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

[0010] In aspects of the present invention, a heat exchanger capable of functioning in high temperature and / or pressure environments, with a lower profile cost for the same or better performance than aluminum cast tanks, is provided. In addition, the strength and performance characteristics of lower temperature and / or lower pressure environment plastic tank systems are enhanced with the hybrid tanks of the present invention. Examples of high temperature environments are those where tanks for applications where temperature is higher than 220° C., and, particularly where temperatures and pressure are both at a high level. For example, at high temperatures, internal pressure is higher, for example greater than 30 psi.

[0011] Aspects of the present invention, therefore, provide for extended application ranges for hybrid tanks than either cast aluminum or plastic end tanks alone, particularly for use in an automotive vehicle, with lower weight with good performance versus cast aluminum only end tanks, and potentially lower cost (for example, through less time to manufacture and elimination of machining, welding and allowing integration of features not possible through metal casting methods) versus prior heat exchanger art tanks. Otherwise stated, aspects of the present invention allow for a larger degree of design freedom (more integration of features which can not be feasible through metal casting processes).

[0012] Various aspects of the present invention allow for a first material, for example, plastic or plastic like parts, and features of a heat exchanger to exist in conjunction with parts and features made of other, for example, different material (a second material). By other materials, it is meant materials that have different characteristics, such as different strength levels, stress modulus, stiffness levels, or the like. For example, an other material could be a material that has elastic like properties, or rigid properties; in the case of two different plastic based materials, for example, one the plastic or plastic part can be stiff relative to the other part, or visa versa. In an example where one material is plastic or plastic like, the other material can be another plastic or plastic like material with characteristics differing from the material, or the other material could be a metal or metal alloy based material. The plastic or plastic like parts can be formed or produced, for example, with processes such as, but not limited to, injection molded, blow molded or compression molded or plastic cast components. Produced parts, for example, do not require secondary operation at all or require minimum secondary operations after a main or principle manufacturing step in order to produce the end product. A hybrid tank, therefore, as used herein, is an end tank formed using at least two different materials. In general, the first and second materials, therefore, have different structural characteristics. As used herein, by structurally less flexible, it is meant a material that is more stiff or rigid, and, therefore can lead to a longer lasting or higher performance versus a less stiff or rigid material.

[0014] Various aspects of the present invention, therefore, extend the application range possible for heat exchanger, and, especially for high temperature and / or pressure environment heat exchangers such as CACs (Charged Air Coolers) or intercoolers. By providing for combined properties of two or more materials, strengthened tanks at lower weight and cost than cast aluminum tanks or tanks, gain advantages, especially in terms of design freedom. Use of plastic or plastic like materials, in addition to metal or metal alloy materials in end tanks, as stated above, allows integration of features which are not possible through metal casting.

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.

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