Stackable core system for producing cast plate heat exchanger

Patent metadata

Field	Value
Publication number	US-11480397-B2
Application number	US-201916271308-A
Country	US
Kind code	B2
Filing date	Feb 8, 2019
Priority date	Mar 23, 2018
Publication date	Oct 25, 2022
Grant date	Oct 25, 2022

Abstract

A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.

First claim

What is claimed is:

1. A core assembly for a cast heat exchanger, the core assembly comprising:
at least one hot core plate defining internal features of a heat exchanger plate in the cast heat exchanger and a first set of interlocking features defined as part of a side wall, the side wall including an interior surface defining one of an inlet face and an outlet face of a completed cast heat exchanger, the first set of interlocking features configured to assemble the at least one hot core plate to another hot core plate and comprises rectilinear slots on one side of the at least one hot core plate and a correspondingly shaped rectilinear tab on an opposite side of the at least one hot core plate; and
at least two cold core plates that each include structures defining external features of the heat exchanger plate and a second set of interlocking features, wherein the second set of interlocking features includes a curvilinear slot on one side of the each of the at least two cold plates and a curvilinear tab on an opposite side of each of the at least two cold plates, the at least two cold core plates are configured to interlock together utilizing the second set of interlocking features to define a spacing therebetween, wherein the first set of interlocking features are disposed transversely relative to the second set of interlocking features and the at least one hot core plate is disposed within the spacing separate from and spaced apart from the at least two cold core plates with the first set of interlocking features outside of the spacing between the at least two cold core plates.

2. The core assembly as recited in claim 1 , including a top half cold core plate defining top surface external features of the heat exchanger plate and a bottom half cold core plate defining bottom surface external features of the heat exchanger plate and the top half cold core plate and the bottom half cold core plate are interlocked to a corresponding one of the at least two cold core plates to define top and bottom external features of a completed one piece heat exchanger.

3. The core assembly as recited in claim 2 , wherein the first set of interlocking features of the at least one hot core plate is not compatible to interlock to either the top half cold core plate or the bottom half cold core plate.

4. The core assembly as recited in claim 1 , wherein the external features defined by the cold core plate comprise at least one of fin portions and augmentation structures disposed on top and bottom surfaces of a completed heat exchanger.

5. The core assembly as recited in claim 1 , wherein the external features defined by the at least two cold core plates include an open cooling channel.

6. The core assembly as recited in claim 5 , wherein the at least two cold core plates includes a top, a bottom, a lock side and a slip side, and the second set of interlocking features includes pedestals disposed on the top of the slip side and the bottom of the lock side and indentations on the bottom of the slip side and the top of the lock side.

7. The core assembly as recited in claim 1 , wherein the internal features defined by the at least one hot core plate comprise internal passages extending through a plate portion in the cast heat exchanger.

8. The core assembly as recited in claim 7 , wherein at least one hot core plate includes a top, a bottom, a lock side and a slip side, and the first set of interlocking features includes tabs on the bottom of both the lock side and the slip side and slots on the top of both the lock side and the slip side.

9. The core assembly as recited in claim 8 , wherein the at least one hot core plate includes features defining an inlet face, an outlet face and a plurality of inlets and outlets corresponding to the internal passages.

10. The core assembly as recited in claim 1 , wherein the at least two cold core plates are disposed within the core assembly such that the defined external features are transverse to the internal features defined by the at least one hot core plate.

11. The core assembly as recited in claim 1 , including at least two hot core plates interlocked together and at least three cold core plates interlocked together.

12. The core assembly as recited in claim 1 , wherein the hot core plate does not interlock with either of the at least two cold plates.

13. The core assembly as recited in claim 1 , including a wax pattern that surrounds the surfaces of the at least one hot core plate and the at least two cold core plates and holds the at least one hot core plate in a spaced part orientation relative to the at least two cold core plates.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Disori Michael A
• Verner Carl R
• Bullied Steven J
• Chapdelaine David Donald

Classifications

• B22C9/26

  for ribbed tubes; for radiators · CPC title

• B22C7/02 Primary

  Lost patterns · CPC title

• F28D7/1684

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

• F28F1/26

  the means being integral with the element (F28F1/32 takes precedence) · CPC title

• F28F3/048

  in the form of ribs integral with the element or local variations in thickness of the element, e.g. grooves, microchannels · CPC title