Multi-gusset mount for heat exchanger

Abstract

A heat exchanger includes a heat exchanger inlet, a heat exchanger outlet, and a heat exchanger body. The heat exchanger body includes a plurality of heat exchanger tubes configured to direct a first fluid therethrough between the heat exchanger inlet and the heat exchanger outlet, and one or more mounts formed integral to and connected directly to at least one heat exchanger tube of the plurality of heat exchanger tubes. The one or more mounts are configured to secure the heat exchanger to one or more secondary components.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 63 / 779,713 filed Mar. 28, 2025, the entire contents of which are incorporated herein by reference thereto.BACKGROUND

[0002] Exemplary embodiments pertain to the art of heat exchangers, and in particularly to integrated mount structures for heat exchangers.

[0003] Heat exchangers are used in many different applications, such as aircraft environmental control systems (ECS's), to thermally condition a fluid for use by the ECS. The heat exchangers typically include a plurality of tubes or passages extending from a first end of the heat exchanger to a second end of the heat exchanger. The heat exchanger typically includes one or more mounts or other structures to position and secure the heat exchanger in place relative to the other portions of the system. Depending on the heat exchanger configuration, these mounting structures can be difficult to fabricate and assembly to the body of the heat exchanger.BRIEF DESCRIPTION

[0004] In one exemplary embodiment, a heat exchanger includes a heat exchanger inlet, a heat exchanger outlet, and a heat exchanger body. The heat exchanger body includes a plurality of heat exchanger tubes configured to direct a first fluid therethrough between the heat exchanger inlet and the heat exchanger outlet, and one or more mounts formed integral to and connected directly to at least one heat exchanger tube of the plurality of heat exchanger tubes. The one or more mounts are configured to secure the heat exchanger to one or more secondary components.

[0005] Additionally or alternatively, in this or other embodiments a mount of the one or more mounts includes a center boss having a through opening defined therein. The through opening is configured to be receptive of a fastener therein. One or more gussets extend from the center boss to one or more heat exchanger tubes of the plurality of heat exchanger tubes. Each gusset of the one or more gussets is secured to a different heat exchange tube of the plurality of heat exchanger tubes.

[0006] Additionally or alternatively, in this or other embodiments the one or more gussets are a plurality of gussets spaced apart along the center boss.

[0007] Additionally or alternatively, in this or other embodiments a spacing of the plurality of gussets is defined by a spacing of the plurality of heat exchanger tubes.

[0008] Additionally or alternatively, in this or other embodiments the plurality of gussets are secured to sequentially adjacent heat exchanger tubes of the plurality of heat exchanger tubes.

[0009] Additionally or alternatively, in this or other embodiments the center boss is cylindrically shaped.

[0010] Additionally or alternatively, in this or other embodiments a gusset of the one or more gussets has a gusset thickness less than a tube outer diameter of the heat exchanger tube.

[0011] Additionally or alternatively, in this or other embodiments a gusset of the one or more gussets has a gusset side surface formed at a gusset angle to the heat exchanger tube.

[0012] Additionally or alternatively, in this or other embodiments the gusset angle is in the range of 5 degrees to 45 degrees.

[0013] Additionally or alternatively, in this or other embodiments the one or more mounts are two or more mounts secured to different sides of the heat exchange core.

[0014] In another exemplary embodiment, a method of forming a heat exchanger includes forming a plurality of heat exchanger tubes via one or more additive manufacturing processes. The plurality of heat exchanger tubes extends longitudinally from a build plate of an additive manufacturing apparatus. The plurality of heat exchanger tubes are configured to direct a first fluid therethrough between the heat exchanger inlet and the heat exchanger outlet. One or more mounts are formed integral to the plurality of heat exchanger tubes via the one or more additive manufacturing processes, the one or more mounts configured to secure the heat exchanger to one or more secondary components.

[0015] Additionally or alternatively, in this or other embodiments a mount of the one or more mounts includes a center boss having a through opening defined therein. The through opening is configured to be receptive of a fastener therein. One or more gussets extends from the center boss to one or more heat exchanger tubes of the plurality of heat exchanger tubes. Each gusset of the one or more gussets is secured to a different heat exchange tube of the plurality of heat exchanger tubes.

[0016] Additionally or alternatively, in this or other embodiments the one or more gussets are a plurality of gussets spaced apart along the center boss.

[0017] Additionally or alternatively, in this or other embodiments a spacing of the plurality of gussets is defined by a spacing of the plurality of heat exchanger tubes.

[0018] Additionally or alternatively, in this or other embodiments the plurality of gussets are secured to sequentially adjacent heat exchanger tubes of the plurality of heat exchanger tubes.

[0019] Additionally or alternatively, in this or other embodiments the center boss is cylindrically shaped.

[0020] Additionally or alternatively, in this or other embodiments a gusset of the one or more gussets has a gusset thickness less than a tube outer diameter of the heat exchanger tube.

[0021] Additionally or alternatively, in this or other embodiments a gusset of the one or more gussets has a gusset side surface formed at a gusset angle to the heat exchanger tube in the range of 5 degrees to 45 degrees.

[0022] Additionally or alternatively, in this or other embodiments the through opening is formed via a drilling operation.

[0023] Additionally or alternatively, in this or other embodiments the one or more mounts are two or more mounts secured to different sides of the heat exchange core.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

[0025] FIG. 1 is a plan view of an embodiment of a heat exchanger;

[0026] FIG. 2 is a partial perspective view of an embodiment of a heat exchanger;

[0027] FIG. 3 is a partial side view of an embodiment of a heat exchanger;

[0028] FIG. 4 is a view of an embodiment of a mount of a heat exchanger; and

[0029] FIG. 5 is a schematic illustration of a method of forming a heat exchanger.DETAILED DESCRIPTION

[0030] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

[0031] FIG. 1 illustrates an embodiment of a heat exchanger 10. The heat exchanger 10 includes a heat exchanger inlet 12 and a heat exchanger outlet 14 with a plurality of heat exchanger tubes 16 defining a heat exchanger core 18. The heat exchanger tubes 16 extend between the heat exchanger inlet 12 and the heat exchanger outlet 14. The heat exchanger tubes 16 are configured to convey a first fluid 20 therethrough, such as oil, refrigerant, water, air, gasses, or the like from the heat exchanger inlet 12 to the heat exchanger outlet 14. In travelling through the heat exchanger tubes 16, the first fluid 20 exchanges thermal energy with a second fluid 22 flowing across the heat exchanger tubes 16 to heat or cool the first fluid 20, depending on operation of the heat exchanger 10.

[0032] Referring to the partial perspective view of FIG. 2, in some embodiments the heat exchanger tubes 16 are arrayed in a plurality of tube rows 24 in a first direction and a plurality of tube columns 26 in a second direction, which in some embodiments is perpendicular to the first direction.

[0033] Referring again to FIG. 1, the heat exchanger 10 includes a plurality of mounts 28 secured to the heat exchanger tubes 16 to allow for securing the heat exchanger 16 to adjacent structures, shown schematically as 30. Each of the mounts 28 includes a center boss 32 including a through opening 34 configured for a fastener such as a bolt or the like to be installed therethrough. In some embodiments, the center boss 32 is cylindrical in shape. A plurality of gussets 36 extend from the center boss 32 to the heat exchanger core 18 where the gussets 36 are each connected to a heat exchanger tube 16 of the plurality of heat exchanger tubes 16.

[0034] Referring now to FIG. 3, the gussets 36 are flat and planar elements having a first gusset surface 38 and a second gusset surface 40 opposite the first gusset surface 38, and extend perpendicularly from the center boss 32. The gussets 36 may have a gusset thickness 42 between the first gusset surface 38 and the second gusset surface 40 which is less than a tube outer diameter 44 of the heat exchanger tubes 16, but is sized to support the center boss 32 relative to the heat exchange core 18. A gusset spacing between adjacent gussets 36 is defined by a tube spacing between adjacent heat exchanger tubes 16. In the embodiment illustrated, the gussets 36 are located at sequentially adjacent heat exchanger tubes 16 along the center boss 32, but one skilled in the art will readily appreciate that in other embodiments the gussets 36 may be positioned in other arrangements, such as every other heat exchanger tube 16, while still supporting the center boss 32. In some embodiments, a length of each gusset 36 from the center boss 32 may be identical, while in other embodiments, the length of gussets 36 from the center boss 32 may vary.

[0035] Referring now to FIG. 4, shown is a side view of an embodiment of a mount 28 including the center boss 32 and a gusset 36 extending therefrom to a heat exchanger tube 16. The center boss 32 has an outer boss surface 46, and may have an insert 48 or bushing installed therein for installation of the fastener. The gusset 36 has opposing side surfaces 50 that extend at a gusset angle 52 from the heat exchanger tube 16. In some embodiments, gusset angles 52 are equal, so the gusset is symmetrical, while in other embodiments the gusset angles 52 may be unequal so the gusset is asymmetrical. In some embodiments, the gusset angle 52 is in the range of 5 degrees to 45 degrees.

[0036] The heat exchanger 10 and mount 28 configuration disclosed herein enable the use of manufacturing methods such as additive manufacturing to form the heat exchanger 10 with the mounts formed integral to the heat exchanger 10, and in particular to the plurality of heat exchanger tubes 16. Referring now to FIG. 5, the heat exchanger 10 is formed on a build plate 54. The material, such as a powdered metal material or other material suitable for additive manufacturing and meeting performance requirements of the heat exchanger 10, is deposited along a build direction 56, vertically perpendicular to the build plate 54. The mounts 28, including the center boss 32 and the plurality of gussets 36, are formed integral to the plurality of heat exchanger tubes 16 utilizing the additive manufacturing methods. In some embodiments, the center boss 32 is formed as a solid cylindrical element via additive manufacturing. The through opening 34 is subsequently formed via a secondary operation such as drilling.

[0037] The mount 28 is self-supporting during the additive manufacturing construction, which eliminates the need for additional support structure to be utilized during the additive manufacturing operations, which is later removed. Additionally this support structure may cool at a different rate than the heat exchanger resulting in thermal distortion. Additionally, the mount 28 structure utilized herein reduces thermal distortion of the heat exchanger 10 because the mount is not attached to the build plate, but is formed along the build direction 56 at a distance from the build plate 54. Further, the need to attach the mount via a secondary operation such as welding or brazing is eliminated. Additionally, when the fluid flow 22 is parallel to surfaces 38 and 40, the mount design minimizes pressure loss in fluid stream 22 by minimizing the amount of blocked area. The gusset spacing allows flow around the center boss 32 and in-between gussets 36.

[0038] The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.

[0039] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and / or groups thereof.

[0040] While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.

Claims

1. A heat exchanger, comprising:a heat exchanger inlet;a heat exchanger outlet; anda heat exchanger body, including:a plurality of heat exchanger tubes configured to direct a first fluid therethrough between the heat exchanger inlet and the heat exchanger outlet; andone or more mounts formed integral to and connected directly to at least one heat exchanger tube of the plurality of heat exchanger tubes, the one or more mounts configured to secure the heat exchanger to one or more secondary components.

2. The heat exchanger of claim 1, wherein a mount of the one or more mounts includes:a center boss having a through opening defined therein, the through opening configured to be receptive of a fastener therein; andone or more gussets extending from the center boss to one or more heat exchanger tubes of the plurality of heat exchanger tubes, each gusset of the one or more gussets secured to a different heat exchange tube of the plurality of heat exchanger tubes.

3. The heat exchanger of claim 2, wherein the one or more gussets are a plurality of gussets spaced apart along the center boss.

4. The heat exchanger of claim 3, wherein a spacing of the plurality of gussets is defined by a spacing of the plurality of heat exchanger tubes.

5. The heat exchanger of claim 3, wherein the plurality of gussets are secured to sequentially adjacent heat exchanger tubes of the plurality of heat exchanger tubes.

6. The heat exchanger of claim 2, wherein the center boss is cylindrically shaped.

7. The heat exchanger of claim 2, wherein a gusset of the one or more gussets has a gusset thickness less than a tube outer diameter of the heat exchanger tube.

8. The heat exchanger of claim 2, wherein a gusset of the one or more gussets has a gusset side surface formed at a gusset angle to the heat exchanger tube.

9. The heat exchanger of claim 6, wherein the gusset angle is in the range of 5 degrees to 45 degrees.

10. The heat exchanger of claim 1, wherein the one or more mounts are two or more mounts secured to different sides of the heat exchange core.

11. A method of forming a heat exchanger, comprising:forming a plurality of heat exchanger tubes via one or more additive manufacturing processes, the plurality of heat exchanger tubes extending longitudinally from a build plate of an additive manufacturing apparatus, the plurality of heat exchanger tubes configured to direct a first fluid therethrough between the heat exchanger inlet and the heat exchanger outlet; andforming one or more mounts integral to the plurality of heat exchanger tubes via the one or more additive manufacturing processes, the one or more mounts configured to secure the heat exchanger to one or more secondary components.

12. The method of claim 11, wherein a mount of the one or more mounts includes:a center boss having a through opening defined therein, the through opening configured to be receptive of a fastener therein; andone or more gussets extending from the center boss to one or more heat exchanger tubes of the plurality of heat exchanger tubes, each gusset of the one or more gussets secured to a different heat exchange tube of the plurality of heat exchanger tubes.

13. The method of claim 12, wherein the one or more gussets are a plurality of gussets spaced apart along the center boss.

14. The method of claim 13, wherein a spacing of the plurality of gussets is defined by a spacing of the plurality of heat exchanger tubes.

15. The method of claim 13, wherein the plurality of gussets are secured to sequentially adjacent heat exchanger tubes of the plurality of heat exchanger tubes.

16. The method of claim 12, wherein the center boss is cylindrically shaped.

17. The method of claim 12, wherein a gusset of the one or more gussets has a gusset thickness less than a tube outer diameter of the heat exchanger tube.

18. The method of claim 12, wherein a gusset of the one or more gussets has a gusset side surface formed at a gusset angle to the heat exchanger tube in the range of 5 degrees to 45 degrees.

19. The method of claim 11, further comprising forming the through opening via a drilling operation.

20. The method of claim 11, wherein the one or more mounts are two or more mounts secured to different sides of the heat exchange core.

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