Heat exchanger assembly

Abstract

An improved heat exchanger assembly and method. First and second plates made of a predetermined thermally conductive material are configured when mated to form a hermetically sealed vapor chamber. A wick made of the same predetermined thermally conductive material resides in the vapor chamber forming a gas chamber.

1 . An improved heat exchanger assembly comprising:
 first and second plates made of a predetermined thermally conductive material configured when mated to form a hermetically sealed vapor chamber; and   a wick made of the predetermined thermally conductive material in the vapor chamber forming a gas chamber.   
   
   
       2 . The assembly of  claim 1  in which the wick is foam. 
   
   
       3 . The assembly of  claim 1  in which the wick is braided. 
   
   
       4 . The assembly of  claim 1  in which the wick lines the vapor chamber. 
   
   
       5 . The assembly of  claim 1  in which a peripheral friction stir weld hermetically seals the first and second plates. 
   
   
       6 . The assembly of  claim 1  in which brazing hermetically seals the first and second plates. 
   
   
       7 . The assembly of  claim 1  further including a port into the vapor chamber. 
   
   
       8 . The assembly of  claim 7  further including a plug made of the predetermined material inertia welded in the port. 
   
   
       9 . The assembly of  claim 1  in which the predetermined material includes aluminum. 
   
   
       10 . The assembly of  claim 1  in which the predetermined material includes copper. 
   
   
       11 . The assembly of  claim 1  in which the predetermined material includes carbon composites. 
   
   
       12 . The assembly of  claim 1  in which the wick is attached to walls of the vapor chamber. 
   
   
       13 . The assembly of  claim 12  in which the wick is brazed to the walls of the vapor chamber. 
   
   
       14 . The assembly of  claim 12  in which the wick is bonded to the walls of the vapor chamber and in which the wick is foamed in placed to the walls of the vapor chamber. 
   
   
       15 . The assembly of  claim 1  in which the wick is compressed into a desired shape. 
   
   
       16 . The assembly of  claim 1  in which the wick is machined, molded, or cast into a desired shape. 
   
   
       17 . The assembly of  claim 16  in which the wick includes fins. 
   
   
       18 . The assembly of  claim 17  in which the fins include nanotubes. 
   
   
       19 . An improved heat exchanger assembly comprising:
 first and second plates made of aluminum configured when mated to form a hermetically sealed vapor chamber;   an aluminum foamed wick lining the vapor chamber forming a gas chamber; and   a peripheral stir weld hermetically sealing the first and second plates.   
   
   
       20 . The heat exchanger assembly of  claim 19  further including a port into the vapor chamber. 
   
   
       21 . The heat exchanger assembly of  claim 20  further including a plug inertia welded in the port. 
   
   
       22 . An improved heat exchanger assembly comprising:
 a structure made of a first predetermined thermally conductive material forming a hermetically sealed vapor chamber therein; and   a wick made of a predetermined thermally conductive material the same as the first thermally conductive material or a material galvanically matched with the first thermally conductive material in the vapor chamber forming a gas chamber.   
   
   
       23 . The heat exchanger assembly of  claim 22  in which the structure includes first and second plates configured when mated to form the hermetically sealed vapor chamber between the plates. 
   
   
       24 . A method of making an improved heat exchanger assembly, the method comprising:
 forming cavities in first and second plates made of a predetermined thermally conductive material when mated forming a vapor chamber between the plates;   inserting a wick made of the predetermined thermally conductive material in the vapor chamber to form a gas chamber; and   hermetically sealing the vapor chamber.   
   
   
       25 . The method of  claim 24  in which the wick is foam. 
   
   
       26 . The method of  claim 24  in which the wick is braided. 
   
   
       27 . The method of  claim 24  in which the wick lines the vapor chamber. 
   
   
       28 . The method of  claim 24  in which hermetically sealing the vapor chamber includes stir welding the plates. 
   
   
       29 . The method of  claim 24  in which hermetically sealing the vapor chamber includes brazing the plates. 
   
   
       30 . The method of  claim 24  further including forming a port into the vapor chamber. 
   
   
       31 . The method of  claim 29  further including sealing the port with a plug made of the predetermined material. 
   
   
       32 . The method of  claim 31  in which sealing includes inertia welding. 
   
   
       33 . The method of  claim 24  in which the predetermined material includes aluminum. 
   
   
       34 . The method of  claim 24  in which the predetermined material includes copper. 
   
   
       35 . The method of  claim 24  in which the predetermined material includes carbon composites. 
   
   
       36 . The method of  claim 24  in which the wick is attached to walls of the vapor chamber. 
   
   
       37 . The method  claim 36  in which the wick is brazed to the walls of the vapor chamber. 
   
   
       38 . The method of  claim 36  in which the wick is molded or cast, and bonded to the walls of the vapor chamber. 
   
   
       39 . The method of  claim 24  further including the step of compressing the wick into a desired shape. 
   
   
       40 . The method of  claim 26  further including the step of forming the wick into a desired shape. 
   
   
       41 . The method of  claim 40  in which the wick is formed to include fins. 
   
   
       42 . The method of  claim 41  further including adding nanotubes to the fins.