Heat exchanger with self-retaining bypass seal

Abstract

Gas / liquid heat exchanger (10), which features: (a) a core (12) having a length, a height and a pair of opposite sides (14, 16, 18, 20) extending along the length and height of the core (12), wherein the core (12) has several flat tubes (48) arranged in a stack with a space provided between each adjacent pair of the flat tubes (48), each of the flat tubes (48) having a hollow interior defining a liquid flow passage (50), and each of the spaces defining a gas flow passage (52); wherein each of the flat tubes (48) has a pair of circumferential edges (26, 28) extending along the length of the core (12), wherein the circumferential edges (26, 28) of the flat tubes (48) partially define the sides (18, 20) of the core (12); wherein each of the gas flow passages (52) has a pair of open ends (22, 24) and a pair of opposite sides (51, 53), wherein a width (W1) of each of the gas flow passages (52) is defined between the opposite sides (51, 53) and the opposite sides (51, 53) of the gas flow passages (52) partially define the sides (18, 20) of the core (12); wherein the core (12) has a first region (106) in which the flat tubes (48) have a first width (W) that is greater than the width (W1) of each of the gas flow passages (52), wherein the first width (W) is defined between the circumferential edges (26, 28) of the flat tubes (48) in the first region (106);wherein the core (12) has a second region (108) in which the flat tubes (48) have a second width (W3) which is the same as the width (W1) of each of the gas flow passages (52), wherein the second width (W3) is defined between the circumferential edges (26, 28) of the flat tubes (48) in the second region (108); ; (b) a housing (34) surrounding the core (12), the housing (34) having an inlet end region (36) with a gas inlet opening (40) and an outlet end region (38) with a gas outlet opening (42), wherein the gas inlet and outlet openings (40, 42) communicate with the open ends (22, 24) of the gas flow passages (52) of the core (12); wherein the housing (34) includes at least one lateral cover (68, 70) extending along and at a distance from at least one side (18, 20) of the core (12), wherein a first gap (110) between the lateral cover (68, 70) and the side (18, 20) of the core (18, 20) in the first region (106) of the core (12) is smaller than a second gap (112) between the lateral cover (68, 70) and the side (18, 20) of the core (12) in the second region (108) of the core (12); and (c) a lateral seal (120, 122) which is at least partially incorporated in the gap (112) between the lateral cover (68, 70) of the housing (34) and the second area (108) of the core (12); wherein the lateral seal (120, 122) extends over the height of the core (12) and has a thickness greater than the first gap (110), wherein the seal (120, 122) is elastic and has an uncompacted thickness greater than the second gap (112), wherein the seal (120, 122) has a U-shape with two legs (128, 130) having ends (134, 136) that engage with the core (12) in its second section (10), wherein the second area (108) of the core (12) contains locking elements (138) which engage with and hold the ends (134, 136) of the legs (128, 130), and wherein the ends (134, 136) of the legs (128, 130) have areas of increased thickness which are designed to engage with and be held by the locking elements (138).

Description

AREA OF INVENTION

[0001] The invention relates generally to heat exchangers for cooling a hot gas with a liquid coolant, and in particular to gas / liquid charge air coolers with a housing enclosing a heat exchanger core. BACKGROUND OF THE INVENTION

[0002] Gas / liquid heat exchangers are known to be used to cool compressed charge air in turbocharged internal combustion engines or fuel cell engines, or to cool hot engine exhaust gases. For example, compressed charge air is typically generated by compressing ambient air. During compression, air can be heated to a temperature of around 200 °C or higher and must be cooled before it reaches the engine.

[0003] Several gas-cooled heat exchanger designs are known. For example, gas-cooled heat exchangers generally have an aluminum core consisting of a stack of tubes or plate pairs, with each tube or plate pair defining an internal coolant passage. The tubes or plate pairs are spaced apart, defining gas flow passages that are typically equipped with turbulence-enhancing inserts to improve heat transfer from the hot gas to the liquid coolant.

[0004] In some gas / liquid intercoolers, the aluminum core is enclosed in a housing, typically made of a different material such as plastic. The housing typically includes coolant inlet and outlet ports that are sealed to the coolant passages within the tubes or plate pairs. The housing also contains gas inlet and outlet ports and provides distribution spaces for the gas flow; the core's gas flow passages are open to the interior of the housing.

[0005] Typically, gaps exist between the heat exchanger core and the casing. Along the sides of the core, these gaps are present partly due to the distance between the tubes or plate pairs and the interior of the casing, and partly due to the distance between the edges of the tubing-enhancing inserts and the interior of the casing. If left open, the gaps along the sides of the core allow excessive bypass flow of the warm charge air, reducing the efficiency of the heat exchanger. Therefore, it is common for the casing to incorporate bypass blocking elements with a comb-like profile and fingers extending into the spaces between the tubes or plate pairs. A heat exchanger with bypass blocking elements of this type is described in the joint applicant's provisional U.S. patent application No. 61 / 985,588, which is incorporated herein in its entirety.DE 10 2006 005 106 A1 also discloses a heat exchanger which has a strip inside the housing between two end chambers, extending over at least a substantial part of the end chamber length. DE 10 2008 024 386 A1 describes a seal for sealing a gap between an exhaust gas cooler and a housing encompassing it, and DE 10 2004 017 339 A1 describes a sealing arrangement for a heat exchanger arranged in an air duct. DE 43 13 506 A1 describes a disc-type oil cooler.

[0006] Due to the irregular shape of the core, it is difficult to provide a bypass seal that effectively blocks the bypass flow, is easy to manufacture, and remains in place during the manufacture and use of the heat exchanger.

[0007] There is a need for gas-cooled heat exchangers that offer high reliability while avoiding excessive material and / or manufacturing costs. SUMMARY OF THE INVENTION

[0008] This problem is solved by a gas / liquid heat exchanger according to claim 1. In one embodiment, a gas / liquid heat exchanger is provided, comprising a core with a length, a height, and a pair of opposite sides extending along the length and height of the core. The core has several flat tubes arranged in a stack, with a space between each adjacent pair of flat tubes, each of the flat tubes having a hollow interior defining a liquid flow passage, and each of the spaces defining a gas flow passage. Each of the flat tubes has a pair of circumferential edges extending along the length of the core, the circumferential edges of the flat tubes partially defining the sides of the core.Each of the gas flow passages has a pair of open ends and a pair of opposite sides, the width of each gas flow passage being defined between the opposite sides, and the opposite sides of the gas flow passages partially defining the sides of the core. The core has a first region in which the flat tubes have a first width greater than the width of each of the gas flow passages, the first width being defined between the circumferential edges of the flat tubes in the first region. The core has a second region in which the flat tubes have a second width that is substantially the same as the width of each of the gas flow passages.

[0009] Gas flow passages are defined, where the second width is defined between the circumferential edges of the flat tubes in the second area.

[0010] The heat exchanger further comprises a casing that surrounds the core. The casing has an inlet end with a gas inlet port and an outlet end with a gas outlet port, the gas inlet and outlet ports communicating with the open ends of the core's gas flow passages. The casing includes at least one side cover extending along at least one side of the core and at a distance from it, wherein a first gap between the side cover and the side of the core in the first region of the core is narrower than a second gap between the side cover and the side of the core in the second region of the core.

[0011] The heat exchanger also features a side seal, which is at least partially contained within the gap between the side cover of the housing and the second section of the core. The side seal extends the full height of the core and has a thickness greater than that of the first gap.

[0012] In one embodiment, each of the gas flow passages is provided with a turbulence-enhancing insert. In one embodiment, each of the turbulence-enhancing inserts has a corrugated rib defined by several parallel sidewalls extending along the length of the core, the sidewalls having upper and lower ridges at which they are connected to each other and to adjacent of the flat tubes. In one embodiment, each of the corrugated ribs has a pair of side edges between which a width of the corrugated rib is defined, wherein at least one of the side edges of the corrugated rib is defined by an outermost sidewall of the corrugated rib, and wherein the outermost sidewall is substantially free of perforations and defines one of the opposite sides of one of the gas flow passages.

[0013] In one embodiment, each of the side edges of the corrugated rib is defined by one of the outermost side walls of the corrugated rib. In another embodiment, each of the corrugated ribs has a width that defines the width of the gas flow passage in which it is arranged, such that each of the opposite sides of each of the gas flow passages is defined by one of the outermost side walls of the corrugated rib.

[0014] In one embodiment, each of the flat tubes has a pair of core plates with a planar circumferential flange surrounding a raised central surface, the circumferential edges of the tubes being defined by portions of the planar circumferential flange extending along the length of the core. In another embodiment, each of the raised central surfaces of the core plates and each of the fluid-flow passages of the flat tubes has a width in the second region of the core that is less than a width in the first region of the core. In another embodiment, the planar circumferential flanges include inwardly extending regions in the second region of the core. In another embodiment, the inwardly extending regions extend inward by a maximum length that is substantially equal to a width of the planar circumferential flange along the first region of the core.In one embodiment, each of the inwardly extending areas contains a locking element designed to engage with and hold an inner edge of the side seal.

[0015] In one embodiment, the second region of the core has a length that is shorter than the length of the first region of the core.

[0016] In one embodiment, the second area forms a recessed channel that extends over essentially the entire height of the core.

[0017] In one embodiment, the core further comprises an upper and a lower side, the housing comprising an upper cover arranged over the upper side of the core, a lower cover arranged over the lower side of the core, and a pair of side covers over the sides of the core. In one embodiment, the lower side of the core is spaced from the lower cover of the housing, and a lower seal is arranged between the lower side of the core and the lower cover of the housing. In another embodiment, the upper side of the core is spaced from the upper cover of the housing, and an upper seal is arranged between the upper side of the core and the upper cover of the housing. In another embodiment, the upper seal or the lower seal is partially embedded in a groove in the upper cover or the lower cover of the housing.

[0018] In one embodiment, the seal is elastic and has an uncompressed thickness greater than that of the second gap. In another embodiment, the seal includes several legs with ends that engage with the core in its second region. In yet another embodiment, the seal has a U-shape with two of the legs. In yet another embodiment, the second region of the core includes locking elements that engage with and hold the ends of the legs. In yet another embodiment, the ends of the legs have regions of increased thickness configured to engage with and be held by the locking elements.

[0019] In one embodiment, the side seals, the top seal, and the bottom seal have a continuous sealing portion that extends along the top, bottom, and side surfaces of the core. In one embodiment, all areas of the continuous seal lie in a single transverse plane. In another embodiment, the continuous seal has an elongated elastic portion. In another embodiment, the continuous seal includes foldable corner sections designed to fold over corners between the sides and the adjacent top and bottom surfaces of the core. In another embodiment, the foldable corner sections have notches that extend partially through the thickness of the continuous seal. In another embodiment, the notches are V-shaped and open toward the core.

[0020] In one embodiment, the heat exchanger includes two or more of the side seals that are spaced apart from each other along the length of the core, the core having two of the second areas in which the flat tubes have a second width that is substantially the same as the width of each of the gas flow passages.

[0021] In one embodiment, one of the opposite sides of each of the gas flow passages is defined by coolant inlet and outlet distributors of the core. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The invention will now be described only by way of example with reference to the accompanying drawings, in which: Fig. 1 is a perspective view showing the exterior of a heat exchanger according to a first embodiment disclosed herein; Fig. 2 a perspective top view of a core plate of the heat exchanger according to Fig. 1 is; Fig. 3 shows an enlarged view of an edge of the core and also the side seal and a side cover of the housing; Fig. 4 a perspective view of the heat exchanger according to Fig. 1 with the partially cut-away casing; Fig. 5 a side view of the heat exchanger after Fig. 1 is where the casing is partially cut away to show the core; Fig. 5B a top view of the heat exchanger according to Fig. 1 is, cut along a plane parallel to the core plates; Fig. 5C shows parts of a side seal and a bottom seal joined at a corner; Fig. 6 is a perspective view showing the exterior of a heat exchanger according to a second embodiment disclosed herein; Fig. 7 a side view of the heat exchanger after Fig. 6 is where the casing is partially cut away to show the core; Fig. 8 a top view of the heat exchanger according to Fig. 6 is where the casing has been cut away to show the core; Fig. 9 a top view similar Fig. 8 is, but is cut along a plane parallel to the core plates; Fig. 10 an enlarged cross-section along line 10-10' in Fig. 7 is; Fig. 11 an enlarged cross-section along line 11-11' in Fig. 7 is, from which the sealing part has been removed for the sake of clarity; Fig. 12 an isolated perspective view of a core plate of the heat exchanger according to Fig. 6 is; Fig. 13 an enlarged view of part of the core plate in Fig. 12 is; Fig. 14 is an enlarged view of the edge of the core with the side seal removed; Fig. 15 is an enlarged view of an edge of the core, which also shows the side seal and a side cover of the housing; Fig. 16 is an isolated sectional view of part of the side seal; Fig. 17 a partial cross-section through the first area of ​​the core of the heat exchanger in Fig. 6 is; Fig. 18 a partial cross-section through the second area of ​​the core of the heat exchanger in Fig. 6 is; Fig. Shows 19 parts of a side seal and a top seal joined at a corner; Fig. Figure 20 shows a continuous sealing element in a straight configuration; Fig. 21 the continuous sealing part in Fig. 20 shows that it is placed around a heat exchanger core; Fig. 22 a perspective view of the core of a heat exchanger according to a third embodiment; Fig. 23 a side view of the heat exchanger after Fig. 23, where part of the casing has been cut away; Fig. 24 a front view of the heat exchanger after Fig. 23 is, with part of the casing cut away; and Fig. 25 an expanded view of the core of the heat exchanger in Fig. 23 is. DETAILED DESCRIPTION

[0023] A heat exchanger 10 according to a first embodiment is described below with reference to the Fig. 1 to 5C described.

[0024] The heat exchanger 10 is an intercooler for a motor vehicle powered by an engine that requires compressed charge air, such as a turbocharged internal combustion engine or a fuel cell engine. The heat exchanger 10 can be installed downstream of an air compressor and upstream of an engine air intake manifold to cool the hot compressed charge air before it reaches the engine. However, in some embodiments, the heat exchanger 10 can be integrated with the intake manifold, as discussed further below. In the following description, the coolant circulating through the heat exchanger 10 is a liquid coolant, which can be the same as the engine coolant, which can be water or a water / glycol mixture.

[0025] It should be noted that the specific arrangement and locations of the air and coolant inlet and outlet openings depend at least partially on the specific configuration of a vehicle's air intake system and may vary from application to application.

[0026] As in the Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. As shown in Figure 5, the heat exchanger 10 has a core 12 with an upper side 14, a lower side 16, a first and a second side 18, 20, an inlet end 22, an outlet end 24, coolant openings 25, 27, coolant distributors 54, 56, and a gas inlet and outlet opening 30, 32 located at the inlet and outlet ends 22, 24. The core 12 has a length L, defined between the inlet and outlet ends 22, 24, a width W, defined between sides 18 and 20, and a height H, defined between the upper side 14 and the lower side 16. The dimensions H and L are shown in Figure 5. Fig. 5 shown, and the dimensions L and W are also related to the core plate 100 in Fig. 2 shown.

[0027] It is evident that the first side 18 extends along the length L and height H of the core 12, as does the second side 20. In the present embodiment, the overall shape of the core 12 is that of a rectangular prism, in which the width W of the core 12 is greater than the length L of the core 12.

[0028] The core 12 of the heat exchanger 10 typically consists of a metal such as aluminum or an aluminum alloy, with the components of the core 12 being joined together by brazing. The term "aluminum" as used in relation to all embodiments described herein is intended to include aluminum and its alloys.

[0029] The structure of the core 12 is variable, and the specific construction according to the first embodiment is only one example of a possible core construction. The core 12 has a stack of flat tubes 48, each tube having a hollow interior defining a coolant flow passage 50, and a pair of opposing circumferential edges 26, 28 extending along the length L of the core 12, the circumferential edges 26, 28 of the flat tubes 48 partially defining the sides 18, 20 of the core 12.

[0030] The flat tubes 48 are arranged in a stack with spaces located between adjacent pairs of flat tubes 48, these spaces defining several gas flow passages 52. The gas flow passages 52 extend from the inlet end 22 to the outlet end 24 of the core 12 along the length L of the core 12. As can be seen, each of the gas flow passages 52 has a pair of open ends near the ends 22, 24 of the core 12, and a pair of opposite sides, namely a first side 51 and a second side 53, which extend along the length L of the core 12. A width W1 ( Fig. 5B) Each of the gas flow passages 52 is defined between the opposite sides 51, 53 of these, and the opposite sides 51, 53 of the gas flow passages 52 partially define the sides 18, 20 of the core 12.

[0031] The gas flow passages 52 extending longitudinally through the core 12 can be provided with turbulence-enhancing inserts such as corrugated fins or turbulencers to obtain increased turbulence and a larger surface area for heat transfer, and to provide structural support for the core 12. In the illustrated embodiment, the turbulence-enhancing inserts have several corrugated fins 62. Each of the corrugated fins 62 has a pair of side edges 63, 65, between which the width W2 of the corrugated fin 62 is defined, as shown in Fig. Figure 5B is shown. In some embodiments, the width W2 corresponds to, or is essentially the same as, the width W1 of the gas flow passage 52 in which it is arranged. However, in the present embodiment, the width W2 of each corrugated rib 62 is less than the width W1 of the gas flow passage 52 in which it is arranged, as will be discussed further below.

[0032] It is intended that the terms “rib” and “turbulizer” as used herein refer to corrugated, turbulence-enhancing inserts having multiple axially extending ridges or serrations connected by sidewalls, the ridges being rounded or flat. As defined herein, a “rib” has continuous ridges, while a “turbulizer” has ridges that are interrupted along their length, causing axial flow to swirl through the turbulizer. Turbulizers are sometimes referred to as offset or pierced strip ribs, and examples of such turbulencers are described in U.S. Patent No. 35,890 E (So) and U.S. Patent No. 6,273,183 B1 (So et al.). The patents of So and So et al. are incorporated herein in their entirety.

[0033] The wavy ribs 62 of the present embodiment are represented as a cross-hatched area in Fig. 5B shown. However, the corrugated ribs according to the present embodiment are the same as those of the second embodiment described below, having several parallel side walls 44 extending along the length L of the core 12, the side walls 44 having ridges 46 on their upper and lower sides along which they are connected to each other and to adjacent flat tubes 48. The corrugated ribs 62 as in the Fig. 10, Fig. 11, Fig. 17 and Fig. Figure 18 illustrates the wavy ribs 63 of the present embodiment.

[0034] The waveforms defined by the corrugated ribs 62 are open at the ends 22, 24 of the core 12. Each of the side edges 63, 65 of the corrugated rib 62 is defined by one of the outermost side walls 44 of the corrugated rib 62.

[0035] It's out Fig. As can be seen in Figure 5B, one side edge 63 of each corrugated rib 62 is located at and extends along the first side 51 of one of the gas flow passages 52. The other side edge 65 of each corrugated rib 62 is spaced from the second side 53 of one of the gas flow passages 52, as will be discussed further below. Along the side edge 63 of the corrugated ribs 62 located at the first sides 51 of the gas flow passages 52, at least one outermost side wall 44 is substantially free of perforations. It is advantageous that at least the outermost side wall 44 located at the first side edge 63 of each corrugated rib 62 is substantially free of perforations in order to minimize the amount of gas that escapes from and bypasses the corrugated rib 62.The opposing side edges 65 of the corrugated ribs 62, which are located towards the second sides 53 of the gas flow passages (but at a distance from them), can likewise be substantially free of perforations. In embodiments where it is desirable to provide the side walls 44 with lamellar slots or other types of perforations (not shown), at least the outermost side wall 44 can be deformed such that the perforations are substantially closed, or the corrugated rib 62 can be provided in several sections, comprising a central section with lamellar slots or other perforations, and one or two edge sections arranged along the side edges 63, 65 and free of perforations.

[0036] The 48 tubes can have different designs and consist of pairs of core plates 100 ( Fig. 2), each of which has a flat circumferential flange 102 surrounding a raised central surface 104. The flat tubes 48 are formed by joining a pair of core plates 100 facing each other, the core plates 100 being sealed along their circumferential flanges 102, for example by brazing. In the assembled tube 48, the coolant flow passage 50 is defined by the raised central surfaces 104 of the joined plates 100 and is sealed around its edges by the joined circumferential flanges 102. The core plates 100 according to the present embodiment are mirror images of each other and can optionally be identical.

[0037] As shown, parts of the planar circumferential flanges 102, which extend along the length of the core 12, define the circumferential edges 26, 28 of the flat tubes 48.

[0038] The coolant flow passages 50 of the core 12 are connected by a pair of coolant distributors 54, 56. In the illustrated embodiment, the distributors 54, 56 are separated by open, raised ridges or bubbles 55, 57 (shown in Fig. 2) in each of the plates 100 forming the tubes 48, the ridges of adjacent pairs of plates are connected to form continuous distributors 54, 56. The distributors 54, 56 are connected to each of the coolant flow passages 50 and extend over the height of the core 12 from the upper side 14 to the lower side 16. The lower ends of the distributors 54, 56 are closed by a bottom plate 58, which defines the bottom 16 of the core 12, while the upper side 14 of the core 12 is defined by a top plate 60 in which the coolant openings 25, 27 are defined.

[0039] In the heat exchanger 10 according to the first embodiment, the two coolant distributors 54, 56 are located adjacent to the second side 20 of the core 12 near the edge 28, wherein the coolant flow passages 50 are U-shaped, as shown in the Fig. 2 and Fig. As can be seen in Figure 5B. Thus, the directions of the air and coolant flow in the heat exchanger 10 are essentially perpendicular to each other (cross-flow arrangement). In other embodiments described here, the coolant distributors can have a mutual distance along the length L of the core 12, such that the air and coolant flow run in opposite directions (counter-flow arrangement) or in the same direction (co-flow arrangement).

[0040] The heat exchanger 10 further comprises a housing 34 surrounding the core 12, the housing having an inlet end 36 and an outlet end 38. The inlet end 36 contains a gas inlet port 40 that communicates with the gas inlet port 30 of the core 12, which can be connected directly or indirectly to an upstream component of a vehicle engine system, such as an air compressor (not shown). The outlet end 38 contains a gas outlet port 42 that communicates with the gas outlet port 32 of the core 12, which can be connected directly or indirectly to a downstream component of a vehicle engine system, such as an intake manifold (not shown). In some embodiments, the housing 34 can include an intake manifold of a vehicle engine, in which case the gas inlet port 32 of the core 12 can communicate directly with the vehicle engine (not shown).For the following description, it should be noted that references to the housing 34 include embodiments in which the housing is an inlet distributor.

[0041] To simplify assembly, the housing 34 typically has two or more separately formed segments, as described, for example, in the aforementioned US patent application No. 61 / 985 588. However, the specific design of the housing 34 is not necessarily essential to the invention, and therefore these details are omitted from the present discussion and the drawings.

[0042] The housing 34 includes at least one side cover 38 or 70 extending along at least one side 18 or 20 of the core 12 and at a distance from it. In the illustrated embodiment, the housing 34 is continuous and surrounds the core 12, comprising a pair of side covers 68, 70 over the sides 18, 20 of the core 12, and further comprising an upper cover 64 arranged over the upper side 14 of the core 12, and a lower cover 66 arranged over the upper side 16 of the core 12. Together with the end regions 36, 38, the covers 64, 66, 68, 70 of the housing 34 form a substantially continuous enclosure of the core 12, with the exception of an inlet and an outlet opening, respectively, for the gas and the coolant.

[0043] In the present embodiment, the upper cover 64 of the housing 34 can be separated from the rest of the housing 34, such that the core 12 is inserted into the housing 34 from above, and the upper cover 64 is then sealed against the rest of the housing 34. Optionally, in the present embodiment, the upper cover 64 is integrated with the core 12, comprising a relatively thick flat flange plate 160 ( Fig. 5), which may be made of aluminum and whose lower surface is brazed to the upper plate 60 of the core 12. The flange plate 160 is provided with a pair of coolant openings 72, 74 that communicate with the coolant distributors 54, 56, and the upper surface of the flange plate 160 is provided with a pair of coolant ports 78, 80. The edges of the flange plate 160 are sealed to the rest of the housing 34 by any suitable means, such as a mechanical connection, brazing, or welding. The terms “upper” and “lower” are used with respect to the housing 34 as terms of suitability and do not necessarily indicate that the housing 34 must have a particular orientation in use.

[0044] The coolant openings 25, 27 of the core plates 100 and the upper plate 60 enable communication between the distributors 54, 56 and the coolant openings 72, 74, which are arranged in the upper cover 64 of the housing 34 (the flange plate 160 in the present embodiment). Furthermore, coolant connections 78, 80 communicate with the respective coolant openings 72, 74 and are adapted for connection to coolant lines (not shown) in a coolant circulation system (not shown).

[0045] In the first embodiment, both sides 18, 20 of the core 12 are spaced from the respective side covers 68, 70 of the housing 34, and the lower side 16 of the core 12 is spaced from the lower cover 66 of the housing 34. In this particular embodiment, as described above, the upper side 14 of the core 12 is in direct contact with the flange plate 160, which defines the upper cover 64 of the housing 34. In other embodiments, the distance between the upper side 14 of the core 12 and the upper cover 66 can be so small that it is negligible with respect to the bypass flow.

[0046] The corrugated fins 62 impart a certain resistance to the gas flow to the core 12, and therefore the gas to be cooled tends to bypass the corrugated fins 62 and flow through any spaces located outside the side edges 63, 65 of the corrugated fins 62, including any spaces between the housing 34 and the core 12 that allow free flow between the gas inlet opening 40 and the gas outlet opening 42 of the housing 34, such as the aforementioned spaces between the housing 34 and the core 12. Similarly, due to the location of the distributors 54, 56 within the gas flow passage 52, the gas to be cooled tends to flow around the outer edges of the distributors 54, 56 through the space between the core 12 and the housing 34.

[0047] The spaces between core 12 and side covers 68, 70 of case 34 are best made of the Fig. 3 and Fig. 5B. This distance results partly from the distance between the circumferential edges 26, 28 of the tubes 48 and the side covers 68, 70 of the housing 34, partly from the distance between the side edge 63 of the corrugated fins 62 and the side cover 68 of the housing 34, and partly from the distance between the outer edges of the coolant inlet and / or outlet distributor 54, 56 and the side cover 70 of the housing 34. If these are left open, they allow excessive bypass flow of the gas, thereby reducing the efficiency of the heat exchanger 10.

[0048] In the core construction of the first embodiment, the circumferential edges 26, 28 of the tubes 48 consist of the circumferential flanges 102 of the core plates 100 from which the tubes 48 are formed. As shown from Fig. As can be seen in Figure 5B, the side edges 63 of the corrugated ribs 62 do not extend to the circumferential edges 26 of the circumferential flanges 102 of the tubes 48. For this reason, the first side 18 of the core 12 has an irregular, comb-like shape. As discussed above, it is difficult to achieve a reliable seal against this irregular surface.

[0049] Similarly, the coolant inlet and outlet distributors 54, 56 do not extend to the circumferential edges 28 of the circumferential flanges 102 along the second side 20 of the core 12, and for this reason the second side 20 has an irregular comb-like shape which is difficult to seal.

[0050] According to the first embodiment, the difficulty of forming seals against the first and second sides 18, 20 of the core 12 is overcome by modifying the shapes of the first and second sides 18, 20. In this respect, the core 12 has at least a first region 106 in which the flat tubes 48 have a width W (measured between the circumferential edges 26 and 28 in this first region 106, and shown in the Fig. 2 and Fig. 5B) have, which is greater than the width W1 of each of the gas flow passages 52 defined above.

[0051] In the first regions 106 of the core 12, the corrugated fins 62 are arranged only between regions of tubes 48 through which the coolant circulates, these regions being defined by the raised central regions 104 of the core plates 100. Therefore, along the first side 18 of the core 12, the side edges 63 of the corrugated fins 62 terminate at or near the edges of the coolant flow passages 50. Similarly, on the second side 20 of the core 12, the distributors 54, 56 are arranged in regions of tubes 48 through which the coolant circulates, and therefore, along the second side 20 of the core 12, the outer edges of the distributors 54, 56 are located at or near the edges of the coolant flow passages 50.

[0052] Therefore, in the first regions 106 of the core 12, the sealed circumferential flanges 102 of the core plates 100 project outwards over the edges 63 of the corrugated ribs 62 along the first side 18, and in the same way, the sealed circumferential flanges 102 project outwards over the outer edges of the distributors 54, 56 along the second side 20, thereby forming the irregular comb-like shape along both the first and the second sides 18, 20, as described above. Three such first regions 106 are included in the present embodiment, and they are shown in Fig. 5B is designated with 106a, 106b and 106c.

[0053] As in Fig. As shown in Figure 5B, the core 12 according to the present embodiment also contains at least a second region 108 in which the flat tubes 48 have a width W3 (measured between the circumferential edges 26 and 28 in the second regions 108, and shown in Fig. 5B), which are essentially the same as the width W1 of each of the gas flow passages 52. The present embodiment includes two of these second areas, which are in Fig. 5B will be designated as 108a and 108b.

[0054] These narrower second regions 108 of the core 12 are formed by extending the circumferential flanges 102 inwards to the centers of the flat tubes 48 in these second regions 108. This results in a local reduction in the width of the raised central regions 104 of the core plates 100 and a corresponding reduction in the width of the coolant flow passages 50 in the second regions 108, while the width W1 of the gas flow passages 52 and the width W2 of the corrugated fins 62 are the same across the first and second regions 106, 108. The reduction in width in the second regions 108 is sufficient such that the width W3 between the circumferential edges 26, 28 in at least a portion of each second region 108 is substantially the same as the width W of the gas flow passages 52, within acceptable manufacturing tolerances.It can be seen from the drawings that the width W3 corresponds to the minimum width between the circumferential edges 26, 28 within the second areas 108, and that the width of the circumferential flange 102 is somewhat variable in the second areas 108. It is important to note that a certain minimum width of the circumferential flange 102 must be maintained within the second areas 108 to ensure a reliable seal of the coolant flow passages 50, and this requirement is responsible for the narrowing of the coolant flow passages 50 in these areas.

[0055] With the configuration described above, it is best to use the following: Fig. 3 and Fig. As can be seen in Figure 5B, there is a first gap 110 between the side cover 70 and the second side 20 of the core 12 in the first areas 106 of the core 12, wherein the first gap 110 is smaller than a second gap 112 between the side cover 70 and the second side 20 of the core 12 in the second areas 108 of the core 12. Similarly, a first and a second gap 110, 112 exist between the first side 18 of the core 12 and the side cover 68 of the housing, as shown in Figure 5B. Fig. 5B is shown. It should be noted that the second gap 112 is the distance between the housing 34 and every second region 108 of the core 12, and more precisely between the housing 34 and those parts of the second regions 108 where the width W3 between the circumferential edges 26, 28 is essentially the same as the width W of the gas flow passages 52, with acceptable manufacturing tolerances.

[0056] The locations and relative lengths of the first and second regions 106, 108 of the core 12 along the length L of the core 12 are variable. For example, in the present embodiment, the second regions 108a, 108b are located near the ends of the core 12, and three regions 106a, 106b, and 106c are provided. In other embodiments, a second region 108 may be provided, which can be located anywhere along the length L of the core 12.

[0057] In the present configuration, the length of the first regions 106 (i.e., the combined lengths 106a, 106b, and 106c) is greater than the individual and combined lengths of the second regions 108a and 108b, where the lengths of regions 106 and 108 are measured along the length L of the core 12. The lengths of regions 106 and 108 may differ from those shown. However, it will be evident from the following description that, for a number of reasons, it is desirable to make the second regions 108 shorter than the first regions 106.

[0058] As mentioned above, the second regions 108 of the core 12 are formed by inwardly extending regions 114 of the circumferential flanges 102 of the core plates 100. The maximum length of the inward extension of the circumferential flange 102 can be approximately equal to the width of the circumferential flange 102. As can be seen from the Fig. 3 and Fig. As can be seen in Figure 5B, the inward extension of the flanges 102 along the first side 18 of the core 10 results in an edge region of the corrugated rib 62 that extends beyond the raised central surfaces 104 of the core plates 100 and the coolant flow passages 50, due to the reduction in the width of the central surfaces 104 and the coolant flow passages 50, as shown on the left side of Figure 5B. Fig. 5B is shown. Thus, the side edges 63 of the corrugated ribs 65 are not supported in the inwardly extending area 114 of the circumferential flange 102, resulting in narrow gaps 98 (in Fig. (11 shown) between the unsupported area of ​​the corrugated fin 62 and the adjacent flat tube 48. The inventors found that this gap 98, due to its small size, does not result in a significant bypass gas flow, and due to the convoluted path the gas must follow to flow through this gap 98. It should be noted that the appearance of the core 12 of the heat exchanger 10, as shown on the left side of Fig. 5B shows that when cut in a plane extending through the height H of kernel 12, it has an essentially identical appearance to that shown in the Fig. 11 and Fig. The core 12 of the heat exchanger 200 is shown.

[0059] In the first embodiment, the provision of the narrower second regions 108 of the core 12 results in the formation of relatively narrow side channels 116, 118, which extend over substantially the entire height H of the core 12. These side channels 116, 118 extend at substantially right angles to the length L of the core 12, although it should be noted that in some embodiments the side channels 116, 118 may instead be angled relative to the length L. An enlarged view of one of the side channels 116 is shown in Fig. Figure 14 shows the side channels 116, 118, and the side channels 116, 118 according to the present embodiment are identical in appearance. At least one side channel 116, 118 is arranged along each of the sides 18, 20 of the core 12. For example, in the heat exchanger 10 according to the first embodiment, there are two side channels 116 along the first side 18 of the core 12 and two side channels 118 along the second side 20 of the core 12.

[0060] The heat exchanger 10 further comprises at least one side seal 120 and at least one side seal 122. Each side seal 120 is at least partially incorporated in the second gap 112 and in the side channel 116 along the first side 18 of the core 12, and each side seal 120 is at least partially incorporated in the second gap 112 and in the side channel 118 along the second side 20 of the core 12. The side seals 120, 122 extend over the height H of the core 12 and the heights of the side channels 116, 118.

[0061] The following description focuses primarily on the features of each side seal 120, noting that in the present embodiment, each side seal 122 is identical. The following description refers to the side seals of the second embodiment as described in the Fig. 16 and Fig. Reference is made to the side seals shown in Figure 19, which are identical to the side seals 120, 122 with the exceptions specifically set out below.

[0062] It is evident that the side seal 120 has at least one outer edge 124 which is in substantially sealed engagement with the side cover 68 of the housing 34, and at least one inner edge 126 which is in substantially sealed engagement with the first side 18 of the core 12 in one of the second regions 108 thereof, i.e., with the circumferential edges 26 of the flat tubes 48 and the outermost side walls 44, which are arranged along the side edges 63 of the corrugated ribs 62. As can be seen from Fig. As can be seen in Figure 16, the side seals 120, 122 have a thickness T, and this thickness is greater than the width of the first gap 110.

[0063] Similarly, the side seal 120 has at least one outer edge 124 which is in substantially sealed engagement with the side cover 70 of the housing 34, and at least one inner edge 126 which is in substantially sealed engagement with the second side 20 of the core 12 in the second area 108 thereof, i.e., with the circumferential edges 28 of the flat tubes 48 and in close proximity to or in contact with the outer edges of one of the coolant inlet and outlet manifolds 54, 56. This is best seen from Fig. 3 visible.

[0064] The inner and outer edges 126, 124 of the side seal 120 are straight edges, which means that the structure of the side seal 120 has a relatively simple shape and is less expensive to manufacture than known seals that have a comb-shaped inner edge. For example, the side seal 120 can be easily manufactured by extrusion, followed by cutting the extruded profile into segments of the desired length. Alternatively, the side seal 120 can be manufactured by any other suitable means, such as by molding.

[0065] The side seal 120 can be made of an elastic material such as a foamed polymer. If the side seal 120 is elastic, it has a thickness sufficient to withstand some compression when placed between the core 12 and the housing 34. For example, the side seal 120 can have an uncompressed thickness greater than the width of the second gap 112.

[0066] The cross-sectional shape of the side seal 120 is highly variable. For example, the side seal 120 can have a simple cross-sectional shape such as square, rectangular, circular, oval, etc. In the present embodiment, as shown in Fig. As shown in Figure 16, the side seal 120 has a U-shaped profile with a pair of legs 128, 130 extending from a curved base section 132, which forms an outer edge 124 of the side seal 120 and engages with the side cover 68. The legs 128, 130 have free ends 134, 136 located at the inner edge 126 of the side seal 120 and engaging with the side 18 of the core 12.

[0067] Although the side seal 120 is U-shaped and has two legs 128, 130, it should be noted that the side seal 120 can have more than two legs 128, 130; for example, the side seal 120 can have three or four legs. Furthermore, although the side seal 120 is positioned with the free ends 134, 136 of the legs 128, 130 engaging with the first side of the core 12 and the base section 132 engaging with the side cover 68 of the housing 34, this orientation can be reversed in some embodiments, with the curved base section 132 engaging with the first side 18 of the core 12, and with the free ends 134, 136 of the legs 128, 130 engaging with the side cover 68 of the housing 34.

[0068] Providing the side seal 120 with multiple legs 128, 130 offers the advantage that the legs 128, 130 provide multiple contact points with the core 12, with each free end 134, 136 forming a seal with the first side 18 of the core 12. This arrangement creates a labyrinth seal, whereby any gas flowing through a small space between the first side 18 of the core 12 and the free end 134, 136 of one of the legs 128, 130 loses energy in the space between the legs 128, 130. Providing multiple seals 120 also offers a similar advantage in that multiple sealing points are obtained along the length L of the core 12.

[0069] In the present embodiments, the legs 128, 130 also contribute to holding the side seal 120 in its position in the side channel 116 formed in the first side 18 of the core 12. In this respect, the second regions 108a, 108b of the core 12, and more precisely the circumferential flanges 102 within the second regions 108a, 108b, can be shaped such that they provide a positive locking action with the side seal 120. This helps to hold the side seal 120 in the side channel 116 during the manufacture and use of the heat exchanger 10 and avoids the need for other retaining agents such as adhesives.

[0070] How best to get from the Fig. 2 and Fig. As can be seen in Figure 13, every second area 108 of the core 12 can contain locking elements 138 designed to engage with and retain the free ends 134, 136 of the legs 128, 130 of the side seal 120. For example, the free ends 134, 136 can have an increased thickness relative to the rest of the legs 128, 130, and the locking elements 138 of the core 12 can have appropriately shaped recesses 140 designed to hold the free ends 134, 136 in an engagement fit. It should be noted that there are numerous possible shapes and configurations that result in the free ends 134, 136 being held in the flanges 102.

[0071] As mentioned above, there may also be potential for bypass flow between the upper side 14 of the core 12 and the upper cover 64 of the housing 34 and / or between the lower side 16 of the core 12 and the lower cover 66 of the housing 34. In the present embodiment, there is a space between the lower side 16 of the core 12 and the lower cover 66 of the housing 34, and therefore the heat exchanger 10 includes a lower seal 142 between the lower side 16 of the core 12 and the lower cover 66 of the housing 34. In other embodiments, a similar upper seal (not shown) may be provided between the upper side 14 of the core 12 and the upper cover 64 of the housing 34, either in addition to or instead of the lower seal 142.

[0072] The following describes the characteristics of the lower seal 142 with specific reference to Fig. 5C. Since some of the elements of the bottom seal 142 are the same as the features of the side seal 120, they are identified with the same reference numbers.

[0073] The lower seal 142 has an outer edge 124 that is essentially in sealing engagement with the lower cover 66 of the housing 34, and at least one inner edge 126 that is essentially in sealing engagement with the lower side 16 of the core 12, more precisely with the base plate 58. The inner and outer edges 126, 124 of the lower seal 142 are straight edges, and therefore the lower seal 142 can be easily manufactured by extrusion or molding. The lower seal 142 can be made of an elastic material such as foamed polymer, and it can have an uncompressed thickness greater than the width of the gap between the lower side 16 of the core 12 and the lower cover 66 of the housing 34, such that it is subject to compression during installation. The cross-sectional shape of the lower seal 142 is highly variable.For example, the lower seal 142 can have a simple cross-sectional shape such as square, rectangular, circular, oval, U-shaped, or any other shape of the side seal 120 described above. In the first embodiment, the lower seal 142 has a flat rectangular profile.

[0074] The upper and lower sides 16 of the core 12 do not contain retaining features corresponding to the side channels 116, 118. However, as described below, heat exchangers as described here may contain features for securely retaining the lower and upper seals 142, 144 during the manufacture and use of the heat exchanger 10.

[0075] Although the seals 120, 122, and 142 described here are individually formed and installed in the heat exchanger 10, it is possible to combine two or more of these seals into an integrated sealing structure. For example, as shown in Fig. As shown in Figure 5C, one or both of the side seals 120 and / or 122 are integrated into a single structure with the top seal 142, which is referred to here as a continuous sealing element 150 and extends along the top side and along one or both lateral sides 18, 20 of the core 12. Such an integrated sealing structure can be produced, for example, by molds.

[0076] A heat exchanger 200 according to a second embodiment is described below. The heat exchanger 200 contains a number of elements that are common to the previously described heat exchanger 10. These identical elements are identified in the drawings and in the following description by the same reference numerals, and the description of these elements in connection with the heat exchanger 10 applies equally to the heat exchanger 200.

[0077] The heat exchanger 200 is an intercooler for a motor vehicle powered by an engine that requires compressed charge air, such as a turbocharged internal combustion engine or a fuel cell engine. The heat exchanger 200 can be installed downstream of an air compressor or upstream of an air intake manifold of the engine to cool the hot, compressed charge air before it reaches the engine. However, in some embodiments, the heat exchanger 200 can be integrated with the intake manifold, as mentioned above. The coolant circulating through the heat exchanger 200 is a liquid coolant, which can be the same as the engine coolant, such as water or a water / glycol mixture.

[0078] As in the Fig. 6, Fig. 7, Fig. 8, Fig. 9, Fig. 10 to Fig. As shown in Figure 11, the heat exchanger 200 has a core 12 with an upper side 14, a lower side 16, a pair of side faces 18, 20, an inlet end 22, an outlet end 24, coolant openings 25, 27, coolant distributors 54, 56, and a gas inlet and outlet opening 30, 32 located at the inlet and outlet ends 22, 24. The core 12 has a length L defined between the inlet and outlet ends 22, 24 and a height H defined between the upper side 14 and the lower side 16. It can be seen that side 18 extends along the length L and height H of the core 12, as does the opposite side 20.

[0079] The core 12 comprises a stack of flat tubes 48, each tube having a hollow interior defining a coolant flow passage 50, and circumferential side edges 26, 28 extending along the length L of the core 12. The flat tubes 48 are arranged in a stack, with spaces provided between adjacent pairs of the flat tubes 48, these spaces defining multiple gas flow passages 52. The gas flow passages 52 extend from the inlet end 22 to the outlet end 24 of the core 12 along the length L of the core 12. As can be seen, each of the gas flow passages 52 has a pair of open ends near the ends 22, 24 of the core 12, and a pair of substantially closed sides 51, 53 extending along the length L of the core 12. A width W1 ( Fig. 9) Each of the gas flow passages 52 is defined between the substantially closed sides 51, 53 thereof.

[0080] The turbulence-enhancing inserts of the heat exchanger 200 have several corrugated fins 62. Each of the corrugated fins 62 has a pair of side edges 63, 65, between which a width W2 of the corrugated fin 62 is defined, as shown in Fig. Figure 9 is shown. In the second embodiment, the width W2 corresponds to the width W1 of the gas flow passage 52 in which it is arranged, or is essentially the same.

[0081] The corrugated ribs 62 are defined by several parallel side walls 44 extending along the length L of the core 12, the side walls 44 having ridges 46 on their upper and lower sides along which they are connected to each other and to adjacent flat tubes 48. Thus, each corrugated rib 62 consists of a series of transversely extending waves that are open at the ends 22, 24 of the core 12.

[0082] Along both sides 63, 65 of the corrugated rib 52, one outermost of the side walls 44 is substantially free of perforations and defines one of the substantially closed sides 51 or 53 of one of the gas flow passages 52. It is advantageous that at least the outermost side wall 44 is substantially free of perforations in order to minimize the amount of gas that escapes from and bypasses the gas flow passages 52 and the corrugated ribs 62. In embodiments where it is desirable to provide the side walls 44 with lamellar slots or other types of perforations (not shown), the outermost side wall 44 can be deformed to substantially close the perforations, or the corrugated rib 62 can be provided in several sections, comprising a central section with lamellar openings or other perforations and two edge sections that are free of perforations.

[0083] The coolant flow passages 50 of the core 12 are connected by a pair of coolant distributors 54, 56, as shown in Fig. Figure 7 is shown. In the second embodiment, the distributors 54, 56 are formed by the fact that raised beads or bubbles 55, 57 (shown in Figure 7) are provided with openings. Fig. 12) are provided in each of the plates 100 that form the tubes 48, the beads of adjacent pairs of plates being connected to form continuous distributors 54, 56. The distributors 54, 56 are connected to each of the coolant flow passages 50 and extend over the height of the core 12 from the upper side 14 to the lower side 16. The lower ends of the distributors 54, 56 are closed by a bottom plate 58 that defines the lower side 16 of the core 12, while the upper side 14 of the core 12 is defined by an upper plate 60 in which the coolant openings 25, 27 are defined.

[0084] The coolant distributors 54, 56 are arranged at a mutual distance along the length L of the core 12, and therefore the air and the coolant can flow in opposite directions (counterflow arrangement) or in the same direction (co-flow arrangement).

[0085] The heat exchanger 200 further comprises a housing 34 that surrounds the core 12, the housing having an inlet end region 36 and an outlet end region 38. The housing 34 includes at least one side cover 68 or 70 that extends along and at a distance from at least one side 18 or 20 of the core 12. In the second embodiment, the housing 34 is continuous and surrounds the core 12, comprising a pair of side covers 68, 70 over the sides 18, 20 of the core 12, and further comprising an upper cover 64 that is arranged over the upper side 14 of the core 12, and a lower cover 66 that is arranged over the lower side 16 of the core 12. Together with the end regions 36, 38, the covers 64, 66, 68, 70 of the housing 34 form an essentially continuous enclosure around the core 12 with the exception of inlet and outlet openings for the gas and the coolant.

[0086] The coolant openings 25, 27 of the upper plate 60 provide a connection between the distributors 54, 56 and the coolant openings 72, 74, which are located in the upper cover 64 of the housing 34. The housing 34 further features a pair of coolant ports 78, 80 that communicate with the respective coolant openings 72, 74 and are designed for connection to coolant lines (not shown) in a coolant circulation system (not shown). The ports 78, 80 are sealed to the core 12 by means of nipples that are brazed to the core and fit into collars received in the coolant openings 72, 74 of the housing 34.

[0087] Both sides 18, 20 of the core 12 are spaced from the respective side covers 68, 70 of the housing 34, and the upper side 14 of the core 12 is spaced from the upper cover 64 of the housing 34. In this particular embodiment, the lower side 16 of the core 12 can be in direct contact with the lower cover 66 of the housing 34, or the distance between the lower side 16 of the core 12 and the lower cover 66 can be so small that it is negligible with respect to the bypass flow.

[0088] How best to get from the Fig. 8, Fig. 9, Fig. 15, Fig. 17 and Fig. As can be seen in Figure 18, the sides 18 and 20 of the core 12 are spaced apart from the side covers 68 and 70 of the housing 34. These distances result in part from the distances between the circumferential side edges 26 and 28 of the tubes 48 ( Fig. 8 and Fig. 9) and the side covers 68, 70 of the housing 34, and partly by gaps between the side edges 63, 65 of the corrugated ribs 62 ( Fig. 9) and the side covers 68, 70 of the housing 34. If left open, these spaces allow excessive bypass flow of the gas, thereby reducing the efficiency of the heat exchanger 200.

[0089] In the core construction shown in the drawings, the edges of the tubes 48 consist of the circumferential flanges 102 of the core plates 100 from which the tubes 48 are formed. As shown from Fig. As can be seen in Figure 9, the width W2 of the corrugated ribs 62 is approximately the same as the width of the raised areas 104 of the core plates 100. Therefore, the inserts 62 do not extend to the edges 26, 28 of the circumferential flanges of the tubes 48. For this reason, the sides 18, 20 of the core 12 have an irregular, comb-like shape. As discussed above, it is difficult to achieve a reliable seal between the sides 18, 20 of the core 12 and the housing 34.

[0090] The difficulty in forming seals against sides 18 and 20 of the core 12 is overcome by modifying the shape of sides 18 and 20. In this respect, the core 12 has at least a first region 106 in which the flat tubes 48 have a width W (measured between the circumferential side edges 26 and 28 in the first region 106, as shown in Fig. (as shown in Figure 12) have dimensions larger than the width W1 of each of the gas flow passages 52. In these regions of the core 12, the corrugated ribs 62 are arranged only between those regions of the tubes 48 through which the coolant circulates, defined by the raised areas 104 of the core plates 100 and terminating at the edges of the coolant flow passages 50. Therefore, in the first region 106 of the core 12, the sealed circumferential flanges 102 of the core plates 100 project outwards beyond the edges 63, 65 of the corrugated ribs 62, forming the irregular comb-like shape along both sides 18, 20 of the core 12. Three such first regions 106 are included in the present embodiment and are shown in Fig. 12, designated 106a, 106b and 106c.

[0091] As in Fig. As shown in Figure 12, the core 12 also contains at least one second region 108 in which the flat tubes 48 have a width W3 (measured between the circumferential side edges 26 and 28 in the second region 108), which is essentially the same width W1 as each of the gas flow passages 52. The present embodiment contains two of the second regions, labelled 108a and 108b in Fig. These narrower second regions 108 of the core 12 are formed by extending the circumferential flanges 102 inwards to the centers of the flat tubes 48 in these second regions 108. This results in a local reduction in the width of the raised central regions 104 of the core plates 100 and a corresponding reduction in the width of the coolant flow passages 50 in the second regions 108, while the width W1 of the gas flow passages 52 and the width W2 of the corrugated fins 62 remain constant across the first and second regions 106, 108. The reduction of the width in the second areas 108 is sufficient such that the width W3 between the circumferential side edges 26, 28 in at least a part of each second area 108 is essentially the same as the width W1 of the gas flow passages 52 and the width W2 of the corrugated ribs 62 within acceptable manufacturing tolerances.

[0092] It is evident from the drawings that the second width W2 corresponds to the minimum width between the circumferential side edges 26, 28 within the second regions 108, and that the width of the circumferential flange 102 is somewhat variable in the second regions 108. It is important to note that a certain minimum width of the circumferential flange 102 within the second regions 108 must be maintained to ensure a reliable seal of the coolant flow passages 50, and this requirement is responsible for the narrowing of the coolant flow passages 50 in these second regions 108.

[0093] In the configuration described above, the best way to proceed is from Fig. As can be seen in Figure 15, there is a first gap 110 between the side cover 68 and the side 18 of the core 12 in the first regions 106 of the core 12, wherein the first gap 110 is smaller than a second gap 112 between the side cover 68 and the side of the core 12 in the second regions 108 of the core 12. In the present embodiment, the core 12 is symmetrical, and therefore the same first and second gaps 110, 112 exist between the side 20 of the core 12 and the side cover 70 of the housing. It should be noted that the second gap 112 is the distance between the housing 34 and the second area 108 of the core 12, and more precisely between the housing 34 and those parts of the second area 108 where the width W3 between the circumferential side edges 26, 28 is essentially the same as the width W1 of the gas flow passages 52 and the width W2 of the corrugated ribs 62 within acceptable manufacturing tolerances.

[0094] The locations and relative lengths of the first and second regions 106, 108 of the core 12 along the length L of the core are variable. For example, in the present embodiment, the second regions 108a, 108b are located near the ends of the core 12, and three first regions 106a, 106b and 106c are provided.

[0095] In the first embodiment, the length of the first regions 106 (i.e., the combined lengths of 106a, 106b and 106c) is greater than the individual and combined lengths of the second regions 108a, 108b, wherein the lengths of regions 106, 108 are measured along the length L of the core 12.

[0096] The maximum length of the inward extension of the circumferential flange 102 can be approximately equal to the width of the circumferential flange 102. The inward extension of the flanges 102 results in edge regions of the corrugated ribs 62 near edges 63, 65 that extend beyond the raised central surfaces 104 of the core plates 100 and the coolant flow passages 52 due to the reduction in the width of the central surfaces 104 and the coolant flow passages 52. Thus, the corrugated ribs 62 are unsupported in the inwardly extending region 114, leaving small gaps 98 between the unsupported region of the insert 62 and the adjacent flat tube 48.

[0097] The provision of the narrower second regions 108 of the core 12 leads to the formation of relatively narrow side channels 116, 118, which extend over essentially the entire height H of the core 12. These side channels 116, 118 extend at essentially right angles to the length L of the core 12.

[0098] The heat exchanger 200 further comprises a pair of side seals 120 and a pair of side seals 122. Each side seal 120, 122 is at least partially contained within the second gap 112 between a second area 108a or 108b of the core 12 and the side cover 68 of the housing 34, i.e., at least partially contained within the side channel 116. The side seals 120, 122 extend over the height H of the core and the heights of the side channels 116, 118. As can be seen from the Fig. 9, Fig. 15 and Fig. As can be seen in Figure 16, the side seals 120, 122 have a thickness T that is greater than the width of the first gap 110.

[0099] The following description focuses on the features of each side seal 120, noting that each side seal 122 is identical in the present embodiment.

[0100] It is evident that the side seal 120 has at least one outer edge 124 which is in substantially sealed engagement with the side cover 68 of the housing 34, and at least one inner edge 126 which is in substantially sealed engagement with the side 18 of the core 12 in the second areas 108 thereof, i.e., with respect to the circumferential side edges 24 of the flat tubes 48 and the outermost side walls 44 of the corrugated ribs 62 which define the substantially closed sides 51 or 53 of one of the gas flow passages 52.

[0101] The inner and outer edges 126, 124 of the side seal 120 are straight edges, which means that the structure of the side seal 120 has a relatively simple shape and results in lower manufacturing costs than known seals with a comb-shaped inner edge. For example, the side seal 120 can be easily manufactured by extrusion or forming, followed by cutting the extruded profile into segments of the desired length.

[0102] The side seal 120 can be made of an elastic material such as a foamed polymer. If the side seal 120 is elastic, it has a thickness sufficient to withstand compression when placed between the core 12 and the housing 34. For example, the side seal 120 can have an uncompressed thickness greater than the width of the second gap 112.

[0103] The cross-sectional shape of the side seal 120 is highly variable. For example, the side seal 120 can have a simple cross-sectional shape such as square, rectangular, circular, oval, etc. In the present embodiment, the side seal 120 has a U-shaped profile with a pair of legs 128, 130 extending from a curved base section 132, which forms the outer edge 124 of the side seal 120 and engages with the side cover 68. The legs 128, 130 have free ends 134, 136 located at the inner edge 126 of the side seal 120 and engaging with the side 18 of the core 12.

[0104] Although the side seal 120 is U-shaped and has two legs 128, 130, it should be noted that the side seal 120 can have more than two legs 128, 130; for example, the side seal 120 can have three or four legs. Furthermore, it should be noted that, although the side seal 120 is positioned with the free ends 134, 136 of the legs 128, 130 engaging with the core and the base section 132 engaging with the side cover 68, this orientation can be reversed in some embodiments, with the curved base section 132 engaging with the core 12 and the free ends 134, 136 of the legs 128, 130 engaging with the side cover 68.

[0105] The legs 128, 130 also contribute to holding the side seal 120 in its position in the side channel 116 formed in the side of the core 12. In this respect, the second regions 108a, 108b of the core 12, and more precisely, the circumferential flanges 102 within the second regions 108a, 108b, can be shaped to provide a positive locking action with the side seal 120. This helps to hold the side seal 120 in the side channel 16 during the manufacture and use of the heat exchanger 200 and avoids the need for other retaining agents such as adhesives.

[0106] How best to get from the Fig. 13, Fig. 14 to Fig. As can be seen in Figure 15, every second area 108 of the core 12 can contain locking elements 138 designed to engage with and retain the free ends 134, 136 of the legs 128, 130 of the side seal 120. For example, the free ends 134, 136 can have an increased thickness relative to the rest of the legs 128, 130, and the locking elements 138 of the core 12 can have appropriately shaped recesses 140 designed to hold the free ends 134, 136 in an engagement fit. It should be noted that there can be numerous possible shapes and configurations that result in the free ends 134, 136 being held in the flanges 102.

[0107] As described above, there may also be potential for bypass flow between the upper side 14 of the core 12 and the upper cover 64 of the housing 34 and / or between the lower side 16 of the core 12 and the lower cover 66 of the housing 34. In the present embodiment, there is a space between the upper side 14 of the core 12 and the upper cover 64 of the housing 34, and therefore the heat exchanger 200 includes an upper seal 142 between the upper side 14 of the core 12 and the upper cover 64 of the housing 34. In other embodiments, a similar lower seal (not shown) may be provided between the lower side 16 of the core 12 and the lower cover 66 of the housing 34, either in addition to or instead of the upper seal 142.

[0108] The following describes the characteristics of the upper seal 142 with specific reference to the Fig. 7, Fig. 10 and Fig. 19 described. Since many of the elements of the upper seal 142 are the same as the features of the side seal 120, they are identified with the same reference numbers.

[0109] As in the Fig. 7 and Fig. As shown in Figure 10, the upper seal 142 has an outer edge 124 that engages in a substantially sealed manner with the upper cover 64 of the housing 34, and at least one inner edge 126 that engages in a substantially sealed manner with the upper side 14 of the core 12, more precisely, with the upper plate 60. The inner and outer edges 126, 124 of the upper seal 142 are straight edges, and therefore the upper seal 142 can be easily manufactured by extrusion. The upper seal 142 can be made of an elastic material such as a foamed polymer, and it can have an uncompressed thickness greater than the width of the gap between the upper side 14 of the core 12 and the upper cover 64 of the housing 34, such that it is subject to compression during installation. The cross-sectional shape of the upper seal 142 is highly variable.For example, the upper seal 142 can have a simple cross-sectional shape such as square, rectangular, circular, oval, U-shaped, or any other shape of the side seal 120 described above. In the embodiment according to... Fig. 19 The upper seal 142 has a U-shaped profile that differs slightly from the side seal 120. However, for reasons explained below, the upper seal 142 and the lower seal 144 can have the same profile as the side seals 120 and 122.

[0110] Although the upper side 14 and the lower side 16 of the core 12 do not contain retaining features corresponding to the side channels 116, 118, the heat exchanger 200 may contain features for securely holding the upper and lower seals 142, 144 during the manufacture and use of the heat exchanger.

[0111] For example, as in Fig. As shown in Figure 10, upper seals 142 are partially embedded in grooves 146 in the upper cover 64 of the housing 34. Similarly, if a lower seal is used, it can be embedded in a similar groove (not shown) in the lower cover 66 of the housing 34. The retention of the upper seal 142 and / or the lower seal can be enhanced by the use of an adhesive between the core 12 and / or the housing 34.

[0112] Instead of or in addition to providing retaining grooves 146 or 148 in the housing 34, it may be possible to arrange retaining features (not shown) in the upper plate 58 and / or the bottom plate 60 to retain the inner edge 126 of the upper seal 142 or the lower seal 144. For example, such a retaining feature may have one or more raised ridges formed in the upper plate 58 or the bottom plate 60 of the heat exchanger core 12.

[0113] Although the seals 120, 122, and 142 described here can be individually formed and installed in the heat exchanger 200, it is possible to combine two or more of these seals in an integrated sealing structure. For example, as shown in Fig. As shown in Figure 19, one or both of the side seals 120 and / or 122 are integrated into a single structure with the top seal 142, which is referred to here as a continuous sealing part 150 and extends along the top side and along one or both lateral sides 18, 20 of the core 12.

[0114] The continuous sealing element 150 has a single, elongated, elastic extrusion and can be folded around the core 12 before the core 12 is installed in the housing 34. The continuous sealing element 150 includes foldable corner sections 152 ( Fig. 10 and Fig. 19), which are folded around the corners of the core 12 where the sides 18, 20 of the core intersect the upper side 14. The foldable corner areas 152 may be pre-shaped or may be provided with features that facilitate folding around the core 12. For example, as in the Fig. 20 and Fig. As shown in Figure 21, the foldable corner areas 152 have V-shaped notches 154 that extend partially through the thickness of the sealing part 150, with the notches 154 being open at the inner edge 126 of the sealing part 150. If the extruded part has two or more legs 128, 130, the notches 154 are formed in both legs.

[0115] The continuous sealing part 150 in Fig. 20 is configured to be completely wrapped around core 12, as in Fig. Figure 21 shows that seals are formed along both lateral sides 18, 20 and along the top side 14 and the bottom side 16. The sealing element 150 contains three pairs of notches 154 to form corner areas 152 at three of the four corners of the core 12. The ends of the continuous sealing element 150 meet at the fourth corner of the core 12 and can be held together by adhesive. For this purpose, the ends of the continuous sealing element can be mitered, as shown in Figure 156. Fig. 21 is shown.

[0116] Providing the seals in the form of a continuous sealing part 150 simplifies installation and can also improve the retention of the seals as well as result in improved sealing at the corners of the core 12.

[0117] The heat exchanger 200 described above comprises two separate sets of seals, each set comprising a pair of side seals 120, 122 and a top seal 142, and the two sets of seals being located at opposite ends 22, 24 of the core 12. However, it should be noted that heat exchangers according to the invention may comprise one or more sets of seals located at different positions along the length of the core 12, and that each set of seals may comprise a side seal 120, a side seal 122, a top seal 142 and / or a bottom seal, and that such sets may or may not be formed separately or integrated into a continuous sealing section 150.If a single set of seals is provided, it can be located at any position along the length L of the core 12, including positions near the ends 22, 24, or the center of the core 12. The core plates 100 are configured as required according to the number and locations of the seals needed.

[0118] A heat exchanger 300 according to a third embodiment is described below. The heat exchanger 300 contains a number of elements common to the previously described heat exchangers 10 and 200.

[0119] These same elements are identified in the drawings and in the following description by the same reference numbers, and the description of these elements in connection with heat exchangers 10 and / or 200 applies in the same way to heat exchanger 300.

[0120] The heat exchanger 300 is similar in its overall shape to the previously described heat exchanger 200, the main difference being that the inlet and outlet distributors 54, 56 of the heat exchanger 300 are located in the middle inside the core 12 and are aligned along the length L of it, with each gas flow passage 52 being divided into two segments 52a, 52b and each corrugated fin 62 also being divided into two segments 62a, 62b.

[0121] Like the previously described heat exchanger 200, the heat exchanger 300 comprises a housing 34 with an upper cover 64 integrated with the core 12. The upper cover 64 has a relatively thick, flat flange plate 160, which may be made of aluminum and whose lower surface is brazed to the upper plate 60 of the core 12. The flange plate 160 is provided with a pair of coolant ports 72, 74, which are connected to the coolant distributors 54, 56, and the upper surface of the flange plate 160 is provided with a pair of coolant ports 78, 80. The edges of the flange plate 160 are sealed to the rest of the housing 34 by any suitable means, such as a mechanical connection, brazing, or welding.

[0122] In the present embodiment, the coolant connections 78, 80 are offset from the center of the core 12, and therefore they are attached to the flange plate 160 by means of an intermediate plate 302 with displacement channels 304, 306, which establish a connection between the coolant distributors 54, 56 and the respective coolant connections 78, 80. As is best done from Fig. As can be seen in Figure 24, the sides 18 and 20 of the core 12 are spaced apart from the side covers 68 and 70 of the housing 34. This space is partly due to the distance between the circumferential side edges 26 and 28 of the tubes 48 and the side covers 68 and 70 of the housing 34, and partly due to the distance between the side edges 63 and 65 of the corrugated ribs 62 and the side covers 68 and 70 of the housing 34. This results in an irregular, comb-like shape along both sides 18 and 20 of the core 12.

[0123] The core 12 of the heat exchanger 300 differs from the heat exchangers 10 and 200 in that it contains a pair of first regions 106a, 106b separated by a second region 108, wherein the first and second regions 106, 108 are defined as in the first and second embodiments described above. This results in the formation of a side channel 116, 118 on each side 18, 20 of the core 12, the channels 116, 118 extending over substantially the entire height H of the core 12.

[0124] The heat exchanger 300 also features a side seal 120, a side seal 122 and a bottom seal 142, which have essentially the same configuration as the seals 120, 122 and 142 of the heat exchanger 10.

[0125] Each side seal 120, 122 is at least partially enclosed in the second gap 112 between a second area 108a or 108b of the core 12 and the side cover 68 or 70 of the housing 34, i.e., at least partially enclosed in the side channel 116 or 118. The side seals 120, 122 extend over the height H of the core 12 and the heights of the side channels 116, 118.

[0126] The lower seal 142 has a rectangular profile and is incorporated in substantially sealed engagement with the lower cover 66 of the housing 34 and with the base plate 58 of the core 12.

[0127] Although the invention has been described in connection with certain embodiments, it is not limited thereto. Rather, the invention includes all embodiments that may fall within the scope of the following claims.

Claims

[1] Gas / liquid heat exchanger (10) which has: (a) a core (12) having a length, a height and a pair of opposite sides (14, 16, 18, 20) extending along the length and height of the core (12), wherein the core (12) has several flat tubes (48) arranged in a stack with a space provided between each adjacent pair of the flat tubes (48), each of the flat tubes (48) having a hollow interior defining a liquid flow passage (50), and each of the spaces defining a gas flow passage (52); wherein each of the flat tubes (48) has a pair of circumferential edges (26, 28) extending along the length of the core (12), wherein the circumferential edges (26, 28) of the flat tubes (48) partially define the sides (18, 20) of the core (12); wherein each of the gas flow passages (52) has a pair of open ends (22, 24) and a pair of opposite sides (51, 53), wherein a width (W1) of each of the gas flow passages (52) is defined between the opposite sides (51, 53) and the opposite sides (51, 53) of the gas flow passages (52) partially define the sides (18, 20) of the core (12); wherein the core (12) has a first region (106) in which the flat tubes (48) have a first width (W) that is greater than the width (W1) of each of the gas flow passages (52), wherein the first width (W) is defined between the circumferential edges (26, 28) of the flat tubes (48) in the first region (106);wherein the core (12) has a second region (108) in which the flat tubes (48) have a second width (W3) which is the same as the width (W1) of each of the gas flow passages (52), wherein the second width (W3) is defined between the circumferential edges (26, 28) of the flat tubes (48) in the second region (108); (b) a housing (34) surrounding the core (12), the housing (34) having an inlet end region (36) with a gas inlet opening (40) and an outlet end region (38) with a gas outlet opening (42), wherein the gas inlet and outlet openings (40, 42) communicate with the open ends (22, 24) of the gas flow passages (52) of the core (12); wherein the housing (34) includes at least one lateral cover (68, 70) extending along and at a distance from at least one side (18, 20) of the core (12), wherein a first gap (110) between the lateral cover (68, 70) and the side (18, 20) of the core (18, 20) in the first region (106) of the core (12) is smaller than a second gap (112) between the lateral cover (68, 70) and the side (18, 20) of the core (12) in the second region (108) of the core (12); and (c) a lateral seal (120, 122) which is at least partially incorporated in the gap (112) between the lateral cover (68, 70) of the housing (34) and the second area (108) of the core (12); wherein the lateral seal (120, 122) extends over the height of the core (12) and has a thickness greater than the first gap (110), wherein the seal (120, 122) is elastic and has an uncompacted thickness greater than the second gap (112), wherein the seal (120, 122) has a U-shape with two legs (128, 130) having ends (134, 136) that engage with the core (12) in its second section (10), wherein the second area (108) of the core (12) contains locking elements (138) which engage with and hold the ends (134, 136) of the legs (128, 130), and wherein the ends (134, 136) of the legs (128, 130) have areas of increased thickness which are designed to engage with and be held by the locking elements (138). [2] Heat exchanger (10) according to claim 1, wherein each of the gas flow passages (52) is provided with a turbulence-enhancing insert. [3] Heat exchanger (10) according to claim 2, wherein each of the turbulence-enhancing inserts has a corrugated rib (62) defined by several parallel side walls (44) extending along the length of the core (12), the side walls (44) having ridges (46) at their upper and lower ends where they are connected to each other and to adjacent of the flat tubes (48); wherein each of the corrugated ribs (62) has a pair of side edges (63, 65) between which a width of the corrugated rib (62) is defined, wherein at least one of the side edges (63, 65) of the corrugated rib (62) is defined by an outermost side wall (44) of the corrugated rib (62), and wherein the outermost side wall (44) is free of perforations and defines one of the opposite sides (51, 53) of one of the gas flow passages (52). [4] Heat exchanger (10) according to claim 3, wherein each of the side edges (63, 65) of the corrugated rib (62) is defined by one of the outermost side walls (44) of the corrugated rib (62). [5] Heat exchanger (10) according to claim 4, wherein each of the corrugated fins (62) has a width that defines the width of the gas flow passage (52) in which it is arranged, such that each of the opposite sides (51, 53) of each of the gas flow passages (52) is defined by one of the outermost side walls (44) of the corrugated fin (62). [6] Heat exchanger (10) according to any one of claims 1 to 5, wherein each of the flat tubes (48) has a pair of core plates (100) with a planar circumferential flange (102) surrounding a raised central surface (104), wherein the circumferential edges (26, 28) of the tubes (48) are defined by areas of the planar circumferential flange (102) extending along the length of the core (12). [7] Heat exchanger (10) according to claim 6, wherein each of the raised central surfaces (104) of the core plates (100) and each of the liquid flow passages (50) of the flat tubes (48) in the second region (108) of the core (12) has a width that is smaller than a width in the first region (106) of the core (12). [8] Heat exchanger (10) according to claim 6 or 7, wherein the planar circumferential flanges (102) include inwardly extending regions (114) in the second region (108) of the core (12). [9] Heat exchanger (10) according to claim 8, wherein the inwardly extending regions (114) extend inward over a maximum length equal to a width of the planar circumferential flange (102) along the first region (106) of the core (12). [10] Heat exchanger (10) according to claim 9, wherein each of the inwardly extending areas (114) contains a locking element (138) configured to engage with and hold an inner edge (126) of the side seal (120, 122). [11] Heat exchanger (10) according to any one of claims 1 to 10, wherein the second region (108) of the core (12) has a length that is less than the length of the first region (106) of the core (12). [12] Heat exchanger (10) according to any one of claims 1 to 11, wherein the second area (108) forms a recessed channel (116, 118) extending over the entire height of the core (12). [13] Heat exchanger (10) according to any one of claims 1 to 12, wherein the core (12) further comprises an upper side (14) and a lower side (16), the housing (34) comprising an upper cover (64) arranged over the upper side (14) of the core (12), a lower cover (66) arranged over the lower (16) side of the core (12), and a pair of side covers (68, 70) over the sides of the core (12). [14] Heat exchanger (10) according to claim 13, wherein the lower side (16) of the core (12) has a distance from the lower cover (66) of the housing (34) and a lower seal (142) is arranged between the lower side (16) of the core (12) and the lower cover (66) of the housing (34). [15] Heat exchanger (10) according to claim 13 or 14, wherein the upper side (14) of the core (12) has a distance from the upper cover (64) of the housing (34) and an upper seal (142) is arranged between the upper side (16) of the core (12) and the upper cover (66) of the housing (34). [16] Heat exchanger (10) according to claim 14 or 15, wherein the upper seal (142) or the lower seal (142) is partially embedded in a groove (146) in the upper cover (64) or the lower cover (66) of the housing (34). [17] Heat exchanger (10) according to any one of claims 12 to 16, wherein the lateral seals (120, 122), the upper seal (142) and the lower seal (142) have a continuous sealing part (150) extending along the upper, lower and lateral sides (14, 16, 18, 20) of the core (12). [18] Heat exchanger (10) according to claim 17, wherein all areas of the continuous sealing (150) run in a single transverse plane. [19] Heat exchanger (10) according to claim 18, wherein the continuous seal (150) has an elongated elastic part. [20] Heat exchanger (10) according to claim 19, wherein the continuous seal (150) includes foldable corner areas (152) which are designed to be folded around the corners between the sides (18, 20) and the respective adjacent upper and lower sides (14, 16) of the core (12). [21] Heat exchanger (10) according to claim 20, wherein the foldable corner areas (152) have notches (154) which extend partially through the thickness of the continuous seal (150). [22] Heat exchanger (10) according to claim 21, wherein the notches (154) are V-shaped and open towards the core (12). [23] Heat exchanger (10) according to any one of claims 1 to 22, wherein the heat exchanger (10) includes two or more of the lateral seals (120, 122) which are spaced apart along the length of the core (12), the core (12) having two of the second regions (108) in which the flat tubes (48) have a second width which is the same as the width of each of the gas flow passages (52). [24] Heat exchanger (10) according to one of claims 1 to 4 or 6 to 23, in which one of the opposite sides (51, 53) of each of the gas flow passages (52) is defined by coolant inlet (54) and outlet distributors (56) of the core (12).

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