Patent Description:
Heat exchangers comprising corrugated heat transfer sheets are known in the art.

One of the disadvantages associated with known heat exchangers comprising corrugated heat transfer sheets is that they are complex to manufacture.

Examples of known heat exchangers according to the preamble of claim <NUM> are described in publications <CIT>, <CIT>, <CIT> and <CIT>.

An object of the present invention is to provide a heat exchanger, a cooled device assembly comprising the heat exchanger, and a method for manufacturing the heat exchanger so as to alleviate the above disadvantage. The objects of the invention are achieved by a heat exchanger, a cooled device assembly comprising the heat exchanger, and a method for manufacturing the heat exchanger which are characterized by what is stated in the independent claims. The preferred embodiments of the invention are disclosed in the dependent claims.

The invention is based on the idea of providing a first flow channel and a second flow channel on opposite sides of a corrugated heat transfer sheet by means of a channel dividing system, wherein a first fluid flow is adapted to be in contact with a first surface of the corrugated heat transfer sheet, and a second fluid flow is adapted to be in contact with a second surface of the corrugated heat transfer sheet.

An advantage of the heat exchanger of the invention is a simple and inexpensive structure thereof. The cooled device assembly of the invention has the same advantage as the heat exchanger of the invention. An advantage of the method of the invention is that forming a corrugated heat transfer sheet from a sheet material simplifies manufacturing of the heat exchanger.

<FIG> shows a heat exchanger according to an embodiment of the invention, the heat exchanger comprising a corrugated heat transfer sheet <NUM>, a channel dividing system, sealing means, and longitudinal support means. <FIG> shows the heat exchanger of <FIG> form a direction parallel to a longitudinal direction of the heat exchanger. <FIG> shows an exploded view of the heat exchanger of <FIG>. <FIG> shows a cut off portion of the heat exchanger of <FIG> for exhibiting an internal structure of the heat exchanger.

The corrugated heat transfer sheet <NUM> has a first surface <NUM> and a second surface <NUM> on opposite sides thereof. Referring to <FIG> and <FIG>, the corrugated heat transfer sheet <NUM> comprises a plurality of ridges <NUM> and grooves <NUM> which alternate in a width direction and have crests <NUM> and troughs <NUM> spaced apart in a depth direction. The ridges <NUM> and grooves <NUM> extend in a longitudinal direction. The width direction, the depth direction and the longitudinal direction are mutually perpendicular directions.

Herein, the crests <NUM> are peaks of the ridges <NUM>, and troughs <NUM> are bottoms of the grooves <NUM> such that the crests <NUM> and the troughs <NUM> are extreme portions of the corrugated heat transfer sheet <NUM> in the depth direction. In <FIG>, the longitudinal direction is perpendicular to the image plane, the depth direction is vertical, and the width direction is horizontal.

A thickness of the corrugated heat transfer sheet <NUM> is <NUM>. In an alternative embodiment, a thickness of the corrugated heat transfer sheet is less than or equal to <NUM>.

The corrugated heat transfer sheet <NUM> is made of steel. In an alternative embodiment, the corrugated heat transfer sheet is made of another metal such as aluminium. Since the corrugated heat transfer sheet is thin, temperature difference between the first surface and second surface is small even if the corrugated heat transfer sheet is made of a material having only moderate thermal conductivity. Therefore, in a further alternative embodiment, the corrugated heat transfer sheet is made of plastic such as polypropylene or polycarbonate. In a yet further alternative embodiment, the corrugated heat transfer sheet is made of graphene.

The channel dividing system provides a first flow channel <NUM> and a second flow channel <NUM> on opposite sides of the corrugated heat transfer sheet <NUM>. The first flow channel <NUM> is adapted for a first fluid flow in a first flow direction parallel to the longitudinal direction. The first fluid flow is adapted to be in contact with the first surface <NUM>. The second flow channel <NUM> is adapted for a second fluid flow in a second flow direction parallel to the longitudinal direction, the second flow direction being opposite to the first flow direction. The second fluid flow is adapted to be in contact with the second surface <NUM>. The heat exchanger is adapted to transfer heat between the first fluid flow and the second fluid flow.

In <FIG>, a direction of the first fluid flow is towards the viewer, and a direction of the second fluid flow is away from the viewer. The directions of the fluid flows have significance due to flow deflectors discussed later on.

If accidental leaks are ignored, the first fluid flow is not adapted to be in contact with the second surface <NUM> at all. Similarly, if accidental leaks are ignored, the second fluid flow is not adapted to be in contact with the first surface <NUM> at all.

The heat exchanger comprises a top wall <NUM> adjacent the crests <NUM> of the corrugated heat transfer sheet <NUM>, and a bottom wall <NUM> adjacent troughs <NUM> of the corrugated heat transfer sheet <NUM>. The top wall <NUM> and the bottom wall <NUM> are planar walls spaced apart from each other in the depth direction. The top wall <NUM> and the bottom wall <NUM> are parallel to each other. Normals of the top wall <NUM> and the bottom wall <NUM> are parallel to the depth direction.

In the depth direction, the first flow channel <NUM> is limited by the first surface <NUM> and the top wall <NUM>, and the second flow channel <NUM> is limited by the second surface <NUM> and the bottom wall <NUM>. In <FIG>, <FIG>, <FIG>, the top wall <NUM> is provided with a top wall aperture <NUM>, and in <FIG> and <FIG>, the bottom wall <NUM> is provided with a bottom wall aperture <NUM>. The top wall aperture <NUM> and the bottom wall aperture <NUM> are additional apertures added to the Figures in order to better show the corrugated heat transfer sheet <NUM>. The top wall aperture <NUM> and the bottom wall aperture <NUM> are not present in the actual heat exchanger.

The first fluid flow and the second fluid flow are air flows. In alternative embodiments the first fluid flow and the second fluid flow are different type of gas flows or liquid flows.

The channel dividing system comprises a first channel dividing element <NUM> and a second channel dividing element <NUM> spaced apart in the longitudinal direction. The first channel dividing element <NUM> is located at a first longitudinal end of the corrugated heat transfer sheet <NUM>, and the second channel dividing element <NUM> is located at a second longitudinal end of the corrugated heat transfer sheet <NUM>.

The first channel dividing element <NUM> and the second channel dividing element <NUM> have first blocking portions <NUM> adapted to block top portions of the ridges <NUM>, and second blocking portions <NUM> adapted to block bottom portions of the grooves <NUM>. The first blocking portions <NUM> and the second blocking portions <NUM> protrude from a body part <NUM> of channel dividing element. The first blocking portions <NUM> protrude in the direction of the ridges <NUM>, and the second blocking portions <NUM> protrude in the direction of the grooves <NUM>. In <FIG>, the first blocking portions <NUM> protrude upwards from the body part <NUM>, and the second blocking portions <NUM> protrude downwards from the body part <NUM>. Dimensions of the first blocking portions <NUM> and second blocking portions <NUM> in the longitudinal direction are less than <NUM>% of a dimension of the corrugated heat transfer sheet <NUM> in the longitudinal direction.

On a first side of the body part <NUM>, the first blocking portions <NUM> prevent a fluid flow from getting into contact with the second surface <NUM> of the corrugated heat transfer sheet <NUM>. On a second side of the body part <NUM>, the second blocking portions <NUM> prevent a fluid flow from getting into contact with the first surface <NUM> of the corrugated heat transfer sheet <NUM>. In <FIG>, the first side of the body part <NUM> is above the body part <NUM>, and the second side of the body part <NUM> is below the body part <NUM>.

There is a division plane such that the first flow channel <NUM> is located on one side of the division plane, and the second flow channel <NUM> is located on the other side of the division plane. A distance between the division plane and the crests <NUM> is equal to a distance between the division plane and the troughs <NUM>. The longitudinal direction and the width direction are parallel to the division plane.

Since dimensions of the first blocking portions <NUM> and second blocking portions <NUM> in the longitudinal direction are small compared to a longitudinal dimension of the corrugated heat transfer sheet <NUM>, the first blocking portions <NUM> allow the second fluid flow to flow in a majority of length of top portions of the ridges <NUM>, and the second blocking portions <NUM> allow the first fluid flow to flow in a majority of length of bottom portions of the grooves <NUM>. Consequently, the first fluid flow is adapted to be in contact with approximately <NUM>% of an area of the first surface <NUM>, and the second fluid flow is adapted to be in contact with approximately <NUM>% of an area of the second surface <NUM>. In an alternative embodiment, the first fluid flow is adapted to be in contact with at least <NUM>% of an area of the first surface, and the second fluid flow is adapted to be in contact with at least <NUM>% of an area of the second surface.

The first channel dividing element <NUM> and the second channel dividing element <NUM> support the corrugated heat transfer sheet <NUM> for maintaining the corrugated heat transfer sheet <NUM> in its correct corrugated shape. This supporting function of the first channel dividing element and the second channel dividing element enables manufacturing the corrugated heat transfer sheet of thin sheet material.

The sealing means provide sealing between the corrugated heat transfer sheet <NUM> and the channel dividing system, thereby improving separation between the first flow channel <NUM> and the second flow channel <NUM>. Consequently, the sealing means provide sealing, inter alia, between the corrugated heat transfer sheet <NUM> and the first channel dividing element <NUM>, and between the corrugated heat transfer sheet <NUM> and the second channel dividing element <NUM>.

The sealing means prevent dust and water from transferring between the first flow channel <NUM> and the second flow channel <NUM>. In an embodiment, a level of ingress protection is IP55.

The sealing means comprises a first end support element <NUM>, a second end support element <NUM>, a first side support element <NUM>, and a second side support element <NUM>. The first end support element <NUM> co-operates with the first channel dividing element <NUM> for sealing the corrugated heat transfer sheet <NUM> against the first channel dividing element <NUM>. The first longitudinal end of the corrugated heat transfer sheet <NUM> is located between the first end support element <NUM> and the first channel dividing element <NUM> in the depth direction, and the first end support element <NUM> presses the corrugated heat transfer sheet <NUM> against the first channel dividing element <NUM> in the depth direction. The second longitudinal end of the corrugated heat transfer sheet <NUM> is located between the second end support element <NUM> and the second channel dividing element <NUM> in the depth direction, and the second end support element <NUM> presses the corrugated heat transfer sheet <NUM> against the second channel dividing element <NUM> in the depth direction.

The first end support element <NUM> and the second end support element <NUM> have contact surfaces whose shapes correspond to a shape of the corrugated heat transfer sheet <NUM> such that a contact area between the first end support element <NUM> and the corrugated heat transfer sheet <NUM> is large, and a contact area between the second end support element <NUM> and the corrugated heat transfer sheet <NUM> is large. Consequently, the contact surfaces of the first end support element <NUM> and the second end support element <NUM> have corrugated shapes.

The first end support element <NUM> and the second end support element <NUM> each comprises a flow deflector adapted to deflect corresponding fluid flow towards the corrugated heat transfer sheet <NUM> in order to improve heat transfer between the fluid flow and the corrugated heat transfer sheet <NUM>. In <FIG>, a flow deflector of the second end support element <NUM> is denoted with a reference number <NUM>.

Dimensions of the first end support element <NUM> and the second end support element <NUM> in the longitudinal direction are less than <NUM>% of a dimension of the corrugated heat transfer sheet <NUM> in the longitudinal direction. In an alternative embodiment, dimensions of the first end support element and the second end support element in the longitudinal direction are less than or equal to <NUM>% of a dimension of the corrugated heat transfer sheet in the longitudinal direction.

In an alternative embodiment, the heat exchanger does not comprise any end support elements. For example, if connections between the corrugated heat transfer sheet and the first and second channel dividing elements are firm and tight enough by themselves, there might not be need for any end support elements.

The first side support element <NUM> and the second side support element <NUM> extend in the longitudinal direction and are spaced apart in the width direction. The first side support element <NUM> is located on the first lateral side of the corrugated heat transfer sheet <NUM>, and supports the corrugated heat transfer sheet <NUM> in a first lateral direction parallel to the width direction. The second side support element <NUM> is located on a second lateral side of the corrugated heat transfer sheet <NUM>, and supports the corrugated heat transfer sheet <NUM> in a second lateral direction opposite to the first lateral direction. The first side support element <NUM> takes part in sealing a first side edge of the corrugated heat transfer sheet <NUM>, and the second side support element <NUM> takes part in sealing a second side edge of the corrugated heat transfer sheet <NUM>.

The first channel dividing element <NUM>, the second channel dividing element <NUM>, the first end support element <NUM>, the second end support element <NUM>, the first side support element <NUM>, and the second side support element <NUM> are made of plastic by injection moulding.

The first side support element <NUM> comprises a first support groove <NUM> extending in the longitudinal direction. The first side edge of the corrugated heat transfer sheet <NUM> is received in the first support groove <NUM>. The second side support element <NUM> comprises a second support groove <NUM> extending in the longitudinal direction. The second side edge of the corrugated heat transfer sheet <NUM> is received in the second support groove <NUM>.

In an embodiment, there is sealing compound in the first support groove and second support groove for improving sealing between the corrugated heat transfer sheet and the side support elements. Further, it is possible to use sealing compound also between the corrugated heat transfer sheet and the channel dividing elements.

The longitudinal support means are adapted for preventing relative movement in the longitudinal direction between the first channel dividing element <NUM> and the corrugated heat transfer sheet <NUM>, and between the second channel dividing element <NUM> and the corrugated heat transfer sheet <NUM>. The longitudinal support means comprises a plurality of screws <NUM> connecting the corrugated heat transfer sheet <NUM> to the first end support element <NUM> and the first channel dividing element <NUM>, and to the second end support element <NUM> and the second channel dividing element <NUM>.

A first set of screws <NUM> passes through the first end support element <NUM> and the corrugated heat transfer sheet <NUM> to the first channel dividing element <NUM>. A second set of screws <NUM> passes through the second end support element <NUM> and the corrugated heat transfer sheet <NUM> to the second channel dividing element <NUM>. The screws <NUM> are shown in <FIG> and <FIG>.

It should be noted that also the longitudinal support means takes part in providing sealing between the corrugated heat transfer sheet <NUM> and the channel dividing system. The plurality of screws connecting the corrugated heat transfer sheet <NUM> to the channel dividing elements <NUM> and <NUM> press the corrugated heat transfer sheet <NUM> against the channel dividing element. In embodiments where there is adhesive between the corrugated heat transfer sheet and the channel dividing elements, the adhesive functions both as longitudinal support means and sealing means. Therefore, in many embodiments it is not possible to clearly divide structures in sealing means and longitudinal support means.

The first channel dividing element <NUM>, the second channel dividing element <NUM>, the first side support element <NUM> and the second side support element <NUM> are connected together such that they form a heat exchanger frame which supports the corrugated heat transfer sheet <NUM> from all four sides thereof, and is adapted for connecting the heat exchanger to a body part of a cooled device assembly.

In an alternative embodiment, the heat exchanger comprises an intermediate support element adapted to support the corrugated heat transfer sheet between the first channel dividing element and the second channel dividing element. The intermediate support element is located between the first channel dividing element and the second channel dividing element in the longitudinal direction. The intermediate support element is in contact with the corrugated heat transfer sheet in order to brace the corrugated heat transfer sheet. The intermediate support element is also adapted to increase turbulence in the first fluid flow and/or the second fluid flow.

<FIG> shows a cooled device assembly comprising a body part <NUM>, an outer casing <NUM> defining a device space inside thereof, and the heat exchanger of <FIG>. The heat exchanger is mechanically connected to the body part <NUM>, and is accommodated inside the outer casing <NUM>.

In alternative embodiments, the outer casing and/or the body part of the cooled device assembly form parts of the heat exchanger. For example, in an embodiment, the heat exchanger does not comprise a top wall or a bottom wall but the first flow channel and the second flow channel are limited in the depth direction by portions of the outer casing of the cooled device assembly. Further, in another embodiment, at least one of the following components is an integral part of the body part of the cooled device assembly: the first channel dividing element, the second channel dividing element, the first side support element, and the second side support element. It is possible to form said at least one integral component by the same injection moulding process as the body part of the cooled device assembly.

In <FIG>, several parts of the cooled device assembly have been omitted. The omitted parts comprise an electrical device requiring cooling, and a user interface. In an embodiment, the electrical device requiring cooling is a converter device such as a frequency converter.

A method for manufacturing the heat exchanger of <FIG> comprises providing an elongated piece of sheet material, folding the elongated piece of sheet material into the form of the corrugated heat transfer sheet <NUM>, providing the channel dividing system, and combining the corrugated heat transfer sheet <NUM> and the channel dividing system. Said combining comprises pushing the corrugated heat transfer sheet <NUM> in the depth direction relative to the first channel dividing element <NUM> and the second channel dividing element <NUM> until the corrugated heat transfer sheet <NUM> is in contact with the first <NUM> and second <NUM> channel dividing elements. In an embodiment, the sheet material is supplied to the manufacturing process from a roll.

In an embodiment, the folding process comprises forming a plurality of creases into the elongated piece of sheet material. Subsequently, the elongated piece of sheet material is folded into the form of the corrugated heat transfer sheet along the plurality of creases. In an alternative embodiment, the manufacturing method does not comprise forming creases into the elongated piece of sheet material.

The channel dividing system is made of different material, and with different manufacturing process than the corrugated heat transfer sheet. In an embodiment, the first channel dividing element, the second channel dividing element, the first end support element, the second end support element, the first side support element, and the second side support element are manufactured at one location, and are transported to a second location at which the corrugated heat transfer sheet is formed by folding an elongated piece of sheet material, and the heat exchanger is manufactured.

The heat exchanger of <FIG> only has one corrugated heat transfer sheet <NUM>. In an alternative embodiment, the heat exchanger comprises a plurality of corrugated heat transfer sheets wherein the corrugated heat transfer sheets are arranged in a stack such that planes defined by individual sheets are parallel to each other and are spaced apart in the depth direction. The first flow channel and the second flow channel each comprises a plurality of subchannels. The individual corrugated heat transfer sheets are separated from each other by separation plates. In an embodiment, the first and second end support elements, and/or the first and second channel dividing elements are provided with fastening means for fastening the separation plates.

Claim 1:
A heat exchanger comprising:
a corrugated heat transfer sheet (<NUM>) having a first surface (<NUM>) and a second surface (<NUM>) on opposite sides thereof, the corrugated heat transfer sheet (<NUM>) comprising a plurality of ridges (<NUM>) and grooves (<NUM>) which alternate in a width direction, and have crests (<NUM>) and troughs (<NUM>) spaced apart in a depth direction, wherein the width direction, the depth direction and a longitudinal direction are mutually perpendicular directions;
a first flow channel (<NUM>) for a first fluid flow in a first flow direction parallel to the longitudinal direction;
a second flow channel (<NUM>) for a second fluid flow in a second flow direction parallel to the longitudinal direction, the second flow direction being opposite to the first flow direction, and
a channel dividing system which provides the first flow channel (<NUM>) and the second flow channel (<NUM>) on opposite sides of the corrugated heat transfer sheet (<NUM>) such that the first fluid flow is adapted to be in contact with the first surface (<NUM>), and the second fluid flow is adapted to be in contact with the second surface (<NUM>)
wherein the channel dividing system comprises a first channel dividing element (<NUM>) and a second channel dividing element (<NUM>) spaced apart in the longitudinal direction,
the heat exchanger being characterized in that the first channel dividing element (<NUM>) and the second channel dividing element (<NUM>) having first blocking portions (<NUM>) adapted to block top portions of the ridges, and second blocking portions (<NUM>) adapted to block bottom portions of the grooves, wherein dimensions of the first blocking portions (<NUM>) and second blocking portions (<NUM>) in the longitudinal direction are less than or equal to <NUM>% of a dimension of the corrugated heat transfer sheet (<NUM>) in the longitudinal direction.