Heat exchanger

Abstract

A heat exchanger (100) includes a first manifold (102), a second manifold (108), and a plurality of heat exchange tubes (114) providing fluid communication between the first manifold (102) and the second manifold (108). Each of the tubes (114) includes an inner surface (118) defined by a sidewall (120), a first end (116A), and a second end (116B) opposite the first end (116A). Each of the manifolds (102, 108) includes a box member (106, 112) and a header plate (104, 110), the header plate (104, 110) including a plurality of holes (144) to receive respective ends (116A, 116B) of the tubes (114). At least one intermediate plate (122) is disposed at at least one end (114A, 114B) of the tube (114). The intermediate plate (122) includes a plurality of apertures (128) aligned with the arrangement of tubes (114) and the apertures (144) of the header plate (104, 110).

Description

Technical Field

[0001] The present invention relates to a heat exchanger. In particular, the present invention relates to a heat exchanger for a motor vehicle. Background Art

[0002] Heat exchangers, such as radiators, charge air coolers, oil coolers, etc., are used in various applications to transfer heat from one medium to another. Typically, a heat exchanger includes a pair of manifolds and a plurality of heat exchange tubes stacked between the manifolds to provide fluid communication between the manifolds. Each manifold includes a header having a plurality of openings to accommodate the plurality of heat exchange tubes. At least one fin is disposed between two adjacent heat exchange tubes. The first manifold includes an inlet port for accommodating a first heat exchange fluid, and the second manifold includes an outlet port. The first fluid flows from the inlet manifold to the outlet manifold through the plurality of heat exchange tubes. In addition, a second fluid flows around the heat exchange tubes and through the fins. The first fluid and the second fluid are in a heat exchange configuration.

[0003] Heat exchangers transfer thermal energy between fluids at different temperatures due to heating or cooling of the tubes. Thermal differences may result in non-uniform dimensional changes in the interconnected parts of the heat exchanger. For example, the length of the tubes may increase while the ends of the tubes remain in fixed positions relative to the first manifold and the second manifold, and the header length may change, which results in thermal and mechanical stresses. Since the tubes are typically rigidly attached to the relatively non-deformable headers by soldering, brazing, welding, etc., the resulting stresses may result in joint fatigue failure or tube fatigue in the vicinity of the tube-to-header connection. Ultimately, heat exchangers have a limited lifespan because of the high stresses at their tube-to-header connections.

[0004] Therefore, there is a need for an improved heat exchanger that can reduce the stress at the connection between the tube and the header. In addition, there is a need for a heat exchanger whose connection between the tube and the header has the necessary strength to increase the reliability and service life of the heat exchanger.

[0005] In this specification, some elements or parameters may be indexed, such as first element and second element. In this case, unless otherwise specified, such indexing is only used to distinguish and name similar but not identical elements. The concept of priority should not be inferred from such indexing, as these terms can be interchanged without departing from the present invention. In addition, such indexing does not imply any order of installation or use of the elements of the present invention. Summary of the invention

[0006] The present invention discloses a heat exchanger, comprising a first manifold, a second manifold and a heat exchanger core. The second manifold is arranged parallel to and spaced apart from the first manifold. The heat exchanger core comprises a plurality of heat exchange tubes, which provide fluid communication between the first manifold and the second manifold. Each heat exchange tube comprises an inner surface defined by a side wall. In addition, each heat exchange tube comprises a first end and a second end opposite to the first end. Each manifold comprises a box member and a header plate. The header plate comprises a plurality of holes to accommodate the corresponding ends of the heat exchange tubes. The heat exchanger further comprises at least one intermediate plate, which is arranged at at least one end of the plurality of heat exchange tubes. The intermediate plate comprises a plurality of orifices aligned with the arrangement of the plurality of heat exchange tubes and the plurality of holes of the header plate.

[0007] The intermediate plate at least partially contacts the ends of the plurality of heat exchange tubes and at least partially contacts the header plate. The heat exchanger core also includes at least one fin within the inner surface of the at least one heat exchange tube. In addition, a flange extends from the at least one orifice toward the heat exchanger core to conform to at least a portion of the side wall of the corresponding heat exchange tube.

[0008] In one embodiment, a flange extends from the intermediate plate to at least partially surround the aperture. The flange is configured to contact an inner surface of a corresponding heat exchange tube.

[0009] In one embodiment, the flange is at least partially located between the fin and the inner surface of the side wall of the heat exchange tube.

[0010] The heat exchange tube includes a generally rectangular side wall defined by a pair of short side walls and a pair of long side walls.

[0011] Each aperture includes a rectangular configuration defining a first side and a second side opposite the first side.

[0012] The flange includes a first flange portion extending from a first side of the aperture and a second flange portion extending from a second side of the aperture.

[0013] The flange portion contacts the inner surface of the corresponding heat exchange tube.

[0014] In one embodiment, the flange portion is brazed to the side wall of the corresponding heat exchange tube.

[0015] In one embodiment, the first flange portion and the second flange portion extend to conform to at least a portion of a long side wall of a corresponding heat exchange tube.

[0016] In another embodiment, the first flange portion and the second flange portion extend to conform to at least a portion of a short side wall of a corresponding heat exchange tube. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Other features, details and advantages of the present invention can be inferred from the following description of the invention. A better understanding of the present invention and its attendant advantages can be obtained by reference to the following detailed description considered in conjunction with the accompanying drawings, in which:

[0018] Figure 1 A perspective view of a heat exchanger according to an embodiment of the present invention is exemplarily shown.

[0019] Figure 2 It is shown by way of example that there is no Figure 1 A perspective view of the casing of a heat exchanger.

[0020] Figure 3 It is shown as an example Figure 1 Exploded view of the heat exchange tube bundle and manifold.

[0021] Figure 4 It is shown as an example Figure 3 A perspective view of the middle panel of FIG.

[0022] Figure 5 It is shown as an example Figure 3 Another perspective view of the middle plate of FIG.

[0023] Figure 6 It is shown as an example Figure 1 The arrangement of the intermediate plate at the connection between the tubes and the headers of the heat exchanger.

[0024] Figure 7 The bonding is shown exemplarily Figure 3 The flange at the end of the heat exchange tube. DETAILED DESCRIPTION

[0025] The present invention discloses a heat exchanger 100, which includes a first manifold 102, a second manifold 108 and a heat exchanger core 105. The heat exchanger core 105 includes a plurality of heat exchange tubes 114, which provide fluid communication between the first manifold 102 and the second manifold 108. Each of the heat exchange tubes 114 includes an inner surface 118 defined by a sidewall 120, a first end 116A and a second end 116B opposite to the first end 116A. Each of the manifolds 102, 108 includes a box member 106, 112 and a header plate 104, 110, which includes a plurality of holes 144 to accommodate the respective ends of the heat exchange tubes 114. The heat exchanger 100 also includes at least one intermediate plate 122, which is arranged at at least one end 116A, 116B of the plurality of heat exchange tubes 114. The intermediate plate 122 includes a plurality of apertures 128 aligned with the arrangement of the plurality of heat exchange tubes 114 and the plurality of holes 144 of the header plates 104, 110. A flange 126 extends from at least one aperture 128 toward the heat exchanger core 105 to conform to at least a portion of the sidewall 120 at the inner surface 118 of the heat exchange tubes 114. The provision of the intermediate plate 122 increases the mechanical resistance of the connection between the tubes 114 and the header plates 104, 110, which increases the reliability and life of the heat exchanger 100.

[0026] Figure 1 A perspective view of a heat exchanger 100 according to an embodiment of the present invention is exemplarily shown. Figure 2 The example shows a case without housing 132. Figure 1 106, and the second manifold 108 includes a second manifold 110 and a second manifold 112. The manifolds 104, 110 include a plurality of holes 144 (in the middle) of the manifold 104 and the second manifold 110. The manifold 104, 110 includes a plurality of holes 144 (in the middle) of the manifold 104 and the second manifold 110. Figure 3 144, and each hole 144 is aligned with a corresponding tube 114. The header plates 104, 110 may be relatively thick plates made of a metallic material such as steel or aluminum.

[0027] refer to Figure 3, a plurality of heat exchange tubes 114 are arranged substantially in parallel and spaced apart from each other to form a tube bundle. The heat exchange tubes 114 are hollow and may be made of a thin-walled material, such as aluminum or other suitable metals. Each heat exchange tube 114 includes a first end 116A and a second end 116B opposite to the first end 116A. The first end 116A of each heat exchange tube 114 is received in a corresponding hole 144 of the first header plate 104 of the first manifold 102. The opposite second end 116B of the heat exchange tube 114 is received in a corresponding hole 144 of the second header plate 110 of the second manifold 108. Here, the terms heat exchange tube 114 or tube 114 are used interchangeably herein. The plurality of heat exchange tubes 114 are aligned in the longitudinal direction, and their lengths are such that the first end 116A is coextensive and aligned together, and the second end 116B is coextensive and aligned together. Thus, the tube bundle has a generally rectangular shape, with the first manifold 102 and the second manifold 108 being generally perpendicular to the plurality of heat exchange tubes 114 and perpendicular to the longitudinal direction of the heat exchange tubes 114. It is contemplated that some embodiments include multiple rows of tubes 114.

[0028] refer to Figure 1 , the heat exchanger 100 also includes a shell 132, which surrounds the heat exchanger core 105 and the manifolds 102, 108. The shell 132 also includes a first shell portion 132A and a second shell portion 132B. The first shell portion 132A extends between the manifolds 102, 108 and at least a portion of the tube bundle, and the second shell portion 132B extends between the manifolds 102, 108 and at least a portion of the tube bundle. The first shell portion 132A and the second shell portion 132B are different parts. The first shell portion 132A and the second shell portion 132B together surround the tube bundle. The first shell portion 132A and the second shell portion 132B are each made of a bent metal plate, and the plates are brazed together. The heat exchanger 100 also includes a first inlet port 134 configured on the first manifold 102 and a first outlet port 136 configured on the second manifold 108. The first inlet port 134 is suitable for connecting to a first external circuit that supplies at least one first heat exchange fluid. The housing 132 further comprises a second inlet port 138 and a second outlet port 140 adapted to be connected to a second external circuit supplying at least one second heat exchange fluid.

[0029] The first fluid may flow in from the first inlet port 134 of the first manifold 102, pass through the plurality of heat exchange tubes 114, and flow out of the second manifold 108 via the first outlet port 136. The second heat exchange fluid flows in from the second inlet port 138, flows around the heat exchange tubes 114, and reaches the second outlet port 140. The flow of the heat exchange fluid inside and around the heat exchange core 105 enables heat exchange between the first heat exchange fluid and the second heat exchange fluid.

[0030] refer to Figure 2 , the heat exchanger 100 also includes heat exchanger fins 142, which are located between the heat exchange tubes 114 to promote heat transfer between the first heat exchange fluid in the tubes 114 and the second heat exchange fluid flowing through the tubes 114. According to an exemplary embodiment, the heat exchanger fins 142 are made of aluminum and are brazed or otherwise joined to the tubes 114. However, according to other exemplary embodiments, the heat exchanger fins 142 can be made of other materials that promote heat transfer and can extend parallel to or at different angles relative to the flow of the heat exchange fluid. The heat exchanger fins 142 can be louvered fins, corrugated fins, or any other suitable type of fins.

[0031] The heat exchanger 100 also includes at least one intermediate plate 122 disposed between at least one header plate 104, 110 and the box members 106, 112. In this embodiment, the intermediate plate 122 is disposed between the first header plate 104 and the first box member 106. Figure 3 , the intermediate plate 122 includes a plurality of apertures 128. The apertures 128 are aligned with the arrangement of the plurality of heat exchange tubes 114 and the plurality of holes 144 of the first header plate 104. In another embodiment, the intermediate plate 122 is arranged between the second header plate 110 and the second box member 112, which is not shown in the figure. In yet another embodiment, at least the intermediate plate 122 is arranged between the first header plate 104 and the first box member 106, and at least one intermediate plate 122 is arranged between the second header plate 110 and the second box member 112, which is not shown in the figure. In the assembled configuration, the ends 116A of the heat exchange tubes 114 are introduced into the corresponding holes 144 of the header plate 104. Then, the intermediate plate 122 is arranged to receive the ends 116A of the corresponding heat exchange tubes 114 passing through the header plate 104 at the corresponding apertures 128 of the intermediate plate 122.

[0032] Furthermore, in this embodiment, the heat exchange tube 114 is a flat tube. In another embodiment, the heat exchange tube 114 may be a multi-channel tube including a plurality of flow channels or paths. The heat exchange tube 114 includes an inner surface 118 defined by a side wall 120, and at least one fin 124 disposed within the inner surface 118 of the heat exchange tube 114, such as Figure 6 shown.

[0033] All components of the heat exchanger 100 described above may be made of materials suitable for brazing, such as aluminum, steel and alloys thereof. In order to obtain a suitable fluid tightness of the assembly, all components of the assembly are connected to each other by brazing or any other suitable means.

[0034] Figure 4 It is shown as an example Figure 3 122 of the middle plate. Figure 5 It is shown as an example Figure 3 Another perspective view of the intermediate plate 122 of FIG. The intermediate plate 122 includes a first side 130A and a second side 130B opposite to the first side 130A. The intermediate plate 122 is arranged so that the first side 130A at least partially contacts at least one end 116A of the heat exchange tube 114 and the first header plate 104, and the second side 130B at least partially contacts the first box member 106. The intermediate plate 122 includes a substantially flat surface, and a plurality of orifices 128 are formed on the flat surface. The plurality of orifices 128 are arranged at predetermined positions, and each orifice 128 corresponds to the position of a corresponding heat exchange tube 114. The intermediate plate 122 also includes a flange 126 extending from the at least one orifice 128 toward the heat exchanger core 105. In one example, the flange 126 extends from the intermediate plate 122 so as to at least partially surround the orifice 128.

[0035] refer to Figure 6 , the flange 126 extends from the at least one orifice 128 toward the heat exchanger core 105 to fit at least a portion of the side wall 120 of the corresponding heat exchange tube 114. The profile of the orifice 128 is complementary to the profile of the heat exchanger 114. The flange 126 is formed along the profile of the orifice 128 so that the flange 126 has a profile complementary to the profile of the heat exchange tube 114 to conform to the side wall 120 of the corresponding heat exchange tube 114. In a preferred embodiment, the flange 126 is configured to contact the inner surface 118 of the corresponding heat exchange tube 114. In one embodiment, the flange 126 is at least partially located between the fin 124 and the inner surface 118 of the side wall 120 of the heat exchange tube 114. The flange 126 contacts the end 116A of the heat exchange tube 114, and the header plate 104 strengthens the connection between the tube and the header to increase the reliability and service life of the heat exchanger 100.

[0036] The number of orifices 128 corresponds to the number of heat exchange tubes 114 and holes 144 of the first header plate 104. Each orifice 128 includes a rectangular profile that corresponds to the profile of the holes 144 of the first header plate 104 and the heat exchange tubes 114. Figure 5 and Figure 6, the orifice 128 includes a first side 146A and a second side 146B opposite the first side 146A. The orifice 128 also includes a third side 146C and a fourth side 146D opposite the third side 146C of the orifice 128. The flange 126 extending from the orifice 128 includes a first flange portion 126A and a second flange portion 126B. The first flange portion 126A extends from the first side 146A of the orifice 128, and the second flange portion 126B extends from the second side 146B of the orifice 128. In another embodiment, the first flange portion 126A extends from the third side 146C of the orifice 128, and the second flange portion 126B extends from the fourth side 146D of the orifice 128, which is not shown in the figure. In yet another embodiment, the flange 126 extends from all sides 146A, 146B, 146C, 146D of the rectangular profile of the aperture 128 and may have a rectangular cross-section complementary to the ends 116A, 116B of the flat heat exchange tubes, not shown.

[0037] The first header plate 104 is arranged to receive the end portions 116A of the heat exchange tubes 114 in the corresponding holes 144 of the first header plate 104. Then, the middle plate 122 is arranged at least at one end portion 116A of the plurality of heat exchange tubes 114. The end portions 116A of the heat exchange tubes 114 pass through the holes 144 of the first header plate 104 and engage with the corresponding flanges 126 of the middle plate 122. Therefore, the middle plate 122 is arranged to at least partially contact the end portions 116A of the plurality of heat exchange tubes 114 and at least partially contact the first header plate 104. In other words, the middle plate 122 is arranged between the end portions 116A of the heat exchange tubes 114 and the first header plate 104 and the first box member 106.

[0038] refer to Figure 6 and Figure 7 , the heat exchange tubes 114 include a generally rectangular sidewall 120 defined by a pair of short sidewalls 120B and a pair of long sidewalls 120. The first flange portion 126A and the second flange portion 126B extend to conform to at least a portion of the long sidewall 120A of the corresponding heat exchange tube 114. In another embodiment, the first flange portion 126A and the second flange portion 126B extend to conform to at least a portion of the short sidewall 120B of the corresponding heat exchange tube 114. In yet another embodiment, the flange 126 includes a profile that is complementary to the ends 116A, 116B of the heat exchange tube 114, and the flange 126 conforms to the entire sidewall 120 at the inner surface 118 of the heat exchange tube 114. The configuration and location of the intermediate plate 122 at the tube-to-manifold connection provides the necessary strength to withstand the stress caused by thermal expansion and contraction of the heat exchange tubes 114 discussed in the background section of this document. Thus, the increase in mechanical resistance at the connection between the tubes 114 and the header plates 104, 110 improves the reliability of the heat exchanger 100 and extends its service life.

[0039] Although the specification describes the arrangement of the intermediate plate 122 at the first end 116A of the heat exchange tube 114, it should be understood that the intermediate plate 122 can be similarly arranged at the second end 116B of the heat exchange tube 114, or simultaneously arranged at the first end 116A and the second end 116B of the heat exchange tube 114, and provide the same advantages and effects for the connection between the tubes of the second manifold 108, or the first manifold 102 and the second manifold 108 and the header, respectively.

[0040] In any case, the present invention cannot and should not be limited to the embodiments specifically described herein, as other embodiments are possible. The present invention should be extended to any equivalent means and any technically feasible combination of means.

Claims

1. A heat exchanger (100), comprising: A first manifold (102); a second manifold (108) arranged in parallel with and spaced apart from the first manifold (102), and A heat exchanger core (105) comprising a plurality of heat exchange tubes (114) providing fluid communication between the first manifold (102) and the second manifold (108), wherein each of the heat exchange tubes (114) comprises an inner surface (118) defined by a side wall (120), a first end (116A), and a second end (116B) opposite the first end (116A), wherein each of the manifolds (102, 108) comprises a box member (106, 112) and a header plate (104, 110), wherein the header plate (104, 110) comprises a plurality of holes (144) to accommodate the respective ends (116B, 116B) of the heat exchange tubes (114), characterized in that: At least one intermediate plate (122) is arranged at least at one end (116A, 116B) of the plurality of heat exchange tubes (114), wherein the intermediate plate (122) includes a plurality of orifices (128) aligned with the arrangement of the plurality of heat exchange tubes (114) and the plurality of holes (144) of the header plates (104, 110).

2. The heat exchanger (100) according to claim 1, wherein: The intermediate plate (122) includes a flange (126) extending from at least one aperture (128) toward the heat exchanger core (105) to conform to at least a portion of the side wall (120) of a corresponding heat exchange tube (114).

3. The heat exchanger (100) according to claim 1, wherein: The intermediate plate (122) at least partially contacts the ends (116A, 116B) of the plurality of heat exchange tubes (114).

4. The heat exchanger (100) according to claim 3, wherein: The intermediate plate (122) is at least partially in contact with the header plates (104, 110).

5. The heat exchanger (100) according to claim 1, wherein: The heat exchange core (105) also includes at least one fin (124) within the inner surface (118) of at least one heat exchange tube (114).

6. The heat exchanger (100) according to claim 2, wherein: The flange (126) is configured to contact an inner surface (118) of the corresponding heat exchange tube (114).

7. The heat exchanger (100) according to claims 1 and 5, wherein: The flange (126) is at least partially located between the fin (124) and the inner surface (118) of the side wall (120) of the heat exchange tube (114).

8. The heat exchanger (100) according to claims 1 and 2, wherein: The flange (126) extends from the intermediate plate (122) to at least partially surround the aperture (128).

9. The heat exchanger (100) according to claim 1, wherein: The heat exchange tube (114) includes a generally rectangular side wall defined by a pair of long side walls (120A) and a pair of short side walls (120B).

10. The heat exchanger (100) according to claim 1, wherein: Each of the apertures (128) includes a rectangular configuration defining a first side (146A) and a second side (146B) opposite the first side (146A).

11. The heat exchanger (100) according to claims 2 and 10, wherein: The flange (126) includes a first flange portion (126A) extending from the first side (146A) of the aperture (128) and a second flange portion (126B) extending from the second side (146B) of the aperture (128).

12. The heat exchanger (100) according to claims 8 to 11, wherein: The first flange portion (126A) and the second flange portion (126B) extend to conform to at least a portion of a long side wall (120A) of the corresponding heat exchange tube (114).

13. The heat exchanger (100) according to claims 8 to 11, wherein: The first flange portion (126A) and the second flange portion (126B) extend to conform to at least a portion of a short side wall (120B) of the corresponding heat exchange tube (114).

14. The heat exchanger (100) according to claims 8 to 11, wherein: The flange portions (126A, 126B) are brazed to the side walls (120A, 120B) of the corresponding heat exchange tubes (114).

15. The heat exchanger (100) according to claims 8 to 11, wherein: The flange portions (126A, 126B) are in contact with the inner surface (118) of the corresponding heat exchange tube (114).

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