Heat exchanger

Abstract

Heat exchanger containing: several tubes (224) each with opposite wide and essentially flat sides, connected by two opposite narrow sides; a collector (204) with several openings (216), each dimensioned to accommodate a corresponding pipe (224) of the several pipes (224); a collection tank (100) coupled to the collector (204) and having an inner chamber in fluid communication with the several pipes (224); a seal (108) arranged between the collection tank (100) and the collector (204); and a tank reinforcement element (104) extending over the inner chamber, wherein the seal (108) is installed on the tank reinforcement element (104), and the tank reinforcement element (104) holds the seal (108) in position between the collection tank (100) and the collector (204).

Description

BACKGROUND

[0001] There is a variety of heat exchangers in which a number of tubes are connected to a collection tank for introducing and / or removing fluid from the flat tubes and are in fluid contact with each other. In many cases, the applications of such heat exchangers result in high pressure and thermal stresses, for example, at and adjacent to the connections between the flat tubes and the collection tank. It is also desirable that such collection tanks and the connections between the flat tubes and them withstand significant pressure without excessive deformation or damage, despite the desire to construct collection tanks from increasingly thinner and lighter materials. This capability should extend to the interface between the collection tank components, especially in cases where the collection tank is constructed from multiple parts (e.g., a collector plate and a structure that defines the rest of the collection tank).

[0002] Further design challenges for many heat exchangers relate to the use of seals between heat exchanger components, such as seals between the tube and manifold plate, seals located between the manifold plates and other collector tank components, and the like. Such seals must perform their hydraulic or pneumatic sealing functions while being subjected to high pressures and / or temperatures, material expansion and contraction, and other challenges in some applications. Reliable seals and a secure seal hold remain elusive in many applications.

[0003] Consequently, it can be seen that heat exchangers with collection tanks and collection tank-flat tube connections designed to withstand thermal and / or pressure stresses and a cycle are welcome additions to the industry, as are reliable heat exchanger gaskets and gasket retention designs, and heat exchangers that are relatively lightweight and can be manufactured more efficiently and at a lower cost.

[0004] DE 10 2004 033 784 A1 relates to a heat exchanger, in particular an intercooler for a motor vehicle, comprising a box, a chamber for distributing and / or collecting a flowing medium, a tube bundle, tubes, a tube sheet, openings, a housing cover, two side walls, a stabilizing element, a first receptacle, a first force transmission element, a second receptacle, a second force transmission element, a force receiving element and a flow guide surface.

[0005] US patent 2002 / 0023734A1 describes an intercooler comprising a tubular block with multiple finned tubes and a tank assembly at each end. Each tank assembly includes a tank body to receive one end of the finned tubes within the tubular block. A connecting plate, a heat-resistant flexible gasket, and a support plate provide an initial elastic seal with each of the tubes and the connecting plate.

[0006] DE 10 2005 007 591 A1 relates to a heat exchanger that can be effectively used in a charge air cooler to cool air (intake air) before it is introduced into an internal combustion engine to support combustion.

[0007] DE 699 03 608 T2 discloses a heat exchanger with a bundle of tubes and fins, in which the ends of the tubes are inserted into the holes of a collector plate, and a collector vessel having an open side limited by a circumferential rim, and in which the collector plate is equipped with means for folding over which can bear against the circumferential rim of the collector vessel by ensuring the compression of a seal.

[0008] US patent 2006 / 0061044A1 shows a heat exchanger with a tank assembly. The tank assembly has a top plate with pipe connections. The tank assembly also includes a tank that is connected to the top plate. A gasket is located between the top plate and the tank. The gasket is inserted into a sealing seat in the top plate. SUMMARY

[0009] Some embodiments of the present invention provide a manifold for a heat exchanger's collection tank. The manifold can provide an increased level of strength for the heat exchanger and for connections between the manifold and the associated pipes. The manifold can have a convex shape configured to reduce mechanical thermal stresses at pipe-manifold connections and to reduce pressure stresses.

[0010] In some embodiments, the collector of the collection tank is made of plastic and is curved about a longitudinal axis of the collection tank, giving it a generally convex shape towards the pipes connected to it and a generally concave shape towards the interior of the collection tank. The pipes can have any desired cross-sectional shape. However, distinct advantages can be achieved by using flat pipes (i.e., pipes with opposing, essentially wide, flat sides connected by opposing, narrow sides) connected to the collector.

[0011] By using a curved manifold, as described above, plastic manifolds can withstand internal tank pressures that would otherwise cause significant manifold deformation. Under pressure, the curved plastic manifold described above exhibits a considerably reduced degree of manifold deformation. In some embodiments, such deformation can even be eliminated. Consequently, the mechanical stress experienced by the connections between the manifold and the pipes attached to it is considerably reduced.

[0012] The curved plastic manifold, as described above, also makes it possible in some embodiments to achieve increased strength of the manifold and the connections between the manifold and the pipes. Since the strength of the manifold and the pipe-manifold connections often decreases from the manifold's periphery towards its center, the manifold curvature described above significantly increases the manifold's strength in a central region. As a result of this increased strength, weight and cost savings can be achieved by reducing the thickness of the material from which the manifold and / or pipes are constructed. The increased mechanical strength also extends the service life of a collection tank and a heat exchanger using such a manifold.Such advantages do not necessarily require any additional expenditure with regard to the manifold and collection tank material, the number of manifold and collection tank components, and the individual production stages of the manifold and collection tank. Reproducible and permanently sealed connections between the manifold and the individual pipes are also possible using the curved manifold described above and relatively low production tolerances.Further aspects of the present invention relate to ways in which a collector can be connected to the rest of a collection tank while a gasket or other seal is held in position with respect to such parts, ways in which a seal is to be provided at the interfaces between the tubes and the collector of a heat exchanger, and ways in which the collection tank and sections of the collection tank and collector interface can be reinforced to increase the pressure capacity of the collection tank and / or to allow the use of thinner and different collection tank materials.

[0013] In some embodiments, a heat exchanger is created and has several tubes, each with opposing wide and substantially flat sides, connected by two opposing narrow sides; a collector with several openings, each dimensioned to receive a corresponding tube of the several tubes; a collection tank coupled to the collector and having an inner chamber in fluid communication with the several tubes; a seal arranged between the collection tank and the collector; and at least one tank reinforcement element extending over the inner chamber.

[0014] Some embodiments of the present invention provide a heat exchanger with several tubes, each having opposite wide and substantially flat sides connected by two opposite narrow sides; a plastic collection tank with an inner chamber in fluid communication with the several tubes; a metal collector coupled to the plastic collection tank and having several openings, each dimensioned to receive a corresponding tube of the several tubes, the metal collector being elongated in a longitudinal direction and curved about a longitudinal axis of the metal collector so that it has a concave shape towards the inner chamber and a convex shape away from the inner chamber; a seal that at least partially separates the metal collector from the plastic collection tank and seals a gap between the metal collector and the plastic collection tank;and a tank reinforcement element that extends over the inner chamber and at least partially holds the seal between the metal collector and the plastic collection tank in position.

[0015] In some embodiments, a heat exchanger is provided and has several tubes, each with opposing wide and substantially flat sides, connected by two opposing narrow sides; a collection tank with an inner chamber in fluid communication with the several tubes; a manifold coupled to the collection tank and having several openings, each dimensioned to receive a corresponding tube of the several tubes, the manifold being elongated in a longitudinal direction and curved about a longitudinal axis of the manifold, so that it has a concave shape towards the inner chamber and a convex shape away from the inner chamber; and a gasket which is received on a tube of the several tubes and is curved about the longitudinal axis of the manifold.

[0016] Further aspects of the invention become apparent from the detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a perspective view of a collection tank with a tank reinforcement element according to an embodiment of the present invention. Fig. 2 is a view of the in Fig. 1 shown collection tanks in a spread-out arrangement. Fig. 3 is a detailed view of the in Fig. 1 and Fig. 2 tank reinforcement elements shown. Fig. 4 is a detailed view of the in Fig. 2 and Fig. 3 shown seals. Fig. 5A is a cross-sectional view of the in Fig. 1 shown collection tanks along line 5A-5A from Fig. 1. Fig. 5B is a perspective composite view of the collection tank and the tank reinforcement element, shown in Fig. 1- Fig. 3 and Fig. 5A are shown. Fig. Figure 6A is a schematic cross-sectional view of a collection tank, a tank reinforcement element and a collector according to an embodiment of the present invention. Fig. Figure 6B is a perspective view of a collection tank arrangement according to an embodiment of the present invention. Fig. 6C is a perspective view of the in Fig. 6B shown collection tank arrangement in a spread-out arrangement. Fig. 6D is a detailed view of the in Fig. 6B and Fig. Collection tank arrangement shown in 6C. Fig. 6E is a perspective view of part of the in Fig. 6B- Fig. Collection tank arrangement shown in 6D. Fig. 6F is a perspective cross-sectional view of a part of the in Fig. 6B- Fig. Collection tank arrangement shown in 6E. Fig. Figure 6G is a perspective cross-sectional view of a part of a heat exchanger according to another embodiment of the present invention. Fig. Figure 6H is a perspective cross-sectional view of a part of a heat exchanger according to another embodiment of the present invention. Fig. Figure 6I is a perspective cross-sectional view of a part of a heat exchanger according to another embodiment of the present invention. Fig. Figure 7 is a perspective top view of a collector according to an embodiment of the present invention. Fig. 8 is a perspective view of the in Fig. 7 collectors shown from below. Fig. Figure 9 is a perspective view of part of a heat exchanger according to another embodiment of the present invention. Fig. Figure 10 is a perspective cross-sectional view of the in Fig. 9 shown heat exchanger along line 10-10 of Fig. 9. Fig. Figure 11 is a perspective cross-sectional view of a heat exchanger according to another embodiment of the present invention. Fig. 12 is a perspective view of a Fig. 9 shown feedthrough seal. Fig. 13 is a front view of the in Fig. 11 shown feedthrough seal. DETAILED DESCRIPTION

[0017] Before any embodiments of the invention are explained in detail, the invention is not, of course, intended to be limited in its application to the details of the construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Naturally, the language and terminology used herein also serve the purpose of description and should not be considered a limitation. The use of "include," "possess," or "feature" and variations thereof herein is intended to encompass the elements and equivalents listed below, as well as additional elements.Unless otherwise specified or limited, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used broadly and include both direct and indirect assemblies, connections, supports, and couplings. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

[0018] Fig. 1- Fig. Figure 5B represents a collection tank assembly 110 designed for a heat exchanger 24. The heat exchanger 24 is suitable for any application in which heat exchange takes place with a fluid flowing through the collection tank. Such applications exist in vehicle systems, such as those used in conjunction with internal combustion engines. In some applications, the heat exchanger 24 can, for example, function as a cooler, condenser, or evaporator. In some applications, the heat exchanger 24 can also be connected to a cooling circuit to exchange heat.

[0019] The in Fig. 1- Fig. The collection tank arrangement 110 shown in 5B has a collection tank 100 (of which only a part is in Fig. 1- Fig. 5B), a tank reinforcement element 104 and a seal 108. The illustrated collection tank 100 consists of a first section 100A, which at least partially defines a housing through which fluid flows, and a further section (in Fig. 1- Fig. 5B not shown), which is called the collector, is constructed. The collector connects to the first section 100A of the collection tank 100 to essentially enclose an inner chamber of the collection tank 100. An example of a collector 204 that can be used in conjunction with the first section 100A of the collection tank is shown in Fig. 7 and Fig. 8 is shown and is described in more detail below.

[0020] In some embodiments, the first section 100A of the collection tank 100 is made of aluminum, steel, iron, or another metal, whereas the collector (e.g., collector 104) is made of plastic. Although this combination of materials provides unique performance results (including a thin-walled but strong first section 100A that can withstand significant pressures while allowing the use of a less expensive and / or easier-to-manufacture plastic collector), other materials and material combinations are possible. In other embodiments, for example, both the first section 100A and the collector are made of plastic. As another example, in other embodiments, both the first section 100A and the collector are made of metal. Alternatively, in still other embodiments, the first section 100A is made of plastic, while the collector is made of metal.

[0021] The first section 100A of the collection tank 100 can be connected to the collector (e.g., to the one in Fig. 7 and Fig. The collector 204 shown in Figure 8 can be attached in a number of different ways, some of which provide a degree of resistance to fluid leakage under collector tank internal pressures. For this purpose, the circumferential edges of the first section 100A can be attached to circumferential edges of the collector, such as the planar circumferential edges of the collector 204 shown in Figure 8. Fig. 7 and Fig. As shown in Figure 8, the first section 100A and the collector can be attached at these and other points by welding, soft soldering, hard soldering, and the like.

[0022] To prevent fluid from escaping the collection tank 100, a seal 108 is arranged between the first section 100A of the collection tank 100 and the collector. The illustrated seal 108 extends around the circumference of the first section 100A and the collector and can be made of rubber, plastic, or any other material suitable for forming a seal.

[0023] As mentioned above, the collection tank assembly 110 shown in Fig. 105B also has a tank reinforcement element 104 to help hold the seal 108 in a position relative to the first section 100A of the collection tank 100 and the collector, preventing fluid from leaving the collection tank 100 during operation of the heat exchanger 24. Fig. The tank reinforcement element 104 shown in Figure 7 is made of plastic and can be manufactured by injection molding. Alternatively, the tank reinforcement element can be made of any other suitable material (including, without limitation, aluminum, steel, iron and other metals, composite materials and the like) and can be manufactured in any other suitable way (including, without limitation, casting, stamping, pressing, deep drawing, extrusion, machining and the like).

[0024] The in Fig. 1- Fig. 3, Fig. 5A and Fig. The tank reinforcement element 104 shown in Figure 5B has locking openings 112 configured to receive the seal 108. The locking openings 112 can be dimensioned to receive and retain sections of the seal 108 by means of an interference fit. The tank reinforcement element 104 shown also has cross ribs 116 that provide additional support to the tank reinforcement element 104. The cross ribs 116 enable the collection tank assembly 110 to withstand higher internal pressures and can enable the collection tank assembly 110 to withstand loads experienced by a collector being squeezed against the collection tank 100.

[0025] The illustrated seal 108 has first sections 120, also referred to as cross ribs or seal cross ribs, configured to provide additional support for the seal 108. In some embodiments, the first sections 120 extend over the inner chamber of the collection tank 100. In some embodiments, the seal 108 further has positioning projections 124 that guide the arrangement of the seal 108 within the locking openings 112 or locking slots (e.g., ensuring that the first sections 120 or cross ribs are correctly positioned within the collection tank 100 during installation of the seal 108, and / or holding a circumferential section of the seal 108 in a correct position within a seat 111 defined by the tank reinforcement element 104).

[0026] During operation, the tank reinforcement element 104 can be positioned in the collection tank 100 immediately after the collection tank 100 has been formed. Alternatively, the tank reinforcement element 104 can be positioned in the collection tank 100 at any time prior to use. The collection tank 100 can be shaped and dimensioned to accommodate the tank reinforcement element 104 by a clearance fit, a snap fit, an interference fit, or by any other engagement mechanism. Fig. 1- Fig. 3, Fig. 5A and Fig. The tank reinforcement element 104 shown in Figure 5B, for example, engages with the collection tank 100 via several sets of projections and openings. This engagement relationship allows the projections and openings to slide relative to one another until they reach a limit of movement (e.g., the underside of each opening), thus defining a necessary stop for a precise alignment of the tank reinforcement element 104 with respect to the collection tank 100. The precise alignment of the tank reinforcement element 104 enables proper sealing and compression without contact or interference with the heat exchanger collector. A locking feature or a heat riveting process can be used to provide further support and retain the tank reinforcement element 104 within the collection tank 100.

[0027] Due to the relationship between the seal 108 and the tank reinforcement element 104 described above with regard to some embodiments of the present invention, the seal 108 can be installed on the tank reinforcement element 104 (e.g., by pressing transverse webs 116 or other sections of the seal 108 into openings, hereinafter also referred to as locking openings 112 in the tank reinforcement element 104), and the tank reinforcement element 104 and the seal 108 can be moved or otherwise handled by a user or a machine for installation in the collection tank 100. In those embodiments in which there is an interference fit between the seal 108 and the tank reinforcement element 104 (e.g., within the locking openings 112 described above), this movement or handling can even arrange the tank reinforcement element and seal assembly in an inverted position.In view of the relationship described above between the seal 108 and the tank reinforcement element 104, the assembly of the resulting heat exchanger can be simplified and improved. The seal 108 can also be kept in the correct position relative to the collection tank 100 and the collector throughout the entire service life of the heat exchanger.

[0028] Although a separate tank reinforcement element 104, as described above, is desirable in many applications, it should be noted that in other embodiments the tank reinforcement element 104 and any of the sealing retention features described above may instead be integral with the collection tank 100 (e.g., formed as part of the collection tank 100).

[0029] Fig. 6A- Fig. Figure 6I represents collection tank arrangements 210 with tank reinforcement elements 203 according to other embodiments of the present invention. As in the illustrated embodiment of the above Fig. 1- Fig. 5B show the collection tank arrangements 210, which are in Fig. 6A- Fig. Figure 6I shows a collection tank 200 with a first collection tank section 200A and a collector 204, a tank reinforcement element 203, and a seal 208. The illustrated collection tank assemblies 210 are well suited, for example, for radiator and charge air cooler applications using brazed or through-sealed pipe-collector connections. As in the embodiment of Fig. 1- Fig. As provided in Figure 5B (but not shown therein), the collector 204 can be attached to flat tubes which are received in slot-shaped openings 216 in the collector 204. The tubes can be attached to and in the collector 204 in a pressure-tight manner by soft soldering, welding, adhesive or cohesive bonding material, or in any other suitable way.

[0030] In the embodiments of Fig. 6A- Fig. 6F and Fig. 6H- Fig. The collectors 204 shown in Figure 6I have a generally curved central section 220 and a circumferential extension 222 that extends laterally therefrom. The curved central section 220 has a convex shape towards the pipes and a concave shape towards the interior of the collection tank 200. The design of the illustrated collector 204 increases the strength of the collector 204 and the connections between the collector 204 and the pipes (not shown) by stiffening the collector 204 near the pipe-collector connections. The curved central section 220 also reduces compressive stresses both in the sealing recess 221 of the collector (i.e., the location where the seal 208 is held) and in the pipe ends. Therefore, it is possible to reduce the cross-sectional thickness of the individual components of the collection tank assembly 210 to achieve weight and cost savings.As a result of the increase in the mechanical strength of the collector 204 (and more generally the collection tank assembly 210), the service life of the collection tank assembly 210 and a correspondingly configured heat exchanger is extended without any additional material expenditure, heat exchanger components or individual production steps.

[0031] Due to the curved shape of the above-described and in Fig. 6A- Fig. 6F and Fig. 6H- Fig. In the central section 220 of the collector 204 shown in Figure 8, deformation of the collector 204 is also expected. It can be seen that under moderate collection tank pressures, deformation of a collector 204 without curvature is likely. However, due to the curved central section 220 of the collector 204, the collector 204 experiences a considerably reduced degree of deformation when subjected to compressive stress. Consequently, the mechanical stress at the connections between the inserted pipes and the collector is reduced, and the bending stress on the collector 204 (e.g., due to internal pressures of the collection tank 200) is converted into tensile stresses, thereby creating increased strength in the collector 204 and the collector-pipe connections.Since the strength of the collector 204 and / or the collector-pipe connections can decrease towards the center of the collector 204 in many embodiments, the curvature of the central section 220 of the collector 204 increases the strength of the collector 204 in the center of the collector 204.

[0032] With continued reference to the collector versions shown, Fig. 6A- Fig. 6F and Fig. 6H- Fig. 8 The collector 204 also has a substantially flat circumferential extension 222, which can extend around the entire circumference of the curved central section 220. This circumferential extension 222 can at least partially define a sealing recess 221 (mentioned above) in which a seal 208 is retained between the collector 204 and the first collection tank section 200A in any of the ways described above.

[0033] In some embodiments, the collector 204 of the collection tank 200 is made of plastic and is curved about a longitudinal axis of the collection tank 200, giving it a generally convex shape towards the pipes connected to it and a generally concave shape towards the interior of the collection tank 200. In other embodiments, other collector materials may be used instead, as desired. Any of the above in conjunction with the embodiment of Fig. 1- Fig. The material combinations described in 5B are in conjunction with Fig. 6A- Fig. 6I also applicable.

[0034] The pipes for the connection with the collectors 204, which are in Fig. 6A- Fig. The components shown in Figure 6I can have any desired cross-sectional shape. However, distinct advantages can be achieved by using flat tubes (i.e., tubes with opposing essentially wide flat sides connected by opposing narrow sides) connected to the collector 204.

[0035] The in Fig. 6A- Fig. 6F and Fig. 6H- Fig. The eight illustrated collection tank arrangements 210 each have a tank reinforcement element 203. The tank reinforcement element 203 can be essentially flat, as shown in Fig. 6A- Fig. 6F and Fig. 6H- Fig. 8, and can have any number of reinforcing ribs 212 extending longitudinally or transversely over the interior of the collection tank 200 (thereby increasing the strength of the collection tank 200) without obstructing or significantly impeding the flow through the collection tank 200 to or from the pipes connected to the collection tank 200. The tank reinforcing element 203 can be connected to the collection tank 200 in any of the ways described above. In some embodiments, for example, slots in the tank reinforcing element 203 accommodate collection tank structures with a snap closure, a press fit, or another mate engagement when the collection tank 200 is installed on a core of a heat exchanger. As shown in Fig. 6A- Fig. 6F and Fig. 6H- Fig. As shown in Figure 6I, in some embodiments the tank reinforcement element 203 is received in and / or rests on the collector 204. In some embodiments, the tank reinforcement element 203 lies in and / or on the circumferential extension 222 of the collector 204 and can extend below, under, or beside the seal 208. The tank reinforcement element 203 can increase the material thickness of the collector tank assembly 210 (for example, by doubling the thickness of the sealing recess 221), such as in a region of the collector tank 200 adjacent to the seal 208. The tank reinforcement element 203 can also reinforce the collector tank 200 in various ways, such as by enhancing the capability of tank-collector compression connections in high-pressure applications.

[0036] In some embodiments, the tank reinforcement element 203 can be joined to the collector 204 before or during core assembly. The tank reinforcement element 203 can be connected to the collector 204 in any desired manner, including, without limitation, brazing or welding, Tox rivets (Tox Pressotechnik GmbH & Co. KG), or any other desired method. A complete brazed connection between the collector 204 and the tank reinforcement element 203 can be used, for example, in those embodiments in which the tank reinforcement element 203 defines at least a partial sealing surface for the seal 208.

[0037] Some embodiments of the present invention use additional collection tank reinforcement elements alone or in combination with any of the above described (e.g. the tank reinforcement elements 104, 203). Fig. 6A and Fig. 6G- Fig. Section 6I provides examples of such reinforcing elements. Referring first to Fig. 6A The collection tank 200 can be provided with one or more reinforcements 250 extending from one or more walls of the collection tank 200 into a position where they engage with a tank reinforcement element 203, as shown schematically in Fig. 6A shown. These reinforcements 250 can have any desired shape, such as elongated fingers, as shown in Fig. 6A, Fig. 6H and Fig. 6I shows wider plates, as schematically shown in Fig. Figure 6G shows (in which case the reinforcements 250 can subdivide the interior of the collection tank 200 in some embodiments) and the like. These reinforcements 250 can also be integral with the collection tank 200 or can be separate elements permanently or detachably attached to it in some manner. The reinforcements 250 can be positioned and oriented such that they engage with the tank reinforcement element 203, thus limiting any bending or other movement of the collection tank 200. The reinforcements 250 can also be movable relative to the tank reinforcement element 203 (e.g., by means of a sliding fit, one or more dead-end connections, and the like), thereby enabling a force to be transmitted via the reinforcements 250 in one direction, but with no or limited capability for force transmission in an opposite or other direction.For example, it may be desirable for the reinforcements 250 to prevent outward bulging or outward bending of a collector tank wall while still allowing inward movement of the same wall, or to allow movement of one or more sections of the collector tank 200 (e.g., collector bending) in response to changes in heat exchanger tube expansion and contraction during heat exchanger operation. Although only two reinforcements 250 of the collector tank are located in specific positions in... Fig. 6A and Fig. 6G are shown and a specific number of such amplifications in Fig. 6H and Fig. As can be seen in Figure 6I, it is evident that any number of such reinforcements 250, extending over the interior of the collection tank 200, can be used, in many cases without interrupting the flow within the collection tank 200.

[0038] Fig. 9- Fig. Figure 13 represents heat exchangers that incorporate various features according to some embodiments of the present invention. Fig. 9, Fig. 10, Fig. 12 and Fig. 13. One option for any of the curved manifold heat exchangers described above is to use curved feedthrough seals 228. Such feedthrough seals 228 may be made of rubber, EPDM, or any other material suitable for creating a fluid-tight seal and may be installed inside the manifold tube openings 204 or at the ends of tubes inserted into the manifold tube openings 204. With particular reference to Fig. 12 and Fig.13 The illustrated feedthrough seal 228 has an opening 232 similar to the openings 216 in the collector 204 and is also configured to accommodate a flat tube 224. The feedthrough seals 228 in the illustrated embodiment are shaped to create an interference fit with the outside of the flat tubes to prevent fluid leakage through the collector-tube connections, while still allowing the tubes to undergo thermal expansion and contraction to move as required. Regardless of the cause of the tube movement, such feedthrough seals 228 can allow the tubes to move independently of each other and forward of the collector 204 (in some cases by sliding within the feedthrough seals 228). The feedthrough seal design can be used for plastic tank jets, charge air coolers, all-aluminum tank and collector assemblies, and a number of other heat exchanger applications.

[0039] The embodiments described above and illustrated in the figures are shown only as examples and are not intended to limit the concepts and principles of the present invention. A person skilled in the art will recognize that various modifications to the elements and their configuration and arrangement are possible without departing from the concept and scope of protection of the present invention.

Claims

[1] Heat exchanger containing: several tubes (224) each with opposite wide and essentially flat sides, connected by two opposite narrow sides; a collector (204) with several openings (216), each dimensioned to accommodate a corresponding pipe (224) of the several pipes (224); a collection tank (100) coupled to the collector (204) and having an inner chamber in fluid communication with the several pipes (224); a seal (108) arranged between the collection tank (100) and the collector (204); and a tank reinforcement element (104) extending over the inner chamber, wherein the seal (108) is installed on the tank reinforcement element (104), and the tank reinforcement element (104) holds the seal (108) in position between the collection tank (100) and the collector (204). [2] Heat exchanger according to claim 1, wherein the at least one tank reinforcement element (104) extends from one side of the inner chamber, across the inner chamber and to an opposite side of the inner chamber. [3] Heat exchanger according to claim 1, wherein the collector (204) is made of either metal or plastic and the collection tank (100) is made of either plastic or metal. [4] Heat exchanger according to claim 3, wherein the material of the collector (204) is separated from the material of the collection tank (100) by the seal (108). [5] Heat exchanger according to claim 1, wherein the seal (108) is held between a substantially flat projection of the collection tank (100) and at least one of the collector (204) and the at least one tank reinforcement element (104). [6] Heat exchanger according to claim 1, wherein at least one section (120) of the seal (108) extends over the inner chamber. [7] Heat exchanger according to claim 1, wherein a section of the reinforcement has several openings (112) which are each dimensioned to accommodate a respective section of the seal (108) extending therein. [8] Heat exchanger according to claim 1, wherein the collection tank (100) has a plastic collection tank; wherein the collector (204) has a metal collector coupled to the plastic collection tank, wherein the metal collector is elongated in a longitudinal direction and curved around a longitudinal axis of the metal collector, so that it has a concave shape towards the inner chamber and a convex shape away from the inner chamber, wherein the seal (108) at least partially separates the metal collector from the plastic collection tank and seals a gap (221) between the metal collector and the plastic collection tank, and wherein the tank reinforcement element (104) at least partially holds the seal (108) between the metal collector and the plastic collection tank in position. [9] Heat exchanger according to claim 8, wherein the seal (108) has a cross-sectional shape and is received within a seat (111) of the tank reinforcement element (104) with a corresponding shape. [10] Heat exchanger according to claim 1, wherein the collection tank (100) has several inserts and the tank reinforcement element (104) has several projections, wherein each of the several inserts engages with each of the several projections to connect the tank reinforcement element (104) and the seal (108) to the collection tank (100).

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