US20140041844A1 - Heat Exchanger Tube, Heat Exchanger Tube Assembly, And Methods Of Making The Same - Google Patents

Heat Exchanger Tube, Heat Exchanger Tube Assembly, And Methods Of Making The Same Download PDF

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Publication number
US20140041844A1
US20140041844A1 US13/570,767 US201213570767A US2014041844A1 US 20140041844 A1 US20140041844 A1 US 20140041844A1 US 201213570767 A US201213570767 A US 201213570767A US 2014041844 A1 US2014041844 A1 US 2014041844A1
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US
United States
Prior art keywords
tube
tube assembly
generally planar
side sheets
assembly
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/570,767
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English (en)
Inventor
Eric Lindell
Girish Mantri
Gregory Hughes
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Modine Manufacturing Co
Original Assignee
Modine Manufacturing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Modine Manufacturing Co filed Critical Modine Manufacturing Co
Priority to US13/570,767 priority Critical patent/US20140041844A1/en
Assigned to MODINE MANUFACTURING COMPANY reassignment MODINE MANUFACTURING COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HUGHES, GREGORY, LINDELL, ERIC, MANTRI, GIRISH
Priority to JP2012254213A priority patent/JP2014035181A/ja
Priority to KR1020120133287A priority patent/KR101562090B1/ko
Priority to BR102012029873-2A priority patent/BR102012029873A2/pt
Priority to CN201210481026.3A priority patent/CN103575147A/zh
Priority to DE102012023990.4A priority patent/DE102012023990A1/de
Priority to US14/175,004 priority patent/US20140182829A1/en
Publication of US20140041844A1 publication Critical patent/US20140041844A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
    • F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
    • F28D1/0535—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
    • F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/02—Tubular elements of cross-section which is non-circular
    • F28F1/025—Tubular elements of cross-section which is non-circular with variable shape, e.g. with modified tube ends, with different geometrical features
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
    • F28F1/126—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/0028—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for cooling heat generating elements, e.g. for cooling electronic components or electric devices
    • F28D2021/0031—Radiators for recooling a coolant of cooling systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2275/00—Fastening; Joining
    • F28F2275/04—Fastening; Joining by brazing

Definitions

  • the present invention generally relates to tubes, and to fin and tube assemblies for heat exchangers, and to methods for making the same.
  • Heat exchanger tube assemblies of the kind described above are typically constructed of copper, with the extended air-side surfaces in the finned region being soldered to the tube. Copper provides the advantages of high thermal conductivity, easy manufacturability, and good strength and durability. However, the steadily increasing price of copper has led to a demand for alternate, lower cost materials.
  • Aluminum has replaced copper as the preferred material of construction in other heat exchangers (automobile and commercial radiators, for example), but has not successfully replaced copper in heavy duty heat exchangers of this kind.
  • Aluminum has substantially lower strength than copper, leading to durability concerns. This is especially problematic in applications where individual tube assemblies need to be removed and inserted in the field, as damage is likely to occur during such handling.
  • the bonding of aluminum components requires substantially higher temperatures than the soldering of copper, leading to manufacturing difficulties.
  • a tube assembly for a heat exchanger includes a tube having a flat section with spaced apart broad tube sides joined by opposing narrow tube sides.
  • the tube assembly further includes two fin structures, each having wave crests and troughs connected by flanks, and two generally planar side sheets. Wave troughs of one fin structure are joined to one of the broad tube sides, and wave crests of that fin structure are joined to a face of one of the side sheets. Wave troughs of the other fin structure are joined to the other broad tube side, and wave crests of that fin structure are joined to a face of the other side sheet.
  • the tube includes cylindrical sections at the lengthwise ends of the tube, with the flat section arranged between the cylindrical sections.
  • the tube, the fin structures, and the side sheets are joined by braze joints, and in some embodiments they are formed of one or more aluminum alloys.
  • the thickness of the broad tube sides is at least twice the thickness of the side sheets.
  • a tube assembly for a heat exchanger includes a fluid flow conduit extending in a lengthwise direction over at least a portion of the tube assembly.
  • the fluid flow conduit has a major dimension and minor dimension, both perpendicular to the lengthwise direction, the minor dimension being substantially smaller than the major dimension.
  • a continuous tube wall surrounds the flow conduit.
  • Two generally planar side sheets are spaced equidistantly from the continuous tube wall in the minor dimension direction, and are connected to the tube wall by thin webs.
  • the continuous tube wall defines a tube wall centroidal moment of inertia with respect to an axis in the major dimension direction.
  • the centroidal moment of inertia of the tube assembly with respect to that axis is at least five times the tube wall centroidal moment of inertia, and in some embodiments at least ten times.
  • a first cylindrical tube section is joined to the continuous tube wall at a first end of the flow conduit, and a second cylindrical tube section is joined to the continuous tube wall at a second end of the flow conduit.
  • the outer perimeter defined by the continuous tube wall is greater than the outer perimeter of at least one of the cylindrical tube sections.
  • a method of making a heat exchanger tube assembly includes providing a tube, first and second corrugated fin structures, and first and second generally planar side sheets.
  • the first corrugated fin structure is arranged between the first side sheet and a first broad and flat side of the tube, and the second corrugated fin structure is arranged between the second side sheet and a second broad and flat side of the tube.
  • a compressive force is applied to opposing sides of the side sheets to place crests and troughs of the fin structures into contact with the side sheets and the broad and flat sides, and braze joints are created between the first fin structure and the first side sheet, the first fin structure and the first broad and flat side, the second fin structure and the second side sheet, and the second fin structure and the second broad and flat side.
  • the tube, fin structures, and side sheets are elevated in temperature in a vacuum environment to create the braze joints. In other environments they are elevated in temperature in a controlled inert gas environment.
  • providing the tube, fin structures, and side sheets includes providing a material coated with a braze filler metal.
  • the compressive force is transmitted through a first separator sheet adjacent to the first side sheet, and through a second separator sheet adjacent to the second side sheet.
  • the separator sheets have a coefficient of thermal expansion that is generally matched to that of the tube, side sheets, and fin structures.
  • the first separator sheet is one of several separator sheets adjacent to the first side sheet.
  • a method of making heat exchanger tube assemblies includes providing several tubes, several corrugated fin structures, and several generally planar side sheets. Each of the tubes is arranged between pairs of the corrugated fin structures, and each of the corrugated fin structures is arranged between one of the tubes and one of the side sheets.
  • the tubes, corrugated fin structures, and side sheets are arranged into a stack. Separator sheets are arranged between adjacent pairs of the side sheets, and adjacent to the side sheets at the outermost ends of the stack. A compressive load is applied to the stack in the stacking direction. Braze joints are created at the points of contact between the corrugated fin structures and the tubes, and between the corrugated fin structures and the side sheets, and the brazed tube assemblies are removed from the separator sheets.
  • the tubes, fin structures, and side sheets are elevated in temperature in a vacuum environment to create the braze joints. In other environments they are elevated in temperature in a controlled inert gas environment.
  • providing the tubes, fin structures, and side sheets includes providing a material coated with a braze filler metal.
  • a tube for a heat exchanger includes a first cylindrical section extending from a first end of the tube, a second cylindrical section extending from a second end of the tube, and a flat section located between the ends and having two broad and flat, spaced apart parallel sides joined by two relatively short sides. Transition regions are located between each of the cylindrical sections and the flat section. The intersections of the transition regions and each of the broad and flat sides of the tube define curvilinear paths.
  • each of the curvilinear paths includes an apex located at a center plane of the tube, and in some such embodiments an arcuate path segment is located at the apex.
  • transition region adjacent to one of the cylindrical sections extends over a length that is at least equal to the diameter of that section.
  • the outer perimeter of the flat section of the tube is greater than the outer perimeter of at least one of the cylindrical sections, and in some embodiments is at least twenty-five percent greater.
  • the flat tube section defines a tube major dimension between outermost points of the two relatively short sides, and the curvilinear paths are each longer than the tube major dimension.
  • the tube is made from an aluminum alloy.
  • a heat exchanger tube is formed from a round tube by reducing a diameter of the round tube in a first section of the round tube, and flattening a second section adjacent to the first section to define two spaced apart, broad and flat sides in the second section.
  • the first sections terminates at an end of the tube.
  • the second section is flattened after reducing the diameter of the first section.
  • the diameter of the first section is reduced by a swaging operation.
  • the second section is flattened by impacting that section in a stamping die.
  • the tube is made from an aluminum alloy.
  • a mandrel is inserted into the tube prior to flattening the second section, and is removed from the tube after flattening the second section.
  • the diameter of a third section of the round tube is reduced, the third section being adjacent to the second section.
  • the third section terminates at a second end of the tube.
  • the second section is flattened after reducing the diameter of the third section.
  • FIG. 1 is a perspective view of a heat exchanger tube assembly according to an embodiment of the invention.
  • FIG. 2 is an elevation view of the heat exchanger tube assembly of FIG. 1 .
  • FIG. 3 is a detail view of the portion of FIG. 2 bounded by the line III-III.
  • FIG. 4 is a plan view of the heat exchanger tube assembly of FIG. 1 .
  • FIG. 5 is an exploded perspective view of the heat exchanger tube assembly of FIG. 1 .
  • FIG. 6 is an elevation view of a stack of heat exchanger tube assemblies being made according to an embodiment of the invention.
  • FIG. 7 is a plan view of certain components of the stack of FIG. 6 .
  • FIG. 8 is a perspective view of a heat exchanger tube according to an embodiment of the invention.
  • FIG. 9 is a partial perspective view of a prior art heat exchanger tube.
  • FIG. 10 is a partial section view along the lines X-X of FIG. 8 .
  • FIG. 11 is a section view along the lines XI-XI of FIG. 8 .
  • FIG. 12 is a partial perspective view of the partially formed tube of FIG. 8 .
  • FIGS. 13A and B are diagrammatic views of a forming operation to produce the tube of FIG. 8 .
  • FIGS. 1-5 A heat exchanger tube assembly 1 according to an embodiment of the invention is shown in FIGS. 1-5 .
  • a tube assembly 1 can be used as one of many individual tubes of a heat exchanger, for example a radiator, in large heavy duty equipment such as an excavator, mining truck, gen-set, etc. It should be understood, however, that the tube assembly 1 can be used in heat exchangers of various types and sizes.
  • the tube assembly 1 includes a tube 2 extending from a first end 7 to a second end 8 .
  • the tube 2 defines a fluid flow conduit whereby a fluid (by way of example, engine coolant) can be transported through the tube assembly 1 .
  • a fluid by way of example, engine coolant
  • the tube assembly 1 can be used in an engine coolant radiator in order to reject waste heat from a flow of engine coolant as that flow of engine coolant flow through the tube 2 from one of the ends 7 , 8 to the other of the ends 7 , 8 .
  • the tube 2 includes a flat section 3 located between the ends 7 , 8 .
  • the flat portion 3 (best described with reference to FIG. 11 ) includes first and second parallel, broad and flat sides 12 .
  • the broad and flat sides 12 are spaced apart from one another, and are joined by two opposing, spaced apart, narrow tube sides 15 .
  • the narrow tube sides 15 are shown as being arcuate in profile in the exemplary embodiment, in other embodiments the narrow tube sides 15 can be straight, or they can be of some other profile shape.
  • the two broad and flat sides 12 and the two narrow sides 15 together define a continuous tube wall 25 of the fluid flow conduit, with an open spaces defined interior to the continuous tube wall 25 in order to allow for the flow of a fluid through the tube 2 . While none are shown in the exemplary embodiment, it can be preferable in some cases to provide surface enhancement or flow turbulation features within the flow conduit in order to enhance the rate of heat transfer between a fluid passing through the tube 2 and the tube wall 25 .
  • the flat section 3 of the tube 2 has a tube minor dimension, d 1 , defined as the distance between the outward-facing surfaces of the two broad and flat sides 12 , and a tube major dimension, d 2 , defined as the distance between outermost points of the two narrow sides 15 .
  • the major dimension, d 2 is several times greater than the minor dimension, d 1 .
  • the major dimension of the exemplary embodiment is nine times greater than the minor dimension.
  • the tube assembly 1 further includes two convoluted fin structures 10 arranged along the flat section 3 .
  • the fin structures 10 include multiple flanks 16 connected in alternating fashion by crests 18 and troughs 17 so that each of the fin structures 10 is of an approximately sinusoidal shape (best seen in FIG. 3 ).
  • the fin structures 10 can be of a plain type, as shown in FIG. 3 , or they can include additional features to increase heat transfer, structural strength, durability, or combinations of the above.
  • the fin structures 10 can include louvers, bumps, slits, lances, or other features that are known to improve heat transfer and/or structural rigidity of the flanks 16 .
  • an edge hem can be provided at one or both of the ends of a fin structure 10 adjacent the narrow tube sides 15 . Such an edge hem can be especially beneficial in providing resistance to damage that may be caused by impingement of rocks or other debris.
  • Thin side sheets 11 are also included in the tube assembly 1 . These side sheets 11 are parallel to the opposing broad and flat sides 12 of the tube 2 , and are spaced equidistantly therefrom on either side by the fin structures 10 . Accordingly, the flanks 16 , crests 18 , and troughs 17 of the fin structures 11 provide a plurality of thin webs to space the side sheets 11 from the continuous tube wall 25 .
  • the side sheets 11 are generally planar, but can include features such as, for example, bent edges in order to provide increased stiffness and/or to aid in assembly.
  • the spaces between the flanks 16 provide flow channels for a fluid to be placed in heat transfer relation with the fluid passing through the tube 2 , so that heat can be exchanged between the two fluids.
  • a fluid to be placed in heat transfer relation with the fluid passing through the tube 2 , so that heat can be exchanged between the two fluids.
  • ambient air can be directed through the flow channels in order to cool engine jacket coolant passing through the tube 2 .
  • various other fluids can be placed in heat transfer relation using the tube assembly 1 .
  • Each of the flow channels between the flanks 16 is further defined by one of the troughs 17 and crests 18 , and by one of the flat sides 12 of the tube 2 and the generally planar side sheets 11 .
  • the tube 2 , fin structures 10 , and side sheets 11 are preferably bonded together to form a monolithic structure in order to provide both good thermal contact between the fluids to be placed in heat transfer relation, and good structural integrity. While a variety of materials can be used to construct the tube assembly 1 , in highly preferable embodiments the tube 2 , fin structures 10 , and side sheets 11 are formed from metals having a high thermal conductivity, such as aluminum, copper, and the like. The components can be bonded together to form the tube assembly 1 by a variety of processes including brazing, soldering, gluing, etc.
  • the fin structures 10 and the side sheets 11 can extend over the full major dimension d 2 of the flat section 3 . In some cases, it may be preferable to extend the fin structures 10 and the side sheets 11 slightly beyond the outer edges of the arrow tube sides 15 in order to protect the fluid flow conduit from damage by impingement of rocks or other debris.
  • the impact of the side sheets 11 on the bending stiffness of the tube assembly 1 about the centroidal axis in the tube major dimension d 2 can be quantified by comparing the centroidal moment of inertia about that axis of the tube assembly 1 to that of the tube 2 alone (the fin structures 10 can be assumed to provide no contribution to the centroidal moment of inertia, other than by maintaining the offset of the side sheets 11 from the flat sides 12 of the tube 2 ).
  • the centroidal moment of inertia about the tube major dimension axis for the tube assembly and the tube alone are calculated to be 925 mm 4 and 76 mm 4 , respectively.
  • the centroidal moment of inertia of the tube assembly about the tube major dimension axis is approximately twelve times that of the tube itself.
  • the centroidal moment of inertia of the tube assembly about the tube major dimension axis is at least five times that of the tube itself, and in highly preferable embodiments, at least ten times. This is especially preferable when the tube 2 is constructed of a material exhibiting relatively low modulus of elasticity, for example, alloys of aluminum.
  • the tube 2 of the exemplary embodiment further includes a first cylindrical section 4 adjacent to the first end 7 , and a second cylindrical section 5 adjacent to the second end 8 , with the flat section 3 arranged between the first and second cylindrical sections.
  • These cylindrical sections 4 , 5 allow for reliable and leak-free insertion of the tube assembly 1 into receiving grommets arranged in opposing headers of a heat exchanger (not shown).
  • the length of the cylindrical end sections are preferably kept to a minimum, and the length of the flat section 3 is preferably 90% or more of the overall length of the tube 2 .
  • a circumferential bead 9 is provided in the cylindrical section 5 of the exemplary embodiment in order to limit the downward movement of the tube assembly 1 when vertically arranged in a heat exchanger.
  • a tube assembly 1 can be devoid of one or both cylindrical end sections 4 , 5 .
  • the corresponding receiving grommets can be provided with receiving openings that correspond to the profile of the continuous tube wall 25 in the flat section 3 .
  • a heat exchanger tube assembly 1 is made by creating braze joints between an aluminum tube 2 , first and second aluminum corrugated fin structures 10 , and first and second aluminum side sheets 11 .
  • the first corrugated fin structure 10 is arranged between the first side sheet 11 and a first broad and flat side 12 of the tube 2
  • the second corrugated fin structure 10 is arranged between the second side sheet 11 and a second broad and flat side 12 of the tube 2 .
  • the assembly is compressed in order to place crests 18 and troughs 17 of the fin structures 10 in contact with the adjacent parts so that braze joints can be formed at the points of contact.
  • a brazing filler metal having a melting temperature that is lower than the melting temperatures of the tube 2 , fin structures 10 , and side sheets 11 is used to create the braze joints.
  • a filler metal is typically aluminum with small quantities of other elements (silicon, copper, magnesium, and zinc, for example) added to reduce the melting temperature.
  • the braze filler metal can advantageously be provided as a coating on one of more of the components to be brazed.
  • both sides of the sheet material used to form the corrugated fin structures 10 is coated with the braze filler metal, thereby providing the required braze filler metal at all of the contact points where braze joints are desired while avoiding having braze filler metal at locations where joints are not necessary or undesirable.
  • vacuum brazing While many methods can be used to elevate the temperature of the tube 2 , the fin structures 10 , and the side sheets 11 in order to melt the braze filler metal and form the braze joints, two especially preferable methods are vacuum brazing and controlled atmosphere brazing.
  • vacuum brazing the assembled parts are placed into a sealed furnace and substantially all of the air is removed in order to create a vacuum environment.
  • magnesium present in the alloys is released as the parts are heated and serves to break up the oxide layer present on the external surfaces of the components, allowing the molten braze filler metal to bond to the exposed aluminum.
  • the oxide layer is prevented from reforming and interfering with the metallurgical bonding by the absence of oxygen in the vacuum environment.
  • FIG. 6 illustrates a method according to an embodiment of the invention wherein four tube assemblies 1 are made simultaneously. It should be understood that the same method can be used to make more than four or fewer than four of the tube assemblies at a time.
  • tubes 2 , corrugated fin structures 10 , and generally planar side sheets 11 are provided.
  • Each of the tubes 2 is arranged between pairs of the corrugated fin structures 10
  • each of the corrugated fin structures 10 is arranged between one of the tubes 2 and one of the generally planar side sheets 11 .
  • Separator sheets 19 are arranged between adjacent pairs of the generally planar side sheets 11 .
  • the tubes 2 , corrugated fin structures 10 , and generally planar side sheets 11 are arranged into a stack 26 .
  • Additional separator sheets 19 are arranged adjacent to the generally planar side sheets 11 at the outermost ends of the stack 26 , and a compressive load is applied to the stack 26 in the stacking direction in order to place the crests 18 and the troughs 17 of the convoluted fin structures into contact with the adjacent side sheets 11 and broad and flat sides 12 of the tubes 2 .
  • bars 21 having a high stiffness can be used on the outermost ends of the stack 26 .
  • the compressive load can be maintained after it has been applied to the stack through the use of metal bands 22 that surround the stack 26 in several locations.
  • the bands 22 are tightened over the bars 21 while the stack 26 is compressed, so that tension in the bands 22 maintains the compressive load.
  • the stack 26 is placed into a brazing furnace in order to create the individual tube assemblies 1 .
  • the stack 26 is heated within the furnace to a temperature suitable for melting the braze filler metal, after which the stack 26 is cooled in order to re-solidify the melted braze filler metal, thereby creating braze joints at the contact points.
  • the individual tube assemblies 1 having been brazed into individual monolithic structures, can be removed from the separator sheets 19 .
  • the separator sheets 19 can be provided with a coating to prevent any metallurgical bonding between the separator sheets 19 and the side sheets 11 , as such undesirable bonding can otherwise occur at brazing temperature even without the presence of braze filler metal.
  • the stack 26 is heated to a brazing temperature, thermal expansion of the metal materials in the stack 26 will occur.
  • the components are typically heated to a brazing temperature of 550° C. to 650° C. This temperature range is substantially higher than that used to solder copper components, and consequently the thermal expansion experienced by the components of the tube assemblies 1 during the bonding process is substantially greater if the components are aluminum than if they are copper.
  • the inventors have found that care must be taken during the brazing process to ensure that the fin structures 10 are not distorted by the heating to brazing temperature and cooling back down to ambient temperature.
  • the flanks 16 of the fin structures 10 are prone to distortion by shearing forces introduced through thermal expansion differences between the components of the tube assemblies 1 and the separator sheets 19 .
  • this problem is remedied by generally matching the thermal expansion coefficient of the separator sheets 19 match that of the tubes 2 , fin structures 10 , and side sheets 11 . This can be achieved by forming the separator sheets 19 from similar aluminum alloys, or from another material exhibiting a similar rate of thermal expansion.
  • multiple individual separator sheets 19 can be used between each adjacent tube assembly 1 , as shown in FIG. 7 .
  • Gaps 20 are provided between adjacent ones of the individual separator sheets 19 .
  • the gaps 20 can increase or decrease during the heating and cooling of the stack 26 , thereby substantially alleviating the distortion of the fin structures 10 that might otherwise result from the mismatch in thermal expansion coefficients.
  • the gaps 20 serve as breaks to avoid the accumulation of the thermal expansion induced distortion, so that any such distortion is limited to the discrete contact areas underneath each of the individual separator sheets 19 .
  • the assembly method depicted in FIG. 7 can be especially beneficial when a more temperature resistant material such as stainless steel is used for the separator sheets 19 , and the components of the tube assemblies 1 are made from aluminum.
  • the embodiment of the tube 2 shown in FIG. 8 includes a flat tube section 3 located between a first cylindrical tube section 4 and a second cylindrical tube section 5 .
  • the first cylindrical tube section 4 extends from the first end 7 of the tube 2
  • the second cylindrical tube section 5 extends from the second end 8 of the tube 2 .
  • Transition regions 6 are located between the flat section 3 and each of the cylindrical sections 4 and 5 . The transition regions 6 provide a smooth continuous flow path for a fluid passing through the tube 2 , as well as avoiding locations of mechanical stress concentration in the tube material.
  • a transition region 6 extends over a length L, spanning from a location 27 proximal to the end 7 of the tube 2 to a location 14 distal to the end 7 .
  • the length L is preferably at least equal to the diameter of the cylindrical end section 4 , although in some alternative embodiments it may be smaller in size than the diameter of the corresponding end section.
  • the broad and flat side 12 extends past the locations 14 at either end so that at least a portion of the broad and flat side 12 is located along the tube 2 between the locations 27 and 14 that define the beginning and end of a transition region 6 .
  • the intersections of the transition regions 6 and the broad and flat sides 12 of the flat tube region 3 define curvilinear paths 13 .
  • These curvilinear paths 13 provide a beneficial stiffening of the flat section 3 of the tube 2 with respect to a bending moment about the tube major dimension axis.
  • a prior art tube 102 is shown in FIG. 9 and includes a flat section 103 joined to a cylindrical section 104 by way of a transition section 106 .
  • the intersection of the transition region 106 and the flat section 103 defines a straight path 113 on the broad and flat side 112 of the flat section 103 .
  • the straight path 113 extends in the tube major dimension, and bending about the major dimension axis is fairly easy.
  • the curvilinear path 13 provides a substantial stiffening effect to resist a bending moment of the aforementioned type, and prevents buckling or other damage to the tube 2 during installation, removal, and other handling of the tube 2 or a tube assembly 1 containing a tube 2 . While benefit can be derived from any non-linear path, it can be especially beneficial for the path 13 to be defined by a series of connected arcuate path segments.
  • the curvilinear paths 13 each include an apex located at the approximate center plane of the tube, so that the apex is located at the point 14 along the path 13 that is furthermost away from the end 7 (in the case of the transition region between the flat section 3 and the first cylindrical end 4 ) or the end 8 (in the case of the transition region between the flat section 3 and the second cylindrical end 5 ).
  • the path 13 preferably includes an arcuate path segment at the apex so that stress concentrations are avoided at the apex.
  • the outer perimeter (i.e. circumference) of at least one of the two cylindrical sections 4 , 5 is less than the outer perimeter of the continuous tube wall 25 in the flat section 3 .
  • a smaller diameter at the ends can be preferable, as it can enable closer spacing of adjacent tube assemblies and requires less sealing surface at the ends, for example.
  • the outer perimeter of the flat section 3 exceeds the outer perimeter of at least one of the two cylindrical end sections by at least 25%.
  • Heat exchangers including fluid conveying tubes having a flattened profile over the entirety of their length are well-known in the art, having been used for decades as radiators and the like.
  • Flat tubes of this type are usually constructed in one of two ways. They are either extruded and/or drawn in the flat shape from a billet of material and cut into discrete lengths, or they are created in a tube mill from coiled sheet by forming the sheet form into a round shape, seam welding, roll flattening to the flat tube shape, and cutting into discrete tube lengths.
  • the transition regions 6 can be formed by initially forming the tube 2 in a round form having an outer diameter equal to the desired outer perimeter of continuous tube wall 25 in the flat section 3 .
  • the ends of the round tube 2 are reduced in diameter to form the cylindrical ends 4 and 5 , as well as a tapered transition region 6 ′ between the ends 4 , 5 and the central section 3 ′ which retains the original round shape.
  • This reduction in diameter can be accomplished by, for example, swaging of the tube ends.
  • the ends are reduced in diameter by at least 20% in order to achieve the desired ratio of outer perimeters between the flat section 3 and the cylindrical end sections 4 , 5 .
  • the profile of the flat section 3 of the tube 2 can be defined by forming that portion 3 ′ of the tube 2 between a first forming die half 22 and a second forming die half 23 .
  • the tube 2 is inserted between the die halves 22 , 23 when the die is in an open position, i.e. when the two die halves are separated from one another, as in FIG. 13A .
  • the die closes so as to be in the closed position of FIG. 13B , thereby forming the flat section 3 of the tube 2 to the minor dimension d 1 and the major dimension d 2 .
  • a mandrel 24 can be placed within the tube 2 prior to the forming operation in order to prevent buckling or other undesirable deformation of the broad and flat tube walls 12 during the forming operation.
  • the mandrel 24 when used, can be removed from the tube 2 after the forming operation is complete.
  • the geometry of the transition regions 6 can be produced by including complementary negative representations of the geometry in the contacting faces of the die halves 22 and 23 , so that the desired geometry of the transition regions 6 is formed into the tube 2 during the forming operation.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Geometry (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)
US13/570,767 2012-08-09 2012-08-09 Heat Exchanger Tube, Heat Exchanger Tube Assembly, And Methods Of Making The Same Abandoned US20140041844A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US13/570,767 US20140041844A1 (en) 2012-08-09 2012-08-09 Heat Exchanger Tube, Heat Exchanger Tube Assembly, And Methods Of Making The Same
JP2012254213A JP2014035181A (ja) 2012-08-09 2012-11-20 熱交換器のためのチューブ、熱交換器のチューブアッセンブリ及びその製造方法
KR1020120133287A KR101562090B1 (ko) 2012-08-09 2012-11-22 열교환기 관, 열교환기 관조립체 및 그 제조 방법
BR102012029873-2A BR102012029873A2 (pt) 2012-08-09 2012-11-23 Tubo de trocador de calor, conjunto de tubo de trocador de calor e métodos de fabricação dos mesmos
CN201210481026.3A CN103575147A (zh) 2012-08-09 2012-11-23 换热器管、换热器管组件和制造它们的方法
DE102012023990.4A DE102012023990A1 (de) 2012-08-09 2012-12-06 Wärmetauscherrohr, Wärmetauscherrohranordnung und Verfahren zum Herstellen desselben
US14/175,004 US20140182829A1 (en) 2012-08-09 2014-02-07 Heat Exchanger Tube Assembly and Method of Making the Same

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US13/570,767 US20140041844A1 (en) 2012-08-09 2012-08-09 Heat Exchanger Tube, Heat Exchanger Tube Assembly, And Methods Of Making The Same

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US20140041844A1 true US20140041844A1 (en) 2014-02-13

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US (1) US20140041844A1 (ja)
JP (1) JP2014035181A (ja)
KR (1) KR101562090B1 (ja)
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DE (1) DE102012023990A1 (ja)

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WO2014138353A1 (en) * 2013-03-07 2014-09-12 Foster Wheeler Usa Corporation Differing thermal properties increase furnace run length
US20170030659A1 (en) * 2015-07-28 2017-02-02 Caterpillar Inc. Tube-and-Fin Assembly with Improved Removal Feature and Method of Making Thereof
US20180238626A1 (en) * 2017-02-20 2018-08-23 Hanon Systems Cab/maar concept improvement
CN112222789A (zh) * 2020-08-23 2021-01-15 蚌埠市神舟机械有限公司 一种船用散热器制造工艺

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US10563570B2 (en) * 2017-08-29 2020-02-18 Caterpillar Inc. High temperature capable joint assembly for use in air-to-air aftercoolers (ATAAC)
CN114290008B (zh) * 2021-12-31 2023-06-06 江苏金荣森制冷科技有限公司 成型扭转顶伸自动化成型装置
CN114290009B (zh) * 2021-12-31 2023-06-02 江苏金荣森制冷科技有限公司 成型扭转顶伸自动化成型装置的生产方法

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Cited By (8)

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Publication number Priority date Publication date Assignee Title
WO2014138353A1 (en) * 2013-03-07 2014-09-12 Foster Wheeler Usa Corporation Differing thermal properties increase furnace run length
US9850431B2 (en) 2013-03-07 2017-12-26 Amec Foster Wheeler Usa Corporation Method and system for utilizing materials of differing thermal properties to increase furnace run length
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US20170030659A1 (en) * 2015-07-28 2017-02-02 Caterpillar Inc. Tube-and-Fin Assembly with Improved Removal Feature and Method of Making Thereof
US20180238626A1 (en) * 2017-02-20 2018-08-23 Hanon Systems Cab/maar concept improvement
US10801780B2 (en) * 2017-02-20 2020-10-13 Hanon Systems CAB/MAAR concept improvement
CN112222789A (zh) * 2020-08-23 2021-01-15 蚌埠市神舟机械有限公司 一种船用散热器制造工艺

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KR101562090B1 (ko) 2015-10-20
CN103575147A (zh) 2014-02-12
BR102012029873A2 (pt) 2015-02-10
JP2014035181A (ja) 2014-02-24
DE102012023990A1 (de) 2014-02-13
KR20140020700A (ko) 2014-02-19

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