Thermal Components, Inc.

Thermalex, Inc.

Thermal Components a Division of Insilco Corporation

James D Gowan

Qi Wang

Norman F Costello

James R Brookins

An extruded D-shaped manifold machined from extruded tubing is generally D-shaped in cross-section, with the header being thicker than the tank. At least two longitudinal external ribs are formed on the header exterior, preferably positioned symmetrically relative to the longitudinal axis of the header. The external ribs provide additional strengthening of the header and act as stops to prevent the heat exchanger fins from contacting the tube/manifold joint (which can lead to leakage when the joint is brazed). The number of external ribs and their location depend on the size of the manifold and the precision required in positioning the heat exchanger tubes in the slots. The manifold can be extruded with lengthwise internal ribs extending along the interior sides of the tank to act as stops for the heat exchanger tubes.

Extruded manifold

A manifold for heat exchangers with a manifold segment having slots which are perpendicular to the tube axis and spaced in the longitudinal direction and separated by webs, into which hollow flat tubes can be inserted and joined to the contact surface of the respective slot. The webs each have a pair of stampings to strengthen the material on each side of each web and the webs are relatively flat in shape such that the cross-section of the manifold segment has a generally D-shaped profile. At least one baffle is inserted in the manifold segment, centered between a pair of adjacent slots. The baffle has a principle circular edge and a truncated edge so as to have a truncated circular profile substantially corresponding to the approximately D-shaped profile of the manifold segment. The baffle also has an outwardly extending lip over a portion of its perimeter at the principle circular edge, the lip having projections extending from its ends, the projections being dimensioned to provide an interference fit between the baffle and the manifold segment. Circular edge of the baffle has a first radius R.sub.1 which is less than the second radius R.sub.2 of the truncated edge.

Manifold for heat exchanger and baffles therefor

A manifold for heat exchangers with a manifold segment having slots which are perpendicular to the tube axis and spaced in the longitudinal direction and separated by webs, into which hollow flat tubes can be inserted and joined to the contact surface of the respective slot. The webs each have a pair of stampings to strengthen the material on each side of each web and the webs are relatively flat in shape such that the cross-section of the manifold segment has a generally D-shaped profile. At least one baffle is inserted in the manifold segment, centered between a pair of adjacent slots. The baffle has a principle circular edge and a truncated edge so as to have a truncated circular profile substantially corresponding to the approximately D-shaped profile of the manifold segment. The baffle also has an outwardly extending lip over a portion of its perimeter at the principle circular edge, the lip having projections extending radially outwardly from its ends, the projections being dimensioned to provide an interference fit between the baffle and the manifold segment. The main circular edge of the baffle has a first radius R.sub.1 which is less than the second radius R.sub.2 of the truncated edge. The baffle also has a third radius R.sub.3, which is a transitional radius between the first and second radii R.sub.1 and R.sub.2 and is substantially smaller than R.sub.1 and R.sub.2, and a fourth radius R.sub.4, which is a reverse radius inset from the third radius R.sub.3 and positioned to register with the stampings.

A cross-counterflow heat exchanger comprising a pair of identical and identically-oriented, spaced manifolds and a plurality of parallel heat exchanger tubes extending between the manifolds. Each of the manifolds has an interior, longitudinally-extending dividing wall. In a 2n pass heat exchanger, each manifold is symmetric about a mirror plane, the dividing wall is configured to define n+1 upper channels and n lower channels, and the passages of the heat exchanger tubes are divided into 2n flow paths, n being a positive integer. In a 2n+1 pass heat exchanger, each manifold is symmetric about a rotation axis, the dividing wall is configured to define n+1 upper channels and n+1 lower channels, and the passages of th heat exchanger tubes are divided into 2n+1 flow paths, n again being a positive integer. Further, in a 2n pass heat exchanger, the dividing wall of each of the manifolds includes 2n-1 vertical webs, and each of the heat exchanger tubes includes 2n-1 partitions dividing the passages into 2n flow paths; while in a 2n+1 heat exchanger, the dividing wall of each of the manifolds includes including 2n vertical webs, and each of the heat exchanger tubes includes 2n partitions dividing the passages into 2n+1 flow paths. When the number of vertical webs is greater than 1 (that is, when n&gt;1), the vertical webs alternately extend from opposite interior surfaces of the manifold. In both 2n and 2n+1 pass heat exchangers, the partitions of the heat exchanger tubes have notches at both ends for engaging the vertical sections of the manifolds. The dividing wall includes two transverse webs extending outwardly from each vertical web. These transverse webs can be configured as, for example, planar webs extending diagonally in opposite directions to form a zig-zag pattern (a series of interlocking, alternatingly-oriented Y-shapes), as coplanar webs, or as reverse curves forming a sinusoidal pattern. Different manifold geometries can be used, including, but not limited to circular, oval, flattened oval, and rectangular.

Extruded manifold with multiple passages and cross-counterflow heat

A manifold for heat exchangers with a manifold segment having slots which are perpendicular to the tube axis and spaced in the longitudinal direction and separated by webs, into which hollow flat tubes can be inserted and joined to the contact surface of the respective slot. The webs each have a pair of stampings to strengthen the material on each side of each web and the webs are relatively flat in shape such that the cross-section of the manifold segment has a generally D-shaped profile. At least one generally D-shaped baffle is inserted in the manifold segment, centered between a pair of adjacend slots. End caps are provided to close the open ends of the manifold, and a bracket can be provided on the manifold to hold it in place. A method of manufacturing the manifolds is also presented.

Manifold for heat exchanger incorporating baffles, end caps, and brackets

A sizing die for sizing a plurality of micro-extruded tubes has a side fence, a clamping fence in substantial parallel relation with and movable with respect to the side fence, a base fence adjacent to and perpendicular to ends of the side fence and the clamping fence, and a movable die platen for applying pressure to the top of the stack of tubes. The side and base fences preferably are fixed. The tubes to be sized are stacked on their sides against the side fence with their internal webs aligned throughout. The clamping fence and die platen are moved to be in mating engagement with the stack. Pressure is applied through the die platen against the top of the stack to compress the tubes to a desired thickness.

Growing community of inventors

Montgomery, AL, United States of America

James D Gowan