Heat Exchanger Tube, Heat Exchanger Tube Assembly, And Methods Of Making The Same

Abstract

A tube assembly for use in a heat exchanger includes a flat section with broad and flat opposing tube sides. Fin structures are bonded to the broad and flat tube sides in the flat section, and side sheets are bonded to the opposite ends of the fin structures. The flat section of the tube is located between cylindrical end sections adapted to be inserted into grommets. The construction of the tube assembly provides a stiff structure to survive insertion and removal of tube assemblies to and from a heat exchanger, for example, a radiator for heavy duty equipment.

We claim: 
     
         1 . A tube assembly for a heat exchanger, comprising:
 a tube having a flat section comprising first and second spaced apart, broad tube sides joined by opposing, spaced apart, narrow tube sides;   a first fin structure comprising a first plurality of wave crests and troughs connected by flanks;   a second fin structure comprising a second plurality of wave crests and troughs connected by flanks; and   first and second generally planar side sheets, wherein the wave troughs of the first fin structure are joined to the first broad tube side, the wave crests of the first fin are joined to a face of the first generally planar side sheet, the wave troughs of the second fin structure are joined to the second broad tube side, and the wave crests of the second fin are joined to a face of the second generally planar side sheet.   
     
     
         2 . The tube assembly of  claim 1 , wherein the tube further includes a first cylindrical section arranged at a first lengthwise end of the tube, and a second cylindrical section arranged at a second lengthwise end of the tube, the flat section being arranged between the first and second cylindrical sections. 
     
     
         3 . The tube assembly of  claim 1 , wherein the tube, the first fin structure, the second fin structure, and the first and second generally planar side sheets are joined by braze joints. 
     
     
         4 . The tube assembly of  claim 1 , wherein the tube, the first fin structure, the second fin structure, and the first and second generally planar side sheets are formed of one or more aluminum alloys. 
     
     
         5 . The tube assembly of  claim 1 , wherein the first and second spaced apart, broad tube sides have a first material thickness, the first and second generally planar side sheets have a second material thickness, and the first material thickness is at least twice the second material thickness. 
     
     
         6 . The tube assembly of  claim 1 , wherein the first and second fin structures and the first and second generally planar side sheets extend from a first one of the opposing, spaced apart, narrow tube sides to the other one of the opposing, spaced apart, narrow tube sides. 
     
     
         7 . A tube assembly for a heat exchanger, comprising:
 a fluid flow conduit extending in a lengthwise direction over at least a portion of the tube assembly and having a major dimension in a first direction perpendicular to the lengthwise direction, and a minor dimension substantially smaller than the major dimension in a second direction perpendicular to the lengthwise direction;   a continuous tube wall extending around the periphery of the fluid flow conduit;   first and second generally planar side sheets spaced equidistantly from, and on opposing sides of, the continuous tube wall in the second direction; and   a plurality of thin webs connecting the first and second generally planar side sheets to the continuous tube wall.   
     
     
         8 . The tube assembly of  claim 7 , wherein the continuous tube wall defines a tube wall centroidal moment of inertia with respect to an axis extending in the first direction, the centroidal moment of inertia of the tube assembly with respect to said axis being at least five times the tube wall centroidal moment of inertia. 
     
     
         9 . The tube assembly of  claim 8 , wherein the centroidal moment of inertia of the tube assembly with respect to an axis extending in the first direction is at least ten times the tube wall centroidal moment of inertia. 
     
     
         10 . The tube assembly of  claim 8 , wherein the centroidal moment of inertia of the tube assembly with respect to an axis extending in the first direction is about twelve times the tube wall centroidal moment of inertia. 
     
     
         11 . The tube assembly of  claim 7 , further comprising:
 a first cylindrical tube section joined to the continuous tube wall at a first end of the fluid flow conduit; and   a second cylindrical tube section joined to the continuous tube wall at a second end of the fluid flow conduit, the first and second cylindrical tube sections defining an inlet and an outlet, respectively, for the fluid flow conduit.   
     
     
         12 . The tube assembly of  claim 11 , wherein the continuous tube wall defines a first tube outer perimeter, the first cylindrical tube section defines a second tube outer perimeter, the second cylindrical tube section defines a third tube outer perimeter, and the first tube outer perimeter is greater than at least one of the second and third tube outer perimeters. 
     
     
         13 . The tube assembly of  claim 7 , wherein the continuous tube wall, the first and second generally planar side sheets, and the plurality of thin webs are joined by braze joints. 
     
     
         14 . The tube assembly of  claim 7 , wherein the continuous tube wall, the first and second generally planar side sheets, and the plurality of thin webs are formed of one or more aluminum alloys. 
     
     
         15 . The tube assembly of  claim 7 , wherein the plurality of webs and the first and second generally planar side sheets extend across the major dimension of the fluid flow conduit. 
     
     
         16 . The tube assembly of  claim 7 , wherein the continuous tube wall has a first material thickness, the first and second generally planar side sheets have a second material thickness, and the first material thickness is at least twice the second material thickness.