Patent Publication Number: US-9417016-B2

Title: Laminated heat exchanger

Description:
BACKGROUND OF THE INVENTION 
     Exemplary embodiments pertain to the art of heat exchangers and, more particularly, to a laminated heat exchanger. 
     Exchanging heat between two fluids is desirable in many applications. Heat exchangers pass a first medium having a first heat energy in proximity to another medium having a second heat energy to facilitate a transfer of the heat energy. More specifically, the mediums are passed in proximity to cause heat from the medium having the higher heat energy to the medium having a lower heat energy. The mediums can be passed in direct contact one with the other, or the mediums can be separated by a heat transfer surface. Conventional heat exchangers, particularly for aerospace applications, include plate/fin designs, or tube/shell designs. 
     Plate/fin heat exchangers employ sandwiched passages that contain fins. The fins provide increased surface area which leads to greater heat exchange. Plate/fin heat exchangers include both cross-flow and counter-flow designs and are provides with various fin arrangements depending on desired heat exchange characteristics. Tube/shell heat exchangers are generally incorporated into high pressure applications and include a shell, such as a pressure vessel, within which are positioned a number of tubes. One medium passes through the tubes and another medium passes through the shell and over the tubes. The tubes are typically formed from a material that facilitates a desired heat transfer. Of course, numerous other heat exchanger arrangements also exist. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Disclosed is a laminated heat exchanger including at least one heat exchange layer having a plurality of side members that define a frame including an interior portion. A plurality of heat exchange members extend between at least two of the plurality of side members across the interior portion. The plurality of heat exchange members are linked by a ligament member to form a heat exchange member chain. 
     Also disclosed is a laminated heat exchanger including at least one heat exchange layer having a plurality of side members that define a frame including an interior portion. At least one tank member is integrally formed with at least one of the plurality of side members. The at least one tank member establishes a medium reservoir that is fluidly connected to the interior portion. 
     Further disclosed is a laminated heat exchanger including at least one heat exchange layer having a plurality of side members that define a frame including an interior portion. A plurality of heat exchange members extend between at least two of the plurality of side members across the interior portion. The plurality of heat exchange members are linked by a ligament member to form a heat exchange member chain. At least one tank member is integrally formed with at least one of the plurality of side members. The at least one tank member establishes a medium reservoir that is fluidly connected to the interior portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  is a lower left perspective view of a laminated heat exchanger constructed in accordance with an exemplary embodiment; 
         FIG. 2  is a partially exploded view of the laminated heat exchanger of  FIG. 1  illustrating a plurality of heat exchange layers and a plurality of heat exchange elements; 
         FIG. 3  is a detail view of the plurality of heat exchange layers and the plurality of heat exchange elements of the laminated heat exchanger of  FIG. 2 ; 
         FIG. 4  is a detail view of a plurality of heat exchange member chains including a plurality of heat exchange members linked by ligament members in accordance with one aspect of the exemplary embodiment; 
         FIG. 5  is a detail view of a plurality of heat exchange member chains including a plurality of heat exchange members linked by ligament members in accordance with another aspect of the exemplary embodiment; 
         FIG. 6  is detail view of a plurality of heat exchange member chains including a plurality of heat exchange members linked by ligament members in accordance with still another aspect of the exemplary embodiment; 
         FIG. 7  is a detail view of a plurality of heat exchange member chains including a plurality of heat exchange members linked by ligament members in accordance with yet another aspect of the exemplary embodiment; 
         FIG. 8  is a detail view of one of the plurality of heat exchange layers in accordance with one aspect of the exemplary embodiment; 
         FIG. 9  is a detail view of one of the plurality of heat exchange layers illustrating a leak detector member in accordance with an exemplary embodiment; 
         FIG. 10  is a detail view of one of the plurality of heat exchange layers illustrating an integrated tank member support element in accordance with an exemplary embodiment; and 
         FIG. 11  is a perspective view of one of the plurality of heat exchange layers in accordance with another aspect of the exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     With reference to  FIGS. 1-3 , a laminated heat exchanger constructed in accordance with exemplary embodiment is indicated generally at  2 . Laminated heat exchanger  2  includes a body  4  having a first medium section  6  and a second medium section  7 . As will become more fully evident below, first medium section  6  is fluidly isolated from second medium section  7 . In this manner, a first medium passes through first medium section  6  in a heat exchange relationship with a second medium flowing through second medium section  7 . First medium section  6  includes a first heat exchange element  8  positioned directly adjacent to, and abutting, a second heat exchange element  9 . Similarly, second heat exchange section  7  includes a first heat exchange layer  15  arranged adjacent to, and abutting, a second heat exchange layer  16 . In addition to abutting first heat exchange layer  15 , second heat exchange layer  16  abuts second heat exchange element  9 . In this manner, second heat exchange element  9  defines a boundary between first and second heat exchange sections  6  and  7 . At this point it should be understood that the number of heat exchange sections can vary depending upon desired heat exchange characteristics. Also, the number of heat exchange layers in a given heat exchange section could also vary. 
     First heat exchange element  8  includes a frame element  20  having a substantially planer surface  23  that establishes a boundary to second heat exchange section  7 . First heat exchange element  8  includes plurality of heat exchange components  25  that project outward from substantially planar surface  23 . Similarly, second heat exchange element  9  includes a frame element  28  having a substantially planar surface  31  that establishes a boundary to an adjacent heat exchange section (not separately labeled). Second heat exchange element  9  includes a plurality of heat exchange components  33  that project outward from substantially planar surface  31  and are positioned to register with the plurality of heat exchange components  25  on first heat exchange element  8 . Heat exchange components  25  and  33  facilitate a heat transfer between first heat exchange section  6  and second heat exchange section  7 . 
     Reference will continue to  FIGS. 1-3  in describing first and second heat exchange layers  15  and  16 ; however, as each heat exchange layer  15  and  16  is similarly constructed, reference will be made to heat exchange layer  15  with an understanding that heat exchange layer  16  includes similar structure. In accordance with the exemplary embodiment shown, heat exchange layer  15  includes a frame  60  having first and second opposing side members  62  and  63  that are joined to third and fourth opposing side members  65  and  66  to establish an interior portion  69 . Heat exchange layer  15  includes a plurality of heat exchange member chains  72  a portion of which, in the exemplary embodiment shown, extend between adjacent ones of side members  62 ,  65  and  63 ,  66  forming a heat exchange core (not separately labeled). In the exemplary embodiment shown, the heat exchange core has a generally rectangular shape/form. However it should be understood that the particular shape/form of the heat exchange core can vary. Each heat exchange member chain  72  is formed from a plurality of linked heat exchange members  74  as will be detailed more fully below. 
     First heat exchange layer  15  also includes a plurality of integrated tank members  80 - 83  that are integrally formed with frame  60 . In the exemplary embodiment shown, tank member  80  extends from side member  65  through a curvilinear section (not separately labeled) and rejoins side member  65 . Similarly, tank member  81  extends from side member  66  through a curvilinear section (not separately labeled) and rejoins side member  66 . Tank members  82  and  83  extend from side member  63  through corresponding curvilinear sections (not separately labeled) and rejoin side member  65 . Tank members  80 - 83  join with tank members (not separately labeled) on heat exchange elements  8  and  9  as well as second heat exchange layers  16  to form a corresponding plurality of tanks or reservoirs  84 - 87  that are configured to hold one of a first heat exchange medium and a second heat exchange medium. In accordance with one aspect of the exemplary embodiment, tanks  84  and  85  define an inlet and an outlet respectively for a first heat exchange medium passing through first medium section  6 . Towards that end, first medium section  6  is fluidly connected to tanks  84  and  85 . Similarly, tanks  86  and  87  define an inlet and an outlet respectively for a second heat exchange medium flowing through second medium section  7 . In order to enhance contact with heat exchange member  74  and guide the second medium between tank  86  and  87 , first heat exchange layer  15  includes a medium guide member  88  that extends from side wall  63  toward side wall  62 . First heat exchange layer  15  is also shown to include a pair of frame flanges  89  and  90  that are machined to produce a desired interface between laminated heat exchanger  2  and a component such as a portion of an airframe. First heat exchange layer  15  is further shown to include a pair of mold members  91  and  92 . Mold members  91  and  92  are formed when producing first heat exchange layer  15  and may be used to establish a desired alignment between adjacent first and second medium sections  6  and  7 . 
     Reference will now be made to  FIGS. 4-7  in describing heat exchange member chains in accordance with various aspects of the exemplary embodiment. In accordance with one aspect of the exemplary embodiment, heat exchange members  74  are joined by ligament members  93  to form heat exchange member chain  72 . In the exemplary aspect illustrated in  FIG. 4 , each heat exchange member  74  includes an outer surface  94  that defines a circular cross-section. In  FIG. 5 , a heat exchange member chain  99  is shown having a plurality of heat exchange members  100  joined by ligament members  101 . Each heat exchange member  100  includes an outer surface  102  that defines an oval cross-section.  FIG. 6  illustrates a heat exchange member chain  106  formed from a plurality of heat exchange members  107  joined by ligament members  108 . Heat exchange member  107  includes an outer surface  109  that defines an airfoil shaped cross-section. In  FIG. 7 , a heat exchange member chain  112  is shown to include a plurality of heat exchange members  113  joined by ligament members  115 . Heat exchange members  113  have an outer surface  117  that defines a diamond shaped cross-section. 
       FIG. 8  illustrates a heat exchange layer  130  formed in accordance with an alternative aspect of the exemplary embodiment. Heat exchange layer  130  includes a frame  132  having first and second opposing side members  133  and  134  that are joined by a third side member  135  and a fourth side member (not shown) to define an interior portion  136 . Heat exchange layer  130  includes a plurality of heat exchange member chains  137  formed from a plurality of linked heat exchange members  139 . In contrast to the above described arrangement, all heat exchange member chains  137  extend between opposing side members, i.e., third side member  135  and the fourth side member (not shown). In a manner similar to that described above, heat exchange layer  130  is shown to include tank members  142  and  143 , and a frame flange  145 . At this point it should be understood that the particular size, shape and arrangement of heat exchange member chains  137  can vary. 
     Reference will now be made to  FIG. 9  in describing a heat exchange layer  160  in accordance with another aspect of the exemplary embodiment. Heat exchange layer  160  includes a frame  164  having first and second opposing side members  166  and  167  that are joined by a third side member  169  and a fourth side member (not shown) to define an interior portion  171 . Heat exchange layer  160  includes a plurality of heat exchange member chains  173  formed from a plurality of linked heat exchange members  175 . Heat exchange layer  160  is also shown to include tank members  177  and  178 , and a frame flange  180 . Heat exchange layer  160  is further shown to include a leak detector member  184  shown in the form of a channel  186  formed in side member  169 . In the event of a tank leak or a leak from interior portion  171 , medium will flow into channel  186  and exit from laminated heat exchanger  2  thereby providing a visual indication of a leak. Alternatively, the leak detector members(s) on each heat exchange layer are fluidly connected and routed to a pressure sensor (not shown) that provides a signal indicating a leakage before two heat exchange mediums can come into contact or leak externally. 
     Reference will now be made to  FIG. 10  in describing a heat exchange layer  190  constructed in accordance with yet another aspect of the exemplary embodiment. Heat exchange layer  190  includes a frame  192  having first and second opposing side members  194  and  195  that are joined by a third side member  197  and a fourth side member (not shown) to define an interior portion  199 . Heat exchange layer  190  includes a plurality of heat exchange member chains  203  formed from a plurality of linked heat exchange members  205 . Heat exchange layer  190  is also shown to include tank members  209  and  210 , and a frame flange  211 . In accordance with the exemplary aspect shown, heat exchange layer  190  includes a plurality of tank member support elements, one of which is indicated at  213 . Tank member support elements  213  extend between adjacent portions of tank member  209  and/or between tank member  209  and side member  197 . Tank member support elements  213  provide internal structural support for a medium tank associated with heat exchange layer  190 . At this point it should be understood that laminated heat exchanger  2  could be formed with one or more heat exchange layers  190  depending upon a need for stiffening the medium tank. It should also be understood that tank member  210  could also be provided with tank member support elements. 
     Reference will now be made to  FIG. 11  in describing a heat exchange layer  220  constructed in accordance with yet another aspect of the exemplary embodiment. Heat exchange layer  220  includes a frame  222  having first and second opposing side members  224  and  225  that are joined by a third side member  227  and a fourth side member  228  to define an interior portion  230 . Heat exchange layer  220  includes a plurality of heat exchange member chains  232  formed from a plurality of linked heat exchange members  234 . Heat exchange layer  220  is also shown to include tank members  237 - 240 , and frame flanges  242  and  243 . In accordance with the exemplary aspect shown, heat exchange layer  220  includes a plurality of medium guide members  245 - 247 . Medium guide member  245  extends from side member  228  across interior portion  230  toward side member  227 ; medium guide member  246  extends from side member  227  across interior portion  230  toward side member  228 ; and medium guide member  247  extends from side member  228  across interior portion  230  toward side member  227 . In this manner, medium guide members establish a serpentine or curvilinear flow path between tank member  237  and tank member  238 . Medium guide members  245 - 247  may be employed when interior portion  230  is fluidly connected to tank members  237  and  238  in order to prolong medium residence time within the medium section and enhance heat exchange. 
     At this point it should be understood that the exemplary embodiment provide a laminated heat exchanger formed from heat exchange layers that can be joined one to another to form a medium section. The number of heat exchange layers can vary. In addition, forming the heat exchange layers with heat exchange member chains eases manufacturing while at the same time providing a flexible building block for a laminated heat exchanger. That is, by eliminating a planar surface previous employed to support heat exchange members, multiple heat exchange layers can be combined to form a medium section. Finally, it should be understood that the material used to form the heat exchange layer can very depending upon desired design characteristics. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims.