Heat exchanger

Abstract

A heat exchanger is provided in which heat exchanger shells are formed by electro forming about a mandrel. The shells are attached and joined to provide a heat exchanger module. As the shells are not press formed problems with respect to material elongation to achieve deep grooves in the shells are potentially avoided and shells can be created with more desirable thickness to achieve more efficient heat exchange. Furthermore, reduced shell thickness will also reduce weight and therefore improve the acceptability of heat exchangers in particular applications such as those associated with aerospace and automotive sports.

We claim: 
     
         1 . A heat exchanger comprising a plurality of hollow heat exchanger shells associated together in a stack by way of association features, each hollow heat exchanger shell having grooves on opposite outside surfaces and a flow pattern on an inside surface, the grooves on the opposite outside surfaces of each hollow heat exchanger shell intersect and apertures extend through each hollow heat exchanger shell where some or all of the grooves on the opposite outside surfaces of the hollow heat exchanger shell intersect. 
     
     
         2 . A heat exchanger as claimed in  claim 1  wherein the flow patterns are diagonal. 
     
     
         3 . A heat exchanger as claimed in  claim 2  wherein the flow patterns in adjacent hollow heat exchanger shells cross at a desired angle. 
     
     
         4 . A heat exchanger as claimed in  claim 3  wherein the desired angle is in the range of about 75° to 105°. 
     
     
         5 . A heat exchanger as claimed in  claim 4  wherein the angle is about 90°. 
     
     
         6 . A heat exchanger as claimed in  claim 1  wherein the heat exchanger incorporates a flat in at least some of the hollow heat exchanger shells in order to create a seal about the periphery of the heat exchanger. 
     
     
         7 . A heat exchanger as claimed in  claim 1  wherein each hollow heat exchanger shell defines its own flow channels. 
     
     
         8 . A heat exchanger as claimed in  claim 1  wherein each hollow heat exchanger shell has apertures to reinforce consolidation. 
     
     
         9 . A heat exchanger as claimed in  claim 8  wherein the apertures are located at contacting junctions of each hollow heat exchanger shell. 
     
     
         10 . A heat exchanger as claimed in  claim 8  wherein the apertures receive a bonding material. 
     
     
         11 . A heat exchanger as claimed in  claim 10  wherein the bonding material is selected from the group comprising a braze material and an adhesive. 
     
     
         12 . A heat exchanger as claimed in  claim 1  wherein the hollow heat exchanger shells incorporate fins to facilitate heat exchange. 
     
     
         13 . A heat exchanger as claimed in  claim 1  wherein the heat exchanger incorporates header elements to couple flow paths in respect hollow heat exchanger shells. 
     
     
         14 . A heat exchanger as claimed in  claim 13  wherein the header elements couple together some of the flow paths in the heat exchanger to one input and one output path whilst areas about the other flow paths within the heat exchanger are coupled by header elements to another input flow path and output flow path from the heat exchanger. 
     
     
         15 . A heat exchanger as claimed in  claim 1  wherein the flow patterns on opposite outside surfaces of each hollow heat exchanger shells comprise diagonal grooves and the diagonal grooves on the opposite outside surfaces of each hollow heat exchangers shell cross at an angle in the range of 75° to 105°.