Method and apparatus for heat exchanging

Abstract

The subject invention pertains to a method and apparatus for heating exchanging. In various embodiments, the application of coating, plating, soldering, and brazing technologies can be used to create high performance heat exchangers. Specific embodiments of the subject heat exchanger can be lightweight and resistant or impervious to oxidation and/or corrosion. Specific embodiments of the subject heat exchanger can be highly manufacturable. Embodiments of the subject invention are directed to a heat exchanger that includes primarily, but not necessarily entirely, components or assemblies that are made from aluminum and/or aluminum alloys, and are coated or plated with a more oxidation and/or corrosion resistant metal. The coated or plated aluminum components or assemblies can be specifically resistant to corrosion or oxidation in the presence of water or water based solutions and mixtures. The metallic coating or plating materials can have excellent thermal conductivity so as to minimize the reduction of heat exchanger performance. Furthermore, these coated or plated components or assemblies can be highly assemblable and manufacturable as a result of the coating or plating process.

1 . An apparatus for exchanging heat, comprising:
 one or more components having an aluminum and/or aluminum alloy barrier, wherein at least a portion of the aluminum and/or aluminum alloy barrier is coated with a metal coating such that the metal coated surface is in contact with a first medium during operation of the apparatus, wherein the metal coated surface is more oxidation and/or corrosion resistant to the first medium than a surface of the uncoated aluminum and/or aluminum alloy barrier.   
   
   
       2 . The apparatus according to  claim 1 , wherein at least one of the one or more components is in thermal contact with a heat source such that heat is transferred from the heat source to the first medium through the aluminum and/or aluminum alloy barrier and the metal coating of the at least one of the one or more components. 
   
   
       3 . The apparatus according to  claim 2 , wherein the one or more components form a first channel for the first medium to flow through, wherein a first interior surface of the first channel is the metal coated surface of the aluminum and/or aluminum alloy barriers of at least one of the one or more components. 
   
   
       4 . The apparatus according to  claim 3 , wherein the one or more components form a second channel for a second medium to flow through, wherein the second medium is the heat source,
 wherein heat is transferred from the second medium to the first medium.   
   
   
       5 . The apparatus according to  claim 4 , wherein a second interior surface of the second channel is the metal coated surface of the aluminum and/or aluminum alloy barriers of a second at least one of the one or more components, wherein the second interior surface is more oxidation and/or corrosion resistant to the second medium than the surface of the uncoated aluminum and/or aluminum alloy barrier. 
   
   
       6 . The apparatus according to  claim 1 , wherein the metal is selected from the following group: zinc, tin, lead, silver, gold, copper, cadmium, nickel, and mixtures or alloys thereof. 
   
   
       7 . The apparatus according to  claim 1 , wherein the metal is copper. 
   
   
       8 . The apparatus according to  claim 1 , wherein the first medium is a refrigerant. 
   
   
       9 . The apparatus according to  claim 1 , wherein the first medium is water or a water-based solution. 
   
   
       10 . The apparatus according to  claim 4 , wherein the first medium and the second medium flow in a counter flow pattern. 
   
   
       11 . The apparatus according to  claim 4 , wherein the first medium and the second medium flow in a parallel flow pattern. 
   
   
       12 . The apparatus according to  claim 4 , wherein the first medium is a refrigerant. 
   
   
       13 . The apparatus according to  claim 8 , wherein the apparatus is a refrigerant condenser. 
   
   
       14 . The apparatus according to  claim 8 , wherein the apparatus is a refrigerant evaporator. 
   
   
       15 . A method for manufacturing a heat exchanger, comprising:
 providing one or more components having an aluminum and/or aluminum alloy barrier, wherein the one or more components form a first channel for a first medium to flow through;   locating a heat source in thermal contact with the one or more components such that heat is transferred from the heat source to the first medium through the aluminum and/or aluminum alloy barrier of at least one of the one or more components;   coating at least a portion of the aluminum and/or aluminum alloy barrier with a metal coating such that the metal coated surface is in contact with a first medium, wherein the metal coated surface is more oxidation and/or corrosion resistant to the first medium than a surface of the uncoated aluminum and/or aluminum alloy barrier.   
   
   
       16 . The method according to  claim 15 , wherein coating at least a portion of the aluminum and/or aluminum alloy barrier comprises:
 performing a zincate treatment to the at least a portion of the aluminum and/or aluminum alloy barrier to form a coat of zinc;   plating the zinc coated at least a portion of the aluminum and/or aluminum alloy barrier with the metal.   
   
   
       17 . The method according to  claim 15 , wherein coating at least a portion of the aluminum and/or aluminum alloy barrier further comprises acid etching the at least a portion of the aluminum and/or aluminum alloy barrier prior to performing the zincate treatment. 
   
   
       18 . The method according to  claim 17 , wherein the metal is selected from the following group: zinc, tin, lead, silver, gold, copper, cadmium, nickel, and mixtures or alloys thereof. 
   
   
       19 . The method according to  claim 17 , wherein the metal is copper. 
   
   
       20 . The method according to  claim 19 , further comprising:
 applying a layer of nickel before metal plating with copper.   
   
   
       21 . The method according to  claim 20 , wherein the layer of nickel is between 0.0001 inches and 0.01 inches thick. 
   
   
       22 . The method according to  claim 16 , wherein plating with the metal comprises electrolytically depositing the metal. 
   
   
       23 . The method according to  claim 16 , wherein the first medium is a refrigerant. 
   
   
       24 . The method according to  claim 16 , wherein the first medium is water or a water-based solution. 
   
   
       25 . The apparatus according to  claim 3 , wherein the metal is copper. 
   
   
       26 . The apparatus according to  claim 25 , wherein the first medium is water or a water-based solution. 
   
   
       27 . An apparatus for exchanging heat, comprising:
 at least two components each having an aluminum and/or aluminum alloy surface that are soldered or brazed to another of the at least two components, wherein at least a portion of the aluminum and/or alloy surface of each of the at least two components that is soldered or brazed to another of the at least two components is coated with a metal coating, wherein the metal coated surface is more solderable or brazable respectively, than the aluminum and/or aluminum alloy surface.