Heat exchanger and method for making

Patent metadata

Field	Value
Publication number	US-10209015-B2
Application number	US-83811410-A
Country	US
Kind code	B2
Filing date	Jul 16, 2010
Priority date	Jul 17, 2009
Publication date	Feb 19, 2019
Grant date	Feb 19, 2019

Abstract

A hybrid plate-fin heat exchanger for exchanging heat between a first fluid and a second fluid is disclosed. The hybrid plate-fin heat exchanger comprises a plurality of plates, each of which comprises channels for conveying the first fluid. Fins are brazed onto each plate, wherein the fins define a plurality of flow channels for the second fluid. The plates are joined to one another via friction-stir welding in such a way that the brazed regions are fluidically isolated from the first fluid during operation. As a result, the heat exchanger is suitable for use in applications that use a first fluid, such as seawater or geothermal fluid, which is corrosive for the brazed regions.

First claim

What is claimed is:

1. A heat exchanger comprising:
a first core having a first end and a second end, wherein the first core comprises;
a first layer comprising a first channel having a first channel inlet at the first end and a first channel outlet at the second end for conveying a first fluid from the first channel inlet to the first channel outlet; and
a second layer comprising a plurality of fins that define a first plurality of second channels, wherein the second layer is brazed to the first layer;

a first plate disposed at and surrounding the first channel inlet of the first layer of the first core, wherein the first plate and the first layer are joined via a first joint that is a galvanic-corrosion-resistant joint consisting of a same material as the first plate and the first layer; and
a second plate disposed at and surrounding the first channel outlet of the first layer of the first core, wherein the second plate and the first layer are joined via a second joint that is a galvanic-corrosion-resistant joint consisting of a same material as the second plate and the second layer.

2. The heat exchanger of claim 1 wherein each of the first joint and second joint comprises a friction-stir weld.

3. The heat exchanger of claim 1 wherein the first core further comprises a third layer comprising a third channel having a third channel inlet at the first end and a third channel outlet at the second end for conveying the first fluid, and wherein the second layer interposes the first layer and third layer.

4. The heat exchanger of claim 3 wherein the first core further comprises a first bar having a first portion and second portion, and wherein the first portion is friction-stir welded to each of the first layer and third layer, and further wherein the second portion is brazed to each of the first layer and third layer.

5. The heat exchanger of claim 4 wherein the first core further comprises a second bar having a third portion and fourth portion, and wherein the third portion is friction-stir welded to each of the third layer and the first plate, and wherein the fourth portion is brazed to the third layer.

6. The heat exchanger of claim 1 wherein the first layer extends further along a length of the first core than the second layer, and wherein the first joint is a friction-stir weld.

7. The heat exchanger of claim 1 further comprising a second core, wherein the second core comprises:
a third layer comprising a third channel having a third channel inlet at the first end and a third channel outlet at the second end for conveying the first fluid from the third channel inlet to the third channel outlet; and
a fourth layer comprising a plurality of fins that define a second plurality of fourth channels, wherein the fourth layer is brazed to the third layer;
wherein the first plate is disposed at and surrounding the third channel inlet of the third layer of the second core, wherein the first plate and the third layer are joined via a third joint that is a galvanic-corrosion-resistant joint consisting of a same material as the first plate and the third layer; and
wherein the second plate is disposed at and surrounding the third channel outlet of the third layer of the second core, wherein the second plate and the third layer are joined via a fourth joint that is a galvanic-corrosion-resistant joint consisting of a same material as the second plate and the fourth layer.

8. The heat exchanger of claim 7
wherein the first plate comprises a first opening and a second opening, the first opening fluidically coupled with the first channel inlet and the second opening fluidically coupled with the third channel inlet; and
wherein the second plate comprises a third opening and a fourth opening, the third opening fluidically coupled with the first channel outlet and the fourth opening fluidically coupled with the third channel outlet.

9. The heat exchanger of claim 1 wherein the first layer comprises an extruded channel plate that forms the first channel.

10. The heat exchanger of claim 1 wherein the first joint surrounds the first channel inlet of the first layer of the first core, and the second joint surrounds the first channel outlet of the first layer of the first core.

11. The heat exchanger of claim 1 further comprising a shell defining an interior, the first core and the second core positioned within the interior of the shell.

12. The heat exchanger of claim 1 further comprising a shell defining an interior, the first core positioned within the interior of the shell.

13. A heat exchanger comprising:
a first core having a first end and a second end, comprising:
a first plurality of first layers, wherein each of the first plurality of first layers comprises a first channel having a first channel inlet at the first end and a first channel outlet at the second end configured to convey a first fluid from the first channel inlet to the first channel outlet;
a first plurality of second layers, wherein each of the first plurality of second layers comprises a plurality of fins that define a first plurality of second channels, and wherein each of the first plurality of second layers is brazed to at least one of the first plurality of first layers;
wherein the first plurality of first layers and the first plurality of second layers are arranged in an alternating stack;

a first port disposed at the first end of the first core, wherein the first port provides the first fluid to the first core; and
a first plate disposed at and surrounding the first channel inlets of the first channels of the first plurality of layers, wherein the first plurality of first layers of the first core and the first plate are joined via a first joint that comprises a friction-stir weld devoid of brazing material, and wherein the first plate and first joint collectively define a barrier that fluidically isolates the first port and the first plurality of second layers.

14. The heat exchanger of claim 13 wherein the first core further comprises a first plurality of bars disposed at the first end:
wherein each of the first plurality of bars has a first portion that is proximal to the first plate and a second portion that is distal to the first plate;
wherein each of the bars interposes a pair of first layers, and wherein the first portion is friction-stir welded to each of the pair of first layers, and further wherein the second portion is brazed to each of the pair of first layers;
wherein the first plurality of bars and the first plurality of first layers collectively define a first face of the first core; and
wherein the first face and the first plate are joined via the first joint.

15. The heat exchanger of claim 13 wherein the first plurality of first layers project beyond the first plurality of second layers at the first end, and wherein each of the plurality of first joints comprise a friction-stir weld.

16. The heat exchanger of claim 15 wherein each of the first plurality of first layers is joined with the first plate such that each of the first plurality of second layers is separated from the first plate by a gap.

17. The heat exchanger of claim 13 further comprising a second core, wherein the second core comprises:
a second plurality of first layers, wherein each of the second plurality of first layers comprises a first channel having a first channel inlet at the first end and a first channel outlet at the second end configured to convey a first fluid from the first channel inlet to the first channel outlet;
a second plurality of second layers, wherein each of the second plurality o

Assignees

• Levings Natalie B
• Nagurny Nicholas J
• Eller Michael R
• Lockheed Corp

Inventors

• Levings Natalie B
• Nagurny Nicholas J
• Eller Michael R

Classifications

• F28D7/1684

  the conduits having a non-circular cross-section · CPC title

• F28F2275/062

  by impact pressure or friction welding · CPC title

• F28D9/0062

  the conduits for one heat-exchange medium being formed by spaced plates with inserted elements (F28D9/0012, F28D9/0025, F28D9/0081, F28D9/04 take precedence) · CPC title

• F28F9/18 Primary

  by welding · CPC title

• F28F2009/226

  Transversal partitions · CPC title