Integrated headers for heat exchangers

Abstract

A plurality of heat exchanger designs with integrated headers are provided. The heat exchanger comprises a heat exchanger matrix with a plurality of flow paths in a first direction wherein the plurality of flow paths are patterned to create a plurality of inputs to the plurality of flow paths on an input surface. The integrated header comprises a primary distribution header and a plurality of distribution header channels that connect to a plurality of feeder tubes that fluidly couple the plurality of distribution header channels with the plurality of matrix inputs such that there is a single feeder tube for each input.

What is claimed is: 
     
         1 . A heat exchanger comprising:
 a heat exchanger matrix with a plurality of flow paths in a first direction wherein the plurality of flow paths are patterned to create a plurality of inputs to the plurality of flow paths on an input surface;   a header comprising:
 a primary distribution header that spans across the input surface in a second direction; 
 a plurality of distribution header channels that span across the input surface in a third direction perpendicular to the second direction wherein each distribution header channel in the plurality of distribution header channels is in fluid communication with the primary distribution header; and 
 a plurality of feeder tubes that fluidly couple the plurality of distribution header channels with the plurality of inputs such that there is a single feeder tube for each input. 
   
     
     
         2 . The heat exchanger of  claim 1 , wherein each distribution header channel tapers from an interface with the primary distribution header towards a distal end of the distribution header channel. 
     
     
         3 . The heat exchanger of  claim 1 , wherein the cross section of each distribution header channel is shaped in a teardrop. 
     
     
         4 . The heat exchanger of  claim 1 , wherein the plurality of distribution header channels comprises at least two layers stacked in the first direction. 
     
     
         5 . The heat exchanger of  claim 4 , where a first layer of distribution header channels is offset in the second direction from a second layer of distribution header channels. 
     
     
         6 . The heat exchanger of  claim 5 , wherein a plurality of fins run in the second direction and a fin mechanically couples each feeder tube to a distribution header channel. 
     
     
         7 . The heat exchanger of  claim 1 , wherein a wall gap separates the input surface from the header. 
     
     
         8 . The heat exchanger of  claim 3 , wherein a point of the teardrop are all oriented in the second direction. 
     
     
         9 . The heat exchanger of  claim 1 , wherein each distribution header channel has more than one feeder tube extending to the input surface along a single plane in the second direction. 
     
     
         10 . The heat exchanger of  claim 1 , wherein each distribution header channel spans more than one input along the second direction. 
     
     
         11 . The heat exchanger of  claim 10 , wherein a cross-section of each distribution header channel is shaped like a “D”. 
     
     
         12 . The heat exchanger of  claim 11 , wherein a tubeplate separates the input surface from the header and the tubeplate forms a flat side of the “D” shaped cross-section. 
     
     
         13 . A heat exchanger comprising:
 a heat exchanger matrix with a plurality of flow paths in a first direction wherein the plurality of flow paths are patterned to create a plurality of inputs to the plurality of flow paths on an input surface;   a header comprising:
 a primary distribution header that spans across the input surface in a second direction; 
 a plurality of distribution header channels that span across the input surface in a third direction perpendicular to the second direction and taper as they extend away in the third direction towards their distal end wherein each distribution header channel in the plurality of distribution header channels is in fluid communication with the primary distribution header; and 
 a plurality of feeder tubes that fluidly couple the plurality of distribution header channels with the plurality of inputs such that there is a single feeder tube for each input. 
   
     
     
         14 . The heat exchanger of  claim 13 , wherein the cross section of each distribution header channel is shaped in a teardrop. 
     
     
         15 . The heat exchanger of  claim 13 , wherein the plurality of distribution header channels comprises at least two layers stacked in the first direction. 
     
     
         16 . The heat exchanger of  claim 15 , wherein a first layer of distribution header channels is offset in the second direction from a second layer of distribution header channels. 
     
     
         17 . The heat exchanger of  claim 16 , wherein a plurality of fins run in the second direction and a fin mechanically couples each feeder tube to a distribution header channel. 
     
     
         18 . The heat exchanger of  claim 13 , wherein a wall gap separates the input surface from the header. 
     
     
         19 . The heat exchanger of  claim 14 , wherein a point of the teardrop are all oriented in the second direction. 
     
     
         20 . A heat exchanger comprising:
 a heat exchanger matrix with a plurality of flow paths in a first direction wherein the plurality of flow paths are patterned to create a plurality of inputs to the plurality of flow paths on an input surface;   a header comprising:
 a primary distribution header that spans across the input surface in a second direction; 
 a plurality of distribution header channels that span across the input surface in a third direction perpendicular to the second direction and taper as they extend away in the third direction towards their distal end wherein each distribution header channel in the plurality of distribution header channels is in fluid communication with the primary distribution header and wherein the plurality of distribution header channels comprises at least two layers stacked in the first direction and wherein a first layer of distribution header channels is offset in the second direction from a second layer of distribution header channels; and 
 a plurality of feeder tubes that fluidly couple the plurality of distribution header channels with the plurality of inputs such that there is a single feeder tube for each input.