Patent Publication Number: US-2022221229-A1

Title: Method for providing a heat exchanger block with a housing as well as heat exchanger block having such a housing

Description:
The invention relates to a method for providing a heat exchanger block with a housing and to a heat exchanger comprising a heat exchanger block with a housing manufactured by said method. 
     It is known to manufacture a heat exchanger block and a housing or housing parts of such a heat exchanger block separately and then put the heat exchanger block and the housing or housing parts together in an assembly operation. 
     This type of assembly does not guarantee a strong and hermetic connection between the heat exchanger block and the housing. In order to provide a strong and hermetic connection between the heat exchanger block and the housing, it is known to use elastomeric seals and/or glue. However, this complicates the method for providing a heat exchanger block with a housing. 
     It is an object of the invention to simplify a method for providing a heat exchanger block with a housing. 
     Therefore, the invention provides a method for providing a heat exchanger block with a housing according to any one of claims  1  to  16  and to a heat exchanger according to claim  17  comprising a heat exchanger block and a housing manufactured by said method. 
     In other words, the present invention provides a method for providing a heat exchanger block with a housing, said heat exchanger block comprising 
     air flow passages for exchanging heat energy between a first air flow which can be passed through said heat exchanger block and a second air flow which can be passed through said heat exchanger block; 
     a first inlet opening fora first air flow; 
     a first outlet opening for said first air flow; 
     a second inlet opening for a second air flow; and 
     a second outlet opening for said second air flow; 
     said method comprising: 
     selecting outer surface regions of said heat exchanger block to be covered by portions of said housing, said selected surface regions being different from said first inlet opening, said first outlet opening, said second inlet opening and said second outlet opening; 
     moulding a portion of said housing to each selected outer surface region. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following description and drawing show an exemplary embodiment of the present invention with a heat exchanger block and a method of providing a housing to said heat exchanger block in order to provide a heat exchanger comprising said heat exchanger block having said housing. 
         FIG. 1  is a perspective view of a heat exchanger block according to the embodiment; 
         FIG. 2  is a perspective view of a mould to be used in the method according to the embodiment; 
         FIG. 3  shows the mould of  FIG. 2  filled with a fluidic polymer; 
         FIG. 4  shows a method step for providing said heat exchanger block with a housing portion; 
         FIG. 5A  is a perspective view of said heat exchanger block provided with one housing portion; 
         FIG. 5B  is a side view of said heat exchanger block provided with said housing portion; 
         FIG. 5C  is another perspective view of said heat exchanger block provided with said housing portion; 
         FIG. 6A  is a perspective view of a mould to be used in the method according to the embodiment; 
         FIG. 6B  shows the mould of  FIG. 6A  filled with a fluidic polymer; 
         FIG. 7  is a perspective view of said heat exchanger block provided with four housing portions; 
         FIG. 8  is a perspective view of a mould to be used in the method according to the embodiment; 
         FIG. 9  shows a method step for providing said heat exchanger block with a housing portion; 
         FIG. 10A  is perspective view of said heat exchanger block provided with five housing portions; 
         FIG. 10B  is a front view of said heat exchanger block provided with said five housing portions; 
         FIG. 11A  is a first perspective view of a heat exchanger comprising said heat exchanger block having a housing comprising six housing portions; 
         FIG. 11B  is a second perspective view of said heat exchanger comprising said heat exchanger block having said housing comprising six housing portions; and 
         FIG. 11C  is a third perspective view of said heat exchanger comprising said heat exchanger block having said housing comprising six housing portions. 
     
    
    
       FIG. 1  is a perspective view of a heat exchanger block B according to the embodiment. The heat exchanger block B comprises a plurality of first air flow passages AFP 1  (shown as solid lines) and a plurality of second air flow passages AFP 2  (shown as interrupted lines) adjacent said plurality of first air flow passages for exchanging heat energy between a first air flow AF 1  (shown as black arrows) passing through said plurality of first air flow passages AFP 1  and a second air flow AF 2  (shown as white arrows) passing through said plurality of second air flow passages AFP 2 . 
     The first air flow passages AFP 1  are defined between a first pair of adjacent heat exchanger plates parallel to each other. Similarly, the second air flow passages AFP 2  are defined between a second pair of adjacent heat exchanger plates parallel to each other. The heat exchanger block comprises N stacked plates and (N-1) consecutive pairs of adjacent heat exchanger plates in the stack, with each pair of adjacent heat exchanger plates alternatingly constituting first air flow passages AFP 1  and second air flow passages AFP 2 . 
     The heat exchanger block B also comprises a first inlet opening region O 11  having inlet openings for said first air flow AF 1  and a first outlet opening region O 12  having outlet openings for said first air flow AF 1  as well as a second inlet opening region O 21  having inlet openings for said second air flow AF 2  and a second outlet opening region O 22  having outlet openings for said second air flow AF 2 . 
     The heat exchanger block B comprises a first outer surface region B 1  and a second outer surface region B 2  opposite said first outer surface region B 1 , as well as a third outer surface region B 3  and a fourth outer surface region B 4  opposite said third outer surface region B 3 , as well as a fifth outer surface region B 5  and a sixth outer surface region B 6  opposite said fifth outer surface region B 5 . 
       FIG. 2  is a perspective view of a first mould M 1  or a second mould M 2  to be used in the method according to the embodiment. The first and second moulds M 1  and M 2  have a first cavity C 1  and a second cavity C 2 , respectively with an inner cavity surface CS 1  and CS 2 , respectively. In the exemplary embodiment, the heat exchanger block B and the housing H moulded to it are symmetrical with the first outer surface region B 1  and the second outer surface region B 2  being symmetrical to each other. 
       FIG. 3  shows the moulds M 1  and M 2  of  FIG. 2  partially filled with a fluidic polymer FP. 
       FIG. 4  shows a method step for providing said heat exchanger block B with a first housing portion W 1 . This method step comprises inserting said first outer surface region B 1  of said heat exchanger block B into said partially filled first cavity portion C 1  by moving said heat exchanger block B towards said first mould M 1 , thereby displacing and spreading said fluidic polymer FP within a first gap region G 1  between said first outer surface region B 1  and said first inner cavity surface CS 1 . This method step further comprises transferring said fluidic polymer FP within said first gap region G 1  from its fluidic state into a solid polymer SP with a solid state or less fluidic state than said fluidic polymer. This method step further comprises withdrawing said first outer surface region B 1  of said heat exchanger block B from said partially filled first cavity portion C 1  by moving said heat exchanger block B away from said first mould M 1 , thereby leaving said moulded first housing portion W 1  covering/engaging said first outer surface region B 1  of said heat exchanger block B. 
       FIG. 5A  is perspective view of said heat exchanger block B provided with said first housing portion W 1  as result of the method step described in in the previous paragraph with respect to  FIG. 4 . 
       FIG. 5B  is a side view of said heat exchanger block B provided with said first housing portion W 1 . 
       FIG. 5C  is another perspective view of said heat exchanger block B provided with said first housing portion W 1 . 
     Analogously, there is provided a method step for providing said heat exchanger block B with a second housing portion W 2  (not explicitly shown) This method step comprises inserting said second outer surface region B 2  of said heat exchanger block B into said partially filled second cavity portion C 2  by moving said heat exchanger block B towards said second mould M 2 , thereby displacing and spreading said fluidic polymer FP within a second gap region G 2  between said second outer surface region B 2  and said second inner cavity surface CS 2 . This method step further comprises transferring said fluidic polymer FP within said first gap region G 2  from its fluidic state into a solid polymer SP with a solid state or less fluidic state than said fluidic polymer. This method step further comprises withdrawing said second outer surface region B 2  of said heat exchanger block B from said partially filled second cavity portion C 2  by moving said heat exchanger block B away from said second mould M 2 , thereby leaving said moulded second housing portion W 2  covering/engaging said second outer surface region B 2  of said heat exchanger block B. 
       FIG. 6A  is a perspective view of a third mould M 3  and a fourth mould M 4  to be used in the method according to the embodiment. The third and fourth moulds M 3  and M 4  have a third cavity C 3  and a fourth cavity C 4 , respectively with a third inner cavity surface CS 3  and a fourth inner cavity surface CS 4 , respectively. In the exemplary embodiment, the heat exchanger block B and the housing H moulded to it are symmetrical with the third outer surface region B 3  and the fourth outer surface region B 4  being symmetrical to each other. 
       FIG. 6B  shows the moulds M 3  and M 4  of  FIG. 6A  partially filled with a fluidic polymer FP. 
     In a manner similar to the first mould M 1  being used to mould the first housing portion W 1  to the first outer surface region B 1  and similar to the second mould M 2  being used to mould the second housing portion W 2  to the second outer surface region B 2 , the third mould M 3  is used to mould a third housing portion W 3  to the third outer surface region B 3  and the fourth mould M 4  is used to mould a forth housing portion W 4  to the forth outer surface region B 4 . 
       FIG. 7  is a perspective view of said heat exchanger block B provided with the four housing portions W 1 , W 2 , W 3  and W 4 . The first and second housing portions W 1  and W 2  are symmetrical to each other and the third and fourth housing portions W 3  and W 4  are symmetrical and/or identical and/or congruent to each other. 
       FIG. 8  is a perspective view of a fifth mould M 5  and a sixth mould M 6  to be used in the method according to the embodiment. The fifth and sixth moulds M 5  and M 6  have a fifth cavity C 5  and a sixth cavity C 6 , respectively with a fifth inner cavity surface CS 5  and a sixth inner cavity surface CS 6 , respectively. In the exemplary embodiment, the heat exchanger block B and the housing H moulded to it are symmetrical with the fifth outer surface region B 5  and the sixth outer surface region B 6  being symmetrical and/or identical and/or congruent to each other. 
       FIG. 9  shows a method step for providing said heat exchanger block B with a fifth housing portion W 5 . This method step comprises inserting said fifth outer surface region B 5  of said heat exchanger block B into said partially filled fifth cavity portion C 5  by moving said heat exchanger block B towards said fifth mould M 5 , thereby displacing and spreading said fluidic polymer FP within a fifth gap region G 5  between said fifth outer surface region B 5  and said fifth inner cavity surface CS 5 . This method step further comprises transferring said fluidic polymer FP within said fifth gap region G 5  from its fluidic state into a solid polymer SP with a solid state or less fluidic state than said fluidic polymer. This method step further comprises withdrawing said fifth outer surface region B 5  of said heat exchanger block B from said partially filled fifth cavity portion C 5  by moving said heat exchanger block B away from said fifth mould M 5 , thereby leaving said moulded fifth housing portion W 5  covering/engaging said fifth outer surface region B 5  of said heat exchanger block B. 
       FIG. 10A  is perspective view of said heat exchanger block B provided with said fifth housing portion W 5  as result of the method step described in in the previous paragraph with respect to  FIG. 9 . 
       FIG. 10B  is a side view of said heat exchanger block B provided with said housing portion W 5 . 
     Analogously, there is provided a method step for providing said heat exchanger block B with a sixth housing portion W 6  (not explicitly shown) This method step comprises inserting said sixth outer surface region B 6  of said heat exchanger block B into said partially filled sixth cavity portion C 6  by moving said heat exchanger block B towards said sixth mould M 6 , thereby displacing and spreading said fluidic polymer FP within a sixth gap region G 6  between said sixth outer surface region B 6  and said sixth inner cavity surface CS 6 . This method step further comprises transferring said fluidic polymer FP within said sixth gap region G 6  from its fluidic state into a solid polymer SP with a solid state or less fluidic state than said fluidic polymer. This method step further comprises withdrawing said sixth outer surface region B 6  of said heat exchanger block B from said partially filled sixth cavity portion C 6  by moving said heat exchanger block B away from said sixth mould M 6 , thereby leaving said moulded sixth housing portion W 6  covering/engaging said sixth outer surface region B 6  of said heat exchanger block B. 
     List of Reference Signs 
     B heat exchanger block 
     H housing of the heat exchanger block 
     AFP 1  first air flow passages 
     AFP 2  second air flow passages 
     AF 1  first air flow 
     AF 2  second air flow 
     O 11  first inlet opening region 
     O 12  first outlet opening region 
     O 21  second inlet opening region 
     O 22  second outlet opening region 
     B 1  first outer surface region 
     B 2  second outer surface region 
     B 3  third outer surface region 
     B 4  fourth outer surface region 
     B 5  fifth outer surface region 
     B 6  sixth outer surface region 
     W 1  first housing portion 
     WS 1  first outer housing surface 
     W 2  second housing portion 
     WS 2  second outer housing surface 
     W 3  third housing portion 
     WS 3  third outer housing surface 
     W 4  fourth housing portion 
     WS 4  fourth outer housing surface 
     W 5  fifth housing portion 
     WS 5  fifth outer housing surface 
     W 6  sixth housing portion 
     WS 6  sixth outer housing surface 
     H 11  first inlet opening 
     H 12  first outlet opening 
     H 21  second inlet opening 
     H 22  second outlet opening 
     FP fluidic polymer in a fluidic state 
     SP solid polymer in a solid state or less fluidic state 
     M 1  first mould 
     C 1  first cavity, first recess 
     CS 1  first inner cavity surface 
     G 1  first gap region (between B 1  and CS 1 ) 
     M 2  second mould 
     C 2  second cavity, second recess 
     CS 2  second inner cavity surface 
     G 2  second gap region (between B 2  and CS 2 ) 
     M 3  third mould 
     C 3  third cavity, third recess 
     CS 3  third inner cavity surface 
     G 3  third gap region (between B 3  and CS 3 ) 
     M 4  fourth mould 
     C 4  fourth cavity, fourth recess 
     CS 4  fourth inner cavity surface 
     G 4  fourth gap region (between B 4  and CS 4 ) 
     M 5  fifth mould 
     C 5  fifth cavity, fifth recess 
     CS 5  fifth inner cavity surface 
     G 5  fifth gap region (between B 5  and CS 5 ) 
     M 6  sixth mould 
     C 6  sixth cavity, sixth recess 
     CS 6  sixth inner cavity surface 
     G 6  sixth gap region (between B 6  and CS 6 )