Microchannel expanded heat exchanger

摘要

A microchannel heat exchanger (800) is manufactured by bonding a first sheet (802a) of material and a second sheet (802b) of material in a first connection pattern for integral formation of a core portion (801) and a manifold portion (808) for the first and second sheets (802a, 802b) of material. A third sheet (802c) of material is then superposed on to the second sheet (802b) of material and bonded in a second connection pattern to the second sheet of material for integral formation of the core portion (801) and the manifold portion (808) for the second and third sheets (802b, 802c) of material. The second and third sheets (802b, 802c) of material are bonded without bonding the second sheet (802b) of the material to the first sheet (802a) of material. The core portion (801) and the manifold portion (808) of the heat exchanger (800) are thus integrally created. The interstices between the first, second, and third sheets (802a, 802b, 802c) of material are then expanded to create fluid flow channels (806). This method can also be used to create a heat sink. The bonding method may be a form of laser welding where an opaque sheet absorbs the laser energy and the heat conducts through the top sheet to the sheet immediately below, but does not cause bonding with subsequent sheets below.

主权项

1. A method of manufacturing a microchannel heat exchanger comprising
providing a first flat sheet of material and a second flat sheet of material; providing a first connection pattern for integral formation of a core portion and a manifold portion between and out of the first and second flat sheets of material; operably bonding the first and second flat sheets of material to form seals between the first and second flat sheets of material according to the first connection pattern; providing a third flat sheet of material; providing a second, different connection pattern for integral formation of the core portion and the manifold portion between and out of the second and third flat sheets of material; superposing the third flat sheet of material onto the second flat sheet of material; operably bonding the third flat sheet of material to the second flat sheet of material to form seals between the second and third flat sheets of material according to the second connection pattern without bonding the third flat sheet of material to the first flat sheet of material to generate the core portion and the manifold portion integrally; providing a fourth flat sheet of material; superposing the fourth flat sheet of material onto the third flat sheet of material; operably bonding the fourth flat sheet of material to the third flat sheet of material to form seals between the third and fourth flat sheets of material according to the first connection pattern without bonding the fourth flat sheet of material to the second flat sheet of material to generate the core portion and the manifold portion integrally; providing at least a fifth flat sheet of material; superposing the fifth flat sheet of material onto the fourth flat sheet of material; operably bonding the fifth flat sheet of material to the fourth flat sheet of material to form seals between the fourth and fifth flat sheets of material according to the second connection pattern without bonding the fifth flat sheet of material to the third flat sheet of material to generate the core portion and the manifold portion integrally; and expanding interstices between the first, second, third, fourth, and fifth flat sheets of material bounded by the seals in the respective first and second connection patterns to create
a first layer of the core portion, including a first fluid flow layer, integrated with a first layer of the manifold portion between the first and second flat sheets of material,a second layer of the core portion, including a second fluid flow layer, integrated with a second layer of the manifold portion between the second and third flat sheets of material,a third layer of the core portion, including a third fluid flow layer, integrated with a third layer of the manifold portion between the third and fourth flat sheets of material, andat least a fourth layer of the core portion, including a fourth fluid flow layer, integrated with a fourth layer of the manifold portion between the fourth and fifth flat sheets of material.