BRPI0706670A2 - flat tube, flat tube heat exchanger and method of manufacture - Google Patents

Abstract

FLAT TUBE, FLAT TUBE HEAT EXCHANGER AND METHOD OF MANUFACTURING THE SAME. Various flat tubes, flat tube heat exchangers and manufacturing methods for both are described and illustrated. Flat tubes can be constructed from one, two or more pieces of sheet material. A profiled insert integral with the flat tube or constructed from another sheet of material can be used to define multiple flow channels through the flat tube. Flat tubes can be constructed of relatively thin material and can be reinforced with folds of flat tube material and / or an insert in areas subject to higher pressure and thermal stresses. Also, a relatively thin flat pipe material can have a corrosion layer allowing the material to resist failure due to corrosion. Heat exchangers having these flat tubes connected to collection tubes are also shown, as are the ways in which these tubes can be provided with fins.

Description

FLAT PIPE, FLAT PIPE HEAT EXCHANGER AND METHOD

MANUFACTURING THE SAME

CROSS REFERENCE TO RELATED APPLICATIONS

A priority is hereby claimed in German Patent Application No. 10 2006 002 627.6, filed January 19, 2006, and German Patent Application No. 102006 002 789.2, filed on January 20, 2006, and German Patent Application. No. 10 2006 002 932.1, filed January 21, 2006, and German Patent Application No. 10 2006 006 670.7, filed February 14, 2006, and German Patent Application No. 10 2006 016 711.2, filed 8 April 2006, and to German Patent Application No. DE 10 2006 029 378.9, filed June 27, 2006, and German Patent Application No. DE 10 2006 032 406.4, filed July 13, 2006, and to Patent Application No. 10 2006 033 568.6, filed July 20, 2006, and German Patent Application No. 10 2006 035 210.6, filed July 29, 2006, and German Patent Application No. 10 2006 041 270.2, filed on September 2, 2006, and German Patent Application No. DE 10 2006 2006 042427.1, after September 9, 2006, the contents of which are incorporated herein by reference.

SUMMARY

In some embodiments, the present invention provides a heat exchanger that includes a collector having a plastic outer wall surrounding an inner chamber, the collector having an opening extending through the outer wall and having an outer end and an inner end in communication with the inner chamber. , a conformal tube extending into the aperture and having a sidewall attached to the outer wall of the collector and an end extending into the collector beyond the outer end opening, and an adhesive securing the finned tube to the aperture.

The present invention also provides a method of forming a heat exchanger which includes the act of attaching a fin to a tube body in an oven for forming a heat exchanger core, forming a collector having a substantially surrounding outer plastic wall. an inner chamber and attach the core to the collector after the core has been removed from the oven.

Furthermore, the present invention provides a heat exchanger deformation method that includes the deformation acts of a collector having a deplastic outer wall surrounding an inner chamber, the collector having an opening extending through the outer wall and having an outer end and an inner end in communication with the inner chamber, inserting a tube of a tube body into the opening in the outer wall beyond the outer end of the opening and attaching a sidewall of the tube body to the outer wall of the collector, and inserting adhesive into the opening between the outer wall of the collector and the side wall of the tube body.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side view of a tube according to some embodiments of the present invention.

FIG. 2 is an enlarged view of a dotted end shown in FIG. 1.

FIG. 3 schematically illustrates a set of exemplary manufacturing steps that can be used for forming the tube shown in FIG. 1.

FIG. 4 is an enlarged side view of the narrow tube shown in FIG. 1.

FIG. 5 is another enlarged view of the narrow side shown in FIG. 1.

FIG. 6 is an enlarged side view of a pipe in accordance with another embodiment of the present invention.

FIG. 7 is an enlarged side view of a pipe still in accordance with another embodiment of the present invention.

FIG. 8 is an enlarged narrow side view of the tube according to another embodiment of the present invention.

FIG. 9 is an enlarged side view of a pipe in accordance with another embodiment of the present invention.

FIG. 10 is an enlarged side view of a tube in accordance with yet another embodiment of the present invention.

FIG. 11 is a narrow side of a pipe according to yet another embodiment of the present invention.

FIG. 12 is an enlarged view of a portion of a tube including internal folds in accordance with another embodiment of the present invention.

FIG. 13 is an enlarged view of a portion of a tube including inner folds in accordance with yet another embodiment of the present invention.

FIG. 14 is an enlarged view of a portion of a tube including an insert in accordance with yet another embodiment of the present invention.

FIG. 15 is an enlarged view of a portion of a tube including an insert according to another embodiment of the present invention.

FIG. 16 schematically illustrates an example set of manufacturing steps that can be used for forming a tube including first and second portions formed from a common piece of bent material.

FIG. 17 is an enlarged view of a tube including first and second portions formed from a common piece of bent material still in accordance with another embodiment of the present invention.

FIG. 18 is an enlarged view of a tube including first and second portions formed from a common piece of folded material in accordance with another embodiment of the present invention.

FIG. 19 is a side view of a tube including the first and second portions formed from a common piece of folded material in accordance with yet another embodiment of the present invention.

FIG. 20 is a side view of a tube including the first and second portions formed from a common piece of folded material in accordance with yet another embodiment of the present invention.

FIG. 21 is a side view of a tube including the first and second portions formed from a common piece of bent material in accordance with another embodiment of the present invention.

FIG. 22 is a side view of a tube including the first and second portions formed from a common piece of folded material in accordance with yet another embodiment of the present invention.

FIG. 23 is a side view of a tube including the first and second portions formed from a common piece of folded material in accordance with yet another embodiment of the present invention.

FIG. 24 is an enlarged view of a tube including first and second portions formed from a common piece of folded material in accordance with another embodiment of the present invention.

FIG. 25 is an exploded view of a tube including first and second portions and an insert positioned between the first and second portions, according to certain embodiments of the present invention.

FIG. 26 is an exploded view of the tube shown in FIG. 25

FIG. 27 is an exploded view of a tube including first and second portions and an insert positioned between the first and second portions, in accordance with yet another embodiment of the present invention.

FIG. 28 is a side view of the tube including the first and second portions and an insert positioned between the first and second portions, in accordance with yet another embodiment of the present invention.

FIG. 29 is an enlarged view of a portion of the tube.

shown in FIG. 28

FIG. 30 is a side view of a tube including the first and second portions and an insert positioned between the first and second portions, in accordance with a further embodiment.

30 Another embodiment of the present invention. FIG. 31 is an enlarged view of a portion of the tubom shown in FIG. 30

FIG. 32A is a side view of a tube including first and second portions and an insert positioned between the first and second portions, according to yet another embodiment of the present invention.

FIG. 32B is an enlarged view of a portion of the tubom shown in FIG. 32A.

FIG. 33 is a side view of a tube including the first and second portions and an insert positioned between the first and second portions, in accordance with another embodiment of the present invention.

FIG. 34 illustrates ten pipe tube embodiments with some embodiments of the present invention.

FIG. 35 is a side view of a tube according to some embodiments of the present invention.

FIG. 36 is a side view of an internal insert for the tube shown in FIG. 35

FIG. 37 is a top view of a portion of the internal insert shown in FIG. 36

FIG. 38 is a perspective view of a portion of the internal insert shown in FIG. 35

FIG. 39 is a side view of a tube according to some embodiments of the present invention.

FIG. 40 is an enlarged perspective view of an internal insert for the tube shown in FIG. 39

FIG. 41 is a perspective view of a portion of the internal insert shown in FIG. 40

FIG. 42 is an enlarged perspective view of the internal insertion shown in FIG. 40. FIG. 43 is a top view of a portion of an inner insert for a pipe according to some embodiments of the present invention.

FIG. 44 is a side view of an insert according to one embodiment of the present invention, shown in a flat tube in dotted lines.

FIG. 45 is a side view of another insert according to one embodiment of the present invention shown in a flat tube in dotted lines.

FIG. 46 schematically illustrates a set of exemplary manufacturing steps that can be used for forming a tube according to some embodiments of the present invention.

FIG. 47 is a partially exploded side view of the pipe shown in FIG. 46

FIG. 48 schematically illustrates a set of exemplary manufacturing steps that may be used for forming a tube according to some embodiments of the present invention.

FIG. 49 is a delamination press manufacturing line that can be used to manufacture tubes according to some embodiments of the present invention.

FIG. 50 schematically illustrates a set of exemplary manufacturing steps that can be used for forming a tube according to some embodiments of the present invention.

FIG. 51 schematically illustrates a set of exemplary manufacturing steps that may be used for forming a tube according to other embodiments of the present invention. FIG. 52 schematically illustrates a set of exemplary manufacturing steps that can be used for forming a tube in accordance with yet other embodiments of the present invention.

FIG. 53 schematically illustrates a set of exemplary manufacturing steps that can be used for forming a tube in accordance with yet other embodiments of the present invention.

FIG. 54 schematically illustrates a set of exemplary manufacturing steps that may be used for forming a tube according to other embodiments of the present invention.

FIG. 55 illustrates an exemplary fabrication line that can be used for the manufacture of tubes according to some embodiments of the present invention.

FIG. 55A is a cross-sectional view showing a drilling station of the manufacturing line shown in FIG. 55

FIG. 55B is a side view showing the drilling station shown in FIG. 55A.

FIG. 55C is a cross-sectional view showing a breaker roll and bar of the manufacturing line shown in FIG.55.

FIG. 55D is a side view of a breaker roll and bar of the manufacturing line shown in FIG. 55

FIG. 56 is a side view of a portion of the drilling station shown in FIG. 55A.

FIG. 57A is a side view showing a sheet of material traveling through a portion of the perforation station shown in FIG. 55A.

FIG. 57B is a top view showing a sheet of material traveling through a portion of the drilling station shown in FIG. 55A.

FIG. 58 is a side view of a breaker roll and bar of the manufacturing line shown in FIG. 55

FIG. 59 is a series of schematic end views of the manufacturing line shown in FIG. 55, shown at different stages of forming a flat tube with an insertion.

FIG. 60 is a schematic top view of a folding roll portion of the manufacturing line shown in FIG. 55

FIG. 60A is an end view of the bending roll portion shown in FIG. 60

FIG. 61 is a schematic end view of a finned flat tube fabrication line according to one embodiment of the present invention.

FIG. 62 is an exploded view of a heat exchanger having finned flat tubes according to one embodiment of the present invention.

FIGs. 63A to C are partial views of rack assemblies according to different embodiments of the present invention.

FIG. 64 is a schematic view of a fin tube manufacturing process according to one embodiment of the present invention.

FIG. 65 is a perspective side view of a portion of the manufacturing process shown in FIG. 64.

FIG. 66 is a detailed view of a heat exchanger having finned flat tubes according to one embodiment of the present invention. FIG. 67 is a detailed view of a flat tube which may be used in the production of a finned flat tube according to one embodiment of the present invention.

FIG. 68 is a detailed side view of a heat exchanger having finned flat tubes in accordance with another embodiment of the present invention.

FIG. 69 is a detailed perspective view of the heat exchanger portion shown in FIG. 68

FIG. 70 is a side view of a collection tank according to one embodiment of the present invention.

FIG. 7A is a final view of the collection tank shown in FIG. 70

FIG. 71 is a detailed view of a heat exchanger having the collection tank illustrated in FIGs. 70 e7 OA.

FIG. 72 is a perspective view of a take-off tank according to another embodiment of the present invention.

FIG. 73 is a detailed perspective view of a heat exchanger having the collection tank illustrated in FIG. 72

FIG. 74 is another detailed perspective view of the heat exchanger shown in FIG. 73

FIG. 75 is a detailed perspective view of the collection tank shown in FIG. 72

FIG. 76 is another detailed view of a heat exchanger having the collection tank illustrated in FIGs. 70 to 71.

FIG. 7 is an elevation view of the heat exchanger illustrated in FIGs. 71 and 76. FIG. 78 is a detailed side view of a heat exchanger having a collection tank in accordance with another embodiment of the present invention.

FIG. 79 is a detailed end view of the heat exchanger illustrated in FIG. 78

FIG. 80 is a detailed side view of the heat exchanger take-off tank illustrated in FIGS. 78 and 79.

FIG. 8A is an end view of the collection tank illustrated in FIGs. 78 to 80.

FIG. 81 is a detailed side view of a heat exchanger having a collection tank in accordance with another embodiment of the present invention.

FIG. 82 is a detailed end view of the heat exchanger take-off tank illustrated in FIG. 81

FIG. 84 is a flow chart of a heat exchanger manufacturing process according to an embodiment of the present invention.

FIG. 84A is a schematic view of a heat exchanger manufactured in accordance with the flow chart of FIG. 84

FIG. 85 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

FIG. 86 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

FIG. 87 is an end view of a heat exchanger flat tube illustrated in FIG. 86

FIG. 88 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention. FIGs. 89 illustrate end views of alternate flat tube embodiments according to the present invention.

FIG. 90 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

FIGs. 91 are views of a flat tube according to another embodiment of the present invention shown at different stages of formation.

FIGs. 92 to 95 illustrate methods of connecting portions of a heat exchanger according to some embodiments of the present invention.

FIG. 96 is a graph showing silicon diffusion depths for heat exchangers connected according to some embodiments of the present invention.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or practiced in various ways. Also, it is to be understood that the phraseology and terminology used herein is for description purposes and should not be considered as limiting. The use of "including", "comprising" or "having" and variations thereof herein is intended to encompass the items listed below and their equivalents as well as additional items. Unless otherwise specified or limited, the terms "mounted", "connected", "supported" and "coupled" and variations thereof are used widely and encompass direct and indirect mounts, fittings, brackets and couplings. Also, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings.

As described in more detail below, many embodiments of the present invention pertain to or are based on the use of tubes having a substantially flat cross-sectional shape taken along a plane perpendicular to a longitudinal axis geometric dot. In particular each pipe such as this may have a larger dimension and a smaller dimension perpendicular to the larger dimension. These dimensions are sometimes referred to herein as "diameters", although the use of the term "diameter" is not intended to merely indicate or imply that the recursive reference is round, rotund or otherwise of any particular shape. Instead, the term "diameter" is used only to refer to a larger tubona size indicated direction and location. Each of these tubes may have two opposite walls defining the pipe faces (referred to herein as the "wide sides" of the pipe) and two shorter and more stable walls (referred to here as the "narrow sides" of the pipe) joining the broad sides. The broad and narrow sides of the tube define an internal space through which a fluid can flow in any state, including, without limitation, gas, liquid, steam and any combination thereof at any pressure or vacuum (including no pressure or vacuum).

Another feature of the flat tubes employed in many embodiments of the present invention (described in greater detail below) is the relatively low thickness of material used to construct at least some of the flat tube walls. In some embodiments, the flat tube wall material has a thickness of no greater than about 0.20 mm (0.007874 in). In still other embodiments, the pipe wall material has a thickness no greater than about 0.15 mm (0.0059055 in). The relatively low material thickness may result in good thermal properties of the flat tubes. Also, by utilizing one or more flat tube features described herein, the inventors have found that several different flat tubes having varying characteristics adapted for a variety of applications can be constructed using significantly reduced material while retaining flat tube heat and heat resistance properties. In some embodiments, a flat tube wall material thickness of not less than about 0.05 mm (i.e. no less than about 0.0019685 in) provides good strength performance and corrosion resistance, while in other embodiments a flat wall thickness of no less than about 0.030 mm (0.00118 in) can be used.

As explained in more detail below, the heat exchange tubes and other portions of heat exchangers described herein may be manufactured using various fabrication techniques and processes, and may include corrosion protection features, such as those techniques and processes described herein. below illustrated in FIGs. 92 to 95. Various manufacturing processes and techniques and the corrosion protection features referred to hereinafter are particularly advantageous when applied to heat exchange tubes and heat-treating portions having significantly reduced material thickness. In addition, these corrosion protection techniques, processes and features provide significant performance advantages over flat tubes and heat exchangers made from this material.

Many embodiments of the present invention utilize flat tubes having larger and smaller diameters as described above (indicated as DeD respectively in the following text) which provide unique advantages in many applications. When used, for example, in conjunction with the material thicknesses described in the various embodiments. Below, flat tubes adapted for many different applications can be produced. Also, the production capacity of flat tubes having some of the larger and smaller dimensions D d described herein is facilitated by the use of the relatively thin wall material described above.

For example, in some embodiments of the present invention, the largest dimension D (i.e. the tuboplane width in the embodiments illustrated herein) is no less than about 10 mm (0.39370 in). Also, this larger dimension D is no larger than around 300 mm (3.93 70 in) in some embodiments. In other embodiments, the largest dimension D is no larger than about 200 mm (7.87402 in). As another example, in some embodiments of the present invention, the smaller dimension d (i.e. the tuboplane thickness in the embodiments illustrated here) is no smaller than about 0.7 mm (0.02756 in). Also, this smaller dimension d is no larger than about 10 mm (0.39370 in) in some embodiments. In other embodiments, the smallest dimension d is no larger than about 7 mm (0.2756 in).

In many embodiments, the larger and smaller dimensions D, d are dependent, at least in part, on flat tube applications. For example, in condenser applications, the largest diameter D of the flat tube is not less than about 10 mm (0.39370 in) in some embodiments. Also, a larger flat tube diameter D in some condenser applications is no larger than around 20 mm (0.78740 in). The smallest diameter d for some flat tube condenser applications is not less than about 1.0 mm (0.039370 in). Also, a smaller flat pipe diameter d in some condenser applications is no larger than around 2.0 mm (0.078740in). As another example, in radiator applications, the largest diameter D of the flat pipe is not smaller than around 10 mm (0.39370 in) in some embodiments. Also, a larger flat tube diameter D in some radiator applications is not larger than around 200 mm (7.8740 in). The smallest diameter d for some flat tube radiator applications is not smaller than around 0, 7 mm (0.027559in). Also, a smaller flat tube diameter d in some radiator applications is no larger than around 2.0mm (0.078740 in). As another example, in charge air cooler applications, the largest diameter D of the tuboplane is not smaller than around 0.78740 mm in some applications. Also, a larger tuboplane diameter D in some carganon air cooler applications is larger than around 160 mm (6.29921 in). The smallest diameter d for some flat tube charge cooler applications is not less than around 4.0 mm (0.155748 in). Also, a smaller tuboplane diameter d in some carbon dioxide air cooler applications is larger than around 10.0 mm (0.39370 in).

Still other flat tube applications according to any of the embodiments described herein include oil coolers. In oil cooler applications, the largest flat tube diameter D is not smaller than around 10 mm (0.49470 in) in some embodiments. Also, a larger flat tube diameter D in some oil cooler applications is not larger. than around 150 mm (5.90551 in). The smallest diameter for some flat tube oil cooler applications is no smaller than around 1.5 mm (0.05906 in). Also, a smaller flat pipe diameter d in some oil cooler applications is no larger than around 4.0 mm (0.15748 in). As yet another example, in some evaporator applications, the largest diameter D of the flat tube is not smaller than about 30 mm (1.1810 in) in some embodiments. Also, a larger tuboplane diameter D in some evaporator applications is no larger than around 75 mm (2.95276 in). The smallest diameter d for some flat tube evaporator applications is not less than about 1.0 mm (0.039370 in). Also, a smaller flat pipe diameter d in some evaporator applications is no larger than around 2.0 mm (0.078740in). It should be noted that other applications (e.g., gas coolers) of flat tubes described herein and / or illustrated here are possible, and fall within the spirit and scope of the present invention.

Many of the flat tube embodiments described above illustrated here are constructed of a metal that includes aluminum (eg aluminum or an aluminum alloy). However, various other types of metals may be used, while still providing resistance, transferability. heat and the desired fabricability characteristics for use in heat depleting devices. In some embodiments, the flat tube material is provided with a plating material coating. The coating of brazing material may have several different possible thicknesses, and in some embodiments is not less than about 10% of the thickness of the flat tube wall material for good performance results. Also, in some embodiments, the brazing material coating is not greater than about 30% of the thickness of the flat tube wall material. In other embodiments in which flat tubes are to be welded with weak weld, instead of brazing, the metal material of the flat tubes may be provided with a coating of weak weld material. Several different clamping operations (brazing, welding, weld welding, and the like) may be used for the construction of any of the various flat tube and heat exchanger assemblies described / or illustrated herein. However, portions of the following text refer only to brazing, although it should be understood that other types of clamping operations (including welding with weak soldering) are equally applicable in such embodiments.

Several of the aforementioned pipe features refer to the construction of pipe walls using relatively thin sheet material. In some embodiments, significant improvements in thin-walled flat tube performance are generated by providing one or both stable narrow sides with folds that are substantially perpendicular or substantially parallel to the broad sides of the flat tube. Such folds may be formed, for example, by winding or folding adjacent longitudinal edges of sheet metal on or together. In these embodiments of the present invention, in which one or both narrow sides of the tuboplane have folds that are substantially parallel to the broad sides of the flat tube, these folds may have the same or different lengths with respect to each other. As will be described in more detail below, the folds The narrow sides of a flat tube may be shaped to hook or interlock with each other - a feature which may be useful in the manufacture of the flat tube and / or heat exchanger employing the tube.

In many of the following embodiments, the tubes are arranged having bent narrow sides and also having other bends and / or deformations formed within the flat tubes. In a manufacturing process, the folds that form narrow sides may be produced subsequent to the manufacture of these other folds and / or deformations, although other manufacturing alternatives are possible. Also, it should be noted that the bends formed in the flat tube may be multiple bends and, in some embodiments, are arranged firmly against or abutted with each other.

A first embodiment of a flat tube 10 according to the present invention is illustrated in FIGS. 1 to 5. Tuboplane 10 is constructed of two portions of sheet material12, 14 shaped for the definition of internal flow channels 16. Each of the two portions 12, 14 may be formed from an endless strip of material or wound through of a manufacturing line having a material cutting device (e.g. laser, saw, waterjet, blade and the like) for producing two strips which are then joined together as described below. Alternatively, the two portions 12, 14 may be formed from two material endless strips or bobbins passed through a fabrication line. In any case, the manufacturing line may be equipped with roller assemblies (as illustrated by the example heading below) or other sheet forming elements for forming the strips, as will be described in more detail below. As used herein and in the appended claims, the term "endless" does not generally mean that the referred element or product has unlimited supply. Instead, the term "endless" only means that the element or product is received from a much larger supply of continuous material in some bulky upstream form, as in the supply of material rewinds.

Although the portions 12, 14 may have thicknesses falling off any of the bands described above, the portions 12,14 in the illustrated embodiment of FIGS. 1 to 5 have a wall thickness of about 0.10 mm (0.0039369 in) by way of example. In some embodiments, portions 12, 14 include a material formed of aluminum or an aluminum alloy.

However, other portion materials (described above) may be used instead in some embodiments. Either side of portions 12, 14 may be coated with a brazing coating such as a brazing coating layer that is about 10 to 30% of the thickness of the portion.

As shown in FIG. 2, the illustrated flat pipe 10 defines a small diameter d. Using the wall thicknesses described earlier, the inventors have found that a small diameter d of about 0.8 mm (0.031496 in) provides good performance results in many applications. Also, using the wall thicknesses described above, the inventors have found that a small diameter d not greater than about 2.0 mm (0.07 874 in) provides good performance results in many applications. However, in some embodiments, a small pipe diameter d of no more than about 1.5 mm (0.059055 in) is used. As shown in FIG. 1, the illustrated flat pipe 10 also defines a large diameter D. Using the wall thicknesses described above, the inventors have found that a large diameter D of at least about 40 mm (1.5748 in) provides good performance results in many applications. . Also, using the wall thicknesses described above, the inventors have found that a large diameter D no larger than around 45 mm (1.7717 in) provides good performance results in many applications. However, it is possible for the flat tube 10 to define a large diameter D and a small diameter d with other dimensions, including those described above with reference to all the flat tubes shown here, based at least in part on the fabrication processes used, the intended application of the tubes, and / or in the use of thicker or thinner wall materials. For this purpose, the particular width portions 12, 14 may be made available, and the manufacturing line installations may be adjusted to the desired diameters D and d.

Flat tube 10 in the illustrated embodiment of FIGS. 1 to 5 includes a narrow first side 18, a second narrow side 20, a broad first side 22, and a second sidewall 24. The first wide side 22 and the second wide side 24 correspond to portions 12 and 14 respectively. Referring in particular to FIG. 1, first wide side 22 and second wide side 24 define various bends 28. Folds 28 extend from first wide side 22 and second wide side 24 to define four flow channels 16. In other embodiments, the flat tube 10 may include more or less flow channels 16 defined between the folds 28. However, the folds 28 may run in an uninterrupted and continuous manner along the entire length of the flat tube 10 for isolation of adjacent flow channels 16. However, in other embodiments, the bends 28 may be interrupted or broken at one or more locations along their length to allow flow between flow channels 16. Regardless of whether the bends 28 are uninterrupted or interrupted, the bends 28 may stiffen the tube plane 10 against compression and may stiffen the flat tube 10 against expansion in those embodiments in which the distal ends of the folds 28 are affixed to a wide side 24 of the flat tube 10 (e.g., by brazing or otherwise suitable). The folds 28 may also serve a stiffening function to resist bending of the tubular 10.

Referring now to FIGS. 1 and 2, the first flange 22 and the second wide side 24 also define various projections 26. In other embodiments, neither side 22,24 has such projections 26. The projections illustrated are generally convex protrusions extending to the flow channels 16 of the tube. plan 10, and may have any desired occupied area, such as a round occupied area, a square, triangular, or other polygon occupied area, any elongated occupied area (e.g., long ribs running along any desired length of flow channels, running transversely). flow channels, and the like), irregular occupied areas, or occupied areas of any other shape (for example, serpentine, zigzag, boundary, and the like). When used, the projections 26 may function to induce or sustain turbulence in the flat tube 10, thereby increasing heat transfer at these locations. Also, as the folds 28 described above, the projections 26 may serve a function of increasing the stiffness of the wide sides 22, 24. The projections 26 may be located in any pattern or in a non-standard manner on the flat tube 10 and, in some embodiments, are located only in particular areas of the flow channels 16 to produce the desired flow and heat transfer effects.

FIG. 3 schematically illustrates a set of exemplary manufacturing steps that can be used for forming a flat tube 10, such as that illustrated in FIGS. 1, 2, 4 and 5. Starting with a first portion of material 12 defining a width W and a second portion of material 14 defining a smaller width w, a desired number of folds 28 is formed, and will aid in defining flow channels 16 The folds 28 in the illustrated embodiment are formed in both portions 12, 14. In other embodiments, the folds 28 are formed in only one portion 12, 14. Similarly, the projections 26 in the illustrated embodiment are formed in only one portion 12, 14. The folds 28 and projections 26 are located between the longitudinal edges of the material defining portions 12, 14 (e.g., the dometal sheet longitudinal edges defining portions 12, 14).

The width W of the first portion 12 and the width w of the second portion 14 in the embodiment illustrated in FIGS. 1 to 5 are reduced during the formation of folds 28 and projections 26. It is to be understood that other deformations may be included in the example manufacturing steps of FIG. 3 for generating other flat tube 10 features as desired. With continued reference to the manufacturing example of FIG. 3, an additional set of folds 30 is formed at each of the longitudinal edges of the portions 12, 14 subsequent to the formation of the necessary folds 28 and projections 26, thereby defining the right sides 18 and 20 of the flat tube 10. In other embodiments, one or more both additional sets of folds 30 may be produced before or at the same time as folds 28 and projections 26, although the process illustrated in FIG. It can provide significant manufacturing advantages based on the configuration and operation of the manufacturing line. As best illustrated in FIG. 4 and 5, the additional folds 30 of each portion 12, 14 fit together to define the first narrow side 18 and second narrow side 20 of the tube, respectively. Because of this engagement between the longitudinal edges of portions 12, 14 From the two-piece flat tube 10, the portions 12, 14 may be held together even before harnessing or other securing of the portions 12,14. More specifically, FIGs. 4 and 5 illustrate the folds 30 of one portion 14 defining a greater length of the folds 30 of the other portion 12. Thus, the folds 30 of one portion 12 may fold around the folds 14 of the other portion, as also shown in FIG. 2.

According to the illustrated embodiment of FIG. 1 to 5 shows, in some embodiments, one of portions 12 is long enough to wrap around and without receiving the longitudinal edge of the other portion 14 (for example, whereby the longitudinal edge of one portion 14 is nested on the folded longitudinal edge). from the other portion12). In other embodiments, one of the portions 12 instead is just long enough to overlap the longitudinal edges of the other portion 14. However, the modalities described above with respect to FIGs. 1 to 5 may provide significant advantages over flat tube assembly and fabrication 10, including retention of portions 12, 14 as described above, and a greater degree of narrow side strength and strength, based on increased material thickness on narrow sides 18 20. Illustrated mode of FIGs. 1 to 5, both right and right sides 18, 20 are provided with the same folded structure better shown in FIGs. 2 to 5. However, in other embodiments, only one of the two narrow sides 18, 20 the flat tube 10 has either of the folded structures described above. In such embodiments, the connection between the two portions 12, 14 on the other narrow side 20, 18 may be made in any other desired manner.

FIGs. 6 to 11 illustrate alternative constructions of flat tubes according to additional embodiments of the present invention. These embodiments employ much of the same structure and have much of the same properties as the flat tube modalities described above with respect to FIGS. 1 to 5. Accordingly, the following description focuses primarily on the structure and features that are different from the modalities described above in relation to FIGS. 1 to 5. Reference should be made to the above description with respect to FIGs. 1 to 5 for additional information regarding the structure and features and possible alternatives to the structure and features of the flat tubes illustrated in FIGs. 6 to 11 and described below. The structure and features of the embodiments shown in FIGS. 6 to 11 that correspond to the structure and resources of the FIGs modalities. 1 through 5 are designated from this point on respective series of hundreds of reference numbers (e.g., 112, 212, 312, and the like).

FIGs. 6 to 11 illustrate other constructions of a narrow side 118, 218, 318, 418, 518, 618 of each tube 110,210, 310, 410, 510, 610, with the other narrow side being understood to be 120, 220, 320, 420, 520, 620 may have the same or a different structure as desired. The right sides 118, 218, 318, 418, 518, 618 shown in FIGs. 6a-11 may be manufactured in steps similar to those described above with reference to FIG. 3. Further, each of the narrow sides 118, 218, 318, 418, 518, 618 shown in FIGs. 6 to 11 provides strength and / or stability for tube 110, 210, 310, 410, 510, 610 compared to conventional flat tube designs, taking into account the relatively small thickness of the material used to construct the pipe walls in some embodiments. : around 0.050 to 0.15 mm (0.0019685 to 0.0059055 in) in some embodiments, as described above, and around 0.030 to 0.15 mm (0.00118 to 0.0059055 in) in other embodiments, and other material thickness ranges described herein.

The narrow sides 118, 218, 418 of the flat tubes 110,210, 310 shown in FIGs. 6, 7 and 9 may be formed by folding or coiling together of adjacent longitudinal edges of the two tube portions 112, 212,412 and 114, 214, 414, thereby defining various bends130, 230, 330, 430, 530, 630. It should be noted. that the shapes are referred to herein and the appended claims as "folds", regardless of whether they were made by rolling or folding operations, and regardless of whether the resulting shapes are rotund (e.g. FIG. 6), stacked (e.g. FIG. 7 to 9) or angled (e.g., FIGS. 10 and 11). With reference to FIGs. 6, 7 and 9, each narrow side 118, 218,418 provides unique heat transfer characteristics, strength and stability, and can be formed using different techniques. At least a portion of the folded or curled longitudinal edges (and, in the case of the narrow sides 218, 418 shown in Figures 7 and 9, the largest part of the folded or curved longitudinal edges) is formed to be approximately perpendicular to the broad sides122, 222, 422 and 124. , 224, 424 of the flat tube 110, 210, 410.

Referring to the narrow sides 518,618 of the flat tubes 510,610 shown in FIGS. 10 and 11, the longitudinal edges of portions 512, 612 and 514, 614 may also be formed by folding or coiling together the adjacent longitudinal edges of the two tube portions 512, 612 and 514, 614. Again, each of the right sides 518, 618 The flat tubes 510, 610 provide unique characteristics of heat transfer, strength and stability, and can be formed using different techniques. In both cases, the longitudinal edges of portions 512, 612 and 514, 614 may be folded over themselves to define a serpentine edge of the flat tube 510, 610. Although the 530.630 folds of this serpentine edge may be bordered with each other. little or no space between adjacent folds 530, 630, in some embodiments (see FIGS. 10 and 11), there is a space between adjacent portions of each fold. Heat transfer, firmness, strength and / or size Flat tubes 510, 610 may be selected as desired based on the orientation of the bends 53 0.630 in such embodiments (e.g. substantially perpendicular to the wide sides 522, 622 and 524, 624, or at a angle significantly less than 90 degrees with respect to the wide sides 522 , 622 and 524, 624) and the space between adjacent portions of each fold 53 0, 63 0.

The embodiment illustrated in FIG. 8 provides an example of how at least a portion of the folds 330 (and in some cases most folds 330) of the narrow side 318 may be parallel or substantially parallel to the broad sides 332, 324 of the flat tube 310. Some or all of these folds 330 can stand against each other for improved heat transfer between them. In some embodiments, the bends 330 of the narrow side 318 may be substantially the same length L, as in cases where a particular flow channel shape is desired adjacent the narrow side 318 of the flat tube 310. However, in other embodiments (such as that Fig. 8), at least some of the narrow side folds 340 parallel to the wide sides 322, 324 are of a different length from the others. For example, differently sized folds may define a generally concave (FIG. 8) or convex side of an adjacent flow channel 316, such as defining a desired flow channel shape adjacent to the narrow side 318. Referring to the illustrated embodiment of FIG. . 8, the length L of each bend 330 decreases from the outside of the flat tube 310 toward the interior of the flat tube 310 (i.e., the first bend 330 against the wide side 322 has a length L greater than the subsequent bend 330 and the last one). fold 330 against the other wide side 3 24 has a length L greater than the previous fold 330). In such embodiments, such narrow side shapes 318 may help to avoid sudden temperature transitions across the flat tube 310, an issue that may otherwise contribute to a tube failure in many applications. As another example, differently sized folds may define a narrow side in shape. Wedge 318, which can provide a non-symmetric heat transfer bridge across the distance between the wide sides 322,324. Still other narrow side shapes 318 defined by the differently sized folds 303 parallel to the wide sides 322, 324 are possible, and fall within the spirit and scope of the present invention.

In those embodiments in which the bends 330 of the right side 318 are parallel or substantially parallel to the broad sides 322, 324 of the two-piece flat tube 310, the bends 330 formed of the first portion 312 may be snapped together or interlocked with the bends330 formed of the second portion 314. (see FIG. 8, for example). As a result, formed flat tube 310 may be held together prior to brazing or other clamping operations on portions 312, 314, which may facilitate mounting of flat tubes 310 on banks and / or heat detectors having such flat tubes 310, as further explained below. It will be appreciated that similar advantages exist in the other narrow side embodiments described above with reference to FIGs. 6, 7 and 9 a11. In those embodiments of the present invention wherein one or both of the narrow sides 18, 118, 218, 318, 418, 518, 618,20, 120, 220, 320, 420, 520, 620 have folds 30, 130, 230,330, 430, 530, 630 as described above, such folds 30,130, 230, 330, 430, 530, 630 may generally provide increased stability for narrow sides 18, 118,218, 318, 418, 518, 618, 20, 120 220, 320, 420, 520, 620 despite the relatively small wall thickness of tuboplane 10, 110, 210, 310, 410, 510, 610 mentioned above. More folds 30, 130, 230, 330,430, 530, 630 on narrow sides 18, 118, 218, 318, 418,518, 618, 20, 120, 220, 320, 420, 520, 620 can also provide better protection for the flat tube 10, 110, 210,310, 410, 510, 610 against damage due to high internal pressures, impact of objects and corrosion, for example. This may be of great importance when using such pipes 10, 110, 210, 310, 410, 510, 610 in motor vehicle heat exchangers.

Although not required in the embodiments described above, the first and / or second portions 12, 112, 212, 312, 412,512, 612 and 14, 114, 214, 314, 414, 514, 614 may have one or more folds 28 located between the sides. 18,118, 218, 318, 418, 518, 618 and 20, 120, 220, 320, 420, 520,620 of the flat tube 10, 110, 210, 310, 410, 510, 610. Accordingly, the description of these folds 28 in illustrated embodiment of FIGs. 1 to 5 shall apply equally to the other modalities described above. For ease of description, additional information regarding these folds 28 will now be made with reference to the illustrated embodiment of FIGS. 12 and 13, using the reference numerals of FIG. 1 to 5.

In some embodiments, the inventors have discovered internal fold chelocations 28 may be selected for the definition of variable size flow channels 16 to allow different fluid and / or flow characteristics (e.g., flow and / or directions, pressures, multiple fluid types and the like) at different locations of the same flat tube 10, and to allow for different ways of heat transfer at different locations. With reference to the illustrated embodiment of FIG. 12, the width or distance "a" between the inner folds 28 is defined substantially parallel to the first and second broad sides 22, 24 of the flat tube 10, and would vary based on the desired degree of resistance to a temperature change along the width of the tube. plan 10.

In some embodiments, such as that shown in FIG. 12, the distance "a" between the inner folds 28 may be increased starting from one or both of the narrow sides 18 and 20 of the flat tube 10 toward the center of the flat tube 10. Thus, in some embodiments, the distance "a" "increases from inner bend 28 to inner bend 28, starting from a narrow bend 18, 20 towards the middle of the flat tube 10, and subsequently decreases again toward the other right side 20, 18. In these embodiments, the cross-sectional area of the individual flow channels 16 formed by the inner folds 28 increases and decreases respectively. In some embodiments, the distance "a" begins at one or both narrow sides 18, 20 at a magnitude of about 0.5 mm (0.019685 in) and increases to a few millimeters.

For example, in such cases, a flat tube 10 with a width of approximately 42 mm (approximately 1.6634in) may include a large number of internal bends 28 and 16 flow channels. It is conceivable that a flat tube 10 may include relatively small flow channels 16. broadly substantially adjacent to one or both sides narrow 18, 20, with the narrowest flow channels 16 near the center of the flat tube 10. Also, although the flow channels 16 in many embodiments have widths "a" of the sizes described above, these widths may be significantly larger in other modalities, including ranges of at least 1 cm (0.3937 in).

In some embodiments, the flat tube 10 may include inner folds 28 immediately adjacent to each other, where these inner folds are in confinement or intimate contact with each other immediately following the formation of the inner folds 28 or after brazing or other portion securing operations 12 For example, multiple internal folds 28 may be arranged firmly against each other. In either of these steps, two or more inner bends 28 may define an inner bend assembly 32. Flat tube 10 may have any number of such inner bend assemblies 28, such as those shown in FIG. 13, alone or in conjunction with any number of single folds 28. Inner fold set 32 shown in FIG. 13 includes three individual inner folds 28. However, in other embodiments, two inner folds 28 may be sufficient to form a set 32, and / or four or more inner folds 28 may form a set 32. Thus, the number of inner folds 28 which form 32 is freely selectable, based on the intended application of the flat tube 10 and other factors. In this sense, one or both portions 12, 14 of the flat tube may have bend assemblies 2 having any number of internal bends 28 and any combination of sets 32with different numbers of inner folds 28.

The single inner folds 28 and / or the inner fold assemblies 32 may all be located in the same portion 12 or 14, or both portions 12, 14 of tuboplane 10 in any desired arrangement. For example, multiple inner bend assemblies 32 may be symmetrically arranged around a central location of the flat tube 10 (such as the inner bend assembly 32 shown in FIG. 13), where corresponding assemblies 32 on opposite sides of the central location extend. from the same portion 12, 14 or from a different portion 12, 14 (e.g. FIG. 13).

Also, in some embodiments, one or more single inner folds 28 and / or one or more inner fold assemblies 32 in one portion 12, 14 of the flat tube 10 may be aligned in the inner folds 28 of an opposing nipple assembly 14, 12 of the flat tube 10.

Inner bend assemblies 32 as described above may be used to provide flat tubes 10 with higher pressure resistance and higher load carrying capacity, and may also be used for varying cross-sectional shape of flow channels 16. It should be noted whereas the features described above with reference to variable 10 flat tubes with variable flow channel widths also apply to the modalities in which the internal bend assemblies 28 are used. Also, in those embodiments where tuboplane 10 is formed with a brazing process, the internal folds 28 on a wide side 22, 24 (in a single form or in assemblies 32) may form brazed joints with the wide outsole 24, 22, thereby. improving the connection between the flat tube 10.

FIGs. 14 and 15 illustrate two additional flat tube constructions according to additional embodiments of the present invention. These embodiments employ much of the same structure and have much of the same properties as the flat tube modalities described above with respect to FIGS. 1 to 13. Therefore, the following description focuses primarily on the structure and features that are different from the modalities described above in relation to FIGS. 1 to 13. Reference should be made to the above description with respect to FIGs. 1 to 13 for additional structure and feature information, and possible alternatives to the structure and features of the flat tubes illustrated in FIGs. 14 and 15 are described below. The structure and features of the embodiments shown in FIG. 14 and 15 corresponding to the structure and features of the embodiments of FIG. 1 to 13 are designated from this point in the 700 and 800 series of reference numbers, respectively.

The flat tubes 10, 110, 210, 310, 410, 510, 610 illustrated in FIGs. 1 to 13 above each have internal walls defined by the inner folds 28 of the first and / or second portions 12, 112, 212, 312, 412, 512, 612, 14,114, 214, 314, 414, 514, 614. In either of these embodiments, however, these walls at least partially defining flow channels 16, 116, 216, 316, 416, 516, 616 may be defined by a separate portion of material which is connected to one or both of the first and second portions 12, 112, 212, 312, 412, 512, 612, 14, 114, 214,314, 414, 514, 614 in the manufacture of flat tubes 10, 110,210, 310, 410, 510, 610. Although different from flat tubes 10, 110, 210, 310, 410, 510,610 described above with respect to FIG. 1 to 13 (e.g., ematerial outer wall thicknesses, pipe diameters, inner wall shapes, locations, spacings and assemblies, and narrow delta constructions).

For example, flat tubes 710, 810 shown in FIGS. 14 and 15 are each constructed using two portions 712, 714 and 812, 814 respectively between which an insert 734, 834 defined by another portion of material is located. In either case, insert 734, 834 has a corrugated shape, whereby insert ridges 734, 834 can form flow channels 716, 816 of flat tube 710, 810. One or both sides 718, 720, and 818, 820 710, 810 (only one of which being shown in each of FIGS. 14 and 15) may incorporate a portion of the insert 734, 834 by commonly folding the edges of the first and second portions 712, 714, and 812, 814 with the edges of the insert. insert 734,834. For example, in some embodiments, flat tube 710 has narrow serpentine sides 718, 720, as shown in FIG. 14, where the edges of the insert 734 are folded with and on the longitudinal sides of the first second portions 712, 714. In other embodiments, the narrow sides 818, 820 of the flat tube 810 are folded firmly together as shown in FIG. 15, where the edges of the insert 834 are again folded with longitudinal sides of the first and second portions 812, 814. In still other embodiments, the longitudinal edges of an insert may be wound on those of the first and second portions on any of the narrow side structures shown. in FIGS. 6 to 10.

The embodiments of the present invention described above each use two separate pieces of material for defining the first and second portions 12, 112, 212,312, 412, 512, 612, 712, 812, and 14, 114, 214, 314, 414,514, 614, 714, 814 of flat tubes 10, 110, 210, 310, 410,510, 610, 710, 810. While these tube constructions have unique advantages, including some portion-to-portion interlocking features and manufacturing advantages, flat-tubes according to The present invention may also be formed as a part, such as by a single or undivided endless sheet metal strip. By deformation of the single part, free longitudinal edges of the single part can be put together and joined by brazing, welding, or other fastening operations. In other words, some embodiments of the flat tubes according to the present invention may be formed from one part (e.g., a sheet metal strip) while still defining two stable narrow sides. Various modalities of these flat tubes in one part are described in detail below. Except for those one-piece flat tube features described below that are inconsistent or incompatible with the above described tube features with reference to the two-piece embodiments of FIG. 1 to 15, the tubes in one part described below may have any of the construction features described above in relation to FIGs. 1 to 15 (e.g., outer wall thicknesses and materials, pipe diameters, inner wall shapes, locations, spacings and assemblies, and narrow side constructions).

The one-piece tubes described below may have improved thermal properties over conventional flat tubes, based at least in part on the use of the relatively thin tube wall material (described above) that may be employed. Additionally, mounting the flat tubes on a heat exchanger can also be simplified.

Like the two-piece flat tubes described above, the bends formed on the narrow sides of the one-piece flat tubes described below may be substantially perpendicular or substantially parallel to the broad sides. For example, a first narrow side of the tuboplane may be formed from a continuous portion of a single sheet metal and may include a multiple fold assembly. In some embodiments, these folds may define multiple lengths (e.g., similar to those described above with respect to FIG. 8), which may help to prevent cracking due to thermal fatigue. A second narrow side of the flat tube may be formed by the free longitudinal edges of the single sheet metal and may also have multiple bends. Despite the sheet metal thickness of 0.05 to 0.15 mm (0.0019685 to 0.00591 in) in some embodiments, and 0.03 to 0.15 mm (0.00118 to 0.00591in) in other embodiments , the longitudinal edges of the single piece of material forming the second narrow side may be coupled by brazing, welding or other fastening operations. Also like the two-piece flat tubes described above, one or both of the wide sides of the flat tubes in one piece may include internal bends and other deformations (for example, inwardly directed beads, ribs, or other projections that do not need to reach inside the flat tubes). The inner bends may form flow channels within the flat tube, and may be arranged in any of the ways described above with reference to the two-piece flat tubes. By way of example only, the inner folds may be in sets, may be particular spaces which may or may not vary across the width of the flat tube, and may increase in direction from one or both narrow sides towards the half of the flat tube. As a result of these internal bends and internal bend arrangements, the ability of the flat tube in a part to withstand temperature change loads can be significantly improved.

Examples of one-piece flat tubes having some of these features are illustrated in FIG. 16 to 24, each having first and second portions 912, 914,1012, 1014, 1112, 1114, 1212, 1214, 1312, 1314, 1412, 1414,1512, 1514, 1612, 1614, 1712, 1714 formed of a piece of common material folded in the illustrated shapes. Although other materials and material thicknesses may be nailed as described in greater detail above with respect to two-piece flat tubes, the first second illustrated portions 912, 914, 1012, 1014, 1112,1114, 1212, 1214, 1312, 1314, 1412, 1414, 1512, 1514, 1612,1614, 1712, 1714 are formed of an aluminum foil or aluminum alloy metal strip having a material thickness of about 0.10 mm (0.003937 in). Any of the flat tubes 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 may have a brazing coating on one or both sides, where each brazed coating layer may have a thickness around it. 10 to 20% of the thickness of the sheet metal strip.

Using the wall thicknesses described above, the inventors have found that a small diameter d of at least 0.8 mm (0.0314 96 in) for the illustrated flat tubes 910, 1010, 1110, 1210, 1310, 1410, 1510,1610, 1710 provides good performance results in many applications. Also, using the wall thicknesses described above, the inventors have found that a small diameter d of no more than about 2.0 mm (0.07874 in) for the illustrated flat tubes 910, 1010,1110, 1210, 1310, 1410 , 1510, 1610, 1710 provide good performance results in many applications. However, in some embodiments, a small diameter d maximum of no more than about 1.5 mm (0.059055 in) for the illustrated flat tubes 910, 1010, 1110, 1210, 1310, 1410, 1510,1610, 1710 is used. . Further, a large diameter D for any of the illustrated flat tubes 910, 1010, 1110,1210, 1310, 1410, 1510, 1610, 1710 is usually freely selectable within certain manufacturing ranges. In some embodiments, for example, the large diameter D is approximately 50 mm (1.999 in). However, one-piece flat tubes 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610,1710 having larger or smaller diameters D, d (including those described with respect to all flat tube embodiments shown herein) and the thicknesses of The foregoing descriptions may also be fabricated, in which case the original width W of the material (see FIG.16, for example) used for forming the flat tubes910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 is available. on the manufacturing line.

As mentioned above, the various types of narrow side folds and inner folds described with respect to the embodiments of FIG. 1 to 15 may be employed in the one-piece planes described herein. In some one-piece tube embodiments, such as those shown in FIGS. 19 to 24, one or both narrow sides 1218, 1220, 1318,1320, 1418, 1420, 1518, 1520, 1618, 1620, 1718, 1720 flat tube 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610,1710 may include multiple folds 1230, 1330, 1430, 1530,1630, 1730 which may provide relatively more stable and stronger narrow sides 1218, 1220, 1318,1320 , 1418, 1420, 1518, 1520, 1618, 1620, 1718, 1720. As a result, the relatively more stable narrow sides1218, 1220, 1318, 1320, 1418, 1420, 1518, 1520, 1618, 1620,1718, 1720 can provide a Sufficient protection of the pipes flat 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 against damage due to temperature and / or pressure fatigue, impact of objects and corrosion, thereby providing better performance when used in a heat exchanger. motor vehicles (for example).

Referring now to FIG. 16, an example of the manner in which a one-piece pipe 910 can be manufactured is shown. In particular, FIG. 16 illustrates at least part of a manufacturing process for forming a flat tube in one piece 910. Single and / or multiple folds are made on a sheet of starting material, and will define at least partially the inner folds 928 of tuboplane 910 and flow channels. 916 in the flat tube 910. In some embodiments, the starting material sheet is an endless sheet that is fed from a material coil downstream of the manufacturing elements used for the production of the folds. At the same time or at a different time, additional bends are created that will at least partially define bends on a narrow side 900 of the flat tube910. For example, a multi-ply assembly 932 930 is produced at or near the center of the metal strip in a part illustrated in FIG. 16, for defining a narrow side 920 by folding the strip in the direction shown by the arrow substantially adjacent to the multi-fold assembly 932 93. As a result of this arrow-indicated fold, the first and second narrow sides 912, 914 of the flat tube 910 are defined. The other narrow side 918 and the folds 930 on the other narrow side 918 may take any of the shapes shown in FIGs. 19 to 23 or those described and / or illustrated above with respect to the narrow sides of the two-piece flat tubes 10, 110,210, 310, 410, 510, 610, 710, 810. FIGs. 17 and 18 illustrate features of alternative one-piece flat tube constructions (narrow sides not shown) which can be nailed. More specifically, FIG. 17 provides an example of how single inner folds 1028 and multiple inner fold assemblies 1032 on one or both wide sides 1022, 1024 can be used on the same tubular in one piece 1010 for defining flow channels 1016 of the same size or a different one. FIG. 18 provides an example of how various single inner folds 1128 may be made at particular locations on one or both wide sides 1122, 1124 for defining flow channels 1116 of varying cross-sectional size, such as cross-sectional sizes that gradually increase in a direction toward the other. the width of the flat tube in one piece1110.

FIGs. 19 to 24 show still other examples of one-piece flat tubes 1210, 1310, 1410, 1510, 1610 according to other embodiments of the present invention. As one-piece tube modalities illustrated in FIGs. 16 to 18, each of the one-piece flat tubes 1210, 1310, 1410, 1510, 1610 illustrated in FIGs. 19 to 24 have internal folds 1228, 1328, 1428, 1528, 1628, 1728 arranged individually and / or in sets for defining flow channels 1216, 1316, 1416, 1516, 1616, 1716. In some cases, the arrangement of individual internal folds1228, 1328, 1428, 1528, 1628, 1728 and / or assemblies 1232,1332, 1532 of these folds 1228, 1328, 1528 are determined to be based on one or more factors (for example single or multiple fluids through tubes 1210, 1310, 1410, 1510 , 1610.1710, predicted temperatures, thermal and cyclothermal stresses to which different portions of pipe width and / or length will be exposed, internal pressures, and the like).

With particular reference, first, to FIG. 19, multiple inner folds 1228 near the center of the flat tube 1210 define a four-fold material thickness that of the unfolded tube material (i.e. two single folds 1228 firmly or immediately disposed adjacent each other). , such as in a non-conforming way). The one-piece flat tube 1210 illustrated in FIG. 19 has two such sets 1232 of inner bends1228, each of which is formed on a wide-different side 1222, 1224 of flat tube 1210. In the embodiment of FIG. 20, four multi-ply sets 1332 each 1328 each define a material thickness of six times that of the unfolded tube material (i.e., three single folds 1328 arranged firmly or immediately adjacent each other, such as in a con fi ned manner). The inner folds 1328 in daFIG mode. 20 are positioned for the definition of flow channels 1316 of varying size, unlike those of FIG. 19, which are substantially the same size. It will be appreciated that any other number of inner bending assemblies 1232, 1332 may be provided on one or both broad sides 1222, 1224, 1322,1324 of flat tubes in one piece 1210, 1310 illustrated in FIG. 19 and 20, with or without additional individual inner folds 1228, 1328 (i.e. inner folds 1228, 1328 not in assemblies 1232, 1332 as also shown in FIGS. 19 and 20).

The embodiments of FIG. 21, 22 and 23 provide examples of one-piece flat tubes 1410, 1510, 1610 in which only single bends 1428, 1528, 1628 are used for forming flow channels 1416, 1516, 1616. By way of example, the internal bends 1428, 1528 of the one-piece flat tubes 1410, 1510 illustrated in FIGS. 21 and 22 are positioned for the definition of variable size flow channels 1416, 1516 (increasing towards the center of each flat tube 1410, 1510, 1610), unlike those of FIG. 23, which are substantially the same size except for a slightly larger flow channel 1616 immediately adjacent to one or both narrow sides 1618, 1620. It should be noted that the internal folds 1228,1328, 1428, 1528, 1628, 1728 of any of the one-piece flat tubes 1210, 1310, 1410, 1510, 1610, 1710 illustrated in FIGs. 19 to 24 may be positioned to define flow channels 1216, 1316, 1416, 1516, 1616,1716 of the same or different size, and that the widths of flow channels 1216, 1316, 1416, 1516, 1616, 1716 may increase. or decreasing toward the center of the pipe planes 1210, 1310, 1410, 1510, 1610, 1710 gradually names the same direction through most or all of the pipe width, or in any other desired manner. Also, other flat tube constructions 1210, 1310, 1410, 1510,1610, 1710 may include different numbers of single bends 1228, 1328, 1428, 1528, 1628, 1728 and multiple inner bend assemblies 1228, 1328, 1428, 1528, 1628, 1728 as desired.

With continued reference to the one-piece flat tube embodiments illustrated in FIGs. 19 to 24, each flat tube1210, 1310, 1410, 1510, 1610, 1710 has a narrow side1220, 1320, 1420, 1520, 1620, 1720 defined by a folded portion of sheet material used for the construction of flat tube 1210, 1310, 1410 , 1510, 1610, 1710, and an opposite right-hand side 1218, 1318, 1418, 1518, 1618, 1718 on which two free longitudinal edges of the sheet of material are placed together and folded to close the tubular plane 1210, 1310, 1410, 1510, 1610, 1710. This opposite right-hand side 1218, 1318, 1418, 1518, 1618, 1718 and the narrow side 1230, 1330, 1430, 1530, 1630, 1730 opposite 1218, 1318, 1418, 1518, 1618, 1718 can take any of the shapes shown in FIG. 19 to 24 or those described and / or illustrated above with respect to the narrow sides of the two-piece flat tubes 10, 110,210, 310, 410, 510, 610, 710, 810.

With respect to the narrow side 1220, 1320, 1420, 1520,1620, 1720 formed by the continuous folded portion, as described above, this narrow side may take any of the shapes shown in FIG. 19 to 24. However, this narrow side 1220, 1320, 1420, 1520, 1620, 1720 can also take any of the shapes described and / or illustrated above with respect to the narrow sides of the two-piece flat tubes 10, 110, 210, 310, 410 , 510, 610, 710,810, in which case the terminal ends of the first and second portions 12, 14, 112, 114, 212, 214, 312, 314,412, 414, 512, 514, 612, 614, 712, 714, 812, 814 on the right sides 18, 118, 218, 318, 418, 518, 618, 718 of the flat tubes 10, 110, 210, 310, 410, 510, 610, 710, 810 would be immunized as part of the same continuous piece of sheet material. Accordingly, the unique benefits of each narrow thin shape described above relative to FIGs. 1 to 11, 14, and 15 may exist for one or both narrow sides1218, 1220, 1318, 1320, 1418, 1420, 1518, 1520, 1618, 1620.1720 of the embodiments illustrated in FIG. 19 to 24.

With particular reference to the embodiment illustrated in FIG. 19, the one-piece flat tube 1210 illustrated therein with narrow bends 1218, 1220 formed with bends 1230 which are arranged substantially perpendicular to the broad sides 1222, 1224 of flat tube 1210. The multiple bends1230 forming the narrow sides 1218, 1220 are differentiated from each other. others by the fact that the bends forming the second narrow side 1220 are formed from a continuous portion of the strip into one. material piece used to create the flat tube 1210, while the bends 1230 forming the first narrow side 1218 are formed from two longitudinal edges of the material strip in one piece. In other embodiments, however, the flat tube 1210 may instead have first and second narrow seconds 1218, 1220 with folds 1230 that are substantially parallel to the broad sides 1222, 1224 the flat tube 1210.

The one piece flat tube 1310 illustrated in FIG. 20 also has a second narrow side 1320 with multiple bends 1330 substantially perpendicular to the broad sides 1322, 1324 of flat tube 1310, while first narrow side 1318 has multiple bends 1330 disposed substantially parallel to the wide sides 1322,1324 of flat tube 1310. In other embodiments, however, the flat tube 1310 may instead have a narrow side 1318 with folds 1330 that are substantially perpendicular to the broad sides 1322, 1324 and a narrow second half 1320 with folds 1330 that are substantially parallel to the broad sides 1322, 1324.

The one piece flat tube 1410 illustrated in FIG. 21 have first and second narrow sides 1418, 1420 with multiple folds 1430 which are substantially parallel to the broad sides 1422, 1424 of flat tube 1410. In other embodiments, the multiple folds 143 0 of one or both narrow sides 1418, 1420 are instead substantially perpendicular. to the wide sides 1422,1424 of the flat tube 1410. While each of the multiple bends 1430 on both narrow sides 1418, 1420 illustrated in FIG. 21 being substantially the same length, those on one or both narrow sides 1418, 1420 may instead be of different lengths (for example, see Figures 22 and 23). In such embodiments, the variable lengths of 1518, 1520, 1618 may take any of the forms described above in relation to the embodiment of FIG. 8, and therefore may produce any of the benefits also described herein. Referring to the embodiments of FIG. 22 and 23, the illustrated arrangement of folds of variable length 1530, 1630 of narrow sides 1518, 1520, 1630 (i.e. shorter folds 1530, 1630 flanked by longer edges 1530,1630) may generally be effective in supporting load shifting loads. temperature. Also, sudden transitions in pressure from narrow sides 1518, 1520, 1618 to wide sides 1522, 1524, 1622, 1624 can be avoided with this arrangement. Additionally, as with the other one-piece flat tube embodiments described herein, one or more internal multi-fold assemblies 152 8 (such as the single assembly shown in FIG. 22) and / or a relatively high number of flow channels 1616 (such as those shown Figure 23) can be used to assist in supporting temperature change loads and to help withstand sudden pressure transitions.

Yet another measure aimed at improving the resistance to the temperature change load is to vary the "a" distance between bends for the definition of increasingly wider flow channels 1516 toward the flat tube centering 1510.

FIG. 24 shows an example of the manner in which any of the narrow side constructions shown in the two-piece flat tube embodiments of FIGs. 6 to 11, 14 and 15 may be employed on the narrow side of a one piece flat tube having a sheet of continuous material as

mentioned above. Narrow side 1718 shown in FIG. 24 is similar in many respects to that of FIG. 11 above, except for the adjacent confinement folds 1730 and a single continuous sheet of material (or two overlapping portions of the same sheet of material). In this

In particular example, the distances "a" between the folds 1730 and the first inner fold 1728 and between the other inner folds 172 8 are relatively small, and may vary in some embodiments from 0.5 mm (0.019685 in) to 2 mm (0, 07874 in) or more - even as large as 1 cm

2.54 in). Further, in some embodiments, this 1610 tuboplane has a width of about 42 mm (0.16535 in) allowing for multiple folds 1728 and flow channels 1716.

Flat tubes according to some embodiments of the present invention may include an internal insertion that forces at least one of the narrow sides of the flat tube, while potentially also performing one or more other functions (e.g., reinforcing the broad sides of the tube, defining multiple channels of flow in fluid communication or not in fluid communication with each other, definition of flow turbulators, and the like). Insertion may be defined by a separate portion of material which is attached to the sheet or sheets of material defining the outer tube walls in the manufacture of flat tubes, and may be used as a complement to or through the inner folds, as described in several of the above embodiments. . Insert examples have already been provided with respect to the illustrated embodiments of FIG. 14 e15.

Although inserts may be employed with single piece flat tubes according to some embodiments of the present invention (described in more detail below), several of the unique advantages are obtained by the use of two piece flat tube inserts. In some embodiments, such advantages are obtained by using two-piece flat tube inserts constructed of sheet material having a relatively small thickness. In some embodiments, the wall material of flat tubes has a thickness no greater than about 0.20 mm (0.007874in). However, in other embodiments, the inventors have found that a pipe wall material having a thickness no greater than about 0.15 mm (0.0059055 in) provides significant performance results relative to overall heat exchanger performance, fabricability and to possible wall constructions (as shown here) that are not possible by using thicker wall materials. The relatively small wall material thickness can result in good thermal properties of the flat tubes in two pieces with inserts. In some embodiments, a wall material thickness of such flat tubes of not less than about 0.050 mm (i.e. not less than about 0.0019685 in) provides good resistance and corrosion resistance performance, while in others In the embodiments a wall material thickness of such flat tubes not less than about 0.030 mm (i.e. no less than about 0.00118 in) can be used. Also, two-piece flat tubes having inserts described below may have similar dimensions to the two-piece flat tubes described above with respect to FIGs. 1 to 15.

As explained in more detail below, the heat exchange tubes and other portions of heat exchangers described herein may be manufactured using various techniques and manufacturing processes, and may include corrosion protection features, such as those techniques and processes described. below illustrated in FIGs. 92 to 95. Various manufacturing processes and techniques and the corrosion protection features referred to hereinafter are particularly advantageous when applied to heat exchange tubes and heat-treating portions having significantly reduced material thickness. In addition, such corrosion protection techniques, processes and features provide significant advantages over the overall performance of flat tubes and heat exchangers made of this material.

FIGs. 25 to 34 illustrate several flat tubes in two parts 1810, 1810A, 1910, 2010, 2110, 2210, 2310, 2410,2510, 2610, 2710, 2810, 2910, 3010, 3110, 3210 each including a first portion 1812, 1812A, 1912 2012,2112, 2212, 2312, 2412, 2512, 2612, 2712, 2812, 2912, 3012,3112, 3212, a second portion 1814, 1814A, 1914, 2014,2114, 2214, 2314, 2414, 2514, 2614, 2714, 2814, 2914, 3014,3114, 3214, and an insert 1834, 1834A, 1934, 2034, 2134,2234, 2334, 2434, 2534, 2634, 2734, 2834, 2934, 3034, 3134,3234, all of which may be constructed of sheets of material, such as strips of metal or other material. For ease of description, the following description refers only to the illustrated embodiment of FIGS. 25 and 26, it being understood that the following description applies equally to all embodiments illustrated in FIGs. 25 a34 (unless an inconsistent or incompatible description).

In some embodiments of the two-piece flat tube 1810 shown in FIGS. 25 and 26, first and second portions 1812, 1814 and insert 1834 may be constructed of a material (e.g. aluminum, aluminum alloy, or other material described herein) having relatively low leaf thicknesses. For example, the inventors have found that a material thickness for these elements of no more than about 0.15 mm (0.0098425in) provides good performance results in many applications. In some embodiments, the material for these elements also has a thickness of no less than about 0.03 mm (0.0011811 in). In many embodiments, it is preferred that a relatively smaller sheet thickness be used for the insert 1834 than for the first second portion 1812, 1814 of the two-piece flat tube 1810. Despite the relatively small sheet thicknesses, the narrow sides 1818, 1820 of the two-piece flat tube 1810 may have relatively improved stability, particularly when used in conjunction with the two-piece flat tube features 1710 described below.

In the illustrated embodiment of FIGs. 25 and 26, each side 1822, 1824 of flat tube 1810 is formed of a separate portion of material (such as a separate strip). Material portions overlap in two locations for defining two longitudinal seams 1844, 1846. These longitudinal tube seams 1844, 1846 and two pieces 1810 extend from respective narrow sides 1818, 1820 of flat tube 1810 to wide opposite sides 1822, 1824 , in contrast to other illustrated embodiments (for example, see FIG. 27 described in greater detail below), where the longitudinal seams extend from respective narrow sides of the tuboplane to the same wide side of the flat tube. In the illustrated embodiment of FIGs. 25 and 26, the longitudinal seams 1844,1846 are both located and extend from a respective narrow side 1818, 1820 of the flat tube 1810 to the broad sides 1822, 1824 of the flat tube 1810. More specifically, the longitudinal seams 1844, 1846, specifically those portions of the flat tube 1810 in which the sheet material of the flat tube 1810 is superimposed, extend around at least part of (and in some embodiments, most or all) narrow lines 1818, 1820, and are partially on a corresponding wide side 1822, 1824 of the flat tube 1810. The width of the stitching 1844, 1846 may be determined according to desirable manufacturing purposes.

In some embodiments, the longitudinal seams 1844, 1846 of the flat tube 1810 have an aligned or substantially aligned outer surface of the flat tube 1810 (e.g., they provide a substantially flat wide side 1822, 1824 of the flat tube 1810). For this purpose, the longitudinal edge of each longitudinal seam 1844,184 6 which is overlapped by the other longitudinal edge may be recessed by the formation of the longitudinal edge superimposed with an indentation 1848, 1850. Thus, the longitudinal edge of a tube portion 1812, 1814. it can be wrapped by and receiving the corresponding longitudinal edge of another tube portion 1814, 1812 in a recess 1848, 1850 for defining longitudinal seam 1844, 1846. Thus, for tabs the seams 1844, 1846, the underlying longitudinal edge of the two overlapping tube portions 1812, 1814 may terminate within the flat tube 1810, and may be free prior to brazing, welding or other fastening techniques. As a result of this construction, the 1810 flat tubes can be produced to precise desired widths (albeit blunt or other machining operations, in some embodiments), despite the fact that the looser tolerances are maintained for the material widths split for the individual tube portions. 1812, 1814, since the overlapping longitudinal seams 1844, 1846 allow a relative lateral positioning of the first second pipe portions 1812, 1814 in an assembled state. In particular, in some embodiments, a longitudinal end edge 1854, 1856 of each tube portion 1812, 1814 does not abut the other tube portion 1812, 1814, thus allowing such adjustment.

The use of overlapping longitudinal seams such as those illustrated in the embodiment of FIG. 25 and 26 provide significant reinforcement of the 1810 flat first-side narrow tube 1818, 1820 - a feature that can be highly important in many applications for thermal stresses, temperature change loads and failures due to common pressure loading and waste impact that are common in pipes. plans. In some embodiments, additional reinforcement of the first and / or second narrow sides 1818, 1820 is provided by one or more folds of the first and / or second tube portions 1812, 1814 on the narrow sides 1818, 1820 (i.e., the longitudinal edges of those portions 1812, 1814. ). Generally, bending the longitudinal edges of the first and / or second tube portions1812, 1814 may increase the resistance of flat tube 1810 and the resistance of flat tube 1810 to damage. In those modalities in which a narrow side 1818, 1820 is defined at least in part by the overlapping longitudinal edges of the first and second tube portions 1812,1814 (one extending around, receiving or surrounding the other), one or both overlapping longitudinal edges (e.g. for example, the wrapped and developing edges) can be folded back to increase the thickness of that longitudinal edge on the narrow side 1818,1820.

For example, it is envisioned that one or both of the overlapping longitudinal edges of tube portions 1812, 1814 on one or both narrow sides 1818, 1820 may include adjacent to the corresponding gradation 1858, 1860 (described in more detail below). For example, in some embodiments, the combined thickness of the first and second pipe portions 1812, 1814 may be about 0.25 mm (0.0098425 in) or less in some embodiments, with one or both overlapping longitudinal edges having at least one bend. for increasing the narrow side thickness 1818, 1820, and with an insert material thickness 1834 being about 0.10 mm (0.003937 in) or less. In such embodiments, the thickness of the first and second tube sections 1818, 1820 may each be in the range 0.05 to 0.15 mm (0.0019685 to 0.0059055 in), and may be in the range 0.03 to 0.15 mm (0.0019685 to 0.0059055 in) in other modalities.

It should be noted that the overlapping longitudinal longitudinal construction of the two-piece flat tube illustrated in FIGs. 25 and 26 may be employed in flat tube embodiments not having an internal insert. For example, such a longitudinal seam construction may be employed in two-piece flat inner tube tendons such as those described above with respect to the embodiments of FIG. 1 to 13 and 16 to 24 or other flat tubes in two pieces.

Although not required, in many embodiments the pipe portions (e.g., the pipe portions 1812, 1814 in FIGS. 25 and 26) have substantially the same shape and may even be identical. When assembled as described, the tube portions 1812, 1814 are arranged with their longitudinal edges reversed with respect to each other. For example, a longitudinal edge of one of the two tube portions 1812, 1814 includes a gradation 1856, 1860 defining a recess 48, 50 as described above, followed by a portion defining an arc 1862, 1864, while a longitudinal overlapping edge corresponding to the other. tube portion 1814, 1812 includes a larger arc portion 1866, 1868 receiving arcomenor 1862, 1864. Accordingly, in the illustrated embodiment of FIGS. 25 and 26, a minor arc portion 18 62, 18 64 and a major arc portion 1866, 1868 form one side right 1818, 1820 as part of the two-piece flat tube fabrication process 1810. It is to be understood that the term " "bow" as used herein and in the claims is not restricted to a half round shape. Further, the term "arc" as used herein and in the appended claims is inclusive of any geometry suitable for forming the narrow sides 1818, 1820, which may include square, triangular or other open polygonal shapes, waveforms and other formations.

By using pipe portions that are substantially the same or identical in shape, fewer part types (and in some cases a single part type) can be used for the two-piece flat tube construction1810, resulting in smaller inventory, an assembly simpler and significant cost reductions.

Inner insert 1834 partially illustrated in FIG. And fully illustrated in FIG. 26 is formed of a third piece of material, and generally includes two longitudinal edges 1838, 1840, one or both of which may be on a respective narrow side 1818, 1820 with flat tube 1810. In some embodiments, the longitudinal edges 1838, 1840 are formed to a shape. for this purpose, so that the longitudinal edges 1838,184 0 can be received in the internal shape of the narrow sides 1818, 1820. Also, in some embodiments, at least part of one or both of the longitudinal edges 183 8,184 0 has a shape corresponding to the narrow sides1818. 1820. For example, one or both of the longitudinal edges 1838, 1840 may be formed in the shape of a loop 1842, so that at least part of the loop 1842 matches the corresponding narrow side shape 1818, 1820 of the flat tube 1810. In some embodiments, this shape match may result in a flat tube reinforcement on the narrow sides 1818, 1820. An additional reinforcement may be the It is achieved by connecting one or both of the longitudinal edges 1838, 1840 with the narrow sides 1818, 1820, such as by brazing, welding or in any other suitable manner.

With reference to FIG. 26, which illustrates the manner in which the two-piece flat tube 1810 can be assembled, the inner insert 1834 is shown received in portions of the first and second tube portions 1812, 1864 of 1812, 1814 according to the first and second tube portions 1812, 1814 are put together during an assembly. More particularly, the longitudinal edges 1838, 1840 of the inner insert 1834 are supported by the arc portions 1862, 1864 of the first and second tube portions 1812, 1814, and will be within the laterally defined narrow sides 1818, 1820 of the tube 1810 for reinforcing the narrow sides 1818, 1820 once the assembly is completed. The resulting two-piece flat tube1810 has narrow sides 1818, 1820 with a double wall thickness due to the overlapping longitudinal seams 1844, 1846 extending over and beyond the narrow sides 1818, 1820, and may also have an additional thickness defined by that of the nested longitudinal edges 1838. , 1840 from the inner insert1834. In some cases, for example, the two-piece flat tube 1810 will include the first and second tube portions 1812, 1814 collectively defining a wall thickness around 0.25 mm (0.0 078 74 in) to help prevent corrosion. or deterioration, and / or for the provision of waste impact resistance, and pressure and temperature change loads.

As explained in more detail below, the heat exchange tubes and other voice-sorting portions described herein may be manufactured using various fabrication techniques and processes, and may include corrosion protection features such as, for example, those techniques and processes described below and illustrated in FIGs. 92 to 95. Various manufacturing processes and techniques and counter-corrosion protection features referenced hereinafter are particularly advantageous when applied to heat exchange tubes and heat exchanger portions having significantly reduced material thickness. In addition, these corrosion protection techniques, processes and features provide significant performance advantages over flat tubes and heat exchangers made from this material.

Internal insert 1834 illustrated in FIGS. 25 and 26 have several corrugations 1852 through the wide flat tube 1810. These corrugations 1852 can be joined to the broad sides 1822, 1824 of the first and second tube portions 1812, 1814 for the formation of flow channels 1816 running in the longitudinal direction of the flat tube 1810. By using this arrangement, flow channels 1816 can be defined in the flat tube 1810 in a cost-effective manner, while also simplifying the two-piece flat tube manufacturing process 1810. Despite the low wall thickness of the inner insert 1834 (a which may be the same as or smaller than the thicknesses mentioned above the first and second tube portions 1812, 1814 described above), flow channels 1816 formed within the two-piece flat tube 1810 may provide improved stability to the internal pressure of tube 1810.

The hydraulic diameter of flow channels 1816 may be determined by an appropriate design of the corrugations1852 described above. In some embodiments, for example, the hydraulic diameter of flow channels 1816 is relatively small, considering that the two-piece flat tube d-diameter 1810 can be around 0.8 mm (0.031496 in), and that The number of wrinkles 1852 may be relatively large.

In some embodiments, at least some of the corrugations 1852 are shaped to have a perpendicular or substantially perpendicular corrugation flank to the broad sides 1822, 1824 of the two-piece flat tube 1810, and an adjacent inclined corrugation flank with respect to the broad sides 1822, 1824 (e.g. see central flushes 1852 illustrated in Figure 25, for example). In other embodiments, at least some of the corrugations 1852 are shaped to each have corrugation flanks of substantial inclination with respect to the broad sides 1822, 1824 (for example, see left flushes 1852 illustrated in FIG. 25, for example). In still other embodiments, at least some of the corrugations 18 52 are shaped to have both sides perpendicular or substantially perpendicular to the broad sides 1822, 1824 of the two-piece flat tube 1810.

An example of such a modality is shown in FIG. 33 which illustrates a two-piece flat tube 2210 which is substantially the same as that of FIGs. 25 and 26 except for the insert format. As the mode of FIG. 25 and 26, insert 2234 illustrated in FIG. Reinforcing the narrow sides 2218, 2220 by the longitudinal edges 2238, 2240 of insert 2234 covering at least a portion of the inner surface of each tube portion 2212,2214 on the narrow sides 2218, 2220. In other embodiments, only one of the longitudinal edges 2238, 2240 of the insertion 2234 extends to a corresponding narrow side 2218,2220. It should be noted that the two-piece flat tube assembly shown in FIG. 33 may have any of the same features described herein with respect to the embodiment of FIGs. 25 and 26. In still other embodiments, at least some of the corrugations 1852 may define a curved (e.g. sinusoidal) wave pattern, or any other profiled surface, wherein the corrugations are identical or different across the width of the two-piece flat tube 1810. In some embodiments, insert 1834 defines multiple flow channels 1816 having the same shape and size across the width of the two-piece flat tube 1810. In other embodiments, insert 1834 may be shaped such that the shape and / or size of flow channels 1816 vary across the width of the two-piece flat tube 1810 (for example, by using an insert 1834 with different types of corrugations 1852 at different locations across the two-piece flat tube width 1810). An example of this is shown in FIG. 25, wherein both types of corrugations described above for the illustrated insert1834 are used. In other embodiments, any number of different deformations and corrugation sizes may be used across the width of the two-piece flat tube 1810. The width across width may provide significant advantages over conventional flat tubes by adapting different portions of the flat tube 1810 to different flow conditions. and / or environmental (for example, different fluids or flow directions through different sections of the same flat tube 1810, different internal or external flow rates, temperatures, and / or pressures in different locations across flat tube width1810, or the like).

The inner insert 1834 illustrated in FIGs. 25 and 26 is formed of a single piece of material. However, it should be noted that in other embodiments, the inner insert 1834 may instead be formed by more than one part (whereas the flat tube assembly illustrated in Figures 25 and 26 may include four or more parts).

With continued reference to the embodiment of FIG. 25 and 26, the thickness of at least one narrow side 1818, 1820 generally corresponds to the sum of the thicknesses of the two wide sides 1822, 1824 (and more precisely the longitudinal edges of the first and second portions 1812, 1814) and the insert 1834. For example, the thickness The combined overlapping longitudinal edges of the first and second sections 1812, 1814, and insert 1834 can be around 0.25 mm (0.0098425 in) or less in some embodiments. It should also be noted that in each case the first and second tube portions 1812, 1814 and insert 1834 may be of substantially the same thickness (in any of the thickness ranges described above), such as in cases where the same sheet material is used for the construction of all three pieces. In such cases, either narrow side 1818, 1820 may be defined by a thickness that is approximately three times the material thickness of the first and second tube portions 1812,1814 (i.e. when a loop 1842 on one or both longitudinal edges of the insert 1834 is received on a corresponding right-hand side (1818, 1820 to increase the thickness thereof, as described above). In some embodiments, one or both of the longitudinal edges of the insert 1834 may be folded over themselves and then provided with a loop 184 or otherwise shaped to at least partially correspond to the interior of the narrow side 1818, 1820 thereby reinforcing. the wall material of the first and second portions 1812,1814 on the narrow sides 1818, 1820. Any number of such longitudinal edge folds for the insert 1834 may be made to obtain a desired thickness, reinforcement and stability of the narrow sides 1818, 1820.

In some embodiments having a narrow side reinforcement insert 1834, as described above, each of the first and second tube portions 1812, 1814 may have a thickness of less than 0.15 mm (0.00591 in), and the thickness of insert 1834 may be no larger than about 0.10 mm (0.003937 in), such as a flat tube 1810 in which the first and second tube portions 1812, 1814 each have a thickness of about 0.12 mm (0, 0047224 in), and wherein insert 1834 has a thickness not greater than about 0.10 mm (0.003937 in). In other embodiments, the thickness of each of the first and second tube portions 1812, 1814, and the insert 1834 may be no less than about 0.05 mm (0.0019685 in) and no greater than about 0, 15 mm (0.0059055 in) for the provision of a cost-effective heat exchanger with good heat transfer properties and strength. In other embodiments, the thickness of each of the first and second tube portions 1812, 1814 and insertion 18 3 4 may be no less than about 0.03 mm (0.00118in) in other embodiments.

At least one of the first and second portions 1812, 1814 and insert 1834 may have a brazing material liner on one or both sides thereof to allow such parts of the illustrated pipe assembly to be brazed together. In the illustrated embodiment of FIGs. 25 and 26 by way of example only, the first and second portions 1812, 1814 and flat tube insert 1834 1810 are made from an aluminum foil or aluminum alloy made available in stripped material coated on at least one side with Brazing material.

As shown in FIGs. 25 and 26, the two-piece flat tube 1810 of the illustrated embodiment defines a small diameter D of a large diameter D. Using the wall thicknesses described above, the inventors have found that a small diameter d is at least about 0.7 mm (0.027559). in) provides good performance results in many applications, such as radiators. Also, using the wall thicknesses described above, the inventors have found that a small diameter d not greater than about 1.5 mm (approximately 0.059055 in) provides good performance results in many applications, such as radiators. In the case of charge air coolers and other applications, the inventors have found that the small diameter d may be larger than about 1 cm (0.3937 in) to provide good performance results. While these small diameter dimensions may be employed in various embodiments, any of the small diameter dimensions described above with respect to the flat tube embodiments shown herein may be used. The large diameter D of the two-piece flat tube 1810 shown in FIGS. 25 and 26 may be any size desired (including those also described above with respect to all flat tube embodiments shown herein), based at least in part on the width of the starting material used for the construction of flat tube 1810.

As mentioned above, in some embodiments, either or both longitudinal edges of insert 1834 may be provided with any number of folds to obtain a desired thickness for increased reinforcement and stability of first and second portions 1812, 1814 on narrow sides 1818, 1820. An example of one embodiment as illustrated in FIGS. 28 and 29. The two-piece flat tube 1910 shown in FIGS. 28 and 29 is substantially the same as that of FIG. 25 and 26, except for the insertion format.

FIG. 28 illustrates the flat tube 1910 with a narrow side 1918 at a stage in which the large arc portion 1968 was not completely fabricated. In other words, a longitudinal edge of the second tube portion 1914 is not wrapped around the smaller arc portion already formed1962 formed by a corresponding longitudinal edge of the first tube portion 1912. This longitudinal edge of the second tube portion 1914 is offset or moved around. smaller bow portion 1962 to complete the narrow side1918. As a consequence, the longitudinal seam 1944 is on a wide side 1922, with another of the two longitudinal seams 1946 being on the other wide side 1924. These longitudinal seams 1944, 1946 are located on the narrow sides 1918, 1920 of the two-piece flat tube 1910 as described in embodiments. previous

In the illustrated embodiment of FIGs. 28 and 29, the longitudinal edges 1938, 1940 of insert 1934 have been folded several times as best shown in FIG. 29. Longitudinal edges 1938 with these 1970 folds are received on the narrow sides 1918, 1920 of the flat tube in two pieces 1910, and can provide significant reinforcement to the overlapping longitudinal edges of the first second tube portions 1912, 1914 on the narrow sides 1918, 1920. In other In both embodiments, only one of the 1938, 1940 longitudinal edges of the 1934 insert has these folds.

number of folds 1970 of longitudinal edges 1938,194 0 may depend at least in part on the dimensions of the flat tube 1910. In some embodiments for example only, the two-piece flat tube 1910 has a small diameter of about 1, 0 mm (0.03937 in), the first and second tube portions 1912, 1914 each have a material thickness of around 0.15 mm (0.0059055in), and the insert material thickness 1934 is around 0.05 mm (0.0019685 in), where around 10 folds are created at each longitudinal edge 1938, 1940 of insertion 1934. Although these multiple folds 1970 may have varying lengths, in some embodiments the maximum length L of these folds is around 1.0 mm (0.03937 in). Also, these multiple folds 1970 may run in a parallel or substantially parallel direction to the broad sides 1922, 1924 of the two-piece flat tube 1910 in some embodiments (see FIGS. 28 and 29), and may run in other directions (e.g., perpendicular to the wide sides 1922, 1924) in other embodiments. It is to be understood that the wall thicknesses of the first and second pipe portions 1912, 1914 and insert 1934 may vary, as may distances d and L, based on the desired specifications of the flat tube 1910.

It should be noted that the two-piece flat tube assembly shown in FIGs. 28 and 29 may have any of the same features described with respect to FIGs. 25 and 26. FIG. 27 illustrates a two-piece flat tube according to an additional embodiment of the present invention. This embodiment employs much of the same structure and has many of the same properties as the above described flat tube embodiments with respect to FIGs. 25, 26, 28, 29 and 33. Therefore, the following description focuses primarily on the structure and features that are different from the modalities described above with respect to FIGS. 25, 26, 28, 29 and 33. A reference should be made to the above description with respect to FIGs. 25, 26, 28, 29 and 33 for additional information regarding structure and features, and possible alternatives to the two-piece flat tube structure and features illustrated in FIG. 27 and written below. Structures and features of the modality shown in FIG. 27 corresponding to the structure and features of the embodiments of FIG. 25, 26, 28, 29 and 33 are designated hereinafter in the 1800 series of reference numbers.

As the embodiments of the present invention described with respect to FIGs. 25 and 26, the pipe assembly illustrated in FIG. 27 has first and second portions 1812A, 1814A and insert 1834A. Opposite longitudinal edges 1838A, 184OA of insert 1834A line the inner surfaces of both pairs of overlapping longitudinal sides of the first and second tube portions 1812A, 1414A thereby reinforcing the narrow sides 1818A, 1820A of the flat tube1810A.

The two-piece flat tube 1810A illustrated in FIG. 27 is an example of the manner in which both longitudinal seams 1844A, 1846A joining first and second portions 1812A, 1814A of flat tube 1810A may extend to and on the same wide side 1822A, 1824A of flat tube 1810A. In the illustrated embodiment of FIG. 27, both longitudinal risers 1844A, 1846A extend to and on the second wide side 1824A of flat tube 1810A. Alternatively the longitudinal seams 1844A, 1846A may be formed on the first desired wide side 1822A. In the illustrated embodiment, the second wide side 1824A defined primarily by the second tube portion 1814A is capable of absorbing relatively loose tolerances (i.e. capable of tolerance equalization) at its opposite longitudinal edges. However, in some embodiments, the first wide side 1822A defined primarily by the first tube portion 1812A does not have the same capacity or the same degree of capacity because each of its longitudinal edges may be directly or directly adjacent to a gradation 1858A, 1860A of the second tube portion 1814A. .

With continued reference to the illustrated mode of FIG. 27, the longitudinal seams 1844A, 1846A extend from respective narrow sides 1818A, 1820A toward the center of the flat tube 1810A. A significant portion of the longitudinal seam 1818A, 1820A (i.e. gradations 1858A, 1860A), however, is in the same direction 1824A, where the cross-sectional length and decay gradation 1858A, 1860A measured at the distal edge of the right sides 1818A, 1820A may be determined according to the desired manufacturing process used for the production of tube portions 1812A, 1814A. In the illustrated mode of FIG. 27, the small diameter d of the two-piece flat tube18IOA is in the range of about 0.7 to 1.5 mm (0.027559 to 0.059055 in) when the 1810A two-piece flat tube is incorporated in a radiator, although other small diameters d are possible for the same stringent applications, including the diameters d described above with respect to the embodiment of FIG. 25 and 26, and those described above with respect to the large and small diameters for all flat tubes of the present invention shown here. For example, in other constructions, the small diameter of the flat tube 1810A may be greater than 1.0 cm (approximately 0 cm). , 3 93 7 in).

As with the other embodiments described herein of two-piece tuboplane, it is envisaged that a flat tube manufacturing process 1910 will at least partially form the two tube portions 1912, 1914 from respective strips of sheet material, and then the joining the at least partially formed strips together, as described herein at the end of the fabrication line.

FIGs. 30 to 32 illustrate two additional flat tube constructions according to additional embodiments of the present invention. These embodiments employ much of the same structure and have much of the same properties as the flat tube modalities described above with respect to FIGS. 25 to 29 and 33. Accordingly, the following description focuses primarily on the structure and features that are different from the embodiments described above with respect to FIGS. 25 to 29 and 33. A reference should be made to the above description with respect to FIGs. 25 to 29 and 33 for further information regarding structure and features, and possible alternatives to the structure and features of flat tubes illustrated in FIGS. 30 to 32 and described below. The structure and features of the flat tubes illustrated in FIGs. 30 to 31 and 32 corresponding to the structure and features of the embodiments of FIGs. 25-29 and 33 are designated from this point on the 2000 and 2100 series of reference numbers, respectively.

The tube assembly illustrated in FIGs. 30 and 31 are substantially the same as that shown in FIG. 27, except for the insert format. The pipe assembly illustrated in FIGs. 30 and 31 is an example of the manner in which insert 2034 may take different shapes for defining flow channels 2016 of different shapes and sizes. By way of example, the internally illustrated insert 2034 includes corrugations 2052 having flanges that are substantially perpendicular to the broad sides 2022,2024 of the two-piece flat tube 2010. The flush flanges are joined together by substantially flat sections that can be brazed, welded or joined in any way. otherwise suitable on the wide-sided inner surfaces 2022, 2024 of the first and second tube sections 2012, 2014. This particular construction of sipes or inner insert 2,034 is generally referred to as flat-top sipes.

With continued reference to FIG. 30 and 31, the longitudinal edges 2038, 2042 of the inner insert 2034 are shaped to each include a gradation 2072 and a connecting arc 2074 received substantially inwardly, reinforcing the narrow sides 2018, 2020 in two pieces 2010. In other embodiments, only one of the longitudinal edges 2038, 2042 is provided with these features.

In any of the insertion embodiments described herein, the inserts may be provided with features that increase or sustain turbulence within the flow channels defined at least in part by the inserts. An example of these features is shown in FIGs. 32A and 32B. In this embodiment, the corrugations and flat sections of corrugations 2152 in the illustrated insert 2134 include small wings 2176 (not shown in FIG. 32A) positioned to increase or sustain flow turbulence in flow channels 2116. Small wings 2176 may be arranged or distributed at intervals along the length of the 2110 flat tube in any standard or non-standard manner, and may be located in any feature or combination of features of the corrugations2152. Also, it should be noted that the small wings 2176 may include shapes other than those shown in FIGS. 32A and 32B.

The flat tube assembly illustrated in FIGs. 3 2A and 3 2B also provides an example of how one or both of the longitudinal edges of an insert in any of the embodiments herein need not necessarily be received or otherwise located on the overlapping longitudinal edges of the first and second portion of the tube, and need not necessarily be part of. or extend to the narrow sides of the flat tube. The particular construction shown in FIGs. 32A and 32B by way of example, the inner insert 2134 includes at least one longitudinal edge 2140 that terminates before the right side 2120. Instead, the longitudinal edge 2140 is adjacent one of the broad sides 2124. Other insertion constructions 2124 may include one or both the longitudinal edges 2138, 2140 adjacent the other wide side 212 of the flat tube 2110, one or both of the rolled longitudinal edges 2138, 2140 not in or nested on a corresponding narrow side 2118, 2120 of the flat tube 2110, and the like.

FIG. 34 illustrates ten flat tube constructions according to additional embodiments of the present invention. These embodiments employ much of the same structure and have many of the same properties as the flat tube modalities described above with respect to FIGS. 25-33. Accordingly, the following description focuses primarily on the structure and features that are different from the above described modalities with respect to FIGS. 25-33. Reference should be made to the above description with respect to FIGs. 25-33 for additional information relating to the structure and features, and possible alternatives to the structure and features of the flat tubes illustrated in FIG. 34 and described below. The structure and features of the embodiments shown in FIG. 34 which correspond to the structure and features of the embodiments of FIG. 25 through 33 are designated here in the respective series beginning with 2300.

As described above with respect to the illustrated embodiment of FIG. 25 and 26, further reinforcement of the first and / or second narrow sides of a flat tube may be provided by one or more folds of the first and / or second tube portions on the narrow sides (i.e., the longitudinal edges of those portions). Generally, bending the longitudinal edges of the first and / or second pipe portions may increase the resistance of the pipe and the resistance of the flat pipe to damage. This recursion may be employed in any of the embodiments described with respect to FIGs. 25 to 33. Examples of flat tubes having bent longitudinal edges are illustrated in FIG. 34, where inserts defining generally rectangular flow channels and not extending to or folded within the folds of the narrow tube sides are illustrated by way of example only. Any of the other types of inserts (or no shape inserts at all) or a longitudinal eposition insertion construct described herein may be used instead as desired.

Each of the flat tubes 2310, 2410, 2510, 2610, 2710,2810, 2910, 3010, 3110, 3210 illustrated in FIG. 34 includes at least one longitudinal edge of at least one of the first and second tube portions 2312, 2412, 2512, 2612,2712, 2812, 2912, 3012, 3112, 3212 and 2314, 2414, 2514,2614, 2714, 2814, 2914, 3014, 3114, 3214 having a bend 2330, 2430, 2530, 2630, 2730, 2830, 2930, 3030, 3130, 3230.Each of the constructions illustrated in FIG. 34 has a wrapped edge 2380, 2382 ... 3280, 3282 (i.e., the longitudinal edge 2380, 2382 ... 3280, 3282 which is at least partially surrounded by a longitudinal edge 2378,2384 ... 3278, 3284 of the other portion of tube 2312, 2314 ... 3212, 3214) with at least one bend 2330 ... 3230. Some of the constructions in FIG. 34 illustrate a wrap-around edge 2978, 2984, 3078, 3074, 3178, 3174, 3278, 3274 (i.e. longitudinal edge 2978, 2984, 3078, 3074, 3178, 3174,3278, 3274 that surrounds at least partially the longitudinal edge 2980 , 2982, 3080, 3082, 3180, 3182, 3280, 3282 of the other tube portion 2912, 2914, 3012, 3014, 3112, 3114,3212, 3214) with at least one bend 2930, 3030, 3130,3230. Although the opposite narrow ends of each two-piece tuboplane illustrated in FIG. 34 employ the same bent construction, in other embodiments (with or without insertions) only one of the two narrow ends has such a construction, in which case the other straight end may have any of the other folded constructions described herein or have no longitudinally folded pipe edge portions of either. not at all. In other embodiments, each of the longitudinal edges of at least one of the narrow ends of the two-piece flat tube (with or without an insert) has at least one bend.

In some embodiments, one of the narrow ends of any of the flat tubes illustrated in FIG. Any of the folded longitudinal edge constructions described and / or illustrated with respect to any of the embodiments shown in FIGS. 1 to 24 (with or without insertions). In such cases, the other narrow end may be defined by a sheet of folded continuous material as described above with respect to the one-piece tube embodiments of FIG. 16 to 22, thereby resulting in a one-piece tube.

The combination of the longitudinally folded constructions of the first and second pipe portions described herein with relatively small thickness dimensions of the material which may be employed in some embodiments (as described above) can produce flat pipes having a significantly reduced weight without compromising strength and stability.

For ease of description, the flat tube constructions 2310 ... 3210 illustrated in FIGs. 34 include a configuration similar to that of the flat tube 1810 shown in FIGS. 25 and 26 with respect to the orientation of the first and second portions 2312, 2314 ... 3212, 3214, and are classified into three groups: B, C, and D. Each of groups B, C, and D illustrates alternative characteristics of tuboplane 2310. ..3210. As mentioned above, it is to be understood that the features illustrated in FIG. 34 are also applicable to other two-piece or one-piece flat tube configurations described and / or illustrated herein, and may be used with or without an insert. The flat tubes 2310, 2410, 2510, 2610, 2710, 2810 of the BeC Groups each include a non-bent longitudinal wrap edge 2378, 2384, 2478, 2484, 2578, 2584, 2678, 2684,2778, 2784, 2878, 2884 first and second tube portions 2312, 2314, 2412, 2414, 2512, 2514, 2612, 2614, 2712,2714, 2812, 2814 respectively. More specifically, the wrapping edges 2378, 2384, 2478, 2484, 2578, 2584,2678, 2684, 2778, 2784, 2878, 2884 surround at least partially the wrapped edges 2382, 2380, 2482, 2480,2582, 2580, 2682, 2680 2782, 2780, 2882, 2880 having at least one fold 2330, 2430, 2530, 2630, 2730, 2830. Folds 2330, 2430, 2530, 2630, 2730, 2830 of the developed edges 2382, 2380, 2482, 2480, 2582, 2580, 2682, 2680,2782, 2780, 2882, 2880 may be substantially parallel to the broad sides 2322, 2324, 2422, 2424, 2522, 2524, 2622,2624, 2722, 2724, 2822, 2824 (e.g., Groups B and C). Also, folds 2330, 2430, 2530 may include a portion parallel to the surrounding edge 2378, 2384, 2478, 2484, 2578.2584 (e.g., Group B).

Group D flat tubes 2910, 3010, 3110 include narrow sides 2918, 2920, 3018, 3020, 3118, 3120, both wrapping edges 2978, 2984, 3078, 3084,3178, 3184 and wrapped edges 2982, 2980, 3082 , 3080,3182, 3180 of the first and second tube portions 2912,2914, 3012, 3014, 3112, 3114 have bends 2930, 3030, 3130. As a result, the stability of the narrow sides 2918,2920, 3018, 3020, 3118, 3120 can be increased with respect to narrow sides 2318, 2320, 2418, 2420, 2518.2520, 2618, 2620, 2718, 2720, 2818, 2820 of the flat tubes 2310, 2410, 2510, 2610, 2710, 2810 in Groups B and C. Further, the wrapped and wrap edges 2982, 2980,3082, 3080, 3182, 3180 and 2978, 2984, 3078, 3084, 3178, 3184 of each of the flat tubes 2910, 3010, 3110 in Group D define only one bend 2930, 3030 , 3130 (although more folding is possible in other embodiments), whereas the edges involved are 2382, 2380, 2482, 2480, 2582, 2580,2682, 2680, 2782, 2780, 2882, 2880 of the tubing. BeC Groups 2310,2410, 2510, 2610, 2710, 2810 define more than one bend 2330, 2430, 2530, 2630, 2730, 2830. Also with reference to Group D flat tubes 2910, 3010, 3110, one bend 2930, 3030 3130 of each surrounding edge 2978.2984, 3078, 3084, 3178, 3184 is substantially parallel to the outermost portion of the flat tube 2910, 3010, 3110, and at least a portion of the bend 2930, 3030, 3130 of each involved edge 2982, 2980 , 3082, 3080, 3182, 3180 is substantially parallel to the broad sides 2922, 2924,3022, 3024, 3122, 3124 of the flat tubes 2910, 3010, 3110.

With continued reference to the various flat tube embodiments illustrated in FIG. 34, it is to be understood that the number of folds 2330 ... 3230 in the wrapping edges involved 2382, 2380 ... 3282, 3280 and 2378, 2384 ... 3278,3284, and the design or shape of the folds 2330 .. .3230 may be adjusted according to a desired set of parameters. Moreover, while the inner insert 2334 ... 3234 of the flat tube embodiments illustrated in FIG. 34 is not used for reinforcing the narrow sides 2318, 2320 ... 3218,3 220, in other embodiments, one or both of the longitudinal edges 2338, 2340 ... 3238, 3240 of insert 2334 ... 3234 are folded with and within the longitudinal edges 2382, 2380 ... 3282, 3280 and 2378, 2384 ... 3278, 3284 of the first and second tube portions 2312, 2314 ... 3212, 3214. Still other flat tube constructions may include bending with the edges strips of a strip into one piece as mentioned above.

In either embodiment of the two-piece flat tube described in connection with FIG. 25-34, it is envisaged that throughout the 1710 ... 3210 tuboplane manufacturing process, the width of any of the longitudinal seams 1744, 1746 ... 3244, 3246 or gradations 1716 ... 3216 can be adjusted for different tubes. 1710 ... 3210.As a result, an abrupt change in thickness of the wide sides 1722, 1724 ... 3222, 3224 can be compensated, reduced or even avoided. For purposes of illustration, it may be noted that the distance is illustrated in FIGS. 31 and 32B (representing the distance from the longitudinal end edge 2156, 2256 to the distal end of the corresponding pipe side 2120, 2220) is significantly longer in the embodiment of FIG. 31 of the embodiment of FIG. 32A and 32B. This distance may be served in either mode as desired.

FIGs. 35-45 illustrate various flat tube inserts according to various embodiments of the present invention, any of which may be used in any of the flat tube embodiments described and / or illustrated herein. In many embodiments, an insert may be described as having several hills and valleys at least partially defining flow channels along a flat tube.

The flat tubes 3310, 3410, 3510, 3610 illustrated in FIGS. 35-45 each include an inner insert 3334,3434, 3534, 3634 with various elongated apertures 3386, 3486,3586, 3686 generally defined on hills 3388, 3488,3588, 3688 and / or valleys 3390, 3490, 3590, 3690 of insert 3334, 3434, 3534, 3634. The elongated apertures 3386, 3486, 3586, 3686 extend in a longitudinal direction generally along the insert 3334, 3434, 3534, 3634 (i.e. in a direction that will generally extend longitudinally. along the interior of a flat tube 3310, 3410, 3510, 3610 into which insert 3334, 3434, 3534,3634 will be installed). In some flat tube constructions 3310, 3410, 3510, 3610, elongated openings 3386, 3486,3586, 3686 may be interrupted by bridges 3392, 3492,3592, 3692. Bridges 3392, 3492, 3592, 3692 may be oriented substantially. parallel to the broad sides 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 with the flat tube 3310, 3410, 3510, 3610, and may be spaced at any regular or irregular interval along the longitudinal direction of the insert 3334, 3434, 3534, 3634 .

By providing the elongated openings 3386, 3486,3586, 3686 in insert 3334, 3434, 3534, 3634 as described above, the weight of insert 3334, 3434, 3534, 3634 (and, consequently, of a heat exchanger equipped with flat tubes 3310 , 3410, 3510, 3610 having these insertions 3334, 3434, 3534, 3634) may be significantly reduced relative to an insert 3334,3434, 3534, 3634 that does not include such elongated openings3386, 3486, 3586, 3686. Based on the design of the internal insert 3334, 3434, 3534, 3634, it is envisaged that the weight of an internal insert 3334, 3434, 3534, 3634 may be reduced by up to 50% by including the elongated openings 3386, 3486, 3586, 3686 compared to a continuously corrugated internal insert 3334 , 3434, 3534, 3634 similar dimensions.

In some embodiments, the inserts 3334, 3434, 3534,3634 described above and illustrated in FIGs. 35-45 are produced by cutting a sheet of material (eg, endless or discrete lengths of aluminum, aluminum alloy, copper, brass or other metal, or other material), and by bending portions of the cut sheet out of the plane with respect to the original sheet. For example, in the constructions of inserts 3334, 3434, 3534, 3634 shown in FIG. 35-45, the internal inserts 3334, 3434, 3534, 3634 may be made from a relatively thin sheet metal thickness of about 0.03 mm (0.0011811 in). The elongated portions may include elongated slits which are opened by the flexing sheet material adjacent to the out-of-plane slits with respect to the original sheet. Flexions can be made in both off-plane directions of the original sheet, or in just one off-plane direction, thereby producing insertions 3334, 3434, 3534, 3634 having different shapes. Additional cuts can be made to facilitate this bending, such as perpendicular slits attached to the elongated slits just described. In some embodiments, the flexed portions include arc-like edges 3394,3494, 3594, 3694 as illustrated in FIG. 35-45, for example. In some embodiments, the cuts in the sheet of material (prior to a bending) and the resulting elongated apertures 3386, 3486, 3586, 3686, and points 3392, 3492, 3592, 3692 define a Double format.

The inventors have found that a desired internal depression stability can be obtained in the flat tubes including the inserts 3334, 3434, 3534, 3634 illustrated in FIG. 35-45. More specifically, the bending surfaces of the inserts 3334, 3434, 3534, 3634 illustrated in FIG. 35-45 (defined by the upper portions of the bow type edges 3394, 3494, 3594, 3694) are large enough to provide strong connections between the inserts 3334, 3434, 3534, 3634 and the broad sides 3322,3324, 3422, 3424, 3522, 3524 3310, 3410,3510, 3610. The arc type edge flanges 3394, 3494,3594, 3694 may also be joined by brazing the arc edge types 3394, 3494, 3594, 3694 to the corresponding broad sides 3322, 3324, 3422 , 3424, 3522, 3524, 3622,3624 from flat tube 3310, 3410, 3510, 3610. These lamellar constructions or internal inserts 3334, 3434,3534, 3634 are often referred to as topoplane lamellae.

The use of the inserts 3334, 3434, 3534, 3634 described above in conjunction with the flat tubes illustrated in FIGS. 5-45 and described anywhere provide excellent results. For example, the above-described fittings provide additional resistance to those flat tubes of the present invention constructed of relatively thin sheet material having dimensions described above. Advantages have also been found with reference to the pressure pressure experienced when using such internal inserts 3334, 3434, 3534, 3634. Further , internal inserts 3334, 3434, 3534, 3634 having the elongated openings 3386, 3486, 3586, 3686 and bridges 3392, 3492, 3592,3692 as described above may help to prevent the first and second portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 of the flat tube 3310, 3410, 3510, 3610 are easily displaced transversely away from each other. For example, this structure can help prevent one of the first and second flat tube portions 3312, 3412, 3512, 3612 from moving in the longitudinal direction of the flat tube 3310, 3410, 3510, 3610 with respect to the other flat tube twisting 3314, 3414, 3514, 3614 during the manufacturing processes carried out for the creation of completed flat tube assembly. One reason is that ascolines 3388, 3488, 3588, 3688 and valleys 3390, 3490, 3590,3690 having the elongated apertures 3386, 3486, 3596, 3696 described above can exert a tensile force from within the flat tube 3310, 3410, 3510, 3610 on the wide sides 3322, 3324, 3422, 3424, 3522, 3524, 3622,3624, thereby placing the broad sides 3322, 3324,3422, 3424, 3522, 3524, 3622, 3624 under traction to prevent or reduce this displacement. .

In each of the embodiments illustrated in FIGs. 35-45the inserts 3334, 3434, 3534, 3634 are received in two-piece flat tubes 3310, 3410, 3510, 3610 in which longitudinal risers 3344, 3346, 3444, 3446, 3544, 3546,3644, 3646 joining the two portions of the tube. plan 3310, 3410,3510, 3610 extend to and are at least partially located in different portions 3312, 3314, 3412, 3414,3512, 3514, 3612, 3614. In each embodiment, the two portions 3312, 3314, 3412, 3414, 3512 , 3514, 3612, 3614 are substantially identical to each other. However, in other embodiments, the inserts 3334, 3434, 3534, 3634 may be used in either one-piece or two-piece flat tubes of the present invention described herein. For example, the two portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 may be arranged such that a longitudinal seam 3344, 3444, 3544, 3644 is on a wide edge 3324, 3424, 3524, 3624 and the other longitudinal corner 3346, 3446, 3546, 3646 is on the other side 3322, 3422, 3522, 3622 of flat tube 3310, 3410,3510, 3610, as in the embodiment of the present invention illustrated in FIGs. 25 and 26. In such embodiments, a longitudinal edge 3354, 3356, 3454, 3456, 3554, 3556, 3654, 3656 of each of the two portions 3312, 3314, 3412, 3414, 3512,3514, 3612, 3614 extends substantially freely. 3310, 3410, 3510, 3610. As a consequence, the two portions 3312, 3314, 3412, 3414, 3512,3514, 3612, 3614 may have relatively large tolerances in their widths, as described above with respect to the illustrated embodiment of FIG. 25 and 26. In other embodiments, both longitudinal seams 3344,3346, 3444, 3446, 3544, 3546, 3644, 3646 are located to extend on the same wide side 3322, 3422, 3522,3622 or 3324, 3424, 3524, 3624, as in the embodiment of the present invention illustrated in FIG. 27

In some embodiments, one or both of the longitudinal edges 3338, 3340, 3448, 3440, 3548, 3540, 3648, 3640 of insert 3334, 3434, 3534, 3634 may extend to a corresponding narrow side 3318, 3320, 3418.3420, 3518, 3520, 3618, 3620, and may be shaped to cover at least a portion of the interior of the narrow side 3318, 3320, 3418, 3420, 3518, 3520, 3618, 3620 in any of the ways described above with respect to the illustrated embodiments of FIG. 25-34. For example, either of the longitudinal edges 3338, 3340, 3448, 3440, 3548, 3540, 3648, 3640 of insert 3334, 3434, 3534, 3634 may include a gradation 3472, 3672 (see, for example, the modalities of FIGS. 42 and 45) and / or an arc-shaped edge 3374, 3474, 3574, 3674 for reinforcing one or both narrow sides 3318, 3320, 3418, 3420, 3518, 3520,3618, 3620.

Such a relationship between insert 3334, 3434.3534, 3634 and flat tube 3310, 3410, 3510, 3610 can provide significant strength and stability advantages as described above. In such embodiments, the thickness of the reinforced narrow sides 3318, 3320, 3418, 3420, 3518, 3520, 3618, 3620 corresponds to the sum of the thicknesses of the first and second tube portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614. insert 3334, 3434, 3534, 3634. In some embodiments having this relationship, each of the first and second pipe portions 3312, 3314, 3412, 3414, 3512, 3514,3612, 3614 may have a thickness no greater than around 0, 15 mm (0.00591 in). Further, each of the first and second tube portions 3312, 3314, 3412, 3414, 3512,3514, 3612, 3614 may have a thickness greater than around 0.10 mm (0.003937 in). Also or alternatively, in such embodiments the insertion thickness 3334, 3434.3534, 3634 is not greater than about 0.10 mm (0.003937in). For example, flat tube 3310, 3410, 3510, 3610 may have first and second tube portions 3312, 3314, 3412,3414, 3512, 3514, 3612, 3614 each having a thickness of about 0.12 mm (0 , 0047224 in), and wherein insert 3334, 3434, 3534, 3634 has a thickness no greater than about 0.10 mm (0.003937 in). In other embodiments, the thickness of each of the first and second tube portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 and insertion 3334, 3434, 3534, 3634 is not greater than around 0.15 mm ( 0.0059055) for the provision of a relatively cost effective heat exchanger with good heat transfer properties and strength.

Also, in some embodiments the thickness of each of the first and second tube portions 3312, 3314, 3412, 3414,3512, 3514, 3612, 3614 and / or insert 3334, 3434, 3534,3634 is not less than around 0.03 mm (0.0011811 in). In other embodiments, inserts 3334, 3434, 3534, 3634 may have any of the insertion thicknesses described above in relation to the illustrated embodiments of FIG. 25-34.

As best shown in FIGs. 35, 39, 44, and 45, in some embodiments the inserts 3334, 3434, 3534, 3634 illustrated in FIGs. 35-45 are shaped such that ascolines 3388, 3488, 3588, 3688 and valleys 3390, 3490, 3590,3690 described above define corrugations 3352, 3452, 3552,3652 running in the longitudinal direction of the inserts 3334,3434, 3534, 3634. The flanks of these corrugations 3352, 3452,3552, 3652 may be perpendicular or substantially perpendicular to the broad sides 3322, 3324, 3422, 3424,3522, 3524 of flat tubes 3310, 3410, 3510 (see FIG.35, 39, and 44). or may form an angle of inclination with respect to the broad sides 3622, 3624 of the flat tube 3610. Any of the illustrated embodiments of FIG. 35-45, perpendicular or angled corrugation flanks may be used as desired. Additionally, the internal insert 3334, 3434, 3534, 3634 may be made of more than one part, so that the resulting flat tube assembly includes four or more parts in some embodiments.

In some embodiments (including embodiments wherein the inner insert 3334, 3434, 3534, 3634 is constructed from a single sheet of material as described above), the inner insert 3334, 3434, 3534, 3634 is generally wound in the longitudinal direction of the inner insert 3334, 3434. , 3534, 3634 or flat tube 3310, 3410,3510, 3610. In some flat tube manufacturing processes 3310, 3410, 3510, 3610, for example, two types of roll are provided for winding the inner insert 3334,3434, 3534, 3634 and generate the elongated openings 3386, 3486,3586, 3686, hills 3388, 3488, 3588, 3688 and valleys 3390, 3490, 3590, 3690 in the longitudinal direction as described above. A first roll can be a cut roll for forming cracks in the substantially flat sheet. A second roll can be a roll forming roll for hills 3388, 3488, 3588, 3688 and valleys 3390,3490, 3590, 3690 defining the edges. bow type 3394,3494, 3594, 3694 in FIG. 35-45. Similar to the constructions described above, the longitudinal seams 3334, 3346, 3444, 3446, 3544, 3546, 3644, 3646 of the first and second tube portions 3312, 3314, 3412, 3414, 3512,3514, 3612, 3614 forming the flat tube 3310 , 3410, 3510,3610 reach from the narrow sides 3318, 3320, 3418,3420, 3518, 3520, 3618, 3620 on the broad sides 3322, 3324,3422, 3424, 3522, 3524, 3622, 3624 of the flat tube 3310, 3410, 3510, 3610. As with the two-piece tube embodiments described above, gradations 3316, 3416,3516, 3616, however, may be on the broad sides 3322,3324, 3422, 3424, 3522, 3524, 3622, 3624. As also described in previous embodiments, the gradation width 3316, 3416, 3516, 3616 (measured to the corresponding narrow distal end 3318, 3320, 3418, 3420, 3518,3520, 3618, 3620) can be determined based on the manufacturing process and desired specifications of flat tube 3310, 3410, 3510, 3610.

With continued reference to the embodiments illustrated in FIG. 35-45 in some flat tube constructions 3,310,3410, 3510, 3610 having an insert 3334, 3434, 3534, 3634 with elongated openings 3386, 3486, 3586, 3686 and bridges 3390, 3492, 3590, 3690 as described herein. (including those embodiments having the relatively thin tubular wall materials described above), the inventors have found that a small flat tube diameter of at least about 0.7 mm (0.027559 in) provides good performance results in many applications, such as radiators. The inventors have also found that a small flat tube diameter of no larger than about 1.5mm (0.059055 in) provides good performance results in many applications, such as radiators, and particularly in those flat tube embodiments of the present invention having the same characteristics. relatively thin-walled wall materials described above. In the case of charge air coolers and other applications, the inventors have found that the small diameter d may be larger than around 10.0 mm (0.3937 in) while still providing good performance results. Also, it should be noted that in other embodiments any of the small and large diameters D, d described above with respect to all flat tube modalities shown herein may be used instead. The large diameter D of the flat tubes in two pieces 3310, 3410, 3510, 3610 shown in FIGS. 35, 39, 44, and 45 may be any desired size (also including those described above with respect to all flat tube modalities shown herein), based, in part, on the width of the starting material used for the flat tube construction. 3310, 3410, 3510, 3610. In this sense, if rolling rolls are used for the production of flat tubes, these rolls (not shown) can be adjusted to produce wider or narrower flat tubes 3310, 3410, 3510, 3610. In other embodiments, the rollers for the manufacture of flat tubes 3310, 3410, 3510, 3610 may be replaced to desired dimensions of flat tube 3310, 3410, 3510,3610.

In some flat tube constructions 3310, 3410,3510, 3610 illustrated in the embodiments of FIG. 35-45, the first and second tube portions 3312, 3314, 3412, 3414,3512, 3514, 3612, 3614 and / or insert 3334, 3434, 3534,3634 may include a brazing liner for two-way joining purposes. or more of these parts and / or, in some cases, another element (for example a cooling grid of a heat exchanger). Although in some embodiments, the first and second tube portions 3312,3314, 3412, 3414, 3512, 3514, 3612, 3614 and / or insert 3334, 3434, 3534, 3634 are constructed of aluminum or an aluminum alloy in other embodiments. Any of these parts may be constructed from other materials suitable or not for brazing.

With particular reference now to the illustrated embodiment of FIG. 35-38, in some embodiments the bridges 3390 interrupting the elongated openings 3386 are not continuous or aligned with the other bridges covering the entire width of the insert 3334. Instead, bridges3390 interrupting an elongated opening may be alternated (i.e. located at different longitudinal positions along insert 3334) with respect to adjacent bridges 3390 on one or both sides of the extended aperture 3386. In other embodiments, such as those shown in FIGs. 39-42, bridges 3492 interrupting elongated openings 3486 may be aligned so that two or more bridges 3492 interrupting adjacent elongated openings 3486 are aligned or substantially aligned in the same longitudinal position along insertion 3444. In either embodiment, the distance along each flow channel 3316, 3416 between bridges 3390, 3492 may be discrete (i.e. not in fluid communication with adjacent flow channels 3316, 3416), since wide sides 3322, 3324, 3422, 3424 may close elongated openings 3386, 3486. illustrated bridge arrangements in the embodiments of FIG. 35-42 provide advantages from a manufacturing point of view, yet in other embodiments the bridges may be arranged in any other desired manner.

The hydraulic diameter defined by flow channels 3316, 3416 is defined by the corresponding design of hills 3388, 3488 and valleys 3488, 3490 of insert 3334,3434. The hydraulic diameter may be relatively small, considering a small diameter d of about 0.8 mm (0.031496 in) and a relatively large number of flow channels 3316, 3416 across the width of the insert 3334, 3434, by example.

With continued reference to the mode shown in FIG. 35-38, the illustrated corrugations 3352 "oscillate" approximately about a median plane of insert 3334 (or flat tube 3310). In other words, the arcuate flanks 3374 of the insert 3334 extend opposite directions toward the first and second tube portions 3312, 3314 from a defined insertion portion 3334 between them and substantially parallel to the broad sides 3322, 3324 of the tube. Although this portion between the broad sides 3322, 3324 may be located in a mid-plane of the insert 3334, such as that shown in FIG. 37, this portion from which the hills 3390 and valleys 3388 may be located anywhere between the ends of the insert 3334 to either side of the original flat sheet. Also, it should be noted that the construction of insert 3334 shown in FIG.35 has elongated openings 3386 formed in hills 3390 and vales 3388 of the illustrated corrugations 3352, although such openings 3386, 3388 need not necessarily be defined in hills 3390 and valleys 3388 in other embodiments.

In the embodiment of FIG. 38-42, corrugations 34 52 are formed instead on one side of insert 3434. In particular, insert 3434 is not in a medium plane with respect to the broad sides 3422, 3424 of flat tube 3410, but rather it is approximately on the lower broad side 3424 of the flat tube 3410. Further, the insert construction 3434 shown in FIG. 39 has elongated openings 3486 only in the hills 3488 of illustrated corrugations 3452.

In some embodiments, any of the inserts described herein may be separated into two or more sections along the width of the inserts so as to define two or more flow channels which, in some embodiments, are fluid isolated from each other. This separation may be produced by one or more partitions extending longitudinally defined in whole or in part by the insert. For example, in the embodiments of FIG. 44 and 45, each of the internal inserts 3534, 3634 is formed 30 with at least one 3596, 3696 for providing the flat tube 3510, 3610 with at least two flow chambers having any desired number of flow channels 3516, 3616. Separation of two flow media within the flat tube 3510, 3610 is performed. Each of the flat tubes 3510, 3610 illustrated in FIGs. 44 and 45 are included in such flow chambers, allowing (for example) one medium to flow forward in one flow chamber in one direction, and allowing the same or a different medium to flow backward into the other flow chamber in an opposite direction.

Various flat tubes according to various embodiments of the present invention have been described as being constructed of a single piece of material (see, for example, the illustrated embodiments of FIGS. 16-23, which show various flat tubes 910, 1010, 1110, 1210, 1310, 1410.1510, 1610 each having several internal folds 928, 1028,1128, 1228, 1328, 1428, 1528, 1628 defined by the first and second portions 912, 914, 1012, 1014, 1112, 1114, 1212,1214, 1312, 1314 , 1412, 1414, 1512, 1514, 1612, 1614 the same piece of tube used for the construction of the tube 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610). As described in more detail above, the internal folds 928,1028, 1128, 1228, 1328, 1428, 1528, 1628 define, at least partially, several flow channels 916, 1016, 1116,1216, 1316, 1416, 1516, 1616 through flat tubes 910.1010, 1110, 1210, 1310, 1410, 1510, 1610.

In other embodiments of the present invention, a one-piece tuboplane may be provided with a constructed insert of a separate piece of material received within (and in some embodiments, trapped) the one-piece tuboplane. Two examples of such flat tubes 3710,3810 having inserts 3734, 3834 are shown in FIGs. 46-47 and 48. Like the one-piece flat tubes described above, the flat tube 3710, 3810 can be constructed of a sheet (e.g., a strip) of relatively thin material defining the broad sides 3722, 3724,3822, 3824 and two sides. reinforced straits 3718, 3720.3818, 3820 of the flat tube 3710, 3810. In some embodiments, the inventors have found that the thickness of the sheet material may be less than about 0.15 mm (0.0059055 in) to provide good results. performance in many applications. Also, in some embodiments, the inventors have found that the thickness of the sheet material may be greater than about 0.03 mm (approximately 0.0011811 in) to provide good performance results in many applications. It is to be understood that the thickness of the sheet material may have other dimensions not listed here.

With continued reference to FIG. 46-48, the longitudinal edges 3778, 3782, 3878, 3882 of the sheet material are shaped and moved together so that a longitudinal edge 3778, 3878 abuts against the longitudinal edge 3782, 3882 for forming a narrow side3718, 3818 of the flat tube. 3710, 3810. This narrow side 3718, 3818 can be defined by at least 180 ° bending of the sheet of material on the narrow side 3718, 3818 or one or more other folds (described in greater detail below) used for closing the narrow side 3718, 3818. The other narrow side 3720, 3820 is formed at least in part by folding the sheet of material to securely place the first and second longitudinal edges 3778, 3782, 3878, 3882 as just described. In some embodiments, this other narrow side 3720, 3820 may include at least one triple wall thickness generated by folding the sheet of material over twice at the location of the narrow side 3720,3820.

In some embodiments, the flat tube manufacturing process 3710, 3810 may include forming or otherwise folding the longitudinal edges 3778,3782, 3878, 3882 which will be placed together to close the flat tube 3710, 3810 prior to folding the sheet material. for producing reinforcement folds 3,730,3830 (shown in F in FIGS. 46-48) on the narrow side 3720,3 820 as described above. In other embodiments, these processes are performed at the same time or substantially at the same time.

In some embodiments of the one-piece flat tube, such as the one-piece flat tube 3710 shown in FIGs. 46 and 47, a longitudinal edge 3778 of the sheet material used for the production of tube 3710 defines an arc shape larger than an arc shape of the other longitudinal edge 3782. An advantage of such a construction is that when it approaches longitudinally larger arch shape No. 3,778 is formed around the smaller rim-shaped longitudinal edge 3782, the finished flat tube 3710 is generally not cracked or resistant to cracking. For example, the longitudinal edges 3878, 3882 illustrated in FIGs. 48 may be joined together and in various different shapes, including without limitation any of the longitudinal edge shapes illustrated and / or described above with respect to FIGs. 2 and 6-11. Also, the longitudinal edges 3878, 3882 illustrated in FIGs. 48 may be joined together with one or both of the longitudinal edges 3738, 3740 and together with different shapes, including without limitation any of the longitudinal edge shapes illustrated and / or described above with respect to FIG. 14 and 15.

The narrow sides 3718, 3720, 3818, 3820 of the one-piece flat tubes 3710, 3810 shown in FIGs. 46-48 each have a thickness of at least twice that sheet material used for the construction of the tubes 3710, 3810. Two of the illustrated narrow sides 3720, 3820 have a thickness that is at least three times that of the sheet material. based on the extra folds 3730, 3830 created in the areas of these narrow sides 3720, 3820. In other embodiments, an additional reinforcement of either side 3718, 3720, 3818, 3820 may be obtained by forming one or more additional folds 3730, 3830 in the narrow side locations 3718. , 3720, 3818, 3820. Any of the types of folds described with respect to any of the embodiments of FIG. 1-24 for reinforcement of a narrow side defined by the two joined longitudinal edges may be used for reinforcement of the first narrow side 3718, 3818 illustrated in FIGS. 46-48. Similarly, any of the types described with respect to any of the embodiments of FIG. 16-24 for reinforcement of a narrow side defined by a sheet of continuous material may be used for reinforcement of the second side 3720, 3820 illustrated in FIGS. 46-48.

In each of the two illustrated embodiments of FIG. 46-48, an internal insert 3734, 3834 is received in tuboplane 3710, 3810 as flat tube 3710, 3810 is fabricated. In some embodiments, the insert 3734, 3834 may be inserted after the production of the second narrow side 3720, 3820 (defining the reinforcing folds 3730, 3830 described above), while the flat tube 3710, 3810 is still partially open as shown in FIGs. Alternatively or additionally, one or both of the broad sides 3722, 3724 of the flat tube 3710, 3810 may have similar internal folds to those illustrated in FIGS. 1-13 and 16-24 (for example) at least partially forming the flow channels.

An exemplary process for forming a one piece 3710 tuboplane with an insert 3734 is illustrated in FIG. 4 6 by way of example. First, a fold 3730 (indicated at F) is created, and the longitudinal edges 3778, 3782 are formed simultaneously. Alternatively, only one longitudinal edge 3778, 3782 is shaped, while the other longitudinal edge 3782, 3778 remains unformed. In the illustrated embodiment of FIG.46, at the manufacturing stage shown in illustration (a) of FIG. 46, a longitudinal edge 3782 with an arc 3762 is already completed, and the other longitudinal edge 3778 has been provided with a single flexion which will later further be formed into a larger arc 3766 extending at least partially around the arc 3762 defined by the first edge. longitudinal 3782.

At the manufacturing stage shown in illustration (b) ofFIG. 46, two reinforcing folds 3730 have been completed by the addition of a fold 3 73 0 to the fold 3 73 0 shown in illustration (a). Therefore, in the area of these bends 3730, a triple thickness of the sheet material used for forming the flat tube in a part 3,710 is formed.

At the manufacturing stage shown in illustration (c) daFIG. 46, the folds 3730 are beginning to form the narrow second 3720 of the flat tube 3710 by bending of the folds 3730. In this intermediate step of the fabrication process, the gradation 3758 is formed on one broad side 3722 substantially adjacent to the folds 3730 for the provision. of a smooth outer surface of the flat tube in one piece 3710. The gradation 3758 may also be formed on the other wide side 3,724 substantially adjacent to the bends 3730 in an alternate construction of the tube 3710. The smooth surface of the tube 3710 produced by these gradations 3,758 and its ability to receiving a recess 3730 or longitudinal edge 3778 in a recessed manner may be advantageous in cases where tube 3710 needs to be brazed, welded or glued to other elements.

Next, at the manufacturing stage shown in illustration (d) of FIG. 46, a corrugated inner insert 3734 is inserted into the flat tube 3710, although inserts having any of the other shapes described herein may be used instead. One of the longitudinal edges 3738 of the corrugated inner insert 3,734 may be placed first in the small arc 3,762 of the longitudinal edge 3782. Alternatively, a longitudinal edge 3740 of an internal insertion 3734 may be first placed in a narrow nip 3720 opposite the small arc 3762 as shown in FIGS. 46 and 47. Inner insert 3734 may be under some preliminary pull when inserted into the stage shown in illustration (d) of FIG. 46 and FIG. 47. More specifically, the insert 3734 may have a traction by pulling the insert 3734 slightly away from the shoulder 3724 or forcing an expansion of the insert 3734 against a compression necessary to place the insert 3734 inside the flat tube 3710, and thus is pushed to the sides. 3718, 3720 during complete closure of the one-piece flat tube 3710. At the manufacturing stage shown in illustration (e) of FIG. 46, a large arc 3766 is formed at longitudinal edge 3778 and is placed around a small arc 3762 at the other longitudinal edge 3782, thereby closing the flat tube in one piece 3710. The aforementioned small curvature of the internal insert 3734 (if present) is thus removed, and both shaped longitudinal edges 3,738, 3740 of the inner insert 3734 are installed within the narrow sides 3718, 3720 of the flat tube 3710.

The process for forming the one-piece flat tube3810 illustrated in FIG. 48 is similar in many respects to that described above with reference to the embodiment of FIGS. 46 and 47. Therefore, with the exception of features described hereinafter and any inconsistent or incompatible description above, a reference is thus made to the above description with reference to the manufacture of the flat tube. 3710 for further information regarding the manufacture of 3810 flat tube.

At the manufacturing stage shown in illustration (a) ofFIG. 48, the only sheet of material used for the flat tube forming 3810 includes a bend 3830 of partially defining the second narrow side 3820 of the flat tube in a part 3810. After producing another overlapping bend at the same location as the single sheet of material, the sheet of material is flexed at the location as best shown in illustration (c) of FIG. 48. The first reinforced narrow side 3,818 is formed at least partially from the opposite longitudinal edges3878, 3882 placed together to close the one-piece tuboplane 3810 (see illustrations (d) and (e) of FIG. 48). A one-piece flat tube closure 3810 occurs through a joint bending or folding of the opposing longitudinal edges 3878, 3882 and a longitudinal edge 3838 of the inner insert 3834. More specifically, the longitudinal edge 3838 of the inner insert 3834 lies between the two longitudinal edges 3878 , 3882. It should be noted that the flat tube 3810 shown in illustration (f) of FIG. 48 is not necessarily in a final manufacturing stage. The folds defined by the edges 3878, 3882, 3838 may be arranged against each other FIG. 14 and 15. However, as mentioned above, any of the other reinforced narrow-side bend constructs described and / or illustrated herein may be used instead as desired. In general, the number of folds or bends made for production of the narrow side 3818 at least partially determines the stability of the narrow side 3818.

If desired, flat tubes 3710, 3810 illustrated in FIGS. 46-48 may be provided with reinforcements placed in predetermined areas, such as locations on one or both broad sides 3722, 3724, 3822, 3824 of flat tubes 3710, 3810, where heat exchange is expected to occur. The reinforcements may take any number of different shapes, such as one or more layers of sheet material separated from the sheet material defining the flat tubes 3710, 3810 and affixed by brazing, welding, or in any other suitable manner, one or more additional folds of the sheet material. used for the construction of flat tubes 3710, 3810, and the like.

Due to the relatively finely described wall material used above in some embodiments for the construction of flat tubes 3710, 3810 (with or without reinforcements), the weight of a heat exchanger formed with flat tubes 3710,3810 can be significantly reduced while improving capacity. heat exchange. One reason for the reduced weight and increased heat exchange capacity is that the wide sides 3722, 3724, 3822, 3824 with flat tube 3710, 3810 are formed so that the tubes 3710, 3810 ensure good brazed connections with fins, ribs or other elements. heat exchanger (not shown) which can be arranged in a heat exchanger between two or more of the 3710, 3810 flat tubes. Combining the features of the one-piece flat tube 3710, 3810 described above, the 3710, 3810 flat tubes have a substantially flat external surface area for connection to these heat exchange elements.

Additionally, it is to be understood that the characteristics of flat tubes 3710, 3810 described with respect to FIGs. 46-48 may also be applied to any of the other evaporator constructions (3) described in this application. With respect to the manner in which flat tubes 3710,3810 can be manufactured in some embodiments endless sheets of sheet material are fed for a roller conveyor line 3701 as illustrated in FIG. 49. In many cases, aluminum or an aluminum alloy is considered a preferred material for the manufacture of flat tubes 3710, 3810. However, other metals and materials are suitable for the manufacture of tuboplane 3710, 3810. With reference to tubes 3710, 3810 shown in FIGS. . 46-48, the first and second portion forming material sheet 3712, 3714, 3812, 3814 of tuboplane 3710, 3810 may be received from an endless strip of material (e.g. sheet metal), and the inner insert 3734 3834 may be formed from an endless array of material (e.g. sheet metal). In one of the beginning stages of the roller conveyor line 3701 (prior to forming the strips of material, in some embodiments), perforations may be added to the material strips at distances corresponding to the individual tube lengths. In some embodiments, sheets of material may be formed after perforation of sheet metal strips, although perforation may occur during or after deflection. As shown in FIG. 49, an insertion area 3703 in which the inner insert 3734, 3834 is inserted into the flat tube 3710, 3810 is located in a downstream portion of the roller conveyor line 3701. Prior to insertion of the inner insert 3734, 3834 in the flat tube in a part 3710, 3810, the above-mentioned perforations should be substantially aligned with each other (i.e. all being in a common plane substantially perpendicular to the flat tube in one piece 3710, 3810 and some embodiments) so that individual tubes 3710,3810 can be separated thereafter.

The embodiments in a flat tube piece illustrated in FIG. 46-48 each have an insert 3734, 3834 which is separated from and received with a respective flat tube 3710,3810. In other embodiments, however, the inventors have found that it is possible to construct a flat tube in one piece by having an insert integrally formed with the tube in one piece (i.e., formed from the same unit piece of sheet material used to construct the flat tube3710, 3810). Five such flat tubes 3910, 4010, 4110,4210, 4310 are illustrated in FIGs. 50-54 by way of example. It should be noted that the features described below with reference to FIGs. 50-54 also apply to any of the other flat tube embodiments described herein, except features that are inconsistent or incompatible with this.

In each of the illustrated embodiments of FIG. 50 to 54, a single piece of sheet material (e.g., a sheet metal strip, for example) is formed for tuboplane 3910, 4010, 4110, 4210, 4310 and an insert 3934,4034, 4134, 4234, 4334. The flat tubes 3910, 4010, 4110,4210, 4310 illustrated in FIGs. 50-54 include opposite reinforced narrow sides 3918, 3920, 4018, 4020, 4118,4120, 4218, 4220, 4318, 4320 relatively low wall thicknesses. In some embodiments, the inventors have found that the thickness of the sheet material may be less than about 0.15 mm (0.0059055 in) to provide good performance results in many applications. Also, in some embodiments, the inventors have found that the thickness The material sheet thickness may be greater than about 0.03 mm (approximately 0.0011811 in) to provide good performance results in many applications. It is to be understood that the thickness of the material sheet may have other dimensions not listed here. As a result of these relatively thin sheet material thicknesses which may be used in some embodiments, heat exchangers with these flat tubes 3910, 4010, 4110, 4210, 4310 may have a comparatively low weight and an improved heat loss rate. Also, by virtue of the fact that both narrow sides 3918, 3920, 4018, 4020, 4118,4120, 4218, 4220, 4318, 4320 of the flat tubes in one piece 3910, 4010, 4110, 4210, 4310 can be reinforced as described below. In more detail below, the need to denote the orientation of the flat tubes in one piece 3,910, 4,010,4110, 4210, 4310 while mounting a heat exchanger can be reduced or eliminated.

Each of the tubes described below with respect to FIG. 50 to 54 may have any of the dimensions described above with reference to the embodiments of FIG. 1 to 34. For example, in some embodiments, any of the one-piece flat tubes 3910, 4010, 4110, 4210, 4310 illustrated in FIG. 50 to 54 may have a small diameter d greater than about 0.7 mm (0.027559 in). Also, in some embodiments, any of these tubes 3910, 4010, 4110, 4210, 4310 may have a small diameter d of less than about 15 mm (0.59055 in). As another example, any of the one-piece flat tubes 3910, 4010, 4110, 4210, 4310 illustrated in FIG. 50-54 may have a large diameter D greater than around 8 mm (0.31496 in). Also, in some embodiments, any of these tubes 3910, 4010, 4110, 4210, 4310 may have a large diameter D of less than about 300 mm (11.811 in). However, it should be noted that in other embodiments, any of the small and large diameters d, D described above with respect to all tuboplane embodiments shown herein may be used.

With particular reference first to the illustrated embodiment of FIG. 50, the flat tube 3,910 shown therein is formed of a single sheet of material having a central portion 3,905 shaped in a wave-like manner to form flow channels 3,916 in the flat tube in a resulting part 3910. The central portion 3905 of the material sheet is flanked on both sides by bend assemblies 3 93 0 used to reinforce a corresponding narrow side 3918, 3920 of the flat tube in one piece 3910. In other embodiments, the central portion 3905 is flanked on only one side by bend assemblies 3 93 0 ( such as where only a narrow side 3918, 3920 of the one-piece tuboplane 3910 needs to be reinforced in this way). Also, it should be noted that the central portion 3905 can be flanked on either side by any number of reinforcing folds, and that the folds need not necessarily be of the same number, shape or size on opposite sides of the central portion 3905. In the illustrated embodiment of FIG. 50, the sheet material also outer timings 3907 defining the broad sides 3922, 3924 of the flat tube in one piece 3910. The outer portions 3907 extend from and are integral with the folding assemblies 3,900 described above and are shaped to develop by least partially the fold sets3930. In other embodiments, the outer portions 3907 do not fully engage or engage the folds 3,930, in which case the outer portions 3,907 are flexed to at least close the flow channels 3916 within the tuboplane in one piece 3910. Also, it should be noted that the sheet material is formed for the definition of only one outer portion (e.g., extending from the folds and only one side of the central portion 3,905), which may extend around the central portion 3905 to close the flow chambers 3916.

In some embodiments, the flat tube 3,910 shown in FIG. 50 may be efficiently produced in a roll-up line (such as roll line 3701 shown in FIG. 49) from an endless sheet of material, such as a sheet metal strip or belt 3909 or other suitable material as shown. in FIG. 50 (a). Material strip 3909 includes two longitudinal edges 3938, 3940. First, and as shown in FIG. 50 (b), two multi-ply assemblies 3 990 are created on the material strip 3909 to form narrow sides 3918, 3920 and the flat tube 3910 to be created later. Each illustrated multi-fold assembly 3 990 is formed by six 180 ° bends in the strip of material 3909, where adjacent folds 3 990 abut each other with little or no space between the adjacent folds 3 990 between the bends defining the 3 930 folds. The spaces shown between the folds 3930 illustrated in FIG. 50 are for illustration purposes only to show individual folds 3 93 0 in greater detail. Moreover, although six folds 3930 are shown in the set illustrated in FIG. 50, it should be noted that any other number of folds 3930 may exist adjacent central portion 3905 as described above, determined in many embodiments at least in part by the desired specifications (e.g. dimensions) of tuboplane 3910.

As shown in FIG. 50 (c), a staggered section 3911 is then formed between the multi-fold sets 3930. However, in other embodiments, the waveform section 3911 may instead be formed at the same time or subsequent to the formation of the 3930 folds. Wave 3911 may have any number of corrugations of any desired shape, including without limitation corrugations with inclined flows with respect to the broad sides 3922, 3924 of the flat tube in one piece 3910 once assembled, corrugations having a square wave shape, corrugations having a curved waveform. (for example, a sine wave), corrugations having any other format described here, and any combination of these formats.

The manufacturing process for forming the flat tube 3910 in FIG. (D) proceeds according to the arrows shown with dashed lines. In particular, subsequent to the formation of folds 3930 and wave type section 3911, belt sections 3913 connected to the multi-fold sets 3930 are placed around corresponding corresponding folds 3930 and through wave section 3911, thereby forming flow channels which extend. lengthwise 3916 of the flat tube in one piece. In other words, each wrapped strap section 3913 at least partially surrounds a plurality of folds 3930 from the outside and further extends to cover wave type section 3911. Also, a longitudinal edge 3978 is flexed to be on the first right side 3 918 and to extend around and engage the multiple folds 3230 on the first narrow side 3918, and the other longitudinal edge 3980 is flexed to be on the second narrow side 3920 and to extend around the multiple folds 3230 on the second narrow side 3920, as shown in the illustrations. (c) and (d) of FIG.50. In some embodiments of the flat tube 3910, the longitudinal edges 3978, 3980 do not or only partially cover the corresponding narrow sides 3918, 3920, because the narrow sides 3928, 3920 may be sufficiently stable by providing the multiple bends 3930 described above.

In a complete version of the flat tube 3,910, as shown in FIG. 50 (d), the wave peaks and wave valleys of wave type section 3911 (or other centrally deposited features 3905 having different shapes defining flow channels 3,916) are brazed, welded, or otherwise secured to one or more both sides 3,922, 3,924 of the flat tube in one piece 3,910. More specifically, the points on the wave peaks and valleys shown in FIG. 50 (d) schematically illustrate the brazed connections that may be made between wave type section 3911 and adjacent wide sides 3922, 3924.

FIG. 51 illustrates a one-piece flat tube with an integral insertion according to a further embodiment of the present invention. This embodiment employs much of the same structure and has many of the same properties as the flat tube modalities described above with respect to FIGS. 50. Accordingly, the following description focuses primarily on the structure and features that are different from the modalities described above with respect to FIGS. 50. A reference should be made to the above description with respect to FIGs. 50 for additional information regarding structure and features, and possible alternatives to the structure and features of the flat tube in one piece with an integral insert illustrated in FIG. 51e described below. The structure and features of the modality shown in FIG. 51 corresponding to the structure and features of the embodiment of FIG. 50 are designated below in the 4000 series reference numbers.

With particular reference now to FIG. 51, the one-piece tuboplane 4010 shown therein is formed from a sheet of material (e.g., the sheet metal strip). In this particular embodiment, a central portion 4005 of the sheet of material is shaped in a wave-like manner to produce a wave-like section at least partially forming the flow channels 4016 located between the broad sides 4022, 4024 of the flat tube 4010. Center appendage 4005 may have any of the formats described above with reference to the illustrated embodiment of FIG. 50

As an alternative to or in addition to the use of multiple bends 3930 to reinforce the narrow ends 3918,3920 of the one-piece flat tube 3910 (see FIG. 50), the one-piece flat tube 4010 illustrated in FIG. 51 uses profiles 4015 (i.e. wire reels, chucks, solid or solid inserts, and the like) on narrow sides 4018,4020. A profile 4015 may be located on one or both narrow sides 4018, 4020, and in some embodiments may supplement one or more folds produced on one or both narrow sides 4018, 4020, where these folds are similar to the folds 3030 described above with respect to FIGs. 50 During the process of fabricating the flat tube in one piece 4010, the profile 4015 may be unwound or otherwise deposited longitudinally parallel to the material sheet 4009. Subsequent to the processing of wave section 4011 between the placed profiles 4015, decking sections 4013 of the material sheet adjacent to the profiles 4015 are wrapped around the profiles 4015 from the outside, and are deposited through the wave type section 4011 to form the broad sides 4022, 4024 of the flat tube in one piece 4010 as shown by the dotted arrows in FIG. 51. Belt sections 4013 are connected to wave section 4011, and may also be connected to profiles 4015 on narrow sides 4018, 4020. Also, each of the longitudinal edges 4078, 4080 of sheet material 4009 is bent around a corresponding profile. 4,015 placed on a respective narrow side 4018, 4020.

Accordingly, the narrow sides 4018, 4020 of the one-piece tuboplane 4,010 in FIG. 51 are each formed from a profile 4015 so that the narrow sides 4018, 4020 are surrounded by a corresponding longitudinal edge 4078, 4080 of the sheet material 4009.

FIGs. 52 to 54 illustrate one-piece flat tubes with integral inserts in accordance with further embodiments of the present invention. These embodiments employ much of the same structure and have many of the same properties as the flat tube modalities described above with respect to FIGS. 50 and 51. Accordingly, the following description focuses primarily on the structure and features which are different from the modalities described above with respect to FIGS. 50 and 51. A reference should be made to the above description with respect to FIGs. 50 and 51 for additional structure and feature information, and possible alternatives to the structure and features of flat tubes in a fully inserted part illustrated in FIGS. 52-54 and described below. The structure and features of the embodiments shown in FIGs. 52, 53, and 54 which correspond to the structure and resources of the FIGs. 50 and 51 are hereinafter referred to in the series reference numerals 4100, 4200, and 4300, respectively.

FIGs. 52 to 54 each illustrate exemplary embodiments of a 4110, 4210, 4310 flat tube formed from a single sheet of material 4109, 4209, 4309 (e.g., an aluminum strip, aluminum alloy or other metal or suitable material), and show these flat tubes4110, 4210, 4310 before complete formation. In these particular embodiments of the flat tube 4110, 4210, 4310, a portion 4105, 4205, 4305 of the sheet material 4109,4209, 4309 is waveform shaped and extends between the wide sides 4122, 4222, 4322 of tubular 4110 , 4210, 4310 to form flow channels 4116, 4216, 4316. Additionally, each of the right sides 4118, 4120, 4218, 4220, 4318, 4320 is formed at least partially by a connecting section 4117, 4119.4217, 4219, 4317, 4319 of sheet material 4109, 4209,4309 and the longitudinal edge 4178, 4180, 4278, 4280, 4378,4380 surrounding the connecting section 4117, 4119, 4217, 4219,4317, 4319.

In the illustrated embodiments of FIG. 52 and 53, the overlapping longitudinal edges 4178, 4180, 4278, 4280 and connecting sections 4117, 4119, 4217, 4219 provide a double wall thickness on the narrow sides 4118, 4120,4218, 4220, which is generally stable enough to be numerous. flat tube applications 4110, 4210, 4310 where relatively thin walled materials (described above) are used. In other embodiments, such as the illustrated embodiment of FIG. 54, a relatively more narrow-sided reinforcement 4118, 4120, 4218, 4220 may be obtained through one or more folds 4330 of the connecting sections 4317, 4319. In other words, those portions of the material sheet 4309 that will be overlapped by the longitudinal edges 4378, 4380 on the narrow sides 4318, 4320 may be further reinforced by one or more folds4330. In such embodiments, these folds 4330 are shaped (e.g., rounded) to at least partially define the narrow sides 4318, 4320 when the sheet material 43 09 is flexed to place the first and second wide sides 4322, 4324 in their closed positions. Alternatively or additionally, longitudinal edges 4378, 4380 on narrow sides 4318,4320 may be provided with one or more of these reinforcing folds 4330 in a manner similar to the Group D tubular embodiments illustrated in FIG. 34, for example. In these modalities using 4330 reinforcing bends, the right sides 4318, 4320 include a relatively thicker thickness than the thicknesses of the waveform section 4311 and the broad sides 4322, 4324. Thus, sufficient reinforcement can be provided for the relatively stronger tensioned portions of the tube. 4310, such as the narrow sides 4318, 4320, and leaving relatively tightly stretched parts, such as the broad sides 4322, 4324e and / or the relatively thinner walled wave type section 311.

Although the reinforcing folds 4330 may be employed in any of the narrow side locations described above with respect to FIGs. 52-54, it should be noted that either narrow side 4118, 4120, 4218, 4220,4318, 4320 may be devoid of such reinforcing folds in other embodiments. Also, the number of these 4130, 4230, 4330 reinforcing folds on one narrow side 4138.4238, 4318 may differ from the number on the other right side 4120, 4220, 4320, and / or the location of the 4130, 4230, 4330 reinforcing folds on one of the narrow sides (for example, only at the connection section 4117, 4119, 4217, 4219,4317, 4319 or only at a longitudinal edge 4178, 4180,4278, 4280, 4378, 4380 overlapping the connection section4117, 4119, 4217, 4219, 4317, 4319) may differ from the location of the 4130, 4230, 4330 reinforcement folds in the narrow other (e.g., only at the longitudinal edge 4178, 4180, 4278, 4280, 4378, 4380 or only in the disconnect section 4117, 4119 , 4217, 4219, 4317, 4319 overlapped by the longitudinal edge 4178, 4180, 4278, 4280, 4378, 4380, respectively).

In any of the embodiments just described with respect to the one piece flat tubes 4110, 4210, 4310 illustrated in FIGs. 52-54, the overlapping longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380 of sheet material 4109, 4209, 4309 may be in a wall gradation 4158, 4160, 4258, 4260, 4358, 4360, ambient temperature as a wall 4158, 4160, 4258,4260, 4358, 4360 located near or on the narrow side 4118, 4218 on which the longitudinal edge 4178, 4180, 4278,4280, 4378, 4380 is located. In this way, when the longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380 are moved toward their closed positions for forming the flat tube in one piece 4110, 4210, 4310 (shown by the dashed lines on each of FIGS. 52-54) , the longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380 may be received in the wall gradations 4158, 4160, 4258, 4260,4358, 4360 so enveloped. In some embodiments, a wall gradation 4158, 4160, 4258, 4260, 4358, 4360 is provided on each wide side 4122, 4124, 4222, 4224, 4322,4324 of the flat tube 4110, 4210, 4310.

As with the illustrated embodiment of FIG. 51, the wave peaks and wave valleys of wave type sections 4111,4211, 4311 (or other features of central portion 4105,4205, 4305 having different shapes defined the flow channels 4116, 4216, 4316) illustrated in FIGS. 52-54 may be brazed, welded or otherwise fastened to one or both broad sides 4122, 4124, 4222,4224, 4322, 4324 of the flat tube in one piece 4110, 4210,4310.

As mentioned above, each of the flat tubes in one piece 4110, 4210, 4310 illustrated in FIGs. 52-54 has a waveform section 4111, 4211, 4311 for defining flow channels 4116, 4216, 4316. The 4105, 4205, 4305 portion defined in this waveform section 4111, 4211, 4311 can have any of the formats described above with reference to the illustrated embodiment of FIG. In the embodiments illustrated in FIG. 52 and 54, for example, wave type section 4111.4 311 defines multiple flow channels 4116, 4316 having a generally triangular design and generally having the same cross-sectional area size and format (although one or both may vary across the width of the flat tube in one piece 4110, 4310). FIG. 53 illustrates a 4211 bead type section provided with more than one wave design, so that the 4211 bend type section forms flow channels 4216 by minus two different cross-sectional sizes. Wave type section 4211 shown in FIG. 53 includes a group of seven flow channels 4216 each having a relatively large cross-sectional area, and another group of seven channels 4216 each having a relatively smaller cross-sectional area. In other embodiments, any other combination of flow channel shapes and sizes arranged in flat tube sections in one piece 4210 may be employed. Certain requirements for a heat exchange may be better considered with these illustrations of the heat exchanger tube 4210. Although the cross-sectional shape of these variable flow channels 4216 is generally rectangular in FIG. 53, it is anticipated that the waveform section 4216 can define flow channels 4216 with other shapes, based at least in part on the desired specifications of the 4210 flat tube. As indicated above, the design of the waveform section W is not limited to the design. Any of the flat tubes described herein can be produced in many different ways. However, by using one or more fabrication improvements discovered by the inventors and described in greater detail below, these tubes can be produced at significant cost efficiencies at a higher speed, and / or in a more reliable and reproducible manner compared to many. conventional flat tube manufacturing techniques.

An improvement such as that discovered by the inventors relates to the manner in which the flat tubes according to the present invention can be separated from a flat pipe end length (i.e. from a continuous supply of materials fed through the manufacturing equipment), thereby resulting in discrete pipe planes having desired lengths. As used herein and in the appended claims, the term "end pipes" is used to refer to a flat pipe according to any of the embodiments described herein produced by forming one or more sheets of material flowing from respective supplies (e.g., coils). ) before separation into discrete tubes at desired lengths and therefore incorporates the previous definition of "endless" described above. It will be appreciated by those skilled in the art that there are significant challenges in cutting or separating elements otherwise constructed at least in part from relatively thin walled products without creating deformations, smudges, brilliance or other undesirable features in the end products. While there are similar problems with products constructed of thicker wall materials (which can be considered equally with some improvements described below), in many cases these problems most often result in unacceptable thin-walled end products. With reference to the thin-walled flat tube modalities described herein, many of these embodiments have a tube wall thickness no greater than about 0.15 mm (0.00591 in). Pipe walls may have a thickness of at least around 0.03 mm (0.0011811 in) in some embodiments. Also, in those pipe mounting embodiments having an insertion as described herein, many of these embodiments have a thickness of insertion material not larger than about 0.10 mm (0.003937 in). Insertion material thickness may be no less than about 0.03 mm (0.00118 in) in some embodiments.

The inventors have found that individual (i.e. discrete) flat tubes can be produced in a superior manner from an endless pipe of one or more sheets of material fed through a fabrication equipment by perforating at least one of the sheets. At least a portion of the pipe may be drilled to facilitate improved separation of endless tubing pipe. Such perforations may occur before forming operations are performed on the upstream sheet material, after the sheet material has formed a continuous length of flat tubing, or at any other stage or stages in between. Also, the locations of these perforations may vary between the different material sheets (or different locations on the same material sheet) used to produce different portions of the continuous flat tubing.

An advantage of the formation of perforations in the sheet metal strip for making flat tubes is that in some embodiments, flat tubes can be produced substantially without the formation of deformations, dregs, glares and / or other undesirable features of the end products. The process of using perforations in a pipe splitting process can be applied to any of the pipe modalities described herein.

As an example of the drilling and separation process used for producing one piece flat tubes, reference is thus made to the process of separating one piece flat tubes such as those illustrated in FIGS. 19-21, 52, and 53, wherein the one-piece flat tube 1210,1310, 1410, 4110, 4210 can be formed from a single endless sheet of material. In FIGs. 52 and 53, the one-piece flat tubes 4110, 4210 are shown in a manufacturing process state shortly before completion, and should still be closed in the direction of the arrows shown in dotted lines before being separated into the preferences already made. Accordingly, perforations may be formed prior to bending the sheet of material as shown in FIGS. 52 and 53. A similar concept may apply to tubes 1210, 1310, 1410 shown in FIGs. 19-21 and other one-piece flat tubes described herein.

As an example of this process used for producing two-piece flat tubes, a reference is thus made to the process of separating two-piece flat tubes as described in FIG. 28. As described in more detail above, the two-piece flat tube 1910 shown in FIG. 28 has first and second portions 1912,1914 defining respective broad sides 1922, 1924 of tuboplane 1910, and an insert 1934 received therebetween.

As also described above, first and second portions 1912, 1914 may be identical or substantially identical, but reversed with respect to each other, wherein one of the longitudinal edges of a tube portion 1914 has a larger arc portion 1968 at least partially surrounding the minor arc portion 1962 in one longitudinalalignal of the other tube portion 1912. Bends 1970 in one or both of the longitudinal edges 1938, 1940 of insert 1934 may be used to reinforce the narrow sides 1918, 1920 of the two-piece flat tube 1910. Although the drilling and separation process described herein may be applied to two-piece flat tubes having any of the tube and tube part dimensions described above with respect to the embodiment of FIG. 19, insert 1934 described with reference to FIGs. 55-58 has a thickness of about 0.03 - 0.09 mm (0.0011811 - 0.0035433 in), the sheets of material forming the first and second tube portions1912, 1914 have a thickness of around 0 .03 - 0.15 mm (0.0011811 - 0.0059055 in), and the flat tube completed in two pieces 1910 has a small diameter d of about 1-10 mm (0.03937 - 0.3937 in) to example title only. In FIG. 28, the two-piece flat tube 1910 is illustrated shortly before a conclusion, where the perforations are already formed in the first and second portions 1912, 1914 and the insert 1934, and have been reconciled so that the perforations in the first and second portions 1912, 1914 and the insertion 1934 are substantially aligned.

FIGs. 55 to 58 illustrate an example 1900 manufacturing line similar to the 3701 manufacturing line shown in FIG. 49. In this particular case, the manufacturing line 1900 is designed to form the three-piece flat tube assemblies (i.e., having a two-piece first and second part flat tube 1912, 1914, and also having an insertion 1934), while the Manufacturing line 3701 is designed for forming two-piece flat tube assemblies (that is, having a flat tube in one piece defining the first and second portions 1212, 1214, 1312,1314, 1412, 1414, 4112, 4114, 4212, 4214 , and also had an insertion 1234, 1334, 1434, 4134, 4234). Although manufacturing lines 3701, 1900 are described herein with reference to the production of particular flat tube embodiments also described in this patent application, that is by way of example only. Accordingly, it is to be understood that the processes described with reference to FIG. 49 and FIG. 55-58 may be applied for the manufacture of all tubes described in this application.

As shown in FIG. 55, manufacturing line 1900 includes three coils of sheet material RI, R2, R3, such as aluminum foil, aluminum alloy, or other material suitable for forming three-piece tubular assemblies. In this particular example, a sheet material from the first coil R1 is used for the production of a first portion 1912 or 1914, a sheet material from the third coil R3 is used for the production of a second portion 1914 or 1912, and a material in Second coil sheet R2 is used for production of insert 1934 for two-piece flat tube1910. Depending, at least in part, on the paths of the material sheets, other possible positions of the reels with respect to a manufacturing line, and the orientation resulting from the flat tube 1910 as it proceeds through the manufacturing process, each reel RI, R2, R3 may have a material Sheet metal used for the production of any portion of the 1910 flat tube in other modalities.

FIG. 55 illustrates roller assemblies 1921, 1923, 1925 for processing sheet material provided from coils R1, R2, and R3, respectively. Each set of rollers 1921, 1923, 1925 may be arranged for the definition of a respective sheet material travel loop as shown schematically in FIG. 55, although any other arrangement of rollers is possible. Any or more of the rollers in each set 1921, 1923, 1925 may be driven by a suitable motor or prime mover, so as to stretch the material being provided by coils R1, R2, and R3. Also, any one or more of the rollers together 1921, 1923, 1925 may be of crazy rollers allowing the free travel of a corresponding sheet of material thereon. Further, any of the rollers in each assembly 1921, 1923, 1925 can perform both functions, such as by being selectively driven through a clutch, or otherwise selectively activated in any other conventional manner. It will also be appreciated that coils of material R1, R2, R3 may only be driven by suitable motors or other primary drives. By way of example, it is envisaged that sheets of material supplied from coils R1, R2, and R3 may move in some embodiments at a linear velocity of about 100 - 200 m / min. (328.08 - 656.16ft / min.). Slower or faster speeds are possible in other modalities.

By controlling the motor (s) by driving each material spool RI, R2, R3 and / or driving any of the rollers in the roll sets 1921, 1923, 1925, it is possible to control the speed of each sheet of material, such as by selectively providing a force. braking on any of the sheets of material. In some embodiments, this allows the speed of each sheet of material to be controlled independently of the others - even to the stopping point of one or two of the sheets while moving the others. Also, the roller assemblies1921, 1923, 1925 may function to allow some damping of the sheet material supplied to downstream paralocations.

Manufacturing line 1900 illustrated in FIG. 55 includes a first perforation station 1927 for forming perforations 1929 in the sheet of material received from the second coil R2 (for the production of insert 1934 in a posterior flat tube 1910). This 1927 drilling station is located at the beginning of the 1900 inFIG manufacturing line. 55, but may instead be downstream from other modalities. Subsequently, the sheet of material forming the insert 1934 is formed by a set of rollers shown schematically in FIG.55 as a forming section 1931. The sheets of material from the first and third coils R1, R3 (for producing the first and second portions) 1912, 1914 in a posterior flat tube 1910) are carried along the distance defined by the formation section 1931.

Subsequently, sheet material from the first coil R1 reaches a second punch station 1933, and sheet material from the third reel R3 reaches a third punch station 1935 adjacent to the second punch station 1933. In other embodiments, the three punch stations 1927, 1933, 1935 may be in different locations with respect to each other and / or other portions of the 1900 manufacturing line. Also, in other embodiments, one or more of the drilling stations 1927, 1933, 1935 may be used for drilling more than one Material sheet.

With continued reference to the illustrated mode of FIG. 55, the second and third perforation stations 193,1935 form perforations 1929 in the first and third sheets of material for the first and second portions 1912, 1914 of the flat tube 1910, respectively, while the second insert sheet 1934 is passed between the first and third sheets. at the second and third drilling stations 1933, 1935. An example of perforations produced at the second and third drilling stations is shown in FIG. 57, and may be similar to the perforations produced in the first drilling station 1927 described above. Namodality of FIGs. 57, perforations 1929 are relatively thin apertures separated by souls 1937 located at predetermined spacings between perforations 1929. However, in other embodiments perforations may each be areas of reduced thickness of the material, and need not be defined by the apertures through the material. In any case, the description here referring to the shape, size and other features of the holes applies equally.

The souls 1937 are ruptured as part of the flat tube manufacturing process 1910. In some embodiments, the length of the perforations 1929 extending in the transverse direction of the perforated sheets of material (from the first, second or third coils R1, R2, and R3) is. at least 1 cm (0.3937 in). Also, in some embodiments the length of each web 197 is less than 1 mm (0.03937 in).

The shape (e.g. length) and arrangement of the holes 192 9 illustrated in FIG. 57 are given by way of example only. Longer or shorter perforations 1929 and longer or shorter souls 1937 may be used as desired on any of the sheets of material used for forming the flat tube 1910. For example, each of the perforations 1929 may instead be substantially rounded or may assume other desired formats, potentially resulting in fewer or more perforations through the sheet of material. Also, for example, the length or other shape features of perforations 1929 may vary across the width of the sheet of material being perforated, such as by providing perforations and / or souls near the longitudinal edges of the sheet that are longer than those in the center of the sheet, or vice versa. The types and features of the 1929 perforations depend, at least in part, on the material properties of the sheet being perforated. Based on the perforation dimensions and the relatively thin sheet materials that can be used, as described above, in some embodiments 1937 perforations generally do not are visible to the naked eye.

For many fabrication operations, advantages may be gained by locating a web 1937 near the longitudinal edge of a sheet of material being perforated, thereby reducing the opportunity for parts of the material sheet to accumulate at these locations during further processing of the sheet.

In those flat tube embodiments described herein in which one or more sheets of material (e.g. sheet metal strips) are used for the production of a tuboplane, the sheets of material may be punched for separation in the perforations. In those embodiments in which two or more sheets of material are used for the production of a flat tube, two or more sheets may be perforated, after which time the perforations in the different sheets may be aligned (for example, in a common plane substantially perpendicular to the sheets, the direction leaves, and / or the flat tube produced by the sheets), and individual tubes may be separated into the perforations from the continuous length of heaping material. The newly written punch alignment can be achieved in some embodiments by controlling the speed of one or more drives by feeding one or more of the material sheets through the fabrication process. More specifically, if perforations of any two or more sheets of material are not yet aligned, one or more of the sheets may be moved at different speeds until the perforations are aligned to be able to separate individual tubes at a downstream location. In this regard, it should be noted that this alignment process can occur for any number of perforated sheets of material being used for the production of flat tubes.

For example, and with continued reference to the modalities of FIG. 55 to 58, the 1929 perforations in the three material sheets from the coils RI, R2, and R3 are aligned in an alignment section 193 9 of the manufacturing line 1900 by one or more controlled drives for adjusting the speeds of the material sheets with respect to each other. . In light of the fact that speed adjustments of one or more of the sheets may be required for alignment of perforations 1929, the alignment section 1939 of FIG. 55 is generally placed on the 1900 assembly line for a 1941 melt section. The 1941 melt section is an area of the manufacturing line in which the flat tube parts 1910 (e.g., the first and second portions 1912, 1914 and insert 1934, in the illustrated embodiment) are connected to one another for forming flat tube 1910. Fusion section 1941 may include rollers or other sheet-forming elements for fusing parts of flat tube 1910 to form an endless tube 1910. In those embodiments wherein none or only some of the longitudinal edges of the first and second tube portions 1912,1914 have not yet been formed in one or more heaving locations, the fusing section 1941 may also include rollose / or other sheet forming elements for carrying out other forming operations. conformation at the longitudinal edges of the first and second portions 1912, 1914.

The continuous length of immediately assembling material from this separation location may be a continuous length of completed flat tubing.

Alternatively, the continuous length of material immediately upstream of this separation location may be from sheet (s) of material used for forming the flat pipe at any stage of this formation. For example, in some embodiments, after perforations in the material sheets have been aligned, partially formed sheets of material may be combined into a continuous length of completed flat tubing so that completed tubing is available after separation. As a result, individual tubes may be quoted, which have no imprints on the tuboplane ends.

In some fabrication line constructions, the perforations are usually formed by one or more perforation rollers. For example, the manufacturing line may include at least one pair of punch rollers. One of the pair rollers may run with one or more sheets of endless material which will be used to form at least part of the flat tube, and the other pair roll may be equipped with a tool (for example, one or more perforating blades or stamps). for forming perforations in the sheet (s) of material. FIGs. 56 and 57 illustrate schematically a drilling process according to one embodiment of the present invention. For ease of description, the following description is with reference to the first drilling station 1927 described above. However, the same description applies equally to the other drilling stations 1933, 1935 in the illustrated embodiment of FIG. 55-58, although one or more of the drilling stations may be different in other embodiments (for example, they may have different blades, use only one single roll instead of two rolls, and the like). As previously described, the number and type of perforations, and locations of perforation stations may vary. Changes in these features may be based, at least in part, on the desired specifications of flat tube 1910 produced on manufacturing line 1900.

With reference to the embodiment of FIG. 56 and 57, perforation station 1927 includes a pair of perforation rollers having a first perforation roll 1943 and a second perforation roll 1945. In some embodiments, these perforation rollers 1943, 1945 may be arranged in any other desired orientation depending upon the part of the orientation of the perforated sheet by the perforation rollers 1943, 1945 and adjacent portions of the manufacturing line 1900. The first roll 1943 runs parallel to the eagle one or more of the passing material sheets (from coils R1, R2, and R3), while the lower roll 1945 has a punch design designed 1947.

To prevent sheet build-up as perforations are created, some embodiments of the present invention utilize perforation rollers with one or more perforation blades or stamping having a hold position. In the standby position, at least one of the drill rollers is rotated or moved to a position where sheet (s) of material pass freely through the drill rollers.

For example, the second roll 1945 illustrated in FIG. 56 has a drive mechanism (not shown) so that the second roll 1945 can hold the punching punch 1947 in a stand-by position in which the punching punch 197 does not fit into the sheets of material passing from the coils R1, R2, and R3. In the hold position of the second roll 1945, the punching punch 1947 may be rotated a distance from the position shown in FIG. 56 to prevent this engagement such as can be rotated approximately 90 degrees to a substantially horizontal position on the second roll 1945. In other embodiments, one or both rollers 1943, 1945 may be mounted on respective axes which are moved with respect to the sheet thereby passing. allowing itself or both rollers 1943, 1945 to translate with respect to the passing sheet and defining stand and punch positions or action.

For perforation of the sheet of material supplied from the second coil R2 (again with reference to the illustrated embodiment of FIG. 55-58 by way of example), the second roll 194 may be actuated to a perforation or action position such as for substantial vertical upper position shown in FIGS. 56 and 57. This tattooing may be performed by a motor, actuator, or other engagement connected to the second roller for rotation of the second roller from the hold position to drilling position or action at a rotation speed. In the punching position of the first and second rollers 1943, 1945, the punching stamp 1947 fits into the sheet of material supplied from the second coil R2, and forms perforations 1929 therein. In some embodiments, the rotational speed (and thus the circumferential speed) of the second roll 1945 is higher than the material sheet transport speed to ensure that the sheet material does not accumulate during drilling operations. In other embodiments, the rotational speeds (and therefore the circumferential speeds) of both rollers 1943, 1945 are higher than the speed of conveying the sheet of material for stiffness. It should be noted that the terms "action position" or "punch position" as used herein and in the appended claims not only indicate or imply that the roll (s) in question are stationary, but, instead, they are indicative of the positions of the roll (s) at which perforations are made.

In some embodiments, the rotation speed of one or both rollers 1943, 1945 of the punching station 1927 is faster than that of the sheet of passing material. Following the creation of the punches in the punching position, one or both of the punching rollers 1943, 1945 may be moved back to a standby position to be reactive in the next drilling process. In some embodiments, movement of one or both of the punch rollers 1943, 1945 back to a hold position is accomplished by rotating the punch roll (s) 1943, 1945 in the same direction used for movement of the roll (s). ) 1943, 1945 toward a punching position (rather than by switching the directions of rotation of the roll (s) 1943, 1945). Accordingly, actuation of the punching rollers 1943, 1945 as described above may help to prevent a buildup of the passing sheet of material.

It is envisaged that finished pipes may be separated at the end of a manufacturing process due at least in part to the perforations described above. In some embodiments, the pipes are separated into the perforations at or near the end of a manufacturing line. Separation of the individual tubes can be accomplished by some use of a pair of breaker rollers or a single breaker roller. In the embodiment of FIG. 58, for example, a rupture roller 194 9 and a bar 1951 are used for separating the endless tubing running between the rupture roller 194 9 and the bar 1951 in individual flat finished tubes 1910. The rupture roller 194 9 is equipped with a split blade. projected rupture 1951 or another tool for rupturing 1937 souls between the 1929 perforations described earlier.

Rupture roll 194 9 and / or bar 1951 may be controlled to include a holding position in which a through-pipe is not decelerated or otherwise operated, and a rupture position in which roller roll 194 9 and / or bar 1951 it is moved for fitting with through-pipe and for separation of the tube in the holes 1929. For example, in the illustrated embodiment of FIG. 58, the rupture roller 194 9 is rotatable to and from a rupture position in which the rupture blade 1951 of the rupture roller 194 9 fits into a flat tubing passed through the rupture bar 1951, thereby rupturing (and thus in some embodiments, also by cutting) the tubing running between the breaker roll 194 9 and the break bar1951 in a line of 1929 perforations. In other embodiments, the break roll 194 9 and / or the break bar1951 are translated with respect to the tubing. flat for setting break positions and waiting for a break station.

Although a flat pipe may be broken by the use of a 1949 breaker roll and the breakout bar 1951 as described above, in other embodiments the souls 1937 defined by the planar pipe perforations 1929 are not ruptured or cut by a blade or similar tool but instead, they are torn by a force on the flat pipe in a general longitudinal direction of the endless pipe, thereby forming individual flat tubes 1910. Such a force can be generated, for example, by the passage of the endless pipe by a roller fitting into the pipe and running at a higher speed than the pipe. Through experimentation it has been found that this way of separation can result in desirable pipe ends as described above.

In some embodiments, one or more 1949 rollers on a portion of the manufacturing line used for tubing breakage may be used to assist in advancing the tubing along the manufacturing line. This is also true for any of the drilling stations 1927, 1933, 1935 described herein. It should also be noted that in any of the embodiments described herein, stamping, the blade or other tool on a roll of any 1927, 1933, 1935 and / or 1949 breakage punch station may be retractable to allow the roll to be driven to pipe advance, no other action on it. In such cases, the retracted position of the tool can also define the hold position described here.

Additional aspects of flat tube manufacturing described here may also allow these tubes to be produced with significant cost savings, improved efficiency, at a higher speed and / or in a more reliable and reproducible manner compared to many conventional flat tube manufacturing techniques. As will now be described, some of these additional aspects relate to the manner in which the flat tube parts are formed and / or the manner in which these parts are assembled together for the production of the flat tubes. By way of example only, these processes will now be described and illustrated with reference to the production of two-piece tubes, and more specifically to the two-piece tube 1910 shown in FIG. 28 and described above, produced using fabrication line 1900 illustrated in FIG. 55 is also described above. The following description and associated drawings apply equally to the production of any of the other two-piece tubes (with or without inserts) described herein. Also, except for an inconsistent or inconsistent description, the following description and associated illustrations apply equally to the production of any of the tubes in one piece (with or without inserts) also described herein.

The inventors have found that significant advantages can be obtained by certain ways of assembling the first and second portions 1912, 1914 and the pipe insert 1934 1910. In some embodiments, for example, the inner insert 1934 is wound in a corrugated direction in a longitudinal direction. 1900, is inserted between the two flat tube portions 1912, 1914 of the rear flat tube 1910. The longitudinal edges of the two flat tube portions 1912, 1914 may be coiled or otherwise formed with longitudinal right arc-type edges, after which At this time the coarse-like edges may be arranged together to snap together to form the flat tube 1910 shown in FIG. 28. This process is illustrated schematically in FIGS. 55, 59, and 60, and will now be described in greater detail.

As previously described, FIG. 55 shows three coils of sheet material R1, R2, and R3 supplying a sheet material to be used in the production of flat tube1910. As also described above, material sheets of coils R1, R2, and R3 are used to fabricate a first tube portion 1912, an insert 1934 (using the widest sheet material in some embodiments), and a second tube portion 1914. The sheets of material used for forming these parts run in generally parallel directions with respect to each other through the illustrated manufacturing line 1900.

Although other fabrication line arrangements may be possible, fabrication of flat tubes 1910 on fabrication line 1900 illustrated in FIG. 55 generally begins with formation of insert 1934 in the first sections of manufacturing line 1900. In some embodiments, the sheets of material used for forming first and second tube sections 1912, 1914 may be guided without being deformed. In such embodiments, when the insert deformation process 1934 has been completed, the process for forming the first and second tube portions 1912,1914 will generally begin. Alternatively, one or more forming operations may be performed on one or both of these sheets of material while insert 1934 is being formed in one or more of the same locations along manufacturing line 1900. In many cases, the manufacturing process of the first and second portions of the tube 1912, 1914 may be significantly shorter than that for the manufacture of insert 1934, due to the fact that the amount of deformation of the material used for forming the first and second tube portions 1912, 1914 may be relatively small (see, for example, the assembly of flat tube shown in Figure 28).

The two-piece flat tube 1910 illustrated in FIG. 28 have first and second identical or substantially identical portions 1912, 1914. Fabrication line 1900 illustrated in FIG. 55 is adapted to produce these portions 1912, 1914. By virtue of their identical or substantially identical shapes, one portion 1912 is inverted with respect to the other before portions 1912, 1914 are joined together. As described above, the manufacturing line 1900 illustrated in FIG. 55 has forming rollers or other forming devices suitable for producing the arc-shaped edges of the portions 1912,1914 described above.

In some cases, forming roll assemblies or other suitable forming devices used to create the same type of longitudinal edge in both tube portions 1912, 1914 are located on the same side of manufacturing line 1900 (for example, assemblies used for the production of larger rim-like longitudinal edge of both portions 1912, 1914 (located near each other in the plane of the leaves being formed). In these and other embodiments, the forming rollers or other suitable forming devices may be arranged such that the two portions 1912, 1914 have the same orientation after formation of some or all of the longitudinal edges. In such embodiments, the manufacturing line 1900 may be provided with rollers to turn one of the portions 1912, 1914 around a longitudinal geometrical axis such that the two portions 1912, 1914 may be joined at the fusing section 1941 of the manufacturing line 1900. In other embodiments In such embodiments, the forming rollers or other suitable forming devices may be arranged on a manufacturing line1900 so that the two portions 1912, 1914 already have orientations which are reversed with respect to one another (ie with their longitudinal sides reversed) after forming. some or all of the edges in dearco format. In such embodiments, the two portions 1912, 1914 may be parallel to each other, and may be combined in the 1941 fusion section of manufacturing line 1900.

As described in greater detail above in relation to FIG. 28, a longitudinal edge of the first tube portion 1912 surrounds a corresponding longitudinal edge of the second tube portion 1914, while an opposite longitudinal edge of the first tube portion surrounds an opposite corresponding longitudinal edge of the second tube portion 1914 for joining the tube portions 1912, 1914 together. . In these and other embodiments described herein which may be produced on fabrication line 1900, the first and second wall portions 1912, 1914 may be identical or substantially identical. In other embodiments described herein that may also be produced on the 1900 fabrication line, the first and second wall portions 1912, 1914 are not identical, such as where each of the first and second tube portions 1912, 1914 includes two smaller arc portions or two portion portions. archwires.

With continued reference to the embodiment of FIG. 55 to 60 in conjunction with the flat tube assembly illustrated in FIG. 28, the inner insert 1934 of the assembly may be fabricated into a third roll assembly for introducing the first and second tube portions 1912, 1914 of the tube and two parts 1910. This process is illustrated schematically in FIG. 59, and may occur after the first and second tube portions 1912, 1914 have been formed or completely formed (as is the embodiment in FIG. 59). In this embodiment, the first and second tube portions 1912, 1914 are not in one plane, but are at two planes at a distance from each other, while the forming roll assembly or other suitable forming devices producing the insert 1934 are positioned so that the sheet of material forming the insert 1934 is located between the sheets of material forming the first and second portions of the insert. tube 1912, 1914. This allows internal insertion 1934 to be "threaded" into and between the two tube portions 1912, 1914. In other words, the manufacturing layout 1900 illustrated in FIG. 55 is such that the sheet of material used for forming the insert 1934 is located between the sheets of material used for forming the first and second tube portions 1912, 1914.

With reference to FIG. 59, insertion of the inner insert 1934 as just described may be performed between first and second tube portions 1912, 1914 running substantially parallel to each other along a longitudinal section of the first and second tube portions 1912, 1914 on manufacturing line 1900. In other embodiments, however, the planes in which the first and second broad sides 1922, 1924 of the first and second tube sections 1912, 1914 need not necessarily be parallel to each other at any location other than immediately upstream of the 1941 melt section of the 1900 manufacturing line.

In the illustrated embodiment (see FIG. 59 (a)) and in other embodiments, the sheet of material used for forming the insert 1934 is substantially parallel to one or both sheets of material used for forming the first and second tube portions 1912, 1914. prior to the insertion process of insert 1934 in the first second tube portions 1912, 1914. In other embodiments, further orientations of these three sheets upstream of the insertion process are possible. However, in some embodiments, the process of inserting the inner insert 1934 into the first and second tube portions 1912, 1914 begins with orienting the inner insert 1934 between the first and second tube portions 1912, 1914 was an inclination with respect to at least one of the first and second planes. wide-sided 1922, 1924. For example, the illustrated embodiment of FIG. 59, the inner insert 1934 is introduced into and between the first and second portion of the tube 1912, 1914 at an inclination with respect to both first and second wide side planes 1922, 1924.

As used herein and in the appended claims, the "inclined" form in its various forms expresses the position of insert 1934 with respect to the broad sides 1922, 1924 of tube portions 1912, 1914 (which may be parallel to each other in some embodiments). In this regard, it should be noted that one or both of the wide sides 1922, 1924 of the first and second tube portions 1912,1914 may be in their respective non-horizontal planes, whereby insert 1934 would be inclined with respect to these non-horizontal orientations.

This inclined insertion may occur in a range of locations to assemble the 1941 melt section of the 1900 fabrication line, and in some embodiments approximately at the beginning of the 1900 fabrication line. In some embodiments, the angle of the 1934 insert (with respect to the plane from which a wide side 1922, 1924of at least one of the tube portions 1912, 1914 is at least about 25 degrees in at least one location of the insert 1934 between the sheets used to produce the first and second tube portions 1912, 1914. , as at the beginning of the insertion process. In other modalities, this angle is at least around 30 degrees for good performance results. Also, in some embodiments, the angle of insert 1934 as described above is no greater than around 45 degrees at least one location of insert 1934 between the sheets used for the production of first and second portions of tube 1912, 1914, as in the beginning. of the insertion process. In other embodiments, this angle is no greater than about 40 degrees for good performance results.

Subsequently, the inner insert 1934 is placed in an orientation in which the inner insert 1934 is parallel to or substantially parallel to the broad sides 1922, 1924 of the first and second tube portions 1912,1914. FIGs. 59 (b) - (e) show an example of changing or decreasing the inclined position of insert 1934, as well as the gradual convergence of first and second portions of tube 1912, 1914 to maintain insert 1934 between them.

In those embodiments (such as that of FIG. 28) in which one or both of the longitudinal edges 1938, 1940 of the inner insert 1934 are received on the narrow side (s) 1918, 1920 of the flat tube 1910, the shape of the longitudinal edges 1938, 1940 may provide a firm fit against the inner surface of the first and second tube portions 1912, 1914 on the narrow sides 1918, 1920. For example, in those embodiments in which one or both of the longitudinal edges 1938, 1940 of insert 1934 are arc-shaped or have a series of bends 1970, features may be received within arc-shaped longitudinal edges of the first and second tube portions 1912, 1914. In these and other embodiments of insert 1934, a longitudinal edge 1938 of insert 1934 may be placed on an arc-type longitudinal edge of a first portion. at which time or thereafter the insert 1934 may be inclined with respect to the broad sides 1922, 1924 of the first and second by tube connections 1912, 1914.

As mentioned above, the inclination of insert 1934 may be reduced to zero (i.e. insert 1934 may be moved to a parallel position or substantially parallel to the broad sides 1922, 1924 of the first and second tube portions 1912, 1914). In this way the opposite longitudinal edge 1940 of insert 1934 can assume a qualitatively correct position on the arcal longitudinal-type arc of the second tube portion 1914. Both the first and second tube portions 1912, 1914 may be put together during any part of this process after which time. the longitudinal edges of the first and second tube portions 1912, 1914 surrounding the inner insert 1914 are closed as shown schematically in FIG. 59 (e). It should be noted that by closing the flat tube 1910 as described here, insert 1934 is deformed in some embodiments. Insertion 1934 into enclosed flat tube 1910 may remain under compression against either the wide or narrow sides 1922, 1924, 1918, 1920 of flat tube 1910, particularly in those embodiments (such as FIGS. 55 to 60) wherein insert 1934 has been substantially deformed. insert insert 1934 into the flat tube.

In the illustrated embodiment, a closure of the first and second flat tube portions 1912, 1914 is provided by bending the adjacent longitudinal edges of the first and second tube portions 1912, 1914 in a manner as described and shown in greater detail above with respect to the embodiments of FIG. 25, 26 and 28 (i.e. by flexing depositions of the larger arc longitudinal edges into smaller arc portions of adjacent longitudinal edges of the tube portions 1912, 1914). Accordingly, manufacturing line 1900 illustrated in FIG. 55 may be used for the production of flat tubes 1900 wherein one or both longitudinal edges of an insert 1934 are received at respective flexed edges corresponding to tube portions 1912, 1914 on the narrow sides 1918,1920 of flat tube 1910.

Following the closure of the 1910 flat tube on the 1900 manufacturing line, 1910 flat finished tubes may be attached to one or more sets of fins or other elements (not shown), and may also be attached to one or more heat exchanger manifolds (also not shown). In many embodiments, heat exchanger manifolds are brazed in a brazing furnace, such as flaps or other heat exchange elements for flat tubes 1910, and flat tubes 1910 in their 1934 inserts.

Insert 1934 may have any of the shapes and features described herein with respect to tuboplane inserts. In many of these embodiments, insert 1934 is formed from a sheet of flat starting material. Therefore, as insert 1934 is formed with corrugations or other features, at least partially define flow channels 1916 through tube 1910, the width Insertion 1934 may decrease. This process is shown schematically in FIG. 60, which illustrates the sheet of material in which corrugations 1952 are successively created by forming rollers 1955 as the sheet advances in a longitudinal direction (indicated by the straight line in FIG. 60) through manufacturing line 1900. Although three such forming rollers 1955 are shown in FIG. 60, manufacturing line 1900 may have any number of forming rollers 1955 for producing any number of desired corrugations 1952 or other insertion features as described with respect to various insertion modalities herein. The type and location of the corrugations or other wall features may at least partially determine how many forming rollers 1955 are required on manufacturing line 1900. For example, some embodiments in which insert 1934 include continuous corrugations 1952, such as those illustrated in FIG. 25-34, a corresponding number of forming roller assemblies (e.g., each roller assembly defined by a pair of rollers - one on each side of the sheet material) may be required for the formation of corrugations 1952 successively as described herein.

Thus, in some embodiments, the manufacturing line 1900 may extend for a length of around 20m (65.62 ft.) Or more.

Fabrication line 1900 may also include more than one type of roll 1955 for forming insert 1934. For example, different rollers 1955 may be used for forming different types of corrugations 1952 through insert width 1934. As another example, one or more More rollers 1955 may be cutting rollers used to create slits in a sheet of material for later formation of corrugations in the sheet of material, such as by bending portions of the sheet near the slots, as described above with respect to any of the embodiments of FIG. -45. Any number of such rollers 1955 may be used in conjunction with any number of other roll types (for example, for bending portions of the sheet of material) to create any type of insert described herein.

In some embodiments, such as that shown in FIG. 60, the manufacturing process of insert 1934 first includes forming one or more central corrugations 1952 in the sheet of material, and subsequently forming additional corrugations 1952 closer to the longitudinal edges of insert 1934. More specifically, and with reference to the embodiment of FIG. By way of example, a first set of rollers 1955 (i.e., the leftmost roll set in FIG. 60) included two grooves 1957 for forming corresponding corrugations 1952 in the sheet of passing material. The next roll assembly 1955 includes four grooves 1957 forming corresponding corrugations 1952 on the passing sheet of material. This process can continue to produce as many corrugations on a sheet of material as desired. At any point before, during or after such corrugation formation, one or both of the longitudinal edges 1938, 1940 of insert 1934 may be formed to take any shape, including any of the shapes described and / or illustrated herein. For example, both longitudinal edges 1938, 1940 of insertion 1934 produced in the embodiment of FIG. 55 to 60 are provided with arc-type shapes subsequent to the formation of all 1952 corrugations, as best shown in FIG. 28

In some embodiments, the width of the sheet used for forming the insert 1934 is reduced to a greater extent than the width of the sheet used for forming the first and second tube portions 1912, 1914. This may be the case, for example, when the sheets used for forming the first and second pipe portions 1912,1914 are deformed only (or primarily) at their opposite longitudinal edges, as in the case of the two-piece flat pipe arrangement illustrated in FIG. 28. An advantage of such a flat tube construction is that wide flat sides 1922, 1924 of flat tube 1910 can provide relatively better surfaces for bending joints between wide sides 1922, 1924 of flat tube 1910 and insert 1934 and / or between wide sides 1922, 1924 of flat tube 10 and fins or other (not shown) elements affixed to flat tube 1910.

In those embodiments in which an insert 1934 is threaded between two portions of tube 1912, 1914 (and possibly also moved from an inclined position to a parallel or substantially parallel position as described above), the forming rollers or other forming devices suitable for The production of insert 1934 may be located upstream from which two portions of pipe 1912, 1914 are placed together to close flat tube 1910. Therefore, some or all features of insert 1934 may be formed prior to this location. In other embodiments, however, some or all of the insertion deformation devices may be located on the same part of the manufacturing line as the two tube portions 1912,1914 are placed together for closure of tubular 1910. Thus, insert 1934 may still being in the process of being formed as the pipe portions 1912, 1914 are put together for closure, and / or as the insert 1934 is shifted from an inclined position to a position parallel or substantially parallel to the wide sides 1922, 1924 of the pipe portions 1912, 1914 as described. above.

In some embodiments of the 1900 fabrication line, roll assemblies used for the production of any one or more of the various parts of flat tube 1910 and insert 1934 may be adjustable for production of flat tubes 1910 and / or 1934 inserts with different cross-sectional dimensions and characteristics. transverse Alternatively or additionally, an advantage of some of the embodiments of manufacturing line 1900 is that one or more roller assemblies (also referred to as roller banks) used to produce any of the tubular mounting parts may be fully interchanged for other assemblies. the formation of flat tubes 1910 and / or inserts 1934 with different dimensions and characteristics. It should be noted that roll assemblies without individual adjustability can often be produced in a more cost effective and efficient manner.

Another feature of the 1900 manufacturing line that can define significant manufacturing advantages relates to the flexibility in sheet widths used to create flat tubes according to embodiments of the present invention. In some embodiments, one or more of the sheets of material may be formed with additional folds and / or for the definition of additional flow channels as required for use over an entire sheet width. For example (and with continued reference to the machining line mode illustrated in FIGS. 55-60), the width of the material sheet used for producing the inner insert 1934 is generally greater than the width of the material sheets used for the manufacture of the first and second. tube portions 1912, 1914. This may be the result of insertion 1934 having corrugations 1952 and deformed longitudinal edges 1938, 1942, while the first and second tube portions 1912, 1914 have only deformed longitudinal edges or otherwise require less material width for forming the portions. 1912, 1914, in some modalities. Any additional width of the sheet material used for forming insert 1934 may be used for creating additional features of insert 1934, such as one or more additional folds on the right sides 1918, 1920 of flat tube 1910, and / or one or more additional folds defining the blanks. flow channels 1916 through flat tube 1910.

Still other features of the present invention also relate to the manner in which the described flat tubes can be produced here, flat and vane and spring tube assemblies by which such mounts can be produced, and / or flat tube and vane assemblies incorporated in heat exchange devices. heat. By way of example only, these aspects of the present invention will now be described and illustrated with reference to the production of two-piece tubes, and more specifically the two-piece tubes 1910 illustrated in FIG. 28 and described above. The following description and associated drawings apply equally to the production of any of the other two-piece tubes (with or without insertions) described herein. Also, except for an inconsistent and incompatible description, the following description and associated illustrations apply equally to the production of any of the tubes in one piece (with or without insertions) also described herein.

Some advantages of forming finned tubes 1910 according to the present invention include a relatively simpler method of manufacturing such assemblies for the manufacture of different types of heat exchangers. In some embodiments of the present invention, an end tube 1910 (i.e. created by a continuous supply of sheet material from one or more heaping locations and the formation of sheet material in a continuous flat tube 1910), such as the tube without end 1910 illustrated in FIG. 61, 64, and 65 may be carried along the manufacturing line for affixing the endless tube 1910 to at least one set of fins 1959. It is to be understood that a reference to the process of coupling fins 1959 to a flat tube or a tube. Endless may be used interchangeably herein (unless otherwise indicated), without limitation of the scope of the present invention. In some embodiments, only one of the two wide sides 1922, 1924 of endless tube 1910 is provided with a fin assembly 1959 in this manner. Flat tubes 1910 produced with single-sided fins 195 9 may be used, for example, at the edges of a heat exchanger core 1965, in which case the flat tube 1910 may be positioned to return inwardly, so that the flat tube 1910 is adjacent to a fin assembly 1959 of an adjacent pipe 1910, or outwardly such that the fin assembly 1959 is adjacent to a fin assembly 1959 of an adjacent tubing 1910. In other embodiments, such as those shown in FIGs. 61-66, both broad sides 1922, 1924 of endless tube 1910 are provided with a respective set of fins 1959 in this manner. In either case, the fin set (s) 1959 may define a two-dimensional interface with the wide side (s) 1922,1924 of the flat tube 1910.

Many of the flat tube and vane embodiments described below and illustrated herein are constructed of sheet metal including aluminum (e.g. aluminum or an aluminum alloy), although other non-metallic sheet metal materials may be used instead for other embodiments. In some embodiments, the sheet material used for the production of flat tubes 1910 is provided with a brazing layer (not shown) on at least one side thereof, whereas the sheet fin material 1959 does not have a folding coating. In other embodiments, different locations of brazing coatings are possible.

While the various aspects of finned tube production and finned tube features described herein may be applied to flat tubes having any dimensions, unique advantages are obtained in their application to flat tubes 1910 formed of the relatively thin material also described herein. By way of example only, the relatively thin tubing material may permit continuous line production of 1910 finned flat tubes (described in more detail below) where previously not possible. In some embodiments, the tube wall material has a thickness no larger. than around 0.20 mm (0.007874 in). However, in other embodiments, the inventors have found that a tuboplane wall material having a thickness no greater than about 0.15mm (0.0059055 in) provides significant performance results relative to the overall performance of heat exchangers using the flat tube. fabricability and possible wall constructions (as shown here), which are not possible using thicker wall materials. Also, in some embodiments, a flat tube wall material thickness of not less than about 0.050 mm (i.e. no less than around 0.0019685in) provides good strength and corrosion resistance performance, although a wall material thickness of no less than around 0.30 mm (0.00118 in) can be used in other modalities.

As explained in more detail below, the heat exchanger tubes and other heat exchanger portions described herein may be fabricated using various manufacturing techniques and processes, and may include corrosion protection features such as, for example, those techniques and processes. described below illustrated in FIGs. 92-95. Various technical manufacturing processes and corrosion protection features referenced hereinafter are particularly advantageous when applied to heat exchanger tubes and heat exchanger portions having significantly reduced material thickness. In addition, such corrosion protection techniques, processes and features provide significant performance advantages over flat tubes and heat exchangers made from such material.

The flat tube 1910 in the embodiment illustrated is a two piece tuboplane with one insert. With reference to the illustrated embodiment of FIG. 66 by way of example, each of the illustrated flat tubes 1910 may have a small diameter d of at least about 0.8 mm (0.0314 96 in) to provide good performance results in many applications. Also, the small diameter d no larger than about 2.0 mm (0.07874 in) provides good performance results in many applications. However, in some embodiments, a small pipe maximum diameter d of no larger than about 1.5 mm (0.059055 in) is used. Any of the other flat tube embodiments described herein (e.g., constructed from a single piece or any number of additional pieces) may be used to create the finned tubes of the present invention. Also, in other embodiments, any of the other small and large diameters d, D described above with respect to all flat tube modalities shown herein may be used instead.

The manufacture of flat tubes 1910 and baffle assemblies 1959 in the illustrated embodiment are shown schematically in FIG. 61 only for a few pairs, 1971, 1973, which represent part of an upstream fabrication line not shown in more detail.

This upstream fabrication line may also include intermediate buffers (e.g., core assemblies, not shown) for feed rate control of flat tube 1910 and / or fins 1959. Further, embellished pairs of rollers 1973 are shown in FIG. 61 For schematically depicting the production of two 1959 fin assemblies, it should be noted that a single upstream fin fabrication line may be used instead in some embodiments.

Flat tubes which may be used for the creation of finned tubes may be closed by brazing, welding, light solder welding, or in any other suitable manner described herein along one or more longitudinal seams upstream of the location at which the fins are attached to the tubes. plans. Such tube production may be used, for example, in those embodiments wherein a flat joint between flat tube 1910 and a set of fins 1959 is an adhesive joint. Alternatively, flat tube1910 may be joined by brazing, welding, or weak weld welding during the production of finned tubes.

Flat tubes 1910 illustrated in FIGs. 61-66, 68, e69 are described in more detail above with respect to FIG. 28. As noted above, the description and associated drawings for finned flat tubes and their manufacture apply equally to other one-piece and two-piece tubes (with or without inserts) described herein. By way of example only, FIG. 67 illustrates another tuboplane 310 that may be used in any of the finned tube embodiments described herein, and is described in greater detail above with respect to FIG. 7. In some embodiments, flat tube 310 shown in FIG. 67 has a wall thickness of around 0.10 mm (0.003 93 7 in).

A feature of this particular flat tube 310 is that the narrow sides 318, 320 are designed to be very stable. For example, narrow side 318 includes a bend assembly 330. Another feature of this tube 310 is that the flat tube 310 is divided into multiple flow channels 316 by single bends 328, or multi-bend assemblies 328 in other embodiments. In some embodiments, the distance between bends 330 may be less than 1.0 mm (0.003937 in). However, stistance may be increased to the centimeter range. As described in greater detail above with respect to (e.g.) the embodiments illustrated in FIG. 1-13, it should be noted that the folds 330 forming the narrow side 318 may be designed with different lengths and / or shapes, thereby increasing relative resistance to temperature change load, pressure resistance and / or impact resistance of the tuboplane 310.

The fins 1959 described herein may be of any suitable thickness, and may be produced from a sheet of endless material in some embodiments. However, the use of 1959 fins formed from a sheet of material no thicker than about 0.09 mm (0.0035433 in) can provide good performance results in many applications. Also, fins 1959 formed from a sheet of material with a thickness no less than about 0.03 mm (0.0011811in) can provide good performance results in many applications. FIG. 63 illustrates alternative fin constructions 1959 which may be used in the various embodiments of the present invention. The fins 1959 illustrated in FIGs. 61.62, 64-66, and 68-68 correspond to the fins 1959 illustrated in FIG. 63 (a). However, it is to be understood that other designs of the 1959 fins are possible and fall within the spirit and scope of the present invention.

With reference to FIG. 66 by way of example, the wall thickness of the fins 1959 may be about 0.06 mm (0.0023622 in), and may have a height H around 3.00 mm (0.011811 in). It can be seen that a 2H distance between two flat tubes 1910 may therefore be around 6.0 mm (0.023622 in) subsequent to the manufacturing process described here which adjacent flap assemblies 195 9 of adjacent flat tubes 1910 are confine with each other.

The fin assemblies 1959 may be secured to the broad sides 1922, 1924 of the flat tube 1910 by adhesive or a metal joint (e.g., welding, brazing, or weld welding), where the flat surfaces of the wide sides 1922, 1924 provide a significant surface area. for these postings. In some embodiments, the flat joint between the flat tube 1910 and one or more fin assemblies 1959 defines less surface area than the wide flat sides 1922, 1924 of the flat tube 1910.

The fin assemblies 1959 attached to the flat tubes 1910 as described herein may be oriented in a number of different ways with respect to the flat tubes 1910. For example, the longitudinal direction of the fins 195 9 on a tuboplane 1910 may be substantially perpendicular to the longitudinal direction of the flat tube 1910. However The inventors have found that sets of fins 1959 may instead be attached to the flat tube (i.e., wide sides 1922, 1924 thereof) so that the longitudinal direction of the fins 1959 is inclined with respect to the longitudinal direction of the flat tube 1910 and a direction perpendicular to it. this (ie, in the direction of airflow, in many applications). Examples of such 1959 fins are shown in FIG. 68 and 69 which show a flange assembly 1959 brazed to the wide side 1924 of a flat tube 1910 (transparent in FIG. 69), and another flap assembly 1959 brazed to the wide side 1922 of another flat tube1910. Accordingly, and as indicated by the arrows in FIG.68, an air flow through one vane assembly 1959 is not parallel to air flow through the other vane assembly 1959. In those embodiments wherein FIG. 68 represents an elevation view of the fin assemblies 1959 in use, the cooling air in one fin assembly 1959 is deflected downward from the horizontal incoming and cooling air, while the cooling air in the other fin assembly 1959 is directed upwards from the entering and cooling horizontal air.

In some embodiments, the angle of inclination for each fin assembly as described above is not less than about 8 ° (measured between the longitudinal direction of the fins 1959 and that of the flat tube 1910) for good performance results in many applications. Also, in some embodiments, this tilt angle is no greater than around 8 ° for good performance results in many applications. In some embodiments, including those in which a set of fins 1959 in a flat tube 1910 is adjacent to another set of fins 1959 in another flat tube 1910, as described in greater detail below, this inclination of a set of fins 1959 may be in a direction that is different from an inclination of another adjacent set of fins 1959 (see, for example, FIGS. 68 and 69).

In some embodiments of the present invention, a brazing method may be used, wherein the flat endless tube 1910 and one or more sets of fins 1959 are continuously or uninterruptedly transported through a junction station 1969, an example of which is shown schematically in FIGS. . 61 and 64. The fin assemblies 1959 may be brazed to the auger tube 1910 at one or more of these 1969 junction stations, all or any of which being located at later stages of a full-length tube fabrication line in some embodiments. Generally, the junction station may be a relatively small device producing the brazing temperature with an induction coil, for example. It should be noted that bending parameters (and thus the type and power of the 1969 brazing station (s) used) may vary according to the desired parameters of flat tube 1910.

In some embodiments, the 1959 fin assemblies are held against the broad sides 1922, 1924 of the 1910 tuboplane with a predetermined force, while the 1959 fin assemblies are brazed to them as described above. Although the tubular fabrication process occurs upstream of the flap affixing process, significant advantages can be gained by brazing or otherwise joining various parts of the flat tube (for example, from insert 1934 to flat tube 1910, at least one edge). length of the flat tube 1910, and similar) while the fin assemblies 1959 are affixed to the flat tube 1910, as by the same brazing process described herein. In cases where one or more longitudinal seams of flat tube 1910 have already been completed by the time flat tube 1910 reaches the flap affixing portion, however, flat tube 1910 may be used in the manufacturing process structure. For example, with reference to FIG. 64 and 65, fin assemblies 1959 may be joined endlessly to the broad sides 1922, 1924 of a completed flat endless tube 1910 in any of the ways described herein.

In some embodiments, the manufacturing process also includes forming sections of straight tube assemblies (otherwise referred to herein as "coiled tubes", and generally indicated by reference numeral 1961) by separating the desired lengths of the finned tubes 1961 from a single tube. 1910 having one or more vane assemblies 1959. For example, a 1959 vane assembly supplied for connection to a flat worm tube 1910 may be cut to a desired length and removed from the flat worm tube 1910 before or after fitting the vane assembly. 1959 to flat end pipe1910 (e.g. by brazing or in any other way described above).

In other embodiments, a continuous supply of nipples 1959 from a bulging manufacturing process may be cut to desired lengths, whereby the nipple lengths 1959 may be placed at intervals and joined to a flat end tube surface 1910 in any manner as provided. That. Referring to the illustrated embodiment of FIG. 61, in still other embodiments one or more spacers 1975 (e.g., blocks) may be placed between bracket assemblies 1959 on the flat tube 1910, and thus may be used for positioning the fins 1959 to establish a desired distance between the fin assemblies 1959. coupled to the same wide endless end tube 1910. As shown in FIG. 61, the separators 1975 may be removed from the flat tube 1910 in the downstream location, allowing the formation of flat-tube finned-free tube sections at one or both ends of the flat tube 1910.

In any case and in other embodiments, interruptions between the fin assemblies 1959 may provide exposed flat tube portions 1910 which may be useful for other tube cutting or separating processes between formed gaps and / or for drilling or other operations performed on the flat tube. 1910 in these locations. Accordingly, the individual fin tube sections formed may include a flat tube 1910 and fin assemblies 1959 located on one or both flat sides of the flat tube 1910.

1961 finned tubes produced in accordance with the present invention may be incorporated into a wide variety of heat exchangers of any desired manner. In some embodiments, however, unique heat exchanger characteristics and heat exchanger mounting features have been identified by the inventors. For example, the heat exchanger 1963 illustrated in FIGs. 61,62, and 66 may include finned tubes as described above, where a finned set 1959 of a finned tube 1961 is positioned next to another finned set 1959 of an adjacent finned tube 1961. FIG. 62 (which is an exploded view of a 1965 fin tube block or core) illustrates four 1961 fin tubes of a 1965 fin core. The number of 1961 fin tubes can be determined, at least in part, based on the application of the exchanger. of heat. Accordingly, the finned tube arrangement described above may be repeated as often as desired for the definition of the 1965 finned tube core 1961. Such a 1965 core can be assembled and then fitted with one or more collecting tanks1967. In particular, the ends of the flat tubes 1910 of the 1965 core may be free and may fit 1967 collection tanks (for example, received in respective slots or openings in collection tanks 1967 or connected in fluid communication with the interior of collection tanks 1967 of any other manner) to be secured and sealed to it using any suitable adhesive or sealant. For example, FIG. 62 inserts indicating the general direction for mounting the 1967 collecting tanks on the 1965 finned tube core 1959.

As described above, finned tubes may be arranged in a heat exchanger such that a finned set 1959 of a finned tube 1961 is positioned near another fin set 195 9 of an adjacent finned tube 1961. These finned sets 1959 may be in contact with each other. In some heat exchanger embodiments employing this 1961 complete tube arrangement, there is a neutral zone of this structure, which does not participate in heat exchange, because the temperature of the 1959 finned tubes in the neutral zone is substantially similar, or in some embodiments it is even the same. same. Depending on the number of 1961 finned tubes arranged in this manner, any number of these neutral zones may exist in a 1965 core between adjacent 1959 fin assemblies.

As a result, when mounting a 1963 heat exchanger from several 1961 finned tubes and in other embodiments, it is possible to affix a finned assembly in a 1961 finned tube to the 1959 fins of another adjacent finned tube 1961, thereby making it possible that a heat exchanger core having such a finned tube construction be manipulated as a single structural unit. In relatively large heat exchangers, an advantage of joining adjacent flap assemblies 1959 in this manner is that vibrations or oscillations (and noise generated thereby) adjacent flapper tubes 1961 may be suppressed. Attachment of adjacent finned tubes 1959 as just described may be accomplished in some embodiments by a bonding material (e.g., adhesive, weak weld welding, brazing, welding, and the like) applied between adjacent finned tube sets 1959 adjacent bulkheads so that the 1965 heat exchanger core can be manipulated as a single structural unit. In other cases, the finned tube assemblies 1959 with adjacent finned tubes 1961 may be joined for the production of heat exchanger cores 1965 from such finned tube 1961. For example, in some embodiments, an intermediate sheet (e.g., a sheet of metal or other relatively thin material) may be located between and joining adjacent vane assemblies 1959. In other embodiments, a narrow air space may exist between adjacent vane assemblies 1959 of adjacent comforter tubes 1961. In other words, a 1959 vane assembly of a Finned tube 1961 may be "adjacent" to a finned set 1959 of another finned tube 1961 in a heat exchanger according to some embodiments of the present invention, even without a material layer or element joining the finned sets 1959.

Once several 1961 finned tubes have been assembled in a desired arrangement, the assembly may be clamped together in a number of different ways, such as weak weld brazing, welding, and / or brazing. In some embodiments, the process of manufacturing a 1965 fin-tube core may include the use of CAB bending technology. 1965 vane cores as described herein can be manufactured with relatively reduced energy consumption. In those embodiments in which the fin tube cores 1965 are constructed with flat tubes 1910 formed from the relatively thin sheet materials described herein, the various stages of attachment of the finned tubes 1961 together (for example, in a CAB bending process) can be significantly reduced. For example, the velocity or travel speeds of these 1965 vane cores through temperature ranges other than a CAB brazing furnace may be significantly increased over those required for conventional vane cores. One reason for these faster clamping processes is the relatively low wall thickness of the flat tubes 1910 (and also the fins 1959), allowing brazing temperatures (or high temperatures needed for other clamping processes) to be significantly faster achieved in cases where materials thicker sheets are brazed. Transport speeds and / or exposure times at various stages of the manufacturing process can be optimized by the selective adjustment of temperature regimens, for example based on the use of these finer materials. In addition, the use of suitable suspenders, fittings, or assistive devices in the fabrication process can help reduce the opportunity and / or degree of fin-tube core deformation such as subsequent completion of a brazing process for attachment of the fin-tube assembly. . More specifically, an expansion and contraction of the 1965 fin-tube cores occurring during heating and cooling need not cause unacceptable delays.

Additional aspects of the present invention pertain to the resting of flat tubes shown herein on heat exchangers having one or more tanks used for establishing fluid communication between the flow channels of the various flat tubes and / or for a fluid supply or a water outlet connection. heat exchanger to another equipment. These aspects of the present invention are adapted for the flat tubes shown herein having the relatively thin walled materials described above (e.g., no larger than about 0.20 mm (0.007874 in) in some embodiments, and no larger than around 0.15 mm (0.0059055 in) in other modalities).

However, the inventors have found that the aspects of the present invention described in greater detail below can be used in applications where thicker flat constructed tubes are used.

Therefore, the various aspects of the present invention described below apply to heat exchangers having other types of flat tubes, including any of the flat tubes described and / or illustrated herein.

As explained in more detail below, the heat exchanger tubes and other heat exchanger portions described herein may be manufactured using various manufacturing techniques and processes and may include corrosion protection features such as, for example, those techniques and processes described. below illustrated in FIGs. 92-95. Various technical manufacturing processes and corrosion protection features referenced hereinafter are particularly advantageous when applied to heat exchanger tubes and heat exchanger portions having significantly reduced material thickness. In addition, these corrosion protection techniques, processes, and features provide significant advantages over the overall performance of flat tubes and heat exchangers made from such material. As described above, the flat tubes described and illustrated here may be used in conjunction with heat exchangers having one or more tanks, manifolds, and other fluid closures adapted for establishing fluid communication between the flat tubes and / or between the flat tubes and a fluid supply or a tank outlet. Such tanks are collectively referred to herein as "collection tanks" for ease of description, it being understood that such tanks may perform other functions, may be larger or smaller and may have any other desired shape, while still incorporating aspects of the present invention described below.

One embodiment of a collection tank according to the present invention is illustrated in FIGS. 70, 70A, 71, 76, e77, and is generally indicated by reference numeral 4467.

Although heat exchanger 4463 illustrated in FIG. 77 shown with two 4467 pickup tanks, it should be noted that any number of 4467 pickup tanks can be nailed to several possible heat exchangers, including a single 4467 pickup tank and more than 4467 pickup tanks. Both 4467 pickup tanks shown in FIG. 77 have substantially the same features and are connected to the flat tube 4410 in substantially the same manner as described below illustrated in FIGS. 70, 70A, 71, 76, and 77.

The collection tank 44 67 can be constructed from any number of different parts. For example, collecting tank 4467 illustrated in FIG. 70, 70A, 71, 76, e77 is formed from a single unitary body, such as by injection molding or by another suitable method. In this and other embodiments, at least one row of receiving openings 4479 (described in greater detail below) ) is integrally formed with the take-off tank 44 67. In other constructions, such as the collection tank mode illustrated in FIGS. 72-75 and described below, the collection tank is formed from two or more parts separated by injection molding or in any other suitable manner and connected together, with at least one row of receiving openings in one or more of the parts. In such embodiments, for example, the collecting tank 4467 may have one or more walls in which the receiving openings 44 7 9 are defined, and one or more other walls defined by separate portions of the collecting tank 4467, so that the other walls may be mounted on one another. a stage later than that in which flat tubes 4410 are received at receiving openings 4479.

The illustrated collection tank 4467 includes a series of receiving openings 44 7 9 along a same surface. Each receiving opening 44 7 9 is surrounded by a wall integrally formed with at least a portion of the collecting tank 4467 and shaped to receive a corresponding free end 44 77 of a flat tube 4410. Flat tubes 4410 may take any of the shapes described herein, and may be cut to a length specified by the desired parameters of tube 4410 or a corresponding application. With reference to FIG. 70, 7A, and 71, part of the manufacturing process a heat exchanger 4463 includes the placement of free ends 4477 of flat tubes 4410 (according to any of the embodiments described herein) in recess 4479 of the collection tank 4467. In some embodiments, this This process may be accomplished by appearing to collect the collection tank 4467 over the free ends of flat tube 4477 in a similar manner to that shown schematically in FIG. 62. Alternatively, the free ends 4477 of the flat tubes 4410 may be pushed into the receiving openings 4479, or the flat tubes 4410 and the collection tank 4467 may be moved towards each other and pushed together to establish these connections.

In some embodiments, flat tubes 4410 connected to collecting tank 44 67 may have one or more fin assemblies 4459 (see FIG. 77) according to any of the embodiments described herein. By way of example only, tubes with vane 44 61 already assembled and brazed in upstream fabrication steps (such as those described above) may have vane 4559 with wall thicknesses of about 0.030 - 0.090 mm (0.0011811 - 0.0035423 in. ), and subsequently can be attached to a 4467 collection tank. For example, projected free ends 4477 of individual 4410 flat tubes with fins 4459 already brazed thereto, or those tubes with 4461 fins already assembled and brazed in a block or core 44 65 may remain free for (eg, while in a brazing furnace), and therefore do not have fins 4559 to interfere with their subsequent insertion into receiving openings 4479 of a 4467 pickup tank. Both ends of the 4410 flat tubing in any such mode may project. and be free exactly as described for connecting to opposite collection tanks 4467.

In those embodiments in which the core 4465 is connected as described above, the core 4465 may be formed from 4410 flat tubes and fin assemblies 4459 by alternating stacking of the 4410 flat tubes and fin assemblies 4459. An example of such a core construction is illustrated. in FIG. 77, which shows a brazed fin-core tube 4465 having two collecting tanks4467 each with a window for connection to another apparatus, where cooling air flows through the fins 4459 for cooling a fluid into the flat tubes 4410. The exchanger 4463 illustrated in FIG. 77 is just one of many possible types of heat detectors to which one or more of the 4467 take-off tanks can be connected. By way of example only, any of the illustrated collection tanks 4467 may be a reversing tank so that both inlet and outlet windows are arranged on the same collection tank 4467.

Flat tubes 4410 (with or without fins connected to them as described in previous embodiments above) may be individually inserted into respective receiving openings 4479 of a 4467 collection tank.

However, significant advantages may be obtained by inserting two or more of the 4410 flat tubes, and in some cases all 4410 flat tubes of a 4465 core, in their respective receiving openings 4479 at the same time or substantially at the same time, as in a single step.

This process can be performed when two or more are 4410 flat tubes are already connected together, such as by a brazing process or other fastening processes (including those described herein) for defining a 4465 flat tube heat exchanger core or a portion of it. Such a process can make it possible to use a larger number of collection tank materials. However, depending, in part, on the material used for the collecting tank4467 and the process used for securing the fins 4459 to the flat tubes 4410, in some embodiments it is desirable to insert the free ends 4477 of the flat tubes4410 into the respective receiving openings 4479 of the tank. collects 4467 subsequent to a post brazing cooling of the 4465 fin-tube core.

Many heat exchanger manufacturing processes require exposing the pipes and collection tank to elevated temperatures for low solder welding, soldering, brazing, and other affixing processes, such as receiving flat tubes and collecting tanks from an oven or a another heated environment for joining flat pipes to the collection tank. These processes therefore prevent the use of many take-off tank materials - at least those materials used for collection tank parts by defining the connection locations for flat pipes (for example, the collection wall or walls defining the receiving openings). ).

Therefore, these collection tank parts are typically comprised of metal. By connecting the collection tank to two or more flat tubes that have been welded, welded, brazed or otherwise connected together, as described above, a plastic or other lower temperature material can be used for all parts, for all parts. or substantially all of the collecting tank 4467. For example, the part or parts of the take-off tank 4467 defining the receiving openings 4479 may comprise a plastic. The entire collection tank 4467 in the illustrated embodiment of FIGS. 70, 70A, 71, 76, and 77 is made from a plastics material, although other materials may be used in other embodiments.

In those embodiments in which part or all of the take-off tank 4467 comprises a plastic, such parts may be manufactured by injection molding, for example.

Referring again to FIGS. 70 and 71, the receiving openings 4479 of the collection tank 4467 shown have curved surfaces 4481 to assist in the insertion of flat tube ends 4477. In other embodiments, other shapes (e.g., flat inclined surfaces, perpendicular corner surfaces, and the like) are. used instead.

When fully inserted into respective recess openings 4479, flat tube ends 4477 reach respective locations below the inner surface 4483 of collection tank 4467, as best shown in FIG. 71, thereby preventing an undesirable depression loss created by the flat tube ends4477 during an operation of heat exchanger 4463.

In the illustrated embodiment of FIGs. 70, 70A, 71, 76, e77, receiving openings 4479 of collecting tank 4467 are shaped to define a rear portion 4485 (with reference to the insertion direction of tuboplane in Figures 70, 70A, 71, 76, and 77 ) which is substantially the same as the cross-sectional shape of the flat tube ends 4477. Although the rear portion 4485 of each receiving opening 4479 may be sized to define a slack fit with a flat tube end 4477, in other embodiments (such as those 70, 70A, 71, 76, and 77) an interference fit is used. In those embodiments in which an interference fit is employed, slight pressure is exerted on the collecting tank 4467e and / or flat tube 4410 to fully insert the flat tube end 4477 into the rear portion 4485 of the receiving port 44 79, thereby providing a seal. between the collection tank 4467 and the fluid-tight tubular end 44 77 or substantially fluid-tight.

In some embodiments, a feature of the 4467 pickup tank and / or flat tube ends 4477 is used to control or limit the amount of insertion of the flat tube ends 4477 into the recess openings 4479. For example, a stop (not shown in FIGS. 70, 70A, 71, 76, and 77, but visible in Fig. 80, indicated by reference numeral 4675) may be formed on the flat tube end 4477 and / or on the inner surface of the receiving opening 4479 for limiting the insertion depth of the end. flat tube 4477.

In other embodiments, one or more of the flat tube ends 4477 may extend through a corresponding receiving opening 4479 and into an inner chamber 4487 of the collection tank 4467. In such embodiments, the flat tube end 4477 may be deformed in any manner, such as being bent over the surfaces of the inner chamber walls 44 83 adjacent the receiving aperture 4479 to at least partially match the shape of those surfaces.

In the illustrated embodiment of FIGs. 70, 70A, 71, 76, e77, an adhesive 4489 is used to secure the flat tube ends 4477 within the receiving openings 4479 (see FIG. 71) of the collection tank 4467. Various different adhesives may be used, including those that harden immediately or over time, and those want a degree of flexibility after fixation. For example, silicone adhesives produced by Dow Corning® can be used in many embodiments. In some embodiments, the adhesive 4489 ensures a permanent and firm gasket between the flat tube ends 4477 and the inner surfaces of the receiving openings 4479.

Adhesive 4489 may still function as a sealant to prevent fluid loss from the take-off tank 4467. In other embodiments, tubular ends 4477 are sufficiently secured within the receiving openings 4479 by inserting them into the rear portions 4485 of receiving openings 4479, in which case a sealant having no or substantially no adhesive properties may be used in place of a 4489 device. For ease of description, the term "adhesive" with reference to flat tube connections in collection tank refers to an adhesive that may or may not function. as a sealant, it being understood that in other embodiments such material may function instead only or primarily as a sealant.

As best shown in FIG. 71, the adhesive 4489 may substantially cover a significant portion of the flat tube end 4477, and in some embodiments surrounds the entire periphery of the flat tube end 4477 at at least one location along its length. In the illustrated embodiment of FIGs. 70, 70A, 71, 76, and 77, a terminal portion of the flat tube end 4477 is not covered with an adhesive 4489 due to its location within the rear portion 4485 of the receiving opening 4479. By virtue of the relatively close fit between the rear portions 4485 of the receiving openings 4479 and the flat tube ends 44 7 7 as described above, a fluid passing through the collection tank 4467 (for example, a liquid cooler or other fluid used as a means of heat exchange) may be prevented from contacting adhesive 4489.

The adhesive 4489 may be inserted between the flat tube ends 4477 and the inner surfaces of the receiving openings 44 7 9 in various different ways according to various embodiments of the present invention, many of which include the introduction of the adhesive 44 8 9 after or as the ends 4477 are received at their respective recess openings 4479. Prior to further description of such embodiments, it should be noted that the adhesive 4489 may be applied to the interior of the receiving openings 4479 and / or to the outside of the flat tube ends 4477 (for example). by spray, roller or other applicator, and the like) prior to insertion of the flat tube ends 4477 into the receiving openings 4479.

An introduction of adhesive 44 89 between the flat tube ends 4477 and inner surfaces of the recess openings 44 7 9 during or after insertion of the tube end may provide greater control over the amount and / or resulting locations of adhesive 4489 on the finished heat exchanger 4463, and may result in a more reliable connection and / or seals between the 4477 flat tube ends and the 4467 pickup tank.

In order to provide space for the adhesive 4489 to be inserted between the flat tube ends 4477 and the inner surfaces of the receiving openings 4479, the receiving openings 4479 and / or tubular ends 4477 may be shaped to define one or more spaces 4493 between. they. For ease of description, the term "space" (when used herein to refer to the space in which adhesive 4489 is received as described herein) refers to one or more of these spaces, regardless of a particular peripheral location around the flat tube end. 44 77 and independently of two or more such spaces for the same flat tube end 4477 to be in fluid communication with each other.

In some embodiments, the gap 4493 between the flat tube end 4477 and the adjacent inner surface defining the receiving aperture 4479 may be at least about 0.3 mm (0.011811 in) wide to allow for proper adhesive injection ( described below). Also, through experimentation, the inventors have found that this space width no larger than around 1.0 mm (0.03937 in) provides good performance results. Several considerations may at least partially define the size of the gap 4493, so that the amount of adhesive required, the characteristics of the adhesive (eg, viscosity and fixation time), the distance between adjacent flat tubes4410. Another consideration concerns the need, in some embodiments, for collecting tank 4467 to have a thickness or depth that is minimized. For example, in some embodiments the 4467 pickup tank protrudes flat tube core 4465 by a minimal amount so as to reduce the amount of space lost by the heat exchanger 4463 in a vehicle.

In some constructions, the 4467 pickup tanks have no protruding parts toward the depth of the 4465 fin-tube core to avoid the loss of available space required to install a 4463 heat exchanger in a vehicle. For example, the illustrated embodiment of FIGs. 70, 70A, 71, 76, and 77, and with reference in particular to FIG. 76, a non-deformed end of flat tube 4477 requires a minimal or substantially no part of the collection tank 4467 in front of the fin-core flat tube 4465, which addresses the need for a reduced heat-gauge space requirement 4463. In some embodiments, The stressed portion can also be reduced (for example, to the order of a few millimeters) when the process of manufacturing heat exchanger 44 63 includes the use of 4477 flat tube deformed ends (described below). In some embodiments, adhesive 4489 is introduced by injection. through one or more openings in the 4467 take-off tank or through one or more spaces between the 4477 flat tube ends and the 4467 collection tank accessible from the outside of the 4467 collection tank and 4410 flat tubes once these parts are assembled, at least partially. For example, collecting tank 4467 illustrated in FIGS. 70, 70A, 71, 76, and 77 have various injection openings 44 91, each extending through the collecting tank wall 4495 4467 to a defined space 4493 between the flat tube end 44 7 7 and one or more walls defining the opening of receipt 4479.

These 4491 injection ports may be located on one or both longitudinal sides of the 4467 pickup tank. Also, more than one injection port4491 may extend to the same receiving port4479. In such cases, the adhesive 4489 may be injected simultaneously into the same receiving opening 4479, such as through two opposite longitudinal 4491 injection ports of the collection tank 4467. One adhesive may also be injected into the corresponding 4493 space each flat tube 4410 one at a time, in space banks 4493 (corresponding to respective flat tubes 4410) at the same time or at substantially the same time in all spaces 4493 of a core 4465 at the same time or substantially at the same time. In some embodiments, the adhesive 4489 coats the entire periphery of each flat tube end 4477, and / or may fill the space 4493 between the flat tube end 4477 and the adjacent walls defining the receiving opening4479. Also, in some embodiments (e.g., those of FIGS. 70, 70A, 71, 76, and 77) the end ends of the flat tubes 4410 may be left uncoated with common adhesive 4489.

An alternative manner by which adhesive is introduced between the flat tube end 4477 and the inner walls of the receiving openings 4479 is to inject adhesive through a bottom opening or space 44 97 between these parts in fluid communication with the space 44 93 described above. This type of adhesive introduction may be used in addition to or in place of an injection through injection ports 44 91 as also described above, and may eliminate the need for injection ports 4491.

FIG. 84 is a block diagram depicting a process of manufacturing a heat exchanger 44 63 according to an embodiment of the present invention, referring to manufacturing stations or steps, and is accompanied by a schematic view of a 4463 heat exchanger being manufactured by this process. The term "station" is used herein for ease of description only, and by itself does not indicate or imply that there is a physical separation between these "stations" on the manufacturing line. For example, the 4467 collection tanks may be located at the free end of 4477 flat tube (Station III) in the same location or in a different manner than the application of the 4489 adhesive (Station IV).

FIGs. 72 to 75 illustrate a collection tank 4467 according to an additional embodiment of the present invention. This embodiment employs much of the same structure and has many of the same properties as the collection tank 4467 embodiments described above with respect to FIGS. 70, 70A, 71, 76, and 77. Accordingly, a reference should be made to the above description with respect to FIGs. 70, 70A, 71, 76, and 77 for additional structure and resource information, and possible alternatives to the collection tank structure and resources illustrated in FIG. 72-75 and below. The structure and features of the modality shown in FIG. 72-75 corresponding to the structure and features of the embodiments of FIGs. 70, 70A, 71, 76, and 77 are designated hereinafter in the 4500 series of reference numbers.

As the collection tank 4467 illustrated in FIG. 70, 70A, 71, 76, and 77, collection tank 4567 shown in FIGS. 72-75 has an inner chamber 4,587 for flow-through communication with flat tubes 4510, several receiving openings 4579 each having rear portion 4585 for receiving ends 4577 of flat tubes 4510, various injection openings 4591 along longitudinal sides (only one 72-75) of collecting tank 4567. FIG. 75 provides additional details regarding the receiving ports 4579, including the 4585 rear portions used for receiving and supporting the ends 4 577 of the flat tubes 4 510 (not shown in FIG. 75), and the injection ports 4591 in fluid communication with the ports. receiving openings 4579.

Flat tubes 4510 received through receiving openings 4579 define corresponding spaces 4593 between the inner surfaces of receiving openings 4579 and flat tube ends 4577. With particular reference to FIG. 73, flat tube flow channels 4516 in respective receiving port 4579 are in fluid connection with inner chamber 4587 of collection tank 4567. FIG. 73 also illustrates the connections between the injection openings 4591 and the receiving openings 4579 for adhesive injection 4589 (not shown) in space 4593 as described above.

As best shown in FIG. 74, the inlet of receiving openings 4579 may be closed or substantially closed on one or more sides of each flat tube end 4477 by inlet walls of inlet walls 4599 (not shown in FIG. 75). The inlet walls 4599 may be defined by one or more elements of the collection tank 4567, such as by a plate which is defined as multiple openings that define the inlet of each receiving opening 4,579, when the plate is installed with the multiple openings aligned with the Alternatively, inlet walls 4499 may be defined by terminal ends of the receiving aperture that have been enlarged, tapered, bent or otherwise shaped to at least partially close the spaces 4593 described above. In some embodiments, the inlet walls 4599 are shaped to match or substantially match the cross-sectional shape of the flat tube ends4577 received therein. Also, inlet walls 4599 may be sized to set a loose fit with the flat tube end 4577, or may instead set an interference fit so that slight pressure may be exerted on the collection tank4567 and / or over the flat tubes 4510 to push the flat tubes 4,510 in front of the inlet walls 4,599 and the rest of the receiving openings 4579. In this way, seals at the inlets of the receiving openings4579 may be provided between the collecting tank 4,567 and the ends. 4577. These seals may be fluid-tight or substantially fluid-tight in some embodiments and may prevent leakage during adhesive injection in some embodiments.

It should be noted that the collection tank construction4567 illustrated in FIG. 72 to 75 (and the other figures) is by way of example only and is not limiting to the scope of the present invention.

In some embodiments, the flat tube ends4477, 4577 may be deformed. For example, flat tube ends 4477, 4577 may be deformed such that the large diameter D of flat tube 4410, 4510 is increased and the small diameter d of flat tube 4410,4510 is decreased at the flat tube ends 4477,4577. Considering the relatively small thickness of the flat tube 4410, 4510 in some embodiments, such deformation can be performed without significant load on the flat tube walls 4410, 4510. In some embodiments, the undersized end dimensions of the flat tube 4477, 4577 remain substantially the same as those of the deformed end of flat tube 4477, 4577. As a result, the walls of flat tube 4410, 4510 in such embodiments do not undergo significant expansion or contraction.

In some embodiments where tubular ends 4477, 4577 are deformed, such deformation may be performed prior to introduction of tubular ends 4477, 4577 into corresponding receiving openings 4479, 4579 of collecting tank 4467, 4567.

Examples of flat tube connection to collection tank where flat tube ends have been deformed will now be described with reference to FIGs. 78 to 83.

FIGs. 78 to 83 illustrate collection-level flat tube fittings according to three additional embodiments of the present invention. These embodiments employ much of the same structure and have many of the same properties as the flat tube to collection tank connection modalities described above with respect to FIGs. 70-77. Accordingly, the following description focuses primarily on the structure and features that are different from the above described embodiments with respect to FIGs. 70-77. A reference should be made to the above description with respect to FIGs. 70-77 for additional structure and feature information, and possible alternatives to the structure and features of the connection embodiments illustrated in FIGs. 78-83 and described below. The structure and features of the embodiments shown in FIGs. 78 to 83 corresponding to the structure and features of the embodiments of FIGs. 70-77 are designated hereinafter in the 4600 series, 4700, and 4800 series of reference numbers, respectively.

In each of the embodiments illustrated in FIGs. 78 to 84, the 4677, 4777, 4877 flat tube ends are deformed, with the collecting tanks 4667, 4767, 4867 having correspondingly shaped receiving openings 4679, 4779, 4879. A deformation of the tubular ends 4677, 4777, 4877 shown in FIG. 78 to 84 was performed upon completion of the brazing process (Station II in FIG. 84) - prior to placement of the flat tube ends 4677, 4777, 4877 in the receiving openings 4679, 4779, 4879.

In the embodiment of FIG. 78 to 80, each flat tube 4610 has an end 4677 that is firmly received at a corresponding rear portion 4685 of the recess opening 4679. In this embodiment, the broad sides 4622,4624 of each flat tube 4610 have been expanded (i.e. flexed away from one of the another) for the definition of a tapered end of flat tube 4677, while narrow sides 4618, 4620 were compressed (i.e. bent toward each other). Also, each receiving opening 4679 also has stops 4675 (see FIG.80) for limiting the insertion of flat tubes 4610 to a desired distance.

As the embodiment of FIG. 78 to 80, in the embodiments of FIG. 81 to 83, the broad sides 4722, 4724, 4822, 4824 of each flat tube 4710, 4810 were expanded to define a tapered end of flat tube 4777.4877, while the narrow sides 4718, 4720, 4818.4820 were compressed. . However, that part of the take-off tank 4767, 4867 defining the receiving openings 4779, 4879 has one or more slits 4773, 4873 extending alongside at least a portion of the receiving openings 4779, 4879, and in some embodiments extending around the opening. In both cases, the slots 4773, 4873 are positioned and sized to receive the free ends 4777.4877 of the flat tubes 4710, 4810. The slots 4773, 4873 also function as stops for limiting the insertion depth of the tube ends. plan 4777, 4877.

Following insertion of the flat tube ends 4777, 4877 into the receiving openings 4779, 4879 and slots 4773, 4873, adhesive 4789, 4889 (not shown) can be injected into the spaces 4793, 4893 between the flat tube ends 4777, 4877 and the surfaces. receiving ports 4779, 4879. This injection may be performed in any of the ways described herein, and is performed by injection into injection ports 4791, 4891 in the illustrated embodiments of FIG. 81-83 by way of example. In some embodiments, including those in which the deformed flat tube ends are used, one or more inserts 4771 may be placed between the flat tube ends 4777 to help prevent deformation of the flat tube ends 4777 when flat tube ends 777 are exposed to the loads. internal pressure. For example, internal folds formed in the embodiment of FIG. 1-5 may be protected from deformation when exposed to internal pressures by these inserts 4771. In the embodiment illustrated in FIG. 81 and 83, for example, inserts 4771 have a generally trapezoidal cross-sectional shape, although any other cross-sectional format may be used, depending at least in part on the adjacent shapes of flat tube ends 4777. Inserts 4771 may be introduced to their positions. adjacent to flat tube ends 4777, before or after application of adhesive 4789 (e.g., after Station III, or before or after Station IV in FIG. 84).

If used, the inserts 4771 may be made from any material, including without limitation plastic or metal, may be solid or hollow, and in some embodiments may be defined by an easily deformable or flowable mass which is later hardened.

Also, multiple inserts 4771 may be connected before and during an insertion, such as a common bar or bar for defining a comb type (not shown) format. This type of insertion, such as by a common bar or bar, may allow two or more and, in some embodiments, all inserts 4771 to be made in one step. In some embodiments, the connections between the common bar and inserts 4771 are frangible, allowing the common bar or rail to be removed subsequent to insertion of inserts 4771.

To allow insertion of the inserts 4771 into desired locations between adjacent ends of the flat tube 4777, one or both of the opposed longitudinal walls 4795 of the collection tank 4767 may have openings (see FIG. 83, for example) aligned with these locations and sized to allow the Insertion 4771. In this regard, it should be noted that insertions 4771 need not necessarily occupy the spacer between adjacent flat tube ends 4777, and need to occupy only enough space between the flat tube ends 4777 to support the pressurized ends as required.

It should be noted that the varied ways of introducing adhesive at locations between the tubular ends 4477, 4577, 4677, 4777, 4877 and the inner surfaces of the receiving openings 4479, 4579, 4679,4779, 4879 described herein may be used, regardless of whether or not. flat tube ends 4477,4577, 4677, 4877 are deformed or undeformed.

In some embodiments of the present invention, the collecting tank 4467, 4567, 4667, 4767, 4867 may include stiffening walls 4469, 4569, 4669, 4769, 4869 extending between and / or at least partially defining receiving opening walls 4469, 4569, 4679 , 4779, 4879 Collection Tank 4467, 4567, 4667, 4677, 4877. These stiffening walls 4469, 4569, 4669, 4769, 4869 can be used to stiffen parts of the collection tank4467, 4567, 4667, 4767, 4867 as required, and are not visible in all illustrated take-off tank modalities. For example, one or more stiffening walls 4669, 4769, 4869 may extend in the transverse direction of the collection tank 4667, 4767, 4867 (for example, by connecting opposite longitudinal walls 4695, 4795.4895 of collection tank 4667, 4767, 4867 ), and may provide additional strength and / or stiffness to the collection tank 4667, 4767, 4867. The stiffening walls 4669, 4769,4869 may be formed anyway, and may be integral with the collection tank 4667, 4767, 4867 or separate elements. connected to it in any appropriate way. In some embodiments, the stiffening walls 4669, 4769, 4869 are formed during injection molding of the collection tank 4667, 4767, 4867, and thus are an integral part of the collection tank 4667,4767, 4867.

Some embodiments of collecting tanks 4667, 4767,4867 in accordance with the present invention may also, or instead, have stiffening walls extending longitudinally with respect to collecting tank 4667,4767, 4867. For example, such stiffening walls may be formed between and connecting walls defining receiving openings 4679, 4779, 4879 of the take-off tank 4667, 4767, 4867. A cross section of a longitudinal stiffening wall such as this 4469 is shown in FIG. 70A by way of example, and is located halfway between the front and rear faces of the take-off tank 4667, 4767, 4867 (although these longitudinal stiffening walls may be located in other positions as desired). These longitudinally extending stiffening walls 4469 may extend along any or all of the collection tank length 4667, 4767, 4867 (interrupted as necessary by the recessing openings 4679, 4779, 4879).

As mentioned above, the collection tank may be constructed from any number of parts connected together in any suitable manner. By way of example, FIG. 72 and 82 illustrate collection tanks 4467, 4867 wherein collection tank 4467, 4867 is formed of two parts 446 7a, 446 7b, and 4867a, 4867b. In both illustrated embodiments, parts 4467a, 4467b, and 4867a, 4867b are joined along a Z-shaped interface, and may be joined by welding or adhesive. Still other ways of establishing this connection are possible, based at least in part on the material used for the collection dot formation 4467, 4867. In some embodiments, this connection is releasable, as shown in the embodiments of FIG. 72 to 75 where clamps in the 4467 take-off tank can be used for formally securing part of the 4467a collection tank in place relative to the remainder of the 4467b collection tank.

The various flat tube embodiments described herein may be used in a variety of different heat exchangers adapted for different uses. In so doing, the flat tubes may be modified with respect to the embodiments illustrated in FIGs. 1 to 54 and / or may be mounted on heat exchangers in a variety of different ways to adapt heat exchangers to particular applications.

FIGs. 85 to 90 illustrate four heat-detecting constructions according to different embodiments of the present invention. While still other heat-producing embodiments are possible by modifying the number and arrangement of flat tubes and / or modifying flat tube types (e.g., tube size and shape, insert size and shape, and the like), each of the heat exchangers. heat illustrated in FIGs. 85-91 provides unique advantages in many applications.

Before describing each of the heat exchangers 4963, 5053, 5163, 5263 illustrated in FIGS. 85 to 90 in more detail, it should be noted that each of the flat tubes 4910, 5010, 5110, 5210 illustrated herein may be replaced by flat tubes 4910, 5010, 5110, 5210 having any of the shapes and constructions of any of the ways described above with reference to the above. FIG modalities. 1-54, and that any of the mounting capabilities in heat exchanger mounting methods (e.g., with respect to flat tubes, core construction, and core to manifold attachment) also described herein with respect to the embodiments of FIG. 1-84 may be used in the construction and manufacture of the heat exchangers 4963, 5063, 5163,5263 illustrated in FIGS. 85-90. For example, each of the four flat tubes 4910, 5010, 5110, 5210 illustrated in FIG. 85-90 is a two piece flat tube 4910, 5010, 5110, 5210 with an insert 4934, 5034, 5134, 5234, where two separate pieces of sheet material are used for forming each illustrated tube 4910, 5010, 5110, 5210. and where a third separate piece of sheet material is used for forming the inner insert 4934, 5034, 5134, 5234. Although the particular two-piece (with insert) flat tube constructions illustrated in FIG. 85-90 are desirable for the described applications and other applications, either of these 4910, 5010,5110, 5210 flat tubes may be replaced by either of the one-piece flat tubes or other two-piece flat tubes (with inserts) described above and / or illustrated here, to adapt the flat tubes 4910, 5010, 5110, 5210 and the resulting heat exchangers 4963, 5063, 5163, 5263 for any desired application. In this regard, a combination of flat tubes 4910, 5010, 5110, 5210 with insertions formed of different sheet numbers may be used in the same heat exchanger 4963, 5063, 5163, 5263. In the illustrated tube constructions of FIGS. 85 to 91 and in either of the aforementioned alternative pipe constructions, one or both narrow sides of the plain pipe may be formed by the longitudinal edges adjacent to the material overlap, depending at least in part on the number of sheets of material used for the pipe construction. plan. Each pair of overlapping longitudinal edges thus defines a reinforced narrow side of the flat tube. In some embodiments, one or both of the flat tube overlapping longitudinal edges may be bent one or more times to define even more material thickness on the narrow side (s) of the flat tube. In some such embodiments, a sheet of reinforcing material defining the insert may have one or both longitudinal edges formed to be adjacent the longitudinal overlapping edges of the tuboplane, thereby providing an additional layer of pipe reinforcing material on the narrow sides. Also, one or both of the longitudinal edges of the insert may be folded to have a multilayer thickness adjacent to the overlapping longitudinal edges of the tuboplane, thereby further providing reinforcement on both narrow sides. Accordingly, one or both right sides of the flat tubes may exhibit an aqual thickness totaling at least two, and in some embodiments more than twice the thickness of the sheet material used for the formation of the flat tube walls, which may be formed by rolling a thicker sheet material in some embodiments.

As described in more detail above, in those modalities in which flat tubes are constructed of a single part (with or without an insert), a reinforcement of the narrow sides may be obtained by rounding one or more folds of the sheet material to form the first narrow side of the tube. and overlapping opposite longitudinal edges of the sheet of material to form the second narrow side of the flat tube (e.g., by receiving or wrapping a flexion of one longitudinal edge into a greater flexion of the other longitudinal edge, or in other ways described herein).

In some one-piece flat tube embodiments, a sheet of material may form the outer walls of the tuboplane as well as the interior of the flow channels. In such embodiments, a gradation may be located at flexions of the sheet of material (defining the narrow sides of the tuboplane) where the longitudinal edge of the sheet of material veins so that the outer surface of the flat tube remains as smooth as possible. Additionally, in those embodiments wherein the insert is defined by a separate sheet of material, the two longitudinal edges of this separate sheet of material may be rounded or otherwise shaped to be received at the narrow sides of the flat tube (e.g., see the illustrated embodiment of the sheet). Fig. 46).

As also described in greater detail above, in those embodiments in which flat tubes are constructed in two separate parts (with or without an insert), the two separate parts may be constructed identically, in which case a longitudinal edge of each part may have a bending involving a minor flexion of an adjacent longitudinal edge of the other part. These two separate parts can therefore be transported with respect to each other to form the flat tube. In other embodiments, the two separate parts are not identical to one another, and have opposite longitudinal edges joined together in any of the ways described herein (including without limitation nested longitudinal edges in arc format).

Also, the substantially flat broad sides of any of the tube embodiments described and / or illustrated herein may be used for providing improved flap joints affixed thereto, thereby resulting in improved heat exchanger heat exchange efficiency 4963, 5053, 5163, 5263.

Also, in any two-piece and three-piece flat tube constructions that may be employed in the heat exchangers of FIG. 85-89, the inner insert may be corrugated or otherwise shaped for the definition of two or more flow channels through the flat tube. The internal insertion may have differently shaped and / or sized corrugations at different locations across the width of the insert so as to define two or more laterally disposed regions of different tendoformed flow channels and / or sizes (e.g. see FIGS. 85 to 89, for example) . More broadly, the internal insert can be shaped for the definition of flow channel regions having different shapes and / or sizes in different locations across the width of the flat tube in two pieces or in three pieces. In some embodiments, different regions of flow channels may be isolated from each other, whereas in other embodiments different regions are in fluid communication with each other (for example, at one or more locations along the length of one or more flow).

Also, in some embodiments, each of the flow channels in one region is isolated from the other flow channels in the region along the length of the flat tube, whereas in other embodiments, the flow channels in the region are in fluid communication with each other. others (for example, through openings between adjacent flow channels), but are isolated from other flow channels in other regions.

It will be appreciated that many of the advantages of using flat tubes 4910, 5010, 5110, 5210 according to the present invention in the illustrated embodiments of FIG. 85-89 refer to the manufacturing capacity of these flat tubes at lower cost, with reduced material quantities, and / or with improved heat exchange performance. These advantages are realized by the use of sheet materials having the relatively low thicknesses described above for forming flat tubes and inserts. Although any of the material thicknesses of the flat tubes described above may be used in the embodiments of FIG. 85 to 89, the sheet material used for forming the flat tube walls in the illustrated embodiments has a thickness no greater than about 0.15 mm (0.0059055in). Also, this sheet material has a thickness of not less than about 0.03 mm (0.0011811 in.). These wall thickness types may be used to withstand compression loads, and may exhibit relatively good stability at an internal pressure, in many embodiments in light of the fact that the insert may be bored into the wide walls of the flat tube. Similarly, although any of the insertion material thicknesses described above may be used in the embodiments of FIG. 85 to 89, the sheet material used for forming the inserts in the illustrated embodiments has a thickness no greater than about 0.09 mm (0.003543 in). Also, this sheet material has a thickness of no less than about 0.03 mm (0.0011811 in.).

By utilizing the various flat tube constructions for the illustrated heat exchangers 4963, 5053, 5163,5263 and for other heat exchanger designs, advantages of increased production speed and / or reduced mounting material costs can be realized. For example, based on the relatively low amount of deflection deformation required for forming the various flat tubes in one or two pieces according to the present invention described above, flat tubes can be produced more economically in a tube lamination (e.g., manufacturing lines 3701 and 1900, for example) even high operating speeds using sheets of endless material. Further, with relatively low modification expense, heat exchangers having approximately any depth can be fabricated using the same flat tubing font (e.g. continuous or endless tubing and finned tubing produced as described above, for example).

Heat exchangers 4963, 5063, 5163, 5264 illustrated in FIG. 85-90 are presented only for illustration of heat exchanger embodiments that provide performance results in many applications, but also for illustration of various heat exchanger features that can be used alone or in combination in heat exchangers according to embodiments of the present invention. These features include, without limitation, collector tanks that are internally split for directing separate flows through different internal regions of the same flat tubes and possible flow arrangements through the heat exchanger.

Referring now to heat exchanger 4963 illustrated in FIG. 85, heat exchanger 4,963 has a single row of flat tubes 4910 having a depth T (generally similar to the large diameter D of each flat tube 4910). While any of the other small and large diameters D, d described above may be used for flat tubes 4,910, the large diameter D of flat tubes 4,910 shown in FIG. 85 is no larger than around 300 mm (11.811 in). In some embodiments, a large diameter Dde not less than about 10 mm (0.3937 in) is used to provide good performance results. Also, the small diameter d of the flat tubes 4,910 shown in FIG.85 is no larger than around 15 mm (0.5 9055 in). In some embodiments, a small diameter d of no less than about 0.7 mm (0.02756 in) is used to provide good performance results. These dimensions of the flat tubes 4910 in the illustrated embodiment of FIG. 85 are particularly suitable for 4 963 motor heat exchangers. However, other applications are possible and fall within the spirit and scope of the present invention. Heat exchanger 4963 illustrated in FIG. 85 is adapted for cooling two or three fluids through a common flow of coolant (e.g., air) passing between the flat tubes 4,910. The cooling air is illustrated in Fig. 86 as a bloc multiple arrow which flows through fins (not shown) between flat tubes 4910.

According to the illustrated embodiment of FIG. 86, the cooling flame may flow from left to right or vice versa through the cooling network defined by the fin tube block 4965. Each of the flat tubes 4910 includes four internal regions 4975a, 4975b, 4975c, 4975d at locations other than along the wide flat tube 4910. The four illustrated inner regions 4975a, 4975b, 4975c, 4975d have the same or substantially the same width, although inner regions 4975a, 4975b, 4975c, 4,975d of different widths are possible in other embodiments. Also, each illustrated inner region 4975a, 4975b, 4975c, 4975d has multiple flow channels 4916a, 4916b, 4916c, 4916d, each having a different format and / or size relative to the flow channels 4916a, 4916b, 4916c, 4916d of the other internal regions4975a, 4975b, 4975c, 4975d. The shape and size of flow channels 4916a, 4916b, 4916c, 4916d in each internal region 4975a, 4975b, 4975c, 4975d is defined at least in part by the shape of insert 4,934 in that internal region 4975a, 4975b, 4975c, 4975d. While the internal region to internal region format variene insert 4975a, 4975b, 4975c, 4975d in the embodiment illustrated, each tuboplane 4410 is substantially the same as the other heat notor 4963.

Although four internal regions 4975a, 4975b, 4975c, 4975d are employed in heat exchanger 4963 illustrated in FIG. 85, any number of internal regions 4975a, 4975b, 4975c, 4975d may be defined by one or more flat tubes 4910 in other embodiments, and may have any desired relative sizes. Also, although the insertion 4934 is vaporized in each internal region 4975a, 4975b, 4975c, 4975d of the flat tube 4910 illustrated in FIG. It has a different shape from that in the other internal regions 4975a, 4975b, 4975c, 4975d (thereby defining flow channels 4916a, 4916b, 4916c, 4916d which are different in each internal region 4975a, 4975b, 4975c, 4975d), in other embodiments two or more of the other. inner regions 4975a, 4975b, 4975c, 4975d may have identical or substantially identical flow channels 4916a, 4916b, 4916c, 4916d.

With continued reference to FIG. 85, in some embodiments, each 4410 flat tube in a heat exchanger 4963 or a section of heat exchanger 4,963 has the same number of internal regions 4975a, 4975b, 4975c, 4975d as flow channels 4916a, 4916b, 4916c, 4916d having the same format and size or substantially the same. However, this is not necessarily the case in other modalities. The number, size and shape of regions on each 4910 tubular plane and 4910 flat tube assembly can be determined based at least in part on the requirements of the application.

Heat exchanger 4963 of FIG. 85 includes collection ducks 4967a and 4967b. A collection tank 4967 includes three partition walls 4973a, 4973b, and 4973c, which extend in a direction substantially perpendicular to the depth T of heat exchanger 4,963, and which run lengthwise with respect to collection tanks 4967a, 4967b. The other collection tank4967b includes two split walls 4973d and 4973e.

FIG. 85 illustrates various arrows indicating the directions of flow through the heat exchanger 4963. On the left side (with respect to FIG. 85), a medium flows into the collection tank 4967a first and through the first internal region 4975a of each flat tube 4910. A second medium it flows into the first collecting tank 4,967a and through the second inner region 4,975b of each flat tube 4,910, and is separated from the flow of the first medium through the first inner regions 4,975a by a first dividing wall4973a there. The second medium is also separated from the first medium in the second collection tank 4,967b by the first split wall 4973d there and a third medium (which may be the second medium second pass through the heat exchanger 4963, in some embodiments, or another medium). in other embodiments) in the second collection tank 4 967b by the second partition wall 4973e there. The dome partition wall 4973b of the first collection tank 4967a separates the flow of the second medium entering the heat exchanger 4,963 and the return flow of the second medium exiting the heat exchanger 4,963 after passing through the third internal region 4975c of each flat tube 4910. The third half passes through the heat exchanger 4963 as it flows through that inner region 4975d of each flat tube 4910, and is separated from the second medium in the first collection tank 4967 by the third partition wall 4973c there.

In some applications of the newly described 4,963 heat exchanger, the left section of the 4963 heat exchanger (with reference to the perspective of FIG. 85) may be a high temperature region for charge air. The charge air from this section of heat exchanger 4,963 after passing through the first inner region 4975a of each flat tube 4910 may flow back to heat exchanger 4963 and in some embodiments, passing through the fourth inner region 4,975b of each flat tube 4,910 in heat exchanger 4963. Therefore, this return flow can then be a low temperature region for the charge air. In such embodiments, a cooling fluid passing between the flat tubes 4910 may flow from right to left in the embodiment illustrated in FIG. 85. Nationing of the heat exchanger medium 4 963, a high temperature cooling fluid may enter the first collection tank 4 967a, pass through the second internal region 4 97 5b of each flat tube 4 910, and return through the second collection tank 4967b. and through the third internal region 4975c of each 4910 flat tube to exit the heat exchanger 4963. The return pass of this fluid (first pass mount, as referenced with respect to the direction of flow of cooling fluid passing between the 4910 flat tubes), therefore, defines a low temperature cooler region. In some embodiments, 10% of this fluid passing through the second and third inner regions 4975b, 4975c may flow through these regions again, to reduce their temperature further, although other percentages (including only) may be possible in other embodiments. Also, in other embodiments, any number of partition walls 4973a, 4973b, 4973c, 4973d, 4973e and any number of collection tanks 4967a, 4967b having any number of fluid inlet and outlet windows may be provided in other ways for the provision of other designs. heat exchanger functions.

FIG. 86 illustrates a heat exchanger 5063 according to another embodiment of the present invention, wherein flat tubes 5010 having the features shown in FIG. 87 are used. The illustrated heat exchanger 5063 is adapted for use on a vehicle coolant radiator, although other applications for the 5063 heat exchanger are possible. This heat exchanger 5063 includes an internal region 5075a which may be a high temperature region in some embodiments based on the fact that the temperature of the coolant is relatively high there. The heat exchanger 5063 may also include a low temperature internal region 5075b, wherein the temperature of at least part of the cooling fluid leaving the first internal region 5075a may be further reduced.

Further details with reference to flat tubes 5010 illustrated in FIG. 86 can be seen in FIG. 87, which shows a flat tube 5010 according to an embodiment of the present invention that can be used in heat exchanger 5063 of FIG. 86. Although the flat tube 5010 illustrated in FIG.87 provides unique performance results, it should be noted that any of the other tuboplane embodiments shown herein may be used instead. Tuboplane 5010 illustrated in FIG. 87 is formed by two sheets of separate material each of which form the first and second portions 5012, 5014 of the tube in two pieces 5010. A third sheet of material is used for forming the insert 5034. The first and second portions 5012, 5014 in the illustrated embodiment are identical or substantially identical, but may be transposed with respect to one another. In the manufacturing process, a larger bend defining the larger arc portion is formed at one longitudinal edge of each portion 5012, 5014, and surrounds the smaller arc portion formed at the corresponding longitudinal edge of the other portion 5014, 5012, so that two narrow sides 5018, 5020 of the flat tube 5010 each have a double wall thickness. Further, the opposite longitudinal edges 5038, 5040 of insert 5034 are shaped to fit within the narrow sides 5018, 5020 of flat tube 5010. In this particular construction, a three-layer thickness is defined on a narrow edge 5018. This thickness can be three times that one. of the material used for forming the first and second portions 5012, 5014 in those embodiments wherein the thickness of the insert 5034 is the same as that used for the first and second portions 5012, 5014, although the insert 5034 may be made of a finer material in other portions. modalities. It should be noted that the features shown in FIG. 8 7 may be applied to any of the other flat tube embodiments described and / or illustrated herein.

The two inner regions 5075a, 5075b of the flat tubes 5010 in the heat exchanger of FIG. 86 are defined, at least in part, by the corresponding insert section 5,034 in each inner region 5075a, 5075b. The first internal region 5075a may be used in some embodiments to withstand relatively higher pressures of the second internal region fluidone 5075b, by virtue of the relatively narrow flow channels 5016 defined by the narrower spaces between insertion corrugations 5034 in the first internal region 5075a. Also, the second narrow side 5020 corresponding to the second inner region 5075b has greater reinforcement than the opposite (first) narrow side 5018. This reinforcement is formed by a longitudinal edge 5040 of insert 5034 having two additional folds on the second narrow side 5020, thereby providing the narrow second 5020 with five layers of material. This design provides an example of how the 5010 flat tubes according to the present invention may be reinforced as necessary due to the stresses in selected areas of the 5010 flat tubes and may be provided with thinner wall areas (e.g. 0.03mm - 0.15 mm (0.0011811 - 0.0059055) in some embodiments) in other areas where the predicted stresses are relatively low. The weight of materials used to construct 5010 flat tubes and manufacturing losses of the 5010 heat exchanger can therefore be considerably reduced.

FIG. 88 illustrates a heat exchanger according to another embodiment of the present invention using the flat tubes 5110 illustrated in FIGs. 89. In the illustrated embodiment of FIG. 88 and 89, the inner flat tube region 5175 5110 has several flow channels 5116 defined at least in part by an insert 5134 that is uniformly or substantially uniformly shaped across the width of the insert 5134. However, the heat exchanger 5163 is provided with two different groups G1, G2 of flat tubes 5110 having flow channels 5116 which are different from each other. In other embodiments, any number of these groups is possible. A fluid flowing to and from each group G1, G2 of flat tubes 5110 is separated from that other group G2, G1 by a transverse division wall5173 in collection tank 5167 extending toward the depth of heat exchanger 5163. Different fluids may flow in each group G1, G2 of flat tubes 5110. For example, in one group G1, a first medium (eg, oil) may flow, while in the other group G2, a second medium (eg, a coolant) may flow. Group G2 flat tubes 5110 are generally adapted for a medium which is under higher pressure than that in Group G flat tubes 5110, as may be served from the use of narrower flow channels5116 and shorter distances between insert walls 5134 in group G2 flat tubes 5110, and the greater degree of reinforcement of narrow sides 5118, 5120 in group G2 flat tubes 5110 for relatively more stability. In some applications, group G2 flat tubes 5110 may define a portion of the low temperature coolant radiator heat exchanger 5163, while flat tubes 5110 of G1 may define a high temperature coolant radiator heat portion 5163.

Under the assumption that the medium in the G10 group 5110 flat tubes is under higher pressure than the G1 group 5110 flat tubes medium, the wide sides 5122, 5124 and the narrow sides 5118, 5120 of the G2 group 5110 flat tubes are reinforced by insert design 5134 used there. In particular, the corrugations of the 5134 flat nostubes inserts 5110 of the G2 group are significantly narrower than those of the flat tubes 5110 in the G1 group.

Additionally, the narrow sides 5118, 5120 of the flat tubes 5110 in group G2 have five layers of material (two defined by the longitudinal overlapping edges of the first and second tube portions 5112, 5114 on the narrow sides 5118, 5120, and three defined by two folds at each longitudinal edge). 5138, 5140 of insert 5134), whereby only three layers of material are located15 on the narrow sides 5118, 5120 of flat tubes 5110 in group G1 based on the lack of such insert bends. It should be noted that flat tubes 5110 in both groups G1, G2 may be identical or substantially identical, and both may also be adapted to receive different types of inserts 5134 shown in FIG. 89

Thus, the two different inner regions 5175 flat nostubes 5110 are created in this particular mode by the different inserts 5134 defining two different groups of flat tubes 5110 for the heat exchanger 5163.

FIG. 90 illustrates a heat exchanger according to yet another embodiment of the present invention using flat tubes 5210 similar to those of FIG. 53. In this particular embodiment, the relative sizes of the inner regions 5275a, 5275b vary between the heat-treated flat tubes 5210 5263. In some embodiments (including the illustrated embodiment of FIG. 90, for example), the relative sizes of the inner regions 5275a, 5275b vary gradually. 5210 flat tube to 5210 flat tube through at least a portion of the heat exchanger 5263. Thus, a collection tank 5267 attached to the flat tubes 5210 may have a dividing wall 5273a extending obliquely with respect to the ends of the flat tubes 5210. The position of this split wall 5273a may correspond to the size change of the inner regions 5275a, 5275b in the flat tubes 5210. If desired, one or more additional split walls (for example, the split wall 5273b shown in FIG. 90) may be included in the tank. 5267 to provide additional flow separations through heat exchanger 5263 as desired.

An example of a one piece flat tube 5310 that can be used in any of the heat exchanger embodiments described above is shown in FIG. 91 by way of example. The one-piece flat tube 5310 in FIG. 91 is substantially the same as that shown in FIG. 54 described above, with the exception of insertion corrugations 5252 which are substantially rectangular in the embodiment of FIG. 91 (as opposed to substantially triangular corrugations 4352 in the embodiment of FIG.54), and with the exception and flow channels 4316, 5316 having the same size as FIG. 54, and having different sizes in FIG.91. Accordingly, a reference is thus made to the associated description of FIG. 54 for further information with reference to the flat tube embodiment illustrated in FIG.91.

Flat tubes 4310, 5310 in FIG. 54 and 91 may be made from a single sheet of material, and may be used in place of the flat tubes in the embodiments described above with respect to FIGs. 85-90. It should also be noted that any of the other one-piece or two-piece flat tubes shown herein may be used in place of any of the flat tubes in the embodiments described above with respect to FIGs. 85-90. The narrow sides 4318,4320, 5318, 53210 of both flat tubes 4310, 5310 illustrated in FIGs. 54 and 91 include a double thickness of the sheet material used for forming the flat tube 4310,5310. The sheet of material may be folded twice into the two areas of the sheet of material that will be flexed to form the narrow sides 4318, 4320, 5318, 5320 with the flat tube 4310, 5310 (i.e., the adjacent areas and flanking that portion of the sheet of material shaped to the definition of the integral insert 4334, 5334), thereby increasing the thickness of the narrow areas by three times that of the thickness of original material. Further, each longitudinal edge of the sheet of material may be flexed and moved to surround a respective reinforced section in the manner shown in FIGS. 54 and 91. Both reinforced stations may be provided with a gradation 4358,4360 (not visible in FIG. 91, but visible in FIG. 54) to receive the corresponding longitudinal edges in a recessed manner. In order to further reinforce the narrow sides 4318, 4320, 5318, 5320 of the flat tube 4310, 5310, additional folds may be incorporated into the reinforced sections shown in FIGs. 54 and 91. In the flat tube 5310 illustrated in FIG. 91, two groups of flow channels 5316 are defined, each having a size that is different from those of the other group. In contrast, all flow channels 4316 in the embodiment illustrated in FIG. 54 are substantially the same size.

FIGs. 19 to 23 show several different flat tubes that can be produced from a single sheet of material. Like the other flat tubes in one piece illustrated here, each of the embodiments shown in FIGS. 19 to 23 is especially suitable for the heat exchanger 4963, 5063, 5163, 5263 discussed with respect to FIG.85 to 90. In particular, the flat tubes described above with respect to FIG. 19 to 23 include narrow sides that are reinforced by the provision of vertical or horizontal folds. Additionally, FIG. 46 illustrates a tuboplane 3,710 which may be produced from a single sheet of material, with an insert 3,734 which may be produced from another sheet of separate material. This particular flat tube 3710 may also serve as a replacement for any of the flat tubes 4910, 5010, 5110, 5210 described above with respect to FIG. 85 to 90. As described in greater detail above, in the embodiment of FIG. 46, a reinforced narrow side 3718 is formed by bending a portion of the sheet of material having additional folds. The other narrow, reinforced side 3720 is formed by a longitudinal edge of the sheet of material surrounding the opposite longitudinal edge of the same sheet of material. This other narrow side 3720 can also be distinguished by the fact that one or both longitudinal edges of the sheet of material can be folded for further reinforcement. The second sheet of material may be provided with various corrugations as described above, and may also be provided with flexions or folds at one or both longitudinal edges 3738, 3740 for additional internal reinforcement of one or both right sides 3718, 3720.

FIGs. 92 to 95 illustrate exemplary heat exchanger structures and methods for connecting the sheets of material for forming a heat exchanger or a portion of a heat exchanger (e.g., a heat exchanger core, a portion of a heat exchanger core , a tube insert, heat exchanger tubes, ribs or fins of a heat exchanger, the collector of a heat exchanger, and the like). For example, in the illustrated embodiments of FIG. 93 to 95, fins 8313 are broken into a heat exchanger tube 8310. In these illustrated embodiments, heat exchanger tubes 8310 are formed from a first sheet of generally flat material 8317, and fins 8313 are formed from a second sheet. of material 8333 having a corrugated format. In other embodiments, the sheets of material being brazed are different portions of the same sheet of material. Also, in other embodiments and as explained in more detail below, heat exchanger tubes 8310 and / or fins 8313 may have different shapes.

Although the methods described herein are with reference to the production of particular heat exchanger embodiments described in this patent application, that is by way of example only. Accordingly, it is to be understood that the processes described with reference to FIG. 92 through 95 may be applied to the manufacture of all heat exchangers and heat exchanger portions described in this application.

As explained above, the relatively small foil thickness of heat exchanger tubes 8310 and / or fins 8313 in some embodiments of the present invention may provide significant advantages over overall heat exchanger performance, fabricability and possible wall constructions (as shown herein). ) which are not possible using thicker wall materials. Also, by using one or more of the flat tube features described herein, the inventors have found that several different flat tubes having various characteristics adapted for a variety of applications can be constructed using significantly reduced materials while retaining strength and heat exchange properties. of heavier planes. Moreover, while a reference is made herein to flat heat exchanger tubes, the present invention may also, or alternatively, be applied to heat exchanger tubes having different cross-sectional shapes, including without limitation round, rectangular, triangular or other polygonal shapes, irregular shapes, and the like.

In some embodiments, heat exchanger tubes 8310, heat exchanger fins 8313, and / or other portions of a heat exchanger may be formed from sheets of material having the same or substantially the same thickness. Alternatively, in other embodiments, two or more heat exchanger portions may be formed from sheets of material having different thicknesses. In some of these other embodiments, heat exchanger tubes 8310 may be formed from material leaflets 8317 having a first thickness, and heat exchanger fins 8313 may be disposed adjacent housings 8310 and may be formed from material leaflets 8333 having a different thickness.

In such embodiments, the first portion of the heat exchanger (e.g. a manifold) may be formed from deflections of material having the first thickness, the second heat exchanger portion (e.g. at least one tube) may be formed from of sheets of material having the second thickness, and a third heat producing portion (e.g., fins 8333) may be formed from sheets of material having a third thickness.

For example, in some embodiments of the present invention, a flat tube 8310 may be formed from material stoppers 8317 having a thickness no greater than about 0.20 mm (0.007874 in). However, in other embodiments and as mentioned above, the inventors have found that heat exchanger tubes formed from sheets of material having a thickness no greater than about 0.15 mm (0.0059055 in) provide significant advantages over overall performance. planes and heat exchangers made from this material, fabricability, and possible wall-mounted constructions (as shown here) that are not possible using thicker wall materials. Alternatively or additionally, the fins 8313 may be formed from sheets of material 8333 having a thickness no greater than about 0.20 mm (0.007874 in). In other embodiments, the fins 8313 may be formed from foil 8333 having a thickness no greater than about 0.15 mm (0.0059055 in). In still other embodiments, the fins 8313 may be formed from foil 8333 having a thickness in the range of 0.03 - 0.15 mm (0.0011811 - 0.0059055 in) or slightly more. In still other embodiments, the heat-deflecting fins 8313 may be formed from foil 8333 having a thickness no greater than about 0.03 - 0.09 mm (0.0011811 - 0.0035433 in).

As shown in FIGs. 92 to 95, a first sheet of material 8317 manufactured in accordance with certain embodiments of the present invention may include a folding layer 8335 providing at least a portion of an outer surface X1 of the first sheet of material 8317, an inner sacrificial layer or corrosion protection layer 8337 disposed under brazing layer 8335 or a portion of brazing layer 8335, and a core 8315 disposed under sacrificial layer 8337 (shown as a single layer in FIGS. 92 and 94, and as having two or more layers in FIGS. 93 and 95 ). As used herein and in the appended claims, terms such as "under", "below", "over", and "above" are used for ease of description only, and alone do not indicate or imply that the referenced structure should have any particular orientation taken on its own. or employed in any structure.

The core 8315 in the illustrated embodiments of FIG. 92 comprises an aluminum alloy by way of example. Aluminum alloy may have adequate amounts of one or more other materials, such as manganese, magnesium, titanium, copper, and the like, used to increase the strength and / or corrosion resistance of the 8315 core, or to change one or more other characteristics. 8315 core as desired.

In some embodiments, core 8315 is changed to produce a layer 8339 (sometimes referred to herein as a sublayer of core 8315) having one or more different properties than the remainder of core 8315. For example, by diffusing silicon into an upper portion of core 8315 to a At elevated temperature, such as during a brazing process, the structure and / or composition of an aluminum alloy in the upper portion may change to the definition of layer 8339 in which the silicon is diffused (see FIG. 93, which illustrates such a process performed on the structure). 92). In some embodiments, change may occur by the production of intermetallic compounds comprising silicon, such as an intermetallic silicon-manganese aluminum compound. In doing so, one or more components of the 8339 layered aluminum alloy (e.g., manganese, by way of example only) may accumulate while the sheet material 8317 is sufficiently heated to allow such accumulation, resulting in a modified layer 8339 of the layer. core 8315 wherein an intermetallic compound has accumulated locations across the modified layer 8339. In some embodiments, silicon may facilitate this accumulation, such as by removing one or more alloying components from the solid solution, or otherwise facilitating this accumulation.

The thickness of the modified layer 8339 may be dependent on the temperature at which the above referenced diffusion occurs and the time allowed for such diffusion to occur (e.g., the length of a brazing cycle). In some embodiments, the modified layer 8339 is anodic with respect to the remainder of core 8315. For example, in those modalities where manganese was withdrawn from solid solution and accumulated as an intermetallic, as a result of silicon diffusion in core 8315, the modified layer 833 9 may be anodic with respect to the remaining core 8315.

With continued reference to the embodiments of FIG. 91 a95, and as described above, the illustrated sheet of material 8317 includes one or more sacrificial layers 8337 (one in FIG. 92 and 93, and two in FIG. 94 and 95). Each sacrificial layer 8337 may include a metal material, and may be a relatively pure or non-thin metal material. In some embodiments, sacrificial layer 8337 comprises an aluminum alloy through which silicon sediments at a slower rate than that through the underlying core material 8315, and has a potential corrosion as described herein. For example, in some embodiments, sacrificial layer 8337 comprises an aluminum alloy through which silicon diffuses at no more than 50% of the rate at which silicon diffuses through underlying core material 8315. In other embodiments, sacrificial layer 8337 comprises an aluminum alloy through which silicon diffuses at no more than 70% of the rate at which silicon diffuses through the underlying core material 8315. In this sense, sacrificial layer 8337 may have trace amounts of one or more additional materials (e.g., iron, copper, zinc, manganese, magnesium, as metals and combinations of these metals, by way of example). In some embodiments, sacrificial layer 8337 has a corrosion potential that is substantially similar to the corrosion potential of the residual brazing material adjacent to a brazing layer 8335 following a brazing process. In this regard, it should be noted that following a brazing process, a residual amount of brazing material may remain in any portion or all of the sheet material 8317. Also, in some embodiments, the sacrificial layer material 8337 is anodic to the material of the brazing material. core 8315 (e.g. for modified layer 833 9e and / or the remainder of core 8315).

In some embodiments, brazing layer 8335 comprises an aluminum-silicon alloy brazing material. In other embodiments, other bending materials may also or alternatively be used, some of which comprise silicon. The tear-off layer 8335 may extend across the entire outer surface of the sheet of material 8317, or instead may extend across less than the entire outer surface (e.g., through desired tear-off locations only) of the sheet of material 8317. Brazing 8335 may be part of the sheet material 8317 to be used in a brazing operation, or may be deposited on and / or formed by a portion of the sheet 8317 during the brazing process. In any case, the residual brazing material of a brazing layer 8335 following a brazing process may be anodic to the decriting layer material 8337.

Any of the layers and / or sublayers of the sheet material 8317 described herein and / or illustrated in FIGS. 92-95 may be secured together by a roll connection. By way of example only, the sublayer 8339 of core 8315 described above may be produced by the roll bonding of one layer of material having the above sublayer properties described above another layer of core producing material 8317 illustrated in FIG. 93.

As will now be explained, sheets of material formed in accordance with the present invention may reduce and / or prevent corrosion (such as microporous corrosion by way of example). In some embodiments, one or more of the layers and sublayers of sheet material 8317 (for example, brazing layer 8335, sacrificial layer 8337, sublayer 8339, and / or core 8315) may be formed from a material or in alloys with a material such that it is anodic to one or more of the underlying layers or sublayers of the sheet 8317. For example, in some embodiments, each layer and sublayers of the sheet 8317 (i.e., residual brazing material of a brazing layer) 8335 following a brazing process, sacrificial layer 8337, sublayer 8339, and / or the remainder of core 8315) may be formed from a material or alloyed with a material such that they are anodic to an underlying layer or sublayer. and are cathodic to an adjacent overlying layer or sublayer after brazing.

In some embodiments, one or more sublayer layers of the sheet material 8317 (i.e. the tear layer 8335, the sacrifice layer 8337, the sublayer 8339, and / or the remainder of the core 8315) are formed from a material or alloy with a material such that there is a difference of at least about 30 millivolts between one or more of the underlying layers or sublayers. For example, in some embodiments, each of the layered layers of the sheet material 8317 (e.g., the brazing layer 8335, the sacrificial layer 8337, the sublayer 8339, and / or the remainder of the core 8315) may be formed from a material. or in alloy with a material such that there is a difference of at least about 30 millivolts between each adjacent layer, or between separate or sublayered layers of each other.

As mentioned above, in some embodiments the core 8315 includes titanium. In sufficient quantities, titanium may form dendrites during core casting8315, resulting in titanium-rich aluminum layers dispersed throughout core 8315. Depending, at least in part, on the manner in which the sheet material defining core 8315 is produced, Titanium-rich aluminum may be located primarily in the sacrificial layer 8337, primarily in the remainder of core 8315, or completely throughout the 8315 core. In some embodiments, titanium-rich aluminum may form sublayers in core8315, and may serve as another measure of corrosion resistance of core material. These sublayers may also be anodic to adjacent portions of the 8315 core for additional corrosion resistance.

In those embodiments in which titanium-rich aluminum is formed into sublayers of the core material as just described, titanium-rich aluminum can help to increase corrosion resistance by forcing corrosion to propagate parallel or substantially parallel directions to core 8315, or in parallel or substantially parallel directions. titanium-rich aluminum sublayers, thereby helping to slow or reduce corrosion with micro-porosity. In some embodiments, the 8315 core material comprises about 0.05 - 0.30% in pesotitanium. In other embodiments, the core layer 8315 having about 0.10 - 0.25 wt.% Titanium provides good strength performance and corrosion resistance.

However, in many embodiments, the sheet material 8317 having core 8315 having a core layer 8315 having a slightly higher or slightly higher titanium ether yields improved overall performance.

In some embodiments, the sheet material 8317 has a thickness no greater than about 0.15 mm (it is noted that any of the relatively thin insertion tube wall thicknesses may be used).

For example, the sheet of material in the embodiment illustrated in FIG. 92 and 93 have a thickness of approximately 100μιτι (3,937 thousand). As described above, some embodiments of the present invention have a modified core sublayer 8339 that can be produced by silicon diffusion therein. Silicon may diffuse from the sacrificial layer 8337 or from the bending material 8335 to the core 8315 in such embodiments. This diffusion may occur during a brazing process. In light of the fact that the diffusion rate for core 8315 can at least partially determine the depth resulting from the modified core sublayer 8339, a control of this diffusion is possible through the sacrificial layer8337. In this sense, sacrificial layer 8337 may prevent (but not stop) such silicon diffusion, and may comprise a material (eg an aluminum alloy more resistant to silicon diffusion and having the potential for corrosion as described above) in which silicon sediments at a slower rate than the core material8315. By using such a sacrificial layer such as 8337, silicon diffusion can be limited to a depth of 50 μπι (1,969 mil) while still allowing sufficient brazing time at a sufficiently high brazing temperature for fin 8313 brazing to a sheet of material 8317 In some embodiments, the manufacturing process described herein may prevent our significantly reducing diffusion beyond a depth of 30 μιη (1.181 mil).

In embodiments in which two or more portions of the heat exchanger are attached together, the second heat exchanger portion (e.g. fins 8313) may also alternatively include the brazing layer formed on or applied to an external surface, an internal layer. sacrificial layer disposed under the brazing layer or a portion of the brazing layer, and a core disposed under the sacrificial layer. Alternatively or additionally, a core of the sheet material used for forming the second portion of the heat exchanger (e.g., fins 8313) may include an outer or layered portion of modified core material as described above. Further, each of the layers and sublayers of the sheets of material used for forming the second portion of the heat exchanger (e.g., fins 8313) may be anodic to one or more underlying layers or sublayers.

In some of these embodiments, each of the layered layers of the sheets of material 8333 used for forming the second portion of the heat exchanger (e.g., fins 8313) is formed from a material or alloyed with a material such that there is a difference. at least about 30 millivolts between each adjacent layer of the second portion of the heat exchanger.

In some embodiments where two or more heat exchanger portions are attached together, the first heat exchanger portion may be formed from a sheet of material having an outer portion or layer which is substantially anodic to a second outer layer or portion. heat exchanger portion. For example, as shown in FIGs. 92 to 95, in some of these embodiments, an outer portion or layer of fin 8313 may be formed from a sheet of material 833 which is anodic to a sheet of material 8317 used for forming heat exchanger tube 8310.

Alternatively or additionally, the outer or layered portion of the fin 8313 may be formed from a sheet of material 83 3 3 which is anodic to a residual alpha phase layer 8341 formed from the material bending between the outer surfaces of the heat exchanger tube. 8310 and fin 8313. In some of these embodiments, residual alpha phase layer 8341 is anodic to sacrificial layer 8337 of sheet material 8317 that forms heat exchanger tube 8310.

In some embodiments of the present invention, the first and second portions of a heat exchanger may be connected to opposite sides of a third heat exchanger portion. For example, in the illustrated embodiment of FIGS. 94 and 95, a heat exchanger tube 8310 having first and second outer surfaces XI, X2 is formed from a first sheet of material 8317. As shown in FIGS. 94 and 95, each side of the material sheet 8317 may include a brazing layer 8335 providing at least a portion of the outer surfaces XI, X2 of the first material sheet 8317, an inner layer or a corrosion protection layer 8337 disposed under the brazing layer 8335 or a portion of a brazing bed 8335, and the core 8315 disposed between sacrificial layers 8337. In some embodiments, both outer sides of the core 8315 may include the modified core material sublayer 8339.

The inventors have found that a countercorrosion protection for heat exchangers or heat exchanger portions of relatively small wall thicknesses (e.g., wall thicknesses of less than about 0.00 mm (0.007874 in)) can be improved if the Brazing time (ie, the time when the heat exchanger or the heat exchanger being brazed passes through the brazing furnace) is reduced. The inventors have determined that an approximately 10% reduction in brazing time shows the desired results and can provide, among other advantages, good strength and corrosion resistance. Further, the results can be improved if the breakage time is halved approximately.

More particularly, the inventors have found that an increase in brazing speed can reduce the disillusion diffusion from a brazing layer 8335 to underlying layers or sublayers of the sheet material1717. Silicon diffusion is illustrated in FIGs. 93 and 95 dashed comets. The silicon diffusion depth may be less than about 50 μπι (1,969,000), or some modalities, may be significantly smaller. AFIG. 96 graphically illustrates this relationship. The curved curve in FIG. 96 represents the progression of the diffusion of the silicon, while the solid curve represents the progression of the diffusion according to conventional brazing materials and techniques.

In some embodiments of the present invention, heat exchangers or portions of folded heat exchangers are placed in a conveyor or similar transport device which passes through different temperature zones of a CAB brazing furnace. In some of these embodiments, the brazing furnace temperature may be in the range of approximately 577 to 610 ° C (1070 - 1130 ° F).

The optimum brazing time for a specific heat exchanger or for a specific portion of a heat exchanger depends at least in part on the total heat exchanger mass or the portion of the heat exchanger folded, the tempering condition of the brazed material sheets, the thickness of the folded material sheets, and the composition of the folded material sheets. For example, in some embodiments, the conveying speed for heat exchanger brazing or heat exchanger portions of 0.207 mm (0.007 874 in) or more wall thickness in a CAB brazing furnace is approximately 0.5 - 1. 0.5 m / min (19.69 - 59.055in / min).

Prior to brazing a heat exchanger or portion of a heat exchanger, the inventors have found that material samples having material properties substantially similar to or identical to those of the heat exchanger or heat exchanger portion being brazed can be used to experimentally determine a temperature profile. optimum for the specific heat exchanger material or heat exchanger portion being brazed. The inventors have also found that by determining an optimal temperature profile, it is possible to increase the transport speed of the heat exchanger or the heat exchanger portion being brazed to around 1.5 - 4.0 m / min (4,921.12 ft / min), thereby reducing the break time.

In some embodiments, a non-corrosive flux may be applied to the outer surface X1 of one or both sheets of aluminum material 8317, 8333 prior to abrading. In some embodiments, it may not be necessary to apply the flow material to the outer surface X1 of one or both sheets of material 8317, 8333, to obtain high quality brazed connections. Moreover, in some embodiments, including embodiments in which a flux material is not applied to the sheet surfaces of material 8317, 8333 prior to brazing, the inventors have determined that high quality brazing connections may be created in an atmosphere controlled by the addition of one or more alloys. such as, for example, magnesium and / or lithium to sheets of material 8317, 8333.

Various features and advantages of the invention are set forth in the following claims.

Claims (20)

1. Heat exchanger, characterized in that it comprises: a collector having a plastic outer wall having an inner chamber, the collector including an opening extending through the outer wall and having an outer end and an inner end communicating with the inner chamber; a finned tube extending into the aperture and having a sidewall attached to the outer wall of the collector and an end extending to the collector beyond the outer end of the aperture, the sidewall defined at least in part by a sheet of material of smaller thickness than around 0.15 mm; It is an adhesive facing the finned tube in the opening. Heat exchanger according to claim 1, characterized in that the thickness of the materialser sheet is less than about 0.10 mm. Heat exchanger according to Claim 1, characterized in that it further comprises a luvapositioned between the sidewall of the pipe and the plastic collector. Heat exchanger according to Claim 1, characterized in that it further comprises a dead channel extending through the outer wall of the collector in communication with the opening. Heat exchanger according to Claim 1, characterized in that the engagement between the pipe sidewall and the outer wall of the manifold substantially seals the manifold and prevents the adhesive from entering the inner chamber of the manifold. Heat exchanger according to claim 1, characterized in that the outer wall includes a lip extending around a perimeter of the opening between the inner end and the outer end of the opening, and that the side wall of the pipe seen fit on the edge. Heat exchanger according to Claim 6, characterized in that the sidewall is sealed against the lip to prevent the adhesive from contacting the end of the tube. Heat exchanger according to Claim 1, characterized in that the sidewall defines at least partially an inner chamber of the finned tube having a broad side and first and second narrow sides and further comprising an insert extending through the inner chamber. of the finned tube and at least partially defining a first flow path and a second flow path, the insert having opposite ends received within and reinforcing the first narrow side and the second narrow side. Heat exchanger according to Claim 1, characterized in that the sidewall defines, at least partially, an inner chamber of the finned tube having a wide side and a narrow side, and a first portion of the sidewall. overlap a second section of the sidewall and define a seam extending to a substantially flat portion of the ladolar. Heat exchanger according to claim 1, characterized in that the side wall has a first layer comprising an aluminum alloy, a second layer comprising an aluminum alloy having accumulations of an intermetallic compound including silicon, and a third layer. A layer comprising a metal material which is anodic with respect to the second layer and which is more resistant to silicon diffusion than the second layer, the second layer located between the first and third layers. A method of forming a heat exchanger, the method comprising: forming a collector having a deplastic outer wall surrounding an inner chamber, the collector including an opening extending through the outer wall and having an outer end and an inner end in communication with the inner chamber, inserting one end of a tube body into the opening in the outer wall beyond the outer end of the opening and attaching a side wall of the tube body to the outer wall of the manifold, the side wall of the tube body having a thickness of less than about 0.15 mm; and inserting adhesive into the opening between the collector's external wall and the side wall of the tube body. A method according to claim 11, further comprising attaching a fin to the tube body in an oven for forming a heat exchanger core, and inserting the end of the tube body into the The opening in the outer wall includes the end frame of the tubona body. Opening in the outer wall after the core has been removed from the oven. Method according to claim 11, characterized in that the fixing of the pipe body side wall to the collector external wall includes the fitting of the tube body side wall against a lip extending about a perimeter of the opening between an inner end and an outer end of the opening. Method according to claim 13, characterized in that the sidewall fitting of the pipe body against the lip includes sealing the sidewall of the pipe against the lip to prevent the adhesive from contacting the pipe end. The method of claim 11 further comprising forming a sheet of material having a thickness of less than about 0.10 mm for forming at least a portion of the side wall of the tube body. . Method according to Claim 11, characterized in that it further comprises opposing a sleeve between the side wall of the pipe body and the plastic collector. A method according to claim 11, further comprising forming at least a portion of the side wall of the tube body, the side appearing defining an inner space and having an arcuate shaped inner side, and further comprising nesting a portion. of an insertion of the shaped inner side of the tube body, the insert separating a first flow path and a second flow path. A method according to claim 11, characterized in that it further comprises forming at least a portion of the side wall of the tube body, the side appearing defining an inner space and having a lateral and narrow side, and further comprising the forming a seam that extends to a substantially flat portion of the broad side of the sidewall between the first and second overlapping portions of the lateral wall. A method according to claim 11, characterized in that the side wall of the tube body has a first layer comprising an aluminum alloy, a second layer comprising an aluminum alloy having accumulations of an intermetallic compound including silicon, and a third layer. A layer comprising a metal material which is anodic with respect to the second layer and which is more resistant to silicon diffusion than the second layer, the second layer located between the first and third layers. Method according to claim 11, characterized in that the tube body has a cross-sectional shape with two opposite wide sides connected by two opposite narrow sides.