Heat exchanger having winding micro-channels

A micro-channel heat exchanger comprising:

• a heat transfer member including at least one stackable heat transfer layer constructed and arranged to be stacked so as to tailor the heat transfer capability of the micro-channel heat exchanger, each of the at least one stackable heat transfer layer having a first surface and a second surface and including a thickness extending between the first surface and the second surface;
• a plurality of winding micro-channels disposed in each of the at least one stackable heat transfer layer, the plurality of winding micro-channels each having a diameter of no more than five hundred micrometers, and having a non-linear flow axis, the plurality of micro-channels together defining an active area of the heat transfer member;
• a manifold including an inlet port and an outlet port constructed and arranged to distribute a fluid and collect the fluid throughout the active area of the heat transfer member;
• a plurality of inlet openings disposed throughout the active area of the at least one stackable heat transfer layer and extending through the at least one stackable heat transfer layer from the first surface to the second surface and in communication with the manifold;
• a plurality of outlet openings disposed throughout the active area of the at least one stackable heat transfer layer and extending through the at least one stackable heat transfer layer from the first surface to the second surface and in fluid communication with the manifold;
• wherein the non-linear flow axis defines a non-linear path between one of the plurality of inlet openings and one of the plurality of outlet openings, the non-linear flow path having an inlet side adjacent the corresponding inlet opening and an outlet side adjacent the corresponding outlet opening, the non-linear path further including at least one pair of bends, each pair having:
• a) a first bend constructed and arranged to reverse the direction of the flow of the fluid as it travels between the corresponding inlet opening and the corresponding outlet opening such that the fluid flows toward the inlet side after passing through the first bend;
• and
• b) a second bend constructed and arranged to reverse the direction of the flow of the fluid as it travels between the corresponding first opening and the corresponding second opening such that the fluid flows toward the outlet side after passing through the second bend;
• and
• wherein during use the fluid is distributed from the manifold, through the corresponding inlet opening, into at least one of the plurality of winding micro-channels and flows into the first bend which reverses the direction of the fluid flow toward the inlet side of the micro-channel, the fluid then flowing into the second bend which reverses the direction of the fluid flow toward the outlet side of the micro-channel, and traveling along the non-linear path to the outlet opening, the flow of the fluid reversing directions at least twice along the non-linear path.

A method of cooling a heat source with a heat exchanger including a heat transfer member having a plurality of winding micro-channels, the method comprising the steps of:

• providing a manifold to distribute a fluid to the heat transfer member;
• directing the fluid through an inlet port of the manifold;
• directing the fluid from the inlet port to a plurality of inlet channels;
• distributing the fluid onto a surface of at least one stackable heat transfer layer of the heat transfer member;
• directing the fluid through a plurality of inlet openings disposed throughout an active area of the at least one stackable heat transfer layer and extending through the at least one stackable heat transfer layer from a first surface to a second surface;
• providing each of the plurality of winding micro-channels with a diameter of no more than five hundred micrometers and a non-linear flow axis that defines a non-linear path between the plurality of inlet openings and a plurality of outlet openings, the non-linear flow path having an inlet side adjacent the inlet openings and an outlet side adjacent the outlet openings;
• directing the fluid toward the outlet side of the non-linear path;
• reversing the direction of the fluid flow a first time so that the fluid flow is directed toward the inlet side of the non-linear path;
• reversing the direction of the fluid flow a second time so that the fluid flow is directed back towards the outlet side of the non-linear path;
• directing the fluid through the plurality of outlet openings disposed throughout the active area of the at least one stackable heat transfer layer and extending through the at least one stackable heat transfer layer from a first surface to a second surface and into a plurality of outlet channels disposed in the manifold, the outlet channels being interdigitated with the inlet channels;
• directing the fluid through the plurality of outlet channels into an outlet port of the manifold;
• and
• wherein reversing the direction of the fluid flow toward the inlet side and back toward the outlet side of the non-linear path results in substantially uniform heat transfer capability throughout the active area of the heat transfer member.