Heat exchanger with extruded multi-chamber manifold with machined bypass

Abstract

The present invention heat exchanger with extruded multi-chamber manifolds includes at least two panels, with each panel having a row of at least one channel which communicates fluid. The heat exchanger includes a first manifold and a second manifold, the first manifold and the second manifold each having at least two manifold chambers. Each panel is attached to a manifold chamber of the first manifold and a manifold chamber of the second manifold, with each chamber having an inner wall and outer wall. The outer wall has a surface exposed outside the manifold chambers. There is also an opening through the outer wall including a bypass slot. The bypass slot allows fluid communication between the chambers.

1 . A heat exchanger comprising:
 at least two panels, each panel comprising at least one channel;   a first manifold and a second manifold, the first manifold and second manifold each having at least two manifold chambers, each panel attached to a manifold chamber of the first manifold and of the second manifold, the first manifold chambers and second manifold chambers including an inner wall and outer wall, the outer wall having a surface exposed outside the manifold chambers; and   an opening in the outer wall, the opening including a bypass slot, the bypass slot allowing fluid communication between two manifold chambers.   
     
     
         2 . The heat exchanger of  claim 1 , wherein panels connected to the first manifold and the second manifold allow fluid flow in only one direction. 
     
     
         3 . The heat exchanger of  claim 1 , wherein the opening is filled with a bypass plug. 
     
     
         4 . The heat exchanger of  claim 3 , wherein the bypass plug is sealed to the manifold by welding. 
     
     
         5 . An extruded multi-chamber manifold comprising:
 a manifold having at least two manifold chambers, each of the at least two manifold chambers including an inner wall and outer wall; and   an opening in the outer wall which extends to a bypass slot, the opening filled with a plug.   
     
     
         6 . The extruded multi-chamber manifold of  claim 5 , wherein the bypass slot allows fluid communication between at least two manifold chambers. 
     
     
         7 . The extruded multi-chamber manifold of  claim 6 , wherein the manifold includes at least three manifold chambers, with at least one manifold chamber lacking a bypass slot. 
     
     
         8 . A method of forming an extruded multi-chamber manifold with internal bypass comprising:
 creating an extruded manifold with at least two manifold chambers;   machining at least one opening in an outer wall and an inner wall of the manifold chambers, the opening including a bypass slot and a seat; and   inserting a plug into the bypass slot to seal the at least two manifold chambers, the plug located in the seat.   
     
     
         9 . The method of  claim 8 , wherein the method further comprises welding the plug. 
     
     
         10 . The method of  claim 8 , wherein an additional step is included comprising machining the seat to be wider than the bypass slot. 
     
     
         11 . The method of  claim 8 , wherein the bypass slot and the seat are machined separately.