GB2136335A - Tube Corrugating Apparatus and Method - Google Patents

Abstract

A corrugating die for metal tubing comprises a hollow body having teeth 4 uniformly spaced around the internal cavity thereof. Each tooth has a flat shape with a curved surface 9 and extends into the die cavity somewhat on a helical line. When a thin-walled, hollow tubing is inserted into the die at the end adjacent to the roots of the die teeth and held against rotation and the die body rotated relative to the tubing, the die teeth corrugate the tubing. The corrugated tubing may be further reduced in size by passing through a stationary reducing draw die. The surface of the tubing is preferably pitted by shot or sandblasting or etching or the like. <IMAGE>

Description

SPECIFICATION Tubing Corrugating Apparatus and Method Background of the invention Field of the Invention This invention relates to apparatus and methods for forming corrugations in metal heat exchange tubing.

Brief Description of the Prior Art Finned heat exchange tubing is well known in the art for use in radiators, heat exchangers, refrigeration condensors, etc. Many types of apparatus and methods are known for the application of heat exchange fins to heat exchanger tubing.

It is also well known to form heat exchange fins integrally from the wall of heat exchange tubing members. It is also known to corrugate heat exchange tubing into longitudinally extending or circumferentially or helically extending corrugations to provide an increased surface area for heat exchange somewhat equivalent to the application of external fins to the tubing. The production of helical corrugations and tubing, however, has in the past required the use of an internal mandrel and an external corrugation die cooperable therewith to form the desired corrugations. Such equipment has limited the length of the helically corrugated tubing to the length of mandrel used in the corrugation operation. This has not been a practical method for continuous corrugating of an indefinite length of thin walled heat exchange tubing.

Benson U.S. Patent Specification 2,954,212 discloses apparatus for extrusion of metal tubing with helical fins formed integrally thereon.

Slade U.S. Patent Specification 3,008,187 discloses an extrusion die for extruding thermoplastics having helical corrugations for orienting the plastic material in different directions.

Atkin U.S. Patent Specification 3,267,712 discloses an extrusion die for extruding tubing with longitudinally extending fins thereon.

Brothers U.S. Patent Specification 4,159,739 discloses a method and apparatus for forming heat exchange fins integrally from the material of heat exchange tubing.

Ford U.S. Patent Specification 3,850,227 discloses a helically corrugated heat exchange tubing and makes reference in his specification to other types of tubing and to apparatus used for forming such tubing.

Regner U.S. Patent Specification 3,988,804 discloses the use of a rotating die having helical internal fins for forming thin walled tubular cellophane film into a pleated or shirred form having helically formed pleats.

Summary of the Invention According to the invention there is provided: A metal tube corrugating die operable to corrugate tubing without a supporting mandrel comprising a hollow die body having a longitudinally extending bore therethrough, a plurality of die teeth supported in said die body equidistantly around the circumference of and extending into said bore, each of said die teeth having a straight supporting base portion supported in said die body at an angle to the longitudinal axis thereof, and a corrugating die portion comprising a flat planar plate extending from said base portion radially inward of said bore and having an edge curving inward from a root portion adjacent to the surface of said bore to a peak portion radially inward therefrom and having an arcuate length of a small fraction of one helical coil of the tubing corrugated therein, the angle and spacing of said die teeth being such that multiple uniform helical corrugations in thin walled tubing are produced by passing such tubing therethrough while rotating said die.

Brief Description of the Drawings Fig. 1 is an end view of one tube corrugation die representing a preferred embodiment of the invention, said die having eight corrugating teeth.

Fig. 2 is a side view of the corrugating die shown in Fig. 1.

Fig. 3 is a sectional view taken on the line 33 of Fig. 1, with the upper portion of the section taken along a flat surface of the corrugating die tooth.

Fig. 4 is a view in elevation of one of the die teeth shown in Fig. 1.

Fig. 5 is a plan view of the die tooth of Fig. 4.

Fig. 6 is a view in left elevation of the die tooth of Fig. 4.

Fig. 7 is a view in right elevation of the die tooth shown in Fig. 4.

Fig. 8 is a side view of another embodiment of corrugating die having four corrugating teeth.

Fig. 9 is an end view, similar to Fig. 1, of the die shown in Fig. 8.

Fig. 10 is an end view, similar to Fig. 1, of a rotating die having a single die tooth.

Fig. 11 is an end view, similar to Fig. 1, of a rotating die having two die teeth.

Fig..1 2 is an end view, similar to Fig. 1, of a rotating die having five die teeth.

Fig. 13 is an end view, similar to Fig. 1, of a rotating die having six die teeth.

Fig. 14 is an end view of a rotating die, similar to Fig.1, in which the die body is formed of four separate segments.

Fig. 1 5 is a side view of the die shown in Fig. 14.

Fig. 16 is a plan view of one of the die body segments of the embodiment shown in Fig. 14, showing the location of the die teeth therein.

Fig.17 is a schematic view illustrating the assembly of the rotating die shown in Fig. 1, in a tube corrugating apparatus and illustrating the progress of tubing through the die.

Fig. 1 8 is a view in left elevation of the rotating die apparatus shown in Fig.17.

Fig. 19 is a view in elevation, and partly in broken section, of a piece of thin walled tubing which has been partially corrugated using the apparatus and method of the invention.

Fig. 20 is an end view of the corrugated portion of the tubing shown in Fig. 19.

Fig. 21 is a view partially in section and partially in elevation showing a stationary reducing draw die for reducing the size of the helically corrugated tubing of Fig. 19 or Fig.17 to a predetermined smaller uniform size.

Fig. 22 is a view in elevation of corrugated tubing after passing through the reducing die of Fig. 21 and further subjected to sandblasting or shot blasting or etching to produce a pitted surface.

Description of the Preferred Embodiments Referring to the drawing by numerals of reference and more particularly to Fig. 1-7, there is shown a novel tube corrugating die 1 comprising a die body 2 which is cylindrical in shape, but could be of a regular shape such as square, hexagonal, octagonal, etc. Die body 1 has a cylindrical bore 3 therethrough into which protrude a plurality of die teeth 4. Die body 2 also is provided with a plurality of mounting holes or apertures 5. Die teeth 4 are positioned in flat slots 6 in die body 2 and have the tooth portion extending into the bore 3 as seen in Fig. 3.

The die teeth 4 are shown in detail in Figs.4 7, respectively. Die teeth 4 comprise a supporting base portion 7 which is rectangular in cross section and has parallel sides which fit into slots 6 in die body 2. The tooth portion 8 of die teeth 4 is curved as indicated at 9 in Fig. 4 in the side view of the die tooth structure. The root of the die tooth portion 8 adjacent to the supporting portion 7 is narrow and constitutes approximately a knife edge as seen at the right of Fig. 5 and at the front of Fig. 7. The curved surface 9 of the die tooth portion 8 increases in width from knife edge 10 to a wide rounded portion 11 at the upper end of the die tooth. The shape of the die teeth is important in corrugating and gathering a metal tubing.

The die teeth 4 are positioned in slots 6, as shown in Fig. 2, and lie at a substantial angle to the longitudinal axis of die body 2. Consequently, die teeth 4 are positioned with root portion 10 of narrow, almost knife edge, construction adjacent to the inner surface of bore 3. The die teeth curve along line 9 inwardly of bore 3 with the innermost projecting portion 11 projected substantially into bore 3. Die teeth 4 are all set at substantially the same angle from the longitudinal axis of die body 2 whereby the curved surfaces 9 of the die teeth lie approximately on a segment of a helix. The angle of slot 6 is preferably the angle of pitch of a helix which will provide helical indentations in tubing being corrugated which are about the same width as the corrugations being produced.

In Figs. 17 and 18 corrugating die 1 is illustrated in position in an apparatus for producing helical corrugations in thin walled tubing. Die body 2 is positioned in hollow supporting block 12 and is held in place by retaining screws or bolts 13 which extend into apertures 5. Supporting body 12 has a cylindrical outer surface and is supported on bearings 14 on the outside and bearings 1 5 at the end surface. Die supporting body 12 is provided with a sprocket or gear 16 6 which may be connected to a suitable drive means (not shown) which drives a direct drive gear or a drive chain for the gear or sprocket.

The supporting structure shown in Fig.17 is somewhat schematic and it is to understood that any suitable die support table could be used. This equipment is preferably used with a conventional draw bench and the schematic supporting structure shown in Fig.17 refers to the supporting elements of a draw bench and any support members thereon required to support the corrgugation die in a horizontal position for rotation, as shown.

A thin walled cylindrical tubing 17 is introduced into the end of die body 2 into the bore 3 adjacent the root portion 10 of die teeth 8. Die body 2 is rotated by action of the drive means (not shown) on sprocket or gear 16 which causes supporting body 12 to rotate. As die body 2 is rotated, die teeth 8 grip tubing 17 and start to indent the tubing along helical lines. Die body 2 is rotated clockwise, as seen in Fig.18, which causes the root portion 10 of each of die teeth 8 to engage the surface of hollow tubing 17 and progressively indent said surface along helical lines which are equally spaced.As tube 17 is indented by progressive movement of curved surface 9 of the die teeth 8, a plurality of helical corrugations are formed which correspond in number to the number of die teeth (in this embodiment, 8 die teeth) and said corrugations have a pitch determined by the angle of slots 6 in which die teeth 8 are mounted. The corrugations which are produced have a depth determined by the height of the peak portion 11 of die teeth 8.

The shape of die teeth 8 which varies from nearly a knife edge at the root portion 10 to a fairly wide surface 11 at the peaked portion of the tooth is effective to start the creasing or corrugating of tubing 17 along a narrow line which is progressively spread by the progressing width of die teeth 8 which gathers the tubing in a longitudinal direction.

During rotation of die body 2, tubing 1 7 must be restrained from rotating. The corrugated tubing 1 8 which emerges from the rotating die body 2 is corrugated with a plurality of helical corrugations which correspond in number to the number of die teeth 8 (in this embodiment, 8 die teeth) and in which the width of the corrugations is about the same as the width of the grooves formed by die teeth 8 in making the corrugations. After the corrugated tubing 1 8 emerges from the rotating die, it may be secured in clamp 19 which may be the draw block of a draw bench and movable along the surface of the bench (not shown). The clamp or draw block 19 is effective to prevent tubing 17 and corrugated tubing 18 from rotating during the corrugating of the tubing by rotation of die body 2.

The rotation of die body 2 may be effected by a positive drive operating on gear or sprocket 16 which rotates supporting body 12. Alternatively, the supporting body 12 may be allowed to rotate freely once the corrugated portion 1 8 of the tubing 17 has emerged from die body 2 and been fastened to clamp or draw block 1 9. Clamp or draw block 19 may then pull tubing 1 7 through die body 2 and the die body will rotate and produce corrugations in the same manner as when it is positively driven. In most cases, however, it is desirable to provide a positive drive to rotate supporting body 12 and die body 2 since the rotation of die teeth 8 functions not only to corrugate tubing 17 but also to positively drive the tubing through the rotating die. When operated in this manner, it is possible to corrugate indefinite lengths of thin walled hollow tubing.For example, it is possible to feed great lengths of hollow tubing directly from a suporting spool and corrugated the tubing continuously. In the erribodiment shown in Figs. 1-7 and in the apparatus shown in Figs. 1 7-1 8, the tubing produced has eight helical corrugations of substantial pitch. Details of this tubing are shown more clearly in Fig. 1 9 wherein part of the wall of the corrugated tubing portion 18 is broken away to show the corrugations. Also, in Fig. 20, an end view of the corrugated tubing is shown.

In corrugating tubing using this apparatus and method, there is some slight variation in size of the corrugations. It is desired to produce a corrugated tubing of uniform size and shape.

Accordingly, the corrugated tubing 18 is preferably passed through a stationary draw die 20 where it is further reduced in size by being drawn therethrough. The corrugated tubing emerging from draw die 20 is indicated as 21 to have a smaller but uniform diameter. The rate of pulling the corrugated tubing through draw die 20 is usually different from the rate that the tubing is passed through the rotating corrugating die and so the draw die should be at a different location.

Of course, in apparatus where the corrugating die and the stationary draw die can be operated at the same speed, the dies can be located in-line for continuous operation. Since the corrugating tubing is designed for use in heat exchangers, its heat exchange capacity may be increased by sand blasting or shot blasting or etching to produce a roughened surface 22 as shown in Fig. 22. The product thus obtained has a roughened surface and corrugations of selected size and shape and has a greatly enhanced heat exchange capacity.

This corrugated tubing is particularly useful in refrigeration and air-conditioning equipment, and may also be used in industrial heat exchangers, radiators and the like.

Corrugating die 1 is versatile in design. The die teeth 4 may be varied in shape and the extent of protrusion of the individual die tooth portion 8 may be varied to produce a desired depth of corrugation in the tubing being corrugated.

Likewise, the width of the upper portion 11 of die tooth portion 8 may be varied in size to vary the amount of gather of the tubing in forming the corrugations. The angle of slots 6 in die body 2 may likewise be varied to set the pitch of the helical corrugations at any desired value. The number of die teeth 4 used in corrugaging die 1 may be varied in number according to the number of corrugations desired. Any desired number of die teeth may be used from a single die tooth up to a substantial number. Figs. 8-1 3 of the drawings illustrate other embodiments of the corrugating die which illustrate this point.

Alternate Embodiments In Figs. 8 and 9 there is shown an alternate form of corrugaging die 1 having die body 2 as in the preferred embodiment. In Figs. 8 and 9, die body 2 has only four equally spaced slots 6 around the surface of the die body 2 in which die teeth 4 are positioned with the die tooth portions 8 thereof extending into internal bore 3. In this embodiment, the angle of slots 6 from the longitudinal axis of die body 2 is substantially greater than in Fig. 2 to insure that the width of the corrugations and of the grooves between the corrugations will be substantially the same.

In Fig. 10, corrugating die 1 is provided with only single die tooth for having a single die tooth portion 8 extending into bore 3. When a single die tooth is used, the slot 6 in which it is supported will be almost at right angles to the longitudinal axis, which will be just sufficient to permit the die tooth portion 8 to advance along a single helical line in corrugating the tubing 1 7. This angle of the die tooth form the longitudinal axis is necessary so that when a single helical corrugation is formed the width of the groove will be approximately equal to the width of the corrugation. It should be noted that when a single tooth is used and the angle of the tooth is almost at right angles to the longitudinal axis of the die body 2, the die must be positively rotated.The tubing cannot be pulled through this die because of the angle of positioning of the die tooth 8. The rotation of the die body, however, will be effective to corrugate tubing 17 in a single helical corrugation.

In Fig.11, corrugating die 1 has two die teeth with die teeth portion 8 extending into bore 3 of die body 2. The angle of positioning of the die teeth in the slots 6 is such that the die teeth will form double helical corrugations with the width of corrugations being about the same as the width of the grooves between the corrugations. This embodiment likewise requires that the die body be positively rotated.

In Fig. 12, an embodiment is shown of corrugating die 1 consisting of die body 2 having five die teeth portion 8 extending into bore 3. This corrugating die will produce five helical corrugations when positively rotated or when tubing 17 is drawn through the die which is allowed to rotate freely.

In Fig.13, a still further embodiment is shown of corrugaging die 1 in which die body 2 has six die teeth portions 8 positioned in bore 3. Rotation of this die will produce six helical corrugations in tubing 17. The pitch of the individual helixes is determined by the angle of the individual die teeth from the axis of the rotating die body. The angle positioning of the die teeth also determined to some extent the spacing of the corrugations.

Another Embodiment In the embodiment previously described, die body 2 has been of a unitary construction and die teeth 4 have been inserted into die body 2 through slots 6 extending from the outer surface of die body 2 into inner bore 3 thereof. In Figs.

14-1 6, there is shown a further embodiment of the invention in which die body 2 is segmented and the die teeth are inserted into slots adjacent to the bore when the segments are disassembled.

In Fig. 14, corrugating die 1 is shown to have a die body 2 having internal bore 3 with die teeth portions 8 extending into said bore. Die body 2 is formed of four body segments 23, 24, 25, and 26.

These segments have apertures or passages 27, 28,29, and 30. Screws or bolts 31 are positioned in the respective apertures or passages 27-30 to secure the die body segments together as shown in Fig. 14 and 1 5. Die body 2 has a plurality of flats 32 cut in the surface thereof to define a hexagonal shape in the portion. At the other end of die body 2 there is provided a cylindrical extension 33 of reduced diameter.

In Fig.16, there is shown a detailed view of one of the die body segments 25 showing angularly extended slots 34 in which die teeth 4 are positioned. In this embodiment to the invention, the corrugating die 1, when assembled, does not require an external supporting block 12 to secure the die teeth against radial displacement during operation. In this embodiment, the die teeth are supported rigidly in slots 34 and cannot move radially outward. This segmented die, when assembled, may be used directly in corrugating the thin walled tubing 17 without the need for a supporting die body.

In the several embodiments of this invention, it is seen that the novel corrugating die 1 may be of a unitary die body construction or may be formed of segments which are assembled, as in Figs.

14-1 6. Any desired number of die teeth 4 may be used according to the number of helical corrugations desired. When a few die teeth are used, e.g. one, two, three, the angle at which the die teeth must be set in die body 2 to produce equally spaced corrugations is such that the die body must be positively rotated. When more die teeth are used, the angle at which the die teeth are set in the die body is such that the die body may be positively rotated, if desired or may be allowed to rotate freely and the tubing pulled through the die by use of the clamp or draw block 19. Of course, the die body would have to be positively rotated to initiate the formation of the corrugated tubing portion 18 to which the clamp or draw block would be attached. The number of corrugation may be varied according to the number of die teeth used. The pitch of the helical corrugations may be varied according to the angle at which the die teeth are set. The depth and width of the corrugations are determined partially by the angle of setting of the die teeth and partially by the width of the die teeth, and particularly the variation in width from the root portion 10 to the protruding portion 11. The depth of the corrugation is largely determined by the extent of protrusion of the protruding portion 11 of the die teeth. The product of any of the corrugating dies is a tubing having one or more corrugations which provides a greatly increased surface area for heat exchange purposes. The tubing may be further sized by passing through a stationary reducing draw die 20 as shown in Fig.

21 and may be roughened or pitted as described is connection with Fig. 22.

Claims (12)

1. A metal tube corrugating die operable to corrugate tubing without a supporting mandrel comprising a hollow die body having a longitudinally extending bore therethrough, a plurality of die teeth supported in said die body equidistantly around the circumference of and extending into said bore, each of said die teeth having a straight supporting base portion supported in said die body at an angle to the longitudinal axis thereof, and a corrugating die portion comprising a flat planar plate extending from said base portion radially inward of said bore and having an edge curving inward from a root portion adjacent to the surface of said bore to a peak portion radially inward therefrom and having an arcuate length of a small fraction of one helical coil of the tubing corrugated therein, the angle and spacing of said die teeth being such that multiple uniform helical corrugations in thin walled tubing are produced by passing such tubing therethrough while rotating said die.

2. A metal tube corrugating die according to claim 1 in which each of said die teeth has said curved surface of varying width from a narrow edge at said root portion widening gradually to a wide portion at the peak portion thereof.

3. A metal tube corrugating die according to claim 1 in which said die body includes a plurality of radially extending each of which is rectangular in cross section, opening into said bore to support the base portion of a die tooth therein with said plate portion extending into said bore.

4. A metal tube corrugating die according to claim 1 in which said die body comprises a plurality of segments releasably secured together, and each of said die body segments having a slot extending along the surface of said bore at an angle to the longitudinal axis thereof to support said die tooth base portion with said corrugating die portion extending into said bore.

5. A metal tube corrugating apparatus operable to corrugate tubing without a supporting mandrel comprising: a supporting base member, a hollow tube corrugating die, means supporting said tube corrugation die on said base member for rotation about a horizontal axis, means for rotating said corrugating die, said corrugating die comprising a hollow die body having a longitudinally extending bore therethrough, a plurality of die teeth supported in said die body equidistantly around the circumference of and extending into said bore, each of said die teeth having a straight supporting base portion supported in said die body at an angle to the longitudinal axis thereof, a corrugating die portion comprising a flat planar plate extending from said base portion radially inward of said bore and having an edge curving inward from a root portion adjacent to the surface of said bore to a peak portion radially inward therefrom and having an arcuate length of a small fraction of one helical coil of the tubing corrugated therein, the angle and spacing of said die teeth being such that multiple uniform helical corrugations in thin walled tubing are produced by passing such tubing therethrough while rotating said die, and said base member including means to draw a tubing through said die and to secure the leading end of said tubing against rotation while passing through said corrugating die.

6. A metal tube corrugating apparatus according to claim 5 in which said tubing securing means comprises a draw clamp movable along the surface of said supporting base member.

7. A metal tube corrugating apparatus according to claim 5 including a stationary draw die positioned on said supporting base member for sizing unreinforced corrugated tubing produced by said tube corrugating die.

8. A metal tube corrugation apparatus according to claim 5 in which said die tooth has said curved surface of varying width from a narrow edge at the root portion thereof widening gradually to a wide portion at the peak portion thereof.

9. A metal tube corrugating apparatus according to claim 7 in which said draw die is aligned with said corrugating die.

10. A method of forming helical corrugations in thin wall metal tubing comprising: holding the leading end of said tubing against rotation and drawing the same longitudinally through a rotating corrugating die as defined in claim 1 or 2.

11. A method of forming helical corrugations in thin wall metal tubing comprising: holding said tubing against rotation and passing the same longitudinally into a corrugating die as defined in claim 1, and positively rotating said die.

12. A method of forming helical corrugations in thin wall metal tubing in accordance with claim 11 in which said corrugated tubing is subsequently passed through a stationary draw die to further reduce the outer diameter of said corrugations to a predetermined size.