An air-to-air heat exchanger, is provided that comprises a folded fin core formed from a continuous sheet of thermally conductive material that has been folded into alternating flat ridges and troughs; an insert overlay having an opening including two sets of uniform fingers, wherein each finger has a portion protruding into and essentially filling each trough on one surface of the folded fin core; an inset region between each finger portion and the end edges of each trough; a sealant within each inset region sealably attaching the insert overlay to the folded fin core; and an air flow divider plate. Heat exchanger components are also provided.
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is related to and claims priority from U.S. Provisional Patent Application No. 60/552,414, filed on Mar. 11, 2004.
A low-cost, high-temperature heat exchanger is made from a notched piece of metal, the metal being folded back and forth upon itself to form a monolith. The notches in the metal piece create openings, communicating with distinct sides of the monolith. Ducts are attached to the openings. Cut pieces of corrugated metal, which may have a catalyst coating, are inserted between folds of the monolith. The heat exchanger may be used as part of a fuel cell system, or in other industrial applications, to recover waste heat, or to conduct various catalytic and non-catalytic reactions. The invention also includes an element, or building block, for a high-temperature heat exchanger, including a folded metal monolith with metal combs inserted, the monolith and the combs defining seams which are hermetically sealed.
