A heat exchanger assembly

Abstract

The subject matter of the invention relates to a heat exchanger assembly (1000) comprising at least one heat exchanger (100) and a mounting structure (200), the heat exchanger (100) being configured to be mounted to the mounting structure (200) along a first axis (XX'), wherein the heat exchanger (100) comprises a housing (10) that defines an enclosure (10a), wherein the heat exchanger (100) is mounted to the mounting structure (200) using one or more engaging members (122, 142) integrally formed with the housing (10), wherein at least one of the heat exchanger (100) and the mounting structure (200) comprises at least one securing means (24) configured to restrict the degree of freedom of the heat exchanger (100) with respect to the mounting structure (200) along the first axis (XX').

Description

TECHNICAL FIELD

[0001] The present invention relates to heat exchanger such as a chiller, a water gas-cooler, or the like for a vehicle.BACKGROUND OF THE INVENTION

[0002] Electric vehicles utilize a heat-exchanger, particularly, a chiller for heat dissipation from the battery pack to cool the battery pack of a vehicle. The chiller is used to cool a coolant (such as water) and the coolant is used to cool the battery. Usually, the chiller is supplied with high pressure refrigerant and thus needs to be structurally strong that contributes to the mass of the chiller. Thus a heavy part such as the chiller needs to be securely mounted to the vehicle since the vibrations coming from the vehicle operation can compromise the rigid mounting of the chiller. Usually the chiller is mounted to a bracket of the vehicle, and it often involves complicated securing arrangements such as welded fastening brackets that add to the weight, additional manufacturing steps such bending of external housing covers of the heat exchanger as mounting points, or the like. Further, as a consequence, the assembly method is also complex and time consuming.SUMMARY OF THE INVENTION

[0003] The present invention relates to a heat exchanger assembly that includes at least one heat exchanger and a mounting structure. The heat exchanger is adapted to be mounted to the mounting structure along a first axis. The heat exchanger includes a housing that defines an enclosure. The heat exchanger is mounted to the mounting structure using one or more engaging members that are integrally formed with the housing. At least one of the heat exchanger and the mounting structure i.e. any one or both of the heat exchanger and the mounting structure includes at least one securing means configured to restrict the degree of freedom of the heat exchanger with respect to the mounting structure along the first axis.

[0004] Generally, the housing includes at least one first plate, at least one second plate, and at least one third plate.

[0005] Specifically, the one or more engaging members are integrally formed with at least one of the first plate, the second plate, and the third plate.

[0006] More specifically, the one or more engaging members are substantially coplanar with at least one of the first plate, the second plate, and the third plate of the housing.

[0007] Generally, the heat exchanger comprises at least one manifold that includes at least one cover plate.

[0008] Particularly, the securing means is integrally formed with the cover plate.

[0009] Particularly, the securing means is integrally formed with the housing.

[0010] Generally, the securing means is in the form of a protrusion that comprises an aperture configured to allow a fastener to pass therethrough.

[0011] Particularly, the fastener is a threaded fastener.

[0012] Particularly, the securing means is of snap-fit type.

[0013] Generally, the first plate includes at least two engaging members and the second plate includes at least two engaging members integrally formed therein.

[0014] Particularly, at least one of the securing means and the engaging members, further restrict the degree of freedom of the heat exchanger with respect to the mounting structure along the second axis YY' that is perpendicular to the first axis XX'.

[0015] Generally, the manifold includes at least one header that secures the cover plate to the manifold.

[0016] Particularly, the header comprises an incision to allow the securing means to protrude from the cover plate.

[0017] Generally, the heat exchanger includes a core that includes a plurality of heat exchange tubes. The core is positioned in the enclosure.

[0018] The subject-matter of the invention allows simple and easy assembly of the heat exchanger to a vehicle with minimum additional components, minimum process steps, minimum additional connection components, mass, and material addition without substantially increasing the manufacturing steps.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other characteristics, details and advantages of the invention may be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein: FIG. 1 illustrates a schematic representation depicting a heat exchanger assembly in accordance with an embodiment of the present invention. FIG. 2 illustrates an exploded view depicting elements of the heat exchanger assembly of FIG. 1. FIG. 3 illustrates an exploded view depicting the components of a housing of the heat exchanger assembly of FIG. 1. FIG. 4 illustrates an isometric view of a manifold of the heat exchanger assembly of FIG. 1. FIG. 5 illustrates an isometric view of a core of the heat exchanger assembly of FIG. 1. FIG. 6 illustrates a long plate that combines one first plate, one second plate and one third plate. DETAILED DESCRIPTION

[0020] It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention, if need be. The invention should however not be limited to the embodiments disclosed in the description.

[0021] The present invention envisages a heat exchanger assembly of a vehicle. More specifically, the invention relates to a heat exchanger for cooling a coolant by allowing it to exchange heat with a cold refrigerant. The heat exchanger is usually mounted to a mounting structure of the vehicle. Usually, mounting of the heat exchanger requires additional brackets attached to the heat exchanger body, or bending operation of the external housing of the heat exchanger to secure it to the mounting structure. Such approaches add weight and complexity to the assembly and also involve additional manufacturing steps leading to additional cost and efforts.

[0022] The heat exchanger assembly of the present invention involves a simplified approach for mounting of the heat exchanger to the vehicle wherein engaging members extending from the housing of the heat exchanger are used to mount the heat exchanger to a mounting structure of the vehicle, while a securing means extending from a cover plate of a header is used to fix the securing means to the mounting structure using a fastener, thus arresting the degree of freedom of the heat exchanger.

[0023] FIG. 1 illustrates an isometric view of a heat exchanger assembly 1000 depicting a heat exchanger 100 and a mounting structure 200. The mounting structure 200 includes mounting members 202 that engage and support the heat exchanger 100. The heat exchanger 100 is usually mounted to the mounting structure 200 along a first axis XX'. A second axis YY' is depicted in FIG. 1 as being perpendicular to the first axis XX' and the mounting structure 200 is positioned with respect to the heat exchanger 100 along the second axis YY'. The mounting structure 200 also includes a hole 204 for fastening the heat exchanger 100 to the mounting structure 200 using a fastener 60.

[0024] FIG. 2 illustrates an exploded view depicting elements of the heat exchanger assembly of FIG. 1. Including a housing 10, a first manifold 20, a core 30, a second manifold 40, and nozzles 50. Further, the figure depicts an enclosure 10a defined and bounded by the housing 10. The core 30 is located inside the enclosure 10a. The first manifold 20 and the second manifold 40 are disposed at the two ends (along XX' axis) of the housing 10. Together, the housing 10, the first manifold 20 and the second manifold 40 fluidically seal the enclosure 10a and the core 30 therein.

[0025] FIG. 3 illustrates an exploded view depicting the components of a housing 10 of the heat exchanger assembly 1000. The housing 100 comprises of a first plate 12, a second plate 14, and at least one third plate 16 that constitute the bounding walls of the enclosure 10a in which the core 30 is located. Preferably, two third plates 16 are implemented. The figure further depicts the first plate 12 that includes engaging members 122 and the second plate 14 that includes engaging members 142 for engaging with the mounting members 202 of the mounting structure 200. The first plate 12 includes apertures 121 that fluidically connect to the nozzles 50.

[0026] FIG. 4 illustrates an isometric view of the first manifold 20 that includes multiple flow control plates 21, a cover plate 22 and a header 28. The header plate 28 crimps the multiple flow control plates 21 and a cover plate 22 together to form the first manifold 20. The cover plate 22 includes an integrally formed securing means 24 protruding from the cover plate 22. Further, the securing means 24 includes an aperture 26. The securing means 24 protrudes outwards from the cover plate 22 through an incision 28a in the header 28.

[0027] FIG. 5 illustrates an isometric view of the core 30 depicting a plurality of heat exchange tubes 32 that are stacked together to form the core 30.

[0028] FIG. 6 illustrates a long plate 10a that combines one first plate 12, one second plate 14 and one third plate 16. The figure further depicts engaging members 122 and 142 protruding from the long plate 10a an imaginary dotted lines depicting folding lines.

[0029] The heat exchanger assembly 1000 includes at least one heat exchanger 100 and the mounting structure 200. The heat exchanger 100 is configured to be mounted to the mounting structure 200 along the first axis XX'. The housing 10 of the heat exchanger 100 defines an enclosure 10a. The engaging members 122, 142 are integrally formed in in the housing 10. The engaging members 122, 142 are used to mount the heat exchanger 100 on to the mounting structure 200. The at least one securing means 24 provided in either the heat exchanger 100 or the mounting structure 200 or both. The securing means 24 is adapted to restrict the degree of freedom of the heat exchanger 100 with respect to the mounting structure 200 along the first axis XX'.

[0030] In a preferred embodiment, the heat exchanger 100 is detachably mounted to the mounting structure 200 along an axis XX'. Usually, the axis XX' is substantially along the vertical direction of gravity to facilitate easy mounting of the heat exchanger 100 to the mounting structure 200. It must be appreciated that the mounting structure 200 may be a separate structure mounted to the vehicle, or a suitably modified portion of the vehicle, such as a vehicle frame. The housing 10 of the heat exchanger 100 is formed preferably using four plates i.e. one first plate 12, one second plate 14 and two third plates 16, to form an enclosure 10a that has a four sided shape. By way of example and not limitation, the first plate 12, the second plate 14 and the two third plates 16 are joined using a suitable joining process such as a brazing, welding, or the like. The first plate 12 and the second plate 14 are positioned substantially opposite to each other while the two third plates 16 are positioned substantially opposite to each other. The first plate 12 and the second plate 14, of the housing 10, respectively include engaging members 122 and 142, integrally formed therein. Preferably, the first plate 12 includes at least two engaging members 122 and the second plate 14 comprises at least two engaging members 142. Alternatively, more or less engaging members 122, 142 may be used without departing from the scope of the invention. The engaging members 122, 142 are preferably in the form of inverted U-shaped hooks adapted to accommodate the mounting members 202 of the mounting structure 200. The mounting members 202 may have any suitable shape such as a protrusion or a depression in the mounting structure 200 conforming to the shape of the engaging members 122, 142. Preferably, the heat exchanger 100 is mounted to the mounting structure 200 by moving the heat exchanger 100 along the first axis XX' i.e. in a downward gravity direction, till the engaging members 122, 142 of the housing 10 engage the mounting members 202 of the mounting structure 200. The engaging members 122, 142 are substantially coplanar with at least one of the first plate 12, the second plate 14. More specifically, engaging members 122 are substantially coplanar with the first plate 12 and the engaging members 142 are substantially coplanar with the second plate 14. Such coplanarity implies that the first plate 12 and the second plate 14 can be manufactured simply by cutting a blank into the suitable shape eliminating the need for any bending process to create the engaging members 122, 142. This saves manufacturing time, effort and costs. The first plate 12 the second plate 14 and the third plates 16 of the housing 10 along with the first manifold 20 and the second manifold 40, fluidically sealed the enclosure 10a. The apertures 121 of first plate 12 that fluidically connect to the nozzles 50 for ingress and egress of a fluid, preferably a coolant fluid, in to and out of the enclosure 10a. Alternatively, any of the first plate 12, the second plate 14 and the third plate 16 or any combination thereof may include the apertures 121 for nozzles 50 for fluidically connecting the nozzles 50. The core 30 is disposed in the enclosure 10a. The core 30 includes a plurality of plate type heat exchange tubes 32 that are in fluidic communication with the first manifold 20 and the second manifold 40. A first fluid (such as a refrigerant fluid) flows within the first manifold 20, the second manifold 40 and the heat exchange tubes 32 of the core 30. A second fluid (such as a coolant fluid) ingresses and egresses the fluidically sealed enclosure 10a through the nozzles 50. Inside the enclosure the second fluid comes in contact with the heat exchange tubes 32 the core 30 to undergo heat exchange with the first fluid. The first manifold 20 includes multiple flow control plates 21 that facilitate multiple passes of the refrigerant fluid within the heat exchange tubes 32 of the core 30. The first manifold 20 also includes the cover plate 22 abutting the stack of the plurality of the flow control plates 21. The flow control plates 21 and the cover plate 22 are securely held together as a unit to the manifold 20 by the header 28. Although not shown, the manifold 40 also includes similar features as the first manifold 20. The securing means 24 is in the form of a protrusion that protrudes outwards (along XX' axis towards the mounting structure 200) from the cover plate 22 through the incision 28a in the header 28. The aperture 26 of the securing means 24 is aligned with the aperture 204 of the mounting structure 200 allowing a fastener 60 to pass therethrough to securely fasten the heat exchanger 100 to the mounting structure 200, thus restrict the degree of freedom of the heat exchanger 100 with respect to the mounting structure 200 along the first axis XX'. The fastener 60 used in this case is preferably a threaded fastener or a snap-fit fastener. However, any suitable fastening means can be used here without departing from the scope of the invention. Generally, the engaging members 122, 142 restrict the degree of freedom of the heat exchanger along the axis XX' in a substantially downward direction (in the direction of gravity) while the securing means 24 restrict the degree of freedom of the heat exchanger along the axis XX' in a substantially upward direction (in the opposite direction of gravity). Thus, the position of the heat exchanger 100 with respect to the mounting structure 200 is completely restricted along the axis XX'. The securing means 24 and / or the engaging members 122, 142 further restrict the degree of freedom of the heat exchanger 100 with respect to the mounting structure 200 along the second axis YY' perpendicular to the first axis XX'. Specifically, the heat exchanger 100 abuts the mounting structure 200, and thus, the degree of freedom of the heat exchanger 100 with respect to the mounting structure 200 is restricted along the second axis YY' perpendicular to the first axis XX'. Additionally, the mounting structure 200 in conjunction with the engaging members 122, 142 also restricts the translational degree of freedom along the axis that is mutually perpendicular to axis XX' and YY'.

[0031] During assembly of the heat exchanger 100 to the mounting structure 200, the engaging members 122, 142 of the heat exchanger 100 are brought in alignment with the mounting members 202 mounting members 202 of the mounting structure 200 and then the heat exchanger 100 is translated along the axis XX' in a substantially downward direction in the direction of gravity with respect to the mounting structure 200 till the engaging members 122, 142 engage with the mounting members 202 of the mounting structure 200. Thus, when engaged, the engaging members 122, 142 rest on the mounting members 202 of the mounting structure 200 and the weight of the heat exchanger is substantially supported by the mounting members 202. Thus the translational degree of freedom of the heat exchanger 100 along the axis XX' in a substantially downward direction of gravity is restricted. When the heat exchanger 100 and the mounting structure 200 are engaged in this way, the aperture 26 of the securing means 24 aligns with respect to the hole 204 of the mounting structure 200. The aperture 26 and hole 204 are adapted to accommodate a fastener 60 that, when installed, restricts the translational degree of freedom of the heat exchanger 100 with respect to the mounting structure 200 along the axis XX' in a substantially upward direction in the opposite direction of gravity.

[0032] In an embodiment, the engaging members 122, 142 may be integrally formed with the third plate 16 of the housing. In the present embodiment, as a preferred approach, the engaging members 122, 142 are formed substantially coplanar with the third plate 16 facilitating easier manufacturing, for example by simply cutting the third plate 16 in the preferred shape accordingly. The mounting structure 200 and the mounting members 202 may be suitably shaped to engage the engaging members 122, 142.

[0033] In yet another embodiment, engaging members 122, 142 may be notches that are integrally formed in the first plate 12 and the second plate 14, respectively. The mounting members 202 of the mounting structure 200 may be accordingly formed as a protrusion adapted to be inserted in to the notches of the engaging members 122, 142 to support the heat exchanger 100 on the mounting structure 200.

[0034] In an embodiment, the securing means 24 is integrally formed with the housing 10 i.e. at least one of the first plate 12, the second plate 14 and the third plates 16 in isolation or in addition to the securing means 24 that is integrally formed on the cover plate 22 of the first manifold 20 in the above embodiments. The mounting structure 200 includes additional hole(s) 204 so that the securing means 24 integrally formed on the housing 10 can be fastened to the mounting structure 200. In another aspect of this embodiment, an aperture can be provided in at least one of the engaging members 122, 142 for securing the heat exchanger 100 to the mounting structure 200. Advantageously, such an arrangement restricts the degree of freedom in a plane substantially perpendicular to the axis XX'.

[0035] In an alternate embodiment, the securing member 24 may be formed integrally with the mounting structure 200, while at least one of the first plate 12, the second plate 14, the third plates 16 and the cover plate 22 include aperture(s) (similar to the aperture 204 in the above embodiments) to allow securing the heat exchanger 100 to the mounting structure 200 using fastener 60.

[0036] In yet another embodiment, the housing 10 is formed using one third plate 16 that faces the mounting structure 200 and a long plate 10a. The long plate 10a is folded twice along the fold lines (dotted lines shown in FIG. 6) at an angle (preferably at substantially right angles) to form three sides of the housing 10 similar to the first plate 12, the second plate 14 and the third plate 16 as described in the above embodiments. The long plate 10a includes engaging members 122 on one edge and the engaging members 142 on the opposite edge. The folds, hence formed, eliminate the requirement of joining steps and also improves fluidic sealing in that area.

[0037] The invention shall not be limited to the means and configurations described and illustrated in this patent specification, and shall also extend to any equivalent means or configuration described and illustrated herein, and to any technical combination operating such means. Persons having ordinary skill in the art will recognize certain modifications, permutations, additions and sub-combinations therefore. It is therefore intended that the following appended claims hereinafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations are within their true spirit and scope.

Claims

1. A heat exchanger assembly (1000) comprising at least one heat exchanger (100) and a mounting structure (200), the heat exchanger (100) being configured to be mounted to the mounting structure (200) along a first axis (XX'), wherein the heat exchanger (100) comprises a housing (10) that defines an enclosure (10a), wherein the heat exchanger (100) is mounted to the mounting structure (200) using one or more engaging members (122, 142) integrally formed with the housing (10), wherein at least one of the heat exchanger (100) and the mounting structure (200) comprises at least one securing means (24) configured to restrict the degree of freedom of the heat exchanger (100) with respect to the mounting structure (200) along the first axis (XX').

2. The heat exchanger (100) as claimed in the previous claim, wherein the housing (10) comprises at least one first plate (12), at least one second plate (14), and at least one third plate (16).

3. The heat exchanger (100) as claimed in the previous claim wherein the one or more engaging members (122, 142) are integrally formed with at least one of the first plate (12), the second plate (14), and the third plate (16).

4. The heat exchanger (100) as claimed in the previous claim wherein the one or more engaging members (122, 142) are substantially coplanar with at least one of the first plate (12), the second plate (14), and the third plate (16) of the housing (10).

5. The heat exchanger (100) as claimed in any of the preceding claims, comprises at least one first manifold (20) comprising at least one cover plate (22).

6. The heat exchanger (100) as claimed in any of the preceding claims in combination with claim 5 wherein, the securing means (24) is integrally formed with the cover plate (22).

7. The heat exchanger (100) as claimed in any of the preceding claims wherein, the securing means (24) is integrally formed with the housing (10).

8. The heat exchanger assembly (1000) as claimed in any of the preceding claims wherein, the securing means (24) is in the form of a protrusion that comprises an aperture (26) configured to allow a fastener (60) to pass therethrough.

9. The heat exchanger assembly (1000) as claimed in the previous claim wherein, the fastener (60) is a threaded fastener.

10. The heat exchanger assembly (1000) as claimed in any of the preceding claims wherein, the securing means (24) is of snap-fit type.

11. The heat exchanger (100) as claimed in any of the preceding claims in combination with claim 2, wherein the first plate (12) comprises at least two engaging members (122) and the second plate (14) comprises at least two engaging members (142) integrally formed therein.

12. The heat exchanger assembly (1000) as claimed in any of the preceding claims wherein, at least one of the securing means (24) and the engaging members (122, 142) further restrict the degree of freedom of the heat exchanger (100) with respect to the mounting structure (200) along the second axis (YY') perpendicular to the first axis (XX').

13. The manifold (20, 40) as claimed in claim 5, comprises at least one header (28) that secures the cover plate (22) to the manifold (20).

14. The header (28) as claimed in any of the preceding claims in combination with claim 13, wherein the header (28) comprises an incision (28a) to allow the securing means (24) to protrude from the cover plate (22).

15. The heat exchanger (100) as claimed in any of the preceding claims, comprises a core (30) comprising a plurality of heat exchange tubes (32), wherein the core (30) is positioned in the enclosure (10a).

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