Heat Exchanging Apparatus and Method of Making Same

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to heat exchangers, specifically to a disk type heat exchanger unit with plurality of tubes and disk units for transporting heat exchange medium within.

2. Discussion of the Related Art

Heat exchangers are typically utilized where heat from one medium is desired to be transported to another medium. Typical heat exchangers are made of tubes with plurality of fin attachments on surface of tubes. Heat exchange medium is transported through tubes, carrying heat within said heat exchange medium. The heat transported through tubes by means of heat exchange medium is transferred generally by means of conduction from heat exchange medium to tube and fin structure of heat exchanger assembly, as the heat exchange medium flow through tubes. The tube and fin structure is surrounded by another heat exchange medium, absorbing away heat from the tube and fin structure. The efficiency of a heat exchanger is generally dictated by the ratio of volumetric capacity of tubes to the overall surface area of tubes and fins, with greater surface area generally yielding higher performance. Typical application of this type of high performance heat exchangers are condensers and evaporators for use in commercial and residential air conditioner units. Variants of this type of heat exchangers are commonly utilized in commercial and automotive applications such as oil coolers, evaporators, condensers, heater cores, and radiators.

Efforts to enhance performance of heat exchangers is generally achieved by creating complex fin structures that have myriad bends and folds to create as much surface area within a given confine. Fins effectively increase surface area of tubes. In another effort to improve the performance, fins in addition to bends and folds may have plurality of louver features created on surface of fins. High performance heat exchangers are generally utilized where space is limited, thus is generally more favorable to achieve higher heat exchanging performance with heat exchangers of smaller footprint. Enhancement efforts by means of utilizing complex fin structures may improve performance of heat exchangers, but potential additional manufacturing processes may adversely affect the total manufacturing cost of heat exchangers.

In another embodiment of this effort, instead of round tubes, flat tubes are made with plurality of small diameter holes. Generally of aluminum extrusion, intricate tubes are made with plurality of small diameter holes. To further improve performance of heat exchangers, thickness of a material used to create fins and tubes may be made thinner. By making the thickness of a material thinner, performance of a heat exchanger may be improved by shortening a distance that heat has to travel within walls of tube and fin structures, improving heat conduction efficiency. Thinning a material has the adverse effect of weakening a structure, however. Also, in an application such as automobiles where potential for debris hitting a heat exchanger surface is high, having a weak structure is not favorable, as a heat exchanger may be easily damaged, or worse having a puncture within tubes, causing heat exchange medium within to leak out, rendering the heat exchanger useless. A manufacturing process of assembling together various heat exchanger components may be complicated as well, when components utilized are manufactured of thin walled tubes and fins. When components comprise of thin material, components are susceptible to damage during assembling process, requiring due care during assembly, typically raising manufacturing cost. Complication of manufacturing method typically has an adverse effect on the manufacturing cost, generally raising cost of individual components. Fragile components may also complicate handling of components during an assembly stage, as well as requiring stricter tolerance components as well as assembly machines capable of meeting strict tolerances, all of these factors typically resulting in higher component costs and assembly costs.

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

A variant of a disk type heat exchanger is described in Nitta, U.S. patent application Ser. No. 12/856,179 and Nitta, U.S. patent application Ser. No. 12/886,559. In these embodiments, a heat exchanger core comprises of plurality of tube and chamber unit with a heat exchange medium directing member disposed within. In the U.S. patent application Ser. No. 12/856,179, a chamber is structurally supported by a heat exchange medium directing member and a disk unit shell structure to prevent a disk unit from deforming in high pressure application, such as for a condenser unit in an air conditioner application. Structurally, under extremely high pressure, such structure may be prone to deformation, as the chamber structure may lack rigidity. The U.S. patent application Ser. No. 12/886,559 improves upon the earlier embodiments by having additional structural rigidity by means of connecting members or protrusion members, having additional means of connecting the respective second sides of the first disk member and the second disk member, providing additional structural rigidity to a disk unit, resisting the tendency for a disk unit walls to expand outwardly when a chamber is supplied with heat exchange medium under high pressure. The additional features is beneficial in applications requiring high pressure environment for a heat exchange medium, such as a condenser unit utilizing newer refrigerant, such as R-410, for example. The present invention improves upon discussed prior art by having features enabling higher heat exchanging performance by having means to improve the ratio of volumetric capacity of the chamber to the overall surface area of the disk unit, a flexible chamber structure enabling favorable volumetric capacity of the chamber to the overall surface area of the disk unit, resulting in higher performance heat exchanger.

A first prior art example of a conventional tube and fin heat exchanger is described in Rhodes, U.S. Pat. No. 6,612,031. In this patent, an aluminum tube with multiple partitions within a tube is first extruded, and then cut into desired length. These tubes are then combined with additional fins, as tube surface alone is often insufficient and incapable of dissipating heat carried by a heat exchange medium. Fins are sandwiched in between each row of tubes comprising a core of a heat exchanger. There are certain drawbacks to this type of heat exchanger cores. First, and foremost, tube extrusions with intricate inner partitions are very difficult to manufacture, requiring precision instruments to obtain a desired shape. Aluminum extrusion machines are typically utilized. An aluminum extrusion machine capable of manufacturing intricate extrusions are often very expensive machines, as well as being notoriously high in operating costs. The more intricate the extrusion shape, an aluminum extrusion machine's extrusion speed has to be reduced not only to obtained a desired shape, but also to protect an extrusion die, as complex extrusion shape causes the extrusion die to be very delicate, prone to damage. Due to the complex nature of extrusion machines, as well as slow operation and delicate extrusion dies that often break during operation, extruded tubes are sold at a relatively high cost, not to mention that there are only a handful of companies with extrusion machines capable of manufacturing intricate tube designs driving up costs. With tube and fin heat exchanger design, various components are combined together to form a heat exchanger core. These components are typically not designed to maintain its position in relation to each component in a standalone manner pursuant to a heat exchanger design parameters during an assembly process, prior to a brazing process which would braze together all components to form a unitary unit. As such, specialized assembly fixtures are often necessary during a manufacturing process to keep the parts together. As a fixture is critical in yielding a good working part, fixtures are often designed to close tolerances resulting in high cost. Also, as a fixture is needed for each heat exchanger assembled at a time, in a large manufacturing operations, where high volume of heat exchangers have to be manufactured at a time, a significant investment has to be made in fixtures, to have on hand enough sufficient quantity of assembly fixtures to support an assembly line. All these investments results in added costs to the manufacturing cost of tube and fin heat exchangers.

Fins utilized are generally of complicated design as described in a second prior art example of a conventional tube and fin heat exchanger in Hiramatsu, U.S. Pat. No. 4,332,293. In this patent, an aluminum tube is combined with corrugated fins to comprise a heat exchanger core. Fins discussed in this patent are corrugated to enhance performance of a heat exchanger. Corrugation is added to fins, as flat sheeted fins often do not yield a desired performance expectation. Therefore, fins are generally fabricated with corrugation feature at an additional fabrication cost and manufacturing processes.

A third prior art example of a conventional heat exchanger is commonly known as plate and fin heat exchangers described in Patel, U.S. Pat. No. 3,976,128. In this patent, instead of extruded tubes, individual tubes comprise of two formed plate halves, split along the long axis of the tube. By eliminating usage of extruded aluminum tubes, and by creating individual tubes by combining two formed plates, the main benefit is the cost savings, as formed plates are often less expensive to manufacture in comparison to aluminum extrusion tubes. As with tube and fin heat exchangers, however, tubes of plate and fin heat exchangers often do not have sufficient surface area in relation to the volumetric capacity of a tube assembly to dissipate heat carried by heat exchange medium within, rendering a heat exchanger useless without additional surface area addition. In order to enhance performance of plate and fin heat exchangers, fin structures are sandwiched in between each row of formed plate tube structures to obtain added surface area to dissipate heat. There are certain drawbacks to this type of heat exchangers. First, and foremost, although the cost of components may be saved in comparison to extruded tubes, an assembly process of plate and fin heat exchanger remains similar to tube and fin heat exchangers, resulting in a complex assembly process often requiring a specialized assembly fixture to secure all components together until components are brazed together to form a unitary unit. The use of assembly fixture is often essential, driving up initial investment cost necessary to manufacture plate and fin heat exchangers, as significant investment has to be made in assembly fixtures for manufacture of specific configuration heat exchanger cores.

Unlike extruded aluminum tubes, a plate and fin heat exchanger cannot be created with too much intricate details, as an assembly of two plate halves are often imprecise, and if a plate design is too intricate, the possibility of misaligning the two halves increase dramatically, rendering a completed heat exchanger useless. Therefore, plate and fin heat exchangers are commonly designed with larger inner partitions, typically resulting in lower performance than extruded aluminum tubes. Another common disadvantage with plate and fin heat exchangers is due to the nature of the design of stacking together plurality of plates without much opening between individual plates. With reduced opening between individual plates, a heat exchange efficiency from a heat exchanger surface to an atmosphere surrounding a heat exchanger, medium such as air, is often poor, leading to a low efficiency heat exchanger performance.

SUMMARY OF THE INVENTION

The present invention is an enhanced heat exchanging apparatus with disk type heat exchanger core comprising of disk units with means to increase the overall surface area of a heat exchanger core in relationship to the volumetric capacity of disk units, thereby improving the ratio of overall surface area of a heat exchanger core to the volumetric capacity of heat exchange medium within said disk units, generally enhancing the performance of a heat exchanging apparatus. A disk type heat exchanger core in the present embodiment comprises of plurality of disk units. Disk units are formed by combining two disk members, a first disk member comprising a first side of the disk unit, said first side of said first disk member generally having an inlet as a tubular member, and a second disk member comprising the other end of the disk unit, first side of said second disk member generally having an outlet as a tubular member. The first disk member on its second side has near the outer circumference of said disk member a raised ring-like member, said ring-like member having a generally planar top surface, a generally perpendicular annular wall extending outwardly from the second side of said disk member connected to the ring-like member at the inner circumference of said ring-like member. The first disk member and the second disk member are coupled together on respective second side of said disk members creating a disk unit, top surface of the raised ring-like member on the first disk member engaging the second side of the second disk member.

Generally, disk units are made of aluminum with cladding on one or both sides of a material. By having a raised surface on the second side of the first disk member as a result of having a raised ring-like member on the second side of the first disk member, a gap is formed between the respective second side of the first disk member and the second disk member when the two disk members are coupled together, creating a chamber between the first disk member and the second disk member to allow flow of heat exchange medium herein. Disposed within said disk unit is a heat exchange medium directing member. A heat exchange medium directing member is generally of a cylindrical member with first end of the generally cylindrical member end coupled to the inlet of the first disk member. Said first end of the heat exchange medium directing member has a channel cut into a face of the first end of said heat exchange medium directing member, said channel cut at an angle generally between 30 to 45 degrees to facilitate flow of heat exchange medium without significant flow resistance. Second end of said heat exchange medium directing member also has a channel cut at an angle, generally on a side diagonally opposite from the channel on the first side, said channel cut at an angle generally between 30 to 45 degrees to facilitate flow of heat exchange medium without significant flow resistance.

In an embodiment of the present invention, a disk unit may have connecting members integrally of the chamber formed within the disk unit to enhance structural rigidity in high internal pressure applications. In a preferred embodiment of the present invention, when connecting members are incorporated into the disk unit, connecting members are generally integral component of the first disk member, formed as protrusion members on the second side of the first disk member. The heights of the connecting members are generally set at the same height as the ring-like member on the second side of the first disk member. Therefore, when the first disk member and the second disk members are coupled together on respective second side of the disk members, the ring-like member and the connecting members on the second side of the first disk member both engage the second side of the second disk member. Generally, connecting members are formed on the second side of the first disk member as protrusion members by forming the face of the second side of the first disk member by utilizing stamping dies, for example. The ring-like member and the connecting members, when the disk unit is processed through an operation such as a brazing process by which the clad material layer is melted to form a braze fillet, the ring-like member and the connecting members on the second side of a first disk member form a brazed joint between the first disk member and the second disk member, forming a strong union between the first disk member and the second disk member. Generally, when connecting members are utilized, connecting members are positioned within the chamber.

In another embodiment of the present invention, the first disk member may have the ring-like member near the outer circumference on the second side of said first disk member, said ring-like member having a generally planar top surface. The second disk member may have connecting members, generally positioned in the chamber. The height of the ring-like member and the height of the connecting members may be set at a generally similar height, so when the first disk member and the second disk members are coupled together on respective second sides of said disk members, the ring-like member on the first disk member engages the second side of the second disk member, while the connecting members on the second side of the second disk member engages the second side of the first disk member, forming a chamber between the respective second side of the first disk member and the second disk member. In this embodiment, the connecting members on the second disk member are generally positioned, so that when the first disk member and the second disk member are coupled together to form the disk unit, the connecting members are generally positioned within the chamber.

In another embodiment of the present invention, the first disk member may have the ring-like member near the outer periphery of the second side of said first disk member, said ring-like member having a generally planar top surface, while the second disk member may have a ring-like member near the outer periphery of the second side of said second disk member, said ring-like member having a generally planar top surface. In this embodiment, when the first disk member and the second disk member are coupled together on the respective second side of disk members, the top surface of the ring-like member on the first disk member and the top surface of the ring-like member on the second disk member engage each other, forming the chamber within a combined unit. In this embodiment, connecting members may be an integral component of the first disk member, an integral component of the second disk member, or may be a separate component entirely, inserted between the first disk member and the second disk member when said disk members are coupled together to form a disk unit.

In yet another embodiment of the present invention, a ring-like member and connecting members may be separate components, inserted within a disk unit to function similarly to other embodiments of the present invention. Said separate ring-like member or said separate connecting members may comprise of cladded material, allowing for said members to form a strong joint by means of a brazing process. Said cladded material in a preferred embodiment would be a double sided clad material. However, in another embodiment, if disk units themselves are cladded material, with the clad side on respective second side of the first disk member and the second disk member, connecting members may not be cladded material.

The performance of a heat exchanger is generally dictated by the ratio of volumetric capacity of a heat exchanger and the overall surface area of a heat exchanger. Generally, when the volumetric capacity of a heat exchanger is reduced, while the surface area of a heat exchanger is kept the same, the performance of a heat exchanger is generally enhanced. Alternatively, when the volumetric capacity of a heat exchanger is kept the same, while the surface area of a heat exchanger is increased, the performance of a heat exchanger is generally enhanced. The present invention permits design of a heat exchanger with desired ratio of volumetric capacity of a heat exchanger to heat exchanger surface area ratio, whereby the ring-like member is an integral component of a disk member, by restricting flow of heat exchange medium to the area encompassed by the ring-like member, essentially transforming the area encompassed by the ring-like member as a surface extension to a disk unit, thereby enhancing the performance of said disk unit. The added surface area is accomplished, while generally maintaining the benefits of a disk unit feature. The disk unit feature, by means of the chamber, enhances the performance of a heat exchanger by spreading the heat exchange medium within a heat exchanging unit into a thin layer, while increasing the heat exchange medium to heat exchanger surface area contact within the chamber, allowing for more surface area contact for heat exchange medium to internal surface of a disk unit structure, facilitating efficient heat conduction of heat contained within heat exchange medium to the disk unit structure, thereby enhancing the heat exchanger performance. As the chamber generally permits only a thin layer of heat exchange medium to occupy the chamber at any given time, while covering a large surface area, the present invention may minimize the distance that the heat contained within the heat exchange medium must travel to reach the structure of the heat exchanger, thereby enhancing the heat exchange efficiency.

In the present embodiment, heat exchange medium first flows in to the disk unit through the inlet on the first disk member. The heat exchange medium then flows in to the chamber within the disk unit. The heat exchange medium, when directed in to the chamber is generally directed substantially to one side of the chamber by a heat exchange medium directing member. Once the heat exchange medium flows into the chamber, the heat exchange medium is directed towards the other end of the chamber, flow directed by the contour of the chamber wall. The second end of the heat exchange medium directing member also has a channel cut at an angle on a side generally diagonally opposite from the channel on the first side, to facilitate flow of heat exchange medium herein. The heat exchange medium, following the wall contour of the chamber wall is then drained out of the disk unit through an outlet formed on the second disk member. The heat exchange medium is directed to the outlet on the second disk member from the chamber by the heat exchange medium directing member disposed within the disk unit. Plurality of said disk units may be coupled together to form a single unitary unit. When one or more disk units are combined to form a single unit, an outlet of a first disk unit may be coupled to an inlet of a second disk unit. This arrangement is repeated as needed to obtain a unitary unit with a desired disk unit quantity. One end of said single unitary unit of plurality of disk units may be coupled on one end to a first header or a manifold. The other end of said unitary unit of plurality of disk units may be coupled to a second header or a manifold member. Plurality of said unitary unit of plurality of disk units may be coupled on first end with a first manifold member, and second end coupled with a second manifold member. One or more baffles may be disposed within first and second manifold to facilitate desired heat exchange medium flow pattern.

In another embodiment of the present invention, the inlet and the outlet may be an orifice member.

The present invention is also a method of making a disk type heat exchanging apparatus. The method includes the steps of providing a first generally planar material having a tubular member formed on first side of said material, creating an inlet on the first material. The method includes a step of shaping said material by cutting out a desired shaped disk member, removing away excess material, creating a first disk member. The method includes a step of forming a ring-like member near the outer circumference of said material on its second side, said ring-like member generally extending outwardly from said second side, top surface of said ring-like member generally having a planar surface, a generally perpendicular annular wall extending outwardly from the second side of said disk member connected to the ring-like member at the inner circumference of said ring-like member. Said ring-like member is generally formed by plurality of folds on the second side of said material, said folds formed by utilizing stamping dies comprising of a top die and a bottom die that when pressed together yields a desired shape, for example. The method includes the steps of providing a second generally planar material having a tubular member formed on first side of said second material, creating an outlet on said second material. The method includes the step of shaping said second material by cutting out a desired shaped disk member, removing away excess material, creating a second disk member. The method includes the steps of providing a generally cylindrical material, said material having a channel cut at an angle on both ends, creating a heat exchange medium directing member. The method further includes the steps of disposing said heat exchange medium directing member, first end of the heat exchange medium directing member engaging the inlet of the first disk member, second end of said heat exchange medium directing member engaging the outlet of the second disk member. The method further includes the steps of coupling said first disk member and second disk member, ring-like member on the first disk member engaging the second side of the second disk member, creating a chamber between the respective second side of the first disk member and the second disk member, forming a disk unit. The method further includes steps of coupling plurality of said disk units, outlet of a first disk unit engaging an inlet of a second disk unit.

In another embodiment of the present invention, the method includes the steps of providing a first generally planar material having a tubular member formed on first side of said material, creating an inlet on the first material. The method includes a step of shaping said material by cutting out a desired shaped disk member, removing away excess material, creating a first disk member. The method includes the steps of providing a second generally planar material having a tubular member formed on first side of said material, creating an outlet on the material. The method includes a step of forming a ring-like member near the outer circumference of the second material on its second side, said ring-like member generally extending outwardly from said second side, top surface of said ring-like member having generally planar surface, a generally perpendicular annular wall extending outwardly from the second side of said disk member connected to the ring-like member at the inner circumference of said ring-like member. Said ring-like member is generally formed by plurality of folds on the second side of said material, said folds created by utilizing stamping dies comprising of a top die and a bottom die that when pressed together yields a desired shape. The method includes the step of shaping said second material by cutting out a desired shaped disk member, removing away excess material, creating a second disk member. The method includes the steps of providing a generally cylindrical material, said material having a channel cut at an angle on both ends, creating a heat exchange medium directing member. The method further includes the steps of disposing said heat exchange medium directing member, first end of the heat exchange medium directing member engaging the inlet of the first disk member, second end of said heat exchange medium directing member engaging the outlet of the second disk member. The method further includes the steps of coupling said first disk member and second disk member, ring-like member on the second disk member engaging the second side of the first disk member, creating a chamber between the respective second side of the first disk member and the second disk member, forming a disk unit. The method further includes steps of coupling plurality of said disk units, outlet of a first disk unit engaging an inlet of a second disk unit.

In yet another embodiment of the present invention, the method includes the steps of providing a first generally planar material having a tubular member formed on first side of said material, creating an inlet on the first material. The method includes a step of forming a ring-like member near the outer circumference of said material on its second side, said ring-like member generally extending outwardly from said second side, top surface of said ring-like member having generally planar surface, a generally perpendicular annular wall extending outwardly from the second side of said disk member connected to the ring-like member at the inner circumference of said ring-like member. The method includes a step of shaping said material by cutting out a desired shaped disk member, removing away excess material, forming a first disk member. The method includes the steps of providing a second generally planar material having a tubular member formed on first side of said material, creating an outlet on the material. The method includes a step of forming a ring-like member on the outer circumference of said material on its second side, said ring-like member generally extending outwardly from said second side, base of said ring-like member connected to the said second side of said material, top surface of said ring-like member having generally planar surface, a generally perpendicular annular wall extending outwardly from the second side of said disk member connected to the ring-like member at the inner circumference of said ring-like member. The method includes the step of shaping said second material by cutting out a desired shaped disk member, removing away excess material, forming a second disk member. Said ring-like member is generally formed by plurality of folds on the second side of said material, said folds created by utilizing stamping dies comprising of a top die and a bottom die that when pressed together yields a desired shape, for example. The method includes the steps of providing a generally cylindrical material, said material having a channel cut at an angle on both ends, creating a heat exchange medium directing member. The method further includes the steps of disposing said heat exchange medium directing member, first end of the heat exchange medium directing member engaging the inlet of the first disk member, second end of said heat exchange medium directing member engaging the outlet of the second disk member. The method further includes the steps of coupling said first disk member and said second disk member, ring-like member engaging the second side of the opposing disk member, creating a chamber between the respective second side of the first disk member and the second disk member, forming a disk unit. The method further includes steps of coupling plurality of said disk units, outlet of a first disk unit engaging an inlet of a second disk unit.

In an embodiment of the present invention, the method may include the steps of forming connecting members on the first disk member, connecting members generally positioned within a chamber to enhance the structural rigidity of a disk unit, for applications where disk units may be supplied with heat exchange medium under high pressure. The method includes the steps of forming connecting members on the second side of the first material, said connecting members extending outwardly from the second side of said first material, base of connecting members connected to the second side of said material. Said connecting members are generally formed by plurality of folds, generally accomplished by a stamping die, comprising of a top die and a bottom die, when pressed together forms a desired shape.

In another embodiment, connecting members may be formed on the second side of the second material, said connecting members extending outwardly from the second side of said second material, base of connecting members connected to the second side of said material. In yet another embodiment of the present invention, connecting members may be formed on the respective second side of the first disk member and the second disk member. Said connecting members generally formed by plurality of folds, generally accomplished by a stamping die, comprising of a top die and a bottom die, when pressed together forms a desired shape.

In a preferred embodiment, the method further includes the step of making an annular bend on the outer edge of the second material forming an annular wall projecting outwardly from the second side of said second material, base of said annular wall generally connected to the second side of said second material. The method further includes the step of bending the annular wall on the second disk member onto the first side of the first disk member, coupling the first disk member and the second disk member together.

In another embodiment of the present invention, the method includes providing first material and second material that are generally planar sheet material, formed into desired shape by stamping said materials, an inlet formed on a first side of the first material and an outlet formed on a first side of the second material, formed generally by stamping said materials. The method further includes providing a generally planar material, forming said material to form a ring-like member, placing said ring-like member between the second sides of the first material and second material, dispose said ring-like member to generally couple the outer circumference of the first material and the second material. The method includes providing another generally planar material, forming connecting members, placing said connecting members between the second sides of the first material and the second material, dispose said connecting members generally around the inlet of the first material and the outlet of the second material. The method further includes a step of creating a generally annular bend on the outer periphery of the second material, made generally perpendicular from the second side of said material, forming an annular wall projecting outwardly from the second side of said material. The method includes the steps of coupling said first material and said second material on respective second side of materials, first side of the ring-like member and the first side of the connecting members engaging the second side of the first material, and second side of the ring-like member and the second side of the connecting members engaging the second side of second material. As the ring-like member and the connecting members are disposed between the second side of the first material and the second material, a gap is formed between the second side of the first material and the second side of second material where the ring-like member and the connecting members are not present, forming a chamber. The method further includes the steps of bending the annular wall on the second material on to the first side of the first material, coupling said first material and said second material together, forming a disk unit. The method further includes the steps of providing a generally cylindrical material, said material having a channel cut at an angle on both ends, creating a heat exchange medium directing member. The method further includes the steps of disposing said heat exchange medium directing member in the disk unit. The method further includes the steps of coupling plurality of said disk units, outlet of a first disk unit engaging an inlet of a second disk unit.

In another embodiment of the present invention, the first material and second material may be formed by machining said materials, removing away excess material from said materials until a desired shape is achieved.

In another embodiment of the present invention, when connecting members are utilized, connecting members may be a single connecting member or plurality of connecting members

In an embodiment of the present invention, disk type heat exchangers 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 various applications. An advantage of the present invention is that the heat exchange medium is introduced into a chamber within individual disk units, thereby increasing the surface area that a heat exchange medium comes in to contact within a heat exchanger structure, improving the efficiency of heat exchangers. Conventional heat exchangers, wherein heat exchange medium flows in a generally round tube, heat exchange medium flows in generally laminar layers, carrying varying amount of heat within each layer. In such an arrangement, heat exchange medium closest to a tube surface may more effectively transfer heat from heat exchange medium to the tube surface. However, heat exchange medium closer to center of the tube may be less efficient at transferring heat on to the tube surface, as heat has to travel through different layers of heat exchange medium generally by conduction, in order to reach the tube surface. In comparison, present invention improves heat transfer efficiency of heat exchange medium by spreading out the heat exchange medium in a chamber, thereby increasing the heat exchange medium to heat exchanger structure contact, increasing heat transfer efficiency.

A chamber also has an added benefit of reducing the distance heat contained within heat exchange medium has to travel thereby improving heat exchange efficiency, as spreading the heat exchange medium within the chamber has an added benefit of creating a thinner layer of heat exchange medium, while increasing the heat exchange medium to heat exchanger surface contact, thereby enhancing the performance of a heat exchanger. Another advantage of the present invention is that a heat exchange medium directing member coupled within a disk unit effectively routes heat exchange medium to contact heat exchanger surface more effectively. A heat exchange medium directing member also has an added benefit of effectively mixing and stirring heat exchange medium within a disk unit chamber preventing laminar flow of heat exchange medium, thereby increasing heat exchange efficiency. As heat exchange efficiency is improved in the present invention, overall size of a heat exchanger may be made smaller compared to a conventional heat exchanger of equal capacity, which in turn provides for a lower overall cost as less raw material and less packaging is necessary. 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 a manufacturing process may be simpler because the present invention requires less fragile components and less manufacturing steps. Conventional heat exchangers typically require extensive investment in preparing assembly fixtures, as various components may easily fall out of place during assembly without assembly fixtures. Furthermore, conventional heat exchangers require new assembly fixtures to be created for each heat exchanger core design change, even if component level parts remain the same. The present invention improves upon conventional heat exchanger manufacturing process, as entire unit may be brazed together, or any portion of the unit may be brazed first, and then additional components may be brazed or soldered together without use of assembly fixtures if necessary, significantly reducing an investment in assembly fixtures.

In another embodiment of the present invention, the method may include the steps of forming the inlet on the first disk member and the outlet of the second disk member by forming a hole on respective disk members.

In another embodiment of the present invention, tubular member size of an inlet and an outlet may vary between disk units.

In another embodiment of the present invention, a disk unit size may vary from one disk unit to the other.

In yet another embodiment of the present invention, to further enhance the performance, additional fin material may be added to disk units.

In another embodiment of the present invention, the disk unit may have plurality of external surface dimples on the surface of disk units to increase the surface area of the disk unit.

In yet another embodiment of the present invention, disk unit may have plurality of internal surface dimples in the chamber to increase the heat exchange medium to disk unit surface area contact, to enhance the performance of a heat exchanger.

In a further embodiment of the present invention, each heat exchange medium directing member inside a disk unit may be rotated at a predetermined angle from each other.

In another embodiment of the present invention, disk units may be brazed or soldered together to form a unitary unit.

In yet another embodiment of the present invention, disk units may be made of aluminum, either with cladding or without cladding. Disk units may also be made of stainless steel, copper or other ferrous or non-ferrous materials. Disk units may also be a plastic material or other composite materials. Disk units may also be made of combination of any or all of the mentioned materials.

In another embodiment of the present invention, disk units may be manufactured by stamping, forging, hydroforming, or machining

In a further embodiment of the present invention, disk units may be brazed together or soldered together to form a unitary unit.

In a further embodiment of the present invention, disk units may be round, oval, or any other geometric shape.

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 accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a disk type heat exchanger according to embodiments of the present invention.

FIG. 1B is a second side view of a first disk member according to embodiments of the present invention.

FIG. 1C is a second side view of a first disk member according to another embodiments of the present invention.

FIG. 2A is an exploded view of a disk unit according to embodiments of the present invention.

FIG. 2B is a side view of a first disk member according to embodiments of the present invention.

FIG. 2C is an enlarged section view of Section A of FIG. 2B.

FIG. 2D is a side view of a first disk member according to another embodiments of the present invention.

FIG. 2E is an enlarged section view of Section B of FIG. 2D.

FIG. 3A is a perspective view of a first disk member according to embodiments of the present invention.

FIG. 3B is a section view illustrating a side view of section of a disk unit, showing an annular wall on a second disk member prior to a coupling process according to embodiments of the present invention.

FIG. 3C is a section view illustrating a side view of section of a disk unit, showing an annular wall on a second disk member after a coupling process according to embodiments of the present invention.

FIG. 3D is a second side of a first disk member according to another embodiments of the present invention.

FIG. 3E is an enlarged side section view of Section C of FIG. 3A, showing an embodiment of a ring-like member on a first disk member.

DETAILED DESCRIPTION

The present invention is directed to a disk type heat exchanging apparatus having a heat exchange medium directing member within, useful in applications requiring heat exchange from one heat exchange medium to another heat exchange medium.

The details of embodiments of heat exchange medium flow within a chamber is described in US PAT. application referred to above such as Nitta, U.S. patent application Ser. No. 12/148,655, the disclosure of which is hereby incorporated by reference in its entirety.

Referring to the drawings and in particular FIG. 1A, an embodiment of a disk type heat exchanger 100 is shown. The heat exchanger 100 comprises of plurality of disk units 115. Predetermined quantity of disk units 115 may be coupled together to form a unitary unit of plurality of disk units. Each unit of plurality of disk units may be coupled by two manifolds 105A and 105B, said manifolds having plurality of holes to couple ends of plurality of disk units. Manifolds 105A and 105B are typically arranged in a parallel fashion, set apart to a predetermined length to couple first end of plurality of disk units to manifold 105A, and second end of plurality of disk units to manifold 105B. Manifolds 105A and 105B facilitate flow of heat exchange medium between individual rows of plurality of disk units. More than one unit of plurality of disk units may be coupled to manifolds 105A and 105B to obtain desired heat exchange performance. Generally, more rows of plurality of disk units, the higher the performance of a heat exchanger. Manifolds 105A may have an inlet 110A to introduce heat exchange medium to a heat exchanger unit 100. Heat exchange medium flowing in through the heat exchanger 100 may exit through outlet 110B. Manifolds 105A and 105B may have one or more baffles to obtain desired flow pattern between individual rows of plurality of disk units. As heat exchange medium flow through the heat exchanger 100, the heat from the heat exchange medium is transferred to the material comprising individual disk units 115. The heat from the heat exchange medium that has been absorbed by the material comprising individual disk units 115 is transferred to a heat exchange medium surrounding the exterior of the heat exchanger 100. Heat exchange medium utilized within the heat exchanger 100, and heat exchange medium on the exterior of the heat exchanger varies by application. For example, in an application for an air conditioner evaporator, heat exchange medium utilized within a heat exchanger may be a refrigerant, such as R-410. The heat exchange medium surrounding the evaporator in such an application may be air. The composition of heat exchange medium may be a combination of any and all known heat carrying medium known in the art. Although not meant to be limiting, common heat exchange medium known in the art includes various refrigerants (i.e., R-410, R-134, R-22), carbon dioxide, butane, propane, oils, gases (e.g., air), water, and mixture of water and other coolants (e.g. ethylene glycol).

Referring to FIG. 2A and FIG. 3A, a disk unit 115 comprises of a first disk member 120, an inlet 125 generally formed as a tubular member on a first side of the first disk member, and a second disk member 140, an outlet 145 generally formed as a tubular member on a first side of the second disk member. Said first disk member 120 and said second disk member 140 are coupled together on respective second side of said disk members, ring-like member 305B on second side of the first disk member 120 engaging the second side 150 of the second disk member. In this embodiment, referring to FIG. 3E, ring-like member 305B on the second side of the first disk member is formed by plurality of folds near an outer circumference of the first disk member, first generally annular fold 320 extending outwardly from the second side of the first disk member, second generally annular fold 325 made generally perpendicular from the first fold, said second fold extending laterally away from the center of the of the disk member, on the second side of the first disk member, generally forming a stepped surface 305B on the outer circumference of the second side of said first disk member, said stepped surface 305B having a generally planar surface, said surface generally parallel to the second side of said first disk member. Referring to FIG. 3A, the ring-like member 305B has a generally planar top surface. Referring to FIG. 3A, second side 330 of the first disk member, and second side 150 of the second disk member that is not covered by the ring-like member 305B becomes chamber 300B to facilitate flow of heat exchange medium herein.

Referring to FIG. 3A, flow of heat exchange medium once it enters the chamber 300B, is directed towards the outlet of the disk unit 145 generally by the contour of the inner chamber wall, and by sidewall 310B of the chamber. The contour of the chamber wall directs the flow of heat exchange medium. In the present embodiment, the sidewall 310B generally comprises of circular configuration, with smooth wall contour. In other embodiments, the sidewall 310B may have plurality of convex or concave features to obtain the desired heat exchange medium flow characteristics to enhance the heat transfer efficiency. In other embodiments, the sidewall 310B may have plurality of dimples formed on the surface of said sidewall. Referring to FIG. 2A, a heat exchange medium directing member 200 is disposed within said disk unit 115, first end of the heat exchange medium directing member engaging the inlet on the first disk member 120. Said first end of heat exchange medium directing member 200 has a channel 205A cut at an angle. Channel 205A directs heat exchange medium flowing in from the inlet 125 on the first disk member to the chamber 300B. A second side of the heat exchange medium directing member 200 engages the outlet 145 on the second disk member. Said second side of heat exchange medium directing member 200 has a channel 205B cut at an angle. Channel 205B directs heat exchange medium out of the disk unit 115. Generally, although not limiting, channel on the second side of heat exchange medium directing member 205B is positioned on a generally diagonally opposite side from the channel on the first side of the heat exchange medium directing member 205A.

Referring to FIG. 1B and FIG. 1C, the present invention permits the disk unit to have a flexible ratio of volumetric capacity of the disk unit to the surface area of the disk unit to obtain a desired performance characteristics. The performance of a heat exchanger is generally dictated by the ratio of volumetric capacity of a heat exchanger and the overall surface area of a heat exchanger. Generally, when the volumetric capacity of a heat exchanger is reduced, while the surface area of a heat exchanger is kept the same, the performance of a heat exchanger is generally enhanced. Alternatively, when the volumetric capacity of a heat exchanger is kept the same, while the surface area of a heat exchanger is increased, the performance of a heat exchanger is generally enhanced. Referring to FIG. 1B, the surface area encompassed by the ring-like member 305A may be increased in relationship to the overall disk unit surface area as shown in ring-like member 305B in FIG. 1C and FIG. 2C, which may decrease the volumetric capacity of a disk unit in relationship to the overall surface area of the disk unit, which may enhance the heat exchange performance. Separately, the ring-like member 305A may encompass less surface area as referred in FIG. 1B and FIG. 2B, which may increase the overall heat exchange medium flow capacity by increasing the volumetric capacity of the chamber. However, as the volumetric capacity of the chamber is increased while the surface area of the disk unit remains constant, the heat exchange performance may drop. The present invention improves upon heat transfer efficiency of heat exchange medium by spreading out the heat exchange medium in the chamber, thereby increasing the heat exchange medium to heat exchanger structure contact, generally increasing heat transfer efficiency.

Referring to FIG. 2C, in another embodiment of the present invention, in order to obtain a desired heat exchange medium to the overall surface area of the disk unit, the height of chamber wall 310A may be increased or decreased to have a similar effect, while maintaining the diameter of the ring-like member 305A.

Referring to FIG. 2A and FIG. 2B, the heat exchange medium entering the disk unit 115 through the inlet 125 is directed into the chamber 300A by the first channel 205A of the heat exchange medium directing member 200. A heat exchange medium flowing in the inlet 125 is generally flowing in a laminar flow, comprising of multiple layers of said heat exchange medium containing varying amount of heat within said layers. As the heat exchange medium enters the chamber 300A, heat exchange medium that may have been travelling in a laminar flow through the inlet 125 is caused to re-distribute the heat contained within the heat exchange medium as the heat exchange medium flows through the first channel 205A of the heat exchange medium directing member 200. As the heat exchange medium transitions from laminar flow to more of a turbulent flow, the heat contained within the heat exchange medium may be more effectively transferred to the material comprising the disk unit 115 if the heat contained within the heat exchange medium is directly contacting the structure comprising the disk unit 115, as heat generally transfers by conduction. Generally, heat exchange medium travelling in a laminar flow comprise of plurality of layers, with each layer containing varying amount of heat. As heat generally travels by conduction, heat contained within the heat exchange medium that is in direct contact to the disk unit 115 may be more efficient at transferring heat contained within the heat exchange medium to the disk unit 115, but in a heat exchange medium layer far away from the heat exchange structure comprising the disk unit 115 has to travel multiple layers generally by conduction before the heat has an opportunity to reach the heat exchange structure. By having more of a turbulent flow instead of a laminar flow, inefficiency as a result of having to travel through multiple layers by conduction is reduced. As the heat exchange medium enters the chamber 300A, the efficiency of heat conduction is further enhanced as the chamber causes further turbulence to the heat exchange medium that generally may have been flowing in a laminar flow.

The chamber 300A has an added benefit of reducing the distance heat contained within heat exchange medium has to travel to reach the material comprising of a heat exchanger, thereby improving heat exchange efficiency, as spreading the heat exchange medium within the chamber 300A has an added benefit of creating a thinner layer of heat exchange medium, while increasing the heat exchange medium to heat exchanger surface contact, thereby enhancing the performance of a heat exchanger. Referring to FIG. 2A and FIG. 2B, once the heat exchange medium enters the chamber 300A, the heat exchange medium is spread out in a thin layer, thereby increasing the heat exchange medium to the heat exchange surface structure contact generally comprising of second side of first disk member 330A, chamber sidewall 310A and second side of second disk member 330A. The chamber effectively enhances the heat transfer efficiency of heat contained within the heat exchange medium by increasing the surface area contact between the heat exchange medium and the surface of the disk unit within the chamber, therefore generally improving the heat transfer efficiency as heat generally travels by conduction in such an application. Another advantage of the present invention is that a heat exchange medium directing member 200 coupled within a disk unit effectively routes heat exchange medium to contact heat exchanger surface more effectively. A heat exchange medium directing member 200 also has an added benefit of effectively mixing and stirring heat exchange medium within a disk unit chamber 300A by preventing laminar flow of heat exchange medium, thereby increasing heat exchange efficiency. As heat exchange efficiency is improved in the present invention, overall size of a heat exchanger may be made smaller compared to a conventional heat exchanger of equal capacity, which in turn provides for a lower overall cost as less raw material and less packaging is necessary.

Referring to FIG. 3B and FIG. 3C, a second disk member 140 may have an annular wall 160, generally projecting outwardly from the second side of the second disk member, base of said wall generally connected to the second side 150 of the second disk member 140. In a typical embodiment, overall disk diameter of the first disk member 120 may be made slightly smaller than the inner diameter of the annular wall 160 formed on the second disk member 140, allowing the first disk member 120 to be matingly coupled within the annular wall 160 of the second disk member 140. Generally, the first disk member 120 is pressed in within the annular wall 160 of the second disk member, allowing the top face of the ring-like member 305B, referring to an embodiment shown in FIG. 3A, to couple to the second side 150 of the second disk member 140. As the top face of the ring-like member 305B protrudes outwardly from the second side 330 of the first disk member, when the ring-like member 305B engages the second side of the second disk member, chamber 300B is formed between the second side of the first disk member and the second side of the second disk member.

Referring to FIG. 3B and FIG. 3C, once the first disk member and the second disk member are coupled together, generally annular wall 160 is bent in a folding fashion, securing the first disk member and second disk member together. Generally annular wall 160 is folded in, so that the chamber 300 is left intact, as shown in FIG. 3C. The annular wall 160 once folded to couple the first disk member 120 and second disk member 140, generally appear to partially overlap the first side of the first disk member 120 as shown in 160A of FIG. 3C.

Referring to FIG. 3D, in another embodiment of the present invention, connecting members 315A and 315B may be utilized as a means to enhance the structural rigidity of a chamber, to prevent the chamber from deforming when applied with high pressure heat exchange medium, for example. There are many embodiments of connecting members, various embodiments discussed in Nitta, U.S. patent application Ser. No. 12/886,559, the disclosure of which is hereby referenced in its entirety. As illustrated in FIG. 3D, connecting members in an embodiment of the present invention is shown as 315A and 315B, protrusion members 315A and 315B aligned generally parallel to each other, leaving an inlet flow path and an outlet flow path between said two protrusion members. In another embodiment of the present invention, the two connecting members may comprise of plurality of generally circular protrusion members. In yet another embodiment, connecting members may comprise of a plurality of rows of connecting members. In another embodiment, connecting members may comprise of plurality of generally rectangular protrusion members. In a typical embodiment, material with clad material on one or both side of a material is utilized to fabricate a disk member, clad material designed to melt at a temperature lower than the melting temperature of a base material. Typically, the side of the disk member with connecting members is made with clad material. Therefore, when the disk units are brazed together, even when plurality of connecting members comprise a single connecting member, a braze fillet is typically formed between the plurality of connecting members, forming a single unitary connecting member. Generally, connecting members comprise of a pair of connecting members, as with 315A and 315B. However, in other embodiments, each connecting member may comprise of plurality of smaller connecting members. In other embodiments of the present invention when plurality of smaller diameter connecting members comprise a set of connecting members, plurality of smaller connecting members function similarly to connecting member 315A and 315B. Quantities of smaller connecting members may vary by application. Shape, as well as arrangement of plurality of small connecting members may vary by application.

When plurality of disk units is combined together to form a single unitary unit as illustrated in FIG. 1A, disk units may be coupled together between consecutive disk units by coupling a second inlet 125 and a first outlet 145, forming a tubular member. To facilitate ease of assembly, the inlet 125 may be manufactured with an outside diameter that is substantially the same diameter as an inside diameter of the outlet 145. When more than one disk unit is coupled together, the inlet 125 may be disposed in outlet 145, forming a tubular unit. Conversely, the inlet 125 may be manufactured with an inside diameter that is substantially the same diameter as outside diameter of the outlet 145. When more than one disk unit is coupled together, the outlet 145 may be coupled to the inlet 125. In yet another embodiment of the present invention, inlet 125 and outlet 145 may be of substantially the same diameter, plurality of disk units attached in a butt joint method. In such embodiment, a sleeve may be utilized to overlap the inlet 125 and outlet 145, allowing for ease of assembly.

Although not limiting, disk members are generally made of one or more aluminum alloys, typically utilizing cladded alloy sheets, comprising of one or more aluminum alloys, said disk members generally brazed or soldered together to form a unitary unit.

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.

	Number	Date	Country
Parent	12148655	Apr 2008	US
Child	12904932		US

Heat Exchanging Apparatus and Method of Making Same

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CROSS-REFERENCE TO RELATED APPLICATION

Continuation in Parts (1)