Fin array for heat transfer assemblies and method of making same

Abstract

A fin array for a heat exchanger and method of forming same are disclosed. The fin array is an elongated one piece element that includes a plurality of fins. The fins include connected staggered top segments and bottom segments. A top bend axis extends continuously across a plurality of the top segments.

1 . A fin array for a heat exchanger assembly comprising: 
 an elongated one piece fin array including a plurality of fins, the fin including connected staggered top segments and bottom segments, and a top bend axis extending continuously across a plurality of the top segments.    
   
   
       2 . The fin array of  claim 1  wherein a fin material used to form the fin member is cut to generally define the top bend axis.  
   
   
       3 . The fin array of  claim 2  further comprising a bottom bend axis that extends continuously across a plurality of the bottom segments.  
   
   
       4 . The fin array of  claim 3  wherein the fin material is cut to generally define the bottom bend axis.  
   
   
       5 . The fin array of  claim 4  further comprising staggered fin bend axes on both sides of the top bend axis.  
   
   
       6 . The fin array of  claim 5  further comprising staggered fin bend axes on both sides of the bottom bend axis.  
   
   
       7 . The fin array of  claim 6  wherein the cuts used to form the top bend axis and the bottom bend axis are not continuous.  
   
   
       8 . The fin array of  claim 7  wherein the staggered segments have a generally rectangular shape.  
   
   
       9 . The fin array of  claim 8  wherein the top and bottom bend axes are weaker than the staggered fin bend axes.  
   
   
       10 . A fin array for a heat exchanger assembly comprising: 
 an elongated one piece fin array including a plurality of fins, the fins including connected staggered top segments and bottom segments, and a top bend axis and a bottom bend axis that extend continuously through a plurality of the top segments and bottom segments, respectively, and staggered fin bend axes on both sides of the top bend axis and bottom bend axis.    
   
   
       11 . The fin array of  claim 10  wherein the top and bottom bend axes are weaker than the staggered fin bend axes.  
   
   
       12 . The fin array of  claim 11  wherein the top and bottom bend axes extend across a width of the fin.  
   
   
       13 . The fin array of  claim 12  wherein a group of fins forms a fin set with the top and bottom bend axes extending across each fin set.  
   
   
       14 . The fin array of  claim 13  wherein the top and bottom bend axes extend straight through the top and bottom segments.  
   
   
       15 . A method of making a fin array for a heat exchanger assembly comprising: 
 a) providing a sheet of fin stock;    b) positioning and passing the fin stock through a cutting roller which produces a one piece fin member including a plurality of fins, the fins including connected staggered top segments and bottom segments, and the one piece fin member having the top and bottom bend axes extending continuously through the top and bottom segments, and staggered fin bend axes on both sides of the top and bottom bend axes; and    c) bending the fin stock along the top and bottom bend axes such that the top and bottom segments form a generally flat surface.    
   
   
       18 . The method of claim  17  wherein the bend axes are formed by cutting the fin stock.  
   
   
       19 . The method of  claim 18  wherein the bending of the fin stock requires a bending and a re-bending of the fin stock.  
   
   
       20 . The method of  claim 19  wherein the top and bottom bend axes are weaker than staggered fin bend axes.