Compact stacked fin heat exchanger

Abstract

A method and system is disclosed in which an air to air heat exchanger keeps two air streams separate through the use of metal fins. Edges of alternating fins are folded so that the end is in the proximity of the adjacent fin and the remaining gap is sealed. The fin stack is held together by interlocking features or through the use of a tube, in which case the fin stacks may be stamped and stacked on alignment stakes during production using the same holes as the tubes. The heat exchanger may have extended use in removing moisture and heat from a hot humid air stream. The heat exchanger has utility in heat recovery ventilation systems, clothes dryer heat recovery or other air to air heat exchanger processes where the pressure difference between the airstreams is less than approximately 5000 Pa.

What is claimed is: 
     
         1 . An air-to-air heat exchanger consisting of:
 a plurality of adjacent fins with a first end aligned on a first axis and a second end aligned along a second axis, wherein the second ends of alternating fins are folded so that the second end of each alternating fin is proximate to the adjacent fin, thereby creating a first set of channels between the fins;   and wherein first ends of alternating fins are folded so that the first end of each alternating fin is proximate to the adjacent fin, thereby creating a second set of channels between the fins;   a first air stream passing through the first set of channels; and   a second airstream passing through the second set of channels.   
     
     
         2 . The air-to-air heat exchanger of  claim 1 , wherein the first axis is horizontal and the second axis is vertical. 
     
     
         3 . The air-to-air heat exchanger of  claim 1 , wherein the first axis is horizontal and the second axis is not vertical. 
     
     
         4 . The air-to-air heat exchanger of  claim 1 , wherein the gap formed by placing each alternating fin proximate to the adjacent fin is sealed with a sealant. 
     
     
         5 . The air-to-air heat exchanger of  claim 1 , wherein the second ends of alternating fins and adjacent fins are folded to form a lap joint. 
     
     
         6 . The air-to-air heat exchanger of  claim 1 , wherein alternating fins and adjacent fins are held together by one or more tubes passing through a hole located on the interior surfaces of each fin. 
     
     
         7 . The air-to-air heat exchanger of  claim 1 , wherein alternating fins and adjacent fins are held together by a protrusion on one fin that interlocks with a protrusion on an adjoining fin. 
     
     
         8 . The air-to-air heat exchanger of  claim 1 , wherein the gap formed by placing each alternating fin proximate to the adjacent fin is sealed with a powder coating. 
     
     
         9 . The air-to-air heat exchanger of  claim 1 , wherein all fins are formed and folded on a single stamping press. 
     
     
         10 . The air-to-air heat exchanger of  claim 1 , wherein all fins are formed and folded on a single stamping press and alternating fins are rotated 90 degrees before assembling the heat exchanger. 
     
     
         11 . The air-to-air heat exchanger of  claim 1 , wherein all fins are formed and folded on a single stamping press and alternating fins are rotated 90 degrees and stacked onto stakes secured to a table that can rotate back and forth 90 degrees in an alternating sequence as the alternating fins are placed onto the stakes during assembling the heat exchanger. 
     
     
         12 . The air-to-air heat exchanger of  claim 1 , wherein a first set of fins are formed on a first stamping press and a second set of fins are formed on a second stamping press and the first set of fins and the second set of fins are alternatingly stacked onto stakes secured to a table during assembling the heat exchanger.