Abstract:
A heat exchange chamber includes an inlet, an outlet and a plurality of walls defining a chamber interior. The inlet receives a heat exchange medium flowing in a first flow direction in an initial line of flow. Disposed within the chamber interior is a medium directing member, having an inclined surface, which diverts the medium from the initial flow direction so that it disperses within the chamber interior. The medium exits the chamber, via the outlet, in the initial line of flow. The chambers are interconnected by tubes to form assemblies. Plural sets of chamber and tube assemblies are arranged between manifolds to provide a heat exchanger.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to heat exchangers and, more specifically, to a tube and chamber apparatus for transporting heat exchange media. 
     2. Discussion of the Related Art 
     Heat exchangers are commonly utilized in systems where it is desired for heat to be removed. Typical basic heat exchangers are made of pipes, which channel heat exchanging media. Headers or manifolds are attached to each end of the pipes. These headers and manifolds act as receptacles for the heat exchanging media. The efficiency of the pipe heat exchangers is limited by the amount of surface area available for the transfer of heat. 
     To add more surface area, some heat exchangers, such as condensers, incorporate a “tube-and-fin” design. This type of heat exchanger typically includes flattened tubes having a fluid passing therethrough and a plurality of fins extending between the tubes. The fins are attached to the tubes to effectively increase the surface area of the tubes, thereby enhancing heat transfer capability of the tubes. A number of tubes and fins may be stacked on top of each other, which leaves a small opening to allow passage of air in between them. In another tube-and-fin design, the tube can be of a serpentine design, therefore eliminating the need for headers or manifolds, as the tube is bent back and forth in an “S” shape to create a similar effect. Typical applications of this type of heat exchanger, besides condensers, are evaporators, oil coolers, and heater cores. This tube-and-fin design is also utilized in radiators for automobiles. Outside of the automotive field, the tube and fin design is implemented by industrial oil coolers, compressor oil coolers, and in other similar applications requiring a higher efficiency heat exchanger. 
     In another effort to create a greater exchange of heat by increasing surface area, very thin flat tubes with intricate inner rib structures are utilized. This type of heat exchanger is similar to the tube-and-fin design, in that fins are combined with the flat tubes, but in this particular type of heat exchanger, the flat tubes contain intricate internal chambers formed by the inner rib structures. These inner rib structures help to increase the heat exchanging performance of the heat exchanger. To further improve heat transfer efficiency, the tube thickness is made thinner. As a result, the parts are lighter in weight, which in turn makes the overall heat exchanger lighter in weight. However, the pressure resistance is reduced, and the thinner tubes are more prone to damage. Also, the assembly process is complicated because of the fragile nature of the parts. In addition, the internal chambers are prone to plugging during the manufacturing process, particularly if a brazing process is utilized. The complexity of the extruding process potentially results in higher costs and higher defect rates. Also, by utilizing internal chambers within the flat tubes to help disperse heat, the overall cost for the heat exchanging system will be higher because a higher powered compressor may be necessary to move the heat exchanging medium through the smaller openings of the tubes. Conversely, if a higher powered compressor is not utilized, then additional tubes will be necessary to obtain the desired heat exchanging performance because the smaller tubes reduce the flow of the heat exchange media significantly. The additional tubes will increase the overall cost for the heat exchanging system. Currently, this type of heat exchanger is used in applications requiring high heat exchanging capabilities, such as automotive air conditioner condensers. 
     A variation on the tube-based heat exchanger involves stacking flat ribbed plates. When stacked upon each other, these ribbed plates create chambers for transferring heat exchanging media. In essence, this type of heat exchanger performs substantially the same function as tube-and-fin type heat exchangers, but is fabricated differently. This type of heat exchanger is commonly implemented by contemporary evaporators. 
     SUMMARY OF THE INVENTION 
     The present invention is an enhanced tube for heat exchanging applications including a flow tube and a chamber. The flow tube connects to the chamber. One end of the flow tube may connect to a header or a manifold. Heat exchange media flows from the header or the manifold into the flow tube. The heat exchange media then flows into the chamber. The heat exchange media then flows from the chamber into another flow tube, which is connected to another header or manifold. 
     In an embodiment of the present invention, the flow tube and the chamber for a heat exchanger are provided, for example, for a condenser, evaporator, radiator, etc. The heat exchanger may also be a heater core, intercooler, or an oil cooler for an automotive application (i.e., steering, transmission, engine, etc.) as well as for non-automotive applications. An advantage of the present invention is that the heat exchange media contact surface area for radiating heat is greater over a shorter distance than that of a conventional heat exchanger. Therefore, the efficiency of the heat exchanger is increased. Another advantage of the present invention is that the overall length and weight of the enhanced tube for heat exchanging applications may be less compared to a conventional heat exchanger, which in turn provides for a lower overall cost as less raw material and less packaging is necessary. Furthermore, the smaller footprint of the present invention lends itself to be used in applications where space is limited. Yet another advantage of the present invention over a conventional heat exchanger is that the manufacturing process may be simpler because the present invention requires less fragile components and less manufacturing steps. The entire unit may be brazed together, or any portion of the unit can be brazed first, and then additional components may be brazed or soldered together. 
     In another embodiment of the present invention, more than one chamber may be used, which will further increase the surface area of the enhanced tube for the heat exchanger. Also, a first chamber may be connected directly to another chamber. 
     In yet another embodiment of the present invention, the tube size may vary between the chambers, and if more than one chamber is used, the chamber size may vary from one chamber to the next. 
     In a further embodiment of the present invention, each chamber may disperse heat exchanging media throughout the chamber, which further enhances the heat exchanging capabilities of the present invention. Also, each chamber may also mix heat exchanging media. 
     In yet a further embodiment of the present invention, each chamber may include a medium directing member and medium redirection members that direct and redirect heat exchanging media in particular directions through the chamber. 
     In another embodiment of the present invention, the inner surface of the tube may feature indentations to increase the surface area. Also, in yet another embodiment of the present invention, the inner surface of the chamber may also feature indentations to increase the surface area. In a further embodiment of the present invention, the redirection member may also feature indentations. 
     In other embodiments of the present invention, the tube and chamber combination may be repeated, and based on a particular application, there may be multiple tube and chamber assembly rows. Several of the tube and chamber units may be attached to a header or a manifold. There may be a plurality of tube and chamber units arranged in a row that are attached to a header or a manifold to enhance the overall performance of the heat exchanger. 
     In some embodiments, the chamber is of a greater diameter than the inlet and the outlet of the chamber. In other embodiments, the chamber is of a greater diameter than the inlet of the chamber, but may be the same diameter as the outlet. Alternatively, in yet other embodiments, the chamber may be of a greater diameter than the outlet of the chamber, but may be the same diameter as the inlet. 
     In yet some other embodiments, the chamber has at least one greater dimension than the tube. For instance, the chamber may have a greater fluid capacity, circumference, or surface area. The ratio of a particular dimension between the tube and the chamber may be 1:1.1; 1:1.5; or any other suitable ratio. 
     The tube and the chamber may be made of aluminum, either with cladding or without cladding. The tube and chamber may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The tube and chamber may also be a plastic material or other composite materials. 
     The tube and chamber may be manufactured by stamping, cold forging, or machining. The tube and chamber may be manufactured as one piece or may be manufactured as two separate pieces. 
     Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a tube and a chamber illustrated in operational relationship with manifolds to provide a heat exchanger according to embodiments of the present invention; 
         FIGS. 2A through 2B  illustrate two embodiments of the present invention; 
         FIG. 2C  is a perspective view of a tube and chamber with a medium-directing insert; 
         FIG. 3  is a view of a redirect chamber with redirection members; 
         FIGS. 4A through 4E  illustrate various embodiments of the tube; 
         FIGS. 5A through 5D  illustrate various embodiments of the redirect chamber; 
         FIGS. 6A and 6B  are different views of the invention heat exchanger formed by stacked plates; 
         FIG. 7  is a cross-section of an embodiment of the invention surrounded by a compartment; 
         FIGS. 8A and 8B  illustrate an embodiment of the invention illustrating a type of medium directing member; 
         FIGS. 9A and 9B  illustrate another embodiment of the present invention; 
         FIGS. 10A and 10B  illustrate yet another embodiment of the present invention; 
         FIGS. 11A and 11B  illustrate a further embodiment of the present invention; 
         FIG. 12  illustrates another embodiment of the redirection chamber; and 
         FIGS. 13A and 13B  illustrate an embodiment using unsecured redirection members in the redirection chamber. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings and in particular  FIG. 1 , an embodiment of a heat exchanger  100  is shown. The heat exchanger  100  includes a manifold  200  matingly engaged to free ends of tubes  10  that are brazed to redirect chambers  20 . As shown in  FIG. 1 , the redirect chambers  20  have a greater fluid capacity than the tubes  10 . Heat exchange media  50  flows from the outlet  210  of the manifold  200  into the inlet  11  of the tube  10 . The heat exchange medium  50  passes through the outlet  19  of the tube  10  into the inlet  21  of the redirect chamber  20 . The heat exchange media  50  then flows out an outlet  29  of the redirect chamber  20 . The process of going from a tube  10  to a redirect chamber  20  may repeat several times until the heat exchange media  50  is received by another manifold  202 . There may also be several rows of the tube  10  and redirect chamber  20  combinations. Also, one embodiment may allow for just one tube  10  and one redirect chamber  20 . Throughout the transport of the heat exchange media  50  through the heat exchanger  100 , the heat from the heat exchange media  50  is transferred to the environment outside of the heat exchanger  100 . Although not meant to be limiting, common heat exchange media known in the art includes various refrigerants (i.e., R-134A), carbon dioxide, butane, oils, gases (e.g., air), water, and mixtures of water and other coolants. 
     In another embodiment of the heat exchanger  100 , the heat exchanger  100  may be used in a reversed method. Instead of the heat exchanger  100  being used in an environment where heat is transferred from the heat exchange media  50  to the surrounding environment of the heat exchanger  100 , the heat exchanger  100  may be used to increase the temperature of the heat exchange media  50  flowing inside the present invention. For example, water of an ambient temperature may flow through the tube  10  and the chamber  20  of the heat exchanger  100 , where the environment surrounding the heat exchanger  100  is of a higher temperature than that of the water. Continuing with this example, the heat from the environment surrounding the heat exchanger  100  is transferred to the water, thereby increasing the temperature of the water. An example of this embodiment, which is not intended to be limiting, would be a water heater. 
     Referring to  FIG. 2A , the inside of tube  10  is hollow, which allows for the flowing of the heat exchange medium  50 . The tube  10  is mated to the redirect chamber  20 . The redirect chamber  20  houses a medium-directing insert  30 . The medium-directing insert  30  is positioned within the intersecting space between the tube  10  and the redirect chamber  20 . The heat exchanging medium  50  flows through the tube  10  until the heat exchanging medium  50  flows into contact with the medium-directing insert  30 . The medium-directing insert  30  directs the heat exchanging medium  50  into the inside of the redirect chamber  20 . According to the present embodiment, the heat exchange medium  50  disperses throughout the redirect chamber  20  and heat is transferred from the heat exchange medium  50  to the redirect chamber  20 . 
     Referring to  FIG. 3 , an embodiment of the redirect chamber  20  is shown. Redirection members  28  are attached to the redirect chamber  20 . In this embodiment, the redirection members  28  are attached to the inner wall of the redirect chamber  20 . Although not meant to be limiting, in  FIG. 3 , the redirection members  28  are secured at an angle. In addition, other embodiments may secure the redirection members  28  perpendicularly to the inside of the redirect chamber  20 , that is, the redirection members  28  are at 90 degree angles. 
     Referring to  FIG. 2B , the inside of tube  10  is hollow, which allows for the flowing of a heat exchange medium  50 . The tube  10  is mated to the redirect chamber  20 . The redirect chamber  20  houses a medium-directing insert  30 . The medium-directing insert  30  is fixed within the intersecting space between the tube  10  and the redirect chamber  20 . The heat exchanging medium  50  flows through the tube  10  until the heat exchanging medium  50  flows into contact with the medium-directing insert  30 . The medium-directing insert  30  directs the heat exchanging medium  50  into the inside of the redirect chamber  20 . According to the embodiment in  FIG. 2B , redirection members  28  direct the heat exchange medium  50  in a particular direction within the redirect chamber  20  and heat is transferred from the heat exchange medium  50  to the redirect chamber  20 . 
     Referring to  FIG. 2C , a perspective view of tube  10  and chamber  20  is shown. The inside of tube  10  is hollow, which allows for the flowing of the heat exchange medium  50 , the flow direction is illustrated by the arrows. The tube  10  is mated to the redirect chamber  20 . The redirect chamber  20  houses a medium-directing insert  30 . The medium-directing insert  30  is fixed within the intersecting space between the tube  10  and the redirect chamber  20 . The heat exchanging medium  50  flows through the tube  10  until the heat exchanging medium  50  flows into contact with the medium-directing insert  30 . The medium-directing insert  30  directs the heat exchanging medium  50  into the inside of the redirect chamber  20 . According to the present embodiment, the heat exchange medium  50  disperses throughout the redirect chamber  20  and heat is transferred from the heat exchange medium  50  to the redirect chamber  20 . 
     Referring to  FIG. 4A , the tube  10 , in the illustrated embodiment, is hollow and circular. In another embodiment, as shown in  FIG. 4B , the tube  10  is hollow and a non-circle shape. In yet another embodiment, as shown in  FIG. 4C , ribs  18 , which divide the area inside the tube  10  into smaller compartments for transferring the heat exchange media  50 , are placed inside the tube  10  to increase heat exchange performance.  FIG. 4D  illustrates an embodiment of the tube  10  in which the tube wall  12  includes extensions  14 .  FIG. 4E  illustrates a further embodiment of the tube  10  with tube fins  16  shrouding the outer surface of the tube  10 . 
     Referring to  FIG. 5A , redirect chamber  20 , in the illustrated embodiment, is hollow and circular. In another embodiment, as shown in  FIG. 5B , the redirect chamber  20  is hollow and a non-circular shape.  FIG. 5C  illustrates an embodiment of the redirect chamber  20  in which a chamber wall  22  includes extensions  24 .  FIG. 5D  illustrates a further embodiment of the redirect chamber  20  with chamber fins  26  shrouding the outer surface of the redirect chamber  20 . Although not meant to be limiting, the diameter of the inlet  21  of the redirect chamber  20  will be smaller than the overall diameter of the redirect chamber  20 . Also, the diameter of the outlet  29  of the redirect chamber  20  will be smaller than the overall diameter of the redirect chamber  20 . 
     The tube  10  embodiments shown in  FIGS. 4A-4E  may be mated in various combinations with the redirect chamber  20  embodiments shown in  FIGS. 5A-5D . Additional tube fins  16  and chamber fins  26  or other materials can be attached to the outside surface of the tube  10  or the redirect chamber  20 , and the additional material does not have to be attached for the full length of the tube  10 . Tubes  10  and redirect chambers  20  near the inlet side of the invention may feature additional material. Other embodiments of the tubes and chambers not pictured may also be combined, and the invention is not limited to the embodiments described. 
     Referring to  FIGS. 6A and 6B , another embodiment of a heat exchanger is shown. A plate  600  contains at least one hole  610  that goes through the thickness of the plate  600 . On one side of the plate  600 , and centered on the hole  610 , a cavity  620 , which is of a larger diameter than the diameter of the hole  610 , is created in the plate  600  without going completely through the plate  600 . One end of a medium-directing insert  30  is connected to an outer edge of the cavity  620 , and the opposite end of the medium-directing insert  30  is connected to the inner edge of the cavity  620 . When a plate  600   a  is stacked onto another plate  600   b , and the respective holes  610  are aligned, the holes  610  create a tube-like segment and the cavities  620  create a chamber. Heat exchange media  50  may flow through the hole  610  into the cavity  620  where the heat exchange media  50  encounters the medium-directing insert  30  that redirects the heat exchange media  50  into the cavity  620 , the flow direction is illustrated by the arrows. 
     Referring to  FIG. 7 , another embodiment of a heat exchanger is shown. A compartment  700  surrounds a tube and chamber combination  710 . The compartment  700  has an inlet  701  and an outlet  702 . The compartment  700  directs an air flow  750  around a tube and chamber combination  710  while a heat exchange medium  50  flows through the tube and chamber combination  710 . According to this embodiment, the transfer of heat is further facilitated by the movement of the air flow  750  across the tube and chamber combination  710 . 
     Referring to  FIGS. 8A and 8B , one embodiment of the invention is shown. A chamber  20  is directly connected to another chamber  20 , each of which house a medium directing member  30 . In each chamber  20 , the medium directing member  30  redirects heat exchange media  50  throughout the chamber  20 . The arrows illustrate how the heat exchange media  50  may be redirected according to the embodiment as shown. 
     Referring to  FIG. 9A , a cross-section of another embodiment of the invention is shown. A chamber  20  is connected to a tube  10  that is connected to another chamber  20 . Each chamber  20  in the present embodiment houses a redirection member  28 , which in this embodiment attaches to the inner surface of the chamber  20 . The redirection member  28  allows passage of the heat exchange media through multiple holes  90  in the redirection member  28 . The arrows illustrate how the heat exchange media  50  may be redirected according to the embodiment as shown. Referring to  FIG. 9B , an embodiment of a redirection member  28  is shown. The redirection member  28  contains openings  90  that allow for the passage of heat exchange media  50 . 
     Referring to  FIG. 10A , a cross-section of yet another embodiment of the invention is shown. A chamber  20  is connected to a tube  10  that is connected to another chamber  20 . Each chamber  20  in the present embodiment may house a medium directing member  30 , which in this embodiment attaches at certain points to the inner surface of the chamber  20 , which leaves openings  91  along the inner surface of the chamber  20 . The medium directing member  30  allows passage of the heat exchange media  50  through these openings  91 . The arrows illustrate how the heat exchange media  50  may be redirected according to the embodiment as shown. Referring to  FIG. 10B , an embodiment of a medium directing member  30  is shown. The openings  91  allow for the passage of heat exchange media  50 . 
     Referring to  FIG. 11A , a cross-section of yet another embodiment of the invention is shown. The tube  10  is mated to the redirect chamber  20 . The redirect chamber  20  houses a medium-directing insert  30 . The medium-directing insert  30  is fixed within the intersecting space between the tube  10  and the redirect chamber  20 . A chamber  20  is connected to a tube  10  that is connected to another chamber  20 . Each chamber  20  in the present embodiment have indentations  92  in the chamber walls. The arrows illustrate how the heat exchange media  50  may be directed according to the embodiment as shown. Referring to  FIG. 11B , an embodiment of a wall of a chamber  20  is shown. The wall of the chamber  20  contains indentations  92  that redirect and mix the passage of heat exchange media  50  as it flows through the chamber  20 . 
     Referring to  FIG. 12 , the redirect chamber  20 , in combination with any of the above embodiments, does not have to be cylinder-shaped, other embodiments may be shaped like a cube (with various ratios of height, length, and width dimensions), or other geometric shapes. 
       FIGS. 13A and 13B  illustrate an embodiment of the invention where the redirection members  28  are not secured to an inside surface of the chamber  20 . The arrows illustrate how the heat exchange media  50  may be directed according to the embodiment as shown. By way of example, the redirection members  28  could be a ball bearing or combination of multiple ball bearings that participate in a mixing and churning process within the chamber  20 , as shown by the arrows in  FIG. 13 , which aids in the heat exchange process. The invention is not limited to using ball bearings in the chamber, as other unsecured redirection members may be used alone or in combination with one another for achieving greater heat exchange efficiency, such as a redirection member that is moved into a particular position by contact from heat exchange media. 
     The chamber generally has at least one greater dimension than the tube. For instance, the chamber may have a greater fluid capacity, circumference, or surface area. The ratio of a particular dimension between the tube and the chamber may be 1:1.1, 1:1.5, or any other ratio. 
     The tube and the chamber may be made of aluminum, either with cladding or without cladding. The tube and chamber may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The tube and chamber may also be a plastic material or other composite materials. Likewise, the redirect member may be made of aluminum, either with cladding or without cladding. The redirect member may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The redirect member may also be a plastic material or other composite materials. Also, an embodiment of the present invention allows for the tube to be made of a different material than the material used for the chamber, and the redirect members may be made of a different material than the material used for the chamber and tube. If more than one redirect member is used in an embodiment of the invention, one redirect member may be made of a different material than another redirect member. The redirect members may also be of different shapes than one another. Also, in embodiments that use more than one redirect member, one or more of the redirect members may be secured to the inside wall of the chamber and the other redirect members may be free to move around inside the redirect chamber. 
     The tube and chamber may be manufactured by stamping, cold forging, or machining. The tube and chamber may be manufactured as one piece or may be manufactured as two separate pieces. 
     The present invention has been described in an illustrative manner. The term “redirect” means to change the direction or course of, or impede the progress of, the heat exchange media, even if by the smallest difference in angle or velocity. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. 
     Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced other than as specifically described.