Upright seal for a heat exchanger

Abstract

Sealing element (4) for a heat exchanger (2) with: an elongated main body (24), wherein a cross-section of the main body (24) has a height (H1) and a width (W1), wherein the height (H1) is greater than the width (W1), and a plurality of projections (42) projecting laterally from a surface of the main body (24) and spaced at first predetermined intervals along a length of the main body (24), and further comprising a plurality of enlarged portions (30) spaced at second predetermined intervals along the length of the main body (24), wherein a height (H2) of the enlarged portions (30) is the same as a width (W2) of the enlarged portions (30), wherein the height (H2) of the enlarged portion (30) is the same as the height (H1) of the main body (24); wherein the sealing element (4) has a rectangular shape, with a pair of opposite sides (26) connected to each other by a pair of opposite ends (28); wherein the main body (24) is continuous and defines a first side and a second side of the sealing element (4); and wherein each of the sides (26) has the plurality of projections (42) and the plurality of enlarged portions (30), and wherein each of the ends (28) has only the plurality of projections (42).

Description

Technical field

[0001] The present invention relates to a sealing element for a motor vehicle and in particular to an upright sealing element for a heat exchanger of a motor vehicle. Technical background

[0002] Heat exchangers are commonly used in automotive vehicles as a means of transferring thermal energy between fluids. A heat exchanger may include a core having a first fluid flow path and a second fluid flow path, the first fluid flow path being fluidly separated and in thermal communication with the second fluid flow path to enable transfer of thermal energy therebetween. For example, the first fluid flow path may include a plurality of tubes or plates through which a first fluid flows, and the second fluid flow path may include an array of passages formed between the tubes or plates of the first fluid flow path, with thermal energy being transferred from the first fluid to a second fluid through the walls of the tubes or plates.

[0003] Heat exchangers are generally formed from a core configured to facilitate an exchange of thermal energy with a fluid passing through it. A header is provided at at least one end of the core and provides an interface between the core and a fluid reservoir, such as a tank or manifold. One common type of header is known as a recessed header, which has a recessed outer edge configured to receive a sealing element therein.

[0004] To provide a good seal between the fluid reservoir and the manifold, a height or thickness of the sealing element must be sufficient, wherein the sealing element is compressed within the recessed outer edge by the fluid reservoir when the heat exchanger is assembled. In the technical field, it is known to use a sealing element with a circular cross-section. By using a sealing element with a circular cross-section, a maximum height and thickness of the sealing element within the recessed outer edge is ensured. However, although functional for maintaining a fluid seal between the manifold and the fluid reservoir, the use of a cylindrical seal disadvantageously requires the manifold to have a large outer profile, since a width of the recessed outer edge must be sufficient to accommodate the width of the sealing element.

[0005] Another sealing element is known from WO 2014 / 185168 A1. This sealing element seals a space between two elements by closely contacting the other element in a state where the gasket is attached to a mounting groove provided on an opposing surface of one of the two opposing elements. The sealing element has a collapse prevention protrusion, which suppresses collapse of the gasket in the groove, provided on a part of a circumference on a side surface of the gasket, and an injection gate mark, which is formed as an injection gate portion when the gasket is molded, is formed by the collapse prevention protrusion. The height of the collapse prevention protrusion and the height of the injection gate mark are equal to or substantially equal to each other.

[0006] Further seals are known from US 2009 / 0 243 229 A1, US 6 722 660 B2 and US 6 981 704 B2.

[0007] Accordingly, there is a need in the art for an improved sealing element having a reduced width and configured to maintain a maximized height within the recessed outer edge of a manifold. Description of the invention

[0008] According to the present disclosure, an improved sealing element having a minimized width and configured to maintain a maximized height within a recessed outer edge of a manifold is surprisingly discovered.

[0009] Sealing elements according to the present invention are defined in claim 1 and claim 6. Further preferred embodiments are set out in the subclaims.

[0010] In one embodiment, a sealing element for a heat exchanger comprises an elongated main body, wherein a cross-section of the main body has a height and a width. The height of the cross-section is greater than the width. The sealing element further comprises a plurality of protrusions that protrude laterally from the main body. The plurality of protrusions are spaced at first predetermined intervals along a length of the main body. The sealing element further comprises a plurality of enlarged portions that are spaced at second predetermined intervals along the length of the main body. A height of the enlarged portions is the same as a width of the enlarged portions. The height of the enlarged portion is the same as the height of the main body. The sealing element has a rectangular shape, with a pair of opposite sides connected to each other by a pair of opposite ends.The main body is continuous and defines a first side and a second side of the sealing element. Each of the sides has the plurality of projections and the plurality of enlarged portions, and each of the ends has only the plurality of projections.

[0011] In another embodiment, a sealing member includes an elongated main body. A plurality of protrusions are spaced apart at predetermined intervals along a length of the main body. A plurality of enlarged portions are spaced apart at second predetermined intervals along the length of the main body, the plurality of enlarged portions and the plurality of protrusions being alternately arranged along the length of the main body. The sealing member has a rectangular shape with a pair of opposite sides connected to each other by a pair of opposite ends. Each of the plurality of enlarged portions is laterally offset with respect to the main body. Each of the plurality of enlarged portions projects laterally inwardly from the main body and does not project laterally outwardly from the main body.Each of the plurality of enlarged portions has one of the plurality of projections projecting laterally outwardly therefrom.

[0012] In another embodiment, a sealing element for a heat exchanger has a first side and a second side. The first side of the sealing element has a first plurality of protrusions and a plurality of enlarged portions, wherein the first plurality of protrusions and the enlarged portions are arranged alternately along a length of the first side. The second side of the sealing element has a second plurality of protrusions and does not have the enlarged portions. Short description of the drawings Fig. 1 is a partial fragmentary exploded top view of a heat exchanger having a fluid reservoir, a manifold, and an embodiment of a sealing member according to the present disclosure. Fig. 2 is a top plan view of another embodiment of a sealing member according to the present disclosure, wherein the sealing member is received within a manifold for a heat exchanger. Fig. 3 is a perspective top view of the sealing element according to Fig. 2. Fig. 4 is a top plan view of the sealing element of the Fig. 2. Fig. 5 is a fragmentary cross-sectional view of the sealing element of the Fig. 2 along the section line 5-5 in Fig. 4 and shows a main body of the sealing element of the Fig. 2. Fig. 6 is a fragmentary cross-sectional view of the sealing element of the Fig. 2 along section line 6-6 in Fig. 4 and shows an enlarged section of the sealing element. Fig. 7 is a fragmentary cross-sectional view of the sealing element of the Fig. 2 along section line 7-7 in Fig. 4 and shows the enlarged section and a projection of the sealing element. Fig. Figure 8 is a fragmentary cross-sectional view of the sealing element of the Fig. 2 along section line 8-8 in Fig. 4 and shows the main body and a first pair of projections of the sealing element. Fig. 9 is a fragmentary cross-sectional view of the sealing element of the Fig. 2 along section line 9-9 in Fig. 4 and shows the main body and a second pair of projections of the sealing element. Detailed description of the invention

[0013] The following detailed description and the appended drawings describe and illustrate various embodiments of the invention. The description and drawings are provided to enable one skilled in the art to make and use the invention and are not intended to limit the scope of the invention in any way. Regarding the disclosed methods, the steps presented are intended as examples, and thus, the order of the steps is not necessary or critical.

[0014] Fig. 1 shows a heat exchanger 2 with a sealing element 4 according to the present disclosure. The heat exchanger 2 has a manifold 6 configured to be coupled to the open end of a heat exchanger core (not shown), as is known in the art. The manifold 6 is configured to sealingly and releasably couple a fluid reservoir 8 of the heat exchanger 2 to the core.

[0015] The manifold 6 may be coupled to the heat exchanger core using mechanical means such as soldering, caulking, or welding. Alternatively, the manifold 6 may be formed integrally with the heat exchanger core.

[0016] The manifold 6 is configured to cooperate with a portion of the fluid reservoir 8 when the heat exchanger 2 is assembled. In particular, a recessed outer edge 10 surrounds at least a portion of a perimeter of the manifold 6 and is configured to receive at least a portion of the fluid reservoir 8 therein. In other embodiments, a recess may be formed in the fluid reservoir 8 with a portion of the manifold 6 received therein. In the illustrated embodiment, a plurality of attachment tabs 12 extend from the recess, with a single one of the attachment tabs 12 covering each of the sides of the manifold 6. Each of the attachment tabs 12 has a plurality of first coupling features 14 formed therein.

[0017] As in Fig. 1 and Fig. 2, the manifold 6 further includes a plurality of transverse elements 16 traversing a distance between two opposite sides of the manifold 6. In the illustrated embodiment, the transverse elements 16 have a U-shaped cross-section, with opposite ends of the transverse elements 16 terminating at an inner wall of the recessed outer edge 10, and a channel 18 defined by the U-shaped transverse element 16 being continuous with an interior of the recessed outer edge 10.

[0018] With further reference to Fig. 1, the fluid reservoir 8 has at least one continuous sidewall 20, wherein a distal portion of the sidewall 20 is configured to be received within the recessed outer edge 10 of the manifold 6, whereby the sealing element 4 is compressed within the recessed outer edge 10 to sealingly couple the fluid reservoir 8 and the manifold 6. A plurality of second coupling features 22 are spaced along the sidewall 20 of the fluid reservoir 8. In the illustrated embodiment, each of the second coupling features 22 is a protrusion projecting outwardly from the sidewall 20 and is configured to engage a corresponding one of the first coupling features 14 of the manifold 6.

[0019] The sealing element 4 is provided in the recessed outer edge 10 of the manifold 6. In the illustrated embodiment, the sealing element 4 is formed separately from both the fluid reservoir 8 and the manifold 6. Optionally, the sealing element 4 may be formed integrally with at least one of the fluid reservoir 8 and the manifold 6. The sealing element 4 is made of a durable polymer material such as a fluoroelastomer (FKM) or an ethylene propylene diene monomer (EPDM). Other suitable materials for the sealing element 4 will be apparent to those skilled in the art.

[0020] As in Fig. 3-5, the sealing element 4 has an elongated main body 24. In the illustrated embodiment, the main body 24 is continuous and the sealing element 4 has a rectangular shape with a pair of opposite sides 26 connected to each other by a pair of opposite ends 28. As shown in Fig. 5, a cross-section of the main body 24 has a height H1 and a width W1. A size ratio (H1 / W1) of the sealing element 4 is greater than 1:1, wherein the height H1 of the sealing element 4 is greater than the width W1. In one embodiment, the size ratio may be in the range of 1:1 and 2:1, preferably 1.1:1 to 1.5:1, and more preferably 1.3:1. The specific dimensions of the sealing element 4 are selected based on the dimensions of the recess of the manifold 6, wherein when the fluid reservoir 8 is received within the recess of the manifold 6, the seal is compressed to provide a fluid seal between the fluid reservoir 8 and the manifold 6.

[0021] As illustrated, the cross-section of the main body is oblong, with a top and bottom of the sealing element 4 being substantially semi-cylindrical in shape and connected by a pair of straight sidewalls. By forming the main body 24 with an oval cross-sectional shape with a semi-cylindrical top and bottom, the sealing element 4 advantageously provides a round compression zone similar to a perfectly cylindrical sealing ring, while simultaneously minimizing the overall profile of the sealing element 4 and the heat exchanger 2.

[0022] The sides 26 of the sealing element 4 have a plurality of enlarged portions 30 formed therein. The enlarged portions 30 are spaced apart at predetermined intervals along a length of each of the sides 26. The predetermined intervals correspond to a spacing between the cross members 16 of the manifold 6, with the enlarged portions 30 of the sealing element 4 aligned with the channels of the cross members 16 and configured to be partially received therein.

[0023] In one embodiment of the sealing element 4, a cross section of each of the enlarged portions 30 has an equal height H2 and width W2, wherein a size ratio of the cross section of the enlarged portion 30 is 1:1. The enlarged portions 30 are designed to hinder rotation of the sealing element 4 within the recess of the distributor piece 6 during compression. As shown in Fig. 6, the cross-section of each of the enlarged portions 30 includes a pair of opposing horizontal sides forming an upper surface 32 and a lower surface 34 of the enlarged portion 30, and a pair of opposing vertical sides forming an inner surface 36 and an outer surface 38 of the enlarged portion 30. As shown in Fig. 6, the cross-section of the enlarged portion 30 is a rectangle with rounded corners. More specifically, the cross-section of the enlarged portions 30 is a square with rounded corners. In other embodiments, the enlarged portions 30 may be polygonal shapes with opposing horizontal sides and opposing vertical sides between the horizontal sides.

[0024] As in Fig. 4 and Fig. 8, the enlarged portion 30 is offset laterally inwardly of the main body 24, and the height H2 of the enlarged portion 30 is the same as the height H1 of the main body 24, wherein the upper surface 32, the lower surface 34, and the outer surface 38 of the enlarged portions 30 are continuous with the main body 24, and the inner surfaces 36 of the enlarged portions 30 are offset laterally inwardly from the main body 24. As shown in Fig. 3 and Fig. 4, the enlarged portion 30 may include transition surfaces 40 between the main body 24 and the inner surface 36 of the enlarged portion 30, with the sealing member 4 increasingly tapering between the main body 24 and the inner surface 36. By offsetting the enlarged portion 30 laterally inward, the width W2 of the enlarged portion 30 may be maximized without increasing a profile of the manifold 6, since the enlarged portion is advantageously configured to be received within the channel 18 of the cross member 16 without increasing a width of the recess.

[0025] The sealing element 4 further comprises a plurality of projections 42 which protrude laterally from the main body 24. As in Fig. 5-9, each of the protrusions 42 is a truncated portion having a base portion 44 formed adjacent to the main body 24 of the sealing member 4 and a distal portion 46 extending laterally away from the main body 24 of the sealing member 4. Each of the protrusions 42 may be tapered from the base portion 44 to the distal portion 46, with a cross-sectional area of ​​the base portion 44 being greater than a cross-sectional area of ​​the distal portion 46. In the illustrated embodiment, each of the protrusions 42 is frusto-pyramidal, with both the base and distal portion 46 being rectangular. In other embodiments, the protrusions 42 may be hemispherical or frusto-conical, with both the base and distal portion 46 being circular.

[0026] The plurality of projections 42 includes pairs of projections 42 provided on the sides 26 and ends 28 of the sealing member 4. Each of the pairs of projections 42 includes a first projection 42a projecting laterally inward from the main body 24 and a second projection 42b projecting laterally outward from the main body 24 opposite the first projection 42a. In other words, the first projection 42a and the second projection 42b of each of the pairs of projections 42 are aligned along the length of the main body 24 and extend in first and second directions that are opposite to each other.

[0027] First pairs of projections 42 are provided longitudinally at predetermined intervals along each of the sides 26 of the sealing element 4. The first pairs of projections 42 are arranged alternately with the enlarged portions 30 of the sealing element, with one of the enlarged portions 30 being arranged between adjacent ones of the first pairs of projections 42. As shown in Fig. 8, the first protrusions 42a and the second protrusions 42b forming the first pair of protrusions 42 are similar in size and shape. However, in other embodiments, the first protrusions 42a and the second protrusions 42b of the first pair of protrusions 42 may differ in size.

[0028] Second pairs of projections 42 are provided longitudinally spaced at predetermined intervals along each of the ends 28 of the sealing element 4. The first projections 42a and the second projections 42b of the second pair of projections 42a, 42b are different in size, with the first projection 42a projecting further from the main body 24 than the second projection 42b, as shown in Fig. 5 and Fig. 9. In other embodiments, the first protrusions 42a and the second protrusions 42b of the second pair of protrusions 42 may be substantially similar in size.

[0029] As in Fig.7, the sides 26 of the sealing member 4 may further include laterally outwardly projecting protrusions 42c formed on the outer surface 38 of each of the enlarged portions 30. The protrusions 42c formed on the enlarged portions 30 are configured to advantageously bias the enlarged portions 30 into the channels 18 of the cross members 16.

[0030] The use of a combination of protrusions 42 and enlarged portions 30 represents an improvement over the prior art. The protrusions 42 function to maintain the main body 24 of the sealing member 4 in an upright orientation within the recessed outer rim 10, maintaining the sealing member 4 at a maximum height to ensure compression. The laterally offset enlarged portions 39 further provide stability to the sealing member 4 while maintaining a minimal profile of the sealing member 4.

[0031] From the foregoing description, one skilled in the art can easily understand the essential features of this invention and, without departing from its spirit, can make various changes and modifications to the invention to adapt it to different uses and conditions. In particular, the features of all embodiments and all claims may be combined with one another, as long as they do not contradict one another.

Claims

[1] Sealing element (4) for a heat exchanger (2) with: an elongated main body (24), wherein a cross-section of the main body (24) has a height (H1) and a width (W1), wherein the height (H1) is greater than the width (W1), and a plurality of projections (42) projecting laterally from a surface of the main body (24) and spaced at first predetermined intervals along a length of the main body (24), and further comprising a plurality of enlarged portions (30) spaced at second predetermined intervals along the length of the main body (24), wherein a height (H2) of the enlarged portions (30) is the same as a width (W2) of the enlarged portions (30), wherein the height (H2) of the enlarged portion (30) is the same as the height (H1) of the main body (24); wherein the sealing element (4) has a rectangular shape, with a pair of opposite sides (26) connected to each other by a pair of opposite ends (28); wherein the main body (24) is continuous and defines a first side and a second side of the sealing element (4); and wherein each of the sides (26) has the plurality of projections (42) and the plurality of enlarged portions (30), and wherein each of the ends (28) has only the plurality of projections (42). [2] The sealing member (4) of claim 1, wherein the plurality of projections (42) comprise a plurality of pairs of the plurality of projections (42), each of the plurality of pairs comprising a first projection (42a) projecting laterally in a first direction and a second projection (42b) projecting laterally in an opposite second direction, the second projection (42b) being longitudinally aligned with the first projection (42a) in an opposite second direction. [3] The sealing member (4) according to claim 2, wherein the plurality of pairs of the plurality of projections (42) and the plurality of enlarged portions (30) are arranged alternately along the main body (24). [4] The sealing member (4) of claim 1, wherein at least one of the plurality of projections (42) is longitudinally aligned with at least one of the plurality of enlarged portions (30) of the main body (24). [5] The sealing member (4) of claim 4, wherein at least one of the plurality of projections (42) protrudes laterally from the main body (24) in a first direction and the at least one of the plurality of enlarged portions (30) protrudes laterally from the main body (24) in a second, opposite direction. [6] Sealing element (4) for a heat exchanger (2) with: an elongated main body (24), a plurality of projections (42) spaced at first predetermined intervals along a length of the main body (24), and a plurality of enlarged portions (30) spaced at second predetermined intervals along the length of the main body (24), the plurality of enlarged portions (30) and the plurality of projections (42) being arranged alternately along the length of the main body (24); wherein the sealing element (4) has a rectangular shape, with a pair of opposite sides (26) connected to each other by a pair of opposite ends (28) wherein each of the plurality of enlarged portions (30) is laterally offset with respect to the main body (24) and wherein each of the plurality of enlarged portions (30) projects laterally inwardly from the main body (24) and does not project laterally outwardly from the main body (24); and wherein each of the plurality of enlarged portions (30) has one of the plurality of projections (42c) projecting laterally outwardly therefrom. [7] The sealing member (4) according to claim 6, wherein the plurality of projections (42) are a plurality of pairs of the plurality of projections (42), a first one among the plurality of projections (42a) projecting laterally from the main body (24) in a first direction and a second one among the plurality of projections (42b) projecting laterally from the main body (24) in a second direction opposite to the first direction. [8] The sealing member (4) according to claim 6, wherein each of the plurality of projections (42) has a base portion (44) formed adjacent to the main body (24) of the sealing member (4) and a distal portion (46) extending outwardly from the sealing member (4). [9] The sealing member (4) according to claim 6, wherein each of the projections (42) is tapered and wherein a cross-sectional area of ​​the distal portion (46) of each of the plurality of projections (42) is smaller than a cross-sectional area of ​​the base portion (44) of each of the plurality of projections (42). [10] The sealing member (4) according to claim 6, wherein a height (H2) of each of the plurality of enlarged portions (30) is the same as a width (W2) of each of the plurality of enlarged portions (30). [11] The sealing member (4) according to claim 10, wherein a cross section of each of the plurality of enlarged portions (30) is a square with rounded corners.

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