WO2019123024A1 - Tube d'échangeur de chaleur et procédé de fabrication associé - Google Patents

Tube d'échangeur de chaleur et procédé de fabrication associé Download PDF

Info

Publication number
WO2019123024A1
WO2019123024A1 PCT/IB2018/052229 IB2018052229W WO2019123024A1 WO 2019123024 A1 WO2019123024 A1 WO 2019123024A1 IB 2018052229 W IB2018052229 W IB 2018052229W WO 2019123024 A1 WO2019123024 A1 WO 2019123024A1
Authority
WO
WIPO (PCT)
Prior art keywords
ingot
thickness
metal strip
heat exchanger
exchanger tube
Prior art date
Application number
PCT/IB2018/052229
Other languages
English (en)
Inventor
Prasad S. Kadle
Yogendra Singh Kushwah
Original Assignee
Subros Limited
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 Subros Limited filed Critical Subros Limited
Publication of WO2019123024A1 publication Critical patent/WO2019123024A1/fr

Links

Classifications

    • 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
    • F28F1/40—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only inside the tubular element
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2215/00—Fins
    • F28F2215/04—Assemblies of fins having different features, e.g. with different fin densities

Definitions

  • the present disclosure relates generally to heat exchangers, and more specifically, to a method for manufacturing a heat exchanger tube from a single metal strip having different thickness in portions.
  • heat exchangers are employed as condensers and evaporators for use indifferent heat exchanging applications.
  • a heat exchanger includes a large number of relatively thin-walled flat tubes with small-sized ports through which a refrigerant passes and exchanges heat with air on the other side of the heat exchanger before exiting it.
  • the tube-based heat exchangers could fail due to inlet end corrosion or erosion and tube end cracking.
  • the heat exchanger tubes may be subjected to external impacts such as a stone impingement on the nose of the tubes which are exposed to the front of the vehicle. Additionally, the tubes have to withstand internal stresses due to thermal variations and pressure pulsations.
  • a first type of tube is made by an extrusion process wherein the ports are formed in an extrusion die.
  • a second type of tube can be referred to as a fabricated or formed tube.
  • the second type of tube can be described broadly as being manufactured by two different methods. In a first known method, the second type of tube is formed by utilizing a single flat sheet of metal which is folded in various steps to form a structure that has the wails of the ports of the same thickness as the outside wall of the tube.
  • the second type of tube thus created is heavier than would be normally required from a strength and/ora corrosion standpoint.
  • another manufacturing process entails use of two sheets of different thickness to form the second type of tube.
  • the first sheet forms an enclosure while the second, a relatively thinner sheet is corrugated to form channels internally.
  • the second sheet is then inserted into the enclosure. Subsequently, the whole structure is brazed to produce the heat exchanger tube. This is a very difficult and expensive process because of the need to handle two separate pieces that includes a difficult insertion process.
  • the present disclosure seeks to provide a method of fabricating a metal strip adapted to be used for producing a heat exchanger tube.
  • the present disclosure seeks to provide a heat exchanger tube comprising a plurality of heat exchanging channels, a top wall, and a bottom wall folded around the plurality of heat exchanging channels using the metal strip.
  • a method of fabricating a heat exchanger tube includes providing a tube formed with one strip of heat conducting material with at least two thicknesses folded so that the tube has a cross section that defines a bottom wall with two opposing edges transitioning into a top wail spaced apart from the bottom wail to define an interior surface that surrounds a corrugated portion formed of a plurality of heat exchanging channels extending between and in contact with the interior surface of the top and bottom wails, wherein the corrugated portion is substantially thinner than the top and bottom wails.
  • the heat conducting material is a metal strip.
  • the metal strip includes a first portion of a first thickness and a second portion of a second thickness. The first portion forms the top and bottom walls and the second portion forms the corrugated portion.
  • the method of fabricating the heat exchanger tube includes a method of manufacturing the metal strip.
  • the method further includes computing a first volume of the first portion and a second volume of the second portion in accordance with predetermined requirements of the heat exchanger tube and determining an initial length and an initial thickness of a first ingot before performing a roiling operation in accordance with the first volume of the first portion, wherein the first ingot after performing the roiling operation thereupon is transformed into the first portion in such a way that a width of the first ingot after performing the rolling operation is substantially equal to a width of the first portion of the metal strip.
  • the method further includes deriving at least one relation between an initial length and an initial thickness of a second ingot, wherein the at least one relation is dependent on the initial length of the first ingot, initial thickness of the first ingot, the first thickness of the first portion and the second thickness of the second portion, wherein the second ingot after performing the roiling operation thereupon is transformed into the second portion in such a way that a width of the second ingot after performing the rolling operation is substantially equal to a width of the second portion.
  • the method includes performing the rolling operation on the first ingot and the second ingot; and pressing the first ingot and the second ingot at a predetermined temperature upon completion of the rolling operation to fabricate the single metal strip comprising the first portion of the first thickness and the second portion of the second thickness.
  • the method further includes determining at least one of the initial length and the initial thickness of the second ingot in accordance with the at least one relation.
  • the method further includes determining the widths of the first ingot and the second ingot respectively required to undergo the rolling operation, wherein the respective widths of the first ingot and the second ingot remains substantially same after performing the rolling operation.
  • the method includes defining the plurality of heat exchanging channels extending between and in contact with the interior surface of the top and bottom walls; and folding the second portion of the metal strip to create the plurality of heat exchanging channels.
  • the method includes folding the first portion around the folded second portion to create the top and bottom walls around the plurality of heat exchanging channels of the heat exchanger tube.
  • a width of the first ingot is selected based on a perimeter of the walls of the heat exchanger tube.
  • a heat exchanger tube comprising a plurality of heat exchanging channels and a top wall and a bottom wall folded around the plurality of heat exchanging channels.
  • the plurality of heat exchanging channels are made from a first portion of a first thickness of a metal strip and the wall is made from a second portion of a second thickness of the metal strip, wherein the metal strip is fabricated using a method comprising steps of:
  • the first thickness of the first portion is relatively greater than the second thickness of the second portion of the metal strip.
  • the present disclosure provides a method of manufacturing the heat exchanging tube from a metal strip having varying thickness level.
  • the present disclosure provides a greater stability to the heat exchanger tube as the tube has a thicker wall, an increased heating capacity due to a relatively increased number of heat exchanging channels of the heat exchanger tube.
  • Figure 1 is a schematic illustration of an exemplary cross-sectional view of a heat exchanger tube in accordance with an embodiment of the present disclosure
  • Figures 2A and 2B are schematic illustrations of pre-rolling and post-rolling forms of a first ingot and a second ingot in accordance with an embodiment of the present disclosure
  • Figures 3A and 3B are exemplary perspective and cross-sectional views of the single metal strip respectively in accordance with an embodiment of the present disclosure.
  • Figure 4 is a schematic illustration of steps of a method for fabricating the metal strip in accordance with an embodiment of the present disclosure.
  • an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent.
  • a non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
  • the heat exchanging tubes of the present disclosure are used within a condenser of a system.
  • the condenser includes two headers wherein each header among the two headers is disposed on an either side of the condenser.
  • the plurality of heat exchanging tubes are disposed within each header of the condenser.
  • the condenser includes a refrigerant inlet port and a refrigerant outlet port.
  • a super heated refrigerant enters inside the condenser and a condensation of the super- heated refrigerant happens within the plurality of heat exchanging channels of the heat exchanging tubes.
  • the condenser may be installed with an integrated receiver dryer bottle (IRD bottle). Once the refrigerant is condensed within the condenser, the condensed refrigerant goes out from the refrigerant outlet port in a sub cooled state.
  • ITD bottle integrated receiver dryer bottle
  • FIG 1 is a schematic illustration of an exemplary cross-sectional view of a heat exchanger tube 100 in accordance with an embodiment of the present disclosure.
  • the heat exchanger tube 100 is made up from one strip of a heat conducting material with at least portions having different thicknesses.
  • the heat conducting material can be a metal strip.
  • the metal strip is folded in such a manner that the heat exchanger tube 100 has a cross section that defines a bottom wall 102 with two opposing edges transitioning into a top wall 104spaced apart from the bottom wail 102 to define an interior surface 106.
  • the inferior surface 106 surrounds a corrugated portion formed of a plurality of heat exchanging channels such as 108a, 108b, 108c and a 10Sd, collectively hereinafter referred to as 10Sextendlng between and in contact with the interior surface 108of the bottom wall 102 and the top wall 104.
  • the corrugated portion is substantially thinner than the top and bottom walls.
  • the heat exchanging channels 108 facilitates transfer of heat through a contact with the refrigerant.
  • the heat exchanging channels are corrugated channels which are of a triangular shape. However, the corrugated channels can be of a square, rectangular or any other geometric shape in order to maintain the heat transfer efficiency of the heat exchanger tube 100.
  • the heat exchanger tube 100 of the present disclosure is manufactured from a single metal strip.
  • the metal strip includes two portions namely a first portion and a second portion.
  • the first portion has a first thickness and the second portion has the second thickness.
  • the first portion of the metal strip has a relatively higher thickness than the second portion of the metal strip.
  • the heat exchanger tube 100 is formed by folding the first portion and the second portion at specified points respectively in a manner so that the second portion is transformed into the corrugated heat exchanging channels 108 and the first portion is folded over the corrugated heat exchanging channels 108 as the bottom wall 102 and the top wail 104.
  • the first portion of the metal strip provides rigidity to the heat exchanger tube 100 and the second portion of the metal strip facilitates and enhances heat exchanging capabilities of the heat exchanger tube 100.
  • the heat exchanger tube 100 being made from the single metal strip has relatively more tensile strength and a longer life than the heat exchanger tube made from multiple metal strips.
  • a method for manufacturing the heat exchanger tube 100 from the metal strip is disclosed. Firstly, corrugated channels are formed on the second portion of the metal strip. Subsequently, the corrugated heat exchanging channels are folded within the first portion of the metal strip. Further, another fold of the first portion of the metal strip is formed so that the first portion can entirely cover the corrugated heat exchanging channels from top as well as bottom surfaces. In addition, after folding the first portion of the metal strip over the corrugated heat exchanging channels, an end portion of the second portion of the metal strip is prevented from aligning with the top wall 104. This ensures that the end portion does not interfere with the fins which will be brazed to the heat exchanger tube 100.
  • the end portion terminates at least a distance of t3 units from a surface of the top wall 104. Furthermore, the heat exchanger tube 100 is passed through a brazing furnace so that a brazing operation is performed onto the heat exchanger tube 100 and an opening end of the first portion is securely tightened with the folded portion of the heat exchanger tube 100.
  • a method of fabricating the metal strip adapted to be used for manufacturing the heat exchanger tube is disclosed. Normally, the heat exchanger tube specifications are first defined and subsequently, the metal strip requirements are derived so that when folding process is performed on the first portion and the second portion of the metal strip, the heat exchanger tube 100 of desired specifications can be obtained.
  • a first volume of the first portion and a second volume of the second portion is computed in accordance with the desired requirements of the heat exchanger tube.
  • the design engineer may indicate a number of corrugated heat exchanging channels required in the heat exchanger tube 100 and specifications of the wail encircling the corrugated heat exchanging channels of the heat exchanger tube 100.
  • the number of the corrugated heat exchanging channels can be a representative of the specifications for the second portion of the metal strip and the wall encircling the corrugated heat exchanging channels can be a representative of the specifications for the first portion of the metal strip.
  • the different portions i.e. , the first portion and the second portion of the metal strip are obtained after performing a roiling operation on a first ingot and a second ingot.
  • an initial length and an initial thickness of the first ingot before performing a rolling operation is determined in accordance with the first volume of the first portion.
  • the first ingot after performing the rolling operation thereupon is transformed into the first portion in such a way that a width of the first ingot after performing the roiling operation is substantially equal to a width of the first portion of the metal strip.
  • one or more relations are derived between an initial length and an initial thickness of the second ingot.
  • the one or more relations are dependent on the initial length of the first ingot, initial thickness of the first ingot, the first thickness of the first portion and the second thickness of the second portion.
  • the second ingot after performing the rolling operation thereupon is transformed into the second portion in such a way that a width of the second ingot after performing the rolling operation is substantially equal to a width of the second portion of the metal strip.
  • the initial length of the second ingot is determined using the one or more relations and a fixed initial thickness of the second ingot.
  • the initial thickness of the second ingot is determined using the one or more relations and a fixed length of the second ingot.
  • the widths of the first ingot and the second ingot respectively required to undergo the roiling operation are determined in accordance with the specifications of the heat exchanger tube 100.
  • the respective widths of the first ingot and the second ingot remains substantially same after performing the roiling operation.
  • the width of the first ingot is selected based on a perimeter of the wails of the heat exchanger tube 100 and the width of the second ingot is selected based on the number of heat exchange channels required within the heat exchanger tube.
  • the roiled forms of the first ingot and the second ingot are pressed against each other along their respective lengths in such a manner that a longitudinal axis of the rolled form of the second ingot is aligned with a longitudinal axis of the roiled form of the first ingot.
  • the longitudinal axis of the rolled form of the second ingot is above the longitudinal axis of the rolled form of the first ingot and the top surfaces of the roiled forms of the first and second ingots are aligned with each other.
  • the rolled forms of the first ingot and the second ingot are pressed against each other by adding a relative offset between them.
  • Figures 2A and 2B are schematic illustrations of pre-rolling and post-rolling forms of the first ingot and the second ingot respectively in accordance with an embodiment of the present disclosure.
  • a block 202 illustrates a pre-rolling form of the first ingot and a block 204 illustrates a post-rolling form of the first ingot.
  • a block 212 illustrates a pre-rolling form of the second ingot and a block 214 illustrates a post-rolling form of the second ingot.
  • post-roiling forms of the first ingot and second ingot are pressed together at the predetermined temperature to generate the metal strip having two portions. The first portion is obtained from the first ingot and the second portion is obtained from the second ingot.
  • the thickness of the first portion is relatively higher than the thickness of the second portion and the metal strip specification requires length of the first portion and the second portion be of equal size, it is important that a size of the first ingot and the second ingot must be selected in a manner so that the first portion and the second portion are of desired equal length. In other words, either length or thickness of the second ingot is appropriately determined to fabricate the metal strip of desired specifications.
  • a volume of the first ingot after the rolling operation is Volumes tirwi hr;
  • volume of the first ingot before the rolling operation volume of the first ingot after the roiling operation
  • volumear iiwihr
  • volume of the second ingot before the rolling operation volume of the second ingot after the rolling operation
  • the length of the first portion and the second portion of the metal strip is equal. That is to say, the length of the post-rolling form of the first ingot is equal to the length of the post-rolling form of the second ingot.
  • Figure 3A illustrates an exemplary perspective view of the metal strip formed from the first ingot and the second ingot in accordance with an embodiment of the present disclosure.
  • the metal strip includes the first portion of the first thickness t1 and the second portion of the second thickness t2.
  • Figure 3B illustrates an exemplary cross-sectional view of the metal strip formed from the first ingot and the second ingot in accordance with an embodiment of the present disclosure.
  • Figure 4 illustrates exemplary steps of a method for fabricating the metal strip in accordance with an embodiment of the present disclosure.
  • the metal strip is adapted to be used for manufacturing the heat exchanger tube comprising a plurality of heat exchanging channels and a wall folded around the plurality of heat exchanging channels.
  • the plurality of heat exchanging channels are made from a second portion of a second thickness of a metal strip and the wall is made from a first portion of a first thickness of the metal strip.
  • a first volume of the first portion and a second volume of the second portion is computed in accordance with predetermined requirements of the heat exchanger tube.
  • an initial length and an initial thickness of a first ingot before performing a rolling operation in accordance with the first volume of the first portion is determined.
  • the first ingot after performing the rolling operation thereupon is transformed into the first portion in such a way that a width of the first ingot after performing the roiling operation is substantially equal to a width of the first portion of the metal strip.
  • At step 406 at least one relation between an initial length and an initial thickness of a second ingot is derived.
  • the at least one relation is dependent on the initial length of the first ingot, initial thickness of the first ingot, the first thickness of the first portion and the second thickness of the second portion.
  • the second ingot after performing the roiling operation thereupon is transformed into the second portion in such a way that a width of the second ingot after performing the rolling operation is substantially equal to a width of the second portion.
  • the rolling operation on the first ingot and the second ingot is performed.
  • first ingot and the second ingot are pressed against each other at a predetermined temperature upon completion of the rolling operation to fabricate the single metal strip comprising the first portion of the first thickness and the second portion of the second thickness.
  • the present disclosure offers several advantages. Firstly, the second portion, a relatively thinner portion allows an increase in the number of the corrugated heat exchanging channels within the heat exchanger tube 100. As a result, a relatively higher number of corrugated heat exchanging channels can be formed resulting into an increased efficiency of the heat exchanger tube 100. Further, the present disclosure facilitates reduction in the usage of the material and thus renders a cost- effective approach for manufacturing the heat exchanger tube 100. Furthermore, the wall encircling the corrugated heat exchanging channels is relatively thicker which protects the corrugated heat exchanging channels from corrosion and facilitates in sustaining burst pressure specifications.

Abstract

L'invention concerne un tube d'échangeur de chaleur qui comporte une pluralité de canaux d'échange de chaleur, une paroi supérieure et une paroi inférieure, pliées autour de la pluralité de canaux d'échange de chaleur. La pluralité de canaux d'échange de chaleur sont fabriqués à partir d'une seconde partie d'une bande métallique ayant une seconde épaisseur, et les parois supérieure et inférieure sont fabriquées à partir d'une première partie de la bande métallique ayant une première épaisseur. En outre, l'invention concerne un procédé de fabrication de la bande métallique.
PCT/IB2018/052229 2017-12-19 2018-03-30 Tube d'échangeur de chaleur et procédé de fabrication associé WO2019123024A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201711045628 2017-12-19
IN201711045628 2017-12-19

Publications (1)

Publication Number Publication Date
WO2019123024A1 true WO2019123024A1 (fr) 2019-06-27

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ID=66993165

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Application Number Title Priority Date Filing Date
PCT/IB2018/052229 WO2019123024A1 (fr) 2017-12-19 2018-03-30 Tube d'échangeur de chaleur et procédé de fabrication associé

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WO (1) WO2019123024A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110005738A1 (en) * 2006-11-22 2011-01-13 Modine Manufacturing Company Soldered flat tube for condensers and/or evaporators
US20150107812A1 (en) * 2011-03-31 2015-04-23 Valeo Systemes Thermiques Heat Exchanger Tube, And Corresponding Heat Exchanger Production Method

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110005738A1 (en) * 2006-11-22 2011-01-13 Modine Manufacturing Company Soldered flat tube for condensers and/or evaporators
US20150107812A1 (en) * 2011-03-31 2015-04-23 Valeo Systemes Thermiques Heat Exchanger Tube, And Corresponding Heat Exchanger Production Method

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