High temperature plate fin heat exchanger

Abstract

A heat exchanger includes at least one plate including a first end portion. A second end portion is spaced apart from the first end portion. A cavity is disposed between the first end portion and the second end portion. The cavity defines a first flow path. An outer surface portion defines a second flow path. The at least one plate includes a single unitary part without a joint between any two portions. A first end cap defines an inlet disposed at the first end portion. A second end cap defines an outlet at the second end portion. A plate for a heat exchanger and a method are also disclosed.

What is claimed is: 
     
         1 . A heat exchanger comprising:
 at least one plate comprising,
 a first end portion, 
 a second end portion spaced apart from said first end portion, 
 a cavity disposed between said first end portion and said second end portion, the cavity defining a first flow path, 
 an outer surface portion defining a second flow path, 
 wherein the at least one plate comprises a single unitary part without a joint between any two portions; 
   a first end cap defining an inlet disposed at the first end portion; and   a second end cap defining an outlet at the second end portion.   
     
     
         2 . The heat exchanger as recited in  claim 1 , wherein the first end portion and the second end portion include an upper support surface portion within a common upper plane and a lower support surface portion within a common lower plane. 
     
     
         3 . The heat exchanger as recited in  claim 2 , including fin portions extending outward from the outer surface portion. 
     
     
         4 . The heat exchanger as recited in  claim 3 , wherein the outer surface portion comprises a first side and a second side and the fin portions extend from both the first side and the second side. 
     
     
         5 . The heat exchanger as recited in  claim 3 , wherein the fin portions include a tip portion that extends past either of the upper common plane and the lower common plane. 
     
     
         6 . The heat exchanger as recited in  claim 1 , wherein the cavity includes at least one tabulator extending into the first flow path. 
     
     
         7 . The heat exchanger as recited in  claim 2 , wherein the at least one plate comprises a first plate, stacked on a second plate such that the lower support surface portion of the first plate abuts the upper support surface portion of the second plate and the second flow path is defined within a space between the first plate and the second plate. 
     
     
         8 . The heat exchanger as recited in  claim 7 , including additional plates stacked against one of the first plate and the second plate and aligned such that a lower support surface portion of one plate abuts an upper support surface portion of another plate, wherein each of the plates defines a first flow path through the plate and the second flow path is defined in spaced between the stacked plates. 
     
     
         9 . The heat exchanger as recited in  claim 1 , wherein the heat exchanger is an air to air heat exchanger and the first flow path through the at least one plate is configured for an airflow that is to be cooled and the second flow path is for a cooling airflow. 
     
     
         10 . A plate for a heat exchanger, the plate comprising:
 a first end portion spaced apart from a second end portion;   a cavity defining a first flow path between the first end portion and the second end portion; and   an outer surface portion defining a second flow path, wherein the plate comprises a single unitary part without a joint between any two portions.   
     
     
         11 . The plate as recited in  claim 10 , wherein the first end portion and the second end portion include an upper support surface portion within a common upper plane and a lower support surface portion within a common lower plane. 
     
     
         12 . The plate as recited in  claim 11 , wherein the outer surface portion comprises a first side and a second side and the fin portions extend from both the first side and the second side. 
     
     
         13 . The plate as recited in  claim 12 , wherein the fin portions include a top portion that extends past either of the upper common plane and the lower common plane. 
     
     
         14 . The plate as recited in  claim 10 , wherein the cavity includes a means for disrupting flow. 
     
     
         15 . A method of building a heat exchanger comprising:
 creating a core defining internal features including an inner cavity of a completed plate;   inserting the core within a mold cavity that defines outer surfaces of a completed plate;   molding the plate to include the outer surfaces defined by the mold cavity an inner surfaces defined by the core, wherein the completed plate defines a first flow path through the inner cavity and an outer surface defining a second flow path; and   assembling at least one completed plate to a first end cap at a first end portion of a completed plate and a second end cap to a second end portion of the completed plate.   
     
     
         16 . The method as recited in  claim 15 , wherein the mold cavity includes features for defining fin portions that extend outward from an outer surface of a completed plate. 
     
     
         17 . The method as recited in  claim 16 , wherein the core includes portion for defining flow disrupting features within the inner cavity of the completed plate. 
     
     
         18 . The method as recited in  claim 15 , wherein each plate comprises a single unitary part without a joint between any two portions.