Unitary heat exchangers having integrally-formed compliant heat exchanger tubes and heat exchange systems including the same

An integrally-formed compliant heat exchanger tube comprising:

• a tubular member having a proximal tube end, a distal tube end and a tubular wall that extends from the proximal tube end to the distal tube end, the tubular wall having an outer wall surface and an inner wall surface, the inner wall surface having a first section that extends from the proximal tube end toward the distal tube end and a second section that extends from the distal tube end toward the proximal tube end, and the first section overlaps the second section;
• a plurality of integral heat transfer fins extending radially outwardly from at least one portion of the tubular member and formed in the outer wall surface;
• and
• an integral bellows portion formed in the outer wall surface of the tubular wall, the integral bellows portion defined between the proximal tube end and the distal tube end such that the integral bellows portion is spaced apart from the proximal tube end and the distal tube end, the integral bellows portion and the plurality of heat transfer fins formed in the tubular member to form a one-piece heat exchanger tube, the integral bellows portion comprising a bellows in the outer wall surface and a slip joint in the inner wall surface, the bellows having a first end that transitions into the outer wall surface and transitions into the first section of the inner wall surface, and a second end that transitions into the outer wall surface and transitions into the second section of the inner wall surface, the slip joint defined by the overlap of the first section and the second section of the inner wall surface, the overlap of the first section and the second section defined in the bellows between the first end and the second end of the bellows, the overlap of the first section over the second section defines a backward-facing step portion in an interior of the tubular member that is opposite a flow direction inside the one-piece compliant heat exchanger tube, the backward-facing step portion creates flow turbulence within the interior of the tubular member, the bellows surrounds the slip joint and prevents leakage from the integrally-formed compliant heat exchanger tube.

A heat exchange system comprising:

• a unitary heat exchanger including a heat exchanger first flow passage and a heat exchanger second flow passage, the heat exchanger first flow passage configured to receive a first fluid and the heat exchanger second flow passage configured to receive a second fluid, the unitary heat exchanger being configured to transfer heat between the first and second fluids;
• the heat exchanger first flow passage comprises an inlet plenum defining a plurality of tube inlets and an inlet port that receives the first fluid and each of the plurality of tube inlets is countersunk relative to a surface of the inlet plenum, an outlet plenum that discharges the received first fluid and defines a flow direction for the first fluid from the inlet plenum to the outlet plenum, and a plurality of one-piece compliant heat exchanger tubes extending between and integral with the inlet and outlet plenums to form a one-piece heat exchanger, each one-piece compliant heat exchanger tube comprising:
• a tubular member having a proximal tube end, a distal tube end and comprising a tubular wall that extends from the proximal tube end to the distal tube end, the tubular wall having an outer wall surface and an inner wall surface, the inner wall surface having a first section that extends from the proximal tube end toward the distal tube end and a second section that extends from the distal tube end toward the proximal tube end, and the first section overlaps the second section;
• a plurality of integral heat transfer fins extending radially outwardly from at least one portion of the tubular member and formed in the outer wall surface;
• and
• an integral bellows portion formed in the outer wall surface of the tubular wall, the integral bellows portion defined between the proximal tube end and the distal tube end such that the integral bellows portion is spaced apart from the proximal tube end and the distal tube end, the bellows portion and the plurality of heat transfer fins formed in the tubular member to form a one-piece heat exchanger tube, the integral bellows portion comprising a bellows defined in the outer wall surface and a slip joint in the inner wall surface, the bellows having a first end that transitions into the outer wall surface and transitions into the first section of the inner wall surface, and a second end that transitions into the outer wall surface and transitions into the second section of the inner wall surface, the slip joint defined by the overlap of the first section and the second section of the inner wall surface, the overlap of the first section and the second section defined in the bellows between the first end and the second end of the bellows, the overlap of the first section over the second section defines a backward-facing step portion in an interior of the tubular member that is opposite the flow direction of the first fluid inside the one-piece compliant heat exchanger tube and the backward-facing step portion creates flow turbulence within the interior of the tubular member.