Device and method for manufacturing turbulators for use in compact heat exchangers

A device for manufacturing a turbulator from a sheet of material, the device comprising:

• a first preform die having a slot formed by a pair of opposed walls, the opposed walls forming a first angle at a first end and forming a second angle at a second end, the second end of the die disposed opposite from the first end, the first angle being larger than the second angle, the first preform die cooperating with a punch to form a die set adapted to press an initial V-shaped fold in the sheet of material;
• a second preform die disposed adjacent to the first preform die and having a slot formed by a pair of opposed walls, the opposed walls forming a first angle at a first end and the opposed walls being substantially parallel at a second end disposed opposite from the first end, the second preform die cooperating with a punch to form a die set adapted to form a first rib in the sheet of material as it exits the second end;
• and,
• a plurality of progressive die sets having openings and punches adapted for forming a plurality of ribs disposed adjacent to the first rib.

A device for manufacturing a turbulator from a sheet of material, the device comprising:

• a first preform die having a slot formed by a pair of opposed walls, the opposed walls forming a first angle at a first end and forming a second angle at a second end, the second end of the die disposed opposite from the first end, the first angle being larger than the second angle, the first preform die cooperating with a punch to form a die set adapted to press an initial V-shaped fold in the sheet of material, the opposed walls being formed from a trapezium surface disposed adjacent to a triangular surface, the trapezium surface terminating along a top surface, the first end of the die being radiused on opposite sides of the slot to form a curved surface, the curved surface radiused from the first end of the die toward the top surface and the trapezium surface;
• a second preform die disposed adjacent to the first preform die and having a slot formed by a pair of opposed walls, the opposed walls forming a first angle at a first end and the opposed walls being substantially parallel at a second end disposed opposite from the first end, the second preform die cooperating with a punch to form a die set adapted to form a first rib in the sheet of material as it exits the second end;
• and,
• a plurality of progressive die sets having openings and punches adapted for forming a plurality of ribs disposed adjacent to the first rib.

A method of manufacturing a turbulator from a sheet of material, comprising:

• providing at least one preform die having a slot extending from a first end of the die to a second end opposite the first end, the slot formed at the first end of the die by a pair of opposed walls forming an angle there between, the opposed walls being substantially parallel at the second end, the angle between the opposed walls decreasing between the first end and the second end, the at least one preform die adapted to cooperate with a punch to form a die set adapted to form a first rib in the sheet of material as it exits the second end of the die;
• providing a plurality of progressive die sets having openings and punches adapted for forming a plurality of ribs disposed adjacent to the first rib;
• feeding the sheet of material through a press containing the at least one preform die and the progressive die sets so that the material is pushed through the dies and is intermittently stamped to form a corrugated strip of material;
• slitting and offsetting the corrugated strip of material to form a slit, offset corrugated strip of material;
• and,
• cutting the slit, off-set corrugated strip of material into predetermined lengths.