Heat exchanger assemblies having hybrid tanks

Abstract

Heat exchanger assemblies, and, in particular, heat exchanger assemblies that function in high pressure and / or temperature environmental conditions, are described. An essential feature of the heat exchanger assembly is the presence of an hybrid tank comprising both plastic or plastic like materials and metal or metal alloy materials, that provides for good structural integrity and operation of the assembly under high pressure and / or temperature conditions.

Description

[0001] This patent application is a continuation in part of U.S. patent application Ser. No. 11 / 414,706 filed Apr. 28, 2006 and claims priority theretoFIELD OF THE INVENTION [0002] The present invention relates to heat exchanger assemblies, and, in particular, heat exchanger assemblies that function in high pressure and / or temperature environmental conditions. BACKGROUND OF THE INVENTION [0003] Current tank or tanks for heat exchangers, especially high pressure and / or temperature heat exchangers such as charge air coolers, use materials such as cast aluminum for tanks subjected to high temperatures and / or pressure conditions. [0004] JP2003314287 (A) identifies use of cast Aluminum tanks which are welded to the heat exchanger core. EP1524105 (A2, A3) identifies bonding of two material to form a structural part. [0005] The use of cast aluminum tanks, however, means that such heat exchangers are required to have certain limitations, such as design limitations / need for complex features ...

AI Technical Summary

Benefits of technology

The hybrid tanks offer extended application ranges in high temperature and pressure environments, achieving lower weight and potentially lower costs compared to cast aluminum tanks, with improved thermal and chemical resistance, and the ability to withstand higher pressures and temperatures.

Problems solved by technology

The use of cast aluminum tanks, however, means that such heat exchangers are required to have certain limitations, such as design limitations / need for complex features to provide for dimensional stability and / or part integration; additional manufacturing steps or operations to accomplish outcomes not possible using a casting aluminum process alone; higher costs due to these additional or secondary operations, welding necessary for tanks to the heat exchanger for assembly, high weight, and, in certain cases, inadequate corrosion resistance.

For cast aluminum tanks there is some machining required which, as described above, leads to higher overall costs.

Also, cast aluminum tanks can be designed with heavy wall sections and its characteristics mean that the types of part designs that can be implemented do not achieve the goal of reducing overall costs enough to make them as commercially desirable as wanted.

Using of cast aluminum tanks for heat exchanger requires welding of tanks in most cases to the heat exchanger and this either requires robots and more time and quality sensitive manufacturing step in the system.

Images