Aluminum heat exchanger and method of making thereof

Abstract

The present invention relates to an aluminum heat exchanger. More particularly, the present invention relates to an aluminum heat exchanger useful for motorized power systems similar to those utilized in the automotive industry for engine heat exchange, including, in particular, radiators. In a preferred method, the flat tubes of the heat exchanger are formed from flat sheet braze material and at least one portion is formed approximately normal to the wide portion (major axis) and parallel to the minor axis of the tube.

1 . A heat exchanger comprising: 
 a plurality of flat tubes disposed in parallel with respect to the direction of the air flow with at least one corrugated fin disposed between and connected to each pair of flat tubes composing the core portion;    the flat tubes having an height across the minor axis of from about 1.4 to 1.6 millimeters;    the corrugated fin having a thickness of about 0.03 to 0.12 millimeters; and    a tube wall thickness of between about 0.15 to 0.30 millimeters.    
   
   
       2 . A heat exchanger as in  claim 1  wherein the flat tubes have a spacing or tube pitch of about 7.5 to 8.5 millimeters between the tube centers at the center of the minor axes.  
   
   
       3 . A heat exchanger, as in  claim 1 , further having fin density less than or equal to about 25 fins per inch or 1.02 fins per millimeter as measured from center to center of each of the adjacent fin portions.  
   
   
       4 . A heat exchanger as in  claim 1  wherein the tube corrugated fin has a thickness of about 0.05 to 0.12 mm.  
   
   
       5 . A heat exchanger as in  claim 4  wherein the tube height is about between about 1.3 to 1.7 mm, and the fin height from about 6.25 to 6.75 mm.  
   
   
       6 . A heat exchanger, as in  claim 2 , wherein the fin density is less than or equal to about 25 fins per inch or 1.02 fins per millimeter as measured from center to center of each of the adjacent fin portions.  
   
   
       7 . A heat exchanger as in  claim 2  wherein the flat tube is formed from flat sheet braze material and has at least one portion formed approximately normal to the wide portion major axis and parallel to the minor axis of the tube, forming one or more tube passages.  
   
   
       8 . A heat exchanger as in  claim 3 , wherein the corrugated fin has a thickness of about 0.05 to 0.12 millimeters.  
   
   
       9 . A heat exchanger as in  claim 2  wherein the tube spacing or tube pitch is about 8.0 millimeters.  
   
   
       10 . An aluminum-based heat exchanger comprising: 
 a plurality of flat tubes disposed in parallel with respect to the direction of the air flow with at least one corrugated fin disposed between and connected to each pair of flat tubes composing the core portion;    the flat tubes having an height across the minor axis of from about 1.4 to 1.6 millimeters;    the corrugated fin having a thickness of about 0.03 to 0.12 millimeters;    a tube wall thickness of between about 0.15 to 0.30 millimeters; and    at least one fin louver.    
   
   
       11 . An aluminum-based heat exchanger as in  claim 10  such that the fin louver openings are disposed approximately normal to the air flow and angled to the air stream between the fin portions and the length of the louver.  
   
   
       12 . A heat exchanger as in  claim 10  wherein the openings are disposed approximately normal to the flat of the core tubes and have a fin louver width of about 0.8 to 1.2 millimeters.  
   
   
       13 . A heat exchanger as in  claim 12  wherein the lead and trailing fin louver angles are approximately equal to the center neutral area fin louvers and the louver angles are less than the common louver angles relative to the fin face parallel to the air stream.  
   
   
       14 . A heat exchanger as in  claim 10  wherein the common louvers have at least two distinct angle groups in each fore and aft set and wherein the common louver groups increase in angle as they are near the common center neutral area relative to the fin face parallel to the air stream.  
   
   
       15 . An aluminum alloy or aluminum radiator comprising: 
 a plurality of flat tubes disposed in parallel with respect to the direction of the air flow with at least one corrugated fin disposed between and connected to each pair of flat tubes composing the core portion;    the flat tubes having an height across the minor axis of from about 1.4 to 1.6 millimeters;    the corrugated fin having a thickness of about 0.03 to 0.12 millimeters;    a tube wall thickness of between about 0.15 to 0.30 millimeters; and    wherein the tube spacing or tube pitch is about 7.5 to 8.5 millimeters, the fin height is less than 8.00 mm, and the core portion has a thickness of less than 50 mm.    
   
   
       16 . An aluminum alloy or aluminum radiator, as in  claim 15 , wherein the fin density is less than equal to 25 fins per inch or 1.02 fins per millimeter.  
   
   
       17 . A heat exchanger as in  claim 15  wherein the core thickness is between about 12 to 20 millimeters.  
   
   
       18 . A heat exchanger as in  claim 15  wherein the core thickness is between about 25 to 29 millimeters.  
   
   
       19 . A heat exchanger as in  claim 15  wherein the core thickness is between about 32 to 36 millimeters.  
   
   
       20 . A heat exchanger as in  claim 15  wherein the core thickness is between about 40 to 44 millimeters.