US 8,573,285 B2 · Polymer manifold and polymer heat exchanger

Abstract

A variety of methods of forming polymer manifolds and the resulting manifold structures are described. The described manifolds are well suited for use in heat exchangers and a variety of other applications. In one aspect a polymer manifold includes a multiplicity of tubes having first ends that are received by a manifold housing. A polymer film is secured to the manifold housing and to the ends of each of the tubes. The film is arranged to seal the housing while leaving the openings of the tubes exposed to thereby create a manifold. In some embodiments, a potting material is used to reinforce the film. In a method aspect, a manifold may be formed by positioning first ends of the tubes in a manifold housing and welding a polymer film to the manifold housing and to distal tips of the tubes. Openings for the tubes are then formed in the film by directing heat towards the film which melts or vaporizes the film in the regions of the tube openings. A liquid coolant or potting material is placed inside of the chamber within the manifold housing that is sealed by the film during the heating to help prevent the heat from damaging the seals between the film and the tube tips or the film in the interstitial spaces between the tubes.

Claims16

Dependent claims

A polymer manifold comprising:

a multiplicity of polymer tubes, each of the polymer tubes including first and second ends and a passage having first and second openings;
a first polymer manifold housing that harnesses the first ends of the multiplicity of tubes, wherein the first manifold housing includes a chamber that receives and collectively surrounds the first ends of the tubes;
a polymer film secured to a support surface of the first manifold housing and to a distal tip of the first end of each of the multiplicity of tubes, the polymer film being arranged to seal a first end of the chamber while leaving the first openings of the polymer tubes exposed to thereby create a manifold;
and
a potting material disposed within the chamber that reinforces the polymer film.

2 more elements

A polymer heat exchanger comprising:

a multiplicity of polymer tubes, each of the polymer tubes including first and second ends and a passage having first and second openings;
a first manifold housing that harnesses the first ends of the multiplicity of tubes, wherein the first manifold housing includes a first chamber that receives and collectively surrounds the first ends of the tubes and a first threaded section for threadably connecting the polymer heat exchanger to a fluid supply conduit arranged to communicate a fluid to the multiplicity of tubes;
a second manifold housing that harnesses the second ends of the multiplicity of tubes, wherein the second manifold housing includes a second chamber that receives the second ends of the multiplicity of tubes, and a second threaded section for threadably connecting the polymer heat exchanger to a second fluid conduit arranged to communicate a fluid from the multiplicity of tubes;
a first polymer film secured to a supporting surface of the first manifold housing and to a distal tip of the first end of each of the multiplicity of tubes, the first polymer film being arranged to seal a first end of the manifold chamber while leaving the first openings of the polymer tubes exposed to thereby create a first manifold;
and
a second polymer film secured to the second manifold housing and to the second ends of each of the plurality of tubes, the second polymer film being arranged to seal an end of the second manifold chamber while leaving the second openings of the plurality of polymer tubes exposed to thereby create a second manifold;
a first potting material disposed within the first chamber that reinforces the first polymer film;
a second potting material disposed within the second chamber that reinforces the second polymer film;
and
wherein distal tips of the first ends of the tubes are substantially flush with a first face of the first manifold housing and the polymer film is secured to the distal tips of the tubes and the first face of the manifold housing such that the first tube openings are presented on a plane that includes the first face of the manifold housing.

7 more elements

Dependencies are inferred from the claim text.

Polymer manifold and polymer heat exchanger

Life of this patent

Polymer manifold and polymer heat exchanger

Life of this patent

Abstract

Claims16