Heat exchanger comprising plate package and hollow manifold

Abstract

To provide a technique for combining efficiency of a conventional brazing or joining plate heat exchanger with flexibility of a 3D printing heat exchanger.SOLUTION: A plate package comprises a plurality of heat exchanger plates stacked between end plates. The heat exchanger plates are sealed to each other and form alternating first plate interspaces for a first medium and second plate interspaces for a second medium. The plate package defines at least two port channels communicating with the first plate interspaces. At least one of the end plates defines connection ports communicating with a respective port channel. A manifold defines a port opening, a distant opening, and a flow passage extending between the port opening and the distant opening. The manifold is fixedly attached to one of the end plates such that the port opening of the manifold covers one of the connection ports. The manifold is made by additive manufacturing, molding, or casting.SELECTED DRAWING: Figure 1C

Description

[Technical field]

[0001] The present invention relates to a heat exchanger including a plate package and a manifold. [Background technology]

[0002] Plate heat exchangers are used in different sectors of industry for many different heat exchange purposes. A plate heat exchanger includes a plate package having a plurality of heat exchanger plates. Each heat exchanger plate is usually corrugated and made of a stamped sheet of metal. The heat exchanger plates are stacked between first and second end plates. The heat exchanger plates are sealed to each other and to the end plates, forming alternating first interplate spaces for a first medium and second interplate spaces for a second medium. Heat exchange occurs between the first medium and the second medium. At least one of the heat exchanger plates and the end plates is provided with port holes forming port channels extending through the plate package to communicate with the interplate spaces, and the interplate spaces are sealed from the outside environment except for the port channels.

[0003] Port holes in the end plates define the connection ports. Usually, one of the end plates has a port hole and the other is closed. Heat exchangers can be supplied with many different standard connection ports. Conventional designs have one port at each corner, whereby the first pair of connection ports communicates only with the first interplate space and the second pair of connection ports communicates only with the second interplate space.

[0004] It is well known in the art that plate heat exchangers have several advantages compared to other heat exchanger designs. They are very energy efficient, have a high heat transfer coefficient, and are cost-effective to manufacture when compared to other types of heat exchangers. In particular, brazed or bonded plate heat exchangers combine high thermal and mechanical performance with a compact shape. However, when it comes to the flexibility of placement of interfaces such as connection ports and integration of additional functionality such as sensors, plate heat exchanger designs are very limited. The traditional layout of the plate package with rectangular heat exchanger plates with one connection port at each corner dominates the industry.

[0005] In many applications the standard "one port in each corner" layout is not suitable. This may be because the installation has to be carried out in a tight space or because the integration of additional functionality is required. In some applications this can be achieved with a standard brazed heat exchanger combined with a polymer functional block that houses the external interface. This is common for example in domestic water heaters and district heating modules. However, in many applications the demands on integrity, chemical resistance or process parameters require a homogeneous metallic design.

[0006] Additive manufacturing (AM), also known as 3D printing, has recently been introduced as a solution for the efficient and flexible design and manufacture of heat exchangers. 3D printing refers to the process of manufacturing three-dimensional objects by additively depositing metal powder material layer by layer onto a surface, thereby forming a three-dimensional metal structure. While 3D printed heat exchangers allow high flexibility in terms of heat exchanger layout and design, the thermal and mechanical efficiency of conventional plate heat exchangers based on thin stamped plates is difficult to match. Also, the manufacturing costs and production times of 3D printed heat exchangers greatly exceed those for comparable plate heat exchangers made from stamped plates. The use of 3D printed heat exchangers has therefore so far been mostly limited to prototyping.

[0007] US Patent No. 5,399,633 relates to a header for a ducted heat exchanger. The header is made by additive manufacturing. The header is manufactured in situ by additive manufacturing as the tubes are stacked into the heat exchanger.

[0008] US Patent No. 5,399,633 relates to a heat exchanger made entirely by additive manufacturing, making it possible to optimize the configuration of the flow channels of the heat exchanger in order to improve heat transfer performance, to improve resistance to thermal and mechanical stresses, and to optimize based on the environment in which the heat exchanger will be placed.

[0009] No. 5,399,633 relates to additively manufactured headers for heat exchanger cores, which can be considered as plates and fins, shells and tubes, or other air-air or air-fluid passages.

[0010] No. 6,299,333 and U.S. Pat. No. 6,399,423 relate to a heat exchanger having a core with a first end and a second end, and having a first plurality of hot flow channels fluidly isolated from a first plurality of cold flow channels. A first header is connected to the first end of the core. All or a portion of the heat exchanger can be fabricated through additive manufacturing.

[0011] No. 6,239,933 relates to first and second sections of a heat exchanger including flow paths configured for heat exchange between fluids in the flow paths and a central manifold disposed between the first and second sections. Fluid enters the manifold at one end, passes through the first and second sections, and exits the manifold at an opposite end. The central manifold can be fabricated through additive manufacturing.

[0012] US Patent No. 5,399,633 relates to a method for 3D printing plate heat exchangers, by which a stack of layers can be realized, each of which is successively formed by targeting by heating a deposit of metal powder.

[0013] None of the above solutions even come close to having the efficiency of a plate heat exchanger. [Prior art documents] [Patent documents]

[0014] [Patent Document 1] US Patent Application Publication No. 2019 / 0134894 [Patent Document 2] US Patent Application Publication No. 2017 / 0089643 [Patent Document 3] US Patent Application Publication No. 2016 / 0231067 [Patent Document 4] US Patent Application Publication No. 2017 / 363361 [Patent Document 5] US Patent Application Publication No. 2017 / 0146305 [Patent Document 6] US Patent Application Publication No. 2017 / 0211896 [Patent Document 7] French Patent Application Publication No. 3057057 Summary of the Invention [Problem to be solved by the invention]

[0015] It is therefore an object of the present invention to provide a technique that combines the efficiency of traditional brazed or bonded plate heat exchangers with the flexibility of 3D printed heat exchangers. [Means for solving the problem]

[0016] The above object is realized in a first aspect of the present invention by a plate heat exchanger including a plate package and a manifold, both made of metal, the plate package including a plurality of heat exchanger plates stacked between end plates, the heat exchanger plates sealed to each other and to the end plates forming alternating first interplate spaces for a first medium and second interplate spaces for a second medium, the heat exchanger plates sealed to each other at a periphery of each heat exchanger plate, the plate package defining at least four port channels, thereby providing at least two port channels. the port channels communicate with the first interplate space and are sealed from communication with the second interplate space, at least one of the end plates defines a connection port in communication with the respective port channel, the manifold defines a port opening, a remote opening, and a flow path extending between the port opening and the remote opening, the manifold is fixedly attached to one or both of the end plates such that the port opening of the manifold covers one of the connection ports enabling communication between one of the interplate spaces and the remote opening, and the manifold is fabricated by additive manufacturing, molding, or casting.

[0017] The heat exchanger plates are usually made of thin stamped plates and contain port holes for the introduction and removal of fluids. The heat exchanger plates are stacked with respect to each other so that the port holes precisely match to form port channels. The heat exchanger plates are sealed to each other at the periphery forming alternating first and second interplate spaces between the heat exchanger plates. Usually the plate package is made of stainless steel. If a lightweight design is required, both the stamped plate pack and the 3D printed manifold can be manufactured, for example, from aluminum or titanium. Both materials are suitable for joining techniques.

[0018] At least two port channels are provided, each accessible from one of the end plates via a respective connecting port in the end plate, while the opposite end of the port channel is closed at the opposite end plate, but typically all port channels are accessible from the same end plate, which is closed. Two port channels provide access to the first interplate space, thereby preventing access to the second interplate space from the same port channel. A further port channel can be used to access the second interplate space, or access to the second interplate space can be provided through an aperture at the periphery of the plate. The first and second media are fluids, usually liquids, and as they flow through the respective interplate spaces, a heat exchange between the media is established. More than four port channels are possible, such as six port channels, with corresponding connecting ports.

[0019] End plates in this context are understood to be the first and last plates of a stack. These plates are then exposed to the outside, while the other plates only have their periphery exposed to the outside. The end plates form part of the first or second interplate space and therefore can be in direct fluid contact. Alternatively, the end plates can be separate "frame plates" to reinforce the structure. The use of such frame plates can be useful to establish a flat and uniform contact surface for the manifold.

[0020] In the preferred solution plate packs consisting of stamped plates are stacked in a conventional manner. The plate packages are of a standardized type with port connectors in place for optimum efficiency. A manifold is mounted above the plate pack for added flexibility.

[0021] Manifolds, also known as headers or housings, are made by additive manufacturing, molding or casting. Molding and casting should also be considered related techniques in this context. Additive manufacturing and 3D printing are considered synonymous and include methods such as direct metal laser sintering (DMLS) and selective laser sintering (SLS).

[0022] The manifold has at least one port opening covering each connection port of the plate packages and allowing communication between one of the interplate spaces and a remote opening that can be located away from the connection opening of the plate packages. A remote opening in this context is an opening in the manifold that communicates with one of the connection ports of the plate packages through a port opening of the manifold. It can be located directly above the connection port of the plate packages or in any direction. The location of the remote opening is determined by the application of the heat exchanger and the manifold can be custom made to allow the heat exchanger to be accommodated in a tight space.

[0023] According to a further embodiment, the manifold is fabricated by additive manufacturing.

[0024] The present heat exchanger according to a further embodiment combines the best parts of a plate heat exchanger and a 3D printed heat exchanger. The combination of a plate heat exchanger and a 3D printed manifold is also particularly suitable for low volume production.

[0025] According to a further embodiment, the plate package defines at least two further port channels in communication with the second interplate space and sealed from communication with the first interplate space, preferably each heat exchanger plate in the plate package having a rectangular shape and an end plate with a connection port at each corner.

[0026] In a preferred solution the edges of the plates are sealed together, allowing access to the first and second interplate spaces through respective connection ports. The plates are preferably of standard design with ports at the corners providing efficient flow distribution and utilization of the plate area. A 3D printed or cast manifold is mounted above the plate pack.

[0027] According to a further embodiment, more than one connection port of the plate pack is connected to a corresponding flow passage and a distal opening in the manifold.

[0028] In this way, any number of the connection ports can be displaced in location compared to the location of the connection ports in the plate package.

[0029] According to a further embodiment, the manifold includes an integral valve seat and / or an integral thermostat housing and / or an integral sensor housing and / or an integral lifting loop and / or a mounting bracket.

[0030] The use of manifolds can also be used to integrate, for example, valves, sensors, and thermostats in a flexible manner, whereby the 3D printed parts that make up the manifold can include housings for the valves, sensors, thermostats, etc. One or more lifting loops can be included to facilitate lifting and handling of the heat exchanger. One or more mounting brackets can be included to mount the heat exchanger in a fixed position on a wall, frame, or other equipment or object.

[0031] According to a further embodiment, the end plates have a greater thickness than the heat exchanger plates.

[0032] The heat exchanger may also include front and rear end plates that are made of thicker sheet metal than the heat exchanger plates. The purpose of the cover plates is to provide stability to the heat exchanger and to provide mounting locations for brackets and the like.

[0033] According to a further embodiment, the end plates to which the manifolds are attached cover only a portion of the surface of the heat exchange plate that the respective end plate faces.

[0034] The end plates with manifolds must not cover the entire surface of the heat exchange plate that the respective end plate faces, but may exclude some parts, e.g. some of the connection ports that can be connected to other equipment in a conventional manner by piping.

[0035] According to a further embodiment, the manifold is permanently sealed to the first end plate and the heat exchanger plates are permanently sealed to each other and to the end plate by brazing, diffusion bonding or adhesive bonding.

[0036] Flexible and efficient heat exchanger designs can be created by combining "traditional" brazed or bonded plate packs with manifolds created by additive manufacturing. Plate packs and manifolds can also be brazed together in this way.

[0037] In copper brazed heat exchangers, for example when the heat exchanger plates are made of stainless steel, the entire plate package is brazed together, which achieves a brazed copper seal around the edges of the plates. At the same time, the contact points between the plates are also brazed, which helps the heat exchanger to withstand the effects of high pressure and temperature.

[0038] Typically, the brazing also involves placing copper foil between the plates and between the plate pack and the printed manifold. Typically, this is suitable for brazing stainless steel materials, which can be 3D printed.

[0039] Alternatively, the manifold is mounted to the first end plate by screws or bolts, and the heat exchanger plates are permanently sealed to each other and to the end plate by brazing, diffusion bonding or adhesive bonding. In this manner, the manifold can be replaced.

[0040] According to a further embodiment, the port opening and the distal opening are oriented in different directions.

[0041] The printed channels can be oriented in any desired manner or shape to create interfaces required for other equipment and / or to fit into tight spaces.

[0042] According to a further embodiment, the heat exchanger plate has a corrugated pattern, preferably produced by stamping or pressing a metal sheet.

[0043] The corrugated pattern aids heat transfer by inducing turbulence. Pressing metal sheets is an efficient way to establish the corrugations.

[0044] The above object is realized in a second aspect of the present invention by a method of manufacturing a manifold for a plate heat exchanger, the plate heat exchanger comprising a plate package made of metal and including a plurality of heat exchanger plates stacked between end plates, the heat exchanger plates being sealed to each other and to the end plates and forming alternating first inter-plate spaces for a first medium and second inter-plate spaces for a second medium, the heat exchanger plates being sealed to each other at a periphery of each heat exchanger plate, the plate package being connected to the first inter-plate spaces and the second inter-plate spaces being connected to the end plates and the first inter-plate spaces being connected to the end plates ... and at least one of the end plates defines a connection port in communication with the respective port channel, and the method includes manufacturing a manifold by molding, casting or additive manufacturing, the manifold defining a port opening, a far opening, and a flow passage extending between the port opening and the far opening, the port opening of the manifold corresponding to one of the connection ports of one of the end plates of the heat exchanger to enable communication between one of the inter-plate spaces and the far opening.

[0045] The method according to the second aspect is preferably used to manufacture a heat exchanger according to the first aspect.

[0046] According to a further embodiment, the method further includes providing a 3D printer and manufacturing the manifold by additive manufacturing.

[0047] The manifold is preferably manufactured by additive manufacturing for maximum flexibility.

[0048] According to a further embodiment, the manifold is formed by additively depositing material onto the substrate plate.

[0049] In a first variant of this method, the manifold is printed onto a substrate plate, subsequently removed, and then placed and fixed onto the end plates of a plate package, the plates of which are either already sealed to each other or the plates are sealed to each other and to the manifold in the same operation, for example by placing the assembly of heat exchanger plates, end plates and manifold in a brazing oven to form the heat exchanger.

[0050] According to a further embodiment, the manifolds are formed by additively depositing material onto the end plates of the plate package.

[0051] In a second variant, the manifold is printed directly onto the end plate of the plate package. The end plate is subsequently sealed onto the plate package to form the heat exchanger. Either the end plate and the heat exchanger plate of the plate package are already sealed (brazed) to each other, or in a subsequent operation the end plate and the heat exchanger plate are sealed to each other and to the manifold, for example by placing the assembly of the heat exchanger plate and the end plate with the manifold already fixed thereto in a brazing oven to form the heat exchanger.

[0052] According to a further embodiment, the end plate forms part of the plate package and the connection ports are covered by a removable cover during 3D printing.

[0053] In a third variant, the manifolds are 3D printed directly onto the end plates of the already sealed plate package. To avoid metal powder from the 3D printing process entering the port channels of the plate package, the connection ports of the end plates must be covered by removable covers. The covers can be for example meltable or decomposable.

[0054] The above object is realized in a third aspect of the present invention by a plate heat exchanger including a plate package and a manifold, both made of metal, the plate package including a plurality of heat exchanger plates stacked between end plates, the heat exchanger plates sealed to each other and to the end plates and defining alternating first inter-plate spaces for a first medium and second inter-plate spaces for a second medium, the heat exchanger plates sealed to each other at a periphery of each heat exchanger plate, the plate package defining at least two port channels in communication with the first inter-plate spaces and sealed from communication with the second inter-plate spaces, an endoplasmic reticle having a first end and a second end, the plate package including a manifold and a manifold, the manifold including a first end and a second end ... at least one of the end plates defines a connection port in communication with a respective port channel; the manifold defines a port opening, a remote opening, and a flow path extending between the port opening and the remote opening, the manifold is fixedly attached to one or both of the end plates such that the port opening of the manifold covers one of the connection ports allowing communication between one of the interplate spaces and the remote opening, the manifold is fabricated by additive manufacturing, molding or casting, the manifold includes a one-piece housing having an opening and a removable lid covering the opening, the lid includes a mounting bracket for securing the heat exchanger onto another object.

[0055] The housing can be, for example, a valve seat and / or an integrated thermostat housing and / or an integrated sensor housing as described above. The lid thereby serves the dual purpose of being a closure for the housing and a mounting bracket for mounting the plate heat exchanger onto another object, i.e. a piece of equipment for which the plate heat exchange is intended. This saves space on the end plates that could be used for manifolds. The mounting bracket can also function as a lifting aid when transporting the plate heat exchanger. The lid can preferably be manufactured by additive manufacturing.

[0056] The plate heat exchanger according to the third aspect may include any of the features of the heat exchanger according to the first aspect, such as the heat exchanger plates being made of thin stamped plates.

[0057] According to a further embodiment, the mounting bracket extends outwardly from the lid beyond the periphery of each heat exchanger plate.

[0058] In this manner the plate heat exchanger can be easily secured to a structure which surrounds it.Preferably the lid and bracket extend along a vertical plane, for example forming an "L" shape.

[0059] According to a further embodiment, the manifold includes one or more additional mounting brackets that extend outwardly from the manifold beyond the periphery of each heat exchanger plate.

[0060] The plate heat exchanger is preferably mounted by a combination of a mounting bracket extending outwardly from the lid and one or more mounting brackets extending outwardly from the manifold.

[0061] According to a further embodiment, the mounting bracket extends outwardly from the lid and one or more mounting brackets extend outwardly from the manifold in substantially the same plane.

[0062] By having some or all of the mounting brackets at the same level, it will be easier to find a suitable surface for mounting and to use the brackets for lifting, or the bracket locations can be flexible and tailored to the application. [Brief description of the drawings]

[0063] [Figure 1A] 3D printing of the manifold onto a substrate plate. [Figure 1B] 1 shows the assembly of the manifold onto the plate package. [Figure 1C]1 shows the completed plate heat exchanger with manifolds. [Figure 2A] 1 shows a plate heat exchanger with covered connection ports. [Figure 2B] 3D printing of the manifold onto the plate package. [Figure 2C] 1 shows the completed plate heat exchanger with manifolds. [Figure 3A] 3D printing of the manifold onto a separate end plate is shown. [Figure 3B] 1 shows the assembly of end plates onto the plate package. [Figure 3C] 1 shows the completed plate heat exchanger with manifolds. [Figure 4A] 3D printing of the manifold onto a substrate plate. [Figure 4B] 13 illustrates the assembly of end plates onto an alternative plate package. [Figure 4C] 1 shows a completed alternative plate heat exchanger with manifolds. [Figure 5A] 1 shows a plate heat exchanger having a lid with manifold and bracket. [Figure 5B] 1 shows a plate heat exchanger having a manifold and a lid with an alternative bracket. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0064] FIG. 1A shows the inside of a metal 3D printer 10 performing a method of 3D printing a separate manifold 12' (shown in construction) for a plate heat exchanger (not shown) onto a substrate plate (not shown). The substrate plate should be understood in this context as a base placed inside the 3D printer on which the manifold 12' is printed. The input to the 3D printer 10 can be a 3D CAD drawing of the manifold 12', and the 3D printer can manufacture the manifold 12' as an exact copy of the CAD drawing. This means that the manifold 12' can be custom made in very small numbers. There are several different 3D printing processes and are believed to be known in the art. One of the most common processes for metal 3D printing uses a powder bed. This method spreads a thin layer of metal powder onto a substrate plate and uses a laser 14 or similar energy beam to melt and fuse the metal powder in places to form the manifold 12'. The process is performed layer by layer, i.e. when the powder particles forming one layer of the manifold 12' have fused together, another layer of metal powder is spread and the process is repeated until the manifold 12' is completed. Some known processes include "Direct Metal Laser Sintering (DMLS)" and "Selective Laser Sintering (SLS)."

[0065] FIG. 1B shows the assembly of the manifold 12 onto the end plates 16 of a plate package 18. The plate package 18 includes a plurality of heat exchanger plates 18' stacked between opposing end plates 16 (only one end plate is visible). The end plates 16 of the plate heat exchanger 18 include four connection ports 20a / b / c / d. The heat exchanger plates 18' are sealed at their periphery forming an enclosed interplate space. The connection ports 20a / b / c / d define port channels that extend through all of the heat exchanger plates 18' and terminate at the opposite end plate (not shown) and communicate with the interplate spaces between the heat exchanger plates 18' such that every other interplate space communicates only with the connection ports 20a and 20b, and the remaining interplate spaces communicate only with the connection ports 20c and 20d. The first and second interplate spaces are thus sealed against each other, and fluid communication to the interplate spaces is provided only via the port holes.

[0066] The manifold 12 comprises a first hollow portion 12a forming a passage intended to extend to and cover the connection port 20a, and a second hollow portion 12b intended to extend to and cover the connection port 20b. The manifold 12 further comprises a third portion interconnected to the first portion 12a of the manifold 12 and including a first far opening 22a. The second portion 12b of the manifold 12 includes a second far opening 22b. The far opening 22a is therefore intended to communicate with the connection port 20a of the plate package 18 via the first portion 12a, and the far opening 22b is intended to communicate with the connection port 20b of the plate heat exchanger 18.

[0067] This embodiment includes a housing 24 located in the center of the manifold 12 and in communication with the first and second portions 12a, 12b. The housing 24 may include a cavity 24' for housing devices such as valves, thermostats, sensors, etc. Additionally, pipes 26 and 26' are provided for connecting to the respective connection ports 20c and 20d. The pipes 26 and 26' may be conventional connecting pipes or may be 3D printed. They may also form part of the manifold 12. Alternatively, the manifold 12 may be molded or cast. In such a case the mold or die may be made by 3D printing.

[0068] FIG. 1C shows the completed plate heat exchanger including the plate package 18 and the manifold 12. The manifold 12 can be glued or brazed onto the already brazed plate package 18. Alternatively, the end plates 16, heat exchanger plates 18' and manifold 12 are brazed in the same brazing process. A 3D printed manifold 12 is placed and attached on top of the plate package 18 prior to the brazing or joining cycle. Brazing of the entire heat exchanger is typically done in a heated oven, where the heat exchanger is heated above the melting point of the brazing material. Thus, the end plates 16 and heat exchanger plates 18' are brazed together at the same time that the manifold 12 is brazed to the end plates 16. Typically, copper brazing is used.

[0069] Although in this embodiment only one distal opening 22a is displaced relative to the location of the connection port 20a, it is possible to have more than one distal opening displaced relative to the connection port, such as two, three or all four. The pipes 26 and 26' can therefore be omitted and replaced by an appropriately modified manifold 12.

[0070] 2A shows a brazed plate package 18' with the connection ports covered. The connection ports 20a / b / c / d are covered by removable plugs 20'a, 20'b, 20'c and 20'd in the end plates 16 to prevent any material from falling into the port channels. The plate package 18' is otherwise similar to the plate packages of the previous embodiment. The heat exchanger plates 18' and the end plates 16 are brazed together.

[0071] 2B shows the inside of a metal 3D printer 10 performing a method of 3D printing a manifold 12' onto an end plate 16 of a braze plate package 18. In this embodiment, the entire braze plate package 18 is placed into the 3D printer 10, which prints directly onto the end plate 16. The printing of the manifold 12' onto the end plate 16 is performed similarly to the printing of the manifold onto the substrate plate in the previous embodiment, except that the printing of the manifold 12' onto the end plate 16 is done in a non-removable manner, i.e., a first layer is bonded onto the end plate 16. Plugs covering the connection ports prevent the metal powder from falling into the plate package during printing and provide a flat surface for spreading the metal powder.

[0072] Figure 2C shows the completed plate heat exchanger with manifolds 12. This view is identical to that of Figure 1C and has the same features, but is manufactured differently as the manifolds are printed directly onto the end plates 16. As a final step, the plugs covering the ports are removed. The plugs can be removed by melting, disintegrating, or if accessible, by mechanical removal.

[0073] 3A shows the inside of a metal 3D printer 10 performing a method of 3D printing a manifold 12' onto a partial end plate 16'. Additionally, lifting loops / mounting brackets 28a / b / c / d (under construction) are provided. The lifting loops / mounting brackets 28a / b / c / d and partial end plates may be provided in any of the other embodiments as well. Otherwise, the set-up is similar to the previous embodiment in that the printing of the manifold 12' onto the end plate 16' is done in a non-removable manner.

[0074] 3B shows the assembly of a partial end plate 16' including the manifold 12 onto the plate heat exchanger 18. In this case, the end plate 16 only partially covers the top heat exchanger plate 18' of the plate package 18. Thus, the connection ports 20a and 20b are covered by the partial end plate 16', while the connection ports 20c and 20d can be connected by other means. Alternatively, the end plate can be made to cover the entire top heat exchanger plate 18' of the plate package 18. Lifting loops / mounting brackets 28a / b / c / d can be used to move the assembly.

[0075] FIG. 3C shows the completed plate heat exchanger with manifolds. This view is similar to the views of FIGS. 1C and 2C and has the same features, but the manufacturing method is different as the manifolds are printed directly onto the end plates, which are then fixed to the plate package. The plate package 18 may already be brazed, or the heat exchanger plates of the plate package 18 are brazed together in the same operation in which the end plates are brazed to the heat exchanger plates. An opposing end plate is also provided, but this may lack any ports. Lifting loops / mounting brackets 28a / b / c / d can be used to move the heat exchanger or to fix it onto other objects.

[0076] Figure 4A shows the inside of a metal 3D printer 10 performing a method of 3D printing a separate manifold 12' (shown in process) for a plate heat exchanger (not shown) onto a substrate plate (not shown), which is identical to Figure 1A.

[0077] 4B shows the assembly of the manifold 12 onto the end plate 16 of an alternative plate package 18'. The alternative plate package 18' is identical to the plate package 18 of the previous embodiment, except that the connection ports 20c and 20d connecting the second interplate spaces are omitted, and instead side openings 28 are provided at the edges on both sides (only one side is visible here) to access the second interplate spaces. The second medium therefore flows directly through the second interplate spaces without any connection ports or port channels.

[0078] The manifold 12 is identical to the previous embodiment and includes a first hollow portion 12a forming a passageway intended to extend to and cover connection port 20a, and a second hollow portion 12b intended to extend to and cover connection port 20b. This figure shows the assembly of the manifold 12 onto a plate package 18, similar to Figure 1B, but the manifold 12 can also be 3D printed onto a plate package as in Figure 2B, or onto an end plate as in Figures 3A / B.

[0079] FIG. 4C shows a completed plate heat exchanger including plate packages 18' and manifolds 12 as in the previous embodiment.

[0080] FIG. 5A shows a plate heat exchanger similar to the previous embodiment with a manifold 12 and a lid 30 with integral brackets 28b. The lid 30 covers the opening to the cavity of the housing 24. The housing can be used to house devices such as valves, thermostats, sensors, etc. In this embodiment brackets / lifting loops 28a / 28c / 28d are provided as integral parts of the manifold 12 or end plate 16. These brackets / lifting loops 28a / 28c / 28d are similar to those shown in connection with the embodiment of FIGS. 3a-3c designated by reference numbers 28a / 28b / 28c / 28d. In this embodiment the brackets / lifting loops 28a / 28c / 28d extend in the plane of the end plate 16'. However, one bracket / lifting loop 28b is provided as an integral part of the lid 30.

[0081] Brackets 28a / 28b / 28c / 28d can be secured to another object, such as the device for which the heat exchanger is intended, by using respective screws / bolts 32a / 32b / 32c / 32d. Lid 30 is in turn secured to housing 24 of manifold 12 by using screws / bolts 34. The lid thus has a dual purpose, namely, to cover the cavity of housing 24 and to secure the heat exchanger to another object via brackets / lifting loops 28b. This saves space on end plate 16' that could be used for manifold 12.

[0082] The lid 30 can be manufactured by additive manufacturing or any other method such as molding or casting. It is typically made of metal, although other materials are possible.

[0083] Figure 5B shows a plate heat exchanger having a manifold 12 and a lid 30 with an alternative integral bracket 28b. This embodiment is identical to the embodiment of Figure 5a, except that bracket / lifting loop 28b is flush with the other bracket / lifting loops 28a / 28c / 28d and extends from the edge of the lid so that they can extend in the same plane.

[0084] Furthermore, the present invention preferably includes the following examples. [Section 1] 1. A plate heat exchanger including a plate package and a manifold, both made of metal, The plate package includes a plurality of heat exchanger plates made of thin stamped plates stacked between end plates; the heat exchanger plates are sealed to each other and to the end plates and alternately form first interplate spaces for a first medium and second interplate spaces for a second medium; the heat exchanger plates are sealed to one another at a periphery of each heat exchanger plate; the plate package defines at least two port channels in communication with the first inter-plate space and sealed from communication with the second inter-plate space; at least one of the end plates defines a connecting port in communication with a respective port channel; the manifold defines a port opening, a distal opening, and a flow passage extending between the port opening and the distal opening; the manifold is fixedly attached to one or both of the end plates such that the port opening of the manifold covers one of the connection ports providing communication between one of the interplate spaces and the distal opening; 1. A plate heat exchanger, wherein the manifold is fabricated by additive manufacturing. [Section 2] The plate heat exchanger according to item 1, wherein the plate package defines at least two further port channels that communicate with the second interplate space and are sealed from communication with the first interplate space, and preferably each heat exchanger plate in the plate package has an end plate with a rectangular shape and a connection port at each corner. [Section 3] 3. A plate heat exchanger as described in any one of claims 1 to 2, wherein more than one connection port of the plate package is connected to a corresponding flow passage and a remote opening in the manifold. [Section 4] 4. The plate heat exchanger of any one of claims 1 to 3, wherein the manifold includes an integral valve seat and / or an integral thermostat housing and / or an integral sensor housing. [Section 5] 5. The plate heat exchanger of any one of claims 1 to 4, wherein the end plates have a greater thickness than the heat exchanger plates. [Section 6] 6. The plate heat exchanger according to any one of claims 1 to 5, wherein the end plates to which the manifolds are attached cover only a portion of the surface of the heat exchanger plate that faces each of the end plates. [Section 7] 7. The plate heat exchanger of any one of claims 1 to 6, wherein the manifold is permanently sealed to a first end plate, and the heat exchanger plates are permanently sealed to each other and to the end plate by brazing, diffusion bonding or adhesive bonding. [Section 8] 7. The plate heat exchanger of any one of claims 1 to 6, wherein the manifold is mounted to a first end plate by screws or bolts, and the heat exchanger plates are permanently sealed to each other and to the end plate by brazing, diffusion bonding or adhesive bonding. [Section 9] 9. The plate heat exchanger of any one of claims 1 to 8, wherein the portholes and the distal openings are oriented in different directions. [Section 10] Item 10. The plate heat exchanger according to any one of items 1 to 9, wherein the heat exchanger plate has a corrugated pattern, preferably made by stamping or pressing a metal sheet. [Section 11] 1. A method of manufacturing a manifold for a plate heat exchanger, comprising the steps of: The plate heat exchanger includes a plate package including a plurality of heat exchanger plates made of metal and made of thin stamped plates stacked between end plates, the heat exchanger plates are sealed to each other and to the end plates and alternately form first interplate spaces for a first medium and second interplate spaces for a second medium; the heat exchanger plates are sealed to one another at a periphery of each heat exchanger plate; the plate package defining at least two port channels in communication with the first inter-plate space and sealed from communication with the second inter-plate space; at least one of the end plates defines a connecting port in communication with a respective port channel; The method comprises: providing a 3D printer; manufacturing a manifold by additive manufacturing; Including, the manifold defines a port opening, a distal opening, and a flow passage extending between the port opening and the distal opening; the port opening of the manifold corresponds to one of the connection ports of one of the end plates of the plate heat exchanger to allow communication between one of the inter-plate spaces and the remote opening. [Section 12] Item 12. The method of item 11, wherein the manifold is mounted to the first end plate by screws. [Section 13] 13. The method of any one of claims 11 to 12, wherein the manifold is formed by additively depositing material onto a substrate plate. [Section 14] Item 13. The method of item 12, wherein the manifold is formed by additively depositing material onto an end plate of a plate package. [Section 15] Item 15. The method of item 14, wherein the end plate forms part of the plate package and the connection port is covered by a removable cover during the additive manufacturing. [Section 16] 1. A plate heat exchanger including a plate package and a manifold, both made of metal, the plate package includes a plurality of heat exchanger plates stacked between end plates; the heat exchanger plates are sealed to each other and to the end plates and alternately form first interplate spaces for a first medium and second interplate spaces for a second medium; the heat exchanger plates are sealed to one another at a periphery of each heat exchanger plate; the plate package defines at least two port channels in communication with the first inter-plate space and sealed from communication with the second inter-plate space; at least one of the end plates defines a connecting port in communication with a respective port channel, the manifold defines a port opening, a distal opening, and a flow passage extending between the port opening and the distal opening; the manifold is fixedly attached to one or both of the end plates such that the port opening of the manifold covers one of the connection ports providing communication between one of the interplate spaces and the distal opening; the manifold is fabricated by additive manufacturing, molding or casting; the manifold includes a one-piece housing having an opening and a removable lid covering the opening; The lid includes a mounting bracket for securing the plate heat exchanger onto another object. [Section 17] Item 17. The plate heat exchanger of item 16, wherein the mounting brackets extend outwardly from the lid beyond the periphery of each heat exchanger plate. [Section 18] Item 18. The plate heat exchanger of item 17, wherein the manifold includes one or more additional mounting brackets extending outwardly from the manifold and beyond the periphery of each heat exchanger plate. [Section 19] Item 19. The plate heat exchanger of item 18, wherein the mounting bracket extends outwardly from the lid and the one or more mounting brackets extend outwardly from the manifold in substantially the same plane. [Section 20] 20. The plate heat exchanger of any one of claims 16 to 19, further comprising any one of the features of claims 1 to 10. [Explanation of symbols]

[0085] 10 Metal 3D Printer 12 Manifold 12' Manifold 12a First hollow portion 12b Second hollow section 14 Laser 16 End Plate 16' Partial End Plate 18 Plate Package 18' Heat Exchanger Plate 20a / b / c / d connection ports 20'a, 20'b, 20'c, 20'd Removable Plugs 22a First far opening 22b Second Far Aperture 24 Housing 24' cavity 26 Pipe 26' Pipe 28 Side opening 28a / b / c / d Lifting Loops / Mounting Brackets 30 Lid 32a / 32b / 32c / 32d Screws / Bolts 34 Screws / Bolts

Claims

[Claim 1] 1. A plate heat exchanger including a plate package and a manifold, both of which are made of metal, The plate package includes a plurality of heat exchanger plates made of thin stamped plates stacked between end plates; the heat exchanger plates are sealed to each other and to the end plates and form alternating first interplate spaces for a first medium and second interplate spaces for a second medium; the heat exchanger plates are sealed to one another at a periphery of each heat exchanger plate; the plate package defines at least two port channels in communication with the first inter-plate space and sealed from communication with the second inter-plate space; at least one of the end plates defines a connection port in communication with a respective port channel; the manifold defines a port opening, a distal opening, and a flow passage extending between the port opening and the distal opening; the manifold is fixedly attached to one or both of the end plates such that the port opening of the manifold covers one of the connection ports providing communication between one of the inter-plate spaces and the distal opening; 1. A plate heat exchanger, wherein the manifold is fabricated by additive manufacturing.

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