CN101405556B - Flat tube, flat tube heat exchanger and manufacturing method thereof - Google Patents

Abstract

A number of flat tubes, flat tube heat exchangers, and methods of making both are described and illustrated. The flat tube may be constructed from one, two or more pieces of material. A shaped insert, either integral with the flat tube or constructed from another sheet of material, may be used to define a plurality of flow channels through the flat tube. The flat tubes may be constructed of a relatively thin material and may be reinforced with folds and/or inserts of flat tube material in areas subject to high pressure and thermal stresses. Furthermore, the relatively thin flat tube material may have a corrosion resistant layer to enable the material to resist failure due to corrosion. Heat exchangers having such flat tubes connected to a header are also disclosed, as are the ways in which such tubes may be provided with fins.

Description

Flat tube, flat tube heat exchanger and manufacturing method thereof

This application hereby claims priority to the following applications: German Patent Application No. DE10 2006 002 627.6 filed on January 19, 2006, German Patent Application No. DE10 2006 002 789.2 filed on January 20, 2006, 2006 German patent application No.DE10 2006 002 932.1 submitted on January 21, German patent application No.DE102006 006 670.7 submitted on February 14, 2006, German patent application No.DE10 2006 016711.2 submitted on April 8, 2006, German Patent Application No. DE10 2006 029 378.9 filed on June 27, 2006, German Patent Application No. DE10 2006 032 406.4 filed on July 13, 2006, German Patent Application No. DE10 filed on July 20, 2006 2006 033 568.6, German Patent Application No. DE10 2006 035 210.6 filed on July 29, 2006, German Patent Application No. DE10 2006 041 270.2 filed on September 2, 2006, and German Patent Application No. DE10 2006 041 270.2 filed on September 9, 2006 Patent application No. DE10 2006 042 427.1, the entire contents of which applications are hereby incorporated by reference.

Contents of the invention

In some embodiments, the present invention provides a heat exchanger comprising: a duct body at least partially bounded by a sheet of material having a thickness no greater than about 0.15 mm, the duct body having a thickness greater than the thickness and a width generally perpendicular to the thickness, an outer wall at least partially bounded by the sheet of material, an inner chamber having a maximum width extending along the direction of the width of the duct body, a broad side, and each Defining first and second narrow sides of an interior surface of the interior chamber, the sheet of material is curved to at least partially define the first narrow side of the duct body. The heat exchanger of the present invention may further comprise a first portion of said outer wall, said first portion of said outer wall overlapping a second portion of said outer wall at said second narrow side and defining an undercut, wherein said The first portion has an end at a location along the width of the duct, and wherein the interior chamber extends from the center of the duct past the location to the inner surface of the second narrow side.

The invention also provides a heat exchanger tube comprising a sheet of material at least partially forming an outer wall of a tube body, the tube body having a first narrow side, a second narrow side and a wide side, the sheet of material having less than about 0.15 mm in thickness and folded at the first narrow side of the duct body, the first narrow side and the second narrow side being reinforced such that the first narrow side and the second narrow side The narrow sides each have a thickness greater than the thickness of the sheet of material.

In addition, the present invention provides a method of forming a heat exchanger tube, the method comprising the steps of: forming a sheet of material having a thickness not greater than about 0.15 mm to form a tube body having a thickness greater than the a width substantially perpendicular to said thickness, an outer wall at least partially bounded by said sheet of material, an inner chamber having a maximum width extending along said width of said duct body, a broad side, and each Both define first and second narrow sides of the inner surface of the inner chamber. The method may further comprise the steps of: bending the sheet of material to at least partially define the first narrow side of the conduit body; and aligning the first portion of the outer wall with the second portion of the outer wall at the overlaps and forms an undercut at the second narrow side, the first portion of the outer wall has an end at a position along the width of the duct, and wherein the inner chamber extends from the center of the duct The inner surface extends past the location to the second narrow side.

Description of drawings

Figure 1 is a side view of a duct according to some embodiments of the invention.

FIG. 2 is an enlarged view of the end of the pipe shown in FIG. 1 .

FIG. 3 schematically illustrates a set of exemplary fabrication steps that may be used to form the tube shown in FIG. 1 .

FIG. 4 is an enlarged view of the narrow side of the duct shown in FIG. 1 .

FIG. 5 is another enlarged view of the narrow side shown in FIG. 1 .

Figure 6 is an enlarged view of the narrow side of a pipe according to another embodiment of the present invention.

Fig. 7 is an enlarged view of the narrow side of a pipe according to another embodiment of the present invention.

Figure 8 is an enlarged view of the narrow side of a pipe according to another embodiment of the invention.

Figure 9 is an enlarged view of the narrow side of a pipe according to another embodiment of the invention.

Figure 10 is an enlarged view of the narrow side of a pipe according to another embodiment of the invention.

Figure 11 is the narrow side of a pipe according to another embodiment of the invention.

Figure 12 is an enlarged view of a portion of a tube including an inner fold according to another embodiment of the present invention.

Figure 13 is an enlarged view of a portion of a tube including an inner fold according to another embodiment of the present invention.

14 is an enlarged view of a portion of a conduit including an insert according to another embodiment of the invention.

15 is an enlarged view of a portion of a conduit including an insert according to another embodiment of the invention.

Figure 16 schematically illustrates an exemplary set of manufacturing steps that may be used to form a duct comprising first and second portions formed from a common folded piece of material.

17 is an enlarged view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

18 is an enlarged view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

19 is a side view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

20 is a side view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

21 is a side view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

22 is a side view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

23 is a side view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

24 is a side view of a duct including first and second portions formed from a common folded piece of material according to another embodiment of the invention.

25 is an exploded view of a conduit including first and second sections and an insert between the first and second sections, according to some embodiments of the invention.

FIG. 26 is an exploded view of the conduit shown in FIG. 25 .

27 is an exploded view of a conduit including first and second portions and an insert between the first and second portions according to another embodiment of the present invention.

28 is a side view of a duct including first and second portions and an insert between the first and second portions according to another embodiment of the present invention.

FIG. 29 is an enlarged view of a portion of the conduit shown in FIG. 28 .

30 is a side view of a duct including first and second portions and an insert between the first and second portions according to another embodiment of the present invention.

FIG. 31 is an enlarged view of a portion of the conduit shown in FIG. 30 .

32A is a side view of a duct including first and second portions and an insert between the first and second portions according to another embodiment of the present invention.

Figure 32B is an enlarged view of a portion of the tubing shown in Figure 32A.

33 is a side view of a portion of a conduit including first and second portions and an insert between the first and second portions according to another embodiment of the present invention.

Figure 34 illustrates ten examples of conduits according to some embodiments of the invention.

Figure 35 is a side view of a conduit according to some embodiments of the invention.

36 is a side view of an inner insert for the tubing shown in FIG. 35. FIG.

FIG. 37 is a top view of the inner insert shown in FIG. 36 .

38 is a perspective view of a portion of the inner insert shown in FIG. 35. FIG.

Figure 39 is a side view of a conduit according to some embodiments of the invention.

FIG. 40 is an enlarged perspective view of an inner insert for the tubing shown in FIG. 39 .

41 is a perspective view of a portion of the inner insert shown in FIG. 40. FIG.

FIG. 42 is an enlarged perspective view of the inner insert shown in FIG. 40. FIG.

Figure 43 is a top view of a portion of an inner insert for use with tubing according to some embodiments of the invention.

Figure 44 is a side view of an insert according to an embodiment of the present invention shown within a dotted flattened duct.

Figure 45 is a side view of another insert according to an embodiment of the present invention shown within a dotted flattened duct.

Figure 46 schematically illustrates an exemplary set of fabrication steps that may be used to form tubing according to some embodiments of the present invention.

Figure 47 is a partially exploded side view of the duct shown in Figure 46.

Figure 48 schematically illustrates an exemplary set of fabrication steps that may be used to fabricate tubing according to some embodiments of the present invention.

Figure 49 is a roll forming line that may be used to manufacture tubing according to some embodiments of the present invention.

Figure 50 schematically illustrates an exemplary set of fabrication steps that may be used to form tubing according to some embodiments of the present invention.

Figure 51 schematically illustrates an exemplary set of fabrication steps that may be used to form tubing according to other embodiments of the invention.

Figure 52 schematically illustrates an exemplary set of fabrication steps that may be used to form tubing according to other embodiments of the invention.

Figure 53 schematically illustrates an exemplary set of fabrication steps that may be used to form tubing according to other embodiments of the invention.

Figure 54 schematically illustrates an exemplary set of fabrication steps that may be used to form tubing according to other embodiments of the invention.

Figure 55 illustrates an exemplary set of fabrication steps that may be used to fabricate tubing according to other embodiments of the invention.

Fig. 55A is a cross-sectional view showing a punching station of the manufacturing line shown in Fig. 55 .

Fig. 55B is a side view showing the punching station shown in Fig. 55A.

FIG. 55C is a cross-sectional view showing interrupted rolls and bars of the manufacturing line shown in FIG. 55 .

FIG. 55D is a side view showing interrupted rolls and bars of the manufacturing line shown in FIG. 55 .

Figure 56 is a side view of a portion of the punch station shown in Figure 55A.

57A is a side view showing a sheet of material advancing through a portion of the punch station shown in FIG. 55A.

57B is a top view showing a sheet of material advancing through a portion of the punching station shown in FIG. 55A.

Figure 58 is a side view showing interrupted rolls and bars of the manufacturing line shown in Figure 55

Fig. 59 is a series of schematic end views of the manufacturing line shown in Fig. 55 showing the different stages of forming the flat tube with the insert.

FIG. 60 is a schematic top view of the folding roll portion of the manufacturing line shown in FIG. 55 .

FIG. 60A is an end view of the folding roller portion shown in FIG. 60. FIG.

Figure 61 is a schematic end view of a flat tube manufacturing line with fins in accordance with an embodiment of the present invention.

Figure 62 is an exploded view of a heat exchanger including flat tubes with fins in accordance with an embodiment of the present invention.

63A-C are partial views of fin sets according to various embodiments of the invention.

64 is a schematic illustration of a finned flat tube fabrication process in accordance with an embodiment of the invention.

FIG. 65 is a perspective side view of a portion of the fabrication process shown in FIG. 64 .

Figure 66 is a detailed view of a heat exchanger including flat tubes with fins in accordance with an embodiment of the invention.

Figure 67 is a detailed view of a flat tube that may be used to make a flat tube with fins in accordance with an embodiment of the present invention.

Figure 68 is a detailed side view of a heat exchanger including flat tubes with fins according to another embodiment of the present invention.

Fig. 69 is a detailed perspective view of a portion of the heat exchanger shown in Fig. 68 .

Figure 70 is a side view of a header tank according to an embodiment of the present invention.

70A is an end view of the header tank shown in FIG. 70. FIG.

Figure 71 is a detailed view of a heat exchanger having the header tank shown in Figures 70 and 70A.

Figure 72 is a perspective view of a header tank according to an embodiment of the present invention.

Figure 73 is a detailed perspective view of the heat exchanger with header tank shown in Figure 72 .

FIG. 74 is another detailed perspective view of the heat exchanger shown in FIG. 73 .

Fig. 75 is a detailed perspective view of the header tank shown in Fig. 72 .

Figure 76 is another detailed perspective view of the heat exchanger with header tank shown in Figures 70-71.

Figure 77 is a front view of the heat exchanger shown in Figures 71 and 76 .

Figure 78 is a detailed side view of a heat exchanger with a header tank according to another embodiment of the present invention.

FIG. 79 is a detailed end view of the heat exchanger shown in FIG. 78. FIG.

Figure 80 is a detailed side view of the header tank of the heat exchanger shown in Figures 78 and 79 .

Figure 80A is an end view of the header tank shown in Figures 78-80.

Figure 81 is a detailed side view of a heat exchanger with a header tank according to another embodiment of the present invention.

Figure 82 is a detailed end view of a heat exchanger with a header tank according to another embodiment of the present invention.

Fig. 83 is a detailed side view of the header tank of the heat exchanger shown in Fig. 81 .

84 is a flowchart of a heat exchanger manufacturing process according to an embodiment of the invention.

84A is a schematic diagram of a heat exchanger fabricated according to the flow diagram of FIG. 84. FIG.

Fig. 85 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

Fig. 86 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

87 is an end view of the flat tubes of the heat exchanger shown in FIG. 86. FIG.

Fig. 88 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

Figure 89 illustrates an end view of an alternative flat tube according to the present invention.

Fig. 90 is an exploded perspective view of a heat exchanger according to another embodiment of the present invention.

Figure 91 is a view of a flattened tube according to another embodiment of the present invention shown at various stages of formation.

92-95 illustrate a method of connecting sections of a heat exchanger according to an embodiment of the invention.

Figure 96 is a graph showing silicon diffusion depth for connected heat exchangers according to some embodiments of the invention.

Detailed ways

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of parts set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "comprising", "comprising" or "having" and their equivalents herein means the inclusion of the items listed thereafter and equivalents thereof, and additional items are also included. Unless otherwise indicated or qualified, the terms "mount", "connect", "support" and "couple" and variations thereof are used in a broad manner and include direct and indirect mounting, connecting, supporting and coupling meaning. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

As described in more detail below, many embodiments of the invention involve or are based on the use of a duct having a generally flat cross-sectional shape when taken along a plane perpendicular to the longitudinal axis of the duct. In particular, each such duct can have a main dimension and a smaller subdimension perpendicular to the main dimension. These dimensions are sometimes referred to herein as "diameter," although the use of the term "diameter" is not intended to indicate or connote only circular, nearly circular, or other particular shaped features. Instead, the term "diameter" is used only to denote the largest dimension of a conduit in the direction and position indicated. Each such conduit may have two opposing walls that define the faces of the conduit (referred to herein as the "broad sides" of the conduit), and two shorter but more stable walls (referred to herein as the "broad sides" of the conduit) connecting the broad sides. "narrow side"). Together, the broad and narrow sides of the conduit define an interior space through which fluid can flow in any state including, but not limited to, gases, liquids, vapors, and any combination thereof, at any pressure or vacuum (including no pressure or vacuum).

Another feature of the flat tubes in many embodiments of the invention (described in more detail below) is the relatively small thickness of material used to construct at least some of the walls of the flat tubes. In some embodiments, the wall material of the flat tube has a thickness of no greater than about 0.20 mm (0.007874 inches). In another embodiment, the wall material of the flat tube has a thickness of not greater than about 0.15 mm (0.00590055 inches). Furthermore, by utilizing one or more of the flat tube features described herein, the inventors have discovered that significantly less material can be used to Construct a large number of different flat pipes with various characteristics for various applications. In some embodiments, a wall material thickness of not less than about 0.050 mm (i.e., not less than about 0.0019685 inches) of flat tubing provides good strength and corrosion resistance, while in other embodiments, not less than 0.030 mm may be used. (0.00118 inches) of wall material thickness for flat pipes.

As described in more detail below, the heat exchanger tubes and other parts of the heat exchanger described herein can be manufactured using a number of manufacturing techniques and processes, and can include anti-corrosion features, such as described below and in FIGS. 92-95 Those techniques and treatments are illustrated. The extensive manufacturing processes and techniques involved hereafter and the anti-corrosion features are particularly advantageous when applied to heat exchanger tubes and portions of heat exchangers with significantly reduced material thickness. Furthermore, these technical, processing and anti-corrosion features provide significant advantages related to the overall performance of flat pipes and heat exchangers made from this material.

Many embodiments of the present invention utilize flattened ducts having major and minor dimensions (denoted D and d respectively in the text below) as described above, which provide unique advantages in many applications. For example, when used in combination with the material thicknesses just described and with the other features of the flat tubes described in the various embodiments below, it is possible to manufacture flat tubes suitable for a multitude of different applications. Furthermore, the capacity of the flat pipes described herein having a major dimension D and a minor dimension d can be facilitated by using the relatively thinner wall materials described above.

For example, in some embodiments of the invention, the major dimension D (ie, the width of the flat tube in the embodiments shown herein) is not less than about 10 mm (0.39370 inches). Furthermore, in some embodiments, this major dimension D is no greater than about 300 mm (3.9370 inches). In other embodiments, the major dimension D is no greater than about 200 mm (7.87402 inches). As another example, in some embodiments of the invention, the secondary dimension d (ie, the thickness of the flattened tube in the embodiments shown herein) is not less than about 0.7 mm (0.02756 inches). Furthermore, in some embodiments, this minor dimension d is no greater than about 10 mm (0.39370 inches). In other embodiments, the minor dimension d is greater than about 7 mm (0.2756 inches). These major and minor dimensions apply to any of the flat duct embodiments described and/or illustrated herein.

In many embodiments, the major dimension D and the minor dimension d are at least partially independent in the application of flat ducts. For example, in condenser applications, in some embodiments the major diameter D of the flattened tubing is not less than about 10 mm (0.39370 inches). Additionally, the major diameter D of the flat tubes in some condenser applications is no greater than about 20 mm (0.78740 inches). Additionally, the minor diameter d of the flat tubes in some condenser applications is no greater than about 2.0 mm (0.078740 inches). As another example, in radiator applications, the major diameter D of the flat tubing is not less than about 10 mm (0.39370 inches). Additionally, the major diameter D of the flattened tubing in some radiator applications is no greater than about 200 mm (7.8740 inches). Some radiator applications for flat pipes have a minor diameter d of not less than about 0.7 mm (0.027559 inches). Additionally, the minor diameter d of the flattened tubes in some radiator applications is no greater than about 2.0 mm (0.078740 inches). As another example, in a charge air cooler application, the major diameter D of the flat duct is not less than about 20 mm (0.78740 inches). Additionally, the major diameter D of the flat ducts in some charge cooler applications is no greater than about 160 mm (6.29921 inches). Some charge air cooler applications for flat ducts have a minor diameter d of not less than about 4.0 mm (0.15748 inches). Additionally, the minor diameter d of the flattened ducts in some charge cooler applications is no greater than about 10.0 mm (0.39370 inches).

Other applications of flat pipes according to any of the embodiments described herein include oil coolers. In oil cooler applications, the major diameter D of the flat tubing is not less than about 10 mm (0.49470 inches). Additionally, the major diameter D of the flat tubing in some oil cooler applications is no greater than about 150 mm (5.90551 inches). Some oil cooler applications for flat piping have a minor diameter d of not less than about 1.5 mm (0.05906 inches). Additionally, the minor diameter d of the flattened tubing in some oil cooler applications is no greater than about 4.0 mm (0.15748 inches). As another example, in evaporator applications, the flat tubes have a major diameter D of not less than about 30 mm (1.18110 inches). Additionally, the major diameter D of the flat tubes in some evaporator applications is no greater than about 75 mm (2.95276 inches). Some evaporator applications for flat tubing have a minor diameter d of not less than about 1.0 mm (0.039370 inches). Additionally, the minor diameter d of the flattened tubes in some evaporator applications is no greater than about 2.0 mm (0.078740 inches). It should be understood that other applications of the flat ducts described and/or illustrated herein (eg, gas coolers) are possible and within the spirit and scope of the present invention.

Many of the flat tube embodiments described below are constructed of metals including aluminum (eg, aluminum or an aluminum alloy). However, many other types of metals could be used instead and still provide the strength, heat transfer and manufacturing characteristics desired for use in heat exchanger devices. In some embodiments, the metallic material of the flat tube is provided with a brazing material coating. The brazing material coating can be of many different possible thicknesses, and in some embodiments is not less than about 10% of the thickness of the flat pipe wall material for good performance results. Additionally, in some embodiments, the brazing material coating is no greater than about 30% of the thickness of the flattened conduit wall material. In other embodiments where the flat tubes are to be soldered rather than brazed, the metallic material of the flat tubes may be provided with a coating of solder material. Any of the various flat tube and heat exchanger assemblies described and/or illustrated herein may be constructed using a number of different fastening operations (brazing, welding, soldering, etc.). However, some portions of the following text refer only to brazing, although it should be understood that other types of fastening operations (including welding and soldering) could be equally applied in these embodiments.

Many of the flat duct features described above involve the use of relatively thin sheets of material to construct the duct walls. In some embodiments, the performance enhancements to the thin walled flat tubes are produced by providing either or both of the stable narrow sides with folds that are generally perpendicular or generally parallel to the broad sides of the flat tubes. Such a fold may be formed, for example, by rolling or folding adjacent longitudinal edges of the sheet metal onto or into each other. In those embodiments of the invention in which either or both of the narrow sides of the flat tube have folds that are generally parallel to the broad side of the flat tube, such folds may have the same or different lengths relative to each other. As described in more detail below, the folds at the narrow sides of the flat tubes can be formed as hooks or fit into each other—an advantageous feature in the manufacture of flat tubes and/or heat exchangers using them.

In the following embodiments, flattened tubes are disclosed having folded narrow sides, with additional folds and/or deformations formed within the flattened tubes. In the production process, the folds forming the narrow sides can be produced after such other folds and/or deformations have been produced, but other production alternatives are also possible. Furthermore, it should be noted that the folds formed within the flat tube may be multiple folds and in some embodiments are arranged tightly against or against each other.

A first embodiment of a flat duct 10 according to the invention is illustrated in Figures 1-5. The flat duct 10 is constructed with two sheet metal portions 12 , 14 shaped to define an internal flow channel 16 . Each of the two sections 12, 14 may be formed from one endless strip or reel of material passing through a production line with material cutting equipment (e.g., lasers, saws, water jets, knives, etc.) for producing the two parts. strips of material, which are then spliced together as described below. Alternatively, the two sections 12, 14 may be formed from two endless strips or reels of material passing through the production line. In either case, the production line may be equipped with nip rolls (as explained below as an example) or other sheet forming elements to form the strip, as described in more detail below. As used herein and in the appended claims, the term "endless" does not literally denote an element or product having an unlimited supply. In contrast, the term "endless" simply means receiving a component or product from some upstream batch form of a relatively large continuous supply of material (eg, a supply of coils of material).

While portions 12, 14 may have a thickness falling within any of the above ranges, portions 12, 14 in the embodiment shown in FIGS. 1-5 have a thickness of, for example, about 0.10 mm (0.0039369 inches). In some embodiments, portions 12, 14 include a material formed from aluminum or an aluminum alloy. However, other part materials (as described above) may be used instead in other embodiments. Either or both sides of the portions 12, 14 may be coated with a coating of brazing material, for example a brazing coating of about 10-30% of the thickness of the portion.

As shown in FIG. 2 , the flat tube 10 of the illustrated embodiment defines a small diameter d. Using the previously described wall thicknesses, the inventors have found that a small diameter d of at least about 0.8 mm (0.031496 inches) provides good performance results in many applications. Furthermore, using the previously described wall thicknesses, the inventors have found that a small diameter d of no greater than about 2.0 mm (0.78740 inches) provides good performance results in many applications. However, in some embodiments, a maximum minor conduit diameter d of no greater than about 1.5 mm (0.059055 inches) is used. As shown in FIG. 1 , the flattened duct 10 of the illustrated embodiment also defines a major diameter D. As shown in FIG. Using the previously described wall thicknesses, the inventors have found that a major diameter D of at least about 40 mm (1.5748 inches) provides good performance results in many applications. Furthermore, using the previously described wall thicknesses, the inventors have found that a major diameter D of no greater than about 45 mm (1.7717 inches) provides good performance results in many applications. However, the flattened pipe 10 may define a major diameter D and a minor diameter d having other dimensions based at least in part on the manufacturing process used, the intended pipe application, and/or the use of thicker or thinner wall materials, including the above Those dimensions are described with reference to all flat ducts disclosed herein. For this, sections 12, 14 with specific widths are possible and the installation of the production line can be adjusted according to the desired diameters D and d.

The flattened duct 10 in the illustrated embodiment of FIGS. 1-5 includes a first narrow side 18 , a second narrow side 20 , a first broad side 22 and a second broad side 24 . The first broadside 22 and the second broadside 24 correspond to the portions 12 and 14, respectively. Referring specifically to FIG. 1 , the first broadside 22 and the second broadside 24 define a number of folds 28 . Folds 28 extend from the first broadside 22 and the second broadside 24 to define the four flow channels 16 . In other embodiments, the flat tube 10 may include more or fewer flow channels 16 defined between the folds 28 . Although the folds 28 can extend in an uninterrupted and continuous manner along the entire length of the flat tube 10 to separate adjacent flow channels 16 from one another. However, in other embodiments, folds 28 may be interrupted or opened at one or more locations along their length to allow flow between flow channels 16 . Whether the folds 28 are continuous or discontinuous, the folds 28 are capable of strengthening the flat tube 10 against compression, and wherein the ends of the folds 28 are mounted to the ends of the wide sides 24 of the flat tube 10 by brazing or in any other suitable manner. Those embodiments enable the flattened duct 10 to be strengthened against stretching. The folds 28 may also provide a stiffening function against bending of the flat tube 10 .

Referring now to FIGS. 1 and 2 , the first broadside 22 and the second broadside 24 also define a plurality of protrusions 26 . In other embodiments, neither side 22 , 24 has the aforementioned protrusion 26 . The protrusions shown are generally bumps extending into the flow channel 16 of the flat tube 10 and can have any desired footprint, such as a circular footprint, a square, triangular or other polygonal footprint, any elongated footprint (e.g., along any length of the desired flow channel, elongated ribs running transversely to the flow channel, etc.), an irregular shaped footprint, or any other shaped footprint (eg, serpentine, zigzag, herringbone, etc.). Where used, 26 may be used to induce or suppress turbulence in the flat duct 10, thereby enhancing heat transfer at these locations. Additionally, similar to the folds 28 described above, the protrusions 26 may provide a stiffening function to help stiffen the broad sides 22 , 24 of the flat tube 10 . The protrusions 26 can be located in the flat tube 10 in any or no pattern, and in some embodiments only in specific areas of the flow channel 16 to produce the desired flow and heat transfer effects.

FIG. 3 schematically illustrates an exemplary set of manufacturing steps that can be used to form the flat tube 10 shown in FIGS. 1 , 2 , 4 and 5 . Starting with the first material portion 12 that will define the width W and the second material portion 14 that will define the smaller width w, a desired number of folding folds 28 are formed and will help define the flow channel 16 . Folds 28 are formed on both portions 12, 14 in the illustrated embodiment. In other embodiments, the fold 28 is formed on only one of the portions 12,14. Similarly, protrusions 26 are formed on both portions 12, 14 in the illustrated embodiment, although protrusions 26 are formed on only one of portions 12, 14 in other embodiments. Fold 28 and protrusion 26 are located between longitudinal edges of the material bounding portions 12, 14 (eg, longitudinal edges of a sheet of material bounding portions 12, 14).

The width W of the first portion 12 and the width w of the second portion 14 decrease during the formation of the fold 28 and the protrusion 26 in the illustrated embodiment of FIGS. 1-5 . It should be understood that other deformations may be included in the exemplary fabrication steps of FIG. 3 as desired to create other features of the flat tube 10 . Continuing with the manufacturing example of FIG. 3 , after forming the required folds 28 and protrusions 26 , an additional set of folds 30 are formed at each of the longitudinal edges of the portions 12 , 14 to define the narrow diameter of the flat tube 10 . Side 18 and 20. While the process shown in FIG. 3 may provide significant manufacturing advantages based on line setup and operation, in other embodiments either or both of the additional sets of folds 30 may be formed in comparison to folds 28 and protrusion 26 are generated earlier or at the same time. As best shown in Figures 4 and 5, the additional folds 30 of each of the portions 12, 14 cooperate with each other to distribute the first narrow side 18 and the second narrow side 20 defining the duct. With this fit between the longitudinal edges of the sections 12, 14 of the two-piece flat tubing 10, the sections 12, 14 remain together even if brazing or other fastening operations are performed on the sections 12, 14. More specifically, FIGS. 4 and 5 illustrate the situation where the fold 30 of one portion 14 defines a greater length than the fold 30 of the other portion 12 . Thus, a portion 12 of 30 may be folded about a fold of a portion 14, which is also shown in FIG. 2 .

As shown in the illustrated embodiments of FIGS. 1-5 , in some embodiments, one portion 12 is long enough to wrap around and accommodate the longitudinal edge of the other portion 14 (e.g., thereby the longitudinal edge of one portion 14 The edge nests within the folded longitudinal edge of the other part 12). In other embodiments, one section 12 is instead made only long enough to overlap the longitudinal edge of the other section. However, the above-described embodiment in relation to FIGS. 1-5 can provide significant advantages in relation to the assembly and manufacture of the flat pipe 10, including retention of the portions 12, 14 as described above, and due to the fact that they are thicker at the narrow sides 18, 20. A greater degree of reinforcement and strength of the narrow side of the material. In the illustrated embodiment of Figures 1-5, both narrow sides 18, 20 are provided with a folded configuration as best shown in Figures 2-5. However, in other embodiments, only one of the two narrow sides 18, 20 of the flattened duct 10 has any of the folded configurations described above. In such an embodiment, the connection between the two parts 12 , 14 at the other narrow side 18 , 20 can be made in any other desired manner.

6-11 illustrate alternative configurations of conduits according to other embodiments of the invention. These embodiments employ much of the same construction and share many of the same attributes as the flat duct embodiments described above in connection with Figures 1-5. Accordingly, the following description is mainly directed to structures and features that are different from the embodiments described above in connection with FIGS. 1-5 . For additional information regarding the structures and features of the embodiments of the flat ducts shown in Figures 6-11 and alternatives to these structures and features, reference should be made to the description above in connection with Figures 1-5. Structures and features of the embodiment shown in FIGS. 6-11 that correspond to those of the embodiment of FIGS. 1-5 are hereafter assigned a respective series of reference numerals (eg, 112, 212, 312, etc.). .

6-11 illustrate other configurations of narrow sides 118 , 218 , 318 , 418 , 518 , 618 and/or 120 , 220 , 320 , 420 , 520 , 620 . To simplify the description, only one of the narrow sides 118 , 218 , 318 , 418 , 518 , 618 of each duct 110 , 210 , 310 , 410 , 510 , 610 is involved here, it being understood that the other narrow sides 118 , 218 , 318, 418, 518, 618 may have the same or different structures as desired. The narrow sides 118 , 218 , 318 , 418 , 518 , 618 as shown in FIGS. 6-11 can be fabricated in steps similar to those described above with reference to FIG. 3 . Also, take into account the relatively small thickness of the material used to construct the conduit walls in some embodiments: about 0.050-0.15 mm (0.0019685-0.0059055 inches) in some embodiments, about 0.030-0.15 mm (0.00118-0.0059055 inches), and other material thickness ranges described herein, compared to conventional flat duct designs, with narrow sides 118, 218, 318, 418, 518, 618 per Each provides strength and/or stability to the conduit 110, 210, 310, 410, 510, 610.

The narrow sides 118, 218, 418 of the flattened ducts 110, 210, 310 as shown in Figures 6, 7 and 9 can be formed by folding or The rolls are bundled together to define a number of folds 130, 230, 330, 430, 530, 630 to form. It should be noted that forms referred to herein and in the appended claims as "folded" are whether they are formed by rolling or folding operations, and whether the resulting shape is nearly circular (eg, Figure 6), stacked ( eg Figures 7-9) or angled (eg Figures 10 and 11). With continued reference to Figures 6, 7 and 9, each narrow side 118, 218, 418 provides unique heat transfer, strength and stability characteristics and can be formed using different techniques. At least a portion of the folded or rolled longitudinal edge (in the case of the narrow sides 218, 418 shown in FIGS. Broad sides 122, 222, 422 and 124, 224, 424 are approximately vertical.

With reference to the narrow sides 518, 618 of the flattened ducts 510, 610 as shown in Figures 10 and 11, sections may also be formed by folding or rolling adjacent longitudinal edges of two duct sections 512, 612 and 514, 614 together The longitudinal edges of 512,612 and 514,614. Likewise, the narrow sides 518, 618 of the flat tubes 510, 610 each provide unique heat transfer, strength, and stability characteristics and can be formed using different techniques. In both cases, the longitudinal edges of the portions 512 , 612 and 514 , 614 may be folded upon themselves to define the serpentine edges of the flattened ducts 510 , 610 . While in some embodiments, the folds 530, 630 of this meandering edge may abut each other with little or no space between adjacent folds 530, 630, in some embodiments ( See Figures 10 and 11), there is a space between adjacent parts of each fold. In these embodiments, it may be based on the orientation of the folds 530, 630 (e.g., generally perpendicular to the broadsides 522, 622 and 524, 624, or at a significant angle of less than 90 degrees relative to the broadsides 522, 622 and 524, 624) The heat transfer, robustness, strength and/or size of the flat ducts 510, 610 can be selected as desired.

The illustrated embodiment of FIG. 8 provides an example of how at least a portion (in some cases, a majority of the fold 330 ) of the narrow side 318 is parallel or substantially parallel to the broad sides 322 , 324 of the flattened duct 310 . . Some or all of these folds 330 may lie flat against each other to improve heat transfer therebetween. In some embodiments, the folds 330 of the narrow side 318 may have substantially the same length L, such as where a particular flow channel shape is desired adjacent the narrow side 318 of the flattened duct 310 . However, in other embodiments, such as that shown in FIG. 8 , at least some of the narrow side folds 330 that are parallel to the broad sides 322 , 324 have a different length than the other folds. For example, folds of different sizes may define generally concave sides ( FIG. 8 ) or convex sides of adjacent flow channels 316 , such as defining a desired flow channel shape adjacent narrow sides 318 . Referring to the illustrated embodiment of FIG. 8 , the length L of each fold 330 decreases from the outside of the flat tube 310 towards the inside of the flat tube 310 (i.e., a first fold 330 that is flattened against the broad side 322 has a longer length than successive folds 330 . greater length L, and the last fold 330, which is flattened against the other broad side 324, has a greater length than the previous fold 330). In these embodiments, these shapes of the narrow side 310 can help avoid sudden temperature changes along the flat tube 310 that would otherwise lead to tube failure in many applications. As another example, folds of different sizes may define tapered narrow sides 318 that can provide an asymmetrical heat transfer path along the distance between the broad sides 322 , 324 . Other shapes of the narrow side 318 defined by differently sized folds 330 parallel to the broad sides 322, 324 are possible and within the spirit and scope of the invention.

In those embodiments in which the fold 330 of the narrow side 318 is parallel or substantially parallel to the broad sides 322, 324 of the two-piece flat tubing 310, the fold 330 formed by the first portion 312 can be aligned with the fold formed by the second portion 314. Together or in cooperation with each other (see, eg, Figure 8). As a result, the formed flat tube 310 can be held together prior to brazing or other fastening operations on the sections 312, 314, which can aid in assembling the flat tube 310 into a tube set and/or have such a flat tube 310 The assembly of the heat exchanger, which will be explained further below. It will be appreciated that similar advantages exist in the other narrow side embodiments described above with reference to Figures 6, 7 and 9-11.

wherein either or both of the narrow sides 18, 118, 218, 318, 418, 518, 618, 20, 120, 220, 320, 420, 520, 620 have folds 30, 130, 230, 330, 430, 530, 630 of those embodiments of the invention, these folds 30, 130, 230, 330 , 430 , 530 , 630 may generally provide increased stability to narrow sides 18 , 118 , 218 , 318 , 418 , 518 , 618 , 20 , 120 , 220 , 320 , 420 , 520 , 620 . A greater number of folds 30, 130, 230, 330, 430, 530, 630 at the narrow sides 18, 118, 218, 318, 418, 518, 618, 20, 120, 220, 320, 420, 520, 620 can also be used for The flat pipes 10, 110, 210, 310, 410, 510, 610 provide better protection against damage due to eg high internal pressure, impact from objects, corrosion etc. This is of particular importance when these flat tubes 10 , 110 , 210 , 310 , 410 , 510 , 610 are used in heat exchangers of motor vehicles.

Although not required in the flat duct embodiments described above, the first and/or second sections 12, 112, 212, 312, 412, 512, 612 and 14, 114, 214, 314, 414, 514, 614 may have One or Multiple folds fold 28 . In this regard, the description of these folds 28 in the illustrated embodiment of Figures 1-5 is equally applicable to the other embodiments described above. In order to simplify the description further information relating to the fold 28 will now be given with reference to the illustrated embodiment of FIGS. 12 and 13 using the reference numerals of the embodiment of FIGS. 1-5 .

In some embodiments, the inventors have disclosed that the location of the inner folds 28 can be selected to define flow channels 16 of different sizes, enabling different fluid and/or flow properties at different locations on the same flat tube 10 (e.g. , flow rate and/or direction, pressure, multiple fluid types, etc.), and can have different heat transfer patterns at different locations. Referring to the illustrated embodiment of FIG. 12 , the width or distance "a" between the inner folds 28 is defined generally parallel to the first and second broadsides 22, 24 of the flat tube 10 and based on the The width varies with the desired degree of resistance to temperature changes.

In some embodiments, such as the embodiment shown in FIG. The center gets bigger. Thus, in some embodiments the distance "a" increases from one narrow side 18, 20 in a direction towards the middle of the flat tube 10 from inner fold 28 to inner fold 28 and then along the direction towards the other narrow side. The direction of 20, 18 decreases again. In these embodiments, the cross-sectional area of each flow channel 16 formed by folds 28 increases and decreases, respectively. In some embodiments, "a" starts at a size of about 0.5 mm (0.19685 inches) at either or both narrow sides 18, 20 and increases to several millimeters.

For example, in this case, a flattened duct 10 having a width of about 42 mm (about 1.6634 inches) may include a greater number of inner folds 28 and flow channels 16 . It is contemplated that the flattened duct 10 may include a relatively wider flow channel 16 generally adjacent either or both of the narrow sides 18, 20, and a narrower flow channel 16 near the center of the flattened duct 10. . Furthermore, while in many embodiments the flow channel 16 has a width "a" of the dimensions described above, in other embodiments these widths may be significantly greater, including in the range of at least 1 cm (0.39370 inches).

In some embodiments, the flat tube 10 may include inner folds 28 immediately adjacent to each other, wherein such inner folds abut against each other immediately after forming the folds 28 or after brazing or other fastening operations on the portions 12 , 14 . or close contact. For example, a plurality of inner folds 28 may be arranged closely against each other. In either of these cases, two or more folds 28 may define a set 32 of inner folds 28 . The flat tube 10 may have any number of such sets 32 of folds 28 , such as those shown in FIG. 13 , and may have such sets alone or in combination with any number of single folds 28 . Each set 32 of inner folds 28 as shown in FIG. 13 includes three individual inner folds 28 . However, in other embodiments, two inner folds 28 may be sufficient to form group 32 and/or four or more inner folds 28 may form group 32 . Accordingly, the number of inner folds 28 forming groups 32 may be freely selected based on the desired application of the flat tube 10 and other factors. In this regard, either or both of the sections 12 , 14 of the flat tubing 10 may have fold sets 32 including any number of inner folds 28 , and combinations of sets 32 with different numbers of inner folds 28 .

The single inner folds 28 and/or groups 32 of inner folds 28 may all be located on the same portion 12 or 14 , or on both portions 12 , 14 of the flat pipe 10 , in any desired arrangement. For example, groups 32 of a plurality of inner folds 28 may be arranged symmetrically about the central position of the flat tube 10 (such as the arrangement of inner fold groups 32 shown in FIG. The same portion 12, 14 or extend from a different portion 12, 14 (eg, FIG. 13). Additionally, in some embodiments, one or more single inner folds 28 and/or groups 32 of one or more inner folds 28 on one section 12, 14 of the flat tube 10 may be nested within another section 12, 14 of the flat tube 10. Within the set 32 of the inner folds 28 on the parts 14,12.

Sets 32 of inner folds 28 as described above may be utilized to provide a flattened duct 10 with higher resistance to pressure and better load carrying capacity, and may also be used to vary the cross-section of flow passage 16 . It should be noted that the features described above in relation to the various flattened tubes 10 having various flow passages are equally applicable to embodiments in which groups 32 of inner folds 28 are utilized. Furthermore, in those embodiments where brazing is used to form the flattened tube 10, the inner folds 28 on one broadside 22, 24 (whether individually or in groups 32) may be formed with the other broadside 24, 22. Brazed joint, thereby improving the joint in the flat pipe 10.

14 and 15 illustrate other configurations of flat pipes according to other embodiments of the present invention. These embodiments employ many of the same structures and have many of the same attributes as the flat tube embodiments described above in connection with Figures 1-13. Accordingly, the following description is primarily directed to structures and features that differ from the embodiments described above in connection with FIGS. 1-13 . For additional information regarding the structures and features of the flat tubes shown in Figures 14 and 15, and alternatives to these structures and features, reference is made to the description above in connection with Figures 1-13. Hereinafter, structure and features of the embodiment shown in Figures 14 and 15 corresponding to those of the embodiment of Figures 1-13 will be assigned reference numerals in the 700 and 800 series, respectively.

Each of the above flat pipes 10, 110, 210, 310, 410, 510, 610 shown in FIGS. , 14, 114, 214, 314, 414, 514, 614 the inner wall defined by the inner fold 28. However, the walls at least partially defining the flow channel 16, 116, 216, 316, 416, 516, 616 may be connected to the first and second portions 12, 112, 212, 312, 412, 512, 612, 14 , 114, 214, 314, 414, 514, 614 in any one part or two parts of the separate material part to define. While this differs from the flattened ducts 10, 110, 210, 310, 410, 510, 610 described above, such alternative flattened ducts can have any of the constructional features (e.g., outer wall thickness and material, pipe diameter, inner wall shape, location, spacing, and grouping, and narrow side configuration).

For example, the flat ducts 710, 810 shown in Figures 14 and 15 each use two sections 712, 714 and 821, 814, respectively, between which are arranged an insert bounded by another material section 734, 834. In both cases, the insert 734 , 834 has a corrugated shape whereby the corrugations of the insert 734 , 834 can form the flow channels 716 , 816 within the flat tube 710 , 810 . Either or both of the narrow sides 718, 720 and 818, 820 of the flat ducts 710, 810 (Figs. The edges of 714 and 821 , 814 are co-folded with the edges of insert 734 , 834 to join a portion of insert 734 , 834 . For example, in some embodiments, the flattened duct 710 has serpentine narrow sides 718, 720 as shown in FIG. Folds within the longitudinal sides of the first and second portions 712,714. In other embodiments, the narrow sides 818, 820 of the flat tube 810 are folded tightly against each other as shown in FIG. together and fold within the longitudinal sides of the first and second portions 812,814. In other embodiments, the longitudinal edges of the insert may be rolled into these portions of the first and second sections in any of the narrow side configurations shown in FIG. 6 - flat tube 10 .

The embodiments of the invention described above each utilize two separate bodies of material to define the first and second portions 12, 112, 212, 12, 112, 212, 312, 412, 512, 612, 712, 812 and 14, 114, 214, 314, 514, 614, 714, 814. While this duct construction has unique advantages, including part-to-part mating features and manufacturing advantages, the flat ducts of the present invention may also be formed from one piece, such as a single or undivided strip of endless sheet metal. By deforming the individual components, individual components without longitudinal edges may be placed together and joined by brazing, welding or other fastening operations. In other words, some embodiments of flat ducts according to the present invention may be formed from one piece (eg, a strip of sheet metal) while still defining two stable narrow sides. Various embodiments of such a one-part flat duct are described in detail below. In addition to those features of the following one-piece flat pipe that are different or incompatible with the features of the pipe described above with reference to the two-piece embodiment of FIGS. Any of the construction features described in 1-15 (eg, outer wall thickness and material, tubing material, inner wall shape, location, spacing, and grouping, and narrow side configuration).

The one-piece tubing described below has improved thermal performance over conventional flat tubing based at least on the ability to employ relatively thinner tubing wall materials. Furthermore, the assembly of the flat tubes in the heat exchanger can be simplified.

Similar to the two-piece flat tubing described above, the folds formed at the narrow side of the one-piece flat tubing described below may be generally perpendicular or generally parallel to the broad side. For example, the first narrow side of the flat tube may be formed from a continuous section of a single metal sheet and may comprise a plurality of folded groups. In some embodiments, these folds can define multiple lengths (eg, similar to those embodiments described above in connection with FIG. 8 ), which can help avoid crack formation due to thermal fatigue. The second narrow side of the flattened duct may be formed from a single sheet of material without longitudinal edges and may also have a plurality of folds. Although the sheet metal thickness is 0.05-0.15 mm (0.0019685-0.00591 inches) in some embodiments, and 0.03-0.15 mm (0.00118-0.00591 inches) in other embodiments, the single piece of material forming the second narrow side The longitudinal edges may be joined by brazing, welding or other fastening operations. Also similar to the two-piece flat tubing described above, one-piece flat tubing may include inward folds and other deformations (e.g., inwardly pointing flanges, ribs, or unnecessary other protrusions spanning the interior of flat ducts). The inner folds can form flow channels within the flat tube and can be arranged in any of the ways described above with reference to the two-piece flat tube. By way of example only, the inner folds may be grouped, may be at specific pitches along the width of the flat tube, may or may not be variable, and may increase in a direction from either or both of the narrow sides towards the middle of the flat tube. big. As a result of this fold-in and fold-in arrangement, the resistance of the one-piece flat pipe to higher temperature-varying loads can be significantly increased.

Examples of one-piece flat tubing having some of these features are shown in FIGS. 16-24 , each having first and second portions 912 formed from a common body of material folded into the shape shown. , 914, 1012, 1014, 1112, 1114, 1212, 1214, 1312, 1314, 1412, 1414, 1512, 1514, 1612, 1614, 1712, 1714. The first and second portions 912, 914, 1012, 1014, 1112, 1114, 1212, 1214, 1312 shown , 1314, 1412, 1414, 1512, 1514, 1612, 1614, 1712, 1714 are formed from a strip of aluminum or aluminum alloy sheet metal having a thickness of approximately 0.10 mm (0.003937 inches). Any of the flat tubes 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 may have a coating of brazing material on either or both sides, wherein each layer of brazing material is coated The layer may have a thickness of about 10-20% of the thickness of the sheet metal strip.

Utilizing the aforementioned wall thicknesses, the inventors have found that a small diameter d of at least 0.8 mm (0.031496 inches) for the flattened ducts 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 shown provides in many applications good performance results. Also utilizing the aforementioned wall thicknesses, the present inventors have found that a minor diameter d of no greater than about 2.0 mm (0.07874 inches) for the flattened ducts 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 shown in many implementations The example provides good performance results. However, in some embodiments, a maximum minor diameter d of no greater than about 1.5 mm (0.059055 inches) for the flattened tubes 910 , 1010 , 1110 , 1210 , 1310 , 1410 , 1510 , 1610 , 1710 shown is used. Furthermore, the major diameter D for any of the flat tubes 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710 is generally freely selectable within certain manufacturing constraints. In some embodiments, major diameter D is about 50 mm (1.969 inches), as one example. However, one-piece flat tubes 910, 1010, 1210, 1310, 1410, 1510 can also be manufactured with larger or smaller diameters D, d, including those described above for all flat tube embodiments disclosed herein. , 1610, 1710, in these cases, the initial width W of the material used to form the flat tubes 910, 1010, 1210, 1310, 1410, 1510, 1610, 1710 (eg, see FIG. 16 ) may be available on the production line.

As noted above, the various types of narrow side folds and inner folds described in connection with the embodiment of FIGS. 1-15 may be employed in the one-piece tubing described herein. In some one-piece duct embodiments, such as those shown in FIGS. 19-24 , the narrow sides 1218 , 1220 , 1318 , 1320 , 1418, 1420, 1518, 1520, 1618, 1620, 1718, 1720 may include a plurality of folds 1230, 1330, 1430, 1530, 1630, 1730 that can provide a relatively more stable and stronger narrow side of the tube 1218, 1220, 1318, 1320, 1418, 1420, 1518, 1520, 1618, 1620, 1718, 1720. As a result, the relatively more stable narrow sides 1218, 1220, 1318, 1320, 1418, 1420, 1518, 1520, 1618, 1620, 1718, 1720 can provide greater stability to the , 1710 provides adequate protection against damage due to temperature and/or pressure fatigue, impact from objects and corrosion, etc., thereby providing better performance when used in heat exchangers for, for example, motor vehicles.

Referring now to FIG. 16 , an example of the manner in which a one-piece conduit 910 may be manufactured is shown. Specifically, FIG. 16 illustrates at least a portion of the manufacturing process for forming a one-piece flat tubing 910 . Single and/or multiple folds are made in the initial sheet of material that will at least partially define the inner fold 928 of the flattened duct 910 and the flow channel 916 within the flattened duct 910 . In some embodiments, the initial sheet of material is an endless sheet, such as a sheet of material supplied from a coil of material upstream of the manufacturing element used to create the fold. At the same or a different time, an additional fold is created that will at least partially define the fold at the narrow side 920 of the flattened tube 910 . For example, a group 932 of a plurality of folds 930 is created at or near the middle of a one-piece metal strip as shown in FIG. Folding the metal strip defines narrow sides 920 . As a result of this folding, indicated by the arrows, first and second broad sides 912, 914 of the flattened duct 910 are defined. The other narrow side 918 and the fold 930 of the other narrow side 918 may take the form shown in FIGS. Any of the forms described and/or shown on the narrow side. Figure 17 and first narrow side 18 illustrate features of an alternative one-piece flat duct construction (narrow side not shown) that could be employed. More specifically, FIG. 17 provides how a single inner fold 1028 and a set 1032 of multiple inner folds 1028 on either or both sides of the broadsides 1022, 1024 can be utilized in the same one-piece flat duct 1010 to Examples of flow channels 1016 defining the same or different dimensions. Figure first narrow side 18 provides how to create a plurality of individual inner folds 1128 at specific locations on either or both sides of wide sides 1122, 1124 to define cross-sectional dimension variations (e.g., cross-sectional dimension along a piece An example of the flow channel 1116 of the type flat pipe 1110 gradually increasing in the width direction).

19-24 illustrate other examples of one-piece flat tubing 1210, 1310, 1410, 1510, 1610 according to other embodiments of the invention. Similar to the one-piece duct embodiment shown in FIG. 16 - first narrow side 18, the one-piece flat ducts 1210, 1310, 1410, 1510, 1610 shown in FIGS. 19-24 each have individual and/or Or inner folds 1228 , 1328 , 1428 , 1528 , 1628 , 1728 arranged in groups to define flow channels 1216 , 1316 , 1416 , 1516 , 1616 , 1716 . In some cases, based on one or more factors (e.g., single or multiple fluids passing through conduits 1210, 1310, 1410, 1510, 1610, 1710, expected temperature, thermal stress, and different fractions of conduit width and/or length exposure to thermal cycles, internal fluid pressure, etc.) to determine individual inner folds 1228, 1328, 1428, 1528, 1628, 1728 and/or groups 1232, 1332, 1532 of such inner folds 1228, 1328, 1428, 1528 layout.

Referring specifically to FIG. 19 , a plurality of inner folds 1228 near the center of the flattened tubing 1210 define a material thickness four times the material thickness of the unfolded tubing (i.e., two folds arranged in close proximity to each other or immediately adjacent (e.g., in an abutting manner)). single fold 1228). A one-piece flat tube 1210 as shown in FIG. 19 has two such sets 1232 of inner folds 1218 , each set being formed in a different broadside 1222 , 1224 of the flat tube 1210 . In the embodiment of FIG. 20 , four sets 1332 of the plurality of inner folds 1328 each define a material thickness six times the thickness of the unfolded tubing material (i.e., are closely or immediately adjacent to each other (e.g., in an abutting manner). ) arrangement of three single folds 1228). Inner folds 1228 in the embodiment of FIG. 20 are positioned to define flow channels 1316 of varying dimensions, unlike those of FIG. 19 which are generally of the same size. It should be understood that any other number of inner folds 1228, 1328, with or without additional individual inner folds 1228, 1328 (i.e., inner folds 1228, 1328 not in groups 1232, 1332 as also shown in FIGS. 19 and 20 ) The fold sets 1232, 1332 may be provided on either or both of the broad sides 1222, 1224, 1322, 1324 of the one-piece flat duct 1210, 1310 as shown in FIGS. 19 and 20 .

The embodiments of Figures 21, 22 and 23 provide examples of one-piece flat tubing 1410, 1510, 1610 in which only a single fold 1428, 1528, 1628 is used to form the flow channels 1416, 1516, 1616. For example, the inner folds 1428, 1528 of the one-piece flat tubes 1410, 1510 as shown in FIGS. ), which are different from those flow channels of FIG. 23 (except for a slightly larger flow channel 1616 immediately adjacent to either or both of the narrow sides 1618, 1620) which have substantially the same dimensions. It should be noted that the inner folds 1228 , 1328 , 1428 , 1528 , 1628 , 1728 of any of the one-piece flat ducts 1210 , 1310 , 1410 , 1510 , 1610 , 1710 shown in FIG. The flow channels 1216, 1316, 1416, 1516, 1616, 1716 may be positioned to define the same or different sizes, and the width of the flow channels 1216, 1316, 1416, 1516, 1616, 1716 may be along a majority or All taper or taper towards the center of the flat tube 1210, 1310, 1410, 1510, 1610, 1710 in the same direction, or could be any other way. Additionally, other configurations of the flat tubes 1210, 1310, 1410, 1510, 1610, 1710 may include different numbers of single folds 1228, 1328, 1428, 1528, 1628, 1728 and multiple inner folds 1228, 1328, 1428, 1528 as desired , 1628, 1728 groups.

Continuing with reference to the one-piece flat duct embodiments shown in FIGS. One narrow side 1220, 1320, 1420, 1520, 1620, 1720 defined by the continuous folded portion of the sheet of material 1710, and the two free longitudinal edges of the sheet of material are joined together and folded so that the flattened ducts 1210, 1310, 1410, Opposite narrow sides 1218 , 1318 , 1418 , 1518 , 1618 , 1718 of closures 1510 , 1610 , 1710 . The relatively narrow sides 1218, 1318, 1418, 1518, 1618, 1718 and the folding 1230, 1330, 1430, 1530, 1630, 1730 of the relatively narrow sides 1218, 1318, 1418, 1518, 1618, 1718 can be taken as shown in Figures 19-24 The form shown or any of the forms described and/or shown above in connection with the narrow side of the two-piece flat duct 10 , 110 , 210 , 310 , 410 , 510 , 610 , 710 , 810 .

For the narrow sides 1220, 1320, 1420, 1520, 1620, 1720 formed by successive folded sections as described above, the narrow sides may take any shape as shown in Figs. 19-24. However, this same narrow side 1220 , 1320 , 1420 , 1520 , 1620 , 1720 may also take the form described and and/or any of the shapes shown, in these cases the first and second portions 12, 14, 112, 114 of the flat duct 10, 110, 210, 310, 410, 510, 610, 710, 810 , 212, 214, 312, 314, 412, 414, 512, 514, 612, 614, 712, 714, 812, 814 at the ends of the narrow side 18, 218, 318, 418, 518, 618, 718 will be joined Part of the same continuous piece of material. Thus, the unique advantages of each of the narrow side forms described above in conjunction with FIGS. Either or both of the narrow sides 1218, 1318, 1418, 1518, 1618, 1718 are true.

Referring specifically to the illustrated embodiment of FIG. 19 , a one-piece flat tubing 1210 is shown having narrow sides 1218 , 1220 with folds 1230 disposed generally perpendicular to the broad sides 1222 , 1224 of the flat tubing 1210 . The plurality of folds 1230 forming the narrow sides 1218, 1220 differ from each other in that the fold 1230 forming the second narrow side 1220 is formed from a continuous portion of the one-piece material strip used to produce the flat duct 1210, while the fold 1230 forming the first narrow side Fold 1230 of 1218 is formed by the two longitudinal edges of the one-piece strip of material. However, in other embodiments, the flat tube 1210 may instead have first and second narrow sides 1218 , 1220 with folds 1230 generally parallel to the broad sides 1222 , 1224 of the flat tube 1210 .

The one-piece flat tubing 1310 as shown in FIG. 20 also has a second narrow side 1320 whose folds are generally perpendicular to the broad sides 1322, 1324 of the flat tubing 1310, while the second narrow side 1318 has what is known as being generally parallel to A plurality of folds 1330 of the broad sides 1322 , 1324 of the flattened tubing 1310 . However, in other embodiments, 1310 may instead have first narrow side 1318 with fold 1330 generally perpendicular to broad sides 1322 , 1324 , and narrow side 1320 with fold 1330 generally parallel to broad sides 1322 , 1324 .

The one-piece flat tubing 1410 as shown in FIG. 21 has first and second narrow sides 1418 , 1420 with a plurality of folds 1430 generally parallel to the broad sides 1422 , 1420 of the flat tubing 1410 . In other embodiments, the plurality of folds 1430 on either or both of the narrow sides 1418 , 1420 are instead generally perpendicular to the broad sides 1422 , 1424 of the flattened duct 1410 . Although each of the plurality of folds 1430 at both sides of the narrow sides 1418, 1420 as shown in FIG. Different lengths L (see, eg, Figures 22 and 23). In these embodiments, the varying lengths of the narrow sides 1518, 1520, 1618 may take any of the forms described above in connection with the embodiment of Fig. 8, and thus may have any of the advantages described therein. Referring to the embodiment of FIGS. 22 and 23 , the illustrated folds 1530 , 1630 of varying lengths on the narrow sides 1518 , 1520 , 1630 (i.e., shorter folds 1530 , 1630 flanked by longer folds 1530 , 1630 ) can generally be made between Effective for supporting loads subject to temperature changes. Furthermore, this arrangement can be utilized to avoid sudden changes in pressure from the narrow sides 1518 , 1520 , 1618 to the broad sides 1522 , 1524 , 1622 , 1624 . Additionally, one or more sets of multiple folds 1528 (such as a single set as shown in FIG. 23 ) and/or a relatively large number of flow channels may be utilized for other one-piece flat tubing embodiments described herein. 1616 (such as those shown in Figure 23) to help support temperature changing loads and to help withstand sudden changes in pressure. Other means aimed at increasing resistance to temperature changing loads is to vary the distance "a" between the folds to define a flow channel 1516 that widens towards the center of the flat tube 1510 .

Figure 24 shows that any of the narrow side configurations shown in the two-piece flat ducts of Figures 6-11, 14 and 15 can be in the narrow side of a one-piece flat duct with a continuous sheet of material as described above An example of the approach taken. In addition to abutting adjacent folds 1730 and bounding a single continuous sheet of material 1730 rather than two superimposed sheets of material (or two superimposed portions of the same sheet of material), the narrow sides as shown in FIG. 24 1718 is similar in many respects to the narrow side of FIG. 11 as described above. In this particular example, the distance "a" between the fold 1730 and the first inner fold 1728, and between the other inner folds 1728, is relatively small, and in some embodiments can range from 0.5 mm (0.019685 inches) to 2mm (0.07874 inches) or greater (even as large as 1cm (2.54 inches)). Additionally, in some embodiments, this flattened duct 1610 has a width of about 42 mm (0.16535 inches) allowing for multiple folds 1728 and flow channels 1716 .

Flat tubing according to some embodiments of the invention may include an inner insert that provides reinforcement to at least one of the narrow sides of the flat tubing, while also performing one or more other functions (e.g., reinforcing the broad side of the tubing). , define a plurality of flow channels that are in fluid communication or not with each other, define flow disruptors, etc.). The insert may be defined at the time of manufacture of the flat pipe by separate material portions connected to one or more sheets of material delimiting the outer pipe wall and may be used in addition to or instead of the inner fold as described in many of the above embodiments Fold inside. An example of this insert has been provided in connection with the illustrated embodiment of FIGS. 14 and 15 .

While inserts (described in more detail below) may be employed with one-piece flat ducts according to some embodiments of the present invention, a number of unique advantages are obtained by using inserts in two-piece flat ducts. In some embodiments, these advantages are achieved using an insert in a two-piece flat duct constructed from sheet material having a relatively small thickness. In some embodiments, the wall material of the flat tube has a thickness of no greater than 0.20 mm (0.007874 inches). In other embodiments, however, the inventors have found that having a wall material of flat tubing having a thickness of no greater than about) 0.15 mm (0.0059055 inches) provides integrity with the heat exchanger, manufacturability, and stability when thicker walls cannot be used. Significant performance consequences related to the possible wall configuration of the material (as disclosed herein). A relatively small wall material thickness can lead to good thermal properties of the two-part flat pipe with the insert. In some embodiments, such flat pipe wall material thicknesses of not less than about 0.050 mm (i.e., not less than about 0.0019685 inches) provide good strength and corrosion resistance, while in other embodiments, such The wall material thickness of the flat pipe is not less than about 0.030 mm (ie, not less than about 0.00118 inches). Additionally, the two-piece flat tubing with inserts described below has similar dimensions to the two-piece flat tubing described above in connection with Figures 1-15.

As explained in more detail below, the heat exchanger tubes and other parts of the heat exchangers described herein can be fabricated using a number of fabrication techniques and processes, and can include corrosion protection features, such as those described below and in FIGS. 92-95 those techniques and treatments shown. Many of the manufacturing processes and techniques and corrosion protection features involved hereafter are particularly advantageous when applied to heat exchanger tubing and portions of the heat exchanger with relatively reduced material thickness. Furthermore, these technical, processing and corrosion protection features provide significant advantages related to the overall performance of the flat tubes and heat exchangers supported by these materials.

25-34 illustrate various two-piece flat tubing 1810, 1810A, 1910, 2010, 2110, 2210, 2310, 2410, 2510, 2610, 2710, 2810, 2910, 3010, 3110, 3210, each of which Including first part 1812, 1812A, 1912, 2012, 2112, 2212, 2312, 2412, 2512, 2612, 2712, 2812, 2912, 3012, 3112, 3212, second part 1814, 1814A, 1914, 2014, 2114, 2214, 2314, 2414, 2514, 2614, 2714, 2814, 2914, 3014, 3114, 3214, and inserts 1834, 1834A, 1934, 2034, 2134, 2234, 2334, 2434, 2534, 2634, 2734, 2834, 2934, 3034 , 3134, 3234, all of which may be constructed from sheets of material such as metal strips or other materials. For simplicity of description, the following description only refers to the illustrated embodiments of FIGS. 25 and 26 , and it is understood that the following descriptions are equally applicable to all the embodiments shown in FIGS. 25-34 (excluding different or incompatible descriptions).

In some embodiments of the two-piece flat tubing 1810 as shown in FIGS. 25 and 26, the first and second portions 1812, 1814 and the insert 1834 may be made of a material having a relatively small sheet thickness (e.g., aluminum, an aluminum alloy). or other materials described herein). For example, the inventors have found that material thicknesses for these elements of no greater than about 0.15 mm (0.0098245 inches) provide good performance results in many applications. In some embodiments, the material used for these elements may also have a thickness of no less than about 0.03 mm (0.0011811 inches). In many embodiments, it is preferable to use a relatively smaller sheet thickness for the insert 1834 than for the first and second portions 1812 , 1814 of the two-piece flattened duct 1810 . Despite the relatively small sheet thickness, the narrow sides 1818, 1820 of the two-piece flat duct 1810 may have relatively increased stability, especially when combined with the features of the two-piece flat duct 1710 described below.

In the illustrated embodiment of Figures 25 and 26, each broadside 1822, 1824 of the flattened duct 1810 is formed from a separate portion of material (eg, a separate strip). The material portions overlap in two locations to define two longitudinal undercuts 1844,1846. Unlike other illustrated embodiments in which longitudinal undercuts extend from respective narrow sides 1818, 1820 of the flat duct 1810 to the same broad side (eg, see FIG. 27 described in more detail below), these two-piece flat duct 1810 Longitudinal undercuts 1844 , 1846 extend from respective narrow sides 1818 , 1820 of flattened duct 1810 to opposing broad sides 1822 , 1824 . In the illustrated embodiment of FIGS. 25 and 26 , the longitudinal undercuts 1844 , 1846 are both located at and extend from the respective narrow sides 1818 , 1820 of the flat tube 1810 to the wide side 1822 of the flat tube 1810 . , 1824. More specifically, the longitudinal undercuts 1844, 1846, those portions of the flattened duct 1810 where the sheets of material of the flattened duct 1810 overlap, extend at least a portion (and in some embodiments a substantial portion) of the narrow sides 1818, 1820. or all), and partially extend to the respective wide sides 1822, 1824 of the flattened duct 1810. The width of the undercuts 1844, 1846 can be determined according to the desired manufacturing purpose.

In some embodiments, the longitudinal undercuts 1844, 1846 of the flattened duct 1810 present a straight or generally straight outer surface of the flattened duct 1810 (eg, provide generally flat broad sides 1822, 1824 of the flattened duct 1810). To this end, the longitudinal edge of each undercut 1844 , 1846 which overlaps the other longitudinal edge may be recessed by forming the overlapping edge with an offset 1848 , 1850 . Accordingly, the longitudinal edges of one duct portion 1812 , 1814 may be surrounded by corresponding longitudinal edges of the other duct portion 1814 , 1812 and received in the recesses 1848 , 1850 to define longitudinal undercuts 1844 , 1846 . Thus, for both undercuts 1844, 1846, the inner longitudinal edges of the two superimposed portions 1812, 1814 may terminate inside the flat tube 1810 and may be free prior to brazing, welding, or other fastening techniques. of. As a result of this construction, despite the loose tolerances maintained for the width of the initial material of each duct section 1812, 1814 (this is because the overlapping longitudinal undercuts 1844, 1846 allow the first and second duct sections 1812, 1814 to The flattened duct 1810 can still be manufactured to a precise width (in some embodiments, even without cutting or other machining operations) without relative lateral positioning adjustments. Specifically, in some embodiments, the terminal longitudinal edge 1854, 1856 of each duct section 1812, 1814 does not abut the other duct section 1812, 1814, thereby allowing such adjustment.

The use of overlapping longitudinal undercuts such as that shown in the embodiments of Figures 25 and 26 provides reinforcement to the flattened duct 1810 at the first and second narrow sides 1818, 1820, which in conventional flattened ducts is subject to thermal stress, temperature variations This is important in many applications where pressure loads and failures due to pressure loads and debris impact are common. In some embodiments, support for the first and/or second duct sections 1812, 18114 is provided by one or more folds at the narrow sides 1818, 1820 (eg, at the longitudinal edges of these sections 1812, 1814). and/or further reinforcement of the second narrow side 1818,1820. In general, folding the longitudinal edges of the first and/or second duct sections 1812, 1814 can increase the strength of the flat duct 1810 and the resistance of the flat duct 1810 to damage. wherein the narrow sides 1818, 1820 are at least partially defined by overlapping (one extending around the other, receiving the other, or surrounding the other) the longitudinal edges of the first and second duct portions 1812, 1814 In those embodiments, one or both of the overlapping longitudinal edges (eg, the surrounding and surrounding edges) may be folded back to increase the thickness of the edge at the narrow sides 1818 , 1820 .

For example, it is contemplated that either or both of the overlapping longitudinal edges of the duct portions 1812, 1814 at either or both of the narrow sides 1818, 1820 may include corresponding steps 1858, 1860 (described in more detail below). ) adjacent folds. For example, in some embodiments, either or both of the overlapping longitudinal edges have at least one fold to thicken the narrow sides 1818, 1820 and the material thickness of the insert 1834 is about 0.10 mm (0.003937 mm) or In smaller cases, the sum of the thicknesses of the first and second conduit portions 1818, 1820 may be about 0.25 mm (0.0098425 inches) or less in some embodiments. In these embodiments, the thickness of the first and second conduit portions 1818, 1820 can each be in the range of 0.05-0.15 mm (0.0019685-0.0059055 inches), and in other embodiments can be 0.03-0.15 mm (0.0019685 inches). -0.0059055 inches).

It should also be noted that the stacked longitudinal undercut configuration of the two-piece flat tubes shown in Figures 25 and 26 can also be used in flat tube embodiments without an inner insert. For example, such longitudinal undercut configurations may be employed in two-piece flat tubing having inner folds such as those described above in connection with the embodiments of FIGS. 1-13 and 16-24, or in other two-piece flat tubing.

Although not required, in many embodiments the conduit sections (eg, conduit sections 1812, 1814 in Figures 25 and 26) have substantially the same shape, and may even be uniform. When assembled as described above, the duct sections 1812, 1814 are arranged with their longitudinal edges inverted relative to each other. For example, one longitudinal edge of one of the two duct sections 1812, 1814 includes a step 1856, 1860 defining the recess 48, 50 as described above, and then a section defining the arch 1862, 1864, while the other duct section The respective longitudinal edges of 1814, 1812 include portions with larger arches 1866, 1868 that receive smaller arches 1862, 1864. Thus, in the illustrated embodiment of FIGS. 25 and 26, as part of the manufacturing process of the two-piece flat duct 1810, a smaller mutual portion 1862, 1864 and a larger arched portion 1866, 1868 form a narrow One of side 1818, 1820. It should be understood that the term "arched" as used herein and in the appended claims is not limited to semicircular shapes. Furthermore, the term "arched" as used herein and in the appended claims includes any suitable geometric shape for forming the narrow sides 1818, 1820, which may include square, triangular or other open polygonal, wavy and other forms.

By employing pipe sections having substantially the same shape or conformance, fewer part types (and in some cases, a single part type) can be used to construct the two-piece flat pipe 1810, which results in reduced inventory, simpler assembly as well as significant cost reductions.

Inner insert 1834, partially shown in FIG. 25 and fully shown in FIG. within each narrow side 1818, 1820 of the . In some embodiments, the longitudinal edges 1838 , 1840 are shaped for this purpose such that the longitudinal edges 1838 , 1840 can be received within the inner shape of the narrow sides 1818 , 1820 . Also in some embodiments, at least a portion of either or both of the longitudinal edges 1838 , 1840 has a shape that corresponds to the shape of the narrow sides 1818 , 1820 . For example, either or both of the longitudinal edges 1838 , 1840 may be formed in the shape of the ring 1842 such that at least a portion of the ring 1842 matches the shape of the corresponding narrow side 1818 , 1820 of the flattened duct 1810 . In some embodiments, this correspondence of shapes may result in reinforcement of the flattened ducts at the narrow sides 1818,1820. Further reinforcement may be obtained by joining either or both of the longitudinal edges 1838, 1840 to the narrow sides 1818, 1820 via, for example, brazing, welding, or in any other suitable manner.

Referring to FIG. 26 , which illustrates the manner in which the two-piece flat tubing 1810 can be assembled, the inner insert 1834 is shown received in the first and second tubing sections 1812, 1814 when the first and second tubing sections 1812, 1814 are brought together during assembly. Within the arcuate portions 1862 , 1864 of the second duct portions 1812 , 1814 . More specifically, the longitudinal edges 1838, 1840 of the inner insert 1834 are supported by the arcuate portions 1862, 1864 of the first and second duct sections 1812, 1814 and lie within narrow sides 1818, 1820 of the flattened duct 1810, which are hereafter defined , thereby providing reinforcement to the narrow sides 1818, 1820 once assembled. The resulting two-piece flat tubing 1810 has double wall thickness on the narrow sides 1818, 1820 due to overlapping longitudinal undercuts 1844, 1846 extending through and beyond the narrow sides 1818, 1820, and also has a The additional thickness is defined by the thickness of the nested longitudinal edges 1838, 1840. For example, in some cases, two-piece flat tubing 1810 includes first and second tubing sections 1812, 1814 that together define a wall thickness of about 0.20 mm (0.007874 inches) to help prevent corrosion or deterioration, and/or provide Provides resistance to debris impact, pressure and temperature shifting loads.

As explained in more detail below, the heat exchanger tubes described herein and other portions of the heat exchanger tubes can be manufactured using a number of manufacturing techniques and processes, and can include anti-corrosion features, such as those described and described below in FIGS. 92-95 . those manufacturing processes and techniques shown. Many of the manufacturing processes and techniques and corrosion protection features referred to herein are particularly advantageous when applied to heat exchanger tubing and components of the heat exchanger having reduced material thickness. Furthermore, these technical, processing and anti-corrosion features provide significant advantages related to the overall performance of flat pipes and heat exchangers made from these materials.

The inner insert 1834 illustrated in the embodiment of FIGS. 25 and 26 has a number of corrugations 1852 across the width of the flat tube 1810 . These corrugations 1852 may connect inside the broad sides 1822 , 1824 of the first and second duct portions 1812 , 1814 to form flow channels 1816 extending in the longitudinal direction of the flattened duct 1810 . By utilizing this arrangement, a flow channel 1816 can be defined within the flat tube 1810 in a cost-effective manner. Although the inner insert 1834 has a smaller wall thickness (which may be the same as or less than the aforementioned wall thicknesses of the first and second conduit sections 1812, 1814), the flow channels 1816 formed in the two-piece flat conduit 1810 may be relatively The internal pressure of the flat tube 1810 provides increased stability.

The hydraulic diameter 1816 of the flow channel 1816 may be determined by suitable design of the corrugations 1852 as described above. For example, in some embodiments, the hydraulic diameter of flow channel 1816 is relatively small considering that the minor diameter d of two-piece flat tubing 1810 may be about 0.8 mm (0.31496 inches) and the number of corrugations 1852 is relatively large.

In some embodiments, at least some of the corrugations 1852 are formed to have one corrugation side perpendicular or generally perpendicular to the broad sides 1822, 1824 of the two-piece flat duct 1810, and an angled Adjacent corrugation sides (eg, see central corrugation 1852 as shown in FIG. 25). In other embodiments, at least some of the corrugations 1852 are shaped so that each has two corrugation sides that are generally inclined relative to the broad sides 1822, 1824 (see, eg, left corrugation 1852 as shown in FIG. 25). In other embodiments, at least a portion of the corrugations 1852 are formed with two corrugation sides perpendicular or generally perpendicular to the broad sides 1822 , 1824 of the two-piece flat duct 1810 .

An example of such an embodiment is shown in Figure 33, which illustrates a two-piece flat tube 2210 that is generally identical to that of Figures 25 and 26 except for the shape of the insert. Similar to the embodiment of FIGS. 25 and 26, the insert 2234 as shown in FIG. 2238, 2240 to provide reinforcement to the narrow sides 2218, 2220. In other embodiments, only one of the longitudinal edges 2238 , 2240 of the insert 2234 extends into the respective narrow side 2218 , 2220 . It should be noted that the two-piece flat duct as shown in FIG. 33 may have any of the same features described herein in connection with the embodiment of FIGS. 25 and 26 . In other embodiments, at least some of the corrugations 1852 may define a curvilinear waveform (eg, a sine wave) or any other contoured surface where the same or different across the width of the two-piece flat tubing 1810 .

In some embodiments, insert 1834 defines a number of flow channels 1816 of the same shape and size across the width of flattened duct 1810 . In other embodiments, the insert 1834 can be shaped such that the shape and/or size of the flow channel 1816 varies across the width of the two-piece flat tube 1810 (eg, by using differences in the width of the two-piece flat tube 1810 ). Insert 1834 with a different type of corrugation 1852 at the location. An example of this is shown in Figure 25, where both types of corrugations described above are used for the insert 1834 shown. In other embodiments, any number of different corrugation shapes and sizes across the width of the two-piece flat tubing 1810 may be used. This variation in width is achieved by using different portions of the flat duct 1810 for different flow and/or environmental conditions (e.g., different fluid or flow directions through different regions of the same flat duct 1810, over the width of the flat duct 1810). Different internal or external flow rates, temperatures and/or pressures, etc. at different locations of the tubes, can provide significant advantages over traditional flat pipes.

The inner insert 1834 as shown in Figures 25 and 26 is formed from a single piece of material. However, it should be noted that in other embodiments the inner insert 1834 may alternatively be formed from more than one piece (in which case the flat duct assembly as shown in FIGS. 25 and 26 may include four or more pieces) .

With continued reference to Figures 25 and 26, the thickness of at least one narrow side 1818, 1820 generally corresponds to the thickness of the two broad sides 1822, 1824 (and, more specifically, the longitudinal edges of the first and second portions 1812, 1814) and the insert The sum of the thicknesses of 1834. For example, in some embodiments, the combined thickness of the overlapping longitudinal edges of the first and second portions 1812, 1814 and the insert 1834 can be about 0.25 mm (0.0098425 inches) or less. It should be noted that in some cases, each of the first and second conduit portions 1812, 1814 and insert 1834 may have substantially the same thickness (within any of the thickness ranges described above), such as where the same sheet material is used to Construct the case of all three parts. In these cases, either or both of the narrow sides 1818, 1820 may be bounded by a thickness that is about three times the thickness of the material of either of the first and second conduit portions 1812, 1814 (i.e., when As noted above, the rings 1842 on either or both of the longitudinal edges of the insert 1834 are received within the respective narrow sides 1818, 1820 (when increasing their thickness). In some embodiments, either or both of the longitudinal edges of the insert 1834 may be folded over on itself and then provided with a loop 1842 or otherwise formed at least partially opposite the interior of the narrow sides 1818, 1820 so that the Reinforcement is provided to the wall material of the first and second portions 1812 , 1814 at the narrow sides 1818 , 1820 . Any number of such longitudinal edge folds for the insert 1834 can be made to achieve the desired thickness, reinforcement and stability of the narrow sides 1818 , 1820 .

In some embodiments having a narrow side stiffening insert 1834 as described above, the first and second duct portions 1812, 1814 may each have a thickness of less than 0.15 mm (0.00591 inches), and the thickness of the insert 1834 may not Greater than about 0.10 mm (0.003937 inches), such as a flat pipe two-piece flat pipe 1810 as follows: wherein the first and second pipe portions 1812, 1814 each have a thickness of about 0.12 mm (0.0047224 inches), and wherein Insert 1834 has a thickness of no greater than about 0.10 mm (0.0039370 inches). In some embodiments, the thickness of each of the first and second conduit portions 1812, 1814 and the insert 1834 may be no less than about 0.05 mm (0.0019685 inches) and no greater than about 0.15 mm (0.0059055 inches) to provide a Strength properties and relatively cost-effective heat exchanger. In other embodiments, the thickness of each of the first and second conduit portions 1812, 1814 and insert 1834 may be no less than about 0.03 mm (0.00118 inches).

At least one of the first and second portions 1812, 1914 and insert 1834 may have a brazing material on either or both sides thereof to allow these components of the illustrated plumbing assembly to be joined by brazing. By way of example only, in the illustrated embodiment of FIGS. 25 and 26 , the first and second portions 1812, 1814 and the insert 1834 of the flat tube 1810 are formed from an endless strip of material coated on at least one side with a brazing material. Aluminum or aluminum alloy sheet available in .

As shown in Figures 25 and 26, the two-piece flat tubing 1810 of the illustrated embodiment defines a minor diameter d and a major diameter D. Using the aforementioned wall thicknesses, the inventors have found that a small diameter d of at least about 0.7 mm (0.027559 inches) provides good performance results in many applications, such as in heat sinks. Furthermore, utilizing the foregoing wall thicknesses, the inventors have found that a small diameter d of no greater than about 1.5 mm (0.059055 inches) provides good performance results in many applications, such as in heat sinks. In charge air coolers and other applications, the inventors have found that the minor diameter d can be greater than about 1 cm (0.3937 inches) to provide good performance results. While such a small diameter scale may be used in various embodiments, any of the small diameter scales described above for all of the flat tube embodiments disclosed herein may be used. Depending at least in part on the width of the starting material used to construct the flat tubing 1810, the major diameter D of the two-piece flat tubing 1810 shown in FIGS. those described in the examples).

As noted above, in some embodiments, either or both of the longitudinal edges of the insert 1834 may be provided with any number of folds to achieve a desired thickness for the first and second portions 1812, 1814 in narrow Enhanced reinforcement and stability at sides 1818, 1820. An example of such an embodiment is shown in FIGS. 28 and 29 . The two-piece flat tube 1910 shown in Figures 28 and 29 is generally the same as the flat tube of Figures 25 and 26 except for the shape of the insert.

Figure 28 illustrates a flattened duct 1910 with a narrow side 1918 at a stage where the larger arcuate portion 1968 has not yet been fully fabricated. In other words, one longitudinal edge of the second duct portion 1914 does not wrap around the already formed smaller arcuate portion 1962 (which is formed by the corresponding longitudinal edge of the first duct portion 1912). This longitudinal edge of the second duct portion 1914 is displaced or shifted about the smaller arcuate portion 1962 to complete the narrow side 1918 . As a result, the resulting longitudinal undercut 1944 extends into one broadside 1922 , while the other of the two longitudinal undercuts 1946 extends into the other broadside 1924 . These longitudinal undercuts 1944 , 1946 are located at the narrow sides 1918 , 1920 of the two-piece flat duct 1910 as described in previous embodiments.

In the illustrated embodiment of FIGS. 28 and 29 , the longitudinal edges 1938 , 1940 of the insert 1934 have been folded several times, as best shown in FIG. 29 . The longitudinal edge 1938 with these folds 1970 is received within the narrow sides 1918, 1920 of the two-piece flat duct 1910 and may provide for overlapping of the first and second duct sections 1912, 1914 at the narrow sides 1918, 1920. Significant reinforcement of longitudinal edges. In other embodiments, only one of the longitudinal edges 1938 , 1940 of the insert 1934 has such a fold 1970 .

The number of folds 1970 of the longitudinal edges 1938 , 1940 may depend, at least in part, on the dimensions of the flat tube 1910 . By way of example only, in some embodiments, the two-piece flat tubing 1910 has a minor diameter d of about 1.0 mm (0.03739 inches), and the first and second tubing portions 1912, 1914 each have a diameter d of about 0.15 mm (0.00595055 inches). The material thickness, and the material thickness of the insert 1934 is about 0.05 mm (0.0019685 inches), with about 10 folds being created on each longitudinal edge 1938 , 1940 of the insert 1934 . Although the plurality of folds 1970 can have different lengths, in some embodiments, the maximum length L of the folds is about 1.0 mm (0.03937 inches). In addition, these plurality of folds 1970 may in some embodiments extend in a direction parallel or generally parallel to the broad sides 1922, 1924 of the two-piece flat duct 1910 (see FIGS. 28 and 29 ), and in other embodiments along Extend in other directions (eg, perpendicular to broadsides 1922, 1924). It should be understood that the wall thicknesses of the first and second duct sections 1912, 1914 and insert 1934 may vary based on the desired specifications of the two-piece flat duct 1910, as can the distances d and L.

It should be noted that the two-piece flat duct assembly as shown in FIGS. 28 and 29 may have any of the same features described herein in connection with FIGS. 25 and 26 .

Figure 27 illustrates a two-piece flat duct according to other embodiments of the invention. This embodiment employs many of the same structures and has many of the same attributes as the flat duct embodiments described above in connection with FIGS. 25 , 26 , 28 , 29 and 33 . Therefore, the following description is mainly directed to the differences from the embodiments of flat ducts described above in connection with FIGS. 25 , 26 , 28 , 29 and 33 . For alternatives to the construction and features of the two-piece flat duct as shown and described below in FIG. description for reference. Thereafter, structures and features shown in FIG. 27 corresponding to structures and features of the embodiment of FIGS. 25 , 26 , 28 , 29 and 33 are assigned 1800 series reference numerals.

Similar to the embodiment of the invention described in connection with FIGS. 25 and 26, the tubing assembly shown in FIG. 27 has first and second portions 1812A, 1814A and an insert 1834A. The opposing longitudinal edges 1838A, 1840A of the insert 1834A line the inner surfaces of the two pairs of overlapping longitudinal sides of the first and second duct sections 1812A, 1814A, thereby reinforcing the narrow sides 1818A, 1820A of the flattened duct 1810A. .

The two-piece flat duct 1810A shown in FIG. 27 is that the two longitudinal undercuts 1844A, 1846A joining the first and second portions 1812A, 1814A of the flat duct 1810A extend to the same broadside 1822A, 1824A of the flat duct 1810A. And an example of the way to extend on it. In the illustrated embodiment of FIG. 27, two longitudinal undercuts 1844A, 1846A extend to and on the second broadside 1824A of the flattened tube 1810A. Optionally, longitudinal undercuts 1844A, 1846A may be formed into first broadside 1822A as desired. In the illustrated embodiment, the second broadside 1824A, primarily defined by the second duct portion 1814A, is capable of absorbing relatively loose tolerances at its opposing longitudinal edges (ie, capable of balancing tolerances). However, in some embodiments, the first broadside 1822A, which is primarily bounded by the first duct portion 1812A, does not have the same capacity, or the same degree of capacity, because its longitudinal edge cannot abut the stepped portion of the second duct portion 1814A. 1858A, 1860A or their immediate neighbors.

With continued reference to the illustrated embodiment of FIG. 27 , longitudinal undercuts 1844A, 1846A extend from each narrow side 1818A, 1820A in a direction toward the center of the flattened duct 1810A. However, a substantial portion of each longitudinal undercut 1818A, 1820A (i.e., step portion 1858A, 1860A) is located in the same broadside 1824A, where each step may be determined according to the desired manufacturing process for manufacturing the duct portion 1812A, 1814A. The cross-sectional length e of the portion 1858A, 1860A up to the terminal edge of the narrow side 1818A, 1820A. In the illustrated embodiment of FIG. 27, the minor diameter d of the two-piece flat tube 1810A is in the range of about 0.7-1.5 mm (0.027559-0.059055 inches) when the two-piece flat tube 1810A is incorporated in a heat sink, However, other minor diameters d may be used for the same and different applications, including the diameter d described above in connection with the embodiment of FIGS. those described for the larger diameter. For example, in other configurations, the minor diameter d of the flattened duct 1810A may be greater than 1.0 cm (about 0.39370 inches).

As with the other two-piece flat duct implementations described herein, it is contemplated that the fabrication process for the flat duct 1910 includes at least partially forming the two duct sections 1912, 1914 from strips of respective sheet material, and then The at least partially formed strips are joined to each other.

30-32 illustrate two other configurations of flat tubes according to other embodiments of the invention. These embodiments employ much of the same structure and share many of the same attributes as the flat duct embodiments described above in connection with Figures 25-29 and 33. Accordingly, the following description is primarily directed to structures and features that differ from the embodiments described above in connection with FIGS. 25-29 and 33 . Reference should be made to the description above in connection with FIGS. 25-29 for, and additional information related to, the structures and features of the embodiments of the flat tubes shown in FIGS. 30-32 and described below. Thereafter, structure and features of the embodiment shown in Figures 30-31 and 32 corresponding to structure and features of the embodiment of Figures 25-29 and 33 are assigned reference numerals in the 2000 and 2100 series, respectively.

The tubing assembly shown in Figures 30 and 31 is substantially the same as the tubing assembly shown in Figure 27 except for the shape of the insert. In particular, the tubing assembly shown in FIGS. 30 and 31 is an example of the manner in which the insert 2034 may take different shapes to define flow channels 2016 of different shapes and sizes. For example, the illustrated inner insert 2034 includes corrugations 2052 having sides that are generally perpendicular to the broad sides 2022 , 2024 of the two-piece flat tubing 2010 . The corrugated sides are joined together by generally planar portions which may be brazed, welded or secured in any suitable manner to the inner surfaces of the broad sides 2022, 2024 of the first and second duct sections 2012, 2014. This particular configuration of sheets or inserts 2034 is commonly referred to as a flat top sheet.

With continued reference to FIGS. 30 and 31 , the longitudinal edges 2038 , 2042 of the inner insert 2034 are shaped to each include a step 2072 and to be received generally within and against the narrow sides 2018 , 2020 of the two-piece flat duct 2010 . Connecting arch 2074 for reinforcement. In other embodiments, only one of the longitudinal edges 2038, 2042 is provided with these features.

In any of the insert embodiments described herein, the inserts may be configured to increase or maintain turbulence within the flow channels at least partially defined by the inserts. Examples of these features are shown in Figures 32A and 32B. In this embodiment, the sides and flat portions of the corrugations 2152 in the illustrated insert 2134 include fins 2176 (not shown in FIG. 32A ) positioned to increase or maintain flow turbulence within the flow channel 2116 . The fins 2176 can be spaced or distributed along the length of the flat tube 2110 in any patterned or unpatterned manner and can be located in any feature or combination of features of the corrugations 2152 . In addition, it should be noted that the fins 2176 may comprise shapes other than those shown in Figures 32A and 32B.

The flat duct assembly shown in Figures 32A and 32B also provides that either or both of the longitudinal edges of the insert in any of the embodiments herein need not be received or otherwise located in the first and second ducts. An example of the manner in which parts of the overlapping longitudinal edges are within and not necessarily part of or extend to the narrow side of the flat tube. As an example, in a particular configuration as shown in FIGS. 32A and 32B , inner insert 2134 includes at least one longitudinal edge 2140 that terminates forward of narrow side 2120 . Alternatively, longitudinal edge 2140 is adjacent to one of broad sides 2124 . Other configurations of the insert 2124 may include either or both of the longitudinal edges 2138, 2140 adjacent the other broad side 2124 of the flattened duct 2110, either or both of the rolled longitudinal edges 2138, 2140 Not within or nested within the respective narrow sides 2118, 2120 of the flat tube 2110, etc.

Figure 34 illustrates ten configurations of flat tubes according to other embodiments of the invention. These embodiments employ much of the same structure and share many of the same attributes as the flat tube embodiments described above in connection with Figures 25-33. Accordingly, the following description is primarily directed to structures and features that differ from the embodiments described above in connection with FIGS. 25-33 . For the structure and features of the embodiment of the flat tube shown in Figure 34 and described below and for additional information relating to these structures and features, reference should be made to the description above in connection with Figures 25-33. Thereafter, structures and features of the embodiment shown in FIG. 34 that correspond to structures and features of the embodiment of FIGS. 25-33 are assigned 2300 series reference numerals.

As described above in connection with FIGS. 25 and 26 , the first and/or second folds of the flat duct can be provided by one or more folds of the first and/or second duct sections at the narrow sides, ie at the longitudinal edges of these sections. / or further reinforcement of the second narrow side. In general, folding the longitudinal edges of the first and/or second pipe section increases the strength of the flat pipe and the resistance of the flat pipe to damage. This feature can be used in any of the embodiments described in connection with Figures 25-33. An example of a flat tube with longitudinally folded edges is shown in Figure 34, where an insert defining a generally rectangular flow channel and not extending or folding into the narrow side of the tube is shown as an example only. Any of the other types of inserts (or no insert at all) or longitudinal insert configurations and positions described herein may be used instead as desired.

The flat ducts 2310, 2410, 2510, 2610, 2710, 2810, 2910, 3010, 3110, 3210 shown in FIG. At least at least one longitudinal edge of one. The configurations shown in FIG. 34 each include a bounded edge 2380, 2382 . The longitudinal edges 2380, 2382 ... 3280, 3282 surrounded by the longitudinal edges 2378, 2384 of .. 3212, 3214). Some of the configurations shown in Figure 34 show surrounding edges 2978, 2984, 3078, 3074, 3178, 3174, 3278, 3274 with at least one fold 2930, 3030, 3130, 3230 (i.e., at least partially surrounding other conduits longitudinal edges 2980, 2982, 3080, 3082, 3180, 3182, 3280, 3282 longitudinal edges 2978, 2984, 3078, 3074, 3178, 3174, 3278 , 3274). While the opposite narrow ends of each two-piece flat tube as shown in Figure 34 adopt the same folded configuration, in other embodiments (with or without inserts), only one of the two narrow ends has this configuration, in which case the other narrow end may have any of the other folded configurations described herein or have no longitudinally folded duct edge portion at all. In other embodiments, the longitudinal edges of at least one of the narrow ends of the two-piece flat tubing (with or without the insert) each have at least one fold.

In some embodiments, one of the narrow ends of any of the flat tubes shown in FIG. 34 may have any of the longitudinally folded edge configurations as described and/or illustrated herein, while the other The narrow end may have any of the folded configurations described or shown above in connection with any of the embodiments shown in Figures 1-24 (with or without an insert). In such a case, the other narrow end may be bounded by a continuous sheet of material as described in detail above in connection with the one-piece conduit embodiment of Figures 16-22 of the flow channels, thereby forming the one-piece conduit.

The combination of the longitudinally folded configuration of the first and second duct sections described herein with the relatively small thickness of material (as described above) that can be employed in some embodiments can result in a Flat pipe with a compromise in stability.

For ease of description, the configuration of the flat ducts 2310...3210 shown in FIG. 34 includes the same configuration as the flat ducts shown in FIGS. 1810 are of similar construction and are classified into three groups: B, C and D. Groups B, C and D each show optional features of the flat tubes 2310...3210. As noted above, it should be understood that the features shown in FIG. 34 are also applicable to other configurations of two-piece and one-piece flat ducts described and/or illustrated herein, and may be used with or without inserts. used in the case of The flat tubes 2310, 2410, 2510, 2610, 2710, 2810 of groups B and C each include first and second tube sections 2312, 2314, 2412, 2414, 2512, 2514, 2612, 2614, 2712, 2714, 2812, respectively , 2814 non-folded surrounding edges 2378, 2384, 2478, 2484, 2578, 2584, 2678, 2684, 2778, 2784, 2878, 2884. More specifically, surrounding edges 2378, 2384, 2478, 2484, 2578, 2584, 2678, 2684, 2778, 2784, 2878, 2884 at least partially surround the Surrounded edges 2382, 2380, 2482, 2480, 2582, 2580, 2682, 2680, 2782, 2780, 2882, 2880. The folds 2330, 2430, 2530, 2630, 2730, 2830 of the bounded edges 2382, 2380, 2482, 2480, 2582, 2580, 2682, 2680, 2782, 2780, 2882, 2880 may be generally parallel to the broadsides 2322, 2324, 2422 , 2424, 2522, 2524, 2622, 2624, 2722, 2724, 2822, 2824 (eg, groups B and C). Additionally, folds 2330, 2430, 2530 may include portions parallel to enclosed edges 2378, 2384, 2478, 2484, 2578, 2584 (eg, set B).

The flat ducts 2910, 3010, 3110 of group D include narrow sides 2918, 2920, 3018, 3020, 3118, 3120, wherein the surrounding edges 2978, 2984 of the first and second duct sections 2912, 2914, 3012, 3014, 3112, 3114 , 3078, 3084, 3178, 3184 and enclosed edges 2982, 2980, 3082, 3080, 3182, 3180 both have folds 2930, 3030, 3130. As a result, relative to the narrow sides 2318, 2320, 2418, 2420, 2518, 2520, 2618, 2620, 2718, 2720, 2818, 2820 of the flat ducts 2310, 2410, 2510, 2610, 2710, 2810 in groups B and C, The stability of the narrow sides 2918, 2920, 3018, 3020, 3118, 3120 is enhanced. Furthermore, the enclosed and enclosed edges 2982, 2980, 3082, 3080, 3182, 3180 and 2978, 2984, 3078, 3084, 3178, 3184 of each of the flat tubes 2910, 3010, 3110 in set D define only one fold 2930 , 3030, 3130 (though in other embodiments may have more folds), while the surrounded edges 2382, 2380, 2482, 2480, 2582, 2580, 2682, 2680, 2782, 2780, 2882, 2880 define more than one fold 2330, 2430, 2530, 2630, 2730, 2830. Furthermore, for the flat tubes 2910, 3010, 3110 of group D, one fold 2910, 3010, 3110 of each surrounding edge 2978, 2984, 3078, 3084, 3178, 3184 is generally parallel to the outermost side of the flat tubes 2910, 3010, 3110 and a portion of each fold 2930, 3030, 3130 surrounded by edges 2982, 2980, 3082, 3080, 3182, 3180 is generally parallel to the broadside 2922, 2924, 3022, 3024, 3122 of the flattened duct 2910, 3010, 3110 , 3124.

Continuing with reference to the various flat duct embodiments shown in FIG. 34 , it should be understood that the folds 2330 . . . The number, as well as the design or shape of the folds 2330...3230 can be adjusted according to a desired set of parameters. Additionally, while the inner inserts 2334, 3234 of the flat duct embodiment shown in FIG. 34 are not used to reinforce the narrow sides 2318, 2320, . Either or both of the longitudinal edges 2338, 2340...3238, 3240 of 3234 are in contact with the longitudinal edges 2382, 2380...3282, 2382, 3282, 3280 and 2378, 2384...3278, 3284 are folded together and within. Other configurations of the flat duct may include forming the folds for the one-piece longitudinal edges as described above.

In any of the two-piece flat tube embodiments described in connection with FIGS. 25-34 , it is contemplated that the longitudinal bite can be adjusted for different tubes 1710 . . . The width of the sides 1744, 1746...3244, 3246 or the steps 1716...3216. As a result, sudden thickness changes of the broadsides 1722, 1724...3222, 3224 can be compensated for, reduced or even avoided. To illustrate, it can be observed that the distance e (representing the distance from the end of the longitudinal edge 2156, 2256 to the end of the corresponding narrow side of the pipe 2120, 2220) as shown in Figures 31 and 32B is significantly greater in the embodiment of Figure 31 than it is in the embodiment of Figure 31 Situation in the embodiment of Figures 32A and 32B. This distance e can vary in any embodiment as desired.

35-45 illustrate several flat tubes according to various embodiments of the present invention, any of which may be used in any of the flat tube embodiments described and/or shown herein. In many embodiments, an insert may be described as having a number of peaks and valleys that at least partially define a flow channel along the flattened conduit.

The flat tubes 3310, 3410, 3510, 3610 shown in FIGS. 35-45 each include an inner insert 3334, 3434, 3534, 3634 having a peak 3388, 3488, 3588, 3688 and/or elongated openings 3386, 3486, 3586, 3686 in valleys 3390, 3490, 3590, 3690. The elongated openings 3386, 3486, 3586, 3686 are generally longitudinal along the inserts 3334, 3434, 3534, 3634 (i.e., along the inside of the flat tubes 3310, 3410, 3510, 3610, inserts 3334, 3434, 3534, 3634 will be mounted in a generally longitudinally extending direction). In some configurations of the flattened ducts 3310, 3410, 3510, 3610, the elongated openings 3386, 3486, 3586, 3686 may be interrupted by bridges 3392, 3492, 3592, 3692. The bridges 3392, 3492, 3592, 3692 can be oriented generally parallel to the broad sides 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 of the flattened ducts 3310, 3410, 3510, 3610 and can be positioned along the length of the insert. 3334, 3434, 3534, 3634 at any desired regular or irregular intervals in the longitudinal direction.

By providing elongated openings 3386, 3486, 3586, 3686 in inserts 3334, 3434, 3534, 3634 as described above, the weight of inserts 3334, 3434, 3534, 3634 (thus equipped with 3534, 3634 flat tubes 3310, 3410, 3510, 3610 heat exchanger weight) can be significantly reduced compared to inserts 3334, 3434, 3534, 3634 that do not include such elongated openings 3386, 3486, 3586, 3686 . Based on the design of inner inserts 3334, 3434, 3534, 3634, inner inserts 3334, 3434 comprising elongated openings 3386, 3486, 3586, 3686 compared to similarly sized continuously corrugated inner inserts 3334, 3434, 3534, 3634 , 3534, 3634 weight can be reduced by up to 50%.

In some embodiments, by cutting a sheet of material (e.g., endless or discrete lengths of aluminum, aluminum alloy, copper, brass or other metal, or other material) and bending a portion of the cut sheet away from the original sheet plane to make inserts 3334, 3434, 3534, 3634 as described and shown above in FIGS. 35-45. For example, in the configuration of inserts 3334, 3434, 3534, 3634 as shown in FIGS. Manufactured in thickness. The curved portion may comprise an elongated slit which is opened by bending the sheet material adjacent to the slit out of plane relative to the original sheet. These bends can be made in two directions out of the plane of the initial sheet, or in only one direction out of the plane, to make inserts 3334, 3434, 3534, 3634 of different shapes. Different cuts can be made to aid in this bending, such as a slit perpendicular to and connected to the long slit just described. In some embodiments, as shown in the embodiment of FIGS. 35-45 , for example, the curved portion includes arcuate edges 3394 , 3494 , 3594 , 3694 . In some embodiments, the sheet of material and the resulting elongated openings 3386, 3486, 3586, 3686 and bridges 3392, 3492, 3592, 3692 define a double T shape.

The present inventors have discovered that the desired internal pressure stabilization can be achieved within a flat tube comprising inserts 3334, 3434, 3534, 3634 as shown in Figures 35-45. More specifically, the brazing surfaces of inserts 3334, 3434, 3534, 3634 as shown in FIGS. . The arched edges 3394, 3494, 3594, 3694 can also be brazed to the corresponding broad sides 3322, 3324, 3422, 3424, 3522, 3524, 3622, 3624 of the flat tubes 3310, 3410, 3510, 3610. The sides of the sides of the edges 3394, 3494, 3594, 3694 are joined together. This configuration of sheets or inner inserts 3334, 3434, 3534, 3634 is commonly referred to as a flat top sheet.

The use of the inserts 3334, 3434, 3534, 3634 described above in connection with the flat tubing shown in Figures 35-45 and elsewhere herein provided good results. For example, the joining just described provides further strength to those flat tubes of the present invention constructed from relatively thin sheet materials having the aforementioned dimensions. Advantages related to the pressure loss experienced when using these inner inserts 3334, 3434, 3534, 3634 were also found. In addition, inner inserts 3334, 3434, 3534, 3634 having elongated openings 3386, 3486, 3586, 3686 and bridges 3392, 3492, 3592, 3692 as described above can help prevent the collapse of the flat tubes 3310, 3410, 3510, 3610. The first and second portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 are easily laterally offset away from each other. For example, this configuration can help prevent the first and second duct sections 3312, 3412, 3512, 3612 from being flattened relative to the other duct section 3314, 3414, 3514, 3614 during the manufacturing process performed to produce the finished flat duct assembly. Longitudinal offset of conduits 3310, 3410, 3510, 3610. One reason is that the aforementioned slots 3388, 3488, 3588, 3688 and valleys 3390, 3490, 3590, 3690 with long openings 3386, 3486, 3586, 3686 can apply the . .

In each of the embodiments shown in Figures 35-45, inserts 3334, 3434, 3534, 3634 are received in two-piece flat tubing 3310, 3410, 3510, 3610 (wherein the flat tubing 3310, 3410, 3510, Longitudinal undercuts 3344, 3346, 3444, 3446, 3544, 3546, 3644, 3646 of two portions of 3610 connecting to and at least partially located in different portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614) Inside. In each embodiment, the two portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 are substantially identical to each other. However, in other embodiments, inserts 3334, 3434, 3534, 3634 may be used in any of the other one-piece or two-piece flat tubing of the invention described herein. For example, two sections 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 may be arranged such that one longitudinal undercut 3344, 3444, 3544, 3644 is located in one broadside 3324, 3424, 3524, 3624, while Another longitudinal undercut 3346, 3446, 3546, 3646 is located in the other broad side of the flattened duct 3310, 3410, 3510, 3610, such as in the embodiment of the invention shown in FIGS. 25 and 26 . In these embodiments, one longitudinal edge 3354, 3356, 3454, 3456, 3554, 3556, 3654, 3656 of each of the two sections 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 is in the 3310, 3410, 3510, 3610 extend generally freely within. As a result, the two portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 may have relatively greater tolerances in their widths as previously described in connection with the illustrated embodiment of FIGS. 25 and 26 . In other embodiments, both longitudinal undercuts 3344, 3346, 3444, 3446, 3544, 3546, 3644, 3646 are positioned to extend into the same broadside 3322, 3422, 3522, 3622 or 3324, 3424, 3524, 3624 , such as the embodiment of the present invention shown in FIG. 27 .

In some embodiments, either or both of the longitudinal edges 3338, 3340, 3448, 3440, 3548, 3540, 3648, 3640 of the inserts 3334, 3434, 3534, 3634 may extend to the respective narrow side 3318, 3320, 3418, 3420, 2518, 3520, 3618, 3620, and may be shaped to align narrow sides 3318, 3320, 3418, 3420, 2518, 3520 in any of the ways described above in connection with the illustrated embodiment of FIGS. 25-34. , 3618, 3620 at least a portion of the interior provides a liner. For example, either or both of the longitudinal edges 3338, 3340, 3448, 3440, 3548, 3540, 3648, 3640 may include steps 3472, 3476 (see, for example, the embodiments of FIGS. 39-42 and 45) and/or The edges 3374, 3474, 3574, 3674 are arched to provide reinforcement to either or both of the narrow sides 3318, 3320, 3418, 3420, 2518, 3520, 3618, 3620.

This relationship between the inserts 3334, 3434, 3534, 3634 and the flat tubes 3310, 3410, 3510, 3610 can provide significant strength and stability advantages as previously described. In these embodiments, the thickness of the reinforced narrow sides 3318, 3320, 3418, 3420, 2518, 3520, 3618, 3620 corresponds to the thickness of the first and second duct portions 3312, 3314, 3412, 3414, 3512, 3514, 3612 , the thickness of 3614 and the sum of the thicknesses of inserts 3334, 3434, 3534, 3634. In some embodiments having this relationship, the first and second conduit portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 can each have a thickness of no greater than about 0.15 mm (0.00591 inches). Additionally, each of the first and second conduit portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 can have a thickness of not greater than about 0.10 mm (0.003937 inches). Also or alternatively, in these embodiments, the thickness of the insert 3334, 3434, 3534, 3634 is no greater than about 0.10 mm (0.003937 inches). For example, the flat tubing 3310, 3410, 3510, 3610 can have first and second tubing sections 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 each having a thickness of about 0.12 mm (0.0047224 inches), and Wherein the insert 3334, 3434, 3534, 3634 has a thickness of not greater than about 0.10 mm (0.003937 inches). In other embodiments, the thickness of each of the first and second conduit portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 and inserts 3334, 3434, 3534, 3634 is not about about 0.15 mm (0.0059055 inches) to provide a relatively cost-effective heat exchanger with good heat transfer and strength properties. Additionally, in some embodiments, the thickness of each of the first and second conduit portions 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 and/or inserts 3334, 3434, 3534, 3634 is not less than about 0.03mm (0.0011811 inches). In other embodiments, the inserts 3334, 3434, 3534, 3634 may have any of the insert thicknesses described above in connection with the illustrated embodiments of FIGS. 25-34.

As best shown in FIGS. 35, 39, 44, and 45, in some embodiments, the inserts 3334, 3434, 3534, 3634 shown in FIGS. , 3688 and valleys 3390, 3490, 3590, 3690 define corrugations 3352, 3452, 3552, 3652 extending longitudinally along the insert 3334, 3434, 3534, 3634. The sides of these corrugations 3352, 3452, 3552, 3652 may be perpendicular or generally perpendicular to the broad sides 3322, 3324, 3422, 3522, 3524 of the flattened ducts 3310, 3410, 3510 (see Figures 35, 39 and 42) or may be opposite to each other. A certain inclination angle is formed on the wide sides 3622 , 3624 of the flat pipe 3610 . In any of the illustrated embodiments of Figures 35-45, vertical or angled corrugation sides may be used as desired. Furthermore, in some embodiments, inner inserts 3334, 3434, 3534, 3634 may be formed from more than one piece, such that the resulting flattened duct assembly includes four or more pieces.

In some embodiments (including embodiments in which the inner inserts 3334, 3434, 3534, 3634 are constructed from a single piece of material as described above), the inner inserts 3334, 3434, 3534, 3634 generally extend along the length of the inner inserts 3334, 3434. , 3534, 3634 or flat pipe 3310, 3410, 3510, 3610 longitudinal rolling. In some manufacturing processes of the flat pipes 3310, 3410, 3510, 3610, for example two types of rollers are provided to roll the inner inserts 3334, 3434, 3534, 3634 and create the elongated openings 3386, 3486, 3586, 3686, peaks 3388, 3488, 3588, 3688 and valleys 3390, 3490, 3590, 3690. The first roll may be a cutting roll for forming slits in the generally planar sheet. The second roll may be a forming roll for forming the peaks 3388, 3488, 3588, 3688 and valleys 3390, 3490, 3590, 3690 that define the arcuate edges 3394, 3494, 3594, 3694 in FIGS. 35-45. Similar to the configuration described above, the longitudinal undercuts 3344, 3346, 3544, 3546, 3344, 3346, 3544, 3546, 3644, 3646 from narrow sides 3318, 3320, 3418, 3420, 3518, 3520, 3618, 3620 into broad sides 3322, 3324, 3424, 3522, 3524, 3622, 3624 of flat ducts 3310, 3410, 3510, 3610. However, as with the previously described two-piece duct embodiments, the steps 3316 , 3416 , 3516 , 3616 may be located in the broadsides 3322 , 3324 , 3424 , 3522 , 3524 , 3622 , 3624 . Also as described in previous embodiments, the width of the steps 3316, 3416, 3516, 3616 (as measured to the ends of the respective narrow sides 3318, 3320, 3418, 3420, 3518, 3520, 3618, 3620) may be based on the flattened duct 3310, 3410, 3510, 3610 manufacturing process and desired specifications.

Continuing to refer to the illustrated embodiment of FIGS. 35-45 , in the flat panel with inserts 3334 , 3434 , 3534 , 3634 comprising elongated openings 3386 , 3486 , 3586 , 3686 and bridges 3390 , 3490 , 3590 , 3690 as described herein, In some embodiments of the conduits 3310, 3410, 3510, 3610, including those described above with relatively thin conduit wall materials, the inventors have found that a flat conduit minor diameter d of at least about 0.7 mm (0.027599 inches) is in many Good performance results are provided in applications such as in heat sinks. The present inventors have also found that a small diameter d of no greater than about 1.5 mm (0.059055 inches) is useful in many applications (such as in radiators, and particularly in those flat pipes of the invention described above based on relatively thin pipe wall materials). Examples) provided good performance results. The present inventors have also found that in the case of gas-filled radiators, among other applications, the minor diameter d can be greater than about 10.0 mm (0.3937 inches) while still providing good performance results. Furthermore, it should be noted that in other embodiments, any of the minor diameter d and major diameter D described above in connection with all of the flat tube embodiments disclosed herein may be used instead. Based at least in part on the width of the initial material used to construct the flat tubes 3310, 3410, 3510, 3610, the major diameter D of the two-piece flat tubes 3310, 3410, 3510, 3610 shown in FIGS. Can be of any desired size (also including those described above in connection with all of the flat tube embodiments disclosed herein). In this regard, if rolling rolls are used to make the flat tubes, these rolls (not shown) can be adjusted to make wider or narrower flat tubes 3310, 3410, 3510, 3610. In other configurations, the rollers used to make the flat tubes 3310 , 3410 , 3510 , 3610 may be replaced depending on the desired dimensions of the flat tubes 3310 , 3410 , 3510 , 3610 .

In some configurations of the flattened ducts 3310, 3410, 3510, 3610 shown in the embodiments of FIGS. Inserts 3334, 3434, 3534, 3634 may include a coating of brazing material for joining any two or more of these components, and/or in some cases include other elements (e.g., a cooling furnace). Although in some embodiments the first and second conduit sections 3312, 3314, 3412, 3414, 3512, 3514, 3612, 3614 and/or inserts 3334, 3434, 3534, 3634 are constructed of aluminum or an aluminum alloy, in In other embodiments, any or all of these components may be constructed of other materials that may or may not be suitable for brazing.

Referring now specifically to the illustrated embodiments of FIGS. 35-38 , in some embodiments, the bridges 3390 that interrupt the elongated opening 3386 are not continuous or aligned with other bridges that span the entire width of the insert 3344 . Conversely, bridges 3390 interrupting elongated opening 3386 may be staggered (ie, at different longitudinal positions along insert 3344 ) relative to adjacent bridges 3390 on either or both sides of elongated opening 3386 . In other embodiments, such as the embodiment shown in FIGS. 39-42 , bridges 3490 that interrupt elongated openings 3486 may be aligned such that two or more bridges 3492 that interrupt adjacent elongated openings 3486 are aligned. aligned or generally aligned at the same longitudinal position along the insert 3444. In other embodiments, the distance between the bridges 3390, 3492 along each flow channel 3316, 3416 may be discrete (ie, not in fluid communication with an adjacent flow channel 3316, 3416) because the broadside The elongated openings 3386, 3486 may be closed. While the arrangement of the bridges shown in the embodiment of Figures 35-42 provides advantages from a manufacturing standpoint, in other embodiments the bridges can be arranged in any other desired manner.

The hydraulic diameter defined by the flow channels 3316, 3416 is defined by the corresponding design of the peaks 3388, 3488 and valleys 3488, 3490 of the inserts 3334, 3434. For example, the hydraulic diameter may be relatively small given the small diameter d of about 0.8 mm (0.031496 inches) and the relatively large number of flow channels 3316, 3416 across the width of the inserts 3334, 3434.

Continuing with reference to the embodiment shown in FIGS. 35-38, the corrugations 3352 are shown approximately "oscillating" about the mid-plane of the insert 3344 (or flat tubing 3310). In other words, the sides and arcuate edge 3374 of the insert 3334 are directed toward the first and second edges from a portion of the insert 3334 defined between and generally parallel to the broad sides 3322, 3324 of the flattened duct 3310. Two opposing directions of the duct sections 3312, 3314 extend. Although as shown in FIG. 37, the portion between the broad sides 3322, 3324 may lie in the mid-plane of the insert 3334, the portion from which the peaks 3390 and valleys 3388 extend may lie at the end of the insert 3334 to the end of the initially planar sheet. Any position in between on either side. Additionally, it should be noted that the configuration of the insert 3334 as shown in FIG. 35 has elongated openings 3386 formed in the peaks 3390 and valleys 3388 of the illustrated corrugations 3352, although in other embodiments such openings 3386, 3388 need not define In both peak 3390 and valley 3388.

In the embodiment of FIGS. 38-42 , corrugations 3452 are instead formed to one side of insert 3434 . Specifically, the insert 3434 is not in a mid-plane relative to the broadsides 3422 , 3424 of the flattened duct 3410 , but is instead located near the lower broadside 3424 of the flattened duct 3410 . Additionally, the configuration of insert 3434 as shown in FIG. 39 has elongated openings 3486 only in peaks 3488 of corrugations 3452 as shown.

In some embodiments, any of the inserts described herein can be divided into two or more sections along the width of the insert to define two or more flow channels that are in some embodiments fluidly isolated from each other . This separation may be produced by one or more longitudinally derived partitions delimited in whole or in part by the insert. For example, in the embodiment of FIGS. 44 and 45 , the inner inserts 3534 , 3634 are each formed with at least one divider 3596 , 3696 so that the flat tubes 3510 , 3610 are provided with at least one of any desired number of flow channels 2516 , 3616 . Two flow chambers. In this way, separation of the two flow media flowing in the flat ducts 3510, 3610 is achieved. The flat ducts 3510, 3610 as shown in Figures 44 and 45 each include two such flow chambers allowing, for example, a medium to flow in one direction in one flow chamber and the same or a different medium in the other flow chamber. flow in the opposite direction.

Multiple flat tubes according to various embodiments of the present invention have been described above, constructed as a single piece of material (see, for example, the illustrated embodiments of FIGS. . , 1012, 1014, 1112, 1114, 1212, 1214, 1312, 1314, 1412, 1414, 1512, 1514, 1612, 1614 bounded by multiple inner folds 928, 1028, 1128, 1228, 1328, 1428, 1528, 1628) . As described in more detail above, the inner folds 928 , 1028 , 1128 , 1228 , 1328 , 1428 , 1528 , 1628 at least partially define a number of flows through the flat ducts 910 , 1010 , 1110 , 1210 , 1310 , 1410 , 1510 , 1610 Channels 916, 1016, 1116, 1216, 1316, 1416, 1516, 1616.

In other embodiments of the invention, the one-piece flat tubing may be provided with an insert made of a separate material housed (and, in some embodiments, secured therein) the one-piece flat tubing. Two examples of such flat tubes 3710, 3810 with inserts 3734, 3834 are shown in Figures 46-47 and 48. Similar to the previously described one-piece flat ducts, the flat ducts 3710, 3810 may be composed of relatively thinner sides 3722, 3724, 3822, 3824 and two reinforcing narrow sides 3718, 3720, 3818, 3820 that define the flat ducts 3710, 3810. Sheets of material (eg, strips) are constructed. In some embodiments, the inventors have discovered that the thickness of the sheet of material can be less than about 0.15 mm (0.0059055 inches) to provide good performance results in many applications. Furthermore, in some embodiments, the inventors have discovered that the thickness of the sheet of material can be greater than about 0.03 mm (about 0.00118111 inches) to provide good performance results in many applications. It should be understood that the thickness of the sheet of material may have other dimensions not listed herein.

With continued reference to FIGS. 46-48 , the longitudinal edges 3778, 3782, 3878, 3882 of the sheet of material are shaped and moved together such that one longitudinal edge 3778, 3878 abuts the other longitudinal edge 3782, 3882 to form the narrow edge of the flattened duct 3710, 3810. Side 3718, 3818. This narrow side 3718, 3818 may be bounded by at least one 180° bend of the sheet of material at the narrow side 3718, 3818 or by one or more other types of folds (described in more detail below) for closing the narrow side 3718, 3818 . The other narrow side 3720, 3820 is formed at least in part by folding the sheet of material such that the first and second longitudinal edges 3778, 3782, 3878, 3882 are joined together as described. In some embodiments, this other narrow side 3720, 3820 may comprise a triple wall thickness created by folding the sheet of material over itself twice at the location of the narrow side 3720, 3820.

In some embodiments, the process of making the flat tubing 3710, 3810 may include folding or Longitudinal edges 3778, 3782, 3878, 3882 are otherwise formed which will join together to enclose the flattened ducts 3710, 3810. In other embodiments, these processes are performed concurrently or substantially concurrently.

In some embodiments of a one-piece flat duct, such as the one-piece flat duct 3710 shown in FIGS. A larger arch. One advantage of this configuration is that when the more arcuate longitudinal edge 3778 is formed around the lesser arcuate longitudinal edge 3782, the finished flattened duct 3710 generally does not split or is resistant to splitting. However, in other embodiments, the longitudinal edges 3778, 3782 may have shapes other than arcuate. For example, the longitudinal edges 3878, 3882 as shown in FIG. 48 may be joined together and have many different shapes, including but not limited to any of the longitudinal edge shapes shown and/or described above in connection with FIGS. 2 and 6-11. By. Additionally, the longitudinal edges 3878, 3882 as shown in FIG. 48 may be joined to either or both of the longitudinal edges 3738, 3740 and have many different shapes, including but not limited to those shown above in connection with FIGS. 14 and 15 and/or any of the longitudinal edge shapes described.

The narrow sides 3718 , 3720 , 3818 , 3820 of the one-piece flat ducts 3710 , 3810 as shown in FIGS. 46-48 each have a thickness at least twice the thickness of the sheet material used to construct the ducts 3710 , 3810 . Two of the illustrated narrow sides 3720 , 3820 have a thickness three times the thickness of the sheet material due to the additional folds 3730 , 3830 produced in the region of these narrow sides 3720 , 3820 . In other embodiments, further strengthening of any of the narrow sides 3718, 3720, 3818, 3820 may be achieved by forming one or more additional folds 3730, 3830 at the location of the narrow sides 3718, 3720, 3818, 3820. Any of the fold types described in connection with any of the embodiments of FIGS. 1-24 may be used to reinforce the first narrow side 3718, 3818 as shown in FIGS. 46-48. Similarly, any of the types of folds described in connection with any of the embodiments of FIGS. 16-24 for reinforcing narrow sides defined by a continuous sheet of material may be used to The second narrow side 3720, 3820 shown is reinforced.

In each of the two illustrated embodiments of Figures 46-48, the inner insert 3734, 3834 is received within the flat tube 3710, 3810 as the flat tube 3710, 3810 is manufactured. In some embodiments, as shown in FIGS. 46-48 , with the flattened duct 3710 , 3810 still partially open, the inserts 3734 , 3834 may be formed after creating the second narrow side 3720 , 3820 (defining the reinforcing folds 3730 , 3730 , described above). 3830) after inserting. Alternatively or additionally, either or both of the broad sides 3722, 3724 of the flattened ducts 3710, 3810 may have a flow channel similar to that of FIGS. 1-13 and 16-24 (for example) Similar inner folds.

One exemplary process for forming a one-piece flat tubing 3710 with an insert 3734 is shown as an example in FIG. 46 . First, a fold 3730 (indicated at F) is created while longitudinal edges 3778, 3782 are formed. Alternatively, only one longitudinal edge 3778, 3782 is formed and the other longitudinal edge 3782, 3778 remains unformed. In the illustrated embodiment of FIG. 46 , at the stage of manufacture shown in diagram (a) of FIG. 46 , one longitudinal edge 3782 having an arcuate shape 3762 has been completed and the other longitudinal edge 3778 has been provided with a simple bend which is slightly curved. It will then be further shaped into a larger arch 3766 extending at least partially around the arch 3762 defined by the first longitudinal edge 3782 .

At the stage of manufacture shown in Figure (b) of Figure 46, two reinforcement folds 3730 are accomplished by adding folds 3730 to the folds 3730 shown in Figure (a). Thus, in the area of these folds 3730, three times the thickness of the sheet material used to form the one-piece flat duct 3710 is formed.

At the stage of manufacture shown in panel (C) of FIG. 46 , the fold 3730 is newly started forming the second narrow side 3720 of the flattened tube 3710 by bending the fold 3730 . At this intermediate step in the manufacturing process, a step 3758 is formed in one of the broad sides 3722 generally adjacent to the fold 3730 to provide a smooth outer surface for the one-piece flat tubing 3710 . In an alternative configuration of the duct 3710 , a step 3758 may also be formed in the other broadside 3724 generally adjacent to the fold 3730 . The smooth surface of the tube 3710 created by such a step 3758 and their ability to receive the fold 3730 or the longitudinal edge 3778 in a recessed manner is advantageous in situations where the tube 3710 needs to be brazed, welded or bonded to other components.

Next, at the stage of manufacture shown in panel (d) of Figure 46, the corrugated inner insert 3734 is inserted into the flattened tubing 3710, although inserts having any of the other shapes described herein could alternatively be used. One of the longitudinal edges 3738 of the corrugated inner insert 3734 may be seated first in the minor arch 3762 of the longitudinal edge 3782 . Optionally, as shown in FIGS. 46 and 47 , one longitudinal edge 3740 of inner insert 3734 may be placed first in narrow side 3720 opposite minor arch 3762 . The inner insert 3734 may be under a specific pre-tension condition when inserted in the steps shown in panels (d) of FIG. 46 and FIG. 47 . More specifically, insert 3734 may be shaped to have a tension that acts to expand insert 3734 by arching insert 3734 slightly away from broadside 3724 or resisting the compression required to place insert 3734 within flattened tubing 3710 , and thus the insert 3734 is pushed into the narrow sides 3718 , 3720 during full closure of the one-piece flat duct 3710 . At the stage of manufacture shown in panel (e) of FIG. 46 , a large arch 3766 is formed on a longitudinal edge 3778 and arranged around a small arch 3762 of the other longitudinal edge 3782 , thereby enclosing the one-piece flat duct 3710 . The aforementioned small bends (if present) of the inner insert 3734 are thereby removed and the profiled longitudinal edges 3738 , 3740 of the inner insert 3734 both fit within the narrow sides 3718 , 3720 of the flattened duct 3710 .

The process for forming the one-piece flat tubing 3810 as shown in FIG. 48 is similar in many respects to the process described above with reference to FIGS. 46 and 47 . Therefore, reference is made to the above description in relation to the manufacture of the flattened pipe 3710 for more information relating to the manufacture of the flattened pipe 3810, in addition to features described hereinafter and features which are different or incompatible with the above description.

At the stage of manufacture shown in panel (a) of FIG. 48 , the single sheet of material used to form the flat tube 3810 includes a fold 3830 that will partially define the second narrow side 3820 of the one-piece flat tube 3810 . After creating another superimposed fold at the same location on the single sheet of material, the sheet of material is bent at the location best shown in panel (c) of FIG. 48 . The first reinforced narrow side 3818 is formed at least in part by opposing longitudinal edges 3878, 3882 that join together to enclose the one-piece flat duct 3810 (see panels (d) and (e) of Figure 48). The closure of the one-piece flat duct 3810 is created by bending or folding the opposing longitudinal edges 3878 , 3882 and the engagement of the longitudinal edge 3838 of the inner insert 3834 . More specifically, a longitudinal edge 3838 of inner insert 3834 is located between two longitudinal edges 3878, 3882. It should be noted that the flat tube 3810 as shown in panel (f) of FIG. 48 is not necessarily in the final stage of manufacture. The folds bounded by edges 3878, 3882, 3838 may be arranged against each other as shown in FIGS. 14,15. However, as noted above, any of the other reinforcing narrow side fold configurations described and/or illustrated herein may be used instead as desired. In general, the stability of narrow side 3818 is determined, at least in part, by the number of folds or bends that are made to create narrow side 3818 .

If desired, the flat ducts 3710, 3810 as shown in FIGS. or both where heat exchange is desired. These reinforcements may take many different forms, such as one or more sheets of material separate from the sheet of material defining the flat ducts 3710, 3810 and attached thereto by brazing, welding, or in any other suitable manner, with One or more additional folds etc. of the sheet of material used to construct the flattened ducts 3710, 3810.

Utilizing the aforementioned relatively thin-walled materials used in some embodiments to construct the flat tubes 3710, 3810 (with or without reinforcements), the weight of heat exchangers formed with the flat tubes 3710, 3810 can be significantly reduced while improving its heat exchange capacity. Another reason for the weight reduction and heat exchange capacity improvement is that the wide sides 3722, 3724, 3822, 3824 of the flat tubes 3710, 3810 are formed so that , 3810 good brazed connection between fins, ribs or other heat exchanging elements (not shown) arranged in the heat exchanger. Based on the features of the one-piece flat tubes 3710, 3810 described above, the flat tubes 3710, 3810 have a generally planar outer surface for connection with these heat exchange elements.

Furthermore, it should be understood that the features of the flat tubes 3710, 3810 described with respect to Figures 46-48 may also be applied to any of the other configurations of the flat tubes described herein.

For the manner in which flat tubing 3710, 3810 may be manufactured, in some embodiments, two tape gauges of endless sheet material are fed to a roller conveyor line 3701, such as shown in FIG. In many cases, aluminum and aluminum alloys have been considered as the preferred material for making the flat tubes 3710, 3810. However, other metals and materials are suitable for making the flat tubes 3710, 3810. For conduits 3710, 3810 as shown in FIGS. 46-48, the material forming the first and second portions 3712, 3714, 3812, 3814 of the flat conduit 3710, 3810 may be received from an endless strip of material (e.g., sheet metal). sheet, and the inner inserts 3734, 3834 may be formed from another endless strip of material (eg, sheet metal). During one of the initial stages of the roller conveyor line 3701 (in some embodiments, prior to forming the web of material), a punch is added to the web of material in a distance corresponding to the desired individual tube length. In some embodiments, the sheet of material may be formed after the sheet metal strip is punched, although such punching may occur during or after the sheet is formed. As shown in FIG. 49 , the insertion region 3703 where the inner inserts 3734 , 3834 are inserted into the flat ducts 3710 , 3810 is located in the downstream portion of the roller conveyor line 3701 . Prior to inserting the inner insert 3734, 3834 into the one-piece flat tubing 3710, 3810, the above-mentioned orifices should be generally aligned with each other (i.e., in some embodiments, all located approximately in line with the one-piece flat tubing 3710, 3810). vertical common plane) so that the individual flat ducts 3710, 3810 can thereafter be separated.

The one-piece flat tubes each have an insert 3734, 3834 separate from and received by the respective flat tube 3710, 3810 as shown in Figures 46-48. However, in other embodiments, the inventors have discovered that it is possible to construct a one-piece with an insert integrally formed with the one-piece duct (ie, formed from the same integral piece of material used to construct the flat ducts 3710, 3810). flat pipe. As an example, five such flat tubes 3910, 4010, 4110, 4210, 4310 are shown in Figures 50-54. It should be noted that, in addition to features that are different or incompatible therewith, the features described below with reference to FIGS. 50-54 are also applicable to any of the other flat tube embodiments described herein.

In each of the illustrated embodiments of FIGS. 50-54 , a single piece of sheet material (e.g., a sheet metal strip) is formed into flat tubes 3910, 4010, 4110, 4210, 4310 and inserts 3934, 4034, 4134, 4234, 4334 both. The flat ducts 3910, 4010, 4110, 4210, 4310 shown in FIGS. the wall thickness. In some embodiments, the inventors have discovered that the thickness of the sheet of material can be less than about 0.15 mm (0.0059055 inches) to provide good performance results in many applications. Furthermore, in some embodiments, the inventors have discovered that the thickness of the sheet of material can be greater than about 0.03 mm (about 0.0011811 inches) to provide good performance results in many applications. It should be understood that the thickness of the sheet of material may have other dimensions not listed herein. As a result of this relatively thin sheet material thickness that may be used in some embodiments, heat exchangers with these flat tubes 3910, 4010, 4110, 4210, 4310 may have relatively less weight and increased heat exchange rates. Additionally, both the narrow sides 3918, 3920, 4018, 4020, 4118, 4120, 4218, 4220, 4318, 4320 of the one-piece flat tubing 3910, 4010, 4110, 4210, 4310 can be Enhanced by the fact, the need to pay attention to the orientation of the one-piece flat tubing 3910, 4010, 4110, 4210, 4310 during heat exchanger assembly may be reduced or eliminated.

Each of the conduits described below in connection with Figures 50-54 may have any of the dimensions described above with reference to the embodiment of Figures 1-34. For example, in some embodiments, any of the one-piece flat tubing 3910, 4010, 4110, 4210, 4310 as shown in Figures 50-54 can have a minor diameter d greater than about 0.7 mm (0.027559 inches). Furthermore, in some embodiments, any of these conduits 3910, 4010, 4110, 4210, 4310 may have a minor diameter d of less than about 15 mm (0.59055 inches). As another example, any of the one-piece flat tubing 3910, 4010, 4110, 4210, 4310 shown in FIGS. 50-54 may have a major diameter D greater than about 8 mm (0.31496 inches). Furthermore, in some embodiments, any of these conduits 3910, 4010, 4110, 4210, 4310 may have a major diameter D of less than about 300 mm (11.8116 inches). However, it should be noted that in other embodiments, any of the minor diameter d and major diameter D may be used above in connection with the flat tube embodiments disclosed herein.

Referring first to the illustrated embodiment of FIG. 50 in particular, the flattened duct 3910 shown therein is formed from a single sheet of material having a central portion 3905 that is contoured in a wave-like manner to form a flow channel 3916 in the resulting one-piece flattened duct 3910. . The middle portion 3905 of the sheet of material has a set of folds 3930 on both sides for providing reinforcement to the respective narrow sides 3918 , 3920 of the one-piece flat tubing 3910 . In other embodiments, the central portion 3905 has sets of folds 3930 on only one side (eg, where only one narrow side 3918, 3920 of the one-piece flat duct 3910 needs to be reinforced in this way). Furthermore, it should be noted that the central portion 3905 may have any number of reinforcing folds on either side, and that the folds on opposite sides of the central portion 3905 need not be the same in number, shape, or size. In the illustrated embodiment of FIG. 50 , the sheet of material also has an outer side portion 3907 that defines the broad sides 3922 , 3924 of the one-piece flat tubing 3910 . The outer step 3907 extends from and is integral with the aforementioned set of folds 3930 and is shaped to at least partially surround the set of folds 3930 . In other embodiments, outer portion 3907 does not surround or does not completely surround fold 3930 , in which case outer portion 3907 is curved to at least chalk flow channel 3916 within one-piece flat tubing 3910 . Furthermore, it should be noted that the sheet of material is formed to define only one outer portion (eg, extending from a fold on only one of the sides of central portion 3905 ), which may extend around central portion 3905 to enclose flow channel 3916 .

In some embodiments, a flat tube 3910 as shown in FIG. 50 may be formed on a roll production line (such as a roll production line 3701 as shown in FIG. 49 ) from an endless sheet of material (such as sheet metal as shown in FIG. 50( a ) Endless band or strip 3909 or other suitable material) to efficiently manufacture. Strip of material 3903 includes two longitudinal edges 3938,3940. First, as shown in Figure 50(b), two sets of folds 3930 are produced in the strip of material 3909 to form the narrow sides 3918, 3920 of the flattened tube 3910 which is produced later. Each illustrated group of folds 3930 is formed by six 180° bends in the strip of material 3909, wherein adjacent folds 3909 abut each other with no gaps between adjacent folds 3930 between the bends bounding folds 3930. With or almost no space. The illustrated gaps between folds 3930 illustrated in FIG. 50 are for explanatory purposes only to show each fold 3930 in greater detail. Additionally, while six folds 3930 are shown in each set illustrated in FIG. 50 , it should be noted that any other number of folds 3930 may exist adjacent to the central portion 3905 as previously described, which in many embodiments is at least partially Ground is determined by the desired specification (eg, dimensions) of the flat pipe 3910.

As shown in FIG. 50( c ), undulating portions 3911 are then formed between groups of folds 3930 . However, in other embodiments, undulating portion 3911 may alternatively be formed at the same time as or after forming fold 3930 . The corrugated portion 3911 may have any number of corrugations of any desired shape, including but not limited to corrugations having sloped sides relative to the broad sides 3922, 3924 of the one-piece flat tubing 3910 after assembly, corrugations having a square wave shape, Corrugations having the shape of a curved wave, such as a sine wave, corrugations having any other shape described herein, or any combination of these shapes.

The fabrication process for forming the flat tube 3910 in Figure 50(d) continues according to the two arrows shown in dashed lines. Specifically, after forming the folds 3930 and the undulating portion 3911, the band portion 3913 connected to the group of the plurality of folds 3930 is arranged around the corresponding plurality of folds 3930 and across the undulating portion 3911, thereby forming a one-piece flat duct The longitudinally extending flow channel 3916. In other words, each strap portion 3913 externally surrounds, or at least partially surrounds, a set of folds 3930 and extends further to cover the undulating portion 3911 . In addition, as shown in panels (c) and (d) of FIG. , the other longitudinal edge 3980 is curved to be located on the second narrow side 3920 and extend around and surround the plurality of folds 3230 at the second narrow side 3920 . In some embodiments of the flat duct 3910, the longitudinal edges 3978, 3980 do not cover or only partially cover the respective narrow sides 3918, 3920 because by providing a plurality of folds 3930 as described above, the narrow sides 3928, 3920 can be fully Stablize.

In the finished version of the flat tube 3910, such as that shown in Figure 50(d), the peaks and troughs of the undulating portion 3911 (or other features with a differently shaped central portion 3905 defining the flow channel 3916) are brazed , welded, or fastened in any other suitable manner to either or both of the broadsides 3922, 3924 of the one-piece flat tubing 3910. More specifically, the points on the crests and troughs shown in Figure 50(d) schematically illustrate the brazed connections that can be made between the undulating portion 3911 and the adjacent broadsides 3922, 3924.

Figure 51 illustrates a one-piece flat pipe with an integral insert according to additional embodiments of the present invention. This embodiment employs many of the same structures and has many of the same attributes as the flat tube embodiment described above in connection with FIG. 50 . Therefore, the following description is mainly directed to structures and features that are different from the embodiment described above in connection with FIG. 50 . For additional information regarding the structures and features of the one-piece flat duct with integral insert shown in FIG. 51 and described below, and alternatives to these structures and features, the description above in connection with FIG. for reference. Structure and features of the one-piece flat duct with integral insert as shown in FIG. 51 corresponding to those of the embodiment of FIG. 50 are assigned 4000 series reference numerals hereafter.

Referring now specifically to FIG. 51 , there is shown a one-piece flat duct 4010 formed from a single sheet of material (eg, sheet metal strip). In this particular embodiment, the central portion 4005 of the sheet of material is contoured in a corrugated manner to create a corrugated portion that at least partially forms the flow channel 4016 between the broad sides 4022 , 4024 of the flat tube 4010 . The central portion 4005 may have any of the shapes described above with reference to the illustrated embodiment of FIG. 50 .

As an alternative or in addition to using multiple folds 3930 to reinforce the narrow ends 3918, 3920 of the one-piece flat tubing 3910 (see FIG. 50 ), the one-piece flat tubing 4010 shown in FIG. Forming 4015 (ie, coil, mandrel, hollow or solid insert, etc.) at 4018, 4020. The molding 4015 may be located on either or both of the narrow sides 4018, 4020 and in some embodiments may complement one or more folds created at either or both of the narrow sides 4018, 4020 , where these folds are similar to folds 3030 described above in connection with FIG. 50 . During the manufacturing process of the one-piece flat tubing 4010 , the formed piece 4015 may be unfolded or otherwise placed parallel to the overall row of the sheet of material 4009 . After processing the prevented wavy portion 4011 between the profiles 4015, as shown by the dashed arrows in FIG. The broad sides 4022 , 4024 of the one-piece flat duct 4010 are formed through the corrugated portion 4011 . The strap portion 4013 is connected to the undulating portion 4011 and may also be connected to the molding 4015 in the narrow sides 4018 , 4020 . Furthermore, the longitudinal edges 4078 , 4080 of the sheet of material 4009 are each bent around a respective profile 4015 and rest on the respective narrow side 4018 , 4020 .

Thus, the narrow sides 4018, 4020 of the one-piece flat duct 4010 in FIG.

52-54 illustrate a one-piece flat pipe with an integral insert according to additional embodiments of the invention. These embodiments employ many of the same structures and have many of the same attributes as the flat tube embodiments described above in connection with FIGS. 50 and 51 . Accordingly, the following description is primarily directed to structures and features that differ from the embodiments described above in connection with FIGS. 50 and 51 . For additional information regarding the structures and features of the one-piece flat duct with integral insert shown in FIGS. 52-54 and described below, and alternatives to these structures and features, reference should be made to the The descriptions are made by reference. Structures and features corresponding to those of the embodiment of Figures 50 and 51 of the one-piece flat duct with integral insert shown in Figures 52-54 are hereafter assigned the 4100, 4200 and 4300 series of drawings mark.

52-54 each illustrate an exemplary embodiment of a flat duct 4110, 4210, 4310 formed from a single sheet of material 4109, 4209, 4309 (e.g., a strip of aluminum, aluminum alloy, or other metal or suitable material), and These flattened tubes 4110, 4210, 4310 are shown prior to completion of forming. In these specific embodiments of the flat tubes 4110, 4210, 4310, portions 4105, 4205, 4305 of the sheets of material 4109, 4209, 4309 are formed in a corrugated manner and , 4322 to form flow channels 4116, 4216, 4316. In addition, the narrow sides 4118, 4120, 4218, 4220, 4318, 4320 are each at least partially defined by the connecting portion 4117, 4119, 4217, 4219, 4317, 4319 of the sheet of material 4109, 4209, 4309 and surrounding the connecting portion 4117, 4119. , 4217, 4219, 4317, 4319 are formed by the longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380.

In the illustrated embodiment of Figures 52 and 53, the overlapping longitudinal edges 4178, 4180, 4278, 4280 and connecting portions 4117, 4119, 4217, 4219 provide twice the Wall thickness, which is generally stable enough for many applications where relatively thin wall thickness (as described above) flat tubing 4110, 4210, 4310 is used. In other embodiments, such as in the illustrated embodiment of FIG. 54 , relatively stronger reinforcement of the narrow sides 4118 , 4120 , 4218 , 4220 may be achieved by one or more folds 4330 of the connecting portions 4317 , 4319 . In other words, those portions of the sheet of material 4309 at the narrow sides 4318 , 4320 to be overlapped by the longitudinal edges 4378 , 4380 may be further strengthened by one or more folds 4330 . In these embodiments, the folds 4330 are shaped (eg, rounded) to at least partially define the narrow sides when the sheet of material 4309 is bent to bring the first and second wide sides 4322, 4324 into their closed positions. 4318, 4320. Alternatively or additionally, the longitudinal edges 4378, 4380 at the narrow sides 4318, 4320 can be provided with one or more such reinforcing folds 4330, for example in a manner similar to the group D flat duct embodiment shown in FIG. . In these embodiments utilizing reinforcing folds 4330, the narrow sides 4318, 4320 comprise a relatively greater thickness of the wall undulations 4311 and the broad sides 4322, 4324. Accordingly, sufficient reinforcement may be provided for portions of the flattened duct 4310 that are subject to relatively greater stress, such as the broad sides 4322/4324 and/or the corrugated portion 43211 having relatively thinner walls.

While for any of the embodiments described above in connection with FIGS. Any of 4220, 4318, 4320 may eliminate these reinforcing folds. Furthermore, the number of such reinforcing folds 4130, 4230, 4330 at a narrow side 4138, 4238, 4318 may be different from the number at the other narrow side 4120, 4220, 4320, and the reinforcing fold 4130 at one of the narrow sides , 4230, 4330 positions (e.g., only on connecting portions 4117, 4119, 4217, 4219, 4317, 4319, or only on longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380) can be combined with the location of the reinforcement fold 4130, 4230, 4330 at the other narrow side (e.g., only on the even longitudinal edge 4178, 4180, 4278, 4280, 4378, 4380, or Only at the connection portions 4117, 4119, 4217, 4219, 4317, 4319 which overlap the longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380 respectively) differ.

In any of the embodiments described above in connection with the one-piece flat tubing 4110, 4210, 4310 as shown in Figures 52-54, the overlapping longitudinal edges 4178, 4180, 4278 , 4280, 4378, 4380 may be located at or near the narrow side 4118, 4218 of the wall step 4158, 4160, 4258, 5260, 4358, 4360 (for example, the narrow side 4118, 4218 of the longitudinal edge 4178, 4180, 4278, 4280, 4378, 4380) Steps 4158, 4160, 4258, 5260, 4358, 4360). Thus, when the longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380 are moved toward their closed positions to form the one-piece flat ducts 4110, 4210, 4310 (shown by the dashed arrows in FIGS. 52-54 ), the longitudinal edges 4178, 4180, 4278, 4280, 4378, 4380 may be received within and surrounded by wall steps 4158, 4160, 4258, 5260, 4358, 4360. In some embodiments, a wall step 4158 , 4160 , 4258 , 5260 , 4358 , 4360 is provided on each broadside 4122 , 4124 , 4222 , 4224 , 4322 , 4324 of the flattened duct 4110 , 4210 , 4310 .

For the illustrated embodiment of FIG. 51, the peaks and troughs of the undulating portions 4111, 4211, 4311 as shown in FIGS. other features of 4305) may be brazed, welded, or fastened in any other suitable manner to any of the wide sides 4122, 4124, 4222, 4224, 4322, 4324 of the one-piece flat tubing 4110, 4210, 4310 or on both sides.

As mentioned above, each of the one-piece flat tubing 4110, 4210, 4310 as shown in Figs. 52-54 has an undulating portion 4111, 4211, 4311 for defining a flow channel 4116, 4216, 4316. The portion 4105 , 4205 , 4305 delimiting this undulating portion 4111 , 4211 , 4311 may have any of the shapes described above with reference to the illustrated embodiment of FIG. 50 . In the illustrated embodiment of FIGS. 52 and 54 , for example, the undulating portions 4111 , 4311 define a shape having a generally triangular design and having generally the same cross-sectional shape and size (although both could be in a one-piece flat duct 4110 , 4310 A number of flow channels 4116, 4316 that vary in width). Figure 53 illustrates an undulating portion 4211 provided with more than one wave design such that the undulating portion 4211 forms flow channels 4216 of at least two different cross-sectional sizes. The undulating portion 4211 shown in FIG. 53 includes a set of seven flow channels 4216 each having a relatively large cross-sectional area, and a set of six flow channels 4216 each having a relatively small cross-sectional area. another group. In other embodiments, any other combination of flow channel shapes and sizes disposed in the cross-section of the one-piece flat tubing 4210 may be employed. Using this representation of the heat exchanger tubing 4210, specific requirements for the heat exchanger can be best addressed. Although the cross-sectional shape of these variably sized flow channels 4216 is generally rectangular in FIG. . As mentioned above, the design of the wave-shaped section W is not limited to the design shown here.

Any of the flat tubes described herein can be manufactured in many different ways. However, by utilizing one or more manufacturing improvements discovered by the present inventors and described in more detail below, it is possible to achieve significant cost savings, increased efficiency, higher speed and/or A more reliable and reproducible way to manufacture these pipes.

One such improvement issued by the inventors is related to the ability to separate the flat tubes according to the invention from flat tubes of endless length (i.e. from a continuous supply of material fed through manufacturing equipment) and thereby obtain discrete flat tubes of desired length method is relevant. As used herein and in the appended claims, the term "endless conduit" is used to denote that one or more pieces of material travel from individual supplies (e.g., coils) before being separated into discrete conduits at desired lengths. Forming is performed to produce a flat tubing according to any of the embodiments described herein, thus incorporating the previous definition of "endless" above. Those skilled in the art will appreciate that significant challenges exist in cutting or otherwise separating elements constructed at least in part from relatively thin-walled products without producing distortion, flashing, burrs, or other undesirable features on the finished product. While similar problems exist in products constructed of thicker walled materials (which can equally be addressed with some of the improvements described below), in many cases such problems more frequently result in unacceptably thin walled finished products. Referring to the thin-walled flat tubing embodiments described herein, many of these embodiments have a wall thickness of no greater than about 0.15 mm (0.00591 inches). In some embodiments, the conduit wall can have a thickness of at least about 0.03 mm (0.0011811 inches). Additionally, of those conduit assembly embodiments having an insert described herein, many of these embodiments have an insert material thickness of no greater than about 0.01 mm (0.003937 inches). In some embodiments, the material thickness of the insert may be no less than about 0.03 mm (0.00118 inches).

The inventors have discovered that individual (i.e. discrete) flat tubes can be produced in a superior manner from an endless conduit of one or more sheets of material fed through manufacturing equipment by perforating at least one of the sheets . That is, at least a portion of the tubing is ported to help improve tubing separation from the endless line. This opening may be performed prior to the forming operation of the upstream sheet material, or after the sheet material has been formed into a continuous length of flattened tubing, or at any other stage or stages in between. Furthermore, the location of such perforations may vary between different sheets of material (or different locations on the same sheet of material) used to make different portions of the continuous flat tubing.

An advantage of forming perforations in the sheet metal strip used to make flat tubing is that, in some embodiments, the flat tubing can be made without substantial distortion, burrs, burrs, and/or other undesirable features on the finished product. . The use of perforations in the tubing separation process can be applied to any of the tubing embodiments described herein.

As an example of the opening and separation processes used to manufacture one-piece flat pipes, reference is made to the separation processes of one-piece flat pipes such as those shown in Figures 19-21, 52 and 53, where one-piece flat The conduits 1210, 1310, 1410, 4110, 4210 may be formed from a single endless piece of material. In Figures 52 and 53, the one-piece flat ducts 4110, 4210 are shown in a state just prior to completion of the manufacturing process and must be closed in the direction of the arrows as indicated by the dotted lines before the openings can be separated. Thus, the perforations can be formed prior to bending the sheet of material as shown in FIGS. 52 and 53 . Similar concepts can be applied to the pipes 1210, 1310, 1410 shown in Figures 19-21 and the other one-piece flat pipes described herein.

As a smoothness of this process for manufacturing a two-piece flat pipe, reference is made to a process of separating a two-piece flat pipe such as that shown in FIG. 28 . As described in more detail above, the two-piece flat duct 1910 shown in FIG. 28 has first and second portions 1912, 1912, 1914 and insert 1934 received therebetween. As also described above, the first and second sections 1912, 1914 may be identical or generally common, but may be opposite to each other, wherein one of the longitudinal edges of one duct section 1914 has a rim at least partially surrounding the other duct section 1912 The larger arched portion 1968 of the smaller arched portion 1962 on the longitudinal edge. Fold 1970 at either or both of the longitudinal edges of insert 1934. While the opening and separation processes described herein can be applied to two-piece flat tubing having any of the tubing sections and tubing dimensions described above in connection with the embodiment of FIG. 19, the insertion described in connection with FIGS. The piece 1934 has a thickness of about 0.03-0.09 mm (0.0011811-0.0035433 inches), and the sheet of material forming the first and second conduit portions 1912, 1914 has a thickness of about 0.03-0.15 mm (0.0011811-0.0059055 inches), and is by way of example only , the completed two-piece flat tubing 1910 has a minor diameter d of about 1-10 mm (0.03937-0.3937 inches). In FIG. 28 , a two-piece flat duct 1910 is illustrated just before completion, wherein openings have been formed in first and second duct sections 1912, 1914 and insert 1934 and have been adjusted such that the first and The openings in the second portions 1912, 1914 and the insert 1934 are generally aligned.

55-58 illustrate an exemplary manufacturing line 1900 similar to the manufacturing line 3701 shown in FIG. 49 . In this particular case, the manufacturing line 1900 is designed to form a three-piece flat duct assembly (i.e., having a three-piece flat duct that includes first and second portions 1912, 1914 and also includes a sweat wipe as seen at 1934), and Manufacturing line 3701 is designed for forming two-piece flat tubing assemblies (i.e., having One-piece flat tubing for inserts 1234, 1334, 1434, 4134, 4234). Although the manufacturing lines 3701, 1900 are described herein with reference to the manufacture of specific flat tube embodiments also described in this patent application, this is by way of example only. Accordingly, it should be understood that the process described with reference to Figure 49 and Figures 55-58 can be applied to the manufacture of all pipes described in this application.

As shown in FIG. 55, manufacturing line 1900 includes three coils R1, R2, R3 of sheet material, such as sheets of aluminum, aluminum alloy, or other suitable material, for forming a three-piece flat duct assembly. In this particular example, material from the first coil R1 is used to make the first part 1912 or 1914, sheet material from the third coil R3 is used to make the second part 1914 or 1912, material from the second coil R2 Used to make insert 1934 for two-piece flat tubing 1910 . Depending at least in part on the path of the sheet of material, the other possible positions of the coil relative to the manufacturing line, and the orientation of the flat tube 1910 as it passes through the manufacturing process, each coil R1, R2, R3 may have a Sheet material of any of the portions of the flattened duct 1910 in other embodiments.

Figure 55 illustrates the roll sets 1921, 1923, 1925 for distributing the processing of sheet material supplied from coils R1, R2 and R3. Each set of rollers 1921, 1923, 1925 may be arranged as schematically shown in Fig. 55 to define a respective loop of advancing sheet material. Any one or more of the rollers in each set 1921, 1923, 1925 may be driven by a suitable electric motor or prime mover to draw material provided by coils R1, R2 and R3. Additionally, any one or more of the rollers in each set 1921, 1923, 1925 may be idler rollers that allow the corresponding sheet of material to travel freely as a result. In addition, any of the rollers in each set 1921, 1923, 1925 may perform two functions, be selectively driven such as by a clutch, or be selectively driven in any conventional manner. It will also be appreciated that the coils of material R1, R2 and R3 may themselves be driven by suitable electric motors or other prime movers. As an example, it is contemplated that the sheets of material supplied from coils R1 , R2 and R3 may in some embodiments move at a line speed of about 100-200 m/min (328.08-656.16 ft/min). Slower or faster speeds are possible in other embodiments.

By controlling one or more motors that drive each of the material coils R1, R2, R3 and/or any of the rollers in the drive roller sets 1921, 1923, 1925, for example by selectively Either one provides the braking force and can control the maximum velocity of each sheet of material. In some embodiments, this enables the speed of each sheet of material to be controlled independently of the other sheets of material - even controlling a control point for one or both sheets to stop while the other moves. Additionally, roller sets 1921, 1923, 1925 may be used to allow some buffering of the sheet material supplied to the downstream location.

The manufacturing line 1900 shown in FIG. 55 includes a first punching station 1927 for forming in a sheet of material received from a second coil R2 (used to make an insert 1934 in a later formed flat tube 1910). Open mouth 1929. This punching station 1927 is located at the beginning of the manufacturing review display 1900 in Figure 55, but is alternatively located downstream of this location in other embodiments. The sheet of material forming the insert 1934 is then shaped by a set of rollers, schematically illustrated as forming portion 1931 in FIG. 55 . Sheets of material from the first and second coils R1 , R3 (used to manufacture the first and second portions 1912 , 1914 in the later formed flat tube 1910 ) are transported along the distance defined by the forming portion 1931 . Subsequently, the sheet of material from the first coil R1 reaches a second punching station 1933 and the sheet of material from the second coil R3 reaches a third punching station 1935 adjacent to the second punching station 1933 . In other embodiments, the three punching stations 1927 , 1933 , 1935 may be at different positions relative to each other and/or relative to other portions of the manufacturing line 1900 . Furthermore, in other embodiments, one or more of the punching stations 1927, 1933, 1935 may be used to punch more than one sheet of material.

Continuing to refer to the illustrated embodiment of FIG. 55 , second and third perforation stations 1933, 1935 are used to form perforations 1929 on the first and third sheets of material, respectively, for flat tubing 1910, and for forming perforations 1929 on the second sheet of insert 1934. Pass between the first and third sheets at the second and third punching stations 1933,1935. An example of the punching made at the second and third punching stations is shown in FIG. 57 and may be similar to the punching made at the first punching station 1927 described above. In the embodiment of FIG. 57 , perforations 1929 are relatively fine openings separated by grids 1937 located at predetermined distances between perforations 1929 . However, in other embodiments, the perforations may each be regions of reduced thickness of material and need not necessarily be defined by openings through the material. In either case, the description herein in relation to the shape, size and other features of the opening may apply equally.

As part of the fabrication process of the flat tube two-piece flat tube 1910, the mesh 1937 is broken. The perforations 1929 extend at least 1 cm (0.3937 inches) in the transverse direction of the perforated sheet of material (from the first, second or third coils R1, R2 and R3). Additionally, in some embodiments, each grid 1937 is less than 1 mm (0.03937 inches) long.

The shape (eg, length) and arrangement of apertures 1929 shown in FIG. 57 are by way of example only. Longer or shorter perforations 1929 and longer or shorter meshes 1937 may be used as desired in any sheet of material used to form the flattened duct 1910 . For example, each perforation 1929 may alternatively be generally circular or may take other desired shapes, which may result in fewer or more perforations in the sheet of material. Also, as an example, the length or other shape of the perforations 1929 may vary across the width of the perforated sheet of material, such as by providing perforations and/or grids that are longer in the center of the sheet near the longitudinal edges of the sheet (or vice versa). The type and characteristics of the perforations 1929 are based at least in part on the material properties of the sheet being perforated.

Based on the dimensions of the openings and the relatively thin sheet material that can be used as described above, in some embodiments the grid 1937 between the openings 1929 is not visible to the naked eye. For many manufacturing operations, this can be achieved by locating the mesh 1937 near each longitudinal edge of the sheet of material being punched, thereby reducing the likelihood that portions of the sheet of material will accumulate at these locations later during sheet processing. some advantages.

In those flat tubing embodiments described herein in which one or more sheets of material (eg, sheet metal strips) are used to manufacture the flat tubing, the sheets of material may be notched to separate at the notches. In those embodiments where two or more sheets of material are used to make the flat tubing, two or more of the sheets may be perforated, after which the perforations in different sheets may be aligned (e.g., at approximately the same size as the sheet). vertical plane, the direction of travel of the sheet, and/or flat tubing fabricated from the sheet), and individual tubing may be separated at the puncture by a continuous length of upstream material. The just-described punch alignment may be achieved in some embodiments by controlling the speed of one or more drives that feed one or more of the sheets of material through the manufacturing process. More specifically, if the perforations of any two or more sheets of material are not already aligned, one or more of the sheets can be moved at different speeds until the perforations are aligned to separate the individual pipeline. In this regard, it should be noted that this alignment process can be performed on any number of sheets of material to be punched for making the flat tube.

For example, with continued reference to the embodiment of FIGS. 55-58 , the punches 1929 in the three sheets of material from coils R1, R2, and R3 are located at Alignment is performed in an alignment section 1939 of the manufacturing line 1900 . The alignment section 1939 of FIG. 55 is typically placed in the manufacturing line 1900 upstream of the confluence section 1941 in consideration of the fact that speed adjustment of one or more sheets may be necessary to align the punch 1929 . The confluence portion 1941 is the part of the manufacturing line where the components of the flat tube 1910 (e.g., in the illustrated embodiment, the first and second sections 1912, 1914 and the insert 1934) are joined to each other to form the flat tube two-piece flat tube 1910. area. Converging portion 1941 may include rollers and other sheet forming elements for joining components of flattened tubing 1910 to form endless tubing 1910 . In those embodiments where none or only some of the longitudinal edges of the first and second conduit portions 1912, 1914 at one or more upstream locations are not finished, the confluent portion 1941 may also include rollers and/or other forming elements to The longitudinal edges of the first and second sections 1912, 1914 are subjected to other forming operations.

The continuous length of material immediately upstream of this operating location may be a continuous length of finished flat tubing. Alternatively, the continuous length of material immediately upstream of the separation location may be one or more sheets of material used to form the flat tubing at any stage of such forming. For example, in some embodiments, after the perforations in the sheets have been aligned, the partially formed sheets of material may be assembled into continuous lengths of finished flat tubing such that the finished tubing may be obtained after separation. As a result, individual pipes without indentations at the ends of the flat pipes can be obtained.

In some configurations of the manufacturing line, the notch is typically formed by one or more notch rolls. For example, a manufacturing line may include at least one pair of mouth rolls. One of the pair of rollers may travel with one or more endless sheets of material that will be used to form at least a portion of the flat tube, and the other roller of the pair may be equipped A punching tool (eg, one or more punching knives or punching dies). 56 and 57 schematically illustrate a punching process according to an embodiment of the present invention. For simplicity of description, the following description will be directed to the first punching station 1927 described above. However, the same description is equally applicable to the other punching stations 1933, 1935 in the illustrated embodiment of FIGS. It is possible to have different knives, use only a single roller instead of two, etc.). As noted above, the number and type of punches and the location of the punching stations can vary. Variations to these characteristics may be based, at least in part, on the desired specifications of the flat tubing 1910 manufactured in the manufacturing line 1900 .

Referring to the embodiment of FIGS. 56 and 57 , the punching station 1927 includes a pair of punching rolls having a first punching roll 1943 and a second punching roll 1945 . In some embodiments, the mouth rolls 1943, 1945 can be arranged in any other orientation desired, depending at least in part on the orientation of the sheet punched by the rolls 1943, 1945 and the adjacent portion of the manufacturing line 1900. The first roller 1943 runs parallel to and guides one or more of the passing sheets of material (from coils R1, R2 and R3), while the lower roller 1945 has a raised Opening mold 1947.

To prevent sheet build-up as punching occurs, some embodiments of the present invention utilize punching rolls having one or more punching knives or dies with standby positions. In the standby position, at least one of the mouth rolls is rotated or transferred to a position where one or more sheets of material are free to pass over the roll.

For example, the second roller 1945 as shown in Figure 56 has a drive mechanism (not shown) such that the second roller 1945 can hold the punching die 1947 therein out of contact with the passing coils R1, R2. Standby position for coordinating with R3's material sheet. In the standby position of the second roller 1945, the punch die 1947 may be rotated a distance from the position shown in Figure 56 to avoid this engagement, for example by rotating about 90 degrees about the second roller 1945 to a generally horizontal position. In other embodiments, either or both of the rollers 1943, 1945 may be mounted on respective axes that move relative to the passing sheet, thereby enabling either or both of the rollers 1943, 1945 to move relative to the The passing slices are diverted and define the standby position and the punching or working position.

In order to punch a sheet of material supplied from the second coil R2 (for example, referring again to the illustrated embodiment of FIGS. and 57 in the upper and generally vertical position. This actuation may be performed by a motor, actuator or other drive connected to the second roller to rotate the second roller at a rotational speed from the stand-by position to the punching or working position. In the punching position of the first and second rolls 1943, 1945, the punching die 1947 engages the sheet of material supplied from the second coil R2 and forms a punching 1929 therein. In some embodiments, the rotational speed of the second roller 1945 (and thus, its peripheral speed) is higher than the transport speed of the sheet of material to ensure that the sheet of material does not accumulate during the punching operation. In other embodiments, the rotational speed of the two rollers 1943, 1945 (and thus their peripheral speed) is higher than the transport speed of the sheet of material for this purpose. It should be noted that the terms "working position" or "mouth beating position" as used herein and in the appended claims do not mean or imply that the one or more rollers referred to are stationary, but rather indicate that the beating is taking place. Instantaneously position one or more rolls.

In some embodiments, either or both of the rollers 1943, 1945 of the punch station 1927 rotate faster than the speed of the passing sheet of material. After the generation of punching at the punching position, either one or both of the punching rollers 1943, 1945 can move back to the standby position for restarting at the next punching process. In some embodiments, movement of either or both of the mouth beating rollers 1943, 1945 back to the standby position may be achieved by rotating one or more of the rollers 1943, 1945 in the same direction as the mouth beating position. or multiple mouth rolls 1943, 1945 (rather than by switching the direction of rotation of one or more rolls 1943, 1945). Thus, the actuation of the pair of mouth rolls 1943, 1945 as described above can help avoid accumulation of passing sheet material.

It is conceivable that the finished tubing may be separated at the end of the manufacturing process due at least in part to the aforementioned punching. In some embodiments, the tubing is separated at the slit at or near the end of the manufacturing line. In some embodiments, separation of individual conduits may be accomplished by using a pair of interrupting rollers or a single interrupting roller. For example, in the embodiment of FIG. 58 , break rollers 1949 and rods 1951 are used to separate the endless tubing traveling between break rollers 1949 and rods 1951 into individual finished flat tubing 1910 . The breaking roll 1949 is equipped with a protruding breaking knife 1951 or other tool for breaking the mesh 1937 between the punches 1929 as previously described.

Break rollers 1949 and/or rods 1951 may be controlled to include a standby position where passing tubing is not slowed or otherwise manipulated, and where break rollers 1949 and/or rods 1951 move to communicate with passing pipelines. The interrupted location where the tubing fits and separates the tubing at the opening 1929. For example, in the illustrated embodiment of FIG. 58, the break roller 1949 is rotatable toward or away from a break position where the break knife 1951 of the break roller 1949 engages the flat tubing and passes the break rod 1951 to break the break. The flat tubing traveling between roller 1949 and break bar 1951 is broken (ie, cut in some embodiments) at the line of puncture 1929 . In other embodiments, interrupt rollers 1949 and/or rods 1951 are translated relative to the flat tubing to define the interrupt station's interrupt and standby positions.

While the flat tubing can be broken through the use of breaking rollers 1949 and breaking bars 1951 as described above, in other embodiments the grid 1937 defined by the punctures 1929 of the flat tubing is not broken by a knife or other similar tool. open, but instead by generating a force on the flat pipe along the general longitudinal direction of the endless pipe (for example, by passing the endless pipe over rollers that cooperate with the pipe and travel at a higher speed than the pipe) peel off. After experimentation, it was found that this type of separation can lead to the desired line ends as described above.

In some embodiments, one or more rollers 1949 in the portion of the manufacturing line used to interrupt the tubing may be used to assist in routing the tubing along the manufacturing line. This is also true for the punching stations 1927, 1933, 1935 described herein. It should also be noted that in any of the embodiments described herein, the dies, knives, or other tools on the rolls of any punching stations 1927, 1933, 1935 and/or break roll 1949 can be retracted so that the rolls are driven to To advance the tubing without doing anything else to it. In this case, the retracted position of the tool may also define the standby position described herein.

The additional aspects of making the flat tubing described herein may also allow these tubing to be manufactured at significant cost savings, increased efficiency, higher speed, and/or in a more reliable and reproducible manner compared to many conventional flat tubing fabrication techniques. to manufacture. As will be described, some of these additional aspects relate to the manner in which the components form the flattened duct and/or the manner in which these components are brought together to produce the flattened duct. By way of example only, reference will now be made to a two-piece pipe (more specifically, a two-piece pipe 1910 as shown in FIG. 28 and described above, manufactured using a manufacturing line 1900 as shown in FIG. 55 and described above). manufacture to describe these treatments. The following description and figures apply equally to any other two-piece conduit described herein (with or without an insert). Furthermore, the following description and drawings are equally applicable to any one-piece conduit (with or without an insert) described herein, except where different or incompatible.

The present inventors have discovered that by the particular manner in which the first and second portions 1912 , 1914 and the insert 1934 of the duct assembly 1910 are assembled, significant advantages can be obtained. For example, in some embodiments, the inner insert 1934 is rolled in a corrugated fashion along the longitudinal direction of the manufacturing line 1900 and inserted between two flat tube sections 1912 , 1914 of the subsequently formed flat tube 1910 . The longitudinal edges of the two flattened pipe sections 1912, 1914 may be rolled or otherwise formed with longitudinally arched edges, after which the arched edges may be joined together to cooperate with each other to form a flattened pipe as shown in FIG. 1910. This process is shown schematically in Figures 55, 59 and 60 and will now be described in more detail.

As previously mentioned, FIG. 55 shows three rolls R1 , R2 and R3 of sheet material supplying the sheet material to be used in the manufacture of the flat pipe 1910 . Sheets of material from coils R1 , R2 , and R3 are used to make first conduit portion 1912 , insert 1934 (which uses the widest sheet of material in some embodiments), and second conduit portion 1914 , as described above. The sheets of material used to form these components travel through the illustrated manufacturing line 1900 in a direction generally parallel with respect to each other.

Although other manufacturing line arrangements are possible, the manufacture of flattened tubing 1910 in manufacturing line 1900 as shown in FIG. In some embodiments, the sheets of material used to form the first and second duct portions 1912, 1914 may be guided without deformation. In such embodiments, the process of forming first and second conduit portions 1912, 1914 typically begins when the process of forming insert closure insert 1934 has completed. Optionally, one or more forming operations may be performed on one or both of these sheets of material while insert 1934 is being formed at one or more of the same locations along manufacturing line 1900 . In many cases, due to the fact that the amount of deformation of the material used to form the first and second conduit portions 1912, 1914 can be relatively small (see, for example, the flat conduit assembly shown in FIG. The processing of portions 1912 , 1914 may be significantly shorter than the processing used to make insert 1934 .

A two-piece flat duct 1910 as shown in FIG. 28 has identical or substantially identical first and second duct sections 1912 , 1914 . These parts 1912, 1914 are manufactured using a manufacturing line 1900 as shown in FIG. With their identical or substantially identical shapes, one portion 1912 is inverted relative to the other prior to the portions 1912, 1914 being joined together. As noted above, the manufacturing line 1900 shown in FIG. 55 has forming rolls or other suitable forming equipment for forming the arcuate edges of the portions 1912, 1914 described above.

In some cases, the sets of forming rolls or other suitable equipment used to produce the same type of longitudinal edge in both duct sections 1912, 1914 are located on the same lateral side of the manufacturing line 1900 (e.g., for manufacturing The set of larger arcuate longitudinal edges of the two portions 1912, 1914 lying in the plane of the sheet of material being formed). In these and other embodiments, forming rolls or other suitable forming equipment may be arranged such that the two portions 1912, 1914 have the same orientation after forming some or all of the longitudinal edges. In these embodiments, the manufacturing line 1900 may be provided with suitable rollers to invert one of the portions 1912 , 1914 about the longitudinal axis so that the two portions 1912 , 1914 may be joined in a confluent portion 1941 of the manufacturing line 1900 . In other embodiments, forming rolls or other suitable linting equipment may be arranged in the manufacturing line 1900 such that after some or all of the arched edges are formed, the two sections 1912, 1914 already have an inverted orientation relative to each other ( That is, its longitudinal side is inverted). In these embodiments, the two sections 1912 , 1914 may be parallel to each other and may be joined in a confluent section 1941 of the manufacturing line 1900 .

As described in more detail above in connection with FIG. 28 , one longitudinal edge of the first duct portion 1912 surrounds a corresponding longitudinal edge of the second duct portion 1914 and the opposite longitudinal edge of the first duct portion surrounds a corresponding opposite longitudinal edge of the second duct portion 1914 edges to join the duct sections 1912, 1914 together. In these and other embodiments described herein that can be manufactured in the manufacturing line 1900, the first and second conduit portions 1912, 1914 can be identical or substantially identical. In other embodiments described herein that may also be manufactured in the manufacturing line 1900, the first and second conduit sections 1912, 1914 are different, eg, the first and second conduit sections 1912, 1914 each include two The case of a small arch or two larger arches.

Continuing with joining the flat pipe assembly shown in FIG. 28 and referring to the embodiment of FIGS. Part 1912, 1914 between. This process is schematically illustrated in FIG. 59 and may be performed after the first and second conduit portions 1912, 1914 have been formed or substantially fully formed (as in the embodiment of FIG. 59). In this embodiment, the first and second duct sections 1912, 1914 are not in one plane, but in two planes with a distance from each other, and the forming rolls or other suitable forming equipment making the insert 1934 are positioned such that The sheet of material forming the insert 1934 is located between the sheets of material forming the first and second conduit portions 1912 , 1914 . This allows the insert 1934 to be "threaded" between the two duct sections 1912,1914. In other words, the layout of manufacturing line 1900 as shown in FIG. 55 is such that the sheet of material used to form insert 1934 is positioned between the sheets of material used to form first and second conduit portions 1912 , 1914 .

Referring to FIG. 59 , an insert 1934 as just described may be made between first and second conduit sections 1912 , 1914 running generally parallel to each other along a longitudinal portion of first and second conduit sections 1912 , 1914 in manufacturing line 1900 . the insertion. However, in other embodiments, the first and second broadsides 1922, 1924 of the first and second conduit sections 1912, 1914 lie in a plane other than the location immediately upstream of the confluent section 1941 of the manufacturing line 1900. Any positions are not necessarily parallel to each other.

In the illustrated embodiment (see FIG. 59(a)) and other embodiments, the sheet of material used to form the insert 1934 is generally parallel to either or both of the sheets of material used to form the first and second duct portions 1912 , 1914 . In other embodiments, other orientations of the three slices upstream of the insertion process are possible. However, in some embodiments, inserting the inner insert 1934 between the first and second duct sections 1912, 1914 is performed by aligning the orientation of the inner insert 1934 between the first and second duct sections 1912, 1914. Adjusted to an oblique orientation to at least one of the planes of the first and second conduit sections 1912,1914. For example, in the illustrated embodiment of FIG. 59, the inner insert 1934 is introduced between the first and second conduit portions 1912, 1914 in an inclined state relative to both the planes of the first and second conduit portions 1912, 1914. between.

As used herein and in the appended claims, the various forms of the term "inclined" refer to the position of the insert 1934 lower function with respect to the broad sides 1922, 1924 of the duct sections 1912, 1914 (which may be parallel to each other in some embodiments) . In this regard, it should be noted that either or both of the broad sides 1922, 1924 of the first and second duct portions 1912, 1914 may lie in a plane that is not horizontal, whereby the insert 1934 will be relatively A non-horizontal azimuth tilt.

This oblique insertion may be performed at a range of locations upstream of the confluence portion 1941 of the manufacturing line 1900 , and in some embodiments occurs approximately at the beginning of the manufacturing line 1900 . In some embodiments, the angle of the insert 1934 (relative to the duct section The plane in which broadsides 1922, 1924 of at least one of 1912, 1914 lie) may be at least about 25 degrees. In other embodiments, this angle is at least about 30 degrees for good performance results. Furthermore, in some embodiments, at least one location of the insert 1934 between the sheets used to manufacture the first and second conduit sections 1912, 1914, such as at the beginning of the insertion process, the angle of the insert 1934 as described above Not greater than about 45 degrees. In other embodiments, this angle is no greater than about 40 degrees for good performance results.

The inner insert 1934 is then brought into an orientation in which the inner insert 1934 is parallel or generally parallel to the broad sides 1922 , 1924 of the first and second conduit portions 1912 , 1914 . 59(b)-(e) illustrate the change or decrease in the angled position of the insert 1934, and the gradual convergence of the first and second conduit portions 1912, 1914 to retain the insert 1934 therebetween.

In those embodiments (similar to the embodiment of FIG. The shape of can provide a tight fit against the inner surfaces of the first and second duct portions 1912 , 1914 at the narrow sides 1918 , 1920 . For example, in those embodiments in which either or both of the longitudinal edges 1938, 1940 of the insert 1934 are arcuate or have a series of folds 1970, these features may be accommodated in the first and second duct sections 1912 , 1914 inside the arched longitudinal edges. In these and other embodiments of the insert 1934, one longitudinal edge 1938 of the insert 1934 can be placed within the longitudinal arcuate edge of the first wall portion 1912, at which point or thereafter the insert 1934 can be positioned relative to the first and second The broad sides 1922, 1924 of the duct sections 1912, 1914 are sloped.

As noted above, the inclination of the insert 1934 can be reduced to zero (ie, the insert 1934 can be moved to a position parallel or generally parallel to the broad sides 1922, 1924 of the first and second conduit sections 1912, 1914). In this way, the opposing longitudinal edges 1940 of the insert 1934 can assume a substantially correct position within the longitudinally arcuate edges of the second duct portion 1914 . Both the first and second conduit portions 1912, 1914 may be joined together during any portion of this process, after which the longitudinal edges of the first and second conduit portions 1912, 1914 around 1914 are closed. It should be noted that by enclosing the flat tube 1910 as described herein, in some embodiments, the insert insert 1934 is deformed. Insert 1934 within closed flat duct 1910 may be held in compression against broad or narrow sides 1922, 1924, 1918, 1920 of flat duct 1910, particularly wherein insert 1934 is deformed to compress insert 1934 In those embodiments that are inserted into flat tubing (such as in Figures 55-60).

In the illustrated embodiment, the adjacent longitudinal edges of the first and second duct sections 1912, 1914 are curved (i.e., by The closure of the first and second duct sections 1912, 1914 is provided by bending the larger arcuate portions of the longitudinal edges around the lesser arcuate portions of the longitudinal edges of adjacent duct sections 1912, 1914). Thus, a manufacturing line 1900 as shown in FIG. within each corresponding curved edge.

Following closure of the flat tube 1910 in the manufacturing line 1900, the completed flat tube 1910 may be mounted to one or more sets of fins or other elements (not shown), and may also be fastened to a heat exchanger (also not shown). ) header box (header). In many embodiments, the head tank of the heat exchanger is brazed in a brazing furnace, as the fins or other heat exchanger elements are brazed to the flat tubes 1910, which are brazed to their Insert 1934.

Insert 1934 may have any of the shapes and features described herein for flat tubing inserts. In many of these embodiments, insert 1934 is formed from a flat sheet of starting material. Accordingly, when insert 1934 is formed with corrugations or other features to at least partially define flow channel 1916 through conduit 1910, the width of insert 1934 may be reduced. This process is schematically illustrated in FIG. 60, which illustrates a process in which corrugations 1952 are continuously produced by forming rollers 1955 as the sheet advances through the manufacturing line 1900 in the machine direction (indicated by the straight arrows in FIG. 60). Sheet of material. Although three such forming rolls 1955 are shown in FIG. 60, the manufacturing line 1900 may have any number of forming rolls 1955 to produce any number of desired corrugations 1952 or other inserts described herein for various insert embodiments. feature. The type and location of corrugations or other wall features may determine, at least in part, how many forming rolls 1955 are needed in manufacturing line 1900 . For example, in some embodiments where the insert 1934 includes continuous corrugations 1952 such as those shown in FIGS. each set of rollers) to successfully form corrugations 1952 as described herein. Thus, in some embodiments, manufacturing line 1900 may extend a length of about 20 m (65.62 feet) or greater.

Manufacturing line 1900 may also include more than one type of roll 1955 for forming insert 1934 . For example, different rollers 1955 may be used to form different types of corrugations 1952 along the width of insert 1934 . As another example, the one or more rollers 1955 may be cutting rollers that are used to create slits in the sheet of material for later forming corrugations in the sheet of material (such as described above in any of the embodiments collectively FIGS. 35-45 ). described above, by bending the portion of the sheet adjacent to the slit). Any number of such rollers 1955 may be used in conjunction with any number of other types of rollers (eg, used to bend portions of a sheet of material) to create any of the insert types described herein.

In some embodiments, such as shown in FIG. 60 , the manufacturing process of insert 1934 includes first forming one or more central corrugations 1952 in the sheet of material, and then further forming corrugations 1952 closer to the longitudinal edges of insert 1934 . More specifically, referring to the embodiment of FIG. 60 by way of example, a first set of rollers 1955 (i.e., the leftmost set of rollers in FIG. 60 ) includes two grooves 1957 to form corresponding corrugations in the passing sheet of material. 1952. The next set of rollers 1955 includes four grooves 1957 that form corresponding corrugations 1952 in the passing sheet of material. This process can be continued to produce as many corrugations as desired in the sheet of material. At any point before, during or after such corrugation, either or both of the longitudinal edges 1938, 1940 of the insert 1934 may be formed to take any shape, including those described and/or illustrated herein. any shape. For example, both the longitudinal edges 1938, 1940 of the insert 1934 fabricated in the embodiment of FIGS. 55-60 are provided with arches, as best shown in FIG. 28, after all the corrugations 1952 have been formed.

In some embodiments, the width of the sheet used to form the insert 1934 is reduced to a greater extent than the width of the sheets used to form the first and second conduit portions 1912 , 1914 . This may be the case, for example, when the first and second duct portions 1912, 1914 are deformed only (or primarily) at their opposing longitudinal edges, such as the case of the two-piece flat duct shown in FIG. 28 . An advantage of this flat duct configuration is that the smooth broadsides 1922, 1924 of the flat duct 1910 can provide a connection between the broad sides 1922, 1924 of the flat duct 1910 and the insert 1934 and/or between the broad sides 1922, 1924 of the flat duct 10 . Relatively better surface for brazed joints between fins or other elements (not shown) of the flat tube 1910 .

In those embodiments in which the insert 1934 passes between the two pipe sections 1912, 1914 (and is also moveable from an inclined position to a parallel or substantially parallel position as described above), the forming rolls used to make the insert 1934 or Other suitable forming equipment may be located upstream of the location where the two duct sections 1912 , 1914 are brought together to close the flattened duct 1910 . Accordingly, some or all of the features of insert 1934 may be formed prior to this location. However, in other embodiments, some or all of the insert forming equipment may be located in the same part of the manufacturing line where the two tube sections 1912, 1914 join together to enclose the flat tube 1910. Thus, when the duct sections 1912, 1914 are brought together to close, and/or the insert 1934 is changed from an angled position to a position parallel or generally parallel to the broad sides 1922, 1024 of the duct sections 1912, 1914 as described above, the insert 1934 1934 can still be in the molding process.

In some embodiments of manufacturing line 1900, the roll sets used to make one or more of the various components in flattened tubing 1910 and insert 1934 may be adjusted to make flattened tubing 1910 and/or having different cross-sectional dimensions and properties or insert 1934. Alternatively or additionally, an advantage of some embodiments of manufacturing line 1900 is that one or more sets of rolls (also referred to as rows of rolls) used to manufacture any of the flat duct assembly components may be completely replaced with other sets, to form flattened ducts 1910 and/or inserts 1934 having different dimensions and characteristics. It should be noted that roll sets that do not have individual adjustability can generally be manufactured in a relatively more cost-effective and efficient manner.

Other features of the manufacturing line 1900 that may define significant manufacturing advantages are designed for flexibility in the width of the sheets that produce flat tubing according to embodiments of the present invention. In some embodiments, one or more of the sheets of material may be formed with additional folds and/or define additional flow channels as desired to utilize the entire width of the sheet. For example (and with continuing reference to the processing line embodiment shown in FIGS. 55-60 ), the width of the sheet of material used to make the inner insert 1934 is generally greater than the width of the sheets of material used to make the first and second tubing sections 1912, 1914. width. In some embodiments, this may be a result of the insert 1934 having the corrugations 1952 and deformed longitudinal edges 1938, 1942, while the first and second conduit portions 1912, 1914 only have deformed longitudinal edges or otherwise need to be smaller. The width of the material is used to form the duct sections 1912,1914. The extra width of the sheet of material used to form the insert 1934 can be used to create other features of the insert 1934, such as one or more additional folds at the narrow sides 1918, 1920 of the flat tube 1910, and/or define One or more additional folds of flow channel 1916 of conduit 1910 .

Other embodiments of the invention also relate to the manner in which the flat tubes described herein can be manufactured, the flat tube and fin assembly and the manner in which such an assembly can be manufactured, and/or the flat tube and fin incorporated in a heat exchanger apparatus components. By way of example only, these aspects of the invention will now be described and explained with reference to the manufacture of two-piece tubing, and more specifically, with reference to the two-piece flat tubing 1910 as shown in FIG. 28 and described above. The following description and figures apply equally to the manufacture of any of the other two-piece flat tubing described herein, with or without inserts. Except where different or incompatible, the following description and drawings apply equally to the manufacture of any of the one-piece conduits (with or without inserts) also described herein.

Some of the advantages of forming finned tubes 1910 in accordance with the present invention include the relatively simple method of making this assembly for making different types of heat exchangers. In some embodiments of the invention, an endless conduit flat conduit 1910 (i.e., produced by continuously supplying sheet material from one or more upstream locations and forming the sheet material into a continuous flat conduit 1910), such as FIG. 61 , The endless pipe flat pipe 1910 shown at 64 and 65 may be transported along a manufacturing line for installation of the endless pipe 1910 to at least one set of fins 1959 . It should be understood that references to the process of connecting the fins 1959 to the flat pipe or the endless pipe may be used interchangeably herein without limiting the scope of the invention (unless indicated to the contrary). In some embodiments, only one of the two broad sides 1922, 1924 of the endless duct 1910 is provided with a set of fins 1959 in this manner. A flattened tube 1910 provided with fins 1959 on only one side may for example be used at the edge of a heat exchanger core 1965, in which case the flattened tube 1910 may be positioned facing inwards such that the flattened tube 1910 is adjacent to the One set of fins 1959 of a duct 1910 is adjacent, or facing outwardly such that the set of fins 1959 is adjacent to the set of fins 1959 of an adjacent duct 1910 . In other embodiments, such as shown in FIGS. 61-66, both broad sides 1922, 1924 of the endless duct 1910 are provided with a respective set of fins 1959 in this manner. In both cases, each set of fins 1959 may define a two-dimensional interface with the broad sides 1922 , 1924 of the flattened duct 1910 .

Many of the flat tube and fin embodiments shown herein and described below are constructed from sheet metal including aluminum (e.g., aluminum or an aluminum alloy), although in other embodiments other metallic and non-metallic sheet materials may be substituted ground use. In some embodiments, the sheet of material used to make the flat tube 1910 is provided with a braze layer (not shown) on at least one side thereof, while the sheet of material used to make the fins 1959 does not have a braze coating . In other embodiments, different locations of the brazing coating are possible.

While the various aspects of finned pipe fabrication and finned pipe features described herein can be applied to flat pipes of any dimension, they are also applicable to flat pipes formed of relatively thin materials as described herein. Unique advantages are obtained in the application of the pipeline 1910. By way of example only, the relatively thin tubing material enables continuous line fabrication of flat tubing 1910 with fins (described in more detail below), which was not previously possible. In some embodiments, the specific material of the flat tube has a thickness of no greater than about 0.20 mm (0.007874 inches). However, in other embodiments, the inventors have found that the wall material of the flat tubes having a thickness of no greater than about 0.15 mm (0.0059055 inches) provides the same overall performance, manufacturability and Significant performance results associated with possible wall configurations (as described herein) that cannot use thicker wall materials. Furthermore, in some embodiments, a wall material thickness of not less than about 0.050 mm (i.e., not less than about 0.0019685 inches) of the flat duct wall thickness may be used in other embodiments. The material thickness provides good strength and corrosion resistance.

As explained in more detail below, the heat exchanger tubes and other parts of the heat exchanger described herein can be manufactured using point of manufacture techniques and processes, and can include anti-corrosion features, such as those shown in FIGS. 92-95 and described below. those technologies and processes. Many of the manufacturing processes and techniques and corrosion protection features involved hereafter are particularly advantageous when applied to heat exchanger tubing and other parts of the heat exchanger with significantly reduced material thickness. Furthermore, these technical, processing and anti-corrosion features provide significant advantages related to the overall performance of flat pipes and heat exchangers made from this material.

The flat tube 1910 in the illustrated embodiment is a two-piece flat tube with an insert. As an example, referring to the illustrated embodiment of FIG. 66, the flattened tubes 1910 may each have a minor diameter d of at least about 0.8 mm (0.031496 inches) to provide good performance results in many applications. Furthermore, a small diameter d of no greater than about 2.0 mm (0.07874 inches) provides good performance results in many applications. However, in some embodiments, a maximum conduit minor diameter d of no greater than about 1.5 mm (0.059055 inches) is used. Any of the other flat tube embodiments described herein (eg, constructed of only a single piece or any number of additional pieces) may be used to create the finned tubes of the present invention. Furthermore, in other embodiments other minor diameters d and major diameters D described above in connection with all of the flattened tube embodiments disclosed herein may be used instead.

The manufacture of the flat tube 1910 and the sets of fins 1959 in the illustrated embodiment is shown schematically in Figure 61 as being carried out by only a small number of roller pairs 1971, 1973, which represent an upstream manufacturing line not shown in more detail a part of. This upstream manufacturing line may also include an intermediate buffer section for controlling the feed rate of the flat tubes 1910 and/or fins 1959 . Furthermore, while two pairs of rollers 1973 are shown in Figure 61 to schematically represent the manufacture of two sets of fins 1959, it should be noted that in some embodiments a single upstream fin manufacturing line may alternatively be used.

Upstream of the point where the fins are fitted to the flat tube, the flat tube that can be used to create a tube with fins may be undercut along one or more longitudinal edges by brazing, welding, or any other suitable means as described herein. closed. Such tube fabrication may be used, for example, in those embodiments where the flat joint between the flat tube 1910 and the set of fins 1959 is an adhesive joint. Optionally, the flattened tubes 1910 may be joined by brazing, welding or soldering during fabrication of the finned tubes.

The flat duct 1910 shown in FIGS. 61-66 , 68 and 69 is described in more detail above in conjunction with FIG. 28 . As noted above, the description and drawings relating to flat pipes with fins and their manufacture are equally applicable to any of the other one-piece and two-piece pipes (with or without inserts) described herein. manufacturer. By way of example only, FIG. 67 illustrates another flat tube 310 that can be used in any of the finned flat tube embodiments described herein, and described in more detail above in connection with FIG. 7 . In some embodiments, the flat tube 310 as shown in FIG. 67 has a wall thickness of about 0.10 mm (0.003937 inches). A feature of this particular flat duct 310 is that the narrow sides 318, 320 are designed to be very stable. For example, narrow side 318 includes a set of folds 330 . Another feature of this flat tube 310 is that the flat tube 310 is divided into a number of flow channels 316 by a single fold 328 or in other embodiments by groups of multiple folds 328 . In some embodiments, the distance between folds 330 may be less than 1.0 mm (0.003937 inches). However, this distance can be increased to the centimeter range. As described in more detail above in connection with the embodiment shown in FIGS. 1-13 , it should be noted that the folds 330 forming the narrow sides 318 can be designed to have different lengths and/or shapes, thus increasing the temperature variation relative to the flattened duct 310 . Load resistance, compressive strength and/or impact strength.

The fins 1959 described herein may have any desired thickness, and in some embodiments may be fabricated from an endless sheet of material. However, the use of fins 1959 formed from a sheet of material having a thickness no greater than about 0.09 mm (0.0035433 inches) may provide good performance results in many applications. Additionally, sheets of material having a thickness of not less than about 0.03 mm (0.0011811 inches) can provide good performance results in many applications.

Figure 63 illustrates an alternative configuration of fins 1959 that may be used in various embodiments of the invention. The fins 1959 shown in Figures 61, 62, 64-66, and 68-68 correspond to the fins 1959 shown in Figure 63(a). However, it is understood that other designs of fins 1959 are possible and fall within the spirit and scope of the invention.

As an example, referring to FIG. 66, the fins 1959 can have a wall thickness of about 0.06 mm (0.0023622 inches) and can have a height of about 3.00 mm (0.011811 inches). It can be observed that the distance 2H between two flat tubes 1910 may therefore be about 6.0 mm (0.23622 inches) after the manufacturing process described herein wherein adjacent sets of fins 1959 of adjacent flat tubes 1910 abut against each other. .

The set of fins 1959 may be secured to the broad sides 1922, 1924 of the flattened tube 1910 by bonding or by metal bonding (eg, welding, brazing or soldering), wherein the flat surfaces of the broad sides 1922, 1924 provide a Significant surface area for this installation. In some embodiments, the flat junction between the flattened tube 1910 and one or more sets of fins 1959 defines a smaller surface area of the broad sides 1922 , 1924 of the walled flattened tube 1910 .

The set of fins 1959 joined to the flat tube 1910 as described herein can be oriented relative to the flat tube 1910 in many different ways. For example, the longitudinal direction of the fins 1959 on the flattened duct 1910 may be substantially perpendicular to the longitudinal direction of the flattened duct 1910 . However, the inventors have discovered that the set of fins 1959 may alternatively be joined to the flat tube (i.e., its broad sides 1922, 1924) such that the longitudinal direction of the fins 1959 is relative to the longitudinal direction of the flat tube 1910 and a direction perpendicular thereto ( In many applications, the direction of airflow) is inclined. Examples of such fins 1959 are shown in FIGS. 68 and 69 , which show another set of fins 1959 brazed to the broadside 1922 of another flat tube 1910 . Thus, as indicated by the arrows in FIG. 68 , the airflow through one set of fins 1959 is not parallel to the airflow through the other set of fins 1959 . In those embodiments in which FIG. 68 shows a front view of a set of fins 1959 in use, the cooling air in one set of fins 1959 is deflected downward from the incident level of cooling air, while the cooling air in the other set of fins 1959 is deflected downward. The cooling air is directed upwards from the incident level cooling air.

In some embodiments, the angle of inclination for each set of fins is not less than about 8° (measured between the longitudinal direction of the fins 1959 and the longitudinal direction of the flat tube 1910) as described above to obtain good performance results in many applications . Also, in some embodiments, this tilt angle is no greater than about 8° to obtain good performance results in many applications. In some embodiments (including those in which one set of fins 1959 on one flattened tube 1910 is adjacent to another set of fins 1959 on another flattened tube 1910 as described in more detail below), one set of fins This slope of the sheet 1959 may be in a different direction than the slope of another adjacent set of fins 1959 (see, eg, FIGS. 68 and 69 ).

In some embodiments of the invention, where the endless flat tube 1910 and one or more sets of fins 1959 are conveyed through the joint station 1969 continuously or in any interrupted manner, a brazing method may be used, an example of which is shown in FIG. 61 and 64 are shown schematically. Sets of these fins 1959 may be brazed to the endless flat tube 1910 at one or more of such lands 1969, and in some embodiments any or all of the lands are located with fins. sheet at a later stage of the flat tubing manufacturing line. Typically, the bonding station may be a relatively small device that utilizes induction coils to generate the required brazing temperature, for example. It should be noted that the brazing parameters (and thus the type and power of the bonding station(s) 1969 used) may vary depending on the desired parameters of the flat tube 1910 .

In some embodiments, while the set of fins 1959 is brazed to the broad sides 1922, 1924 of the flat tube 1910, the set of fins 1959 can be held against the broad sides 1922, 1924 of the flat tube 1910 with a predetermined force. 1924. Although the pipe fabrication process can be performed upstream of the fin installation process, by attaching the set of fins 1959 to the flat pipe 1910 simultaneously with the various components of the flat pipe (e.g., joining the insert 1934 to the flat pipe 1910, the flat Significant advantages can be realized by having at least one longitudinal edge of the conduit 1910 brazed or otherwise joined for conduit closure, etc. However, in the case where one or more longitudinal undercuts of the flattened pipe 1910 have been completed before the flattened pipe 1910 reaches the fin mounting part of the manufacturing line, the flattened pipe 1910 can be used within the framework of the manufacturing process. For example, referring to Figures 64 and 65, sets of fins 1959 can be joined in an endless manner to the broadsides 1922, 1924 of an endless flat tube 1910 finished in any of the ways described herein.

In some embodiments, the fabrication process also includes a tube and fin assembly (or referred to herein as "pipe with fins"). For example, the set of fins 1959 supplied for connection to the endless flat tube 1910 may be before the set of fins 1959 is joined to the endless flat tube 1910 (e.g., by brazing or in any other manner described above) or It is then cut to the desired length and removed.

In other embodiments, a continuous supply of fins 1959 from an upstream manufacturing process may be cut to desired lengths such that lengths of fins 1959 may be spaced apart and bonded to the surface of endless flat tube 1910 in any manner. Referring to the illustrated embodiment of FIG. 61 , in other embodiments, one or more spacers 1975 (e.g., blocks) may be placed between sets of fins 1959 on the flattened duct 1910 and may thus be used Fins 1959 are positioned to establish a desired distance between sets of fins 1959 coupled to the same broadside of endless tubing 1910 . As shown in FIG. 61 , the spacer 1975 may be removed from the flat tube 1910 at a downstream location, allowing the finned tube section to be formed with free flat tube ends at either or both ends of the flat tube 1910 .

In any event, and in other embodiments, interruptions between sets of sets of fins 1959 may provide exposed portions of flattened tubing 1910 that facilitate cutting or other tubing separation processes between formed spaces, And/or taps or other manipulations of the flat tubing 1910 at these locations. Thus, a separate finned tube section formed may include a flat tube 1910 and a set of fins 1959 on either or both of the flat sides of the flat tube 1910 .

Finned tubes 1961 made in accordance with the present invention may be incorporated in a wide variety of heat exchangers in any desired manner. However, in some embodiments, unique heat exchanger properties and heat exchanger assembly features have been recognized by the inventors. For example, a heat exchanger 1963 as shown in FIGS. 61 , 62 and 66 may include finned tubes as described above, wherein the set of fins 1959 of one finned tube 1961 is separated from the set of fins 1959 of an adjacent finned tube 1961. Another group of fins 1959 is adjacent. FIG. 62 , which is an exploded view of the tubes and fin block or core 1965 , illustrates the four finned tubes 1961 of the finned core 1965 . The number of finned tubes 1961 may be determined, at least in part, based on the specific application of the heat exchanger. Thus, the finned tube arrangement described above may be separated as many times as desired to define the core 1965 of the finned tube 1961 . Such cores 1965 may be assembled and then fitted to one or more header tanks 1967 . In particular, the ends of the flat tubes 1910 of the core 1965 may be free and may engage with the header tank 1967 (e.g., be received in various slots or other openings in the 1967 or be in fluid communication in any other suitable manner). ground to header tank 1967) to be fastened and sealed thereto using any suitable adhesive or sealant. FIG. 62 includes arrows indicating the general direction of mounting header tank 1967 onto core 1965 of finned duct 1959 .

As mentioned above, the finned tubes may be arranged in the heat exchanger such that the set of fins 1959 of one finned tube 1961 is located with the set of fins 1959 of another adjacent finned tube 1961 adjacent. Groups of these fins 1959 may contact each other. In some heat exchanger embodiments employing this arrangement of finned tubes 1961, there is a neutral region of this configuration that does not participate in heat exchange because the temperature of the finned tubes 1959 at the neutral region substantially similar, or in some embodiments even identical. Depending on the number of fins 1961 arranged in this manner, there may be any number of such neutral regions in the core 1956 between adjacent fin set fins 1959 .

As a result, when the heat exchanger 1963 is assembled from a plurality of finned tubes 1961 in these and other embodiments, it is possible to install the set of fins on a finned tube 1961 to another adjacent finned tube 1961. fins on the pipes 1961, so that the heat exchanger core 1965 has such a finned pipe structure that it can be handled as a single structural unit. In relatively large heat exchangers, an advantage of joining adjacent sets of fins 1959 in this manner is that vibration or oscillation between adjacent finned tubes 1961 (and thus generated noise). Mounting of adjacent finned tubes 1959 as just described may in some embodiments be accomplished by bonding material (e.g., adhesive) applied between groups of fins 1959 of adjacent finned tubes 1961. , brazing, soldering, welding, etc.), so that the heat exchanger core 1965 can be handled as a single structural unit. In other cases, groups of fins 1959 of adjacent finned tubes 1961 may be joined in other ways to make a heat exchanger core 1965 from such finned tubes 1961 . For example, in some embodiments, an intermediate sheet (eg, a relatively thin sheet of material or other material) may be positioned between and join adjacent sets of fins 1959 . In other embodiments, there may be a narrower air gap between adjacent sets of fins 1959 of adjacent finned tubes 1961 . In other words, according to some embodiments of the invention, a set of fins 1959 from one finned tube 1961 may be combined with a set of fins 1959 from another finned tube 1961 even without the fins 1959 "Adjacent" in the context of a group of joined material layers or elements.

Once the number of finned tubes 1961 has been assembled into the desired arrangement, the assembly can be fastened together in a number of different ways, such as by soldering, welding and/or brazing. In some embodiments, the fabrication process of the tube-fin core 1965 may include the use of CAB brazing techniques. The tube-fin core 1965 as described herein can be fabricated with relatively reduced energy consumption. In those embodiments in which the tube-fin core 1965 is constructed with flat tubes 1910 formed from relatively thin sheet material as described herein, the various stages of fastening together the tubes 1961 with fins (e.g., at CAB brazing process) can be significantly reduced. For example, the speed of travel of such tube-fin cores 1965 through the different temperature regions of a CAB brazing furnace can be significantly increased relative to those required for conventional tube-fin cores 1965 . One reason for this faster fastening process is that the relatively small wall thickness of the flat tube 1910 (and the wall thickness of the fins 1959), allows Reach brazing temperature (or elevated temperature required for other fastening treatments) faster. The transfer speed and/or exposure time at various stages of the fabrication process can be optimized by selectively adjusting temperature settings, for example based on the use of such thinner materials. In addition, the use of suitable hangers, fixtures or auxiliary equipment in the manufacturing process can help reduce the likelihood of tube-fin core deformation and / or degree. More specifically, the expansion and contraction of the tube-fin core 1965 that occurs during heating and cooling does not cause undesired delays.

Other aspects of the invention relate to the use of the flat tubes disclosed herein in a heat exchanger having features for establishing fluid communication between the flow channels of the individual flat tubes and/or exchanging heat with a fluid supply or with One or more tanks that establish fluid communication with the outlets of the connectors to other equipment. These aspects of the invention are applicable to the materials disclosed herein having the aforementioned relatively thin walled materials (e.g., no greater than about 0.20 mm (0.007874 inches) in some embodiments, and no greater than about 0.15 mm (0.0059055 inches) in other embodiments. )) for flat pipes. However, the inventors have discovered that those aspects of the invention described in more detail below can be used in applications where flat tubing constructed from thicker materials is used. Accordingly, the various features of the invention described below may be applied to heat exchangers having other types of flat tubes, including any of the flat tubes described and/or illustrated herein.

As explained in more detail below, the heat exchanger tubes and other portions of the heat exchanger tubes described herein can be manufactured using a number of manufacturing techniques and processes, and can include anti-corrosion features, such as those shown in FIGS. 92-95 and described below. techniques and treatments described above. Many of the manufacturing processes and techniques and anti-corrosion features involved herein are particularly advantageous when applied to heat exchangers and heat exchanger sections with significantly reduced material thickness. Furthermore, these technical, processing and anti-corrosion features provide significant advantages related to the overall performance of flat tubes and heat exchangers made from these materials.

As noted above, the flat tubes described and illustrated herein may be used in conjunction with heat exchangers having one or more tanks. These tanks may include header tanks, header tanks, and other fluid containers adapted to establish fluid communication between the flat tubes and/or between the flat tubes and a fluid supply or outlet of the tank. For simplicity of description, these tanks are collectively referred to herein as "header tanks", it being understood that these tanks can perform other functions, be larger or smaller, and have any other desired shape while still containing the essential components described below. aspects of invention.

One embodiment of a header tank according to the present invention is shown in FIGS. 70 , 70A , 71 , 76 and 77 and is generally indicated by the reference numeral 4467 . Although the heat exchanger 4463 shown in FIG. 77 is shown with two header tanks 4467, it should be noted that any number of header tanks 4467 may be employed in each possible heat exchanger, including a single header tank 4467 and More than two header boxes 4467. Both header tanks 4467 as shown in Figure 77 have generally the same features and are connected to the flat duct 4410 in generally the same manner as shown in Figures 70, 70A, 71 , 76 and 77 and described below.

Header tank 4467 may be constructed from any number of different components. For example, header tank 4467 as shown in Figures 70, 70A, 71 , 76, and 77 is formed as a single unit, such as by injection molding or other suitable process. In this and other embodiments, at least one row of receiving openings 4478 (described in more detail below) is integrally formed with header box 4467 . In other embodiments, such as the header tank embodiment described below and illustrated in FIGS. 72-75 , the header tank is made of two or more separate The pieces are formed. For example, in these embodiments, the header tank 4467 can have one or more walls defining the receiving opening 4479 therein, and one or more other walls defined by the various components of the header tank 4467, such that the other walls can be more The flat duct 4410 is assembled at a later stage when the flat duct 4410 is accommodated in the accommodation opening 4479 .

The illustrated header tank 4467 includes a series of receiving openings 4479 along its surface. Each receiving opening 4479 is surrounded by a wall integrally formed with at least a portion of header tank 4467 , the wall being shaped to receive a respective free end 4477 of flattened duct 4410 . The flat tubing 4410 may take any of the forms described herein and may be cut to lengths dictated by the parameters of the flat tubing 4410 or the corresponding application. Referring to FIGS. 70 , 70A and 71 , part of the process of fabricating the heat exchanger 4463 includes setting the free ends 4477 of the flat tubes 4410 (which are according to any of the embodiments described herein) to the ends of the header tank 4467. Stored in the opening 4479. In some embodiments, this can be performed by pushing header tank 4467 over free flattened pipe end 4477 in a manner similar to that shown schematically in FIG. 62 . Alternatively, the free end 4477 of the flat tubing 4410 can be pushed into the receiving opening 4479, or the flat tubing 4410 and header box 4467 can be moved towards each other and pushed together to make these connections.

In some embodiments, the flat tube 4410 connected to the header tank 4467 may have one or more sets of fins 4459 according to any of the embodiments described herein (see FIG. 77 ). By way of example only, finned tubing 4461 that has been assembled and brazed in an upstream manufacturing step such as those described above may have fins 4559 with a wall thickness of about 0.030-0.090 mm (0.0011811-0.0035423 inches) . For example, the protruding free end 4477 of each flat tube 4410 having a fin 4459 already brazed thereto or such a finned tube 4416 already assembled and brazed into a span or core 4465 Protruding free ends 4477 may remain free during brazing (eg, in a brazing furnace) and thus not allow fins 4559 to interfere with their subsequent insertion into receiving openings 4479 of header tank 4467 . Both ends of the flat tube 4410 in any such embodiment may be raised and free as just described for connection to opposing header tanks 4467 .

In those embodiments where the core 4465 is connected as just described, the core 4465 may be formed from sets of flat tubes 4410 and fins 4559 by alternating stacks of sets of flat tubes 4410 and fins 4559 . An example of such a core configuration is shown in Figure 77, which shows a brazed flat tube-finned core 4465 with two headers 4467, each with a Ports for connection to other equipment where cooling air flows through the fins 4559 to cool the fluid within the flat tubes 4410. The heat exchanger 4463 shown in Figure 77 is just one of many types of possible heat exchangers to which one or more of the header tanks 4467 may be connected. By way of example only, either of the illustrated header tanks 4467 may be a reversing tank such that both the inlet and outlet are disposed on the same header tank 4467 .

Flat tubes 4410 (with or without fins attached thereto as described in previous embodiments above) can be individually inserted into individual receiving openings 4479 of header tank 4467 . However, by simultaneously or substantially simultaneously inserting two or more flattened tubes 4410 (in some cases, all of the flattened tubes 4410 of core 4465) into their respective receiving openings 4479 in a single step, significant The advantages. This process may be when two or more of the flat tubes 4410 have been brought together, such as by brazing or other installation processes (including those described herein) to define the unitary or flat tube heat exchanger core 4465. its part to execute. The process described above thus enables the utilization of large quantities of header tank material. However, depending at least in part on the material used for the header tank 4467 and the process used to secure the fins 4459 to the flat tubes 4410, cooling after brazing of the tube-fin core 4465 may be desirable in some embodiments After processing, the free ends 4477 of the flat tubes 4410 are guided into respective receiving openings 4479 of the header tank 4467 .

Many heat exchanger manufacturing processes require exposing tubes and headers to elevated temperatures for soldering, welding, brazing and other mounting processes, such as housing flat tubes and headers in furnaces or other heating environment to join flat pipes to header tanks. These processes therefore limit the availability of many header tank materials—at least for those parts of the header tank that define the connection locations for the flat pipes (e.g., one or more header tank walls that define the receiving opening). use. Therefore, these parts of the header tank usually comprise metal. Many components, all or substantially All use plastic or other cryogenic materials. For example, one or more components of header box 4467 that define receiving opening 4479 may comprise plastic. The entire header tank 4467 in the illustrated embodiment of Figures 70, 70A, 71 , 76 and 77 is fabricated from a plastic material, although other materials may be used in other embodiments. In those embodiments where some or all of the header tank 4467 comprises plastic, these parts may be manufactured, for example, by injection molding.

Referring again to FIGS. 70 and 71 , the receiving opening 4479 of the header tank 4467 is shown having a curved surface 4481 to facilitate insertion of the flattened pipe end 4477 . In other embodiments, other shapes (eg, flat sloped surfaces, vertical corner surfaces, etc.) may be used instead.

As best shown in FIG. 71 , the flattened tube ends 4477 when fully inserted into their respective receiving openings 4479 reach various locations below the inner surface 4483 of the inner wall of the header tank 4467 , thereby preventing work on the heat exchanger 4463 . Undesirable pressure drop caused by the flat pipe end 447 during this time.

In the illustrated embodiment of FIGS. 70, 70A, 71, 76 and 77, the receiving opening 4479 of the header tank 4467 is shaped to define a rear portion 4485 having the same cross-sectional shape as the flattened duct end 4477 (see FIG. 70 , 70A, 71, 76 and 77 in the direction of flat pipe insertion). While the rear portion 4485 of each receiving opening 4479 can be dimensioned to define an active fit with the flattened duct end 4477, in other embodiments (such as those shown in FIGS. 70, 70A, 71, 76, and 77 Example), use a tight fit. In those embodiments where a tight fit is employed, light pressure may be applied to the header box 4467 and/or the flat tube 4410 to fully insert the flat tube end 4477 into the rear 4485 of the receiving opening 4479 by This provides a seal between header tank 4467 and flat tubing 4477 that may be liquid-tight or substantially liquid-tight.

In some embodiments, features of header box 4467 and/or flat tubing end 4477 are used to control or limit the amount of insertion of flat tubing end 4477 within receiving opening 4479 . For example, a stopper (not shown in FIGS. 70 , 70A, 71 , 76 and 77, but visible in FIG. 80 , indicated by reference numeral 4675 ) can be formed on the flattened pipe end 4477 and/or on the receiving opening 4479. on the inner surface to limit the insertion depth of the flat tubing end 4477.

In other embodiments, one or more of the flattened conduit ends 4477 may extend through a corresponding receiving opening 4479 and into the interior chamber 4487 of the header box 4467 . In such an embodiment, the flattened conduit end 4477 can be deformed in any manner, such as by bending along the surfaces of the inner chamber wall 4483 adjacent the receiving opening 4479 to at least partially match the shape of these surfaces.

生产的硅酮粘接剂可以用于许多实施例。在一些实施例中，粘接剂4489确保了扁平管道端部4477与收纳开口4479的内表面之间的永久性的紧密接合。In the illustrated embodiment of FIGS. 70, 70A, 71, 76 and 77, adhesive 4489 is used to secure the flattened pipe end 4477 within the receiving opening 4479 of the header tank 4467 (see FIG. 71 ). Many different adhesives can be used, including those that harden immediately or over time, and those that retain some degree of flexibility after setting. For example, by Dow Corning

The silicone adhesive produced can be used in many embodiments. In some embodiments, the adhesive 4489 ensures a permanent tight bond between the flat tube end 4477 and the inner surface of the receiving opening 4479 .

Adhesive 4489 may also act as a sealant to prevent fluid loss from header tank 4467. In other embodiments, the flattened tubing end 4477 is substantially secured within the receiving opening 4479 by inserting the flattened tubing end 4477 into the rear 4485 of the receiving opening 4479, in which case with no or substantially no adhesive. An adhesive sealant can be used in place of Adhesive 4489. For simplicity of description, the term "adhesive" in reference to the flat pipe to header tank means an adhesive that may or may not be used as a sealant, it being understood that in other embodiments this material may instead be used only as or Mainly used as a sealant.

As best shown in FIG. 71 , the adhesive 4489 can generally cover a substantial portion of the flattened pipe end 4477 and, in some embodiments, surround the flattened pipe end 4477 at at least one location along the length of the flattened pipe end 4477. The entire perimeter of 4477. In the illustrated embodiment of FIGS. 70 , 70A , 71 , 76 and 77 , the end portion of the flat tubing end 4477 is not covered with adhesive 4489 due to its position within the rear 4485 of the receiving opening 4479 . With the relative snug fit between the rear portion 4485 of the receiving opening 4479 and the flat tube end 4477 as described above, fluid passing through the header tank 4467 (eg, fluid coolant or other fluid used as a heat exchanger medium) can be prevented. Contact 4489.

According to various embodiments of the invention, the adhesive 4489 can be introduced between the flattened pipe end 4477 and the inner surface of the receiving opening 4479 in many different ways, many of which include where the flattened pipe end 4477 is received. The adhesive 4489 is introduced into the respective receiving openings 4479 after or simultaneously. However, before further describing these embodiments, it should be noted that the adhesive 4489 may be applied to the receiving opening 4479 in any manner (eg, spray, roller, or other application tool) prior to inserting the 447 in the receiving opening 4479. The interior and/or exterior of the flat pipe end 4477.

Introducing adhesive 4489 between the flattened tubing end 4477 and the interior surface of receiving opening 4479 during or after tubing end insertion can provide insight into the amount and/or final location of adhesive 4489 in the finished heat exchanger 4463. Greater control and may result in a more reliable connection and/or seal between the flat pipe end 4477 and the header tank 4467.

To provide space for the introduction of adhesive 4489 between the flattened pipe end 4477 and the inner surface of the receiving opening 4479, the receiving opening 4479 and/or the flattened pipe end 4477 may be shaped to define a gap between them. or multiple gaps 4493 . For simplicity of description, the term "gap" (when used herein to refer to the space where the bonded joint 4489 is received as described herein) means one or more such gaps, regardless of the specific perimeter around the flattened pipe end 4477 Regardless of location, two or more such gaps for the same flat tube end 4477 are in fluid communication with each other.

In some embodiments, the gap 4493 between the flattened tubing end 4477 and the adjacent interior surface that defines the receiving opening 4479 can have a width of at least about 0.3 mm (0.011811 inches) to allow for suitable adhesive injection (see below mentioned). Furthermore, the inventors have found experimentally that such a gap width of no greater than about 1.0 mm (0.03937 inches) provides good performance results. A number of considerations may at least partially define the size of the gap 4493, such as the amount of adhesive required, the characteristics of the bond (e.g., viscosity and specified time), and limitations on the distance between adjacent flat tubes 4410, etc. . Other considerations relate to the requirement for header tank 4467 to have a minimized thickness or depth in some embodiments. For example, in some embodiments, the header tank 4467 extends beyond the flat duct core 4465 by a minimum amount to reduce the space wasted by the heat exchanger 4463 within the vehicle.

In some embodiments, the header tank 4467 does not substantially extend beyond the depth of the tube-fin core 4465 to avoid wasting the available space required to install the heat exchanger 4463 within the vehicle. For example, in the illustrated embodiment of FIGS. 70 , 70A, 71 , 76 and 77 , with particular reference to FIG. 76 , the undeformed flat tube ends 4477 require a minimum of Extended extension, or basically no extension. In some embodiments, this extension may also be reduced when the manufacturing process of the heat exchanger 4463 includes the use of deformed flat tube ends 4477 (described below).

In some embodiments, the adhesive 4489 passes through one or more openings in the header tank 4467 or through one or more gaps between the flattened pipe end 4477 and the header tank 4467 (which, once at least partially bonded to these components, Accessible when assembled) is introduced by injection. For example, a header tank 4467 as shown in Figures 70, 70A, 71, 76 and 77 has a number of injection openings 4491 each extending through a wall 4495 of the header tank 4467 to a gap 4493 defined at the flattened pipe end Between the portion 4477 and one or more walls defining the receiving opening 4479.

The injection openings 4491 may be located on either or both of the longitudinal sides of the header tank 4467. Additionally, more than one injection opening 4491 may extend to the same receiving opening 4479 . In this case, the adhesive 4489 can be injected simultaneously into the same receiving opening 4479 , for example through two injection openings 4491 on opposite longitudinal sides of the header tank 4467 . Adhesive 4489 may be injected one at a time into the gaps 4493 corresponding to each flat tube 4410, into a row of gaps 4493 corresponding to each flat tube 4410 simultaneously or substantially simultaneously, or into the core simultaneously or substantially simultaneously. All gaps 4493 of body 4465. In some embodiments, the adhesive 4489 covers the entire perimeter of each flattened tube end 4477 and/or may fill a gap 4493 between the flattened tube end 4477 and an adjacent wall that defines the receiving opening 4479 . Additionally, in some embodiments (eg, the embodiments of FIGS. 70 , 70A , 71 , 76 , and 77 ), the ends of the flat tubing 4410 may remain uncovered by the adhesive 4489 .

An alternative way to introduce adhesive between the flattened tubing end 4477 and the inner wall of the receiving opening 4479 is to inject the adhesive through a bottom opening or gap 4497 located between these components and in fluid communication with the aforementioned gap 4493 . This manner of introducing the adhesive may be in addition to or instead of injecting through the injection opening 4491 as described above, and may eliminate the need for the injection opening 4491 .

Figure 84 is a block diagram describing the manufacturing process, the stages involved or manufacturing steps, of a heat exchanger 4463 according to an embodiment of the present invention, and is realized by a schematic diagram of a heat exchanger 4463 manufactured by this process. The term "stage" is used here only to simplify the description and does not individually denote or imply that there is a physical division between these "stages" in the manufacturing line. For example, the header tank 4467 may be placed on the free flattened pipe end 4477 (Stage III) at the same or a different location than the process of applying the adhesive 4489 (Stage IV).

72-75 illustrate header tanks 4467 according to other embodiments of the invention. This embodiment employs much of the same structure and has many of the same attributes as the embodiment of header tank 4467 described above in connection with FIGS. 70, 70A, 71, 76 and 77. Accordingly, the following description is primarily directed to structures and features that differ from the embodiments described above in connection with FIGS. 70 , 70A , 71 , 76 and 77 . For additional information regarding the structures and features of header tanks described below and shown in Figures 72-75, and alternatives to these structures and features, reference will be made to the above in connection with Figures 70, 70A, 71, 76 and 77 description for reference. Thereafter, structure and features of the embodiment shown in Figures 72-75 that correspond to structure and features of the embodiment of Figures 70, 70A, 71 , 76 and 77 will be assigned 4500 series reference numerals.

Similar to the header tank 4467 shown in FIGS. 70, 70A, 71, 76, and 77, the header tank 4567 shown in FIGS. A number of receiving openings 4579 for receiving the rear portion 4585 of the end 4577 of the flat tubing 4510, and a number of injection openings 4591 along the longitudinal sides of the header tank 4567 (only one side is visible in FIGS. 72-75). FIG. 75 provides additional details regarding the receiving opening 4579, including a rear portion 4585 for receiving and supporting the end 4577 of the flat tubing 4510 (not shown in FIG. 75 ), and an injection opening 4591 in fluid communication with the receiving opening 4579 .

The flattened tubing 4510 received through the receiving opening 4579 defines a corresponding gap 4593 between the inner surface of the receiving opening 4579 and the flattened tubing end 4577 . Referring specifically to FIG. 73 , the flow channel 4516 of each flat tube 4510 within the respective receiving opening 4579 is in fluid communication with the interior chamber 4587 of the header tank 4567 . FIG. 73 also illustrates the connection between injection opening 4591 and receiving opening 4579 for injecting adhesive 4589 (not shown) into gap 4593 as described above.

As best shown in FIG. 74 , the inlet to receiving opening 4579 may be closed or substantially closed on one or more sides of each flat tube end 4577 by an inlet wall 4599 (not shown in FIG. 75 ). The inlet wall 4599 may be defined by one or more elements of the header tank 4567, such as a plate defining a plurality of openings therein defining an inlet to each receiving opening 4579 (in which the plurality of openings and When installing with the storage opening 4579 aligned). Optionally, the inlet wall 4599 may be bounded by the ends of the receiving opening walls that are enlarged, spread, curved, or otherwise shaped to close the gap 4593 as described above. In some embodiments the inlet wall 4599 is shaped to match or substantially match the cross-sectional shape of the flat tube end 4577 received therein. Additionally, the inlet wall 4599 may be dimensioned to define a play fit with the flat tube end 4577, or may alternatively define a tight fit such that a slight pressure may be exerted on the header tank 4567 and/or the flat tube 4510, to push the flat tube 4510 through the inlet wall 4599 and into the remainder of the receiving opening 4579. In this way, a seal at the entrance to the receiving opening 4579 may be provided between the header box 4567 and the flattened pipe end 4577 . These seals may be liquid-tight or substantially liquid-tight in some embodiments, and may prevent adhesive leakage during adhesive injection in some embodiments.

It should be noted that the configuration of header tank 4567 as shown in Figures 72-75 (and others) is exemplary only and does not limit the scope of the invention.

In some embodiments, the flattened tube ends 4477, 4577 can be deformed. For example, the flat tube ends 4477, 4577 may be deformed such that the major diameter D of the flat tubes 4410, 4510 increases and the minor diameter d of the flat tubes 4410, 4510 decreases at the flat tube ends 4477, 4577. Given the relatively small wall thickness of the flat tubes 4410, 4510 in some embodiments, this deformation can be performed without significant loading on the walls of the flat tubes 4410, 4510. In some embodiments, the dimensions of the perimeter of the deformed flattened tube end 4477, 4577 remain substantially the same as the dimensions of the deformed flattened tube end 4477, 4577. As a result, the walls of the flattened ducts 4410, 4510 do not experience significant expansion or contraction in these embodiments.

In some embodiments where the flattened pipe ends 4477, 4577 are deformed, these deformations may be performed prior to introducing the flattened pipe ends 4477, 4577 into respective receiving openings 4479, 4579 of the header tanks 4467, 4567. An example of a flat pipe to header connection in which the end of the flat pipe has been deformed will now be described with reference to FIGS. 78-83.

78-83 illustrate flat pipe to header connections according to three additional embodiments of the invention. These embodiments employ many of the same structures and have many of the same attributes as the embodiments of the flat pipe to header connection described above in connection with Figures 70-77. Accordingly, the following description is primarily directed to structures and features that differ from the embodiments described above in connection with FIGS. 70-77. For additional information regarding the structures and features of the connection embodiments described below and shown in FIGS. 78-83 , and alternatives to these structures and features, reference is made to the description above in connection with FIGS. 70-77 . Thereafter, structure and features of the embodiment shown in Figures 78-83 that correspond to structure and features of the embodiment of Figures 70-77 will be assigned reference numerals in the 4600, 4700 and 4800 series, respectively.

In various embodiments as shown in Figures 78-84, the flattened pipe ends 4677, 4777, 4877 are deformed and the header boxes 4667, 4767, 4867 have correspondingly shaped receiving openings 4679, 4779, 4879. Deformation of the flattened pipe ends 4677, 4777, 4877 as shown in FIGS. .

In the embodiment of FIGS. 78-80 , each flat tube 4610 has an end 4677 that is snugly received within a corresponding rear portion 4685 of a receiving opening 4679 . In this embodiment, the broad sides 4622, 4624 of each flat tube 4610 have been stretched (eg, bent away from each other) to define an enlarged flat tube end 4677, while the narrow sides 4618, 4820 have been compressed (set, bent towards each other) ). In addition, each receiving opening 4679 also has a stopper 4675 (see FIG. 80 ) for limiting the insertion of the flat tube 4610 to a desired distance.

Similar to the embodiment of FIGS. 78-80 , in the embodiment of FIGS. 81-83 , the broad sides 4722 , 4724 , 4822 , 4824 of each flattened tube 4710 , 4810 have been stretched to define enlarged flattened tube ends 4777 , 4877 , while the narrow sides 4718, 4720, 4818, 4820 are already compressed. However, the portion of the header tank 4767, 4867 that defines the receiving opening 4779, 4879 has one or Multiple slots 4773/4873. In either case, the slots 4773, 4873 are positioned and dimensioned to receive the free ends 4777, 4877 of the flat tubes 4710, 4810. The slots 4773, 4873 also serve as stops that limit the insertion depth of the flat tube ends 4777, 4877.

After the flattened pipe ends 4777, 4877 are inserted into the receiving openings 4779, 4879 and the slots 4773, 4873, adhesive 4789, 4889 (not shown) may be injected into the flattened pipe ends 4777, 4877 and the receiving openings 4779 In the gap 4793, 4893 between the inner surfaces of , 4879. This injection can be performed in any of the ways described herein, and is performed by way of example by injecting through the injection openings 4791, 4891 in the illustrated embodiment of Figures 81-83. In some embodiments, including those in which deformed flat tubing ends are used, one or more inserts 4771 may be disposed between the flat tubing ends 4777 to help prevent Deformation of the flat pipe end 4777 under compressive loading. For example, through the use of these inserts 4771, the inner fold formed in the embodiment of Figures 1-5 can be protected from deformation when exposed to internal pressure. For example, in the illustrated embodiment of FIGS. 81 and 83 , the insert 4771 has a generally trapezoidal cross-sectional shape, although any other cross-sectional shape may be used depending at least in part on the adjacent shape of the flattened conduit end 4777 . Insert 4771 may be introduced into its position adjacent flattened pipe end 4777 before or after application of adhesive 4789 (eg, after stage III in FIG. 84 , or before or after stage IV).

Where used, insert 4771 may be fabricated from any material including, but not limited to, plastic or metal, may be solid or hollow, and in some embodiments may be made of easily deformable or flowable and later cured material to define. Additionally, multiple inserts 4771 may be connected to a common rod or beam prior to or during insertion to define a comb-like shape (not shown). Such insertion, for example through a common rod or beam, may allow two or more (in some embodiments, all) inserts 4771 to be placed in one step. In some embodiments, the connection between the common rod or beam and the insert 4771 is unstable and the common rod or beam can be removed after insertion of the insert 4771 .

In order to be able to insert the insert 4771 at the desired location between adjacent flattened pipe ends 4777, either or both of the opposing longitudinal walls 4795 of the header box 4767 may have features aligned with these locations and made certain. A hole (eg, FIG. 83 ) is dimensioned to enable insertion of insert 4771 . In this regard, it should be noted that the inserts 4771 need not necessarily occupy the entire space of adjacent flattened pipe ends 4777, but only need to occupy enough space between the flattened pipe ends 4777 to support the ends under pressure as required.

It should be noted that the introduction of adhesive into the flattened pipe ends 4477, 4577, 4677, 4777, 4877 and the receiving openings 4479, 4579 as described herein can be utilized regardless of whether the flattened pipe ends 4477, 4577, 4677, 4877 are deformed. , 4679, 4779, 4879 in various ways.

In some embodiments of the invention, the header tank 4467, 4567, 4667, 4767, 4867 may include an opening 4469, 4569, 4679, 4779, 4879 extending from the receiving opening 4469, 4569, 4679, 4779, 4879 of the header tank 4467, 4567, 4667, 4767, 4867. Stiffening walls 4469, 4569, 4669, 4769, 4869 between and/or at least partially delimiting the walls. These stiffening walls 4469, 4569, 4669, 4769, 4869 may be used to provide reinforcement to components of the header tanks 4467, 4567, 4667, 4767, 486 as desired and are not visible in the illustrated header tank embodiment. For example, one or more stiffening walls 4669, 4769, 4869 may extend transversely of the header tank 4667, 4767, 4867 (e.g., connecting opposing longitudinal walls 4695, 4795, 4895 of the header tank 4667, 4767, 4867) , and may provide additional strength and/or rigidity to header tanks 4667, 4767, 4867. The stiffening walls 4669, 4769, 4869 can be formed in any manner and can be integral with the header tank 4667, 4767, 4867 or can be a separate element connected to the header tank 4667, 4767, 4867 in any suitable manner. In some embodiments, the stiffening walls 4669, 4769, 4869 are formed during injection molding of the header tank 4667, 4767, 4867 and are thus an integral part of the header tank 4667, 4767, 4867.

Some embodiments of header tanks 4667, 4767, 4867 according to the present invention may also or alternatively have stiffening walls extending longitudinally relative to header tanks 4667, 4767, 4867. For example, such stiffening walls may be formed between and connect walls defining receiving openings 4679, 4779, 4879 of header tanks 4667, 4767, 4867. As an example, one such longitudinal stiffening wall 4469 is shown in Figure 70A and is located halfway between the front and rear of the header tanks 4667, 4767, 4867 (however, such longitudinal stiffening walls may be located elsewhere as desired) . Such longitudinally extending stiffening walls 4469 may extend along any or all of the length of header tanks 4667, 4767, 4867 (interrupted by receiving openings 4679, 4779, 4879 as desired).

As noted above, header tanks may be constructed from any number of components connected together in any suitable manner. For example, Figures 72 and 82 illustrate header tanks 4467, 4867 in which header tanks 4467, 4867 are formed from two pieces 4467a, 4467b and 4867a, 4867b. In both illustrated embodiments, components 4467a, 4467b and 4867a, 4867b are joined along a Z-shaped interface, and may be joined by welding or gluing. Other ways of making this connection are possible based at least in part on the materials used to form the header tanks 4467, 4867. In some embodiments, this connection is releasable, such as that shown in FIGS. 4467b is releasably fastened in place.

The various flat tubes described herein can be used in a variety of different heat exchangers suitable for different applications. In doing so, the flat tubes can be modified from the embodiment shown in Figures 1-54 and/or assembled in the heat exchanger in various ways to adapt the heat exchanger to a particular application.

85-90 illustrate four configurations of heat exchangers according to different embodiments of the invention. While other heat exchanger embodiments can be obtained by modifying the number and arrangement of flat tubes and/or by modifying the type of flat tubes (e.g., tube size and shape, insert size and shape, etc.), as shown in Figures 85-91 The heat exchangers shown each offer unique advantages in many applications.

Before describing in more detail the individual heat exchangers 4963, 5053, 5163, 5263 shown in FIGS. - any of the shapes described in 54 and constructed in any of the manners described above with reference to Figs. Methods (eg, related to flat tubing, core construction, and core-to-header box installation) may be used in the construction and manufacture of heat exchangers 4963, 5063, 5163, 5263 as shown in Figures 85-90. For example, each of the flat tubes 4910, 5010, 5110, 5210 shown in FIGS. Wherein two separate pieces of sheet material are used to form each of the illustrated conduits 4910, 5010, 5110, 5210 and where a third separate piece of sheet material is used to form the inner inserts 4934, 5034, 5134, 5234. While the specific two-piece flat duct construction (with insert) as shown in FIGS. A is replaced by any of the one-piece or other two-piece flat tubes (with inserts) described and/or shown above to make the flat tubes 4910, 5010, 5110, 5210 and the resulting heat exchanger 4963, 5063, 5163, 5263 are suitable for any desired application. In this regard, combinations of flat tubes 4910 , 5010 , 5110 , 5210 and inserts formed from different numbers of sheets may be used in the same heat exchanger 4963 , 5063 , 5163 , 5263 .

In the illustrated duct configurations of FIGS. 85-91 and any of the alternative duct configurations just mentioned, either or both of the narrow sides of the flat duct may depend at least in part on the number of sheets of material used to construct the flat duct. May be formed by adjacent superimposed longitudinal edges of material. Each pair of overlapping longitudinal edges thus delimits a reinforced narrow side of the flat tube. In some embodiments, one or both of the overlapping longitudinal edges of the flat tube may be folded one or more times to define a greater material thickness at the narrow side of the flat tube. In some of these embodiments, the sheet of reinforcing material defining the insert may have one or both longitudinal edges shaped to lie adjacent the overlapping longitudinal edges of the flattened duct, thereby providing for Additional layer of material for pipe reinforcement. In addition, either or both of the longitudinal edges of the insert may be folded to have multiple layers of thickness adjacent to the overlapping longitudinal edges of the flat tube, thereby providing further strengthening. Thus, either or both of the narrow sides of the flattened duct may achieve a thickness in the amount of at least twice and in some embodiments greater than twice the thickness of the sheet material used to form the flattened duct wall. In , this is formed by rolling thicker sheet material.

As described in more detail above, in those embodiments where the flattened duct is constructed from a single piece (with or without an insert), the first narrow portion of the flattened duct can be formed by rounding one or more folds of the sheet of material. side, and overlapping the opposite longitudinal edges of the sheet of material to form the second narrow side of the flattened duct (e.g. by accommodating or enclosing the bend of one longitudinal edge within a larger bend of the other longitudinal edge, or as described herein other ways) to achieve narrow side reinforcement.

In some one-piece flat tube embodiments, one sheet of material may form the outer walls of the flat tube and the inner flow channels. In these embodiments, the step may be located at the bend of the sheet of material (which defines the narrow side of the flattened tube) where the longitudinal edges of the sheet of material are nested so that the outer surface of the flattened tube remains as smooth as possible. Furthermore, in those embodiments where the insert is defined by a separate piece of material, the two longitudinal edges of the separate piece of material may be rounded or otherwise shaped to be received within the narrow side of the flattened tubing (see e.g. Figure 46 for the illustrated embodiment).

Also as described in more detail above, in those embodiments where the flattened duct is constructed from two separate parts (with or without inserts), the two separate parts may be constructed identically, in which case the One longitudinal edge may have a lesser curved bend surrounding an adjacent longitudinal edge of the other component. The two individual parts can thus be inverted relative to each other to form a flat duct. In other embodiments, the two separate components are not identical to each other and have opposing longitudinal edges joined together in any of the ways described herein (including but not limited to nested arcuate longitudinal edges).

Additionally, the generally planar broad sides of any of the tube embodiments described and/or illustrated herein may be used to provide an improved brazed connection for mounting fins, thereby resulting in heat exchanger 4963, Improved heat exchange efficiency of 5053, 5163, 5263.

Also in either of the two-piece and three-piece flat tube configurations that may be used in the heat exchangers of FIGS. 85-89 , the inner insert may be corrugated or otherwise shaped to define two or more More flow channels. The inner insert may have corrugations of different shapes and/or sizes at different locations along the width of the insert to define two or more laterally arranged regions of flow channels of different shapes and/or sizes (e.g., See Figures 85-89). More broadly, the inner insert may be shaped to define regions of flow channels of different shapes and/or sizes at different locations along the width of the two-piece or three-piece flattened duct. In some embodiments, different regions of a flow channel may be isolated from each other, while in other embodiments, different regions are in fluid communication with each other (eg, at one or more locations along the length of one or more flow channels). Furthermore, in some embodiments, flow channels in one region are each isolated from another flow channel in the same region along the length of the flat tube, while in other embodiments flow channels in the same region are fluidly isolated from each other. In communication (eg, via openings between adjacent flow channels), but isolated from other flow channels in other regions.

It should be appreciated that many of the advantages of utilizing flat tubes 4910, 5010, 5110, 5210 according to the present invention in the illustrated embodiments of FIGS. 85-98 relate to Make this flat pipe. These advantages are achieved by using sheet material having a relatively small thickness as described above for forming flat tubes and inserts. The sheet material used to form the walls of the flattened ducts in the illustrated embodiment has a thickness of no greater than about 0.15 mm (0.0059055 inches). Additionally, the sheet material has a thickness of not less than about 0.03 mm (0.0011811 inches). Given the fact that the insert can be brazed to the wide sidewall of the flat tube, these types of wall thicknesses can be used to withstand compressive loads and in many embodiments can achieve relatively good internal pressure stability. Similarly, while any of the material thicknesses for the insert described above may be used for the embodiments of FIGS. . Additionally, the sheet material has a thickness of not less than about 0.03 mm (0.0011811 inches).

By utilizing the various flat tube configurations for the illustrated heat exchangers 4963, 5053, 5163, 5263 and for other heat exchanger designs, the advantages of increased production speed and/or reduced material and assembly costs may be realized. For example, based on the relatively small amount of sheet deformation required to form the one-piece or two-piece flat pipes described above in accordance with the present invention, it is possible to use endless sheets of material in pipe shops (e.g., manufacturing lines 3701 and 1900) even in Higher operating speeds allow for more economical duty on flat pipes. Furthermore, with relatively low modification expenditure, heat exchangers of almost any depth can be fabricated using the same source of flat tubing (e.g., continuous or endless tubing and tubing with fins fabricated as described above) .

The heat exchangers 4963, 5063, 5163, 5264 shown in Figures 85-90 are used not only to illustrate heat exchanger embodiments that provide good performance results in many A number of heat exchanger features are used in conjunction with features in heat exchangers according to other embodiments of the invention. These features include, but are not limited to, header tanks that are internally divided to direct separate flows through different interior regions of the same flat tube, and possible flow arrangements through heat exchangers.

Referring now to a heat exchanger 4963 as shown in FIG. 85 , the heat exchanger 4963 has a single row of flat tubes 4910 having a depth T (generally similar to the major diameter D of each flat tube 4910 ). While any of the other major diameters D and minor diameters d above may be used for the flat tube 4910 , the major diameter D of the flat tube 4910 as shown in FIG. 85 is no greater than about 300 mm (11.811 inches). In some embodiments, a major diameter D of not less than about 10 mm (0.3937 inches) is used to provide good performance results. Additionally, the minor diameter d of the flattened tubing 4910 as shown in FIG. 85 is no greater than about 15 mm (0.59055 inches). In some embodiments, a small diameter d of not less than about 0.7 mm (0.2756 inches) is used to provide good performance results. These dimensions of the flat tube 4910 in the illustrated embodiment of FIG. 85 are particularly suitable for a heat exchanger 4963 in a motor vehicle. However, other applications are possible and fall within the spirit and scope of the invention.

Heat exchanger 4963 as shown in FIG. 85 is adapted to cool two or three fluids by the flow of a common cooling fluid (eg, air) traveling between flat tubes 4910 . Cooling air is shown in FIG. 86 as a double boxed arrow flowing through fins (not shown) between the flattened ducts 4910 .

According to the illustrated embodiment of FIG. 86 , cooling air may flow from left to right or vice versa through the cooling grid defined by the duct-fin blocks 4965 . The flat ducts 4910 each include four interior regions 4975a, 4975b, 4975c, 4975d at different locations along the width of the flat ducts 4910. The four illustrated interior regions 4975a, 4975b, 4975c, 4975d have the same or substantially the same width, although interior regions 4975a, 4975b, 4975c, 4975d of different widths are possible in other embodiments. Additionally, each illustrated interior region 4975a, 4975b, 4975c, 4975d has a number of flow channels 4916a, 4916b, 4916c, 4916d each having a flow channel 4916a, 4916b with the other interior region 4975a, 4975b, 4975c, 4975d. , 4916c, 4916d have different shapes and/or sizes. The shape and size of the flow channels 4916a, 4916b, 4916c, 4916d in each interior region 4975a, 4975b, 4975c, 4975d is at least partially defined by the shape of the insert 4934 in that interior region 4975a, 4975b, 4975c, 4975d . Each flattened tube 4410 is generally the same as the other flattened tubes in the heat exchanger 4963, although in the illustrated embodiment the shape of the insert varies with the interior regions 4975a, 4975b, 4975c, 4975d.

While four interior regions 4975a, 4975b, 4975c, 4975d are employed in the heat exchanger 4963 shown in FIG. 85, any number of interior regions 4975a, 4975b, 4975b, 4975c, 4975d. In addition, while the various portions of the insert 4934 in each interior region 4975a, 4975b, 4975c, 4975d of the flattened duct 4910 as shown in FIG. (thus defining different flow channels 4916a, 4916b, 4916c, 4916d in each interior region 4975a, 4975b, 4975c, 4975d), in other embodiments, the Two or more may have the same or substantially the same flow channels 4916a, 4916b, 4916c, 4916d.

With continued reference to FIG. 85 , in some embodiments, each flat tube 4410 in a heat exchanger 4963 or portion of a heat exchanger 4963 has the same number of interior regions 4975a, 4975b, 4975c, 4975d, and flow channels 4916a, 4916b, 4916c, 4916d have the same or substantially the same shape and size. However, this is not necessarily the case in other embodiments. The size and shape of the regions within each flat tube 4910 and within groups of flat tubes 4910 may be determined based at least in part on the requirements of the application.

The heat exchanger 4963 of Figure 85 includes two header tanks 4967a and 4967b. One header tank 4967a includes three partition walls 4973a, 4973b, and 4973c extending in a direction substantially perpendicular to the depth T of the heat exchanger 4963 and spread out with respect to the lengthwise direction of the header tanks 4967a and 4967b. Another header tank 4967b includes two dividing walls 4973d and 4973e.

FIG. 85 illustrates a number of arrows indicating the direction of flow through heat exchanger 4963. On the left (relative to FIG. 85 ), media flows into the first header tank 4967a and through the first interior region 4975a of each flat tube 4910 . The second medium flows in the first header tank 4967a and passes through the second inner region 4975b of each flat pipe 4910, and is separated from the flow of the first medium through the first inner region 4975a by the first dividing wall 4973a therein . The second medium is also separated from the first medium through the first partition wall 4973d therein at the second header tank 4967b, and passes through the second partition wall 4973e therein at the second header tank 4967b and passes through the heat exchanger 4963. The third medium (which in some embodiments may be the second pass of the first medium through heat exchanger 4963, or another medium in other embodiments) is separated. The middle dividing wall 4973b of the first header tank 4967a separates the flow of the second medium entering the heat exchanger 4963 with the return flow of the second medium leaving the heat exchanger 4963 after passing through the third inner space 4975c of each flat tube 4910 separate. The third medium passes through the heat exchanger 4963 by flowing through the fourth inner region 4975d of each flat pipe 4910, and is separated from the second medium in the first header tank 4967a by the third dividing wall 4973 therein.

In some applications of the heat exchanger 4963 just described, the left side portion of the heat exchanger 4963 (see perspective view of FIG. 85 ) may be a high temperature region for the intake air. The intake air that exits this portion of the heat exchanger 4963 after passing through the first interior region 4975a of each flat tube 4910 may in some embodiments flow back into the heat exchanger 4963, passing through each of the right side portions of the heat exchanger 4963. A fourth inner region 4975b of a flat duct 4910. Therefore, this recirculation may be followed by a lower temperature region for the intake air. In these embodiments, the cooling fluid passing between the flat tubes 4910 may flow from right to left in the illustrated embodiment of FIG. 85 . In the middle portion of the heat exchanger 4963, high temperature cooling fluid can enter the first header tank 4967a, pass through the second inner region 4975b of each flat tube 4910, and pass through the second header tank 4967b and through the bottom of each flat tube 4910. The third interior region 4975c returns to exit the heat exchanger 4963. The return pass of this fluid (upstream of the first pass, with reference to the flow direction of the cooling fluid passing between the flat tubes 4910) thus defines a low temperature coolant region. In some embodiments, 10% of the fluid passing through the second and third interior regions 4975b, 4975c may reflow through these regions to further reduce the temperature, although in other embodiments other percentages (including 0) are possible of. Furthermore, in other embodiments, any number of dividing walls 4973a, 4973b, 4973c, 4973d, 4973e in any number of headers 4967a, 4967b having any number of fluid inlets and outlets may be otherwise arranged to provide other heat exchanger design and function.

FIG. 86 illustrates a heat exchanger 5063 according to another embodiment of the present invention in which flat tubes 5010 having the features shown in FIG. 87 are used. The illustrated heat exchanger 5063 is suitable for use with an onboard cooling fluid radiator, although other applications for the heat exchanger 5063 are possible. This heat exchanger 5063 includes an interior region 5075a, which in some embodiments may be a high temperature region due to the fact that the temperature of the cooling fluid therein is relatively high. The interior region 5075a may also include a low temperature interior region 5075b, wherein the temperature of at least a portion of the cooling fluid exiting the first interior region 5075a may be further reduced.

Further details relating to the flat tube 5010 shown in FIG. 86 can be seen in FIG. 87 showing a flat tube 5010 that can be used in the heat exchanger 5063 of FIG. 86 according to an embodiment of the present invention. . While the flat duct 5010 as shown in FIG. 87 provides unique performance results, it should be noted that any of the other flat duct embodiments disclosed herein may be used instead. The flattened duct 5010 as shown in FIG. 87 is formed from two separate pieces of material which each form the first and second portions 5012, 5014 of the two-piece flattened duct 5010. A third sheet of material is used to form the insert 5034 . The first and second portions 5012, 5014 in the illustrated embodiment are identical or substantially identical, but inverted relative to each other. During the manufacturing process, a larger bend defining a larger arcuate portion is formed on one edge of each portion 5012,5014 and surrounds a smaller arched portion formed on a corresponding longitudinal edge of the other portion 5014,5012 , such that the narrow sides 5018, 5020 of the flattened duct 5010 each have twice the wall thickness. In addition, opposing longitudinal edges 5038 , 5040 of the insert 5034 are shaped to fit inside the narrow sides 5018 , 5020 of the flat tube 5010 . In this particular configuration, three layer thicknesses are defined on one narrow side 5018 . In those embodiments where the material thickness of the insert 5034 is the same as the material thickness used for the first and second portions 5012, 5014, the aforementioned three layer thicknesses may be used to form the first and second portions 5012, 5014. three times the thickness of the material, although in other embodiments the insert 5034 may be made of thinner material. It should be noted that the features shown in Figure 87 may be applied to any of the other flat tube embodiments described and/or shown herein.

In the heat exchanger of Figure 86, the two interior regions 5075a, 5075b of the flat tube 5010 are at least partially bounded by the portion of the insert 5034 within each interior region 5075a, 5075b. Utilizing the relatively narrow flow channels 5016 defined by the narrower spaces between the corrugations of the insert 5034 in the first interior region 5075a, the first interior region 5075a can be used in some embodiments to support the flow channels in the second interior region 5075b. Fluid higher pressure. Furthermore, the (first) narrow side 5018 opposite the wall of the second narrow side 5020 corresponding to the second inner region 5075b has a greater reinforcing effect. This reinforcement is formed by the longitudinal edge 5040 of the insert 5034 at the second narrow side 5020 with two additional folds, thereby providing the second narrow side 5020 with five layers of material. This design provides an example of how a flat tube 5010 according to the invention can be strengthened where reinforcement is required due to expected stresses in selected areas of the flat tube 5010, and it can be provided in other areas where expected stresses are relatively low. Thinner walled regions (eg, 0.03mm-0.15mm (0.0011811-0.0059055) in some embodiments). The material weight used to construct the flat tube 5010 and manufacturing losses of the heat exchanger 5010 can thus be significantly reduced.

FIG. 88 illustrates a heat exchanger according to another embodiment of the present invention utilizing flat tubes 5110 as shown in FIG. 89 . In the illustrated embodiment of FIGS. 88 and 89 , the inner region 5175 of each flattened duct 5110 has a number of flow channels 5116 at least partially bounded by the insert 5134 formed uniformly or substantially uniformly along the width of the insert 5134 . However, the heat exchanger 5163 is provided with two different groups G1, G2 of flat tubes 5110 having different flow channels 5116 from each other. In other embodiments, any number of such groups is possible. The fluid of each group G1 , G2 flowing into or out of the flat pipe 5110 is separated from the fluid of the other group G2 , G1 by the transverse dividing wall 5173 in the header tank 5167 extending along the depth direction of the heat exchanger 5163 . Different fluids may flow in each group G1 , G2 of flat tubes 5110 . For example, a first medium (eg, oil) may flow in one group G1, while a second medium (eg, cooling fluid) may flow in another group G2. From the use of narrower flow channels 5116 in the flat ducts 5110 of group G2 and the smaller distance between the walls of the inserts 5134, and the narrower sides 5118, 5120 in the flat ducts 5110 of group G2 for a relatively more stable The large degree of reinforcement can be seen that the flat tubes 5110 of group G2 are generally suitable for use at higher pressures than the flat tubes 5110 of group G1. In some applications, the flat tubes 5110 of group G2 may define the low temperature cooling fluid radiator portion of heat exchanger 5163 , while the flat tubes 5110 of group G1 may define the high temperature cooling fluid radiator portion of heat exchanger 5163 .

Assuming that the medium in the flat pipes 5110 of group G2 is at a higher pressure than the medium in the flat pipes 5110 of group G1, the wide sides 5122, 5122, 5124 and narrow sides 5118, 5120 are reinforced. Specifically, the corrugations of the inserts 5134 in the flat tubes 5110 of group G2 are significantly narrower than the corrugations of the inserts in the flat tubes 5110 of group G1. In addition, the narrow sides 5118, 5120 of the flattened ducts 5110 in group G2 have five layers of material (two layers bounded by the overlapping longitudinal edges of the first and second duct sections 5112, 5124 at the narrow sides 5118, 5120, and defined by Three folds on each longitudinal edge 5138, 5140 of the insert 5134 define three layers), while only at the narrow sides 5118, 5120 of the flat duct 5110 in group G1 due to the lack of such insert folds, only Three layers of material. It should be noted that the flat tubes 5110 within the two sets G1, G2 may be the same or substantially the same, and may all be equally applicable to different types of inserts 5134 as shown in FIG. 89 . Thus, by defining different inserts 5134 of flat tubes 5110 for different sets of heat exchangers 5163, two different interior regions 5175 in the flat tubes 5110 are created in this particular embodiment.

FIG. 90 illustrates a heat exchanger according to another embodiment of the present invention utilizing flat tubes 5210 similar to FIG. 53 . In this particular embodiment, the relative dimensions of the interior regions 5275a, 5275b vary among the plurality of flat tubes 5210 of the heat exchanger 5263 . In some embodiments (including, for example, the illustrated embodiment of FIG. 90 ), the relative dimensions of the interior regions 5275 a , 5275 b gradually change along at least a portion of the heat exchanger 5263 along with the flat tube 5210 . Accordingly, the header tank 5267 fastened to the flat pipe 5210 may have the partition wall 5273a extending obliquely with respect to the end of the flat pipe 5210 . The position of this dividing wall 5273a may correspond to the change in size of the inner regions 5275a, 5275b in the flat duct 5210 . If desired, one or more additional dividing walls (eg, dividing wall 5273b shown in FIG. 90 ) may be included in header tank 5267 to provide further separation of flow through heat exchanger 5263 as desired.

An example of a one-piece flat tubing 5310 that may be used with any of the heat exchanger embodiments described above is shown as an example in FIG. 91 . In addition to the generally rectangular insert corrugations 5252 in the embodiment of FIG. 91 (as opposed to the generally triangular-shaped corrugations 4352 in the embodiment of FIG. Aside from the flow channels 4316, 5316, the one-piece flat tubing 5310 in FIG. 91 is substantially the same as the flat tubing shown in FIG. 54 previously described. Therefore, reference is made here to the description accompanying FIG. 54 for more information relating to flattened tubing as shown in FIG. 91 .

The flat tubes 4310, 5310 of Figures 54 and 91 may be fabricated from a single piece of material and may be used in place of any of the flat tubes in the embodiments described above in connection with Figures 85-90. It should also be noted that any of the other one-piece and two-piece flat tubes disclosed herein may be used in place of any of the flat tubes in the embodiments described above in connection with Figures 85-90. The narrow sides 4318 , 4320 , 5318 , 5320 of both the flattened ducts 4310 , 5310 as shown in FIGS. 54 and 91 comprise twice the thickness of the sheet of material used to form the flattened ducts 4310 , 5310 . The sheet of material may be adjacent to the portion of the sheet of material that is formed to define the integral insert 4334, 5334 in two regions (sets) that will be bent to form the narrow sides 4318, 4320, 5318, 5320 of the flattened duct 4310, 5310. and from the area where the sides meet), thereby increasing the thickness of the narrow side area by three times the material thickness. In addition, each longitudinal edge of the sheet of material can be bent and moved in the manner shown in Figures 54 and 91 to enclose the respective reinforced portion. Both of these reinforced portions may be provided with steps 4358, 4360 (not visible in Fig. 91 but visible in Fig. 54) to receive the respective longitudinal edges in a concave manner. To provide further reinforcement to the narrow sides 4318, 4320, 5318, 5320 of the flattened ducts 4310, 5310, additional folds may be incorporated into the reinforced portion as shown in FIGS. 54 and 91 . In the flat tube 5310 shown in FIG. 91, two sets of flow channels 5316 are defined, each having a different size than those in the other set. In contrast, in the illustrated embodiment of FIG. 54 all flow channels 4316 are substantially identical in size.

Figures 19-23 illustrate the many different flat tubes that can be fabricated from a single sheet of material. Similar to the other one-piece flat tubing shown herein, each of the embodiments shown in Figures 19-23 are particularly suitable for use with the heat exchangers 4963, 5063, 5163, 5263 discussed in connection with Figures 85-90. Specifically, the flattened ducts described above in connection with Figures 19-23 include narrow sides that are reinforced by the arrangement of vertical or horizontal folds. Additionally, Figure 46 illustrates a flattened duct 3710 that can be fabricated from a single piece of material with an insert 3734 that can be fabricated from another separate piece of material. This particular flat tube 3710 may also be used in place of any of the flat tubes 4910, 5010, 5110, 5210 described above with respect to FIGS. 85-90. As described in more detail above, in the embodiment of FIG. 46, a reinforced narrow side 3718 is formed by folding a portion of the sheet of material with additional folds. Another reinforced narrow side 3720 is formed by one longitudinal edge of a sheet of material surrounding an opposite longitudinal edge of the same sheet of material. Either or both of the longitudinal edges of the sheet of material may be folded to provide further reinforcement to protrude from this other narrow side 3720 . The second sheet of material may be provided with a plurality of corrugations as described above, and may also be provided with bends or folds at either or both of the longitudinal edges 3738, 3740 to provide for viewing of either or both of the narrow sides 3718, 3720. Strengthen further.

FIGS. 92-95 illustrate the process for joining sheets of material to form a heat exchanger or a portion of a heat exchanger (e.g., a heat exchanger core, a portion of a heat exchanger core, a tube insert, a heat exchanger tube, a thermal Exemplary heat exchanger structures and methods for heat exchanger fins or fins, heat exchanger headers, etc.). For example, in the illustrated embodiment of FIGS. 93-95 , fins 8313 are brazed to heat exchanger tubes 8310 . In these illustrated embodiments, the heat exchanger tubes 8310 are formed from a generally planar sheet of first material 8317 and the fins 8313 are formed from a second sheet of material 8333 having a corrugated shape. In other embodiments, the sheets of material being brazed are different portions of the same sheet of material. In other embodiments, and as explained in more detail below, the heat exchanger tubes 8310 and/or fins 8313 have different shapes.

While the methods described herein relate to the manufacture of specific heat exchanger embodiments in this patent application, this is by way of example only. Accordingly, it should be understood that the processes described with reference to FIGS. 92-95 may be applied to the manufacture of all heat exchangers and portions of heat exchangers described herein.

As explained above, the relatively small sheet material thickness of the heat exchanger tubes 8310 and/or the fins 8313 can provide advantages related to the overall performance of the heat exchanger, manufacturability, and possible wall configurations not available using thicker wall materials ( As disclosed herein) associated significant advantages. Furthermore, by utilizing one or more of the flat duct features described herein, the inventors have discovered that many different flat ducts with properties suitable for a variety of applications can be constructed with significantly reduced material while maintaining ribbed The strength and heat transfer properties of heavier traditional flat tubing. Furthermore, although referred to herein as flat heat exchanger tubes, the invention may also or alternatively be applied to heat exchanger tubes having different cross-sectional shapes, including but not limited to circular, rectangular, triangular or other polygonal, Irregular shapes etc.

In some embodiments, heat exchanger tubes 8310, heat exchanger fins 8313, and/or other portions of the heat exchanger may be formed from a sheet of material having the same or substantially the same thickness. Alternatively, in other embodiments, two or more parts of the heat exchanger may be formed from sheets of material having different thicknesses. In these other embodiments, heat exchanger tubes 8310 may be formed from a sheet of material 8317 having a first thickness, and heat exchanger fins 8313 may be disposed between adjacent tubes 8310 and may be formed from a sheet of material 8333 having a different thickness. form. In these embodiments, a first portion of the heat exchanger (e.g., the header) can be formed from a sheet of material having a first thickness, and a second portion of the heat exchanger (e.g., at least one of the tubes) can be formed from a sheet of material having a first thickness. A sheet of material having a second thickness is formed, while a third portion of the heat exchanger (eg, fins 8333 ) may be formed from a sheet of material having a third thickness.

For example, in some embodiments of the invention, flattened tubing 8310 may be formed from a sheet of material 8317 having a thickness of no greater than about 0.20 mm (0.007874 inches). However, in other embodiments, and as noted above, the present inventors have discovered that heat exchanger tubing formed from a sheet of material having a thickness of no greater than about 0.15 mm (0.0059055 inches) provides There are significant advantages associated with overall performance of the tubing and heat exchanger, manufacturability, and possible wall construction (as described herein) not available with later wall materials. Alternatively or additionally, the fins 8313 may be formed from a sheet of material 8333 having a thickness of no greater than about 0.20 mm (0.007874 inches). In other embodiments, the fins 8313 may be formed from a sheet of material 8333 having a thickness in the range of about 0.03-0.15 mm (0.0011811-0.0059055 inches) or slightly greater. In other embodiments, the heat exchanger fins 8313 may be formed from a sheet of material 8333 having a thickness of no greater than about 0.03-0.03 mm (0.0011811-0.0035433 inches).

As shown in FIGS. 92-95 , the first sheet of material 8317 manufactured in accordance with some embodiments of the present invention may include a brazing layer 8335 disposed on at least a portion of the outer surface X1 of the first sheet of material 83137 , disposed on the brazing layer 8335 . An inner sacrificial layer or anti-corrosion layer 8337 below a portion of layer 8335 or brazing layer 8335, and a core 8315 disposed below sacrificial layer 8337 (a single layer as shown in FIGS. with two or more layers). As used herein and in the appended claims, terms such as "below," "beneath," "above," and "above" are used to simplify description only and do not merely denote or imply that a referenced structure must be employed in any structure or Any particular orientation taken.

The core 8315 in the illustrated embodiment of FIGS. 92-95 comprises, for example, an aluminum alloy, for example. The aluminum alloy may have suitable amounts of one or more other materials, such as manganese, magnesium, titanium, copper, etc., for increasing the strength and/or corrosion resistance of the core 8315, or for varying the shape of the core 8315 as desired. one or more other properties.

In some embodiments, the core 8315 is altered to create one or more layers 8339 (sometimes referred to herein as sub-layers of the core 8315) that differ from the rest of the core 8315. For example, by diffusing silicon within the upper portion of the core 8315 at elevated temperatures, such as during a brazing process, the structure and/or composition of the aluminum alloy in the upper portion can be altered to define a layer 8339 into which the silicon is diffused (see Figure 93, which illustrates such processing on the structure of Figure 92). In some embodiments, this change may be made by creating an intermetallic compound that includes silicon, such as a silicon-manganese-aluminum intermetallic. By doing so, one or more constituents of the aluminum alloy in layer 8339 (e.g., manganese, by way of example only) may accumulate (where material sheet 8317 is heated sufficiently to allow such accumulation), resulting in core 8315 The improved layer 8339, in which the intermetallic compound is accumulated in the entire position of the improved layer 8339. In some embodiments, silicon may assist in this accumulation, for example, by pulling one or more of the alloy constituents out of solid solution, or otherwise.

The thickness of the modifying layer 8339 may depend on the temperature at which the diffusion referred to above occurs and the time allowed for such diffusion to occur (eg, the duration of the brazing cycle). In some embodiments, modifying layer 8339 is anodic with respect to the remainder of core 8315 . For example, in those embodiments where, as a result of the diffusion of silicon into the core 8315, manganese is taken out of solid solution and accumulates as an intermetallic, the resulting modified layer 8339 may be relative to the remainder of the core 8315. anode.

With continued reference to FIGS. 91-95 , and as described above, the illustrated sheet of material 8317 includes one or more sacrificial layers 8337 (one in FIGS. 92 and 93 and two in FIGS. 94 and 95 ). Each sacrificial layer 8337 can include a metallic material, and can be a relatively pure or unalloyed metallic material. In some embodiments, the sacrificial layer 8337 comprises an aluminum alloy through which silicon diffuses at a slower rate than through the underlying core material 8315 and has corrosion capabilities as described herein. For example, in some embodiments, the sacrificial layer 8337 comprises an aluminum alloy through which silicon diffuses at no more than 50% of the rate through the core material 8315 of the underlying layer. In other embodiments, the sacrificial layer 8337 comprises an aluminum alloy through which silicon diffuses at no more than 70% of the rate through the underlying core material 8315 . In this regard, the sacrificial layer 8337 may have trace amounts of one or more additional materials (eg, metals such as iron, copper, zinc, magnesium, and mixtures of these metals). In some embodiments, the sacrificial layer 8337 has a corrosion capability substantially similar to the corrosion capability of the adjacent residual braze material of the braze layer 8335 after the brazing process. In this regard, it should be noted that residual amounts of brazing material may remain on any or all of the sheet of material 8317 following the brazing process. Furthermore, in some embodiments, the material of the sacrificial layer 8337 is anodic to the material of the core 8315 (eg, to the modification layer 8339 and/or to the remainder of the core 8315).

In some embodiments, the brazing layer 8335 includes an aluminum silicon alloy brazing material. In other embodiments, other brazing materials may also or alternatively be used, some of which include silicon. The brazing layer 8335 may extend across the entire outer surface of the sheet of material 8317, or may alternatively extend over less than the entire outer surface of the sheet of material 8317 (eg, only over the desired brazing locations). The brazing layer 8335 may be a portion of the sheet of material 8317 used in the brazing operation, or may be deposited on or formed from a portion of the sheet of material 8317 during the brazing operation. In either case, the residual braze material of braze layer 8335 may be anodic to sacrificial layer 8337 .

Any of the layers and/or sub-layers of the sheet of material 8317 described herein and/or shown in FIGS. 92-95 may be secured together by roll bonding. By way of example only, the secondary layer 8339 of the core 8315 may be fabricated by roll bonding a layer of material having the properties of the secondary layer to another layer of material, thereby fabricating the core 8317 as shown in FIG. 93 .

As will now be explained, the sheet of material 8317 formed in accordance with the present invention can reduce and/or prevent corrosion (eg, pitting corrosion). In some embodiments, one or more of the layers and sublayers of the sheet of material 8317 (e.g., the braze layer 8335, the sacrificial layer 8337, the sublayer 8339, and/or the remainder of the core 8315) may be formed by such a The material is formed or alloyed with such a material that it is anodic to the underlying layer or sublayer of the sheet of material 8317. For example, in some embodiments, each of the layers of the sheet of material 8317 and the sublayers (i.e., the residual braze material of the braze layer 8335 after the brazing process, the sacrificial layer 8337, the sublayer 8339, and/or or the remainder of the core 8315) may be formed from or alloyed with a material such that after brazing it is an anode to the underlying layer or sublayer of the sheet of material 8317 and is For its upper or secondary layer is the cathode.

In some embodiments, one or more layers and sublayers of sheet of material 8317 (i.e., braze layer 8335, sacrificial layer 8337, sublayer 8339, and/or the remainder of core 8315) are formed from such a material Or alloyed with a material such that there is a difference of at least about 30 millivolts between one or more of the underlying layers or sublayers. For example, in some embodiments, each of the layers of material sheet 8317 and sublayers (e.g., braze layer 8335, sacrificial layer 8337, sublayer 8339, and/or the remainder of core 8315) may be formed by such a The material is formed or alloyed with such a material that there is a difference of at least about 30 millivolts between each adjacent layer or between layers or sublayers that are separated from each other.

As noted above, in some embodiments, core 8315 includes titanium. In sufficient amounts, titanium can form dendrites during casting of the core 8315 , resulting in a titanium-aluminum-rich layer distributed throughout the core 8315 . Depending at least in part on how the sheet of material defining the core 8315 is fabricated, the titanium-rich aluminum may be located primarily in the sacrificial layer 8337, primarily in the remainder of the core 8315, or distributed throughout the core 8315. In some embodiments, titanium-rich aluminum may form a secondary layer in the core 8315 and may serve as another means of resisting corrosion of the core material. This secondary layer may also be cathodic to adjacent portions of the core 8315 to further resist corrosion.

In those embodiments in which the titanium-rich aluminum is formed in the secondary layer of the core as just described, the titanium-rich aluminum can be formed by forcing the corrosion in a direction parallel or generally parallel to the core 8315 or along a direction parallel to the titanium-rich aluminum secondary layer. The layers propagate in parallel or substantially parallel directions to help slow or reduce pitting corrosion, thereby helping to increase corrosion resistance. In some embodiments, the material of core 8315 includes about 0.05-0.30 wt% titanium. In other embodiments, the core 8315 material with about 0.10-0.25 wt% titanium provides good strength and corrosion resistance. However, in many embodiments, a sheet of material 8317 including a core layer 8315 having about 0.20 wt% or slightly more titanium provides improved overall performance.

In some embodiments, the sheet of material 8317 has a thickness of no greater than about 0.15 mm (note that any of the relatively thinner conduit wall and insert material thicknesses disclosed herein may be used). For example, the sheet of material in the illustrated embodiment of FIGS. 92 and 93 has a thickness of about 100 μm (3.3937 mils). As noted above, some embodiments of the present invention have a modified core sublayer 8339 that can result from the diffusion of silicon therein. In these embodiments, silicon may diffuse into the core 8315 from the sacrificial layer 8337 or from the brazing material brazing layer 8335 . Control of this diffusion can be performed by the sacrificial layer 8337, given that the rate of diffusion into the core 8315 can at least in part determine the depth of the resulting modified core sublayer 8339. In this regard, the sacrificial layer 8337 may serve to impede (but not stop) such silicon diffusion, and may include materials such as aluminum alloys that are more resistant to silicon diffusion and are capable of corrosion, as described above, in the Silicon diffuses in this material at a slower rate than in the core 8315 material. By utilizing this sacrificial layer 8337, silicon diffusion can be limited to a depth of 50 μm (1.969 mils) while still allowing sufficient brazing time at a high enough brazing temperature to braze the fins 8313 to Sheet 8317 of material. In some embodiments, the fabrication processes described herein can prevent or significantly reduce diffusion beyond a depth of 30 μm (1.181 mil).

In embodiments where two or more parts of the heat exchanger are fastened together, the second part of the heat exchanger (e.g., fins 8313) may also or alternatively include A braze layer on the outer surface, an inner sacrificial layer disposed below the braze layer or a portion of the braze layer, and a core disposed below the sacrificial layer. Alternatively or additionally, the core of the sheet of material used to form the second portion of the heat exchanger (eg, fins 8313 ) may comprise an outer or outer layer of modified core material as described above. Furthermore, each of the layers or sublayers of the sheet of material used to form the second portion of the heat exchanger (eg, fins 8313 ) may be anode to one or more underlying layers or sublayers. In some such embodiments, each of the layers and sublayers of the sheet of material used to form the second portion of the heat exchanger (e.g., the fins 8313) is formed of or alloyed with such a material, Such that there is a difference of at least about 30 millivolts between adjacent layers of the second portion of the heat exchanger.

In some embodiments where two or more parts of the heat exchanger are fastened together, the first part of the heat exchanger may be formed with an outer layer or exterior that is substantially anodic relative to the second part of the heat exchanger. Or the outer sheet of material is formed. For example, as shown in FIGS. 92-95 , in some such embodiments, the exterior or outer layer of the fins 8313 may be formed from a sheet of material that is anodic to the sheet of material 8317 used to form the heat exchanger tubing 8310 .

Alternatively or additionally, the exterior or outer layer of the fins 8313 may be formed from a sheet of material 8333 that is anodic to the residual alpha phase layer 8341 that is between the outer surface of the heat exchanger tubes 8310 and the fins 8313 between brazing materials. In some such embodiments, the residual alpha phase layer 8341 is anodic to the sacrificial layer 8337 of the sheet of material 8317 forming the heat exchanger tubing 8310 .

In some embodiments of the invention, the first and second parts of the heat exchanger may be connected to the opposite side of the third part of the heat exchanger. For example, in the illustrated embodiment of FIGS. 94 and 95 , a heat exchanger 8310 having first and second outer surfaces X1 , X2 is formed from a first sheet of material 8317 . As shown in FIGS. 94 and 95, each side of the sheet of material 8317 may include a braze layer 8335 (which provides at least a portion of the outer surface X1, X2 of the first sheet of material 8317), disposed on the braze layer 8335 or An inner sacrificial layer or anti-corrosion layer 8337 below a portion of the braze layer 8335, the core 8315 disposed between the sacrificial layers 8337. In some embodiments, both outer sides of the core 8315 may include secondary layers 8339 of modified core material.

The present inventors have found that if the brazing time (i.e., the time when the heat exchanger or parts of the heat exchanger is brazed through the brazing furnace) is shortened, the Corrosion resistance of parts of heat exchangers or heat exchangers of about 0.20 mm (0.007874 inch wall thickness) can be improved. The present inventors have determined that a reduction in brazing time of about 10% shows desirable results and may provide good strength and corrosion resistance, among many other advantages. Furthermore, the results could be improved if the brazing time was further reduced by about half.

More specifically, the inventors have discovered that increasing the brazing speed can reduce the diffusion of silicon from the brazing layer 8335 into underlying layers or sub-layers of the sheet of material 8317 . Diffusion of silicon is shown by dashed arrows in FIGS. 93 and 95 . The diffusion depth of silicon may be less than about 50 μm (1.969 mils), or may be significantly less in some embodiments. Figure 96 shows this relationship graphically. The dashed curves in Fig. 96 represent the diffusion process of silicon, while the solid curves represent the diffusion process according to conventional materials and brazing techniques.

In some embodiments of the invention, the brazed heat exchanger or portion of the heat exchanger is held on a conveyor or similar transport device that passes through the different temperature zones of the CAB brazing furnace. In some such embodiments, the temperature of the brazing furnace may be in the range of about 577-610°C (1070-1130°F).

The optimal brazing time for a particular heat exchanger or part of a heat exchanger depends at least in part on the total mass of the heat exchanger or part of the heat exchanger being brazed, the sheet of material The tempering conditions, the thickness of the brazed material sheet, and the composition of the brazed material sheet. For example, in some embodiments, the transport speed used in a CAB brazing furnace for brazing a heat exchanger or portion of a heat exchanger having a wall thickness of 0.20 mm (0.007874 inches) or greater is about 0.5 -1.5 m/min (19.69-59.055 in/min).

Prior to brazing a heat exchanger or part of a heat exchanger, the inventors have found that a sample of material having substantially similar or identical material properties to the heat exchanger or part of the heat exchanger being brazed can Used to experimentally determine the optimum temperature distribution for a brazed heat exchanger or part of a heat exchanger. The inventors have also found that by determining the optimum temperature profile, the transport velocity of the heat exchanger or portion of the heat exchanger can be increased to about 1.5-4.0 m/min (4.92-13.12 ft/min), thereby shortening the brazing time. time.

In some embodiments, a non-corrosive flux may be applied to the outer surface X1 of one or both sheets of aluminum material 8317, 8333 prior to brazing. In some embodiments, it may not be necessary to apply flux material to the outer surface X1 applied to one or both of the sheets of aluminum material 8317, 8333 to achieve a high quality brazed connection. Furthermore, in some embodiments, including embodiments in which a flux material is not applied to the surfaces of the sheets of material 8317, 8333 prior to brazing, the inventors have determined that the and/or lithium) to the material sheets 8317, 8333 to produce a high quality brazed connection in a controlled atmosphere.

Various features and advantages of the invention are set forth in the appended claims.

Claims (23)

1. A heat exchanger pipeline, comprising: A first sheet of material and a second sheet of material which together at least partially form a duct body defining an interior space and having opposing first and second Opposite first and second broad sides joined by two narrow sides, said first and second narrow sides defined by overlapping longitudinal edges of said first and second sheets of material at least from said duct body the first broadside extends to the second broadside of the duct body; and a third sheet of material forming an insert extending through the conduit body and at least partially defining a first flow path and a second flow path, Wherein, the thickness of each of the first sheet of material and the second sheet of material is no greater than about 0.20 mm. 2. The heat exchanger tube of claim 1, wherein: The insert has opposite ends received within the first narrow side and the second narrow side of the duct body and facing the first narrow side and the second narrow side of the duct body. The second narrow side is reinforced. 3. The heat exchanger tube of claim 1, wherein: The longitudinal edges of the insert are supported by the arcuate portions of the first and second sheets of material and are within the first and second narrow sides of the duct body, respectively. 4. The heat exchanger tube of claim 1 , wherein a portion of the first sheet of material defines a recess, and wherein an end of the second sheet of material is at least partially nested within the recess such that The outer surface of the first sheet of material adjacent the recess is flush with the outer surface of the second sheet of material in the recess. 5. The heat exchanger tube of claim 4, wherein the recess extends into a planar portion of one of the opposed first and second broad sides of the tube body. 6. The heat exchanger tube of claim 1, wherein: Edges of the insert are folded such that the insert is generally parallel to at least one of the first and second broad sides of the duct body. 7. The heat exchanger tube of claim 1, wherein said overlapping portion of said first and second sheets of material at said first narrow side extends to said first width of said tube body. position in the generally planar portion of the side and terminates at said position. 8. The heat exchanger tube of claim 1, wherein the first sheet of material and the second sheet of material have substantially the same shape. 9. The heat exchanger tube of claim 1, wherein the first sheet of material and the second sheet of material are substantially identical. 10. The heat exchanger tube of claim 7, wherein said overlapping portion of said first and second sheets of material at said second narrow side extends to said second width of said tube body. and terminate at another location in the generally planar portion of the side. 11. The heat exchanger tube of claim 7, wherein said overlapping portion of said first and second sheets of material at said second narrow side extends to said first width of said tube body. and terminate at another location in the generally planar portion of the side. 12. The heat exchanger tube of claim 1, wherein the thickness of each of the first sheet of material and the second sheet of material is no greater than about 0.15 mm. 13. The heat exchanger tube of claim 1, wherein the thickness of each of the first sheet of material and the second sheet of material is no greater than about 0.10 mm. 14. The heat exchanger tube of claim 1, wherein said first sheet of material and said second sheet of material have a first layer, a second layer, and a third layer, said first layer comprising an aluminum alloy, The second layer includes an aluminum alloy having aggregates of intermetallic compounds including silicon, the third layer includes an anode relative to the second layer and is more resistant than the second layer a silicon diffused metal material, the second layer is located between the first layer and the third layer. 15. A method of forming heat exchanger tubes, the method comprising: forming at least a portion of each of a first broad side, a first narrow side and a second narrow side of the duct body, wherein the first and second the narrow sides face each other; forming at least a portion of each of the second broad side, the first narrow side, and the second narrow side of the conduit body from a second sheet of material having a thickness not greater than about 0.20 mm, wherein the conduit body said first and second broad sides oppose each other and are joined by said first and second narrow sides of said duct body; forming a third sheet of material to form an insert extending through the conduit body and at least partially defining a first flow path and a second flow path; and The first and second sheets of material are stacked at the first and second narrow sides such that the overall thickness of the duct body along the first and second narrow sides is doubled. 16. The method of claim 15, further comprising receiving ends of the insert within the first and second narrow sides of the duct body. 17. The method of claim 16, further comprising having longitudinal edges of said insert supported by arcuate portions of first and second duct sections and respectively at said first and second narrow edges of said duct body. side inside. 18. The method of claim 15, wherein the thickness of the first sheet of material and the second sheet of material is no greater than about 0.15 mm. 19. The method of claim 15, wherein the thickness of the first sheet of material and the second sheet of material is no greater than about 0.10 mm. 20. The method of claim 15, wherein the first sheet of material and the second sheet of material each have a first layer, a second layer, and a third layer, the first layer comprising an aluminum alloy , the second layer includes an aluminum alloy having aggregates of intermetallic compounds including silicon, the third layer includes an anode relative to the second layer and is more energy efficient than the second layer A metallic material resistant to diffusion of silicon, the second layer being located between the first layer and the third layer. 21. The method of claim 15, wherein forming the first sheet of material includes forming an edge of the first sheet of material into the second broad side of the duct body. 22. The method of claim 15, wherein the first sheet of material and the second sheet of material are substantially identical. 23. The method of claim 15, wherein the first sheet of material and the second sheet of material have substantially the same shape.

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