Heat Exchanger Module

Abstract

The heat exchanger module (100) comprises at least one first layer (10) for a first fluid and at least one second layer (20) for a second fluid, the first layer (10) and the second layer (20) being separated by a divider plate (30), the first layer (10) comprising a first wall (12) serpentine between opposite sides (31, 32) of the first layer (10) to define a first passage (14), and the second layer ( The second layer (20) has second walls (22) serpentine between opposing sides (31, 32) of the second layer (20) to define second passages (24), the pitch (p1) of the first walls being less than the pitch (p2) of the second walls, the thickness (e1) of the first walls being less than the thickness (e2) of the second walls, and the ratio of the pitch (p1) to the height (h1) of the first walls being less than the ratio of the pitch (p2) to the height (h2) of the second walls.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to the field of heat exchangers, and more particularly to heat exchanger modules and methods for manufacturing heat exchanger modules. [Background technology]

[0002] The efficiency of a heat exchanger is determined, among other things, by the available transfer area: the fluid flowing through the heat exchanger should be exposed to as much material as possible in order to effectively transfer its heat to the structure of the heat exchanger and ultimately to the other fluid.

[0003] However, this principle can be difficult to apply in practice, as fluid properties and other constraints to which the heat exchanger is subjected, such as mechanical properties, must be taken into account. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, a new type of heat exchanger module and manufacturing method is needed. [Means for solving the problem]

[0005] In this regard, the present disclosure relates to a heat exchanger module comprising at least one first layer for flow of a first fluid between a first inlet and a first outlet, and at least one second layer for flow of a second fluid between a second inlet and a second outlet, wherein the at least one first layer and the at least one second layer are separated by a divider plate, the first layer comprising a first wall serpentine between opposing sides thereof to define a first passage extending between the first inlet and the first outlet, and the second layer comprising a second wall serpentine between opposing sides thereof to define a second passage extending between the second inlet and the second outlet, wherein the pitch of the first walls is less than the pitch of the second walls, the thickness of the first walls is less than the thickness of the second walls, and the ratio of the pitch to the height of the first walls is less than the ratio of the pitch to the height of the second walls.

[0006] A heat exchanger module comprises one or more first layers and one or more second layers. As used herein, for brevity and unless the context dictates otherwise, "a," "an," and "the" are intended to refer to "at least one" or "each" and to include the plural. Also, an element (e.g., a layer, wall, passageway, etc.) referred to without "first" or "second" can refer to either or both of the first and second elements.

[0007] Similarly, although one divider plate is defined, the heat exchanger module may include multiple divider plates, each separating two successive layers of the heat exchanger module. Conversely, each one of the first and second layers, except perhaps for the end layers, may be defined between two divider plates. The opposing surfaces of the two divider plates may define opposite sides of a layer between which the first and second walls snake.

[0008] In meandering, the wall can create multiple junctions between opposing sides of the layer, and these junctions separate the layers in a passageway. That is, the wall can continuously and repeatedly move from one side of the layer to the other while advancing in the other direction. The wall can meander in a plane transverse to the passageway. The wall can meander in a periodic manner.

[0009] The pitch of the wall is defined as the distance between the point where the wall reaches one of the opposing sides of the layer and the corresponding point where the wall next reaches the same side of the layer. The pitch can be constant. If the wall meanders periodically, the pitch of the wall corresponds to the period of the wall.

[0010] The thickness of a wall is defined as the smallest dimension of the wall. The thickness is generally measured transversely to the wall. The thickness may be constant, but if not, an average thickness may be considered.

[0011] The wall height is defined as the height along which the serpentine wall extends, i.e., the distance between two opposite sides of the layer. The height may be constant, but if not, an average height may be considered.

[0012] When discussing parameters, terms such as "large" and "small" should be understood relative to one another, even when used alone. For example, a small pitch of the first wall refers to the pitch of the first wall being relatively small compared to the pitch of the second wall.

[0013] Due to the small thickness, small pitch, and small ratio of pitch to height of the first walls, the first layer has a high density of passages, which promotes heat exchange, especially when the fluid flowing through the first passages is a gas such as air. The small ratio of pitch to height of the first walls also compensates for its small thickness in terms of the mechanical resistance of the heat exchanger module.

[0014] Optionally, the first wall, the second wall, and the divider plate are assembled by diffusion bonding. As known in the art, diffusion bonding is an assembly technique based on the principle of solid-state diffusion. Diffusion bonding is typically performed under high-temperature and high-pressure conditions. Thanks to the previously defined structure, the heat exchanger module can withstand the pressure applied during diffusion bonding. Furthermore, diffusion bonding is a technique that does not require additional welding material, in contrast to other welding techniques such as brazing. Therefore, diffusion bonding the first wall, the second wall, and the divider plate ensures that the heat exchanger module does not include brazing welds in layers that may be eroded by the flow of potentially corrosive fluids, such as molten salts.

[0015] Optionally, the divider plate, first wall, and second wall are metal, which encompasses not only metals but also alloys and metal composites.

[0016] Optionally, the thickness of the divider plate is equal to or greater than the thickness of the second wall. The thickness or height of the divider plate is the smallest dimension of the divider plate and corresponds to the distance between the first and second layers adjacent to each other on either side of the divider plate. Thus, the divider plate contributes to the mechanical strength of the heat exchanger module while facilitating uniform heat transfer between the first and second layers. In other embodiments, the thickness of the divider plate may be less than the thickness of the second wall.

[0017] Optionally, the height of the first wall is greater than the height of the second wall. In other embodiments, the height of the first wall may be less than or equal to the height of the second wall.

[0018] Optionally, the ratio of the height of the first wall to the thickness of the first wall is equal to or greater than 8, preferably equal to or greater than 10, preferably equal to or greater than 12. The serpentine of the first wall may be obtained by bending the first wall.

[0019] Optionally, the ratio of the height of the second wall to the thickness of the second wall is equal to or less than 8, preferably equal to or less than 6, preferably equal to or less than 5, preferably equal to or less than 4. The serpentine of the second wall may be obtained by pressing the second wall.

[0020] Optionally, the ratio of the pitch of the first walls to the height of the first walls is less than or equal to 2, preferably less than or equal to 1, preferably less than or equal to 0.6.

[0021] Optionally, the ratio of the pitch of the second walls to the height of the second walls is 2 or greater, preferably 2.2 or greater, preferably 2.4 or greater.

[0022] Optionally, the ratio of the pitch of the second wall to the pitch of the first wall is greater than 2, preferably greater than 3, preferably greater than 4, preferably greater than 6.

[0023] Optionally, the pitch of the first walls is in the range of 0.5 to 3 millimeters (mm), preferably in the range of 1 to 2 mm.

[0024] Optionally, the pitch of the second walls is in the range of 3 to 10 mm, preferably in the range of 4 to 8 mm.

[0025] Optionally, the height of the first wall is in the range of 2 to 15 mm, preferably in the range of 2 to 5 mm.

[0026] Optionally, the height of the second wall is in the range of 1 to 10 mm, preferably in the range of 1.5 to 4 mm, preferably in the range of 2 to 3 mm.

[0027] Optionally, the thickness of the first wall is in the range of 0.05 to 0.5 mm, preferably in the range of 0.10 to 0.30 mm.

[0028] Optionally, the thickness of the second wall is in the range of 0.2 to 1.2 mm, preferably in the range of 0.30 to 0.50 mm.

[0029] Optionally, the thickness of the divider plate is in the range of 0.4 to 1 mm, preferably in the range of 0.50 to 0.70 mm.

[0030] Optionally, between opposing sides of the first layer, the first wall has a maximum angle with the opposing sides that is 70° or greater. That is, a portion of the first wall joining one of the opposing sides to the other makes an angle with each one of the opposing sides. This angle reaches a maximum of at least 70°. The maximum angle may be greater than 80°, and may reach 90°, in which case the first wall has a portion that is perpendicular to the opposing sides of the first layer.

[0031] Optionally, between opposing sides of the second layer, the second walls have a maximum angle with the opposing sides that is less than 70°. More generally, the maximum angle of the second walls is less than the maximum angle of the first walls.

[0032] Optionally, the heat exchanger module includes multiple second layers, and the serpentine second wall of one of the second layers is out of phase with the serpentine second wall of an adjacent one of the second layers. In other words, the serpentine second wall of one of the second layers is offset by half a pitch relative to the serpentine second wall of an adjacent one of the second layers. Thus, the valleys of the second wall of one of the second layers are aligned with the peaks of the second wall of the adjacent second layer, and vice versa. This ensures good transfer of pressure applied to the heat exchanger module from one second layer to another second layer and reduces deformation of the layers and divider plates.

[0033] Optionally, the first passage and the second passage define a counter-flow flow. Alternatively, the first passage and the second passage can define a co-flow flow or can define a cross-flow flow.

[0034] Optionally, the heat exchanger module includes at least one lateral support separating two adjacent divider plates at the ends of the first and / or second layers, the lateral support supporting the two adjacent divider plates relative to each other. The lateral support can close the corresponding layer in one direction. For example, the lateral support can extend between two opposing sides of the corresponding layer, extending from the inlet to the outlet of the layer. The lateral support contributes to the mechanical strength of the heat exchanger module, in addition to providing fluid containment in the layer.

[0035] The present disclosure provides a method for manufacturing a heat exchanger module as previously described, comprising: - providing a first wall and bending the first wall to meander and define a first passageway extending between a first inlet and a first outlet; - providing a second wall and stamping the second wall to serpentine and define a second passageway extending between the second inlet and the second outlet, wherein the pitch of the first wall is less than the pitch of the second wall, the thickness of the first wall is less than the thickness of the second wall, and the ratio of the pitch to the height of the first wall is less than the ratio of the pitch to the height of the second wall; and - providing a dividing plate between the first wall and the second wall; - assembling a first wall, a second wall, and a dividing plate, whereby the first wall defines a first layer for a first fluid to flow between a first inlet and a first outlet, and the second wall defines a second layer for a second fluid to flow between a second inlet and a second outlet; The present invention is further directed to a method comprising:

[0036] The resulting heat exchanger module can have any of the above characteristics, and the manufacturing method can be modified accordingly.

[0037] Specifically, in the manufacturing method, the assembling step optionally includes diffusion bonding the first wall, the second wall, and the divider plate.

[0038] The invention and its advantages will be better understood on reading the following detailed description of embodiments thereof, given as non-limiting examples, which description refers to the accompanying drawings, in which: [Brief explanation of the drawings]

[0039] [Figure 1] 1 is a cross-sectional view of a heat exchanger module according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0040] A heat exchanger module 100 according to one embodiment is described with reference to Figure 1, which shows a cross section of the heat exchanger module 100. Figure 1 illustrates major aspects of the disclosure and is not to scale.

[0041] The stacking direction or height direction is the vertical direction in Figure 1. The width direction is perpendicular to the stacking direction and corresponds here to the horizontal direction in Figure 1. The length direction is the primary direction in which at least one fluid flows in the heat exchanger module 100 and corresponds in this example to the direction perpendicular to the stacking direction and the width direction. Here, the length direction is perpendicular to the plane of Figure 1.

[0042] The heat exchanger module 100 comprises multiple layers stacked on top of one another, including at least one first layer 10 and at least one second layer 20. The first layer 10 has a first inlet and a first outlet positioned respectively in front of and behind the plane of FIG. 1 and configured to receive a first fluid flow, such as a gas such as air. Similarly, the second layer 20 has a second inlet and a second outlet positioned respectively in front of and behind the plane of FIG. 1 for a parallel flow heat exchanger or in front of and behind the plane of FIG. 1 for a counterflow heat exchanger. The second layer is configured to receive a second fluid flow, such as a liquid such as a molten salt.

[0043] The first layer 10 and the second layer 20 are separated by a divider plate 30. The divider plate 30 extends across the first layer 10 and the second layer 20 to prevent the fluids in the first layer 10 and the second layer 20 from mixing.

[0044] The first layers 10 and second layers 20 are stacked alternately with divider plates 30 between them. A desired number of first layers 10, divider plates 30, and second layers 20 can be stacked on top of each other to obtain a heat exchanger module 100 with a desired flow capacity. At the end of the stack, an end plate 33 can be provided. The end plate 33 can be similar in structure to the divider plates 30, but may be thicker to provide a rigid casing for the heat exchanger module 100.

[0045] Thus, each layer 10, 20 is closed in the stacking direction by a divider plate 30. In the width direction, each layer 10, 20 can be closed by a respective side support 34. That is, the side support separates two adjacent divider plates 30 at the ends of the first layer 10 and the second layer 20, respectively. The side support 34 supports the two adjacent divider plates 30 relative to each other.

[0046] The side struts 34 may take the form of rigid rods extending primarily in the longitudinal direction. The side struts 34 may be at least as thick as the divider plates 30.

[0047] Along their length, the layers 10, 20 are not closed and are open to their respective inlets and outlets as detailed above.

[0048] In this embodiment, the first layer 10 is provided with a passageway structure to facilitate circulation of the first fluid and to enhance heat transfer. Specifically, the first layer 10 comprises a first wall 12 that meanders between opposite sides 31, 32 of the first layer 10 to define a first passageway 14 extending between a first inlet and a first outlet.

[0049] Here, opposing sides 31, 32 of the first layer 10 are formed by the facing surfaces of the respective dividers 30 adjacent to the first layer 10. The first wall 12 may be a metal wall. In this example, the serpentine of the first wall 12 forms a plurality of fins 16, which may be substantially linear and / or oblique, as shown in cross section in FIG. 1 . In this example, the fins 16 form an angle with the opposing sides 31, 32. Here, the angle is generally substantially constant (e.g., constant except for edge effects), but this angle may vary. The angle reaches a maximum angle A1, which may be 70° or greater.

[0050] The fins 16 join together at flat portions 18 that alternately contact each one of the opposing sides 31, 32 of the first layer 10. The space between two consecutive fins 16 and the opposing sides 31, 32 forms one of the first passages 14 mentioned above.

[0051] The first walls 12 have a height h1, a thickness e1, and a pitch p1. The height h1 corresponds to the distance between the opposite sides 31, 32 of the first layer 10. In this embodiment, the first walls 12 are periodically meandering, with the pitch p1 corresponding to the period of the first walls 12.

[0052] The first wall 12 can be formed from a substantially planar sheet by folding it in a serpentine pattern. That is, the first wall 12 can be folded multiple times, for example, one fold at a time in a continuous production line, to form the fins 16 and the flat portion 18. To facilitate the folding process, the height h1 should be relatively large relative to the thickness e1. In other words, the ratio of the height h1 of the first wall 12 to the thickness e1 of the first wall 12, i.e., h1 / e1, can be 8 or greater, preferably 10 or greater, and preferably 12 or greater. In addition, the ratio of the pitch p1 of the first wall 12 to the height h1 of the first wall 12, i.e., p1 / h1, can be 2 or less, preferably 1 or less, and preferably 0.6 or less. The folding allows for a high density of the fins 16 to be achieved within the first layer 10.

[0053] In this embodiment, the second layer 20 is provided with a passageway structure to facilitate circulation of the second fluid and to enhance heat transfer. Specifically, the second layer 20 comprises a second wall 22 that meanders between opposite sides 31, 32 of the second layer 20 to define a second passageway 24 extending between a second inlet and a second outlet.

[0054] Similar to the first layer 10, the opposing sides 31, 32 of the second layer 20 are formed by the facing surfaces of the respective divider plates 30 adjacent the second layer 10.

[0055] The second wall 22 may be a metal wall. In this example, the meandering of the second wall 22 forms a plurality of corrugations 26. Each corrugation 26 contacts one of the opposing sides 31, 32 and is closed by the other of the opposing sides 31, 32. The space between the corrugation 26 and the closing one of the opposing sides 31, 32 forms one of the second passages 24 described above.

[0056] In this example, the portion of the second wall 22 going from one of the opposing sides 31, 32 to the other makes an angle with the opposing sides 31, 32. Here, broadly speaking, the angle is substantially constant (e.g., constant except for edge effects), but this angle may vary. The angle reaches a maximum angle A2, which may be 70° or less.

[0057] The second walls 22 have a height h2, a thickness e2, and a pitch p2. The height h2 corresponds to the distance between the opposite sides 31, 32 of the second layer 20. In this embodiment, the second walls 22 are periodically meandering, with the pitch p2 corresponding to the period of the second walls 22.

[0058] The second walls 22 can be formed by pressing a substantially planar sheet into a serpentine shape. That is, the second walls 22 can be inserted into a press and pressed by a press die to form the sheet into the shape of the die. Appropriate shaping of the die allows the corrugations 26 to be obtained. For the pressing process, the height h2 should be relatively small relative to the thickness e2 to prevent the sheet material from tearing. In other words, the ratio of the height h2 of the second walls 22 to the thickness e2 of the second walls 22, i.e., h2 / e2, can be 8 or less, preferably 6 or less, preferably 5 or less, and preferably 4 or less. In addition, the ratio of the pitch p2 of the second walls 22 to the height h2 of the second walls 22, i.e., p2 / h2, can be 2 or more, preferably 2.2 or more, and preferably 2.4 or more. Pressing allows a low density of the corrugations 26 to be achieved in the second layer 20 with a large thickness e2.

[0059] The parameters of the first wall 12 and the second wall 22 are such that the pitch p1 of the first wall 12 is smaller than the pitch p2 of the second wall 22 (p1 < p2). In addition, the thickness e1 of the first wall 12 is smaller than the thickness e2 of the second wall 22 (e1 < e2). In addition, the ratio of the pitch p1 to the height h1 of the first wall 12 is smaller than the ratio of the pitch p2 to the height h2 of the second wall 22 (p1 / h1 < p2 / h2).

[0060] Therefore, the first wall 12 and the second wall 22 are adapted to be manufactured by bending and pressing respectively. While the first wall 12 provides a surface suitable for efficient heat exchange with a first fluid such as air, the second wall 22 provides a surface suitable for efficient heat exchange with a second fluid such as molten salt. In addition, the relatively dense structure (governed by the height h1 and the pitch p1) for the first wall 12 compensates for the small thickness e1, while the large thickness e2 for the second wall allows for a less dense structure and thus allows for different values of height h2 and pitch p2.

[0061] The dividing plate 30 may have a thickness h3 greater than the thickness e2 of the second wall 22 (h3 > e2). In other embodiments, the thickness h3 of the dividing plate 30 may be less than or equal to the thickness e2 of the second wall 22.

[0062] For example, the ratio of the pitch p2 of the second wall 22 to the pitch p1 of the first wall 12, i.e., p2 / p1, is greater than 2, preferably greater than 3, preferably greater than 4, preferably greater than 6.

[0063] In this embodiment, the parameters of height, pitch, and thickness can have the following values.

[0064] The pitch p1 of the first wall 12 is in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0065] The pitch p2 of the second wall 22 is in the range of 3 to 10 mm, preferably in the range of 4 to 8 mm.

[0066] The height h1 of the first wall 12 is in the range of 2 to 15 mm, and preferably in the range of 2 to 5 mm.

[0067] The height h2 of the second wall 22 is in the range of 1 to 10 mm, preferably in the range of 1.5 to 4 mm, and more preferably in the range of 2 to 3 mm.

[0068] The thickness e1 of the first wall 12 is in the range of 0.05 to 0.5 mm, and preferably in the range of 0.10 to 0.30 mm.

[0069] The thickness of the second wall 22 is in the range of 0.2 to 1.2 mm, preferably in the range of 0.30 to 0.50 mm.

[0070] Across the plane of FIG. 1, ie, lengthwise, first wall 12 and / or second wall 22 may be straight, angled, wavy, etc., as desired.

[0071] Once provided, the first wall 10, second wall 20, and divider plate 30, and, if applicable, end plates 33 and side supports 34, may be assembled to form the heat exchanger module 100. In an embodiment, assembly involves diffusion bonding these components together; that is, after stacking, heat and pressure are applied to cause solid-state diffusion between the components that are in contact with one another.

[0072] To further enhance the mechanical strength of the heat exchanger module 100, particularly during diffusion bonding, the second wall 22A of one of the second layers 20 and the second wall 22B of an adjacent one of the second layers 20 may be in opposite phase. As shown in FIG. 1 , the corrugations 26 of the second wall 22A are inverted at a given location in the width direction relative to the opposing corrugations 26 of the second wall 22B. This ensures that the force exerted by the second wall 22A onto the adjacent divider plate 30 is properly supported by the second wall 22B of the adjacent second layer 20 after being transferred to the first wall 10 and the subsequent divider plate 30.

[0073] Although the present disclosure refers to certain exemplary embodiments, modifications may be provided to these examples without departing from the broad scope of the invention as defined by the claims. In particular, individual features of different illustrated / referenced embodiments may be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative sense, and not in a restrictive sense. [Explanation of symbols]

[0074] 10 First Layer 12 The First Wall 14 First Passage 16 Finn 18 Flat area 20 Second Layer 22, 22A, 22B Second Wall 24 Second Passage 26 waveform 30 split plate 31, 32 Opposite sides 33 End plate 34 Lateral struts 100 Heat Exchanger Module A1 Maximum angle of the first wall 12 A2 Maximum angle of second wall 22 e1 Thickness of the first wall 12 e2 Thickness of the second wall 22 h1 Height of the first wall 12 h2 Height of the second wall 22 h3 Thickness of dividing plate 30 p1 Pitch 12 of the first wall p2 Pitch 22 of the second wall

Claims

1. A heat exchanger module (100) comprising at least one first layer (10) for flowing a first fluid between a first inlet and a first outlet, and at least one second layer (20) for flowing a second fluid between a second inlet and a second outlet, the at least one first layer (10) and the at least one second layer (20) being separated by a divider plate (30), the first layer (10) having a first passageway (14) serpentine between opposite sides (31, 32) of the first layer (10) to define a first passageway (14) extending between the first inlet and the first outlet. a first wall pitch (p1) less than a second wall pitch (p2); a first wall thickness (e1) less than a second wall thickness (e2); and a ratio of the pitch (p1) to the height (h1) of the first wall less than a ratio of the pitch (p2) to the height (h2) of the second wall.

2. 2. The heat exchanger module of claim 1, wherein the first wall (12), the second wall (22), and the divider plate (30) are assembled by diffusion bonding.

3. 3. The heat exchanger module according to claim 1, wherein the height (h1) of the first wall is greater than the height (h2) of the second wall.

4. 4. The heat exchanger module of claim 1, wherein the ratio of the height (h1) of the first wall to the thickness (e1) of the first wall is 8 or more, and / or the ratio of the height (h2) of the second wall to the thickness (e2) of the second wall is 8 or less.

5. 5. A heat exchanger module according to claim 1, wherein the ratio of the pitch (p1) of the first walls to the height (h1) of the first walls is 2 or less, and / or the ratio of the pitch (p2) of the second walls to the height (h2) of the second walls is 2 or more.

6. 6. The heat exchanger module according to claim 1, wherein the ratio of the pitch (p2) of the second walls to the pitch (p1) of the first walls is greater than 2.

7. the pitch (p1) of the first walls is in the range of 0.5 to 3 mm; the pitch (p2) of the second walls is in the range of 3 to 10 mm; the height (h1) of the first wall is in the range of 2 to 15 mm; the height (h2) of the second wall is in the range of 1 to 10 mm; the thickness (e1) of the first wall is in the range of 0.05 to 0.5 mm, preferably in the range of 0.10 to 0.30 mm, and / or 7. The heat exchanger module according to any one of claims 1 to 6, wherein the thickness (e2) of the second wall is in the range of 0.2 to 1.2 mm, preferably in the range of 0.30 to 0.50 mm.

8. 8. The heat exchanger module according to claim 1, wherein, between opposite sides (31, 32) of the first layer (10), the first wall (12) has a maximum angle (A1) with the opposite sides (31, 32) of 70° or more, and / or, between opposite sides (31, 32) of the second layer (20), the second wall (22) has a maximum angle (A2) with the opposite sides (31, 32) of less than 70°.

9. 9. The heat exchanger module of claim 1, comprising a plurality of the second layers (20), wherein the serpentine second wall (22A) of one of the second layers and the serpentine second wall (22B) of an adjacent one of the second layers are in opposite phase.

10. 10. The heat exchanger module of any one of claims 1 to 9, wherein the first passage (14) and the second passage (24) define a counter-flow.

11. 11. A heat exchanger module according to claim 1, comprising at least one lateral strut (34) separating two adjacent dividing plates (30) at the ends of the first layer (10) and / or the second layer (20), the lateral strut (34) supporting the two adjacent dividing plates (30) relative to each other.

12. A method for manufacturing a heat exchanger module (100) according to any one of claims 1 to 11, comprising: providing a first wall (12) and bending the first wall (12) to meander and define a first passageway (14) extending between a first inlet and a first outlet; providing a second wall (22) and stamping the second wall (22) to meander and define a second passageway (24) extending between a second inlet and a second outlet, wherein a pitch (p1) of the first wall is less than a pitch (p2) of the second wall, a thickness (e1) of the first wall is less than a thickness (e2) of the second wall, and a ratio of the pitch (p1) to a height (h1) of the first wall is less than a ratio of the pitch (p2) to a height (h2) of the second wall; providing a dividing plate (30) between the first wall (12) and the second wall (22); assembling the first wall (12), the second wall (22), and the divider plate (30), whereby the first wall (12) defines a first layer (10) for a first fluid to flow between the first inlet and the first outlet, and the second wall (22) defines a second layer (20) for a second fluid to flow between the second inlet and the second outlet; A method comprising:

13. 13. The method of claim 12, wherein the assembling step includes diffusion bonding the first wall (12), the second wall (22), and the divider plate (30).

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