Abstract:
A heat exchange unit having a plurality of chamber assembly coupled to a plate member, said chamber assembly including an inlet flow tube, an outlet flow tube, and a plurality of walls defining a chamber interior. Disposed within the chamber interior is a medium-directing member, having an inclined surface, diverting the heat exchange medium from the initial flow direction so that it disperses within the chamber interior, in to at least two distinct flow patterns. The heat exchange medium exits the chamber, via the outlet, in the initial line of flow. The chambers are interconnected by tubes to form assemblies. A plurality of plate member having plurality of chamber assembly is arranged on a spaced relation between manifolds to complete the medium flow.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to heat exchangers and, more specifically, to a heat exchanger having plurality of disk assemblies coupled to a plate member, each disk assemblies having a tube and a chamber apparatus, said chamber apparatus having a medium directing member within for transporting heat exchange medium. 
         [0003]    2. Discussion of the Related Art 
         [0004]    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 medium. Headers or manifolds are attached to each end of the pipes. These headers and manifolds act as receptacles for the heat exchanging medium. The efficiency of the pipe heat exchangers is limited by the amount of surface area available for the transfer of heat. In a tube and chamber heat exchanger, plurality of tube and chamber extend in spaced relation between a pair of header or manifold, forming a core of a heat exchanger. The present invention provides an effective and efficient means to increase surface area to a core of a tube and chamber heat exchanger, which in turn greatly enhances the performance of a heat exchanger performance with a simple solution. The present invention achieves these enhancements without adversely affecting the overall size of the core, while simplifying the manufacturing process, thereby providing a heat exchanger with vastly improved heat exchanging characteristics without adverse cost impact. 
         [0005]    To increase surface area, typical heat exchangers, such as condensers, incorporate a flat-tube design, usually of extruded tubular material, with extended surfaces provided by corrugated fin material. This type of heat exchanger typically includes flattened tubes having a fluid passing therethrough and a plurality of corrugated 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. 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 extruded tubes 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. 
         [0006]    The overall cost for the flat tube 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 medium 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. 
         [0007]    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. 
         [0008]    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 medium. 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. 
         [0009]    In a typical manufacturing method of tube and fin heat exchangers, plurality of fins are first stacked to a desired quantity. Once fins are bound and stacked together, tubes are inserted into plurality of holes pre-formed on each fin. Holes pre-formed on fins are arranged so that once the fins are bound together, the holes align with each other from the first fin material to the second fin material, allowing a generally straight tube to be inserted through the holes. In order to enhance the heat transfer characteristics, once tubes and fins are assembled together, individual tubes go through an expansion process whereby tubes are expanded from within by mechanical means to increase the diameter of tubes, enhancing the tube to fin surface contact. To facilitate the tube expansion process, at least one free end of tubes is left open to allow the tube expansion device to be inserted, once the tube and fin structure are assembled together. Upon completion of the tube expansion process, open end of tubes are sealed, usually by means of a manifold. 
         [0010]    In a manufacturing process of flat tube heat exchangers, tubes are first cut to a desired length. In a separate line, fins are corrugated and fabricated to a desired shape, then cut to a desired length. Once tubes and fins are ready for assembly, plurality of tube and fin material is stacked together, with fin material coupled between two tubes aligned parallel to each other. Once tube and fin material is stacked together to a desired height, manifolds are assembled onto the free ends of the tubes. In assembling all the components together, a precision assembly fixture is generally required, as tube and fin material are prone to come apart during the assembly process, until the entire assembly is processed through a brazing process, a process which bonds all components together. Especially during the assembly of manifolds onto the free ends of the tubes, tubes need to be held in position firmly by an assembly fixture for a proper assembly. Due to the nature of the flat tube heat exchanger assembly, if the assembly fixture is even slightly off tolerances, the entire heat exchanger assembly may not braze properly. For this type of heat exchanger assembly, significant investment must be made in precision assembly machines and fixtures, in addition to having components made to a very high-precision tolerances, causing the assembly cost of a heat exchanger to rise significantly, in addition to having to pay more for precision made components. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention is an enhanced tube for heat exchanging applications including flow tube and a chamber coupled to a generally planar plate member. The flow tube connects to the chamber. One end of the flow tube may connect to a header or a manifold. Heat exchange medium flows from the header or the manifold into the flow tube. The heat exchange medium then flows into the chamber. The chamber is coupled to a plate member. The heat exchange medium then flows from the chamber into another flow tube, which is connected to another header or manifold. The heat contained within the heat exchange medium is dispersed by a surface area of the flow tube, the chamber, and the plate member. 
         [0012]    In an embodiment of the present invention, the flow tube, the chamber, and the plate member 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 exchanger has larger surface area for radiating heat over a shorter distance than that of a conventional heat exchanger, with the surface area provided by the flow tube and the chamber, along with extended heat exchanging surfaces provided by the plate member. With a provision of a large surface area for heat exchanging purposes, the efficiency of a heat exchanger is greatly 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. Additionally, the flow tube and the chamber may be made from a thicker gage material, while the plate member may be made of thinner gage material. This allows the flow tube and the chamber to handle heat exchanging medium requiring higher internal pressure, which may be common in applications such as a condenser for an air conditioner, for example. Usage of thin gage material for the plate member improves heat conductivity of the plate member, while significantly increasing the surface area for heat exchanging purposes, without adversely affecting cost or the weight. 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. Furthermore, during the assembly process, the plate member on which flow tube and chamber are coupled to, assists in positioning the flow tube and the chamber assembly, acting akin to an assembly tray during the manufacturing process, holding in place components during the assembly process. 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. 
         [0013]    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. Furthermore, more than one chamber may be coupled to a plate member. In another embodiment of the present invention, more than one plate member may be coupled to a chamber. When plurality of chambers are coupled to the plate member, the plate member provides an economical means to maximize the heat exchanging capability of a heat exchanger by filling the voids between plurality of column of chambers to increase the overall surface area of the heat exchanger, without greatly increasing the size of a heat exchanger. 
         [0014]    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. 
         [0015]    In another embodiment of the present invention, plurality of tube size and chamber size positioned on a plate member may vary from one to the next. 
         [0016]    In a further embodiment of the present invention, each chamber may disperse heat exchanging medium throughout the chamber, which further enhances the heat exchanging capabilities of the present invention. Also, each chamber may also mix heat exchanging medium. 
         [0017]    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 medium in a particular directions through the chamber. 
         [0018]    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 medium-directing member may also feature indentations. In an embodiment of the present invention, the plate member may have surface features such as, but not limited to, indentations, louvers, dimples, slits, other extended surface features known in the art, etc. 
         [0019]    In other embodiments of the present invention, the tube, the chamber, and the plate member combination may be repeated, and based on a particular application, there may be multiple tube, chamber, and plate member assembly rows coupled together to form a unitary unit. Plurality of tube, chamber, and plate member units may be attached to a header or a manifold. There may be a plurality of tube, chamber, and plate member units arranged in a row that are attached to a header or a manifold to enhance the overall performance of the heat exchanger. 
         [0020]    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. 
         [0021]    In an embodiment of the present invention, the plate member may be rectangular in shape. In other embodiment of the present invention, the plate member may be other geometric shape like a trapezoid or an oval, for an example. In some embodiments of the present invention, the plate member may have surface feature such as plurality of folds or bends that rise generally perpendicular from the surface of the plane of the plate member to assist in spacing plurality of plate member from one plate member to the other. In such an embodiment, the apex of a fold or a bend from first plate member abut against the base plane of second plate member, whereby the height of a fold or a bend dictate the spaced relation between the first plate member and the second plate member. 
         [0022]    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. 
         [0023]    In an embodiment of the present invention, the plate member has an indentation in the shape of the chamber, coupling the chamber in position within said indentation on the surface of the plate member. In another embodiment of the present invention, the plate member has plurality of indentations in the shape of the chamber, the plate member coupling plurality of chambers. In such an embodiment, chamber coupling locations are dictated by the position of indentations on the surface of the plate member. 
         [0024]    In some embodiment of the present invention, a chamber assembly comprising of the inlet and the outlet flow tubes, the chamber, and the medium-directing member may be assembled as a unit, then coupled to the plate member. In an embodiment of the present invention, plurality of chamber assemblies may be coupled to the plate member. 
         [0025]    In yet another embodiment of the present invention, the plate member has a hole formed in the shape of the chamber, positioning and locating the chamber on the plate member. In another embodiment of the present invention, the plate member has a plurality of holes in the shape of the chamber, to which chambers are coupled. 
         [0026]    In some embodiment of the present invention, the plate member has a hole in the shape of the tube, onto which the tube is inserted for the purpose of holding the tube in position on the plate member. In another embodiment of the present invention, the plate member has a plurality of holes in the shape of the tube. In yet another embodiment of the present invention, the plate member may contain plurality of holes in the shape of chambers and tubes, whereas some of the holes are for coupling chambers, and some of the holes are for coupling tubes. 
         [0027]    In another embodiment of the present invention, the plate member may contain plurality of indentations in the shape of chambers, each indentations having a hole to pass through the tube, wherein indentations are used to couple chambers to the plate member. 
         [0028]    The tube and the chamber may be made of aluminum, either with cladding or without cladding. The plate member may be made of aluminum, either with cladding or without cladding. The medium-directing member may be made of aluminum, either with cladding or without cladding. The tube, the chamber, the medium-directing member, and the plate member may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The tube, the chamber, the medium-directing member, and the plate member may also be a plastic material or other composite materials. 
         [0029]    The tube, the chamber, the medium-directing member, and the plate member may be manufactured by stamping, cold forging, casting, or machining. The tube and the chamber may be manufactured as one piece or may be manufactured as two separate pieces. The tube, the chamber, and the plate member may be manufactured as one piece, or may be manufactured as separate pieces. The chamber and the medium-directing member may be manufactured as one piece, or may be manufactured as separate pieces. 
         [0030]    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 
         [0031]      FIG. 1A  is a perspective view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention; 
           [0032]      FIG. 1B  is a frontal view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention; 
           [0033]      FIG. 1C  is a top view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention; 
           [0034]      FIG. 1D  is a side view of a tube and chamber heat exchanger having plurality of plate members according to embodiments of the present invention; 
           [0035]      FIG. 2A  illustrates flow pattern of heat exchange medium inside the tube and chamber assembly, and the means by which heat is transferred to the surrounding atmosphere through the tube, the chamber and the plate member structure, according to an embodiment of the present invention; 
           [0036]      FIG. 2B  is a side view of tubes, chambers, and plate members illustrated in operational relationship with manifolds to provide a heat exchanger according to embodiments of the present invention; 
           [0037]      FIG. 2C  illustrates a cross-sectional view of an operational relationship of a plate member with plurality of chambers, said chambers having a medium-directing member; 
           [0038]      FIG. 3A  is a perspective view of a plate member according to an embodiment of the present invention; 
           [0039]      FIG. 3B  is a frontal view of a plate member according to an embodiment of the present invention; 
           [0040]      FIG. 3C  is a side view of a plate member according to an embodiment of the present invention; 
           [0041]      FIG. 3D  is a top view of a plate member according to an embodiment of the present invention; 
           [0042]      FIGS. 3E through 3F  illustrate various embodiments of the plate member; 
           [0043]      FIG. 4A  is a frontal view of a prior art embodiment of a plurality of a tube and chamber heat exchanger; 
           [0044]      FIG. 4B  is a top view of a prior art embodiment of a plurality of a tube and chamber heat exchanger; 
           [0045]      FIG. 4C  is a side view of an embodiment of the present invention; 
           [0046]      FIG. 4D  is a top view of an embodiment of the present invention; 
           [0047]      FIG. 4E through 4F  illustrate various side view of yet another embodiment of the present invention; 
           [0048]      FIG. 4G through 4H  illustrate various coupling method of a plate member to a chamber according to an embodiment of the present invention; 
           [0049]      FIG. 5A through 5F  illustrate other various coupling methods of a plate member to a chamber according to yet another embodiment of the present invention; 
           [0050]      FIG. 6A  is a perspective view of yet another embodiment of the present invention; 
           [0051]      FIG. 6B  is a frontal view of yet another embodiment of the present invention; 
           [0052]      FIG. 6C  is a side view of yet another embodiment of the present invention; 
           [0053]      FIG. 7A through 7F  illustrates various shape of the embodiment of the present invention during stages of the manufacturing process; 
           [0054]      FIG. 8A through 8D  illustrate various shape of another embodiment of the present invention during stages of the manufacturing process; 
           [0055]      FIGS. 9A through 9D  illustrate various shapes of yet another embodiment of the present invention during stages of the manufacturing process; 
       
    
    
     DETAILED DESCRIPTION 
       [0056]    Referring to the drawings and in particular  FIG. 1B  and  FIG. 2B , an embodiment of a heat exchanger  105  is shown. The heat exchanger  105  includes a pair of manifolds  200  and  205 . Plurality of tube  20 , chamber  30 , and plate member  35  extend in spaced relation between a pair of manifolds  200  and  205 , comprising a core  100  of the heat exchanger  105 . One free end of tubes  20  coupled to manifold  200 , and the other free end of tubes  20  coupled to manifold  205 . Heat exchange medium  15  flows from the outlet  215  of the manifold  200  into the inlet  5  of the tube  20 . The heat exchange medium  15  passes through the outlet  10  of the tube  20  into the inlet  60  of the chamber  30 . The chamber  30  is coupled to a plate member  35 . The heat exchange medium  15  then flow out outlet  65  of the chamber  30 . The process of going from a tube  20  to a chamber  30  may repeat several times until the heat exchange medium  15  is received by another manifold  205 . There may also be several rows of the tube  20 , chamber  30 , plate member  35  combinations. Also, one embodiment may allow for just one row comprising of one tube  20  and one chamber  30  coupled to a plate member  35 . Throughout the transport of the heat exchange medium  15  through the heat exchanger  105 , the heat from the heat exchange medium  15  is transferred to the environment outside of the heat exchanger  105 . Referring to  FIG. 2A , as the heat exchange medium  15  travel through the tube  20  and chamber  30  assembly, heat travels from the heat exchange medium  15  to the outside environment of the heat exchanger  105 .  FIG. 2A  illustrates flow of heat exchange medium  15 , said flow illustrated by the striped arrows. As the heat exchange medium  15  travels inside the heat exchanger  105 , heat contained within the heat exchange medium  15  is transferred to the environment outside the heat exchanger, transferring heat through the walls of the tube  20 , the chamber  30 , and the plate member  35 . Although not meant to be limiting, common heat exchange medium known in the art includes various refrigerants (i.e., R-134A, R-410A), carbon dioxide, butane, oils, gases (e.g., air), water, and mixtures of water and other coolants (e.g. ethylene glycol). 
         [0057]    In another embodiment of the heat exchanger  105 , the heat exchanger  105  may be used in a reversed method. Instead of the heat exchanger  105  being used in an environment where heat is transferred from the heat exchange medium  15  to the surrounding environment of the heat exchanger  105 , the heat exchanger  105  may be used to increase the temperature of the heat exchange medium  15  flowing inside the present invention. For example, a refrigerant with a low boiling temperature may flow through the tube  20  and the chamber  30  of the heat exchanger  105 , where the environment surrounding the heat exchanger  105  is of a higher temperature than that of the refrigerant. Continuing with this example, the heat from the environment surrounding the heat exchanger  105  is transferred to the refrigerant, thereby increasing the temperature of the refrigerant, hot enough to cause the refrigerant to reach a boiling temperature. An example of this embodiment, which is not intended to be limiting, would be an evaporator for an air conditioning unit. 
         [0058]    Referring to  FIG. 2A , the inside of tube  20  is hollow, which allows for the flowing of the heat exchange medium  15 . The tube  20  is mated to the chamber  30 . The chamber  30  houses a medium-directing member  25 . The medium-directing member  25  is positioned within the intersecting space between the tube  20  and the chamber  30 . The heat exchanging medium  15  flows through the tube  20  until the heat exchanging medium  15  flows into contact with the medium-directing member  25 . The medium-directing member  25  directs the heat exchanging medium  15  into the inside of the chamber  30 . According to the present embodiment, the heat exchange medium  15  disperses throughout the chamber  30 , and heat is transferred from the heat exchange medium  15  to the chamber  30  and the plate member  35 . 
         [0059]    Referring to  FIG. 2C , an embodiment of the chamber  30  is shown. Plurality of chambers  30  are arranged on a plate member  35 . Medium-directing member  25  is attached to chambers  30 . In this embodiment, the medium-directing member  25  is attached to the inner wall of the chamber  30 . Although not meant to be limiting, in  FIGS. 2A and 2C , the medium-directing member  25  is secured at an angle. In addition, other embodiments may secure the medium-directing member  25  at an angle inside the chamber  30 . 
         [0060]    Referring to  FIG. 2A , the inside of tube  20  is hollow, which allows for the flowing of a heat exchange medium  15 . The tube  20  is mated to the chamber  30 . The chamber  30  houses a medium-directing member  25 . The medium-directing member  25  is fixed within the intersecting space between the tube  10  and the chamber  30 . The heat exchanging medium  15  flows through the tube  20  until the heat exchanging medium  15  flows into contact with the medium-directing member  25 . The medium-directing member  25  directs the heat exchanging medium  15  into the inside of the chamber  30 . According to the embodiment in  FIG. 2C , medium-directing member  25  direct the heat exchange medium  15  in a particular direction within the chamber  30  and heat is transferred from the heat exchange medium  15  to the chamber  30 . The heat transferred from the heat exchange medium  15  to the chamber  30 , then transfers to the plate member  35 , where larger surface area of the plate member, allows for efficient dissipation of heat from the heat exchanger core  100 . Although not meant to be limiting, plate members are generally made of thin gage material, providing efficient heat conductivity characteristics. 
         [0061]    Referring to  FIG. 3A , an embodiment of the plate member  35  according to the present invention is shown. The plate member  35  is a generally planar material, having plurality of holes  300 . The holes  300  go through the thickness of the material comprising the plate member  35 , the shape of the holes  300  set to the shape of the chamber  30 , circumference of the holes sized to allow the chamber  30  to be inserted through the holes  300 . Along the circumference of the holes  300 , is an annular wall  305  extending away from the base plane  365  of the plate member  35 , the annular wall  305  initiating from the base plane  365  from a fold  370  on the plate member Annular walls  305  extend generally perpendicular away from the base plane  365  of the plate member  35 . Referring to  FIGS. 5A and 5B , an exploded view of the annular wall  305  is shown. The plate member  35  has an annular wall  305  extending away from the base plane  365  of the plate member  35 . The inner surface of the annular wall  305  is set to the shape of the chamber  30 . Inner surface of the annular wall  305  is generally smooth, allowing lateral surface  40  of the chamber  30  to abut against the inner circumference of the annular wall  305 . Upon assembly of the plate member  35  to the chamber  30 , the components may be brazed together. The plate member  35  may utilize cladded material, the chamber  30  may utilize cladded material, or both components may utilize cladded material, so when brazed, components are firmly bonded together. 
         [0062]    Referring to  FIG. 3E , it represents another embodiment of the plate member  35  according to the present invention. The plate member  35  is shown with plurality of indentations  325  in the shape of the chamber  30 . Plurality of annular walls  305  extends generally perpendicular away from the base plane  365  of the plate member  35 , annular walls initiating from the planar surface  365  of the plate member  35  at the fold  370  on the planar member. Annular wall  305  has an inner circumference generally of the outer diameter of the chamber  30 , allowing the lateral wall  40  of the chamber  30  to abut against the inner circumference of the annular wall  305 . The annular wall terminates at a second plane surface  325  that is generally parallel to the base plane  365  of the plate member  35 . The second plane surface  325  has a hole  320  in the shape of the tube  20 , the hole  320  going through the entire thickness of the second plane surface  325 . The tube  20  connected to the chamber  30  is inserted through the hole  320 . Top surface  45  of the chamber  30  is coupled to the inner surface of the second plane surface  325 . The lateral surface  40  of the chamber  30  is coupled to the inner surface of the annular wall  305 . Upon assembly, entire unit may be brazed together. 
         [0063]      FIG. 3F  is yet another embodiment of the plate member according to the present invention. The plate member  35  is shown with plurality of indentations in the shape of the chamber  30 . Plurality of annular walls  305  extends generally perpendicular away from the base plane  365  of the plate member  35 , said walls initiating from the planar surface  365  of the plate member  35  at the fold  370  on the plate member  35 . Annular wall  305  has an inner circumference generally of the outer diameter of the chamber  30 , allowing the lateral wall  40  of the chamber  30  to abut against the inner surface of the annular wall  305 . The annular wall terminates at a stepped planar surface  345  that is generally parallel to the base plane  365  of the plate member  35 . The stepped planar surface  345  has a hole  340 , diameter of the hole set smaller than the diameter of the chamber, but larger than the diameter of the tube  20 . Referring to  FIGS. 4G and 4H , which is an exploded view of the plate member  35  and the chamber  30 , the top surface  45  of the chamber  30  is coupled to the inner surface  355  of the stepped planar surface  345 . The lateral surface  40  of the chamber  30  is coupled to the inner surface of the annular wall  305 . Upon assembly, entire unit may be brazed together. 
         [0064]    Referring to  FIGS. 4A and 4B , prior art illustration of plurality of chamber assembly  400  are presented. Chamber assembly  400  comprises of tube  20 , chamber  30 , and a medium-directing member  25  contained within the chamber  30 . Plurality of chamber assembly  400  may be combined together, free end of tube  20  of the first chamber assembly  400  connected to a free end of tube  20  on a second chamber assembly  400 , forming a plurality of row of chamber assemblies  400 . As many chamber assembly  400  may be combined together to form a row of chamber assembly  400  of desired quantity. Plurality of chamber assembly  400  may be arranged in a column, plurality of chamber assemblies aligned laterally as shown in  FIG. 4B . Although not meant to be limiting, a column of chamber assemblies  400  may be arranged, allowing for a chamber assemblies on first column of chamber assemblies to align generally to chamber assemblies on a second column of chamber assemblies on a same plane. As plurality of chamber assemblies are arranged on a column, a space  405  is created between plurality of chamber assemblies  400 . 
         [0065]    Referring to  FIGS. 4C and 4D , an embodiment according to present invention is shown. Plurality of chamber assemblies  400  are arranged in a column, aligned laterally on generally of same plane as shown in  FIG. 4D . In an embodiment according to the present invention, plurality of chambers arranged on a same plane is coupled to a plate member  35 . By having plurality of chamber assembly  400  coupled to a plate member  35 , present invention utilizes the space  405  between plurality of chamber assemblies  400  to increase the overall surface area of a heat exchanger, thereby enhancing the performance characteristics of a heat exchanger. By utilizing the space  405  between plurality of chamber assembly  400  to add surface area to the heat exchanger, the present invention increases the overall surface area of the chamber assemblies without significantly impacting the overall size of the heat exchanger core  100 , enhancing the ratio of internal heat exchange medium volume of the heat exchanger to the overall surface area of the heat exchanger. Generally speaking, when overall surface area of the heat exchanger is increased relative to the internal volume of the heat exchanger, performance of a heat exchanger is enhanced. 
         [0066]    Other embodiments of the present invention are illustrated in  FIGS. 4E and 4F . Depending on an application of a heat exchanger, the ratio of the overall surface area of the heat exchanger core  105  to the internal volume of the heat exchanger  105  can be adjusted by increasing the quantity of plate member attached to the chamber assembly  400 . Although not limiting, in  FIG. 4E  two plate members  35  are attached to the chamber assembly  400 . In  FIG. 4F , three plate members  35  are attached to the chamber assembly  400 . The quantity of plate members  35  attached to the chamber assembly  400  can be easily adjusted according to the requirements of the heat exchanger in any particular application. 
         [0067]    Referring to  FIGS. 1A and 1C , the tube  20 , in the illustrated embodiment, is hollow and circular. In other embodiments, the tube  20  may be hollow but non-circular, such as an oval or rectangular shape. 
         [0068]    Referring to  FIG. 1C , in the illustrated embodiment, the chamber  30  is hollow and circular in shape. In other embodiments, the chamber  30  may be hollow, but non-circular in shape. 
         [0069]    The tube  20  embodiments may be mated in various combinations with the chamber  30  embodiments. Additional fin material may be coupled to the inside or the outside of the tube  20 . Additional fin material may be coupled to the inside or the outsize of the chamber  30 . The plate member may have performance enhancing surface treatment. The plate member may have louvers, slits, or additional extended surface features known in the art to improve the heat exchange characteristics of the plate member  35 . Other embodiments of the tubes, chambers, and plate members not pictured may also be combined, and the invention is not limited to the embodiments described. 
         [0070]    Referring to  FIG. 7A through 7F , a method according to the present invention is presented. The method includes a step of providing generally planar sheet  700  of elongate, deformable material such as a cladded aluminum material. The steps include forming plurality of protrusion member  705  to position plurality of chamber assemblies  400  to the planar sheet  700 . The method includes a step of deforming the planar sheet  700  to form plurality of generally large bowl shaped protrusions  705 , gathering sufficient material for the annular wall  305  and the stepped planar surface  355  to be formed in later stages. Referring to  FIG. 7C , the method includes the step of forming the large bowl shaped protrusion into the shape of an indentation with annular wall  305 , said annular wall extending generally perpendicular away from the base plane  365 , annular wall initiating from a fold  370 , terminating at the stepped surface  710 . The inner circumference of the annular wall is generally formed in the shape of the chamber assembly  400 , allowing the lateral wall  40  of the chamber assembly  400  to abut against the inner circumference of the annular wall  305 . The chamber assembly  400  comprises of an inlet, an outlet, a chamber, and a medium-directing member position within the chamber. The method includes the step of forming a hole  340  on the stepped surface  710 , diameter of the hole  340  larger than the diameter of the tube  20 , but smaller than the diameter of the chamber assembly  30 , forming a stepped planar surface  355 . At the completion of said fabricating steps, the planar sheet  700  is made into a plate member  35 . The plane of the stepped planar surface  355  is generally flat, allowing the top surface  50  of the chamber assembly to couple against the surface of the stepped planar surface  355 . The method includes coupling of plurality of chamber assembly  400  to the plate member  35 . The chamber assembly  400  is set against plurality of stepped surface  355  formed on the plate member  35 , lateral wall  40  of the chamber assembly  400  coupled to the inner circumference of the annular wall  305 , and the top surface  50  of the chamber assembly  400  coupled to the stepped planar surface  355 , forming a planar assembly  720  comprising of plate member  35  with plurality of chamber assemblies  400 . The method includes stacking plurality of said assemblies  720  together, free end of plurality of tubes on first planar member assembly  720  to couple to the free end of tubes on a second planar assembly  720 . The entire assembly may be coupled to a pair of manifolds, first free end of first plurality of tubes to couple to a first manifold, the second free end of plurality of tubes to couple to a second manifold. The entire assembly may be brazed together. The planar sheet  700  may be formed by stamping. 
         [0071]    Referring to  FIG. 8A through 8D , another method according to the present invention is presented. The method includes a step of providing generally planar sheet  700  of elongate, deformable material such as a cladded aluminum material. The steps include forming plurality of annular walls  305  to position plurality of the chamber assembly  400  to the plate member  35 . The method includes a step of bending the planar sheet  700  to form plurality of annular wall  305 , said annular wall extending generally perpendicular from the base plane  365 . The inner circumference of the annular wall  305  is generally formed in the shape of the chamber assembly  400 , allowing the lateral wall  40  of the chamber assembly  400  to abut against the inner circumference of the annular wall  35 . The method includes coupling plurality of chamber assembly  400  to the plate member  35 . The chamber assembly  400  is coupled to plurality of annular walls  305  formed on the plate member  35 , lateral wall  40  of the chamber assembly coupled to the inner circumference of the annular wall  305 , forming a planar assembly  720 . The method includes stacking plurality of said planar assemblies together, free end of plurality of tubes on first planar member assembly  720  to couple to the free end of tubes on a second planar assembly  720 . The entire assembly may be coupled to a pair of manifolds, free end of first plurality of tubes on a planar assembly  720  to couple to a first manifold, the second free end of plurality of tubes on a planar assembly  720  to couple to a second manifold. The entire assembly may be brazed together. The planar sheet  700  may be formed by stamping. 
         [0072]    Referring to  FIG. 9A through 9D , yet another method according to the present invention is presented. The method includes a step of providing generally planar sheet  700  of elongate, deformable material such as a cladded aluminum material. The steps include forming plurality of holes  300  to position plurality of chamber assembly  400  to the generally planar sheet  700 . The method includes forming plurality of holes  300  on the planar sheet  700 , the holes  300  go through the thickness of the generally planar sheet  700 . The dimension of the holes  300  is made to the size of the outer circumference of the chamber assembly  400 , allowing the lateral wall  40  of the chamber assembly  400  to pass through the holes  300  on the generally planar sheet  700 , said fabrication step transforming the planar sheet  700  into a plate member  35 . The method includes coupling plurality of chamber assembly  400  to the plate member  35 . The chamber assembly  400  is coupled to plurality of holes  300  formed on the plate member  35 , lateral wall  40  of the chamber assembly coupled to the holes  300  formed on the plate sheet  35 , forming a planar assembly  720 . The method includes stacking plurality of said assemblies  720  together, free end of plurality of tubes on first planar member assembly  720  to couple to the free end of tubes on a second planar assembly  720 . The entire assembly may be coupled to a pair of manifolds, free end of first plurality of tubes to couple to a first manifold, the second free end of plurality of tubes to couple to a second manifold. The entire assembly may be brazed together. The planar sheet  700  may be formed by stamping. 
         [0073]    Referring to  FIG. 2A , a cross-section of an embodiment of the present invention is shown. A chamber  30  is connected to a tube  20  that is connected to another chamber  30 . Each chamber  30  in the present embodiment may house a medium-directing member  25 , which in this embodiment attaches at certain points to the inner surface of the chamber  30 , which leaves openings along the inner surface of the chamber  30 . The medium-directing member  25  allows passage of the heat exchange medium  15  through these openings. The arrows illustrate how the heat exchange medium  15  may be redirected according to the embodiment as shown. 
         [0074]    Referring to  FIG. 2C , the chamber  30 , in combination with any of the above embodiments, does not have to be circular-shaped, other embodiments may be shaped like an oval (with various ratios of height, length, and width dimensions), or other geometric shapes. 
         [0075]    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. 
         [0076]    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 material. The tube and chamber may also be a plastic material or other composite materials. Likewise, the medium-directing member may be made of aluminum, either with cladding or without cladding. The medium-directing member may also be made of stainless steel, copper or other ferrous or non-ferrous materials. The medium-directing member may also be a plastic material or other composite materials. The plate member may be made of aluminum, either with cladding or without cladding. The plate member may also be made of stainless steel, copper or other ferrous or non-ferrous material. The plate member may also be a plastic material or other composite material. 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 medium-directing members may be made of a different material than the material used for the chamber, the tube, and the plate member. The material used for the plate member may be made of different material than the material used for the chamber, the tube, or the medium-directing member. If more than one medium-directing member is used in an embodiment of the invention, one medium-directing member may be made of a different material than another medium-directing member. The medium-directing members may also be of different shapes than one another. Also, if more than one plate member is used in an embodiment of the invention, one plate member may be made of a different material than another plate member. The plate member may also be of different shape than one another. 
         [0077]    The tube, the chamber, the medium-directing member, and the plate member may be manufactured by stamping, cold forging, casting, or machining. The tube, the chamber, the medium-directing member, and the plate member may be manufactured as one piece or may be manufactured as two separate pieces. 
         [0078]    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 medium, 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. 
         [0079]    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.