Inlet and outlet channels for heat exchangers

Abstract

The present disclosure relates to inlet and outlet passages for heat exchangers. Heat exchangers provide a compact profile with consistent cooling performance between the heat exchanger plates. For example, a manifold of a cooling system includes inlet and outlet passages designed to connect to a plurality of plates of a heat exchanger. The inlet and outlet passages include a joint portion, a connection portion, and a transfer portion. The joint portion includes opposing angled contact surfaces that are angled with respect to a horizontal plane of the plates and mate with corresponding angled contact surfaces of the plates. The connection portion receives a coolant hose. The transfer portion is between the joint portion and the connection portion. The passages of the manifold are particularly useful for automotive applications that typically have tight packaging space.

Description

Technical Field

[0001] This disclosure relates to a manifold for a cooling system. This disclosure is particularly relevant to inlet and outlet passages for heat exchangers used in automobiles. Background Technology

[0002] The increasing performance of automotive electronics has led to greater complexity in vehicle electronic systems. For example, traditional electronic control units (ECUs) are being replaced by domain control units (DCUs), which are designed to control multiple functions within a selected domain (e.g., Advanced Driver Assistance Systems (ADAS) or infotainment domain). This increase in the performance and number of control units has necessitated a need for more efficient cooling systems to keep their operating temperatures within safe operating limits. Vehicles typically use liquid cooling systems via heat exchangers (e.g., plate heat exchangers) to efficiently and safely dissipate excess heat from the control units. However, such heat exchangers must be designed to fit into the tight assembly spaces within the vehicle and ensure uniform coolant distribution across the various sections of the heat exchanger to provide a uniform heat distribution leaving the control unit. Summary of the Invention

[0003] This document describes inlet and outlet passages for a manifold connected to a heat exchanger that offers a compact form factor and consistent cooling performance between the heat exchanger plates. The described inlet and outlet passages are particularly useful for automotive applications that typically have limited assembly space. For example, a cooling system manifold includes inlet and outlet passages designed to connect to a heat exchanger with multiple plates. The inlet and outlet passages include a connector portion, a connection portion, and a delivery portion. The connector portion delivers coolant to and from each plate and includes opposing inclined contact surfaces inclined relative to the horizontal plane of the plate. The inclined contact surfaces mate with corresponding inclined contact surfaces of the heat exchanger plates. The connection portion receives a coolant hose. The delivery portion is located between the connector portion and the connection portion.

[0004] Exemplary Example 1. A manifold for a cooling system, the manifold comprising: an inlet passage configured to connect to a heat exchanger comprising a plurality of plates in the cooling system, the inlet passage being configured to guide coolant toward the plurality of plates of the heat exchanger; and an outlet passage configured to connect to the heat exchanger, the outlet passage being configured to guide coolant away from the plurality of plates of the heat exchanger, the inlet passage and the outlet passage comprising: a connector portion configured to deliver coolant to and from the plurality of plates of the heat exchanger, the connector portion including opposing inclined contact surfaces inclined relative to a horizontal plane of the plurality of plates and configured to mate with corresponding inclined contact surfaces of the plurality of plates; a connection portion configured to receive a coolant hose; and a transfer portion extending along a longitudinal axis between the connector portion and the connection portion.

[0005] Exemplary Example 2. The manifold according to Exemplary Example 1, wherein the conveying portions of the inlet channel and the outlet channel have inconsistent cross sections along the longitudinal axis, the cross sections transitioning from a first cross section near the connecting portion to a second cross section near the connector portion.

[0006] Exemplary Example 3. The manifold according to Exemplary Example 1 or 2, wherein the connection portion of the inlet channel and the outlet channel includes an external stop feature to prevent the coolant hose from extending into the delivery portion.

[0007] Exemplary Example 4. The manifold according to any of the foregoing exemplary embodiments, wherein the inlet channel and the outlet channel are made of plastic or reinforced plastic.

[0008] Exemplary Example 5. A manifold according to any of the foregoing exemplary embodiments, wherein the inclined contact surface of the connector portion is configured to allow the inlet channel and the outlet channel to be assembled to the plurality of plates of the heat exchanger along the longitudinal axis of the conveying portion.

[0009] Exemplary Example 6. A manifold according to any of the foregoing exemplary embodiments, wherein the joint portion of the inlet channel and the outlet channel is configured to be attached to the plurality of plates of the heat exchanger using an adhesive on the inclined contact surfaces of the inlet channel and the outlet channel.

[0010] Exemplary Example 7. The manifold according to Exemplary Example 6, wherein the inclined contact surface of the connector portion includes a groove that forms a recess in the inclined contact surface of the connector portion and is configured to receive excess adhesive.

[0011] Exemplary Example 8. A manifold according to any of the foregoing exemplary embodiments, wherein the inclined contact surface of the connector portion includes a pipe clip located at a lateral end of the inclined contact surface, the pipe clip being configured to retain the position of the connector portion when the connector portions of the inlet passage and the outlet passage are attached to the heat exchanger.

[0012] Exemplary Example 9. A manifold according to any one of Exemplary Examples 1 to 5 or 8, wherein the inclined contact surface of the connector portion includes a groove forming a recess in the inclined contact surface and is configured to allow an elastic gasket to fill the space between the inclined contact surface of the connector portion and the respective inclined contact surfaces of the plurality of plates when the connector portion is attached to the heat exchanger.

[0013] Exemplary Example 10. The manifold according to Exemplary Example 9, wherein the connector portion is configured to be attached to the heat exchanger using an external snap-fit.

[0014] Exemplary Example 11. A manifold according to any of the foregoing exemplary embodiments, wherein the conveying portions of the inlet channel and the outlet channel include a first curved profile along a first plane defined by the longitudinal axis and the transverse axis, the transverse axis being orthogonal to the longitudinal axis, the first curved profile producing a leftward or rightward bend as the inlet channel and the outlet channel transition from the connector portion to the connecting portion, the direction of the first curved profile of the inlet channel being opposite to the direction of the first curved profile of the outlet channel.

[0015] Exemplary Example 12. The manifold according to Exemplary Example 11, wherein the conveying portions of the inlet channel and the outlet channel include a second curved profile along a second plane defined by the longitudinal axis and the vertical axis, the second plane being orthogonal to the first plane, the second curved profile producing an upward or downward bend as the inlet channel and the outlet channel transition from the connector portion to the connecting portion, the second curved profile of the inlet channel being in a direction opposite to the second curved profile of the outlet channel.

[0016] Exemplary Example 13. The manifold according to Exemplary Example 12, wherein the length of the inlet channel is different from the length of the outlet channel.

[0017] Exemplary Implementation 14. The manifold according to Exemplary Implementation 13, wherein: the connecting portion of the inlet channel is positioned along the lateral axis at approximately the same lateral position as the connecting portion of the outlet channel; and the connecting portion of the inlet channel is positioned along the vertical axis above or below the connecting portion of the outlet channel.

[0018] Exemplary Example 15. The manifold according to Exemplary Example 14, wherein the combined lateral profile of the connecting portion of both the inlet channel and the outlet channel along the lateral axis is approximately equal to the diameter of the connecting portion.

[0019] Exemplary Example 16. A cooling system comprising: a heat exchanger including at least one plate configured to transfer heat away from electronic components, each plate of the heat exchanger including a first inclined contact surface inclined relative to a horizontal plane of each plate; and a manifold including: an inlet passage configured to connect to the at least one plate of the heat exchanger and guide coolant toward each plate of the heat exchanger; and an outlet passage configured to connect to the at least one plate of the heat exchanger and guide coolant away from each plate of the heat exchanger, the inlet passage and the outlet passage including: a connector portion configured to deliver coolant to and from each plate of the heat exchanger, the connector portion including a second inclined contact surface inclined relative to a horizontal plane of each plate and configured to mate with a corresponding first inclined contact surface of each plate; a connection portion configured to receive a coolant hose; and a transfer portion between the connector portion and the connection portion extending along a longitudinal axis.

[0020] Exemplary Example 17. The cooling system according to Exemplary Example 16, wherein the heat exchanger is made of a first material and the manifold is made of a second material different from the first material.

[0021] Exemplary Example 18. A cooling system according to Exemplary Example 16 or 17, wherein: the second inclined contact surface of the connector portion includes a groove forming a recess in the second inclined contact surface of the connector portion and configured to receive excess adhesive; the first inclined contact surface of each plate of the heat exchanger includes a spacer positioned between the groove of the connector portion and a coolant channel of each plate when the connector portion is attached to the heat exchanger, the spacer being configured to prevent adhesive from entering the coolant channel, the coolant channel guiding coolant into or out of each plate; and each plate of the heat exchanger includes a hard stop configured to hold the connector portion in position when the connector portion of the inlet channel and the outlet channel is attached to the heat exchanger.

[0022] Exemplary Example 19. A cooling system according to any one of Exemplary Examples 16 to 18, wherein the cooling system is configured to be installed in a vehicle.

[0023] Exemplary Example 20. A method of mounting a manifold to a cooling system, the cooling system including a heat exchanger having two plates, the method comprising: connecting the inlet passage to the two plates by engaging opposing inclined contact surfaces of a connector portion of the manifold to corresponding inclined contact surfaces of the two plates of the heat exchanger, the inlet passage being configured to guide coolant toward the two plates, the opposing inclined contact surfaces of the connector portion being inclined relative to a horizontal plane of the two plates; connecting the outlet passage to the two plates by engaging opposing inclined contact surfaces of a connector portion of the manifold to corresponding inclined contact surfaces of the two plates of the heat exchanger, the outlet passage being configured to guide coolant away from the two plates; and attaching a coolant hose to a connection portion of both the inlet passage and the outlet passage of the manifold, the inlet passage and the outlet passage further including a transfer portion between the connector portion and the connection portion, the transfer portion extending along a longitudinal axis parallel to the horizontal plane of the two plates.

[0024] This invention's summary section introduces concepts related to the inlet and outlet channels of a heat exchanger, which are further described in the detailed description and accompanying drawings. This summary section is not intended to identify essential features of the claimed subject matter, nor is it intended to define the scope of the claimed subject matter. Attached Figure Description

[0025] Exemplary embodiments of inlet and outlet passages for a heat exchanger are described herein with reference to the following figures. Throughout the figures, the same reference numerals denote the same features and components:

[0026] Figure 1 An exemplary cooling system is shown, in which inlet and outlet channels for a heat exchanger are implemented;

[0027] Figure 2A and Figure 2B A side view and a top view of an exemplary cooling system are shown, which has a heat exchanger and the aforementioned inlet and outlet channels;

[0028] Figures 3A to 3C A top view, front view, and side view of an exemplary inlet passage of a heat exchanger are shown;

[0029] Figures 4A to 4C A top view, front view, and side view of an exemplary outlet channel of a heat exchanger are shown;

[0030] Figures 5A to 5E An exemplary cross-section of the connection portion and the conveying portion of the inlet channel is shown;

[0031] Figures 6A to 6D A perspective view, front view, side view, and sectional view of an exemplary inlet channel and an exemplary outlet channel in the assembly position are shown respectively.

[0032] Figure 7 A cross-sectional view of an exemplary heat exchanger with two plates and an exemplary inlet channel is shown; and

[0033] Figure 8 An exemplary method for installing a manifold having inlet and outlet passages into a cooling system is shown. Detailed Implementation

[0034] Liquid cooling systems provide an effective means of dissipating heat generated by electronic devices in a vehicle. Such cooling systems may include heat exchangers that direct the flow of liquid coolant above or below high-temperature areas to absorb excess heat generated by electronic components (e.g., ECU, DCU) and transfer that excess heat to another area of ​​the vehicle or the surrounding environment.

[0035] One type of heat exchanger used in automotive applications with liquid cooling systems is the plate heat exchanger. Plate heat exchangers consist of large, flat cooling surfaces (e.g., cold plates) that allow heat from electronic components to be efficiently transferred to the coolant. Existing heat exchanger systems, particularly those with multiple cold plates, struggle to provide uniform cooling performance between the cold plates due to uneven coolant flow between them. Furthermore, these systems may require additional space for attached hoses and manifolds and may not fit the tight spacing constraints of many vehicles.

[0036] Instead, this document describes techniques and systems for providing inlet and outlet channels for manifolds in heat exchangers, which provide uniform cooling performance within the heat exchanger's plates and offer a thin profile to save assembly space within the vehicle. For example, the manifold includes inlet and outlet channels positioned between multiple plates to allow for uniform coolant flow between the plates. Furthermore, the inlet and outlet channels are separate from the overall design of the heat exchanger, allowing these components to be designed with different materials and manufactured individually. This example is merely one exemplary embodiment of the described inlet and outlet channels for heat exchangers. Other exemplary embodiments and implementations are described herein.

[0037] Figure 1 An exemplary cooling system 100 is shown, in which inlet and outlet channels for a heat exchanger are implemented. In the depicted cooling system 100, a heat exchanger 102 is attached to or located near a plurality of electronic controllers 104 (e.g., DCU, ECU, System-on-Chip (SoC)).

[0038] Electronic controllers 104 can control the operation and functions of a vehicle (not shown). For example, a first electronic controller 104 can control an advanced driver assistance system (ADAS). A second electronic controller 104 can control the vehicle's navigation and entertainment functions. The depicted cooling system 100 includes four electronic controllers 104. In other implementations, the cooling system 100 may include fewer or additional electronic controllers 104.

[0039] Heat exchanger 102 uses a liquid cooling system to cool electronic controller 104. Heat exchanger 102 includes multiple plates 106, with an inlet region 108 and an outlet region 110 positioned between the plates 106. Inlet passage 112 and outlet passage 114 are connected to inlet region 108 and outlet region 110, respectively. In other implementations, the positioning of inlet region 108 and outlet region 110 can be interchanged. By positioning inlet region 108 and outlet region 110 between plates 106, heat exchanger 102 has a smaller profile and minimizes the space required for assembly within a vehicle.

[0040] Plate 106 serves as a cooling surface to transfer heat from one or more electronic controllers 104 to the surrounding environment via a liquid coolant (e.g., water) circulating through heat exchanger 102. Plate 106 is generally flat and planar, and can be dimensioned to have a surface area approximately equal to the surface area of ​​the electronic controllers 104. Lateral axis 116 and longitudinal axis 118 define the horizontal plane of plate 106. The relatively large and flat surface area of ​​plate 106 allows for efficient heat transfer from the electronic controllers 104 to the liquid coolant.

[0041] In the depicted cooling system 100, the heat exchanger 102 includes two plates 106 located between four electronic controllers 104, wherein the electronic controllers 104 are positioned above and below each plate 106. In other embodiments, the cooling system 100 may include different numbers and arrangements of electronic controllers 104 and plates 106. For example, the cooling system 100 may include a single heat exchanger 102 having four plates 106 located between eight electronic controllers 104. In another exemplary embodiment, the cooling system 100 may include a heat exchanger 102 having a single plate 106.

[0042] Cooling system 100 introduces coolant into heat exchanger 102 via inlet channel 112. Inlet channel 112 is designed to equally distribute the liquid coolant between plates 106. In this way, equal volume ratios of liquid coolant are guided to each plate 106. After circulating within the plates 106, the coolant is directed to outlet channel 114.

[0043] As described in more detail below, inlet passage 112 and outlet passage 114 are designed to provide a heat exchanger 102 with a compact design. This compact design is advantageous for the relatively tight assembly space of some vehicles. Inlet passage 112 and outlet passage 114 also provide equal coolant circulation between plates 106, resulting in uniform cooling performance of the cooling system 100.

[0044] Inlet channel 112 and outlet channel 114 are also separate components from heat exchanger 102, which simplifies the design of cooling system 100 and heat exchanger 102. The use of separate components also allows heat exchanger 102 and plate 106 to be manufactured separately and in a manner different from inlet channel 112 and outlet channel 114. Thus, plate 106 can be made of a different material than inlet channel 112 and outlet channel 114. For example, plate 106 could be a metal (e.g., aluminum alloy) or other thermally conductive material. Inlet channel 112 and outlet channel 114 could be made of a plastic material (e.g., polyamide 66 (PA66) or a glass fiber reinforced plastic). As a result, inlet channel 112 and outlet channel 114 are manufactured with cheaper and lighter materials, thus saving cost and weight for cooling system 100.

[0045] Figure 2A and Figure 2B A side view 200-1 and a top view 200-2 of an exemplary cooling system are shown, which has a heat exchanger and the aforementioned inlet channel 112 and outlet channel 114. Figure 2A and Figure 2B The cooling system and heat exchanger can be respectively Figure 1 The cooling system 100 and the heat exchanger 102.

[0046] like Figure 2AAs shown in side view 200-1, heat exchanger 102 includes a plate 106 (e.g., upper plate) positioned above another plate 106 (e.g., lower plate). Inlet passage 112 and outlet passage 114 extend laterally away from plate 106 to provide a thin profile for heat exchanger 102 in a first dimension (e.g., vertical direction). Figure 2B As shown in top view 200-2, inlet channel 112 and outlet channel 114 extend generally straight from plate 106 to provide a thin profile for heat exchanger 102 in a second dimension (e.g., lateral direction). In this way, heat exchanger 102 can be fitted into the tight assembly space of many vehicles.

[0047] Figures 3A to 3C Top view 300-1, front view 300-2, and side view 300-3 of an exemplary inlet channel 112 of heat exchanger 102 are shown. In other implementations, Figures 3A to 3C The inlet channel 112 can be used as the outlet channel 114 of the cooling system 100. Top view 300-1 shows a longitudinal axis 302 extending from the connecting portion 308 to the connector portion 312 of the inlet channel 112. The inlet channel 112 also includes a conveying portion 310 extending along the longitudinal axis 302 and located between the connecting portion 308 and the connector portion 312. Top view 300-1 also shows a transverse axis 304 perpendicular to the longitudinal axis 302. Side view 300-3 shows a vertical axis 306 perpendicular to the longitudinal axis 302. The conveying portion 310 may include a non-uniform cross-section along the longitudinal axis 302. For example, near the connecting portion 308, the conveying portion 310 may have a generally circular cross-section. Near the connector portion 312, the conveying portion 310 may have a generally rectangular cross-section.

[0048] The connecting portion 308 may have a generally circular cross-section. The circular connecting portion 308 is adapted to receive a coolant hose. Automotive cooling systems typically use hoses to deliver liquid coolant to and from the heat exchanger 102. For example, the hose is a flexible rubber hose. Clamps or similar attachment devices can be used to attach the hose to the connecting portion 308. The connecting portion 308 also includes an external stop feature 314, which prevents the hose from sliding along the longitudinal axis 302 onto or into the conveying portion 310.

[0049] In top view 300-1 and side view 300-3, the connector portion 312 may have a generally rectangular cross-section. The connector portion 312 of the inlet channel 112 delivers coolant to the plates 106. In the depicted embodiment, the inlet channel 112 is attached to both plates 106, and the connector portion 312 is a T-joint that distributes the coolant equally to both plates 106. The generally rectangular cross-section of the connector portion 312 provides a compact design to minimize the assembly space required for the heat exchanger 102.

[0050] The connector portion 312 also includes inclined contact surfaces 316 at opposing surfaces. Specifically, the inclined contact surfaces 316 are inclined relative to the horizontal plane of the plate 106 defined by the transverse axis 116 and the longitudinal axis 118. The inclined contact surfaces 316 of the connector portion 312 are not parallel to each other and are inclined vertically toward the vertical center of the connector portion 312 along the vertical axis 306. When the heat exchanger 102 is assembled, the inclined contact surfaces 316 mate or abut with the corresponding inclined contact surfaces of the plate 106. (See reference...) Figure 7 Described in more detail, the connector portion 312 and the inclined contact surface 316 are adapted for a single-movement assembly process of the heat exchanger 102, which allows the inlet channel 112 to be assembled to the plate 106 of the heat exchanger 102 along the longitudinal axis 302. The inclined contact surface 316 allows the inlet channel 112 to be assembled to the plate 106 from the front or side along the horizontal plane of the plate 106, which may be necessary due to space constraints.

[0051] The transfer section 310 includes a first curved profile 318 and a second curved profile 320 to minimize the assembly space used by the heat exchanger 102, which will refer to Figures 6A to 6D To describe in more detail. As the inlet channel 112 transitions from the connecting portion 308 to the joint portion 312, the first bend profile 318 introduces a small bend or curve to the right in the inlet channel 112. In other implementations, the first bend profile 318 may produce a left bend in the transfer portion 310. The first bend profile 318 exists in a plane defined by the longitudinal axis 302 and the transverse axis 304.

[0052] As the inlet channel 112 transitions from the connecting portion 308 to the joint portion 312, the second curved profile 320 introduces a small downward bend or curve in the inlet channel 112. In other implementations, the second curved profile 320 may produce an upward bend in the conveying portion 310. The second curved profile 320 exists in a plane defined by the longitudinal axis 302 and the vertical axis 306.

[0053] Figures 4A to 4C A front view 400-1, a top view 400-2, and a side view 400-3 of an exemplary outlet channel 114 of a heat exchanger 102 are shown. In other embodiments, Figures 4A to 4C The outlet channel 114 can be used as the inlet channel 112 of the cooling system 100. Side view 400-3 shows the longitudinal axis 302 extending from the connecting portion 308 to the connector portion 312 of the outlet channel 114. Side view 400-3 also shows the vertical axis 306. Top view 300-1 shows the transverse axis 304.

[0054] Figures 4A to 4C The exit channel 114 is similar to Figures 3A to 3C The inlet channel 112. The outlet channel 114 includes a connecting portion 308, a conveying portion 310, and a connector portion 312. The conveying portion 310 may include a non-uniform cross-section along the longitudinal axis 302. For example, near the connecting portion 308, the conveying portion 310 may have a generally circular cross-section. Near the connector portion 312, the conveying portion 310 may have a generally rectangular cross-section.

[0055] The connecting portion 308 may have a generally circular cross-section. The circular connecting portion 308 is adapted to receive a coolant hose. Automotive cooling systems typically use hoses to deliver liquid coolant to and from the heat exchanger 102. For example, the hose may be a flexible rubber hose. Clamps or similar attachment devices can be used to attach the hose to the connecting portion 308. The connecting portion 308 also includes an external stop feature 314 that prevents the hose from sliding along the longitudinal axis 302 onto or into the conveying portion 310.

[0056] In top view 400-2 and side view 400-3, the connector portion 312 may have a generally rectangular cross-section. The connector portion 312 of the outlet channel 114 delivers coolant away from the plate 106. In the described embodiment, the outlet channel 114 is attached to both plates 106, and the connector portion 312 is a T-joint that distributes coolant equally from both plates 106. The generally rectangular cross-section of the connector portion 312 provides a compact design to minimize the assembly space required for the heat exchanger 102.

[0057] The connector portion 312 also includes inclined contact surfaces 316 at opposing surfaces. Specifically, the inclined contact surfaces 316 are inclined relative to the horizontal plane of the plate 106 defined by the transverse axis 116 and the longitudinal axis 118. The inclined contact surfaces 316 of the connector portion 312 are not parallel to each other and are inclined vertically toward the vertical center of the connector portion 312 along the vertical axis 306. When the heat exchanger 102 is assembled, the inclined contact surfaces 316 mate or abut with the corresponding inclined contact surfaces of the plate 106. (See relevant information...) Figure 7 Described in more detail, the connector portion 312 and the inclined contact surface 316 are adapted for a single-movement assembly process of the heat exchanger 102, which allows the outlet channel 114 to be assembled to the plate 106 of the heat exchanger 102 along the longitudinal axis 302. The inclined surface 316 allows the outlet channel 114 to be assembled to the plate 106 from the front or side along the horizontal plane of the plate 106, which may be necessary due to space constraints.

[0058] The transfer section 310 includes a first curved profile 318 and a second curved profile 320 to minimize the assembly space used by the heat exchanger 102, which will refer to Figures 6A to 6D To describe in more detail. As the outlet channel 114 transitions from the connecting portion 308 to the joint portion 312, the first bending profile 318 introduces a small bend or curve to the left in the outlet channel 114. In other implementations, the first bending profile 318 may produce a right bend in the conveying portion 310. The first bending profile 318 exists in a plane defined by the longitudinal axis 302 and the transverse axis 304.

[0059] As the outlet channel 114 transitions from the connecting portion 308 to the joint portion 312, the second bending profile 320 introduces a small upward bend or curve in the outlet channel 114. In other implementations, the second bending profile 320 creates a downward bend in the conveying portion 310. The second bending profile 320 exists in a plane defined by the longitudinal axis 302 and the vertical axis 306.

[0060] Figures 5A to 5E Exemplary cross-sections 500, 502, 504, and 506 of the connecting portion 308 of the inlet channel 112 and the conveying portion 310 are shown. The outlet channel 114 has a similar cross-section to the inlet channel 112. As shown in cross-sections 500 to 506, the conveying portion 310 has an inconsistent cross-section along the longitudinal axis 302. Specifically, the inlet channel 112 starts from a first cross-section (e.g., as shown in...). Figure 5B and Figure 5C The approximately circular cross-sections shown in cross-sections 500 and 502 transition to the second cross-section (e.g., as shown in cross-sections 500 and 502). Figure 5D and Figure 5E The cross-sections 504 and 506 are generally rectangular cross-sections. The first cross-section of the connecting portion 308 is adapted to attach a coolant hose (e.g., a rubber hose) to guide coolant toward and away from the heat exchanger 102. The second cross-sections of the conveying portion 310 and the connector portion 312 allow for a compact design of the heat exchanger 102.

[0061] Figures 6A to 6D Perspective view 600, front view 602, side view 604, and sectional view 606 respectively show exemplary inlet channel 112 and exemplary outlet channel 114 in their assembled positions. As described above, the transfer portion 310 of the inlet channel and outlet channel 114 includes a first curved profile 318 and a second curved profile 320. In the depicted implementation, the first curved profile 318 of the inlet channel 112 is curved to the right, while the first curved profile 318 of the outlet channel 114 is curved to the left along the longitudinal axis 302 from the connecting portion 308 to the connector portion 312. In other implementations, the first curved profiles 318 of the inlet channel 112 and the outlet channel 114 can be interchanged. The first curved profile 318 allows the connecting portion 308 of the inlet channel 112 to be positioned at approximately the same lateral position as the connecting portion 308 of the outlet channel 114, such as... Figure 6B The front view 602 shows this. Thus, the connection portion 308 of the heat exchanger 102 utilizes the limited lateral assembly space for the coolant hoses.

[0062] Figure 6A Perspective view 600 also shows that the length of inlet channel 112 is longer than the length of outlet channel 114. In other implementations, inlet channel 112 may be shorter than outlet channel 114. By offsetting the longitudinal positions of the joint portions 312 of outlet channel 114 and inlet channel 112, the difference in length facilitates a compact design of heat exchanger 102. This compact design allows the combined lateral profile of the joint portions 312 of inlet channel 112 and outlet channel 114 to be approximately equal to the lateral width of a single joint portion 312.

[0063] In the depicted implementation, the second curved profile 320 of the inlet channel 112 curves downwards, while the second curved profile 320 of the outlet channel 114 curves upwards along the longitudinal axis 302 from the connecting portion 308 to the joint portion 312. In other implementations, the second curved profiles 320 of the inlet channel 112 and the outlet channel 114 can be interchanged. The second curved profile 320 allows the connecting portion 308 of the inlet channel 112 to be positioned above the connecting portion 308 of the outlet channel 114, as shown. Figure 6B The front view 602 shows this. Thus, the connection portion 308 utilizes limited lateral assembly space for the coolant hose. In other implementations, the conveying portions 310 of the inlet channel 112 and the outlet channel 114 may include different curvature profiles to provide minimal vertical assembly space for the coolant hose.

[0064] Figure 7 A cross-sectional view 700 is shown of an exemplary heat exchanger 102 having two plates 106 and a connector portion 312 of an exemplary inlet channel 112. The connector portion 312 of the outlet channel 114 has a similar cross-sectional view having the same features as those described in the reference cross-sectional view 700.

[0065] The joint portion 312 can be bonded to the plate 106 using an adhesive 702 on the inclined contact surface 316 of the inlet channel 112 (or outlet channel 114). The adhesive 702 provides a tight and leak-proof bond between the inlet channel 112 (or outlet channel 114) and the plate 106. Furthermore, the adhesive 702 allows different materials (e.g., aluminum for the plate 106 and plastic for the inlet channel 112 and outlet channel 114) to be bonded. The adhesive 702 also compensates for geometric inaccuracies (e.g., misalignment) in the assembly of the heat exchanger 102, which may be caused by manufacturing or assembly tolerances. For example, the thickness or viscosity of the adhesive 702 is configured to account for manufacturing or assembly tolerances of the joint portion 312 and the plate 106, thereby potentially leading to lower manufacturing costs by reducing the tolerances of the joint portion 312 and the plate 106.

[0066] For reference Figures 3A to 3C and Figures 4A to 4C The inlet channel 112, specifically the connector portion 312, includes opposing inclined contact surfaces 316. The inclined contact surfaces 316 are inclined relative to the horizontal plane of the plate 106 and are adapted to mate with or abut against the corresponding inclined contact surfaces of the plate 106. The inclined contact surfaces 316 provide a simplified assembly process with unidirectional or single-motion connections. The inclined contact surfaces 316 of the connector portion 312 and the corresponding inclined contact surfaces of the plate 106 are designed to provide controlled flow of the adhesive 702 during assembly and to provide appropriate gaps or spaces for adhesive dispensing. The inclined contact surfaces 316 and the plate 106 are also designed to facilitate the correct positioning and retention or clamping of the inlet channel 112 (or outlet channel 114).

[0067] Prior to assembly, adhesive 702 may be applied to the inclined contact surface 316 of the joint portion 312 of the inlet channel 112 (or outlet channel 114). Adhesive 702 is applied to the inclined contact surface 316 near the recess 706. The recess 706 is shaped to provide a recess in the inclined contact surface 316 and to receive excess adhesive 702 during assembly. During assembly, the distance between the inclined contact surfaces 316 decreases, and adhesive 702 flows into the space between the plate 106 and the joint portion 312, which is partially defined by the recess 706. A spacer 710 on the plate 106 protrudes from the inclined contact surface 316 adjacent to a coolant channel 704 that guides coolant into or out of each plate 106. During assembly, the spacer 710 prevents adhesive 702 from flowing out of the application area and into the coolant channel 704 from the recess 706. The spacer 710 also ensures the correct space or gap size between the joint portion 312 and the plate 106.

[0068] Plate 106 also includes a rigid stop 712 to hold the joint portion 312 of the inlet channel 112 (or outlet channel 114) in position during assembly and when the inlet channel 112 (or outlet channel 114) is attached to the heat exchanger 102. Together with the rigid stop 712, a pipe clamp 708 provides a tight connection between the assembled components. The pipe clamp 708 protrudes from the inclined surface 316 of the joint portion 312 and is located at the lateral end opposite the rigid stop 712. When the inlet channel 112 (or outlet channel 114) is attached to the heat exchanger 102, the pipe clamp 708 holds the joint portion 312 of the inlet channel 112 (or outlet channel 114) in position.

[0069] In other implementations, the heat exchanger 102 may use resilient gaskets or similar components instead of adhesive 702. When assembling the heat exchanger 102, the resilient gaskets fill the gap between the recess 706 and the inclined contact surface 316 of the connector portion and the corresponding inclined contact surface of the plate 106. The connector portion 312 may be connected to the plate 106 and the heat exchanger 102 using snaps on the outside of the plate 106 or the inlet channel 112 (or outlet channel 114).

[0070] Figure 8 An exemplary method 800 for installing a manifold having inlet and outlet channels to a cooling system is shown according to the technology of this disclosure. The cooling system may include a heat exchanger having two plates. Method 800 is shown as a set of operations (or actions) performed, but is not necessarily limited to the order or combination of operations shown herein. Furthermore, any one or more operations may be repeated, combined, or reorganized to provide other methods.

[0071] In step 802, the inlet channel 112 is connected to the two plates 106 by mating the opposing inclined contact surfaces 316 of the connector portion 312 of the manifold to the corresponding inclined contact surfaces of the two plates 106 of the heat exchanger 102. The inlet channel 112 guides coolant toward the two plates 106. The inclined contact surfaces 316 of the connector portion 312 are inclined relative to the horizontal plane of the two plates 106. The inlet channel 112 can be connected to the two plates 106 using adhesive 702 or a combination of gaskets and external snaps.

[0072] In step 804, the outlet channel 114 is connected to the two plates 106 by mating the opposing inclined contact surfaces 316 of the connector portion 312 of the manifold outlet channel 114 to the corresponding inclined contact surfaces of the two plates 106 of the heat exchanger 102. The outlet channel 114 guides coolant away from the two plates 106. The inclined contact surfaces 316 of the connector portion 312 are inclined relative to the horizontal plane of the two plates 106. The outlet channel 114 can be connected to the two plates 106 using adhesive 702 or a combination of gaskets and external clips.

[0073] The inclined contact surface 316 of the connector portion 312 allows the inlet channel 112 and the outlet channel 114 to be inserted along the longitudinal axis 302 into the positions of the two plates 106 for assembly into the heat exchanger 102. In other words, the inlet channel 112 and the outlet channel 114 can be inserted from the front or side of the vehicle into a plane horizontal to the plate 106 to accommodate tight spacing constraints.

[0074] At step 806, a coolant hose is attached to the connection portion 308 of both the inlet channel 112 and the outlet channel 114 of the manifold. The inlet channel 112 and the outlet channel 114 also include a conveying portion 310 extending along a longitudinal axis 302 between the connector portion 312 and the connection portion 308. The longitudinal axis 302 is parallel to the horizontal plane of the two plates 106.

[0075] Although various embodiments of the present disclosure have been described in the foregoing description and illustrated in the accompanying drawings, it should be understood that the present disclosure is not limited thereto, but can be practiced in various ways within the scope of the appended claims. It will be apparent from the foregoing description that various changes can be made without departing from the scope of the present disclosure as defined by the appended claims.

Claims

1. A manifold for a cooling system, the manifold comprising: An inlet channel configured to connect to a heat exchanger comprising multiple plates in the cooling system, the inlet channel being configured to guide coolant toward the multiple plates of the heat exchanger; as well as An outlet channel, configured to connect to the heat exchanger, is provided to guide coolant away from the plurality of plates of the heat exchanger. The inlet channel and the outlet channel include: The connector portion, configured to deliver coolant to and from the plurality of plates of the heat exchanger, includes opposing inclined contact surfaces that are inclined relative to the horizontal plane of the plurality of plates and configured to mate with corresponding inclined contact surfaces of the plurality of plates. The connection portion, configured to receive a coolant hose; and A transfer portion between the connector portion and the connecting portion, the transfer portion extending along the longitudinal axis.

2. The manifold according to claim 1, wherein, The conveying portions of the inlet channel and the outlet channel have inconsistent cross-sections along the longitudinal axis, transitioning from a first cross-section near the connecting portion to a second cross-section near the joint portion.

3. The manifold according to claim 1, wherein, The connection between the inlet channel and the outlet channel includes an external stop feature to prevent the coolant hose from extending into the delivery section.

4. The manifold according to claim 1, wherein, The inlet channel and the outlet channel are made of plastic or reinforced plastic.

5. The manifold according to claim 1, wherein, The inclined contact surface of the connector portion is configured to allow the inlet channel and the outlet channel to be fitted to the plurality of plates of the heat exchanger along the longitudinal axis of the conveying portion.

6. The manifold according to claim 1, wherein, The joint portions of the inlet channel and the outlet channel are configured to be attached to the plurality of plates of the heat exchanger using an adhesive on the inclined contact surfaces of the inlet channel and the outlet channel.

7. The manifold according to claim 6, wherein, The inclined contact surface of the connector portion includes a groove that forms a recess in the inclined contact surface of the connector portion and is configured to receive excess adhesive.

8. The manifold according to claim 1, wherein, The inclined contact surface of the connector portion includes a tube clip located at the lateral end of the inclined contact surface, the tube clip being configured to maintain the position of the connector portion when the connector portions of the inlet channel and the outlet channel are attached to the heat exchanger.

9. The manifold according to claim 1, wherein, The inclined contact surface of the connector portion includes a groove that forms a recess in the inclined contact surface and is configured to allow an elastic gasket to fill the space between the inclined contact surface of the connector portion and the corresponding inclined contact surfaces of the plurality of plates when the connector portion is attached to the heat exchanger.

10. The manifold according to claim 9, wherein, The connector portion is configured to attach to the heat exchanger using an external snap-fit.

11. The manifold according to claim 1, wherein, The conveying portions of the inlet channel and the outlet channel include a first curved profile along a first plane defined by the longitudinal axis and the transverse axis, the transverse axis being orthogonal to the longitudinal axis. When the inlet channel and the outlet channel transition from the connector portion to the connecting portion, the first curved profile produces a leftward or rightward bend. The direction of the first curved profile of the inlet channel is opposite to the direction of the first curved profile of the outlet channel.

12. The manifold according to claim 11, wherein, The conveying portions of the inlet channel and the outlet channel include a second curved profile along a second plane defined by the longitudinal axis and the vertical axis, the second plane being orthogonal to the first plane. When the inlet channel and the outlet channel transition from the connector portion to the connecting portion, the second curved profile of the inlet channel bends upward or downward in a direction opposite to that of the second curved profile of the outlet channel.

13. The manifold according to claim 12, wherein, The length of the inlet channel is different from the length of the outlet channel.

14. The manifold according to claim 13, wherein: The connecting portion of the inlet channel is positioned along the lateral axis at approximately the same lateral position as the connecting portion of the outlet channel; and The connecting portion of the inlet channel is positioned above or below the connecting portion of the outlet channel along the vertical axis.

15. The manifold according to claim 14, wherein, The combined lateral profile of the connecting portion of the inlet channel and the outlet channel along the lateral axis is approximately equal to the diameter of the connecting portion.

16. A cooling system comprising: A heat exchanger comprising at least one plate configured to transfer heat away from electronic components, each plate of the heat exchanger comprising a first inclined contact surface inclined relative to a horizontal plane of each plate; as well as The manifold includes: An inlet channel, configured to connect to at least one plate of the heat exchanger and guide coolant toward each plate of the heat exchanger; and An outlet channel is configured to connect to at least one plate of the heat exchanger and guide the coolant out of each plate of the heat exchanger. The inlet channel and the outlet channel include: The connector portion, configured to deliver coolant to and from each plate of the heat exchanger, includes a second inclined contact surface that is inclined relative to the horizontal plane of each plate and configured to mate with a corresponding first inclined contact surface of each plate. The connection portion, configured to receive a coolant hose; and A transfer portion between the connector portion and the connecting portion, the transfer portion extending along the longitudinal axis.

17. The cooling system according to claim 16, wherein, The heat exchanger is made of a first material, and the manifold is made of a second material different from the first material.

18. The cooling system according to claim 16, wherein: The second inclined contact surface of the connector portion includes a groove that forms a recess in the second inclined contact surface of the connector portion and is configured to receive excess adhesive. The first inclined contact surface of each plate of the heat exchanger includes a spacer that, when the connector portion is attached to the heat exchanger, is positioned between the groove of the connector portion and a coolant channel of each plate. The spacer is configured to prevent adhesive from entering the coolant channel, which guides coolant into or out of each plate. Each plate of the heat exchanger includes a rigid stop configured to hold the joint portion in position when the joint portion of the inlet channel and the outlet channel is attached to the heat exchanger.

19. The cooling system according to claim 16, wherein, The cooling system is configured to be installed in the vehicle.

20. A method of installing a manifold into a cooling system, the cooling system including a heat exchanger having two plates, the method comprising: The inlet channel is connected to the two plates by fitting the opposing inclined contact surfaces of the connector portion of the manifold to the corresponding inclined contact surfaces of the two plates of the heat exchanger. The inlet channel is configured to guide coolant toward the two plates, and the opposing inclined contact surfaces of the connector portion are inclined relative to the horizontal plane of the two plates. The outlet channel is connected to the two plates by fitting the opposing inclined contact surfaces of the connector portion of the manifold outlet channel to the corresponding inclined contact surfaces of the two plates of the heat exchanger, and the outlet channel is configured to guide coolant away from the two plates; as well as The coolant hose is attached to the connection portion of the inlet and outlet channels of the manifold, the inlet and outlet channels further including a transfer portion between the connector portion and the connection portion, the transfer portion extending along a longitudinal axis parallel to the horizontal plane of the two plates.

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