阅读说明：本技术 用于制造短舱的结构表面交换器的方法 (Method for manufacturing a structured surface exchanger for a nacelle ) 是由 文森特·佩隆 让-尼古拉·布乔特 弗拉维·胡贝尔-乔伊纳尔 亚历山德拉·杜加丁 于 2020-03-26 设计创作，主要内容包括：本发明涉及一种用于制造用于飞行器的具有经调整或保留的最终形状的结构表面热交换器(10)的方法,包括以下步骤：形成(E1)、成形(E2；E3)和通过焊接或钎焊来组装(E4)第一波纹表层(12'、12”、12)和第二平滑表层(14)以获得通道(16),每个通道由第一表层的波纹和第二平滑表层界定,以形成具有经调整的或保留的最终形状的结构表面热交换器,其中流体旨在在通道中循环,并且空气旨在与第二平滑表层接触地循环。(The invention relates to a method for producing a structured surface heat exchanger (10) for an aircraft having a finished shape that is adjusted or retained, comprising the following steps: forming (E1), shaping (E2; E3) and assembling (E4) the first corrugated surface (12', 12', 12) and the second smooth surface (14) by welding or brazing to obtain channels (16), each channel being delimited by the corrugations of the first surface and the second smooth surface, to form a structured surface heat exchanger having a conditioned or retained final shape, wherein the fluid is intended to circulate in the channels and the air is intended to circulate in contact with the second smooth surface.)

1. A method for manufacturing a structural surface heat exchanger (10; 100) for an aircraft having a finished shape adjusted or retained, comprising the steps of: forming (E1; E'1) a first skin to obtain a first corrugated skin; shaping (E2; E3; E '3) and assembling (E4; E'2) by welding or brazing the first corrugated surface layer (12', 12', 12; 120', 120', 120) and the second smooth surface layer (14; 140) to obtain channels (16; 160), each channel being delimited by the corrugations of the first surface layer and the second smooth surface layer, to form a structured surface heat exchanger having a conditioned or retained final shape, wherein a fluid (F1) is intended to circulate in the channels and air (F2) is intended to circulate in contact with the second smooth surface layer.

2. Manufacturing method according to claim 1, wherein the step of assembling (E4; E '2) the first skin (12; 120 ") and the second skin (14; 140') is carried out by friction stir welding, preferably according to the following parameters:

-using a substantially cylindrical cutter (40) comprising a retractable pin (42) having a diameter in the range of 2 to 5mm and a length in the range of 1 to 5mm, such that the retractable pin penetrates into the first skin (12; 120 ') and into half the thickness of the second skin (14; 140'),

-applying a contact pressure of 1 to 5kN between the two skins by a pressure means, such as a substantially cylindrical cutter (40),

-clamping the two skins by movable clamping means (44),

-the rotational speed of the tool (40) is in the range of 500 to 1500rpm,

-the angle of inclination of the knife (40) with respect to a plane perpendicular to the first and second skin layers is in the range of 1 to 5 °, and

-the advancing speed of the knife (40) is in the range of 100 to 700 mm/min.

3. Manufacturing method according to claim 1, wherein the step of assembling (E4; E '2) the first and second surface layers (12; 120 '), 14; 140') is carried out by brazing, preferably according to the following parameters:

-applying a metal strip (18) having a melting temperature in the range of 450 ℃ to 600 ℃ on the contact area between the two skin layers,

-between the two skin layers, between 50 and 350g/cm²Contact pressure of, and

-applying a heat treatment at a temperature in the range of 120-220 ℃ for 2-20 hours to obtain state T6.

4. Manufacturing method according to claim 1, wherein the step of assembling (E4; E '2) the first skin (12; 120 ") and the second skin (14; 140') is carried out by laser welding, preferably according to the following parameters:

laser power in the range of 2000 to 4000W,

-the laser advancing speed is in the range of 2 to 5m/min,

-the focal distance between the laser and the first or second skin layer is in the range of 300 to 500mm,

-the inclination of the laser with respect to the first and second skin layers is in the range of 3 DEG to 7 DEG,

guiding the welding by pushing the material.

5. Manufacturing method according to any one of the preceding claims, comprising the following steps:

a. forming (E1) the first skin layer (12') to obtain a first corrugated skin layer (12'),

b. shaping (E2) the first corrugated skin obtained in step a) to obtain a first corrugated skin (12) having an adjusted or retained final shape,

c. shaping (E3) the second smooth skin (14'), for example by tensioning, to obtain a second smooth skin (14) having an adjusted or retained shape,

d. Assembling the first skin (12) and the second skin (14) with a conditioned or retained final shape obtained in steps b) and c) to obtain channels (16), each channel being delimited by the corrugations of the first skin and the second smooth skin, to form a structured surface exchanger (10) with a conditioned or retained final shape, wherein a fluid (F1) is intended to circulate in the channels and air (F2) is intended to circulate in contact with the second smooth skin.

6. Manufacturing method according to the preceding claim, wherein the forming steps b) and/or c) are carried out by tensioning.

7. Manufacturing method according to any one of claims 5 to 6, wherein the steps a) and b) of forming (E1) and shaping (E2) the first skin (12', 12 ") are carried out simultaneously, for example in a press.

8. The manufacturing method according to any one of claims 1 to 4, comprising the steps of:

a. forming (E '1) said first skin (120') for example in a press to obtain a first corrugated skin (120 "),

b. assembling the first corrugated skin (120') obtained in step a) on the second smooth skin (140') to obtain channels (160), each channel being delimited by the corrugations of the first skin and the second smooth skin, to form a structured surface exchanger (100') having a suitable intermediate shape,

c. Shaping (E '3) the structured surface exchanger (100') obtained in step b) with a suitable intermediate shape to obtain a structured surface exchanger (100) with a conditioned or retained final shape between a fluid (F1) intended to circulate in said channels and an air (F2) intended to circulate in said second smooth surface contact.

9. Manufacturing process according to the preceding claim, wherein step c) of shaping (E'3) is carried out by tensioning.

10. Manufacturing method according to any one of the preceding claims, comprising, before the step of shaping (E3) the second skin (14') or assembling (E'2) the first corrugated skin (120 ") on the second skin (140'), a step of forming cavities (50, 500) in the first skin (12', 120') and simultaneously with a step of forming (E1, E'1) the first skin (12', 120'), or a step of forming cavities (50, 500) in the second skin (14', 140'), to obtain fluid distributors and collectors when assembling the first and second skins, the step of forming cavities (50, 500) being preferably produced in a press or by machining in the mass of the first or second skin.

11. Manufacturing method according to any one of claims 5 to 6 or 9 to 10, comprising a step of assembling cavities (50') on the first corrugated skin (12 ", 120") obtained in step a) before the step of shaping (E2) the first corrugated skin (12 ") or before the step of assembling (E '2) the first corrugated skin (120") on the second smooth skin (140'), to form a fluid distributor and collector when assembling the first and second skins, preferably by TIG welding.

12. Manufacturing method according to any one of the preceding claims, comprising a step of controlling the assembly and/or shaping steps.

13. Manufacturing method according to any one of the preceding claims, wherein the first and/or second surface layer is made of aluminium or an alloy comprising aluminium, preferably of the 6000 series.

14. A manufacturing method according to any one of the preceding claims, wherein the first skin layer has a thickness in the range of 1 to 3mm and the second skin layer has a thickness in the range of 0.6 to 2 mm.

15. A structural surface heat exchanger for an aircraft, characterized in that it is obtained by a method according to any one of claims 1 to 14.

Technical Field

The present invention relates to a method for manufacturing a structured surface exchanger of a nacelle, and more particularly to a method for manufacturing a structured surface exchanger having a finished shape adjusted or retained.

Background

The adjusted or retained shape means a non-planar shape.

More specifically, the retained shape is a non-developable shape.

The aircraft is propelled by one or more propulsion units, each of which comprises an engine housed in a tubular nacelle. Each propulsion unit is attached to the aircraft by a mast, usually located below or above the wings or at the fuselage level of the aircraft.

The engine may also be referred to as a turbojet. In the remainder of the description, the terms engine and turbojet will be used interchangeably.

The nacelle generally has a tubular structure comprising an upstream section comprising an air intake upstream of the turbojet engine, an intermediate section intended to surround a fan of the turbojet engine, a downstream section which can house thrust reversal means and which surrounds a combustion chamber of the turbojet engine, and generally terminates in a nozzle, the outlet of which is located downstream of the turbojet engine.

Furthermore, the nacelle generally comprises an outer structure comprising a fixed part and a movable part (thrust reversal means), and an Inner Fixed Structure (IFS) concentric with the outer structure at the level of the downstream section. The internal fixed structure surrounds the core of the turbojet engine, behind the fan. These external and internal structures define an annular flow channel, also called secondary flow channel, aimed at guiding a flow of cold air, called secondary, circulating outside the turbojet engine.

The outer structure includes an outer cowl defining an outer aerodynamic surface and an inner cowl defining an inner aerodynamic surface, the inner cowl and the outer cowl being connected upstream by a leading edge wall forming an air intake lip.

The tubular structure of the nacelle has a portion with a modified rear surface, such as a surface surrounding the secondary flowpath, and a portion with a reserved surface, such as an outer cowl of the nacelle outer structure except for the trailing edge.

Generally, a turbojet engine comprises a set of blades (compressor and possibly fan or unducted propeller) driven in rotation by a gas generator through a set of transmissions.

A lubricant distribution system is provided to ensure good lubrication of these transmissions and to cool them. The lubricant is oil. In the remainder of the description, the terms lubricant and oil will be used interchangeably.

A cooling system comprising at least one heat exchanger allows cooling of the lubricant.

There is a lubricant cooling system comprising a first surface exchanger between a heat transfer fluid and a lubricant, and a second surface exchanger between the heat transfer fluid and air. Such cooling systems include a closed loop heat transfer fluid circulation conduit. More specifically, the heat transfer fluid circulation conduit includes a portion disposed in the nacelle in contact with an inner fairing and/or an outer fairing of the nacelle. Even more specifically, the portion of the nacelle that is disposed in contact with the inner and/or outer cowls of the nacelle comprises a plurality of channels disposed in parallel, said channels being formed by the double walls of the inner and/or outer cowls, which is referred to as a structural surface heat exchanger.

The structural surface heat exchanger participates in the mechanical function of the nacelle.

Furthermore, it facilitates the transfer of forces, including during heat exchange.

In a known manner, the channels formed by the double walls of the inner and/or outer fairing are made by a method for assembling by rivets skins with corrugations on so-called smooth or aerodynamic skins, which then form the double walls of the inner and/or outer fairing.

A disadvantage of this approach is that the aerodynamic performance of the inner and/or outer cowls is reduced by the presence of the rivets.

It is therefore desirable to provide a method for manufacturing a structural surface heat exchanger having a tailored or retained final shape that is particularly suitable for manufacturing a nacelle, with little or no impact on the aerodynamic performance of the nacelle, and whose quality is optimized.

Disclosure of Invention

To this end, the method according to the invention is a method for manufacturing a structured surface heat exchanger with a tailored or retained final shape for an aircraft, the method comprising the steps of forming, shaping and assembling a first corrugated surface layer and a second smooth surface layer by welding or brazing to obtain channels, each channel being delimited by the corrugations of the first surface layer and the second smooth surface layer to form the structured surface heat exchanger with a tailored or retained final shape, wherein a fluid is intended to circulate in the channels and air is intended to circulate in contact with the second smooth surface layer.

The second smooth surface layer is for contact with the air stream. It allows maximizing the flow of the air stream. It is also known as an aerodynamic skin. In this way, unlike finned heat exchangers, heat exchangers do not generate aerodynamic losses.

According to other features of the invention, the method of the invention comprises one or more of the following optional features considered alone or in all possible combinations.

According to one feature, the method comprises a step of forming cavities in the first or second skin, preferably in a press, so as to obtain the fluid distributor and collector during the assembly of the first and second skins.

Alternatively, the step of forming the cavity in the first or second skin is performed by machining in a block of the first or second skin.

The fluid distributor is a cavity that allows fluid to be distributed at the entrance of the channel.

The fluid collector is a cavity that makes it possible to collect the fluid at the outlet of the channel.

According to one feature, the step of assembling the first and second skins is carried out by brazing, preferably according to the following parameters:

-applying a metal strip having a melting temperature in the range of 450 ℃ to 600 ℃ on the contact area between the two skin layers,

Application of 50-350g/cm between two skin layers²Contact pressure of, and

-applying a heat treatment at a temperature in the range of 120-220 ℃ for 2-20 hours to obtain state T6.

The condition T6 refers to an aged condition suitable for obtaining the best mechanical strength of the assembly, especially in the case where the first and second skin layers are made of aluminum.

The metal strip is also referred to as a filler metal or solder. The metal strip is preferably an alloy or clad sheet.

According to one feature, the step of assembling the first and second skins is carried out by laser welding, preferably according to the following parameters:

laser power in the range of 2000 to 4000W,

-the laser advancing speed is in the range of 2 to 5m/min,

-the focal distance between the laser and the first or second skin layer is in the range of 300 to 500mm,

-the inclination of the laser with respect to the first and second skin layers is in the range of 3 DEG to 7 DEG,

guiding the welding by pushing the material.

By "guiding the welding by pushing the material" is meant that the laser is pushed during its displacement, opposite to the welding direction in which the laser is pulled during its displacement by pulling the material.

According to one feature, the laser welding is carried out under a gas shield, for example under an argon and/or helium shield.

According to one feature, the laser welding is performed with a filler metal.

Alternatively, the laser welding is performed without the filler metal by melting the materials constituting the first and second skin layers.

According to one feature, the step of assembling the first and second skins is carried out by friction stir welding, preferably according to the following parameters:

-using a substantially cylindrical cutter comprising a retractable pin having a diameter in the range of 2 to 5mm and a length in the range of 1 to 5mm, such that the retractable pin penetrates into the first skin and into half the thickness of the second skin,

applying a contact pressure of 1 to 5kN between the two skins by a pressure device, such as a substantially cylindrical cutter,

-clamping the two skins by movable clamping means,

-the tool rotation speed is in the range of 500 to 1500rpm,

-the angle of inclination of the tool with respect to a plane perpendicular to the first and second skin layers is in the range 1 to 5 °, and

-a tool advancing speed in the range of 100 to 700 mm/min.

According to a first embodiment, the method comprises the steps of:

a. forming a first skin to obtain a first corrugated skin,

b. shaping the first corrugated skin obtained in step a) to obtain a first corrugated skin having an adjusted or retained final shape,

c. Shaping the second smooth surface layer to obtain a second smooth surface layer having an adjusted or retained final shape,

d. assembling the first skin and said second skin with a conditioned or retained final shape obtained in steps b) and c) to obtain channels, each channel being delimited by the corrugations of the first skin and the second smooth skin, to form a structured surface exchanger with a conditioned or retained final shape, wherein the fluid is intended to circulate in the channels and the air is intended to circulate in contact with the second smooth skin.

The steps a) and b) of forming and shaping the first skin layer make it possible to shape the first skin layer to produce corrugations and a tailored or retained shape, while the step c) of shaping the second skin layer makes it possible to shape the second skin layer to obtain a tailored or retained shape.

The method advantageously makes it possible to manufacture structured surface exchangers having a finished shape adjusted or retained with small dimensions, that is to say with a radius of curvature of less than 1 m.

According to one feature, the forming step c) is performed by tensioning.

According to one feature, the forming step b) is performed by tensioning.

Thus, the forming steps b) and/or c) are performed by tensioning.

According to one feature, the steps a) and b) of forming and shaping the first skin are carried out simultaneously, for example in a press.

According to one feature, the steps a) and b) of forming and shaping the first skin are performed sequentially, the forming step a) being performed, for example, in a press and the shaping step b) being performed, for example, by tensioning.

According to one feature, the step of assembling the first and second skins is carried out by brazing, preferably according to the following parameters:

-applying a metal strip having a melting temperature in the range of 450 ℃ to 600 ℃ on the contact area between the two skin layers,

application of 50-350g/cm between two skin layers²Contact pressure of, and

-applying a heat treatment at a temperature in the range of 120-220 ℃ for 2-20 hours to obtain state T6.

The metal strip is also referred to as a filler metal or solder. The metal strip is preferably an alloy or clad sheet.

According to one feature, the step of assembling the first and second skins is carried out by laser welding, preferably according to the following parameters:

laser power in the range of 2000 to 4000W,

-the laser advancing speed is in the range of 2 to 5m/min,

-the focal distance between the laser and the first or second skin layer is in the range of 300 to 500mm,

-the inclination of the laser with respect to the first and second skin layers is in the range of 3 ° to 7 °.

According to one feature, the laser welding is carried out under a gas shield, for example under an argon and/or helium shield.

According to one feature, the laser welding is performed with a filler metal.

Alternatively, the laser welding is performed without the filler metal by melting the materials constituting the first and second skin layers.

According to one feature, the step of assembling the first and second skins is carried out by friction stir welding, preferably according to the following parameters:

-using a substantially cylindrical cutter comprising a retractable pin having a diameter in the range of 2 to 5mm and a length in the range of 1 to 5mm, such that the retractable pin penetrates into the first skin and into half the thickness of the second skin,

applying a contact pressure of 1 to 5kN between the two skins by a pressure device, such as a substantially cylindrical cutter,

-clamping the two skins by movable clamping means,

-the tool rotation speed is in the range of 500 to 1500rpm,

-the angle of inclination of the tool with respect to a plane perpendicular to the first and second skin layers is in the range 1 to 5 °, and

-a tool advancing speed in the range of 100 to 700 mm/min.

According to one feature, the method comprises a step of forming the second skin before step c) of shaping the second skin, so as to obtain a second skin comprising cavities for forming the fluid distributor and collector during the assembly of the first and second skins of step d), for example in a press or by machining in a block of the second skin.

According to one feature, the step of forming the first skin of step a) comprises the step of forming cavities for forming the fluid distributor and collector when assembling the first and second skins of step d), for example in a press or by machining in a block of the first skin.

According to one feature, the method comprises the step of assembling the fluid distributor and collector on the first corrugated surface obtained in step a) by welding, preferably by TIG welding.

According to one feature, the method comprises a step of controlling the assembly and/or shaping steps.

According to one feature, the first and/or second skin layer is made of aluminium or an alloy comprising aluminium, preferably of the 6000 series. This makes it possible to improve the lightness and formability of the skin layer.

According to one feature, the first skin layer has a thickness in the range of 1 to 3mm and the second skin layer has a thickness in the range of 0.6 to 2 mm.

According to a second embodiment, the method according to the invention is a method for manufacturing a structured surface heat exchanger of an aircraft with an adjusted or retained final shape, comprising the steps of:

a. for example forming a first skin in a press to obtain a first corrugated skin,

b. Assembling the first corrugated skin obtained in step a) on a second smooth skin to obtain channels, each channel being delimited by the corrugations of the first skin and the second smooth skin, to form a structured surface exchanger having a suitable intermediate shape,

c. shaping the structured surface exchanger obtained in step b) with a suitable intermediate shape to obtain a structured surface exchanger with a conditioned or retained final shape between the fluid intended to circulate in said channel and the air intended to circulate in said second smooth surface layer contact.

In the same way as described above, the second smooth surface layer is intended to be in contact with the air flow. It allows maximizing the flow of the air stream. We also discuss aerodynamic skins.

In contrast to the adjusted or retained shape, a suitable intermediate shape refers to a substantially planar shape.

The step a) of forming the first skin makes it possible to shape the first skin to produce corrugations, while the step c) of shaping the structured surface exchanger obtained in step b) with a suitable intermediate shape allows shaping the exchanger to obtain an adjusted or retained shape.

The method advantageously makes it possible to manufacture structured surface exchangers having a large adjusted or retained final shape, that is to say having a radius of curvature greater than 1 m.

According to one feature, the forming step c) is performed by tensioning.

According to one feature, the method comprises, before step b) of assembling the first and second skins, a step of forming the second skin to obtain a second skin comprising cavities for forming the fluid distributor and collector when assembling the first and second skins of step b), said forming step being preferably carried out in a press or by machining in a block of the second skin.

According to one feature, the method comprises a step of forming cavities in the first skin to obtain the fluid distributor and collector when assembling the first and second skins, said forming step being preferably carried out in a press or by machining in a block of the first skin.

According to one feature, the method comprises, before step b) of assembling the first and second skins, the step of assembling, by welding, preferably by TIG welding, a fluid distributor and collector on the first corrugated skin obtained in step a).

According to one feature, the step of forming the first skin of step a) comprises a step of forming the cavity to obtain the fluid distributor and collector when assembling the first and second skins, said forming step being produced, for example, in a press or by machining in a block of the first skin.

According to one feature, the step of assembling the first and second skins is carried out by brazing, according to the following parameters:

-applying a metal strip having a melting temperature in the range of 450 ℃ to 600 ℃ on the contact area between the two skin layers,

application of 50-350g/cm between two skin layers²Contact pressure of, and

-applying a heat treatment at a temperature in the range of 120-220 ℃ for 2-20 hours to obtain state T6.

The metal strip is also referred to as a filler metal or solder. The metal strip is preferably an alloy or clad sheet.

According to one feature, the step of assembling the first and second skins is carried out by laser welding, preferably according to the following parameters:

laser power in the range of 2000 to 4000W,

-the laser advancing speed is in the range of 2 to 5m/min,

-the focal distance between the laser and the first or second skin layer is in the range of 300 to 500mm,

-the inclination of the laser with respect to the first and second skin layers is in the range of 3 DEG to 7 DEG,

guiding the welding by pushing the material.

According to one feature, the laser welding is carried out under a gas shield, for example under an argon and/or helium shield.

According to one feature, the laser welding is performed with a filler metal.

Alternatively, the laser welding is performed without the filler metal by melting the materials constituting the first and second skin layers.

According to one feature, the step of assembling the first and second skins is carried out by friction stir welding, preferably according to the following parameters:

-using a substantially cylindrical cutter comprising a retractable pin having a diameter in the range of 2 to 5mm and a length in the range of 1 to 5mm, such that the retractable pin penetrates into the first skin and into half the thickness of the second skin,

applying a contact pressure of 1 to 5kN between the two skins by a pressure device, such as a substantially cylindrical cutter,

-clamping the two skins by movable clamping means,

-the tool rotation speed is in the range of 500 to 1500rpm,

-the angle of inclination of the tool with respect to a plane perpendicular to the first and second skin layers is in the range 1 to 5 °, and

-a tool advancing speed in the range of 100 to 700 mm/min.

According to one feature, the method comprises a step of controlling the assembly and/or shaping steps.

According to one feature, the first and/or second skin layer is made of aluminium or an alloy comprising aluminium, preferably of the 6000 series. This makes it possible to improve the lightness and formability of the skin layer.

According to one feature, the first skin layer has a thickness in the range of 1 to 3mm and the second skin layer has a thickness in the range of 0.6 to 2 mm.

The invention also relates to an exchanger obtained by the above method.

Such exchanger is a structural surface exchanger for aircraft, characterized in that it has a final shape adjusted or retained.

According to one feature, the exchanger comprises a first corrugated skin with an adjusted final shape, assembled on a second smooth skin with an adjusted final shape.

According to another feature, the exchanger comprises a first corrugated skin with a retained final shape assembled on a second smooth skin with a retained final shape.

Thus, the exchanger comprises a first corrugated skin with a conditioned or retained final shape assembled on a second smooth skin with a conditioned or retained final shape.

Drawings

Other features and advantages of the invention will become apparent upon reading the following description and upon viewing the accompanying drawings in which:

figure 1 is a schematic view showing a method of manufacturing a structured surface heat exchanger with an adjusted final shape according to a first variant of the invention,

figure 2 is a detailed view of the exchanger of figure 1,

figure 3 is a schematic diagram showing the steps of forming a first corrugated skin in a press,

figure 4 is a schematic diagram showing the steps of forming and shaping a first corrugated skin in a press,

Figure 5 is a schematic view showing a method for manufacturing a structured surface heat exchanger with an adjusted final shape according to a second variant of the invention,

fig. 6 is a schematic view showing the step of shaping by tensioning, applied to a structural exchanger with a suitable intermediate shape,

figure 7A is a schematic view showing an assembly step by friction stir welding,

figure 7B is a schematic view showing the steps of assembly by laser welding according to the first variant,

fig 7C is a schematic view showing a step of assembling by laser welding according to a second modification,

figure 8 is a schematic showing a first corrugated skin including cavities at each end thereof for forming a fluid distributor and collector,

figure 9 is a schematic diagram showing a variant of including at each of its ends a first corrugated skin for forming the cavities of the fluid distributor and collector,

figure 10 is a partial schematic view showing a variation of the first corrugated skin comprising a cavity at one end thereof for forming a fluid distributor or collector,

figure 11 is a partial schematic view showing a structured surface heat exchanger including a collector,

figure 12 is a schematic view of an exchanger obtained by the process of the invention,

Figure 13 is a schematic view of a distributor of exchangers obtained by the process of the invention.

Detailed Description

In the following description and claims, the same, similar or analogous components will be denoted by the same reference numerals.

Fig. 1 shows a method for manufacturing a structured surface exchanger 10 with an adjusted final shape according to a first variant of the invention.

The exchanger 10 comprises a first corrugated skin 12 with an adjusted final shape assembled on a second smooth skin 14 with an adjusted final shape. The first assembly skin 12 and the second assembly skin 14 form a channel 16. Each channel 16 is defined by the corrugations of the first corrugated skin 12 having the adjusted final shape and the second smooth skin 14 having the adjusted final shape. Thus, each channel has a semi-circular cross-section.

The exchanger 10 is a heat exchanger between a fluid F1 (fig. 12) and air F2 (fig. X), the fluid F1 being intended to circulate in the channels 16, and the air F2 being intended to circulate in contact with the second smooth surface layer 14.

The method comprises the step of forming E1 a first substantially planar skin 12' such that a first corrugated skin 12 "can be obtained, the corrugations of which are semi-circular. The step of forming the E1 first skin 12' is followed by the step of shaping the first corrugated skin 12 "obtained in the forming step E1 of E2, so that a first corrugated skin 12 with an adjusted final shape can be obtained. At the same time, the step of shaping E3 the second substantially planar smooth skin 14' makes it possible to obtain a second smooth skin having an adjusted final shape 14.

Then, during an assembly step E4, the first corrugated skin 12 with the adjusted final shape and the second smooth skin 14 with the adjusted final shape are assembled, so that a structured surface exchanger 10 with the adjusted final shape can be obtained.

The first substantially planar skin layer 12' is preferably in an initial state O, which allows it to be malleable and capable of undergoing the forming step E1.

The initial state O is an annealed state to obtain a state with the lowest mechanical resistance and to increase the ductility of the material, such as aluminum, constituting the first and second skin layers.

During forming step E1, first skin layer 12' undergoes multiple heat treatments between multiple intermediate forming steps to find, prior to each intermediate forming step, an extended state of the elongated material suitable for producing the next forming step.

The first skin layer is then preferably quenched to make it more resistant. It is referred to as state T4.

The step of forming the E1 first skin 12' is performed in a press, as shown with respect to fig. 3. This makes it possible to reduce the cost.

The forming steps E2 and E3 are performed by tensioning, as shown in relation to fig. 6.

During the step of forming the E2 first outer layer 12 ", the first outer layer 12" is preferably in state T4.

During the step of forming the E3 second skin 14', the second skin 14' is preferably in state T4.

The step of assembling E4 the first and second skin layers 12, 14 having the adjusted final shape obtained in the forming steps E2 and E3 is performed by brazing. For this purpose, a metal strip 18 is applied to the contact area between the first corrugated skin 12 having the adjusted shape and the second smooth skin 14 having the adjusted shape. The metal strip 18 has a melting temperature in the range of 500 deg.c. A pressure device (not shown) makes it possible to apply pressure to the contact area between the two skin layers 12, 14. The applied pressure was 200g/cm²Within the range of (1). The assembly by brazing is then carried out by applying a heat treatment cycle comprising a heat treatment suitable to obtain a final state T6.

More particularly, as shown in FIG. 2, the metal strip 18 is placed on the interface between the two skins 12, 14 with a tolerance "t" in the range of 2 mm.

To facilitate assembly by brazing, pins (not shown) are arranged at the ends of the skins 12, 14 in order to index them relative to each other, that is to say to position them relative to each other.

Alternatively, the assembling step E4 is performed by welding, for example by friction stir welding as shown in fig. 7A, or by laser welding as shown in fig. 7B. According to these variants, the exchanger obtained is a structured surface exchanger identical to the structured surface exchanger 100 obtained according to the method of fig. 5.

In a variant not shown, the step of shaping the E2 first skin 12 'enables obtaining a retained first corrugated skin (not shown) in final shape, and the step of shaping the E3 second smooth skin 14' allows obtaining a retained second smooth skin (not shown) in final shape. According to this variant, the step of assembling the first and second skins thus obtained of E4 makes it possible to obtain a structural surface exchanger (not shown) of retained final shape.

In a variant not shown, the step of forming the first skin E1 makes it possible to obtain a first corrugated skin with a corrugated shape that is square or triangular. The exchanger obtained according to this variant has channels of square or triangular section.

Fig. 3 shows the step of forming the E1 first skin 12' (fig. 1) in a press. For this purpose, a first substantially planar surface layer 12' (fig. 1) is placed on a female mould 20 having a groove 21 with a section identical to that of the channel 16 (fig. 1) of the exchanger 10 (fig. 1) to be manufactured. Then, a rubber element 22 of the same section as the channel 16 (fig. 1) of the exchanger 10 (fig. 1) to be manufactured is applied to the first skin 12' (fig. 1) so as to form the corrugations of the first corrugated skin 12 ″. A rubber sheet 24 is then applied to the rubber element 22. Finally, a male die 26 having protrusions 28 of the same section as the channels 16 (fig. 1) of the exchanger 10 (fig. 1) to be produced is applied to the first corrugated surface layer 12 ", in place of the rubber elements 22 and the rubber sheets 24, to complete the formation of the corrugations.

The female mould 20 and the male mould 26 are complementary.

Fig. 4 shows a variant of the method of fig. 1, in which the steps of forming E1 and forming E2 a first skin are performed simultaneously in a press. For this purpose, the method is identical to that shown in fig. 3, but the female die 20', the rubber element 22', the rubber sheet 24 'and the male die 26' have the same adjusted shape as the adjusted shape of the first corrugated surface layer 12 "to be obtained having the adjusted shape.

Alternatively, the female die 20, the rubber element 22, the rubber sheet 24 and the male die 26 have the same retention shape as the retention shape of the first corrugated skin of the retention shape to be obtained.

Fig. 5 shows a method for manufacturing a structured surface exchanger 100 with an adjusted final shape according to a variant of the invention.

The exchanger 100 comprises a first corrugated skin 120 with an adjusted final shape assembled on a second smooth skin 140 with an adjusted final shape. The assembled first skin 120 and second skin 140 form a channel 160. Each channel 160 is defined by the corrugations of the first corrugated skin 120 having the adjusted final shape and the second smooth skin 140 having the adjusted final shape. Thus, each channel has a semi-circular cross-section.

The exchanger 100 is a heat exchanger between a fluid F1 (fig. 12) and air F2 (fig. 12), the fluid F1 being intended to circulate in the channel 160 and the air F2 being intended to circulate in contact with the second smooth surface layer 140.

The method comprises the step of forming a first skin 120 'of E'1 substantially plane, such that a first corrugated skin 120 "can be obtained. The step of forming the E '1 first skin 120' is followed by the step of assembling the E '2 first corrugated skin 120 "on the second smooth skin 140' in order to obtain a structured surface exchanger of a suitable intermediate shape 100 '. Then, a step of shaping E '3 the structured exchanger 100' with a suitable intermediate shape is performed to obtain a structured surface exchanger 100 with an adjusted final shape.

The first substantially planar surface layer 120 'is preferably in an initial state O, which allows it to be malleable and capable of undergoing the forming step E' 1.

During the forming step E '1, the first skin layer 120' is subjected to a plurality of heat treatments between a plurality of intermediate forming steps to find, before each intermediate forming step, an extended state of the elongated material suitable for producing the next forming step.

The first skin layer is then preferably quenched to make it more resistant. It is referred to as state T4.

The step of forming the E '1 first skin 120' is performed in a press, as shown with respect to fig. 3.

The step of assembling E'2 first skin 120 "and second skin 140" is performed by friction stir welding, as shown in fig. 7A.

Alternatively, this step is performed by laser welding or brazing as shown in fig. 2. In a variant of the assembly step E'2 by brazing, the same exchanger as the exchanger 10 is obtained by the method shown in fig. 1.

The step of forming E '3 a suitable intermediate-shaped structural exchanger 100' is performed by tensioning, as illustrated with respect to fig. 6.

Fig. 6 shows a method of shaping by tensioning applied to the structural exchanger 100' of suitable intermediate shape of fig. 5.

A structural heat exchanger 100' having a suitable intermediate shape is applied to a shaped cutter 30 having the same shape as the shaped of the heat exchanger 100 to be obtained, and tension forces 31, 32 are applied to the ends of the heat exchanger 100' in order to shape the heat exchanger 100 '.

This method can be applied to the forming steps E2 and E3 of fig. 1.

Fig. 7A illustrates a friction stir welding method that allows for assembly E '2 of the first skin 120 "and the second 140 skin' according to the method of fig. 5. For this purpose, a substantially cylindrical cutter 40 comprising retractable pins 42 having a length in the range of 3mm is applied to the contact area between the first corrugated surface layer 120 "and the second smooth surface layer 140 'and rotated at a speed in the range of 1000rpm, so that the pins 42 penetrate the first corrugated surface layer 120" and half the thickness of the second smooth surface layer 140'.

In parallel, the movable pinch roller 44 applies a pressure 45 in the range of 3kN to the contact area between the first corrugated skin 120 "and the second smooth skin 140".

The cutter 40 is tilted. It extends in a longitudinal direction having an angle alpha in the range of 3 deg. with respect to the first corrugated skin 120 ".

The knife 40 traverses all contact areas between the first corrugated surface layer 120 "and the second smooth surface layer 140" at an advancement speed in the range of 400 mm/min.

Since the rollers are upstream of the curved path, the cutter 40 can travel the curved path.

The rollers are pressure devices. Which is controlled independently of the tool 40.

The tool 40 is a welding head that is placed on a robot or gantry.

This friction stir welding process softens the materials of the skin layers 120 ", 140" and thoroughly mixes them.

Alternatively, the pin 42 is not retractable.

Fig. 7B illustrates a laser welding method that allows assembly E '2 of the first skin 120 "and the second 140 skin' according to the method of fig. 5. For this purpose, a laser 60 is applied at the level of the contact area between the first corrugated skin 120 "and the second smooth skin 140", which laser is inclined at an angle β relative to the first and second skins, the angle β being in the range of 5 °, and the focal distance between the laser 60 and the first skin 120 "being in the range of 400mm (not visible in fig. 7B). The laser moves along the length of the first skin 120 "in the direction of arrow S, which is referred to as the welding direction by pushing the material as the laser 60 is pushed during its movement. The laser power was 3000W. The forward speed was 4 m/min.

Fig. 7C shows a variation of the laser welding method, which allows the assembly E '2 of the first skin 120 "and the second 140 skin' according to the method of fig. 5. In this variant, the laser 60 is inclined at an angle β' in the range of 175 ° with respect to the first and second skin layers. The laser moves along the length of the first skin 120 "in the direction of arrow S, which is referred to as the welding direction by pulling the material since the laser 60 is pulled during its movement.

Fig. 8 shows a first corrugated skin 12', 120' comprising cavities 50 at each of its ends 51, 52.

The cavity 50 is formed during the forming steps E1, E '1 of the first skin layer 12', 120 '.

These cavities 50 are used to form the fluid distributor and collector, respectively, during the step of assembling the first and second skins, so that a structured surface exchanger comprising the fluid distributor and collector can be obtained.

Fig. 9 shows a variant of the first corrugated skin 12', 120' with cavities 50 at each end thereof.

In this variation, the cavity is formed in the same manner as in fig. 8. More precisely, the first corrugated skin 12', 120' comprises two cavities 50 at a first end 51 and cavities at an opposite end 52. The cavities 50 at the first end 51 are used to form a fluid distributor and collector, respectively, while the cavities 50 at the opposite end 52 are used to form a half-turn collector to allow fluid to circulate between the channels.

Fig. 10 shows a first corrugated skin 12', 120' having cavities 50' at one end thereof.

The cavity 50' is assembled on the first corrugated skin 12', 120' by welding, before the step of assembling the two skins or before the step of shaping the first skin.

In the same manner as described above, the cavity 50' is intended to form a fluid distributor or collector during the assembly step with the second skin.

Fig. 11 shows a structural surface exchanger 100 "comprising a first corrugated skin 120" fitted on a second smooth skin 140', on which second smooth skin 140' a fluid collector 500 is arranged at one end thereof.

According to this variant, the method of fig. 5 comprises a step of forming (not shown) a second skin 140 'before the assembly step E'2 of the skins 120 ", 140 'to obtain a second skin comprising a cavity for forming the collector 500 during the assembly of the two skins 120", 140'. This forming step is performed in a press in the same manner as shown in fig. 3.

Fig. 12 shows a structured surface exchanger 10, 100 with a shaped profile obtained by the method of fig. 1 or 5.

The exchanger 10, 100 comprises a first corrugated skin 12, 120 having a shaped and a second smooth skin 14, 140 having a shaped forming the channels 16, 160.

The exchangers 10, 100 are waterproof at pressures up to 10 bar.

In a variant not shown, it comprises, at one and/or the other end thereof, a fluid distributor and a collector, so as to allow the distribution and collection of the fluid F to be circulated in the channels 16, 160, the collector and distributor being obtained according to the method described above.

In a variant, the exchangers 10, 100 comprise at least one distributor as illustrated with reference to fig. 13.

Fig. 13 shows an example of a distributor 60 comprising a distribution grid 61, which enables the distribution of the fluid in the channels 16, 160 of the exchanger 10, 100 as shown above to be optimized.

Furthermore, in a variant not shown, the step of degreasing the first and second skin layers is carried out before the assembly step E4, E'3 of the first and second skin layers.