Folded tube multiple bank heat exchange unit

Abstract

A multiple bank, flattened tube heat exchange unit includes a first tube bank including a flattened first tube segment extending longitudinally between a first manifold and a second manifold; and a second tube bank including a flattened second tube segment extending longitudinally between the first manifold and the second manifold, the second tube bank disposed behind the first tube bank; wherein an outer surface of the first tube segment and an outer surface of the second tube segment are formed from a single sheet of material.

We claim: 
     
         1 . A multiple bank, flattened tube heat exchange unit comprising:
 a first tube bank including a flattened first tube segment extending longitudinally between a first manifold and a second manifold; and   a second tube bank including a flattened second tube segment extending longitudinally between the first manifold and the second manifold, the second tube bank disposed behind the first tube bank;   wherein an outer surface of the first tube segment and an outer surface of the second tube segment are formed from a single sheet of material.   
     
     
         2 . The multiple bank, flattened tube heat exchange unit of  claim 1  further comprising:
 at least one web joining the first tube segment and the second tube segment. 
 
     
     
         3 . The multiple bank, flattened tube heat exchange unit of  claim 2  wherein:
 the outer surface of the first tube segment, the outer surface of the second tube segment and the at least one web are formed from the single sheet of material. 
 
     
     
         4 . The multiple bank, flattened tube heat exchange unit of  claim 1  further comprising:
 a first corrugated section positioned inside the first tube segment, the first corrugated section defining plurality of discrete flow channels in the first tube segment. 
 
     
     
         5 . The multiple bank, flattened tube heat exchange unit of  claim 4  wherein:
 the first corrugated section and the outer surface of the first tube segment are formed from the single sheet of material. 
 
     
     
         6 . The multiple bank, flattened tube heat exchange unit of  claim 5  further comprising:
 a second corrugated section positioned inside the second tube segment, the second corrugated section defining plurality of discrete flow channels in the second tube segment. 
 
     
     
         7 . The multiple bank, flattened tube heat exchange unit of  claim 6  wherein:
 the second corrugated section and the outer surface of the second tube segment are formed from the single sheet of material. 
 
     
     
         8 . The multiple bank, flattened tube heat exchange unit of  claim 6  wherein:
 the second corrugated section is formed from a second sheet of material. 
 
     
     
         9 . The multiple bank, flattened tube heat exchange unit of  claim 4  wherein:
 the first corrugated section is formed from a second sheet of material. 
 
     
     
         10 . The multiple bank, flattened tube heat exchange unit of  claim 1  further comprising:
 a notch formed in the single sheet of material, the notch positioned between the first tube segment and the second tube segment, the notch positioned proximate to a distal end of the first tube segment and the second tube segment. 
 
     
     
         11 . The multiple bank, flattened tube heat exchange unit of  claim 1  further comprising:
 at least one slot formed in the single sheet of material, the slot positioned between the first tube segment and the second tube segment, the slot positioned intermediate distal ends of the first tube segment and the second tube segment. 
 
     
     
         12 . A method of forming a multiple bank, flattened tube heat exchange unit, the method comprising:
 obtaining a single sheet of material, the single sheet of material having a longitudinal axis;   bending a first portion of the single sheet of material towards the longitudinal axis to define an outer surface of a first tube segment; and   bending a second portion of the single sheet of material towards the longitudinal axis to define an outer surface of a second tube segment.   
     
     
         13 . The method of  claim 12  further comprising:
 defining a first corrugated section, the first corrugated section defining plurality of discrete flow channels in the first tube segment. 
 
     
     
         14 . The method of  claim 13  wherein:
 the first corrugated section includes forming the first corrugated section in the first portion of the single sheet of material. 
 
     
     
         15 . The method of  claim 14  further comprising:
 defining a second corrugated section, the second corrugated section defining plurality of discrete flow channels in the second tube segment. 
 
     
     
         16 . The method of  claim 15  wherein:
 the second corrugated section includes forming the second corrugated section in the second portion of the single sheet of material. 
 
     
     
         17 . The method of  claim 15  wherein:
 the second corrugated section includes forming the second corrugated section in a second sheet of material. 
 
     
     
         18 . The method of  claim 13  wherein:
 the first corrugated section includes forming the first corrugated section in a second sheet of material. 
 
     
     
         19 . The method of  claim 12  further comprising:
 forming a notch in the sheet of material, the notch positioned along the longitudinal axis at a distal end of the sheet of material. 
 
     
     
         20 . The method of  claim 12  further comprising:
 forming at least one slot in the sheet of material, the slot positioned along the longitudinal axis intermediate distal ends of the sheet of material. 
 
     
     
         21 . The method of  claim 12  further comprising:
 brazing the first tube segment and the second tube segment. 
 
     
     
         22 . The method of  claim 12  further comprising:
 assembling the first tube segment and the second tube segment with a first manifold and a second manifold; and 
 brazing the assembled first tube segment, the second tube segment, the first manifold and the second manifold. 
 
     
     
         23 . The method of  claim 12  wherein:
 the single sheet of material is cladded with a brazing material. 
 
     
     
         24 . A method of forming a multiple bank, flattened tube heat exchange unit, the method comprising:
 obtaining a single sheet of material, the single sheet of material having a longitudinal axis;   bending the first portion of the single sheet of material towards the longitudinal axis to define an outer surface of a first tube segment and define an outer surface of a second tube segment.   
     
     
         25 . The method of  claim 24  further comprising:
 forming a first corrugated section and a second corrugated section in the sheet of material prior to bending. 
 
     
     
         26 . The method of  claim 25  further comprising:
 forming a rib in a first portion prior to the bending. 
 
     
     
         27 . The method of  claim 26  wherein:
 upon the bending, the rib is positioned between the first corrugated section and the second corrugated section. 
 
     
     
         28 . The method of  claim 26  further comprising:
 forming a notch in the single sheet of material, the notch located to be positioned between the first tube segment and the second tube segment, the notch positioned proximate to a distal end of the first tube segment and the second tube segment; and 
 forming a notch in the rib, wherein upon bending the notch in the rib is aligned with the notch in the single sheet of material. 
 
     
     
         29 . The method of  claim 26  further comprising:
 forming at least one slot in the single sheet of material, the slot located to be positioned between the first tube segment and the second tube segment, the slot positioned intermediate distal ends of the first tube segment and the second tube segment; and 
 forming at least one slot in the rib, wherein upon bending the at least one slot in the rib is aligned with the at least one slot in the single sheet of material.