Integral heat exchanger core reinforcement

Abstract

An embodiment of a heat exchanger core includes a plurality of walls defining a plurality of layers in at least one heat exchange relationship. At least one of the layers of the core having a first load-bearing portion aligned with and adjacent to a first mount location on a perimeter of the core, and a first non-load-bearing portion distal from the non-load-bearing portion. A topology of the first load-bearing portion has a load bearing capacity greater than a load bearing capacity of the non-load-bearing portion.

1 . A heat exchanger core comprising:
 a plurality of walls defining a plurality of layers in at least one heat exchange relationship, at least one of the layers of the core having a first load-bearing portion aligned with and adjacent to a first mount location on a perimeter of the core, and a first non-load-bearing portion distal from the non-load-bearing portion;   wherein a topology of the first load-bearing portion has a load bearing capacity greater than a load bearing capacity of the non-load-bearing portion.   
     
     
         2 . The core of  claim 1 , wherein the heat exchanger comprises a plate-and-fin heat exchanger or a micro-channel heat exchanger. 
     
     
         3 . The core of  claim 2 , wherein the heat exchanger includes a plurality of corrugated fins. 
     
     
         4 . The core of  claim 3 , wherein a pitch of the plurality of corrugated fins in the first load-bearing portion is less than a pitch of the plurality of corrugated fins in the same layer in the non-load-bearing portion. 
     
     
         5 . The core of  claim 3 , wherein a thickness of the plurality of corrugated fins in the first load-bearing portion is greater than a thickness of the plurality of corrugated fins in the same layer in the non-load-bearing portion. 
     
     
         6 . The core of  claim 3 , wherein a thickness of a plurality of plates separating the plurality of corrugated fins in the first load-bearing portion is greater than a thickness of the plurality of plates in the same layer in the non-load-bearing portion. 
     
     
         7 . The core of  claim 1 , wherein the at least one of the layers of the core also includes a transition region between the load-bearing portion and the non-load-bearing portion. 
     
     
         8 . The core of  claim 1 , wherein a mount portion of the core is integrally formed with at least one of a mount pad and an end plate of the heat exchanger core. 
     
     
         9 . A heat exchanger assembly comprising:
 a mount for supporting a heat exchanger in a system; and   a heat exchanger core comprising:
 a plurality of walls defining a plurality of layers in at least one heat exchange relationship, at least one of the layers of the core having a first load-bearing portion aligned with and adjacent to a first mount location on a perimeter of the core, and a first non-load-bearing portion distal from the non-load-bearing portion; 
 wherein a topology of the first load-bearing portion has a load bearing capacity greater than load bearing capacity of the non-load-bearing portion. 
   
     
     
         10 . The assembly of  claim 9 , wherein the heat exchanger assembly is a plate-and-fin heat exchanger or a micro-channel heat exchanger. 
     
     
         11 . The assembly of  claim 10 , wherein the plate-and-fin heat exchanger includes a plurality of fins, and wherein a pitch of the plurality of fins in the first load-bearing portion of a first layer is less than a pitch of the plurality of fins in the non-load-bearing portion of the same first layer. 
     
     
         12 . The assembly of  claim 10 , wherein the plate-and-fin heat exchanger includes a plurality of fins, and wherein a thickness of the plurality of fins in the first load-bearing portion of a first layer is greater than a thickness of the plurality of fins in the non-load-bearing portion of the same first layer. 
     
     
         13 . The assembly of  claim 10 , wherein a thickness of a plurality of plates separating a plurality of fins in the first load-bearing portion is greater than a thickness of the plurality of plates in the same layer in the non-load-bearing portion. 
     
     
         14 . The assembly of  claim 9 , wherein the heat exchanger is a shell-and-tube heat exchanger. 
     
     
         15 . The assembly of  claim 14 , wherein the mount includes at least one clevis leg or bar integrally supporting at least one tube of the shell-and-tube heat exchanger. 
     
     
         16 . A method of making a heat exchanger, the method comprising:
 forming a housing for a heat exchanger core;   forming a first mount portion;   additively manufacturing the heat exchanger core, the step comprising:
 forming a first load-bearing region in connection with the joint/mount; and 
 forming a first non-load bearing region outward of the non-load bearing region. 
   
     
     
         17 . The method of  claim 16 , wherein the core includes a different topology in the first load-bearing region than in the first non-load-bearing region. 
     
     
         18 . The method of  claim 16 , wherein the first load-bearing region is aligned with the at least one integrally formed joint such that a load path includes both the first load-bearing region and the at least one integrally formed joint. 
     
     
         19 . The method of  claim 16 , further comprising:
 forming a mount for a heat exchanger assembly; and   integrally forming the mount with at least one core wall or at least one manifold wall of the heat exchanger assembly via one or more of a casting process or an additive manufacturing process.   
     
     
         20 . The method of  claim 19 , wherein the mount is integrally formed with at least one of a mount pad and an end plate of the heat exchanger core.