smaller footprint of the present invention lends itself to be used in applications where space is limited. Yet another advantage of the present invention over a conventional heat exchanger is that the manufacturing process may be simpler because the present invention requires less fragile components and less manufacturing steps. Furthermore, during the assembly process, the plate member on which flow tube and chamber are coupled to, assists in positioning the flow tube and the chamber assembly, acting akin to an assembly tray during the manufacturing process, holding in place components during the assembly process. The entire unit may be brazed together, or any portion of the unit can be brazed first, and then additional components may be brazed or soldered together.

In another embodiment of the present invention, more than one chamber may be used, which will further increase the surface area of the enhanced tube for the heat exchanger. Also, a first chamber may be connected directly to another chamber. Furthermore, more than one chamber may be coupled to a plate member. In another embodiment of the present invention, more than one plate member may be coupled to a chamber. When plurality of chambers are coupled to the plate member, the plate member provides an economical means to maximize the heat exchanging capability of a heat exchanger by filling the voids between plurality of column of chambers to increase the overall surface area of the heat exchanger, without greatly increasing the size of a heat exchanger.

In yet another embodiment of the present invention, the tube size may vary between the chambers, and if more than one chamber is used, the chamber size may vary from one chamber to the next.

In another embodiment of the present invention, plurality of tube size and chamber size positioned on a plate member may vary from one to the next.

In a further embodiment of the present invention, each chamber may disperse heat exchanging medium throughout the chamber, which further enhances the heat exchanging capabilities of the present invention. Also, each chamber may also mix heat exchanging medium.

In yet a further embodiment of the present invention, each chamber may include a medium-directing member and medium redirection members that direct and redirect heat exchanging medium in a particular directions through the chamber.

In another embodiment of the present invention, the inner surface of the tube may feature indentations to increase the surface area. Also, in yet another embodiment of the present invention, the inner surface of the chamber may also feature indentations to increase the surface area. In a further embodiment of the present invention, the medium-directing member may also feature indentations. In an embodiment of the present invention, the plate member may have surface features such as, but not limited to, indentations, louvers, dimples, slits, other extended surface features known in the art, etc.

In other embodiments of the present invention, the tube, the chamber, and the plate member combination may be repeated, and based on a particular application, there may be multiple tube, chamber, and plate member assembly rows coupled together to form a unitary unit. Plurality of tube, chamber, and plate member units may be attached to a header or a manifold. There may be a plurality of tube, chamber, and plate member units arranged in a row that are attached to a header or a manifold to enhance the overall performance of the heat exchanger.

In some embodiments, the chamber is of a greater diameter than the inlet and the outlet of the chamber. In other embodiments, the chamber is of a greater diameter than the inlet of the chamber, but may be the same diameter as the outlet. Alternatively, in yet other embodiments, the chamber may be of a greater diameter than the outlet of the chamber, but may be the same diameter as the inlet.

In an embodiment of the present invention, the plate member may be rectangular in shape. In other embodiment of the present invention, the plate member may be other geometric shape like a trapezoid or an oval, for an example. In some embodiments of the present invention, the plate member may have surface feature such as plurality of folds or bends that rise generally perpendicular from the surface of the plane of the plate member to assist in spacing plurality of plate member from one plate member to the other. In such an embodiment, the apex of a fold or a bend from first plate member abut against the base plane of second plate member, whereby the height of a fold or a bend dictate the spaced relation between the first plate member and the second plate member.

In yet some other embodiments, the chamber has at least one greater dimension than the tube. For instance, the chamber may have a greater fluid capacity, circumference, or surface area. The ratio of a particular dimension between the tube and the chamber may be 1:1.1; 1:1.5; or any other suitable ratio.

In an embodiment of the present invention, the plate member has an indentation in the shape of the chamber, coupling the chamber in position within said indentation on the surface of the plate member. In another embodiment of the present invention, the plate member has plurality of indentations in the shape of the chamber, the plate member coupling plurality of chambers. In such an embodiment, chamber coupling locations are dictated by the position of indentations on the surface of the plate member.

In some embodiment of the present invention, a chamber assembly comprising of the inlet and the outlet flow tubes, the chamber, and the medium-directing member may be assembled as a unit, then coupled to the plate member. In an embodiment of the present invention, plurality of chamber assemblies may be coupled to the plate member.

In yet another embodiment of the present invention, the plate member has a hole formed in the shape of the chamber, positioning and locating the chamber on the plate member. In another embodiment of the present invention, the plate member has a plurality of holes in the shape of the chamber, to which chambers are coupled.

In some embodiment of the present invention, the plate member has a hole in the shape of the tube, onto which the tube is inserted for the purpose of holding the tube in position on the plate member. In another embodiment of the present invention, the plate member has a plurality of holes in the shape of the tube. In yet another embodiment of the present invention, the plate member may contain plurality of holes in the shape of chambers and tubes, whereas some of the holes are for coupling chambers, and some of the holes are for coupling tubes.

In another embodiment of the present invention, the plate member may contain plurality of indentations in the shape of chambers, each indentations having a hole to pass through the tube, wherein indentations are used to couple chambers to the plate member.

The tube and the chamber may be made of aluminum, either with cladding or without cladding. The plate member may be made of aluminum, either with cladding or without cladding. The medium-directing member may be made of aluminum, either with cladding or without cladding. The tube, the chamber, the medium-directing member, and the plate member may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The tube, the chamber, the medium-directing member, and the plate member may also be a plastic material or other composite materials.

The tube, the chamber, the medium-directing member, and the plate member may be manufactured by stamping, cold forging, casting, or machining. The tube and the chamber may be manufactured as one piece or may be manufactured as two separate pieces. The tube, the chamber, and the plate member may be manufactured as one piece, or may be manufactured as separate pieces. The chamber and the medium-directing member may be manufactured as one piece, or may be manufactured as separate pieces.

Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention;

FIG. 1B is a frontal view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention;

FIG. 1C is a top view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention;

FIG. 1D is a side view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention;

FIG. 2A illustrates flow pattern of heat exchange medium inside the tube and chamber assembly, and the means by which heat is transferred to the surrounding atmosphere through the tube, the chamber and the plate member structure, according to an embodiment of the present invention;

FIG. 2B is a side view of tubes, chambers, and plate members illustrated in operational relationship with manifolds to provide a heat exchanger according to embodiments of the present invention;

FIG. 2C illustrates a cross-sectional view of an operational relationship of a plate member with plurality of chambers, said chambers having a medium-directing member;

FIG. 3A is a perspective view of a plate member according to an embodiment of the present invention;

FIG. 3B is a frontal view of a plate member according to an embodiment of the present invention;

FIG. 3C is a side view of a plate member according to an embodiment of the present invention;

FIG. 3D is a top view of a plate member according to an embodiment of the present invention;

FIGS. 3E through 3F illustrate various embodiments of the plate member;

FIG. 4A is a frontal view of a prior art embodiment of a plurality of a tube and chamber heat exchanger;

FIG. 4B is a top view of a prior art embodiment of a plurality of a tube and chamber heat exchanger;

FIG. 4C is a side view of an embodiment of the present invention;

FIG. 4D is a top view of an embodiment of the present invention;

FIG. 4E through 4F illustrate various side view of yet another embodiment of the present invention;

FIG. 4G through 4H illustrate various coupling method of a plate member to a chamber according to an embodiment of the present invention;

FIG. 5A through 5F illustrate other various coupling methods of a plate member to a chamber according to yet another embodiment of the present invention;

FIG. 6A is a perspective view of yet another embodiment of the present invention;

FIG. 6B is a frontal view of yet another embodiment of the present invention;

FIG. 6C is a side view of yet another embodiment of the present invention;

FIG. 7A through 7F illustrates various shape of the embodiment of the present invention during stages of the manufacturing process;

FIG. 8A through 8D illustrate various shape of another embodiment of the present invention during stages of the manufacturing process;

FIGS. 9A through 9D illustrate various shapes of yet another embodiment of the present invention during stages of the manufacturing process;

DETAILED DESCRIPTION

Referring to the drawings and in particular FIG. 1B and FIG. 2B, an embodiment of a heat exchanger 105 is shown. The heat exchanger 105 includes a pair of manifolds 200 and 205. Plurality of tube 20, chamber 30, and plate member 35 extend in spaced relation between a pair of manifolds 200 and 205, comprising a core 100 of the heat exchanger 105. One free end of tubes 20 coupled to manifold 200, and the other free end of tubes 20 coupled to manifold 205. Heat exchange medium 15 flows from the outlet 215 of the manifold 200 into the inlet 5 of the tube 20. The heat exchange medium 15 passes through the outlet 10 of the tube 20 into the inlet 60 of the chamber 30. The chamber 30 is coupled to a plate member 35. The heat exchange medium 15 then flow out outlet 65 of the chamber 30. The process of going from a tube 20 to a chamber 30 may repeat several times until the heat exchange medium 15 is received by another manifold 205. There may also be several rows of the tube 20, chamber 30, plate member 35 combinations. Also, one embodiment may allow for just one row comprising of one tube 20 and one chamber 30 coupled to a plate member 35. Throughout the transport of the heat exchange medium 15 through the heat exchanger 105, the heat from the heat exchange medium 15 is transferred to the environment outside of the heat exchanger 105. Referring to FIG. 2A, as the heat exchange medium 15 travel through the tube 20 and chamber 30 assembly, heat travels from the heat exchange medium 15 to the outside environment of the heat exchanger 105. FIG. 2A illustrates flow of heat exchange medium 15, said flow illustrated by the striped arrows. As the heat exchange medium 15 travels inside the heat exchanger 105, heat contained within the heat exchange medium 15 is transferred to the environment outside the heat exchanger, transferring heat through the walls of the tube 20, the chamber 30, and the plate member 35. Although not meant to be limiting, common heat exchange medium known in the art includes various refrigerants (i.e., R-134A, R-410A), carbon dioxide, butane, oils, gases (e.g., air), water, and mixtures of water and other coolants (e.g. ethylene glycol).

In another embodiment of the heat exchanger 105, the heat exchanger 105 may be used in a reversed method. Instead of the heat exchanger 105 being used in an environment where heat is transferred from the heat exchange medium 15 to the surrounding environment of the heat exchanger 105, the heat exchanger 105 may be used to increase the temperature of the heat exchange medium 15 flowing inside the present invention. For example, a refrigerant with a low boiling temperature may flow through the tube 20 and the chamber 30 of the heat exchanger 105, where the environment surrounding the heat exchanger 105 is of a higher temperature than that of the refrigerant. Continuing with this example, the heat from the environment surrounding the heat exchanger 105 is transferred to the refrigerant, thereby increasing the temperature of the refrigerant, hot enough to cause the refrigerant to reach a boiling temperature. An example of this embodiment, which is not intended to be limiting, would be an evaporator for an air conditioning unit.

Referring to FIG. 2A, the inside of tube 20 is hollow, which allows for the flowing of the heat exchange medium 15. The tube 20 is mated to the chamber 30. The chamber 30 houses a medium-directing member 25. The medium-directing member 25 is positioned within the intersecting space between the tube 20 and the chamber 30. The heat exchanging medium 15 flows through the tube 20 until the heat exchanging medium 15 flows into contact with the medium-directing member 25. The medium-directing member 25 directs the heat exchanging medium 15 into the inside of the chamber 30. According to the present embodiment, the heat exchange medium 15 disperses throughout the chamber 30, and heat is transferred from the heat exchange medium 15 to the chamber 30 and the plate member 35.

Referring to FIG. 2C, an embodiment of the chamber 30 is shown. Plurality of chambers 30 are arranged on a plate member 35. Medium-directing member 25 is attached to chambers 30. In this embodiment, the medium-directing member 25 is attached to the inner wall of the chamber 30. Although not meant to be limiting, in FIGS. 2A and 2C, the medium-directing member 25 is secured at an angle. In addition, other embodiments may secure the medium-directing member 25 at an angle inside the chamber 30.

Referring to FIG. 2A, the inside of tube 20 is hollow, which allows for the flowing of a heat exchange medium 15. The tube 20 is mated to the chamber 30. The chamber 30 houses a medium-directing member 25. The medium-directing member 25 is fixed within the intersecting space between the tube 10 and the chamber 30. The heat exchanging medium 15 flows through the tube 20 until the heat exchanging medium 15 flows into contact with the medium-directing member 25. The medium-directing member 25 directs the heat exchanging medium 15 into the inside of the chamber 30. According to the embodiment in FIG. 2C, medium-directing member 25 direct the heat exchange medium 15 in a particular direction within the chamber 30 and heat is transferred from the heat exchange medium 15 to the chamber 30. The heat transferred from the heat exchange medium 15 to the chamber 30, then transfers to the plate member 35, where larger surface area of the plate member, allows for efficient dissipation of heat from the heat exchanger core 100. Although not meant to be limiting, plate members are generally made of thin gage material, providing efficient heat conductivity characteristics.

Referring to FIG. 3A, an embodiment of the plate member 35 according to the present invention is shown. The plate member 35 is a generally planar material, having plurality of holes 300. The holes 300 go through the thickness of the material comprising the plate member 35, the shape of the holes 300 set to the shape of the chamber 30, circumference of the holes sized to allow the chamber 30 to be inserted through the holes 300. Along the circumference of the holes 300, is an annular wall 305 extending away from the base plane 365 of the plate member 35, the annular wall 305 initiating from the base plane 365 from a fold 370 on the plate member Annular walls 305 extend generally perpendicular away from the base plane 365 of the plate member 35. Referring to FIGS. 5A and 5B, an exploded view of the annular wall 305 is shown. The plate member 35 has an annular wall 305 extending away from the base plane 365 of the plate member 35. The inner surface of the annular wall 305 is set to the shape of the chamber 30. Inner surface of the annular wall 305 is generally smooth, allowing lateral surface 40 of the chamber 30 to abut against the inner circumference of the annular wall 305. Upon assembly of the plate member 35 to the chamber 30, the components may be brazed together. The plate member 35 may utilize cladded material, the chamber 30 may utilize cladded material, or both components may utilize cladded material, so when brazed, components are firmly bonded together.

Referring to FIG. 3E, it represents another embodiment of the plate member 35 according to the present invention. The plate member 35 is shown with plurality of indentations 325 in the shape of the chamber 30. Plurality of annular walls 305 extends generally perpendicular away from the base plane 365 of the plate member 35, annular walls initiating from the planar surface 365 of the plate member 35 at the fold 370 on the planar member. Annular wall 305 has an inner circumference generally of the outer diameter of the chamber 30, allowing the lateral wall 40 of the chamber 30 to abut against the inner circumference of the annular wall 305. The annular wall terminates at a second plane surface 325 that is generally parallel to the base plane 365 of the plate member 35. The second plane surface 325 has a hole 320 in the shape of the tube 20, the hole 320 going through the entire thickness of the second plane surface 325. The tube 20 connected to the chamber 30 is inserted through the hole 320. Top surface 45 of the chamber 30 is coupled to the inner surface of the second plane surface 325. The lateral surface 40 of the chamber 30 is coupled to the inner surface of the annular wall 305. Upon assembly, entire unit may be brazed together.

FIG. 3F is yet another embodiment of the plate member according to the present invention. The plate member 35 is shown with plurality of indentations in the shape of the chamber 30. Plurality of annular walls 305 extends generally perpendicular away from the base plane 365 of the plate member 35, said walls initiating from the planar surface 365 of the plate member 35 at the fold 370 on the plate member 35. Annular wall 305 has an inner circumference generally of the outer diameter of the chamber 30, allowing the lateral wall 40 of the chamber 30 to abut against the inner surface of the annular wall 305. The annular wall terminates at a stepped planar surface 345 that is generally parallel to the base plane 365 of the plate member 35. The stepped planar surface 345 has a hole 340, diameter of the hole set smaller than the diameter of the chamber, but larger than the diameter of the tube 20. Referring to FIGS. 4G and 4H, which is an exploded view of the plate member 35 and the chamber 30, the top surface 45 of the chamber 30 is coupled to the inner surface 355 of the stepped planar surface 345. The lateral surface 40 of the chamber 30 is coupled to the inner surface of the annular wall 305. Upon assembly, entire unit may be brazed together.

Referring to FIGS. 4A and 4B, prior art illustration of plurality of chamber assembly 400 are presented. Chamber assembly 400 comprises of tube 20, chamber 30, and a medium-directing member 25 contained within the chamber 30. Plurality of chamber assembly 400 may be combined together, free end of tube 20 of the first chamber assembly 400 connected to a free end of tube 20 on a second chamber assembly 400, forming a plurality of row of chamber assemblies 400. As many chamber assembly 400 may be combined together to form a row of chamber assembly 400 of desired quantity. Plurality of chamber assembly 400 may be arranged in a column, plurality of chamber assemblies aligned laterally as shown in FIG. 4B. Although not meant to be limiting, a column of chamber assemblies 400 may be arranged, allowing for a chamber assemblies on first column of chamber assemblies to align generally to chamber assemblies on a second column of chamber assemblies on a same plane. As plurality of chamber assemblies are arranged on a column, a space 405 is created between plurality of chamber assemblies 400.

Referring to FIGS. 4C and 4D, an embodiment according to present invention is shown. Plurality of chamber assemblies 400 are arranged in a column, aligned laterally on generally of same plane as shown in FIG. 4D. In an embodiment according to the present invention, plurality of chambers arranged on a same plane is coupled to a plate member 35. By having plurality of chamber assembly 400 coupled to a plate member 35, present invention utilizes the space 405 between plurality of chamber assemblies 400 to increase the overall surface area of a heat exchanger, thereby enhancing the performance characteristics of a heat exchanger. By utilizing the space 405 between plurality of chamber assembly 400 to add surface area to the heat exchanger, the present invention increases the overall surface area of the chamber assemblies without significantly impacting the overall size of the heat exchanger core 100, enhancing the ratio of internal heat exchange medium volume of the heat exchanger to the overall surface area of the heat exchanger. Generally speaking, when overall surface area of the heat exchanger is increased relative to the internal volume of the heat exchanger, performance of a heat exchanger is enhanced.

Other embodiments of the present invention are illustrated in FIGS. 4E and 4F. Depending on an application of a heat exchanger, the ratio of the overall surface area of the heat exchanger core 105 to the internal volume of the heat exchanger 105 can be adjusted by increasing the quantity of plate member attached to the chamber assembly 400. Although not limiting, in FIG. 4E two plate members 35 are attached to the chamber assembly 400. In FIG. 4F, three plate members 35 are attached to the chamber assembly 400. The quantity of plate members 35 attached to the chamber assembly 400 can be easily adjusted according to the requirements of the heat exchanger in any particular application.

Referring to FIGS. 1A and 1C, the tube 20, in the illustrated embodiment, is hollow and circular. In other embodiments, the tube 20 may be hollow but non-circular, such as an oval or rectangular shape.

Referring to FIG. 1C, in the illustrated embodiment, the chamber 30 is hollow and circular in shape. In other embodiments, the chamber 30 may be hollow, but non-circular in shape.

The tube 20 embodiments may be mated in various combinations with the chamber 30 embodiments. Additional fin material may be coupled to the inside or the outside of the tube 20. Additional fin material may be coupled to the inside or the outsize of the chamber 30. The plate member may have performance enhancing surface treatment. The plate member may have louvers, slits, or additional extended surface features known in the art to improve the heat exchange characteristics of the plate member 35. Other embodiments of the tubes, chambers, and plate members not pictured may also be combined, and the invention is not limited to the embodiments described.

Referring to FIG. 7A through 7F, a method according to the present invention is presented. The method includes a step of providing generally planar sheet 700 of elongate, deformable material such as a cladded aluminum material. The steps include forming plurality of protrusion member 705 to position plurality of chamber assemblies 400 to the planar sheet 700. The method includes a step of deforming the planar sheet 700 to form plurality of generally large bowl shaped protrusions 705, gathering sufficient material for the annular wall 305 and the stepped planar surface 355 to be formed in later stages. Referring to FIG. 7C, the method includes the step of forming the large bowl shaped protrusion into the shape of an indentation with annular wall 305, said annular wall extending generally perpendicular away from the base plane 365, annular wall initiating from a fold 370, terminating at the stepped surface 710. The inner circumference of the annular wall is generally formed in the shape of the chamber assembly 400, allowing the lateral wall 40 of the chamber assembly 400 to abut against the inner circumference of the annular wall 305. The chamber assembly 400 comprises of an inlet, an outlet, a chamber, and a medium-directing member position within the chamber. The method includes the step of forming a hole 340 on the stepped surface 710, diameter of the hole 340 larger than the diameter of the tube 20, but smaller than the diameter of the chamber assembly 30, forming a stepped planar surface 355. At the completion of said fabricating steps, the planar sheet 700 is made into a plate member 35. The plane of the stepped planar surface 355 is generally flat, allowing the top surface 50 of the chamber assembly to couple against the surface of the stepped planar surface 355. The method includes coupling of plurality of chamber assembly 400 to the plate member 35. The chamber assembly 400 is set against plurality of stepped surface 355 formed on the plate member 35, lateral wall 40 of the chamber assembly 400 coupled to the inner circumference of the annular wall 305, and the top surface 50 of the chamber assembly 400 coupled to the stepped planar surface 355, forming a planar assembly 720 comprising of plate member 35 with plurality of chamber assemblies 400. The method includes stacking plurality of said assemblies 720 together, free end of plurality of tubes on first planar member assembly 720 to couple to the free end of tubes on a second planar assembly 720. The entire assembly may be coupled to a pair of manifolds, first free end of first plurality of tubes to couple to a first manifold, the second free end of plurality of tubes to couple to a second manifold. The entire assembly may be brazed together. The planar sheet 700 may be formed by stamping.

Referring to FIG. 8A through 8D, another method according to the present invention is presented. The method includes a step of providing generally planar sheet 700 of elongate, deformable material such as a cladded aluminum material. The steps include forming plurality of annular walls 305 to position plurality of the chamber assembly 400 to the plate member 35. The method includes a step of bending the planar sheet 700 to form plurality of annular wall 305, said annular wall extending generally perpendicular from the base plane 365. The inner circumference of the annular wall 305 is generally formed in the shape of the chamber assembly 400, allowing the lateral wall 40 of the chamber assembly 400 to abut against the inner circumference of the annular wall 35. The method includes coupling plurality of chamber assembly 400 to the plate member 35. The chamber assembly 400 is coupled to plurality of annular walls 305 formed on the plate member 35, lateral wall 40 of the chamber assembly coupled to the inner circumference of the annular wall 305, forming a planar assembly 720. The method includes stacking plurality of said planar assemblies together, free end of plurality of tubes on first planar member assembly 720 to couple to the free end of tubes on a second planar assembly 720. The entire assembly may be coupled to a pair of manifolds, free end of first plurality of tubes on a planar assembly 720 to couple to a first manifold, the second free end of plurality of tubes on a planar assembly 720 to couple to a second manifold. The entire assembly may be brazed together. The planar sheet 700 may be formed by stamping.

Referring to FIG. 9A through 9D, yet another method according to the present invention is presented. The method includes a step of providing generally planar sheet 700 of elongate, deformable material such as a cladded aluminum material. The steps include forming plurality of holes 300 to position plurality of chamber assembly 400 to the generally planar sheet 700. The method includes forming plurality of holes 300 on the planar sheet 700, the holes 300 go through the thickness of the generally planar sheet 700. The dimension of the holes 300 is made to the size of the outer circumference of the chamber assembly 400, allowing the lateral wall 40 of the chamber assembly 400 to pass through the holes 300 on the generally planar sheet 700, said fabrication step transforming the planar sheet 700 into a plate member 35. The method includes coupling plurality of chamber assembly 400 to the plate member 35. The chamber assembly 400 is coupled to plurality of holes 300 formed on the plate member 35, lateral wall 40 of the chamber assembly coupled to the holes 300 formed on the plate sheet 35, forming a planar assembly 720. The method includes stacking plurality of said assemblies 720 together, free end of plurality of tubes on first planar member assembly 720 to couple to the free end of tubes on a second planar assembly 720. The entire assembly may be coupled to a pair of manifolds, free end of first plurality of tubes to couple to a first manifold, the second free end of plurality of tubes to couple to a second manifold. The entire assembly may be brazed together. The planar sheet 700 may be formed by stamping.

Referring to FIG. 2A, a cross-section of an embodiment of the present invention is shown. A chamber 30 is connected to a tube 20 that is connected to another chamber 30. Each chamber 30 in the present embodiment may house a medium-directing member 25, which in this embodiment attaches at certain points to the inner surface of the chamber 30, which leaves openings along the inner surface of the chamber 30. The medium-directing member 25 allows passage of the heat exchange medium 15 through these openings. The arrows illustrate how the heat exchange medium 15 may be redirected according to the embodiment as shown.

Referring to FIG. 2C, the chamber 30, in combination with any of the above embodiments, does not have to be circular-shaped, other embodiments may be shaped like an oval (with various ratios of height, length, and width dimensions), or other geometric shapes.

The chamber generally has at least one greater dimension than the tube. For instance, the chamber may have a greater fluid capacity, circumference, or surface area. The ratio of a particular dimension between the tube and the chamber may be 1:1.1, 1:1.5, or any other ratio.

The tube and the chamber may be made of aluminum, either with cladding or without cladding. The tube and chamber may also be made of stainless steel, copper or other ferrous or non-ferrous material. The tube and chamber may also be a plastic material or other composite materials. Likewise, the medium-directing member may be made of aluminum, either with cladding or without cladding. The medium-directing member may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The medium-directing member may also be a plastic material or other composite materials. The plate member may be made of aluminum, either with cladding or without cladding. The plate member may also be made of stainless steel, copper or other ferrous or non-ferrous material. The plate member may also be a plastic material or other composite material. Also, an embodiment of the present invention allows for the tube to be made of a different material than the material used for the chamber, and the medium-directing members may be made of a different material than the material used for the chamber, the tube, and the plate member. The material used for the plate member may be made of different material than the material used for the chamber, the tube, or the medium-directing member. If more than one medium-directing member is used in an embodiment of the invention, one medium-directing member may be made of a different material than another medium-directing member. The medium-directing members may also be of different shapes than one another. Also, if more than one plate member is used in an embodiment of the invention, one plate member may be made of a different material than another plate member. The plate member may also be of different shape than one another.

The tube, the chamber, the medium-directing member, and the plate member may be manufactured by stamping, cold forging, casting, or machining. The tube, the chamber, the medium-directing member, and the plate member may be manufactured as one piece or may be manufactured as two separate pieces.

The present invention has been described in an illustrative manner. The term “redirect” means to change the direction or course of, or impede the progress of, the heat exchange medium, even if by the smallest difference in angle or velocity. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced other than as specifically described.

Claims

1. A heat exchanger comprising of plurality of plate members, said plate members having:

a plurality of chambers having:

a tube member as an inlet for receiving a heat exchange medium flowing in;

walls defining a chamber interior which is in fluid communication with the inlet;

a medium directing member, having an inclined surface facing the inlet, said medium directing member diverting the flow of medium from the initial axis of line of flow to at least two distinct flow patterns within the chamber;

a tube member as an outlet for flowing out the heat exchange medium;

said plurality of chambers having tube like segment connecting first chamber to second chamber, creating a fluid communication between first chamber to second chamber.

2. The heat exchanger according to claim 1 wherein the medium directing member diverts flow of the medium to a second flow direction which is substantially perpendicular to the first flow direction.

3. The heat exchanger according to claim 1 wherein the chamber is configured to cause the medium, subsequently to flowing in the second flow direction, to flow within the chamber interior in a generally semi-circular flow path which travels at least partially around the axis of the first flow direction and which lies in a plane perpendicular to the first flow direction.

4. The heat exchanger according to claim 1 wherein the chamber is configured to cause the medium, subsequently to flowing in the second flow direction, to flow within the chamber interior in first and second generally semi-circular flow paths, each of which travels at least partially around the axis of the first flow direction and lies in the axis perpendicular to the first flow direction, the first and second flow paths originating from a same region within the chamber interior and flowing in opposing generally semi-circular routes at least partially around the axis of the first flow direction.

5. The heat exchanger according to claim 1 wherein the chamber interior has a generally cylindrical shape.

6. The heat exchanger according to claim 2 further including at least one redirection member, disposed within the chamber interior, for assisting dispersion of the medium within the chamber interior.

7. The heat exchanger according to claim 1, wherein the heat exchange chamber is realized by a plate, the chamber interior being formed by a cavity within the plate and the inlet being formed by a hole in the plate, the cavity being centered on the hole and having a diameter larger than a diameter of the hole.

8. The heat exchanger according to claim 1 wherein the medium directing member diverts flow of the medium into a plurality of second flow directions having direction of travel components in the first flow direction.

9. The heat exchanger according to claim 8 wherein the medium flowing in the plurality of second flow directions passes through at least one opening between the medium directing member and at least one of the chamber walls.

10. The heat exchanger according to claim 2 wherein plurality of chambers are coupled on a single sheet of material.

11. The heat exchanger according to claim 2 wherein the medium directing member is coupled with medium directing channels, said medium directing channels formed on an interior of the chamber, wherein said medium directing channels are arranged within the chamber to facilitate directional flow of heat exchange medium within the chamber, first medium directing channel receiving the heat exchange medium flowing in the chamber from the inlet, directed in said flow direction by the heat exchange medium-directing member, second medium directing channel working in conjunction with the medium redirecting member to facilitate flow of heat exchange medium out the outlet of the chamber.

12. The heat exchanger according to claim 10 wherein a first free end of said plurality of chambers is coupled to a first manifold member, a second free end of said plurality of chambers is coupled to a second manifold member.

13. A heat exchanger comprising:

a tube member as an inlet for receiving a heat exchange medium flowing in;

walls defining a chamber interior which is in fluid communication with the inlet;

a medium directing member, having an inclined surface facing the inlet, said medium directing member diverting the flow of medium from the initial line of flow to at least two distinct flow patterns within the chamber;

a tube member as an outlet for flowing out the heat exchange medium;

said plurality of chambers having tube like segment connecting first chamber to second chamber, creating a fluid communication between first chamber to second chamber;

wherein plurality of said chambers are coupled to a generally planar plate member.

14. The heat exchange chamber according to claim 13 wherein the chamber is configured to cause the medium, subsequently to flowing in the second flow direction, to flow within the chamber interior in first and second generally semi-circular flow paths, each of which travels at least partially around the line segment and lies in the plane perpendicular to the first flow direction, the first and second flow paths originating from a same region within the chamber interior and flowing in opposing generally semi-circular routes at least partially around the line segment.

15. The heat exchanger according to claim 13 wherein a first free end of said plurality of chambers is coupled to a first manifold member, a second free end of said plurality of chambers is coupled to a second manifold member.

16. A method of making a heat exchanger comprising:

stamping a generally planar material, forming plurality of indentations, said indentations protruding away from below the base plane of the planar material, indentations terminating at a second plane, generally parallel to the base plane;

providing a second planar material, formed into first half of a chamber, stamping a tubular member on first side of said planar material, said tubular member extending outwardly from said first side of the second planar material;

providing a third planar material, formed into second half of a chamber, stamping a tubular member on first side of said planar material, said tubular member extending outwardly from said first side of the third planar material;

couple the first half of the formed second planar material comprising the first half of the chamber and the formed third planar material comprising the second half of the chamber on respective second side of said materials, forming a chamber assembly, said chamber assembly having a fluid flowing chamber between the walls comprising the second side of the first half of the chamber assembly and the second side of the second half of the chamber assembly;

couple a medium-directing member in the chamber assembly, said medium-directing member positioned within the chamber assembly to divert the flow of heat exchange medium flowing from first line of flow through the tube to two semi-circular flow pattern within the chamber, said medium-directing member redirecting flow of heat exchange medium to first line of flow out the chamber assembly;

couple said chamber assembly to plurality of indentations formed on the first planar material;

wherein plurality of planar material with chamber assembly coupled to indentations on said planar material are coupled together.

17. A method according to claim 16, wherein progressive stamping die is utilized.

18. A method according to claim 16, wherein the planar materials are cladded aluminum.

19. A method according to claim 16, wherein plurality of planar material with respective chamber assemblies are coupled together, then brazed together with a pair of manifolds.

20. A method according to claim 16, wherein the entire assembly is brazed together.