Heat exchanger and methods of forming fins in a heat exchanger

Abstract

A method of forming fins in a heat exchanger having a metal body by skiving the metal body to form a first fin in a first orientation, and skiving the metal body again to form a second fin in a second orientation while straightening the first fin into a third orientation.

What is claimed is: 
     
         1 . A method of forming fins in a heat exchanger, the method comprising:
 providing a metal body including fluid cooling passages;   skiving the metal body to form a first fin extending from a first surface of the metal body, with the first fin having a body terminating in a tip and where the body is at a first orientation with respect to the first surface; and   skiving the metal body to form a second fin extending from the first surface of the metal body, with the second fin having a body terminating in a tip and where the body of the second fin is at a second orientation with respect to the first surface and simultaneously shaping the first fin to orient the body of the first fin in a third orientation with respect to the first surface.   
     
     
         2 . The method of  claim 1  wherein the first fin comprises a fin that extends substantially along a width of the metal body. 
     
     
         3 . The method of  claim 1  wherein the body of the first fin in the third orientation includes an arcuate cross section. 
     
     
         4 . The method of  claim 1  wherein skiving the metal body to form the second fin and simultaneously shaping the first fin is accomplished via a single advancing motion of a skiving machine along a lengthwise direction of the metal body. 
     
     
         5 . The method of  claim 4  wherein the skiving machine comprises a skiving blade and an operably coupled fin mover. 
     
     
         6 . The method of  claim 1  wherein skiving the metal body to form the first fin comprises creating of a straight fin at an angle less than 90 degrees from the first surface. 
     
     
         7 . The method of  claim 6  wherein shaping the first fin to orient the body in a third orientation comprises lifting the tip of the first fin away from the first surface. 
     
     
         8 . The method of  claim 7  wherein shaping the first fin to orient the body in a third orientation comprises straightening the fin to a more vertical position. 
     
     
         9 . The method of  claim 8  wherein shaping the first fin to orient the body in a third orientation comprises moving the fin to a 90 degree angle with respect to the first surface. 
     
     
         10 . The method of  claim 1  wherein providing a metal body including fluid cooling passages comprises extruding the metal body. 
     
     
         11 . The method of  claim 10  wherein the metal body is formed from an aluminum-based alloy. 
     
     
         12 . The method of  claim 1 , further comprising shaping the second fin to orient the body of the second fin in the third orientation with respect to the first surface. 
     
     
         13 . The method of  claim 12  wherein the metal body includes a predetermined angled surface that forms a leading edge of the first fin. 
     
     
         14 . A heat exchanger comprising:
 a metal body having an upper surface;   a set of fluid passages extending through at least a portion of a depth of the metal body, where the set of fluid passages is formed along at least a portion of a width of the metal body; and   a set of fins skived from the upper surface, with each of the set of fins having a body with a length and a laterally extending tip and where the length of the body extends substantially along the width of the metal body.   
     
     
         15 . The heat exchanger of  claim 14  wherein the length of a fin of the set of fins is greater than a width of the set of fluid passages. 
     
     
         16 . The heat exchanger of  claim 14  wherein the body includes an arcuate cross section. 
     
     
         17 . An annular surface cooler for an aircraft, comprising:
 a surface cooler metal body having a first surface and a second surface spaced from the first surface and configured to confront a peripheral wall of an annular fan casing;   a set of fluid passages extending through the metal body, where the set of fluid passages is formed along at least a portion of a width of the metal body; and   a set of fins skived from the first surface, with each of the set of fins having a body and a laterally extending tip and where the body extends substantially along the width of the surface cooler metal body.   
     
     
         18 . The annular surface cooler of  claim 17  wherein the body includes an arcuate cross section. 
     
     
         19 . The annular surface cooler of  claim 17  wherein the width of the body is greater than a width of the set of fluid passages. 
     
     
         20 . The annular surface cooler of  claim 17  wherein the metal body comprises an aluminum-based alloy body.