A heat exchanger with a bond and a method for manufacturing the same

A heat exchanger comprising

• a first heat transfer tube having a first primary straight part, a first primary curved part, and a first secondary straight part, the straight parts extending parallel in a first plane in a longitudinal direction,
• a first primary bond part comprising:
• (i) a first primary surface,
• (ii) a first secondary surface opposite the first primary surface,
• (iii) a first tertiary surface, of which at least a part faces in a direction of a normal (of the first plane, the first tertiary surface extending from the first primary surface to the first secondary surface, and which connects the first primary surface and the first secondary surface, and
• (iv)on the first tertiary surface, a first primary hole and a first secondary hole, both extending through the first primary bond part in the longitudinal direction,
• a first secondary bond part comprising:
• (i) a second primary surface,
• (ii) a second secondary surface opposite the second primary surface,
• (iii) a second tertiary surface, of which at least a part faces in a direction of a normal of the first plane, the second tertiary surface extending from the second primary surface to the second secondary surface, and which connects the second primary surface and the second secondary surface, and
• (iv) on the second tertiary surface, a second primary hole and a second secondary hole, both extending through the first secondary bond part in the longitudinal direction,
• a first welding joint that joins the second tertiary surface to the first primary surface or the first secondary surface, and
• a second welding joint that joins the first tertiary surface to the second secondary surface or the second primary surface, respectively,
• wherein:
• the first primary bond part has been welded to the first secondary bond part to form a first primary bond that bonds parts of the first heat exchanger tube, the first primary bond limiting:
• (i) a first primary aperture formed by the first primary hole and the second primary hole, wherein the first primary straight part extends through the first primary bond in the longitudinal direction via the first aperture, and
• (ii) a first secondary aperture formed by the first secondary hole and the second secondary hole, wherein the first secondary straight part extends through the first primary bond via the first secondary aperture,
• a shape of the first primary aperture has been adapted to a shape of an outer surface of the first primary straight part, and
• a shape of the first secondary aperture has been adapted to a shape of an outer surface of the first secondary straight part.

A method for manufacturing a heat exchanger, the method comprising steps of:

• arranging available:
• (i) a first heat transfer tube having a first primary straight part, a first primary curved part, and a first secondary straight part, the straight parts extending parallel in a first plane in a longitudinal direction, and
• (ii) a plate made of material that is suitable for a bond of heat transfer tubes of the heat exchanger, the plate having a thickness in a direction and a main surface, of which surface normal is parallel to the direction of thickness,
• cutting from the plate a first primary bond part comprising:
• (i) a first primary surface and an opposite first secondary surface such that a part of the main surface forms the first primary surface or the first secondary surface,
• (ii) a first tertiary surface,
• (iii) on the first tertiary surface, a first primary hole extending through the first primary bond part from the first primary surface to the first secondary surface and configured to receive a part of the first primary straight part of the first heat transfer tube, and
• (iv) on the first tertiary surface, a first secondary hole extending through the first primary bond part from the first primary surface to the first secondary surface and configured to receive a part of the first secondary straight part of the first heat transfer tube,
• cutting from the plate or a second plate a first secondary bond part comprising:
• (i) a second primary surface and an opposite second secondary surface such that a part of the main surface or a part of a main surface of the second plate forms the second primary surface or the second secondary surface,
• (ii) a second tertiary surface,
• (iii) on the second tertiary surface, a second primary hole extending through the first secondary bond part from the second primary surface to the second secondary surface and configured to receive a part of the first primary straight part of the first heat transfer tube, and
• (iv) on the second tertiary surface, a second secondary hole extending through the first secondary bond part from the second primary surface to the second secondary surface and configured to receive a part of the first secondary straight part of the first heat transfer tube,
• arranging a part of the first primary straight part of the first heat transfer tube to the first primary hole such that an outer surface of the first primary straight part is adapted to the surface of the first primary hole,
• arranging a part of the first primary straight part of the first heat transfer tube to the second primary hole such that an outer surface of the first primary straight part is adapted to the surface of the second primary hole,
• arranging a part of the first secondary straight part of the first heat transfer tube to the first secondary hole,
• arranging a part of the first secondary straight part of the first heat transfer tube to the second secondary hole,
• welding the first primary bond part to the first secondary bond part to form a first primary bond that bonds the straight parts of the first heat exchanger tube,
• forming the first tertiary surface by said cutting from the plate the first primary bond part,
• forming the second tertiary surface by said cutting from the plate or a second plate the first secondary bond part,
• welding the second tertiary surface to the first primary surface or the first secondary surface, and
• welding the first tertiary surface to the second secondary surface or the second primary surface.