Heat Exchangers and Systems Thereof

Abstract

Improved heat exchangers and methods of manufacturing the heat exchangers are provided. The methods include modification of surface(s) of the heat exchanger in an integrated manner during manufacturing, to impart desired properties such as decreased corrosion, pressure drop, and water retention, and increased anti-frosting performance.

1 .- 41 . (canceled) 
     
     
         42 . A method for manufacturing a heat exchanger, comprising:
 (a) assembling and temporarily connecting individual components of a heat exchanger, thereby forming a temporary heat exchanger assembly;   (b) subjecting the temporary heat exchanger assembly to a surface modification process to create a porous, nanostructured surface; and   (c) exposing the temporary heat exchanger assembly with the porous, nanostructured surface to a temperature between 250° C. and 585° C., thereby forming the heat exchanger.   
     
     
         43 . The method according to  claim 42 , wherein a second material is wicked into the porous, nanostructured surface of the heat exchanger in order to improve the mechanical properties of the heat exchanger. 
     
     
         44 . The method according to  claim 43 , wherein the second material comprises a thickness less than 25 microns 
     
     
         45 . The method according to  claim 42 , wherein the individual components of the heat exchanger comprise microchannel heat exchanger components. 
     
     
         46 . The method according to  claim 42 , wherein at least one of the individual components comprises a manifold, a fin, a tube, and/or a microchannel surface. 
     
     
         47 . The method according to  claim 42 , wherein the porous, nanostructured surface comprises a nanostructured material with a thickness of less than 20 microns. 
     
     
         48 . The method according to  claim 42 , wherein the surface modification process adheres parts of the heat exchanger. 
     
     
         49 . The method according to  claim 42 , wherein the porous, nanostructured surface comprises a nanostructured material that comprises silicon, zinc, magnesium, indium, copper, germanium, calcium, or a combination thereof. 
     
     
         50 . The method according to  claim 42 , wherein the surface modification process in step (b) comprises contacting the temporary heat exchanger assembly with a solution that comprises a metal nitrate or sulfate, or mixed metal nitrates and sulfates, and a diamine, triamine, or tetraamine, at a temperature of about 50° C. to about 85° C., for about 5 minutes to about 3 hours. 
     
     
         51 . A method of manufacturing a heat exchanger, comprising:
 (a) subjecting individual components of a heat exchanger assembly to a surface modification process to create a porous, nanostructured surface on at least a portion of each of the individual components;   (b) assembling and temporarily connecting the individual components, thereby forming a temporary heat exchanger assembly with a porous, nanostructured surface; and   (c) exposing the temporary heat exchanger assembly with the porous, nanostructured surface to a temperature between 250° C. and 585° C., thereby forming the heat exchanger.   
     
     
         52 . The method according to  claim 51 , wherein a second material is wicked into the porous, nanostructured surface of the heat exchanger in order to improve the mechanical properties of the heat exchanger. 
     
     
         53 . The method according to  claim 52 , wherein the second material comprises a thickness less than 25 microns 
     
     
         54 . The method according to  claim 51 , wherein the individual components of the heat exchanger comprise microchannel heat exchanger components. 
     
     
         55 . The method according to  claim 51 , wherein at least one of the individual components comprises a manifold, a fin, a tube, and/or a microchannel surface. 
     
     
         56 . The method according to  claim 51 , wherein the porous, nanostructured surface comprises a nanostructured material with a thickness of less than 20 microns. 
     
     
         57 . The method according to  claim 51 , wherein the surface modification process adheres parts of the heat exchanger. 
     
     
         58 . The method according to  claim 51 , wherein the porous, nanostructured surface comprises a nanostructured material that comprises silicon, zinc, magnesium, indium, copper, germanium, calcium, or a combination thereof. 
     
     
         59 . The method according to  claim 51 , wherein the surface modification process in step (a) comprises contacting the temporary heat exchanger assembly with a solution that comprises a metal nitrate or sulfate, or mixed metal nitrates and sulfates, and a diamine, triamine, or tetraamine, at a temperature of about 50° C. to about 85° C., for about 5 minutes to about 3 hours. 
     
     
         60 . A method for bonding aluminum based alloy parts comprising:
 (a) immersing alloy parts in a solution comprising a metal salt, thereby producing a porous, nanostructured surface less than 20 microns in thickness on said alloy parts;   (b) constructing a temporary assembly of said alloy parts;   (c) exposing the temporary assembly of alloy parts to a temperature of 250° C. to 585° C. for about 1 minute to about 1 hour, thereby forming a ceramic bonded assembly of said alloy parts with a nanostructured surface; and   (d) applying a second material to the ceramic bonded assembly, wherein the second material is wicked into the porous, nanostructured surface of the ceramic bonded assembly in order to improve the mechanical properties of the assembly, wherein the second material thickness is less than 25 microns.