Hybrid pin-fin-plate heat exchanger

Abstract

A heat exchanger is provided for allowing heat to be exchanged between a first fluid and a second fluid, wherein the first fluid is a liquid. The heat exchanger comprises a core comprising: a plurality of first flow paths for the first fluid and a plurality of second flow paths for the second fluid; a plurality of pin components extending into the first flow paths; a plurality of fin components extending through the second flow paths; a plurality of first enclosure bars extending between adjacent separating plates that are either side of the first flow paths, the first enclosure bars being arranged to at least partially define the first flow paths; and a plurality of second enclosure bars extending between adjacent separating plates that are either side of the second flow paths, the second enclosure bars being arranged to at least partially define the second flow paths.

1 . A heat exchanger for allowing heat to be exchanged between a first fluid and a second fluid, wherein the first fluid is a liquid, the heat exchanger comprising:
 a core comprising:   a plurality of first flow paths for the first fluid and a plurality of second flow paths for the second fluid;   a plurality of pin components extending into the first flow paths;   a plurality of fin components extending through the second flow paths;   a plurality of first enclosure bars extending between adjacent separating plates that are either side of the first flow paths, the first enclosure bars being arranged to at least partially define the first flow paths; and   a plurality of second enclosure bars extending between adjacent separating plates that are either side of the second flow paths, the second enclosure bars being arranged to at least partially define the second flow paths, and   a manifold arranged in fluid communication with each of the first flow paths of the core, wherein:   the manifold and the core are formed as one integral piece, said integral piece comprising a stack of laminate members with said pin components for the first flow paths and said fin components for the second flow paths, wherein the plurality of laminate members comprise:
 a plurality of first fluid enclosure structures for enclosing the first flow path, each first fluid enclosure structure comprising a first manifold section, the first enclosure bars, a separating plate for separating the first flow path from the second flow path, and the pin components, wherein the pin components are formed integrally with the separating plate and extend from the separating plate into the first flow path; 
 a plurality of second fluid enclosure structures for enclosing the second flow path, each second fluid enclosure structure comprising at least one second enclosure bar, and at least some of the of the second fluid enclosure structures comprising a second manifold section; 
 a plurality of further separating plates for placement at the opposite side of the first flow paths to the separating plates that are integrated with the first fluid enclosure structures, each further separating plate comprising a third manifold section, and each separating plate separating each first enclosure structure from adjacent second enclosure structures such that adjacent first and second flow paths are separated by respective separating plates with each flow path being bounded by two separating plates, 
   wherein the first, second and third manifold sections are shaped to form the manifold when the plurality of laminate members are stacked.   
     
     
         2 . The heat exchanger as claimed in  claim 1 , when in use and comprising the first fluid and the second fluid, wherein the second fluid is a gas. 
     
     
         3 . A heat exchanger as claimed in  claim 1 , wherein the first laminate member comprises a single integrally formed piece including the first enclosure bars, the first manifold section the separating plate and the pin components, which are formed on a surface of the separating plate. 
     
     
         4 . The heat exchanger as claimed in  claim 1 , comprising at least one flange for mounting the heat exchanger to other components, wherein the manifold, the core and the at least one flange are formed as one integral piece, wherein each of the first enclosure structures, the separating plates and at least some of the second enclosure structures comprise respective flange portions, wherein the flange portions are shaped to form the at least one flange when the plurality of laminate members are stacked. 
     
     
         5 . The heat exchanger as claimed in  claim 1 , wherein the first fluid enclosure structures including the first manifold section and the pins with integral separating plate are provided by a plurality of first laminate members, the second fluid enclosure structures including the second manifold section are provided by a plurality of second laminate members, and the further separating plates including the third manifold section may be on a plurality of third laminate members, with the first, second and third laminate members being stacked in sequence. 
     
     
         6 . The heat exchanger as claimed in  claim 1 , wherein the manifold is not welded to the core. 
     
     
         7 . The heat exchanger as claimed in  claim 1 , wherein the manifold comprises manifold features for allowing the first fluid to be supplied to and/or received from the first flow paths, and wherein the first, second and third manifold sections each comprise respective features that form the manifold features when the plurality of laminate members are stacked. 
     
     
         8 . The heat exchanger as claimed in  claim 1 , wherein the laminate members are produced by additive manufacturing and/or subtractive manufacturing. 
     
     
         9 . The heat exchanger as claimed in  claim 1 , wherein the fin components are not made by additive manufacturing or subtractive manufacturing. 
     
     
         10 . A method of manufacturing a heat exchanger, wherein the heat exchanger is the heat exchanger as claimed in  claim 1 , the method comprising:
 stacking the laminate members and the fin components; and   joining the laminate members and the fin components together to form the integral piece.   
     
     
         11 . The method as claimed in  claim 10 , wherein the method does not include joining the manifold and the core together. 
     
     
         12 . The method as claimed in  claim 10 , comprising producing at least some of the laminate members by additive manufacturing. 
     
     
         13 . The method as claimed in  claim 10 , comprising producing at least some of the laminate members by subtractive manufacturing. 
     
     
         14 . The method as claimed in  claim 13 , comprising producing the further separating plates by subtractive manufacturing. 
     
     
         15 . The method as claimed in  claim 10 , comprising removing excess material from the integral piece after the joining process.