Polymer manifold and methods of fabrication

Abstract

A variety of polymer manifolds and associated fabrication methods are described. The described manifolds can be used in heat exchangers and a variety of other applications. In one aspect a polymer manifold is formed by welding distal tips of a multiplicity of polymer tubes to a polymer retainer. The tubes pass through guide passages that extend between opposing faces of the retainer and the distal tip of each tube is welded to a manifold face of the retainer. The welds between the tubes and the manifold face form sealed connections between the tubes and the manifold face. In some embodiments a locking plate is positioned adjacent the retainer. The tubes also pass through the locking plate such that during assembly, the locking plate and/or the retainer can be translated or otherwise moved slightly relative to the other to hold the tubes in place during welding to the retainer.

1 . A device comprising:
 a multiplicity of polymer tubes, each of the polymer tubes including first and second ends and a passage having first and second openings; and   first and second retainers, each retainer having a substantially planar polymer manifold face, an opposing second face and a multiplicity of guide passages that extend between the opposing faces; and   wherein each tube passes through an associated guide passage in both the first and second retainers and the first end of each tube has a first skirt portion that has a wider diameter than the associated first retainer guide passage and is fused to the manifold face of the first retainer outside of the associated first retainer guide passage in a manner that encircles the associated first retainer guide passage and the second end of each tube has a second skirt portion that has a wider diameter than the associated second retainer guide passage and is fused to the manifold face of the second retainer outside of the associated second retainer guide passage in a manner that encircles the associated second retainer guide passage.   
     
     
         2 . A device as recited in  claim 1  wherein each guide passage receives a single associated tube and the fusing of the tubes to the manifold faces form sealed connections between the tubes and the manifold faces. 
     
     
         3 . A device as recited in  claim 2  wherein the first retainer is formed entirely of a polymer material. 
     
     
         4 . A device as recited in  claim 2  wherein the first retainer further comprises a metal backing plate. 
     
     
         5 . A device as recited in  claim 2  further comprising a locking plate positioned adjacent the second face of the first retainer, wherein the locking plate includes a multiplicity of guide passages, each locking plate guide passage being aligned with an associated retainer guide passage and receiving an associate one of the tubes therethrough such that the tubes pass entirely through the locking plate. 
     
     
         6 . A device as recited in  claim 5  further comprising a manifold cap butt welded to the first retainer, wherein the manifold cap encloses the manifold face and forms a manifold plenum adjacent the manifold face. 
     
     
         7 . A device as recited in  claim 5  wherein both the first retainer and the locking plate are formed from plastic and the locking plate is welded to the first retainer. 
     
     
         8 . A device as recited in  claim 5  wherein the locking plate is formed from metal and has a larger diameter or size than the first retainer and includes an exposed coupling surface that extends radially beyond the first retainer to facilitate attachment of the device to other devices. 
     
     
         9 . A device as recited in  claim 5  wherein the locking plate abuts against the first retainer and the guide passages in the locking plate include tapered portions having wide ends that open on a surface facing away from the first retainer. 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . A device as recited in  claim 1  wherein the plurality of tubes and the first retainer are formed from a material selected from the group consisting of Polyethylene, Polypropylene, Polyamide, Polysulfone, and Polyphenylene Sulfide. 
     
     
         13 . (canceled) 
     
     
         14 . A device as recited in  claim 1  wherein the first retainer has a substantially cylindrical or puck shaped geometry. 
     
     
         15 . A device as recited in  claim 1  wherein the number of tubes passing through and fused to the first retainer is in the range of 20 to 250 tubes. 
     
     
         16 . A device as recited in  claim 1  wherein the guide passages include tapered portions having wide ends that open on the second face. 
     
     
         17 . A method of forming a manifold, the comprising:
 inserting a multiplicity of polymer tubes into guide passages in a retainer having a substantially planar polymer manifold face and positioning distal tips of first ends of the tubes such that they extend outward from the manifold face, wherein the distal tip of each tube that extends outward from the manifold face has substantially the same diameter and cross sectional geometry as the portion of such tube that passes through the associated guide passage; and   fusing the distal tips of the tubes to the manifold face to form a sealed connection between the tubes and the retainer to thereby form a manifold, wherein the fusing of the distal tips of the tubes to the manifold face is accomplished by melting the distal tips of the tubes that extend outward from the manifold face and pressing the melted material against the manifold face to form polymer skirts around the guide passages that are fused to the manifold face, the polymer skirts being integral extensions of the tubes.   
     
     
         18 . A method as recited in  claim 17  wherein the multiplicity of tubes are also inserted through a locking plate positioned adjacent the retainer, the method further comprising moving at least one of the locking plate and the manifold relative to the other to thereby apply a force to the tubes to hold the tubes in place during the fusing of the distal tips of the tubes to the substantially planar polymer manifold face. 
     
     
         19 . A method as recited in  claim 17  wherein the fusing of the distal tips of the tubes to the retainer is accomplished using a substantially planar heated platen that melts the distal tips of the tubes that extend outward from the manifold face and moves towards the substantially planar polymer manifold face as the distal tips of the tubes melt to facilitate fusing the tubes to the retainer. 
     
     
         20 . A method as recited in  claim 17  further comprising attaching a manifold cap to the retainer in a manner that forms a manifold plenum adjacent the substantially planar polymer manifold face. 
     
     
         21 . A method as recited in  claim 17  further comprising forming a second manifold at a second end of the multiplicity of polymer tubes. 
     
     
         22 . A method of forming a manifold, comprising:
 inserting a multiplicity of polymer tubes into guide passages in a retainer having a polymer manifold face and positioning distal tips of first ends of the tubes such that they extend outward from the manifold face, wherein the distal tip of each tube that extends outward from the manifold face has substantially the same diameter and cross sectional geometry as the portion of such tube that passes through the associated guide passage; and   fusing the distal tips of the tubes to the manifold face to form a sealed connection between the tubes and the retainer to thereby form a manifold, wherein the fusing of the distal tips of the tubes to the manifold face is accomplished by melting the distal tips of the tubes that extend outward from the manifold face and pressing the melted material against the manifold face to form polymer skirts around the guide passages that are fused to the manifold face, the polymer skirts being integral extensions of the tube;   wherein the multiplicity of tubes are also inserted through a locking plate positioned adjacent the retainer, the method further comprising moving at least one of the locking plate and the manifold relative to the other to thereby apply a force to the tubes to hold the tubes in place during the fusing of the distal tips of the tubes to the manifold face;   wherein the retainer and the locking plate are both formed from polymer materials, the method further comprising:   after the fusing, moving at least one of the locking plate and the manifold relative to the other a second time to release the hold; and   welding the locking plate to the retainer after the hold has been released.   
     
     
         23 . A method of forming a manifold, the comprising:
 aligning a retainer having a multiplicity of retainer guide passages and a substantially planar polymer manifold face with a locking plate having a multiplicity of locking plate guide passages such that each retainer guide passage plate longitudinally aligns with an associated locking plate guide passage;   inserting a multiplicity of polymer tubes into the aligned guide passages in the locking plate and retainer such that each polymer tube passes through a single associated guide passage in the locking plate and a single associated guide passage in the retainer, and positioning distal tips of first ends of the tubes such that they extend outward from the manifold face;   locking the tubes in place at least in part by moving at least one of the locking plate and the retainer relative to the other to thereby apply a force to the tubes to hold the tubes in place;   fusing the distal tips of the tubes to the manifold face with the tubes locked in place to form a sealed connection between the tubes and the retainer to thereby form a manifold, wherein the fusing of the distal tips of the tubes to the manifold face is accomplished by melting the distal tips of the tubes that extend outward from the manifold face and pressing the melted material against the manifold face to form polymer skirts around the guide passages that are fused to the manifold face, the polymer skirts being integral extensions of the tubes.   
     
     
         24 . A polymer manifold comprising:
 a retainer having a substantially planar polymer manifold face, an opposing second face and a multiplicity of guide passages that extend between the opposing faces, each guide passage being arranged to receive a single associated tube;   a multiplicity of polymer tubes, each of the polymer tubes including first and second ends and a passage having first and second openings, wherein each tube passes through an associated guide passage and the first end of each tube has a skirt portion that has a wider diameter than the associated guide passage and is fused to the manifold face of the retainer outside of the associated guide passage in a manner that encircles the associated guide passage, and wherein the fusing of the tubes to the manifold face form sealed connections between the tubes and the manifold face and each guide passage receives a single associated tube;   a manifold cap secured to the retainer, wherein the manifold cap encloses the manifold face and forms a manifold plenum adjacent the manifold face; and   a locking plate that abuts the second face of the retainer, wherein the locking plate includes a multiplicity of guide passages, each locking plate guide passage being aligned with an associated retainer guide passage and receiving an associate one of the tubes therethrough such that the tubes pass entirely through the locking plate; and   wherein the plurality of tubes and the retainer are formed from a material selected from the group consisting of Polyethylene, Polypropylene, Polyamide, Polysulfone, and Polyphenylene Sulfide.   
     
     
         25 . A device as recited in  claim 1  wherein:
 the retainer has a substantially cylindrical or puck shaped geometry; 
 the number of tubes passing through and fused to the retainer is in the range of 20 to 250 tubes; and 
 the guide passages in the locking plate include tapered portions having wide ends that open on a surface facing away from the retainer; and 
 wherein the locking plate is permanently affixed to the retainer.