INLET AND OUTLET PIPE CONNECTION STRUCTURE FOR A HEAT EXCHANGER

Abstract

A heat exchanger comprises a pipe connection structure consisting of a first coupling element and a second coupling element. The first coupling element includes a through-hole formed through it, and the second coupling element includes a blind hole formed within it. A distribution tank comprises a first tank chamber aligned with the through-hole of the first coupling element and a second tank chamber aligned with the blind hole of the second coupling element. The through-hole provides a fluid connection between the interior of the pipe connection structure and the first tank chamber, while the second coupling element forms a fluid barrier wall at one end of its blind hole, preventing fluid communication between the interior of the pipe connection structure and the second tank chamber via the second coupling element.

Description

Technical field

[0001] The disclosure relates to a heat exchanger and in particular an inlet pipe connection structure and an outlet pipe connection structure for a condenser of a heating, ventilation and air conditioning (HVAC) system of a vehicle, wherein the condenser and pipe connection structures occupy a minimized packing space within the vehicle. Technical background

[0002] Heating, ventilation, and air conditioning systems play a vital role in ensuring the comfort and well-being of vehicle passengers. Among the components crucial for the proper functioning of such systems, condensers serve as central elements for heat exchange, facilitating the cooling of refrigerant gases and enabling effective temperature control within the vehicle cabin.

[0003] It has become increasingly common for at least one of the condensers used in the HVAC system of an electric or hybrid (electric) vehicle to be a so-called internal condenser. This is a condenser located within the HVAC enclosure to exchange heat with air intended for the vehicle's passenger compartment. The internal condenser can therefore be used when the electric vehicle does not have access to the heat typically generated by the operation of an internal combustion engine, but instead relies on heat generated by the compression of a circulating refrigerant within the HVAC system.

[0004] Designing an internal condenser for a vehicle's HVAC system requires careful consideration of several factors, including space constraints, performance criteria, and structural integrity. Achieving an optimal balance between these factors presents significant challenges, particularly in scenarios where space is severely limited and performance targets are demanding. Therefore, efficiently utilizing the available packaging space to house the internal condenser unit while simultaneously providing the required cooling efficiency remains an ongoing challenge in vehicle design.

[0005] Furthermore, connecting the inlet and outlet pipes to the distribution tanks of the internal condenser unit presents a challenge due to the limited space available for such connections. These connections are essential for the proper circulation of refrigerant and, potentially, for the structural stability of the internal condenser unit at the junction of the inlet and outlet pipes with the distribution tanks located at opposite ends of the internal condenser unit. This challenge is compounded in cases where extreme packing constraints necessitate complex geometries to accommodate the required connections, such as the refrigerant entering or exiting the condenser in opposite configurations or orientations. Disclosure of the invention Technical problem

[0006] It would therefore be desirable to create an improved design of the inlet and outlet pipe connection structures of a capacitor unit in order to optimize performance, improve structural stability and minimize the packing space of the capacitor unit. Technical solution

[0007] Surprisingly, an improved inlet and outlet pipe configuration was found in accordance with the subject described herein.

[0008] In one embodiment, a heat exchanger has a first pipe connection structure comprising a first outer wall that defines at least a section of the interior of the first pipe connection structure, the interior of the first pipe connection structure containing a first fluid. A first coupling element is received in a first opening formed by the first outer wall of the first pipe connection structure, the first coupling element comprising a first through-hole formed by it. A second coupling element is received in a second opening formed by the first outer wall of the first pipe connection structure.A first distribution tank is coupled to each of the first coupling element and the second coupling element, the first distribution tank comprising a first tank chamber extending longitudinally from the first coupling element and a second tank chamber extending longitudinally from the second coupling element. The first through-hole of the first coupling element provides a fluid connection of the first fluid between the interior of the first pipe connection structure and the first tank chamber, and the second coupling element forms a first fluid barrier wall to prevent a fluid connection of the first fluid between the interior of the first pipe connection structure and the second tank chamber via the second coupling element.

[0009] Further areas of application will become apparent from the description provided here. The description and specific examples in this summary serve only for illustration and are not intended to limit the scope of the present disclosure. Brief description of the drawings

[0010] The drawings described here serve only to illustrate selected embodiments and not all possible implementations, and are not intended to limit the scope of this disclosure. Fig. Figure 1 is a partially schematic top view of an HVAC system with an internal capacitor according to an embodiment of the present invention; Fig. Figure 2 is a perspective front view of the internal capacitor of the HVAC system of Fig. 1; Fig. Figure 3 is a perspective view of a first pipe connection structure of the internal condenser; Fig. Figure 4 is a bottom view of the first pipe connection structure of Fig. 3; Fig. Figure 5 is a vertical cross-sectional view of the first pipe connection structure, as seen from the perspective of section lines 5-5 in Fig. 4; Fig. Figure 6 is an enlarged and fragmentary perspective view of a section of the internal condenser showing the first pipe connection structure coupled to a first distribution tank of the internal condenser; Fig. Figure 7 is a cross-sectional view taken from the perspective of section lines 7-7 in Fig. Figure 6 shows a way of coupling the first pipe connection structure with the first distribution tank via intermediate coupling elements and baffle plates of the internal condenser; Fig. Figure 8 is a cross-sectional view taken from the perspective of section lines 8-8 in Fig. 2 and shows a plurality of heat exchanger tubes of the internal condenser that fluidically couple the tank chambers of oppositely arranged first and second distribution tanks; Fig. Figure 9 is a perspective view from the front to the right of the internal condenser, showing an interior of each of the first pipe connection structure, a first tank chamber of the first distribution tank, and a second tank chamber of the first distribution tank, with the coolant flowing from an interior of the first pipe connection structure to the first tank chamber, and then through a first set of heat exchanger tubes connecting the first distribution tank to the second distribution tank; Fig. Figure 10 is a perspective view from the front left of the internal capacitor. Fig. 9, which shows an interior of a second pipe connection structure, a third tank chamber of the second distribution tank and a fourth tank chamber of the second distribution tank, the refrigerant flows from the first set of heat exchanger tubes to the third tank chamber, flows laterally from the third tank chamber into a first section of the fourth tank chamber, and then through a second set of heat exchanger tubes that connect the first distribution tank to the second distribution tank; Fig. Figure 11 is a perspective view from the front to the right of the internal capacitor. Fig. 9 and Fig. 10 with the refrigerant flowing from the second set of heat exchanger tubes and into the second tank chamber before flowing axially through it to flow back through the second set of heat exchanger tubes towards the fourth tank chamber of the second distribution tank; Fig. Figure 12 is a perspective view from the front to the left of the inner capacitor. Fig. 9-11 with the refrigerant flowing from the second set of heat exchanger tubes and into a second section of the fourth tank chamber before flowing into the interior of the second pipe connection structure; and Fig. Figure 13 is a plan view of a pipe connection structure according to an alternative embodiment of the present invention. Mode for the invention

[0011] The following description of the technology is merely exemplary with respect to the subject matter, manufacture, and use of one or more inventions and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in any other applications that may be filed claiming priority against this application, or in patents granted therefrom. With regard to the disclosed methods, the sequence of steps presented is exemplary, and consequently, the sequence of steps may differ according to various embodiments. "One" and "an," as used herein, indicate that "at least one" of the element is present; a plurality of such elements may be present where possible.Unless expressly stated otherwise, when describing the broadest scope of the technology, all numerical quantities in this description are to be understood as modified by the word "approximately," and all geometric and spatial descriptors as modified by the word "essentially." When "approximately" is applied to numerical values, it indicates that the calculation or measurement permits some minor inaccuracy of the value (with some approximation to the accuracy of the value; approximately or reasonably close to the value; nearly). If, for any reason, the inaccuracy provided by "approximately" and / or "essentially" is not otherwise understood in the field with this ordinary meaning, then "approximately" and / or "essentially," as used herein, at least indicate variations that may result from ordinary procedures for measuring or using such parameters.

[0012] All documents, including patents, patent applications, and scientific literature, cited in this detailed description are included by reference unless explicitly stated otherwise. Where any contradiction or ambiguity should exist between a referenced document and this detailed description, the present detailed description shall prevail.

[0013] Although the open term “featuring” is used here as a synonym for non-restrictive terms such as “comprising”, “containing” or “featuring” to describe and claim embodiments of the present technology, embodiments may alternatively be described using more restrictive terms such as “consisting of” or “essentially consisting of”.Consequently, for any embodiment that specifies materials, components or process steps, the present technology also includes, in particular, embodiments that consist of or essentially consist of such materials, components or process steps, excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes that affect the significant features of the embodiment (for essentially consisting of), even if such additional materials, components or processes are not expressly specified in this application.For example, the specification of a composition or process that includes elements A, B and C, in particular embodiments consisting of A, B and C and consisting essentially of A, B and C, excluding element D, which may be specified in the technical literature, even if element D is not expressly described as excluded here.

[0014] Unless otherwise stated, as mentioned herein, all percentages of compositions refer to the weight of the total composition. Statements of ranges, unless otherwise stated, include the endpoints and encompass all unique values ​​and further subdivided ranges within the overall range. Consequently, for example, a range of "from A to B" or "from about A to about B" includes A and B. The disclosure of values ​​and ranges of values ​​for specific parameters (such as quantities, weight percentages, etc.) does not preclude other values ​​and ranges of values ​​that may be useful here. It is borne in mind that two or more specific exemplary values ​​for a given parameter may define the endpoints of a range of values ​​that may be claimed for the parameter. For example,Where parameter X is illustrated here as having a value A and also as having a value Z, it is made clear that parameter X can have a range of values ​​from approximately A to approximately Z. Similarly, it is made clear that the disclosure of two or more ranges of values ​​for a parameter (whether such ranges are nested, overlapping, or distinct) subsumes all possible combinations of ranges for the value that could be claimed using the endpoints of the disclosed ranges. For example, if it is illustrated here that a parameter X has values ​​in the range of 1-10, 2-9, or 3-8, it is also made clear that parameter X can have other ranges of values ​​that include 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.

[0015] When an element or layer is described as "on," "interacting with," "connected with," or "coupled with" another element or layer, it may be directly on top of, directly interacting with, directly connected or coupled to, or there may be intervening elements or layers. Conversely, when an element is described as "directly on," "directly interacting with," "directly connected with," or "directly coupled with" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted similarly (e.g., "between" as opposed to "directly between," "adjacent" as opposed to "directly adjacent," etc.).As the term “and / or” is used here, it includes any or all combinations of one or more of the associated listed elements.

[0016] Although the terms first, second, third, etc., may be used here to describe different elements, components, areas, layers, and / or sections, these elements, components, areas, layers, and / or sections should not be restricted by these terms. These terms may only be used to distinguish one element, component, area, layer, or section from another. Terms such as "first," "second," and other numerical terms, when used here, do not imply any order or sequence unless clearly indicated by the context.Consequently, a first element, a first component, a first area, a first layer or a first section discussed below could be referred to as a second element, a second component, a second area, a second layer or a second section without deviating from the lessons of the exemplary embodiments.

[0017] Spatially relative terms such as "inner," "outer," "below," "under," "lower," "above," "upper," and the like can be used here for simple description to describe the relationship of one element or feature to one or more other elements or features, as illustrated in the figures. In addition to the orientation shown in the figures, spatially relative terms can also encompass various orientations of the device during use or operation. For example, if the device in the figures is turned upside down, would the elements described as "below" or "underneath" other elements or features then be oriented "above" them? Consequently, the exemplary term "below" can encompass both an orientation above and below.The device may be oriented differently (rotated by 90 degrees or in other orientations), with the spatially relative descriptors used here being interpreted accordingly.

[0018] Fig. Figure 1 illustrates an HVAC system 1 with an internal condenser 10 according to an embodiment of the present invention. The HVAC system 1 comprises a refrigerant circuit 2, at least a section of which is located within a housing 3 of the HVAC system 1. In particular, the internal condenser 10 according to the invention can be located within a condenser chamber 4 of the housing 3, and the condenser chamber 4 can be in fluid communication with air flowing through the housing 3. The condenser chamber 4 can be configured to receive the air in such a way that, as the refrigerant flows through the condenser chamber 4, the air flows around an outer surface of the internal condenser 10, thereby facilitating the transfer of heat from the refrigerant flowing through the interior of the internal condenser 10 to the air flowing over its exterior.

[0019] The refrigerant circuit 2 can comprise, in the order of the refrigerant flow through it, a compressor 101, an internal condenser 10, an expansion element 102, and an evaporator 103. The refrigerant circuit 2 can include additional components while remaining within the scope of the present invention, such as the use of a branching of the refrigerant circuit 2 at selected points to facilitate the ability to flow the refrigerant through two or more flow paths in a parallel flow configuration or to switch the refrigerant flowing between the two different flow paths. For example, the internal condenser 10 can be provided in parallel with an external condenser (acting as a cooler, not shown) of the refrigerant circuit 2, which is in fluid contact with the ambient air, or the circuit can otherwise be switchable between the internal condenser 10 and the external condenser.In other embodiments, the refrigerant circuit 2 can include the external condenser (cooler) and the internal condenser 10 arranged in series to cause the refrigerant to be cooled successively in each condenser, as desired.

[0020] As in Fig. As shown in Figures 1-12, the internal condenser 10 comprises a first (inlet) pipe connection structure 11, a first (inlet) distribution tank 12, a plurality of heat exchanger tubes 13, a second (outlet) distribution tank 14, and a second (outlet) pipe connection structure 15. The first pipe connection structure 11 is configured to be coupled to a first (inlet) fluid line 7 of the refrigerant circuit 2, and the second pipe connection structure 15 is configured to be coupled to a second (outlet) fluid line 8 thereof.The first fluid line 7 can be configured to carry a flow of refrigerant after leaving the compressor 101 to the internal condenser 10, while the second fluid line 8 can be configured to carry the refrigerant exiting the internal condenser 10 to a downstream component of the corresponding refrigerant circuit 2, such as the previously mentioned expansion element 102 of the refrigerant circuit 2, among other possible components (depending on the configuration of the corresponding refrigerant circuit 2).Each of the fluid lines 7, 8 can represent any suitable hose, pipe, or line of the refrigerant circuit 2 capable of conveying the refrigerant through it in a desired manner, including ensuring that the refrigerant is not subjected to an undesirably high pressure drop or a sudden change in the flow area as it passes through one of the fluid lines 7, 8. In some embodiments, each of the fluid lines 7, 8 can extend through a section of the condenser chamber 4 that conveys the air through it, in such a way that the fluid lines 7, 8 can play a role in the exchange of heat between the air flowing through the condenser chamber 4 and the refrigerant conveyed through the interior of the condenser 10.The first (inlet) fluid line 7 may have a greater length extending through the condenser chamber 4 compared to the second (outlet) fluid line 8 in order to result in a greater degree of heat exchange between the air and the refrigerant within the first fluid line 7 than occurs between the air and the refrigerant within the second fluid line 8.

[0021] The internal condenser 10 further comprises a first connecting plate 17 and a second connecting plate 18, which are positioned at opposite ends of a plurality of heat exchanger tubes 13. The first connecting plate 17 connects a first end of the first distribution tank 12 to a first end of the second distribution tank 14, while the second connecting plate 18 connects a second end of the first distribution tank 12 to a second end of the second distribution tank 14. Between each successive row of heat exchanger tubes 13 and / or each of the connecting plates 17, 18, a plurality of fins 19 or similar surface-enhancing features may be provided to provide an additional surface area in heat-exchange relationship with the refrigerant and the air within the condenser space 4. Fig. Figure 2 shows only a representative example of a relatively small section of the fins 19, which is placed between the second connecting plate 18 and one of the heat exchanger tubes 13, so as not to obstruct the features of the heat exchanger tubes 13 and / or connecting plates 17, 18. However, it is understood that the fins 19 can be placed between each of the successive rows of the heat exchanger tubes 13 and / or connecting plates 17, 18 and can extend along a length of each heat exchanger tube 13 and / or connecting plates 17, 18 (which extend between the first and the second distribution tank 12, 14) in order to maximize the heat exchange capacity of the internal condenser 10, while remaining within the scope of the present invention.

[0022] How best to Fig. As shown in Figure 3, the first pipe connection structure 11 comprises a first shell 21 coupled to a second shell 31, each shell forming an outer wall of the first pipe connection structure 11. Each of the first shell 21 and the second shell 31 comprises two perpendicularly arranged side surfaces that are open to provide fluid access to the interior of each shell 21, 31. In particular, the first shell 21 comprises an open pipe connection surface 22 having a semicircular circumferential shape and an elongated and open coupling surface 23 extending from the diametrically opposite ends of the semicircular pipe connection surface 22 in a plane perpendicular to it. The open coupling surface 23 extends longitudinally and defines a closed end 24 opposite the pipe connection surface 22.The second shell 31 comprises an open pipe connection surface 32 with a semicircular circumferential shape and an elongated and open coupling surface 33, which extends from the diametrically opposite ends of the semicircular pipe connection surface 32 on a plane perpendicular to it. The coupling surface 33 extends longitudinally and forms a closed end 34 opposite the pipe connection surface 32.

[0023] The first shell 21 is configured to couple with the second shell 31, with the coupling surfaces 23, 33 facing each other and interlocking around their circumferences, the pipe connection surfaces 22, 32 being aligned to cooperate and forming a cylindrical opening 38 into an interior of the first pipe connection structure 11 for receiving and coupling with an end section of the first fluid line 7, and the closed ends 24, 34 of the coupling surfaces 23, 33 align and interlock to limit a flow of the refrigerant within the interior of the first pipe connection structure 11 with respect to the flow direction of the refrigerant upon entering the first pipe connection structure 11 via the first fluid line 7 and the cylindrical opening 38.One or both of the opposing coupling surfaces 23, 33 can have one or more crimp tabs 35 extending outwards from them to crimp the shells 21, 31 together around the circumferences of the engaging coupling surfaces 23, 33. Each of the respective coupling surfaces 23, 33 can further comprise an outwardly flanged section 36 extending around its circumference and configured to receive one of the crimp tabs 35 from the other of the coupling surfaces 23, 33 around it when the shells 21, 31 are coupled together.

[0024] The first shell 21 further comprises a first coupling element 40 and a second coupling element 50, which extends outwards from there (towards an outside of the first pipe connection structure 11) along a section of the first shell 21 which is placed directly opposite the open coupling surface 23 thereof, wherein each of the coupling elements 40, 50 can extend outwards and axially in a direction transverse (including perpendicular) to the flow direction of the refrigerant entering the interior of the first pipe connection structure 11 via the cylindrical opening 38.In the illustrated embodiment, the first coupling element 40 is an independently provided first connector 41, which is received through a corresponding first opening 27 formed by the wall of the first shell 21, and the second coupling element 50 is likewise an independently provided second connector 51, which is received through a corresponding second opening 28 formed by the wall of the first shell 21. However, the coupling elements 40, 50 can alternatively be provided as machined or otherwise integrally (monolithically) formed sections of the first shell 21, which have the same or similar properties as those shown and described with respect to the disclosed embodiment, wherein the connectors 41, 51 are received in the openings 27, 28 as desired, while remaining within the scope of the present invention.

[0025] The first coupling element 40 comprises an inner section 40a configured to receive through the first opening 27 of the first shell 21, and an outer section 40b projecting outward from the first opening 27 to position the outer section 40b outside the first shell 21 and the first pipe connection structure 11. The second coupling element 50 similarly comprises an inner section 50a configured to receive through the second opening 28 of the first shell 21, and an outer section 50b projecting outward from the second opening 28 to position the outer section 50b outside the first shell 21 and the first pipe connection structure 11. As shown in Fig. As shown in Figure 5, each of the inner sections 40a, 50a can have an axial length to extend through the corresponding opening 27, 28 of the first shell 21, such that an axial end of each of the inner sections 40a, 50a extends beyond the thickness of the wall of the first shell 21 to be positioned inside the interior of the first pipe connection structure 11. Each of the outer sections 40b, 50b protrudes axially from the outer surface of the wall forming the first shell 21 at each of the respective openings 27, 28.

[0026] The outer section 40a of the first coupling element 40, provided as the first connector 41, comprises a radially outwardly extending flange section 42 between the opposite axial ends of the first coupling element 40. The flange section 42 defines a first radially extending surface 43 and an opposite second radially extending surface 44, which is axially spaced from the first radially extending surface 43 by the thickness of the flange section 42. The first radially extending surface 43 is configured to engage with an outer surface of the wall forming the first shell 21, and the second radially extending surface 44 is configured to engage with a surface of a first baffle plate 60 that is accommodated above and around the first coupling element 40, as will be explained in more detail below.The plane of the first radially extending surface 43 of the flange section 42 accordingly represents an axial position in which the first coupling element 40 is divided into the inner section 40a and the outer section 40b with respect to the axial direction of the first coupling element 40.

[0027] The first coupling element 40 comprises a through-hole 45 formed through it, the through-hole 45 extending axially through the first coupling element 40 in the direction of its axial extension from the outer surface of the first shell 21. The through-hole 45 extends axially through both the inner section 40a and the outer section 40b of the first coupling element 40, such that the through-hole 45 penetrates an entire portion of the first coupling element 40 with respect to its axial extension direction. In the provided embodiment, the first coupling element 40 and the corresponding through-hole 45 essentially comprise elliptical, oval, or rounded rectangular (non-circular) cross-sectional shapes, although the use of a circular cross-sectional shape in forming the first coupling element 40 and / or the through-hole 45 is not necessarily outside the scope of the present invention.The through-hole 45 is configured to provide a fluid connection between the interior of the first pipe connection structure 11 and an interior of the first distribution tank 12 via an axial passage of the fluid through an interior of the first coupling element 40.

[0028] The outer section 50b of the second coupling element 50, provided as the second connector 51, comprises a radially outwardly extending flange section 52 between the opposite axial ends of the second coupling element 50. The flange section 52 defines a first radially extending surface 53 and an opposing second radially extending surface 54, which is axially spaced from the first radially extending surface 53 by the thickness of the flange section 52. The first radially extending surface 53 is configured to engage with the outer surface of the wall forming the first shell 21, and the second radially extending surface 54 is configured to engage with a surface of a second baffle plate 70 that is accommodated over and around the second coupling element 50, as will be explained in more detail below.The plane of the first radially extending surface 53 of the flange section 52 accordingly represents an axial position in which the second coupling element 50 is divided into the inner section 50a and the outer section 50b with respect to the axial direction of the second coupling element 50.

[0029] The second coupling element 50 differs from the first coupling element 40 in that the second coupling element 50 does not include a through-hole penetrating its axial length. Instead, the second coupling element 50 includes at least one blind hole 55, 57 formed therein, each of the blind holes 55, 57 penetrating only a portion of the axial length of the second coupling element 50 and not being fluidically connected to each other for conveying the refrigerant through it. In particular, the inner section 50a of the second coupling element 50 includes a first blind hole 55 that partially penetrates the axial length of the second coupling element 50 at a first axial end thereof, and the outer section 50b of the second coupling element 50 includes a second blind hole 57 that partially penetrates the axial length of the second coupling element 50 at a opposite second axial end thereof.The partial axial penetration of the opposing blind holes 55, 57 leads to the formation of a fluid barrier wall 56 of the second coupling element 50, which prevents fluid communication between the interior of the first pipe connection structure 11 and the interior of the first distribution tank 12 via one of the at least one blind hole 55, 57. That is, in contrast to the first coupling element 40, the second coupling element 50 is provided to structurally reinforce the assembly of the first pipe connection structure 11 with the first distribution tank 12 via an additional fixed connection, by which the first pipe connection structure 11 is securely attached to the first distribution tank 12 when no refrigerant flows between them.As explained below, the configuration of the first distribution tank 12, the plurality of heat exchanger tubes 13 and the second distribution tank 14 facilitates the ability to use only one flow channel between the first pipe connection structure 11 and the first distribution tank 12 via only one of the two openings 27, 28 formed by the wall of the first shell 21.

[0030] In the provided embodiment, the second coupling element 50 and the corresponding blind holes 55, 57 are essentially cylindrical and thus have a substantially circular cross-sectional shape, although essentially any shape can be used when forming the blind holes 55, 57. The blind holes 55, 57 are axially aligned and formed directly opposite each other with respect to the axial direction of the second coupling element 50. The fluid barrier wall 56 is formed by a section of the second coupling element 50 that is positioned at an inner axial end of each of the corresponding blind holes 55, 57. In other words, the fluid barrier wall 56 forms a first surface that defines an axial end of the first blind hole 55 and an oppositely arranged second surface that defines an axial end of the second blind hole 57.In the illustrated embodiment, each of the surfaces of the fluid barrier wall 56, which form the axial end of each of the blind holes 55, 57, is concave due to an annular arcuate transition from a cylindrical and axially extending circumferential surface of each of the respective blind holes 55, 57 to a substantially planar axial end surface of the corresponding blind hole 55, 57, which is positioned along the fluid barrier wall 56. The tapered concave shape at the inner axial end of each of the blind holes 55, 57 can be selected to facilitate the fabrication of each of the blind holes 55, 57, such as by the use of a rotary cutting tool (i.e., a drill) or a forming process, wherein the tapered and concave shape allows for easy removal of the rotary cutting tool or the die from the finished blind holes 55, 57.The second coupling element 50 can be provided with at least one blind hole 55, 57 to minimize the material used in forming the second coupling element 50 while maintaining its structural integrity and providing the fluid barrier wall 56 to prevent fluid communication through the second coupling element 50 via the at least one blind hole 55, 57.

[0031] The first distribution tank 12 comprises an assembly of a base wall structure 80, a first wall element 81, and a second wall element 82. The base wall structure 80 interacts with the first wall element 81 to form a first tank chamber 83 of the first distribution tank 12, and the base wall structure 80 further interacts with the second wall element 82 to form a second tank chamber 84 of the first distribution tank 12, which is provided independently of the first tank chamber 83. In particular, the base wall structure 80 comprises a first side wall 80a, a central wall 80b, a second side wall 80c, a first connecting wall 80d that connects the first side wall 80a to the central wall 80b, and a second connecting wall 80e that connects the second side wall 80c to the central wall 80b.The first wall segment 81 can have an essentially semicircular cross-sectional shape and can be configured to be contained within a space formed between the first side wall 80a and the central wall 80b, wherein the first tank chamber 83 is defined by the interaction of the interior space of the first wall segment 81 and the interior spaces of both the first side wall 80a, the first connecting wall 80d, and the central wall 80b. The second wall segment 82 can have an essentially semicircular cross-sectional shape and can be configured to be contained within a space formed between the second side wall 80c and the central wall 80b, wherein the second tank chamber 84 is defined by the interaction of the interior space of the second wall segment 82 and the interior spaces of both the second side wall 80c and the second connecting wall 80e, as well as the central wall 80b.

[0032] The first baffle plate 60 is configured to couple the first coupling element 40 at a position in axial alignment with the first tank chamber 83 to the first distribution tank 12, while the second baffle plate 70 is configured to couple the second coupling element 50 at a position in axial alignment with the second tank chamber 84 to the first distribution tank 12. As shown in Fig. As shown in Figure 7, the first baffle plate 60 comprises an outer circumferential surface 61 with a cross-sectional shape corresponding to the cross-sectional shape of the first tank chamber 83, with the exception of a first coupling tab 63 and a second coupling tab 64, which project radially outwards from opposite sides of the outer circumferential surface 61, the radial direction described being perpendicular to the axial direction described of the corresponding first coupling element 40. The first baffle plate 60 further comprises a central opening 65 for receiving an axial end section 48 ( Fig. 5) of the first coupling element 40 is formed and dimensioned through it when the first baffle plate 60 is accommodated above it. In particular, the axial end section 48 forms an end section of the outer section 40b of the first coupling element 40, which is positioned distal to the wall of the first pipe connection structure 11. The first baffle plate 60 is used as an end plate (guide plate) to limit the flow of the refrigerant in the axial direction from the first tank chamber 83 to the first pipe connection structure 11 by accommodating the first baffle plate 60 above the first coupling element 40 and arranging the base wall structure 80 to the first wall element 81, wherein the outer circumferential surface 61 of the first baffle plate 60 engages in the interior surfaces that define the inner facing surfaces of the first tank chamber 83.The receiving of the first baffle plate 60 within the first distribution tank 12 further comprises the first coupling tab 63 extending through an opening 80f formed by the base wall structure 80, and the second coupling tab 64 extending through an opening 81a formed by the first wall element 81, each of the openings 80f, 81a comprising a circumferential form for tightly receiving the corresponding coupling tab 63, 64 therein.

[0033] The second baffle plate 70 comprises an outer circumferential surface 71 with a cross-sectional shape corresponding to the cross-sectional shape of the second tank chamber 84, with the exception of a first coupling tab 73 and a second coupling tab 74, which project radially outwards from opposite sides of the outer circumferential surface 71, the radial direction being perpendicular to the axial direction of the corresponding second coupling element 50. The second baffle plate 70 further comprises a central opening 75 for receiving an axial end section 58 ( Fig. 5) of the second coupling element 50 is formed and dimensioned through it when the second baffle plate 70 is accommodated above it. In particular, the axial end section 58 forms an end section of the outer section 50b of the second coupling element 50, which is positioned distal to the wall of the first pipe connection structure 11. The second baffle plate 70 is used as an end plate (guide plate) to limit the flow of the refrigerant in the axial direction from the second tank chamber 84 to the first pipe connection structure 11 by accommodating the second baffle plate 70 above the second coupling element 50 and an arrangement of the base wall structure 80 to the second wall element 82, wherein the outer circumferential surface 71 of the second baffle plate 70 engages in the interior surfaces that define the second tank chamber 84.The receiving of the second baffle plate 70 within the first distribution tank 12 further comprises the first coupling tab 73 extending through an opening 80g formed by the base wall structure 80, and the second coupling tab 74 extending through an opening 82a formed by the second wall element 82, each of the openings 80g, 82a comprising a circumferential shape for tightly receiving the corresponding coupling tab 73, 74 therein.

[0034] The second distribution tank 14 and the second pipe connection structure 15 have essentially identical structures to the first distribution tank 12 and the first pipe connection structure 11, except that they are rotated 180 degrees about an axis extending longitudinally from one of the tank chambers 83, 84 to the opposite end of the plurality of heat exchanger tubes 13. Therefore, the following description of their structure is limited to any differences or distinctions that exist between them, where applicable. Additionally, the same reference numerals are used when describing the same features that exist between the first distribution tank 12 and the second distribution tank 14. As shown in the cross-sectional view of Fig. As shown in Figure 8, the second distribution tank 14 defines a third tank chamber 85, which is located opposite the first tank chamber 83, and a fourth tank chamber 86, which is located opposite the second tank chamber 84. A first column 13a of the plurality of heat exchanger tubes 13 extends between the first tank chamber 83 of the first distribution tank 12 and the third tank chamber 85 of the second distribution tank 14 and fluidically couples them, and a second column 13b of the plurality of heat exchanger tubes 13 extends between the second tank chamber 84 of the first distribution tank 12 and the fourth tank chamber 86 of the second distribution tank 14 and fluidically couples them. Fig. Figure 8 shows only one of the heat exchanger tubes 13 that form each of the described columns 13a, 13b, while Fig. Figure 2 shows the entirety of the second column 13b of the heat exchanger tubes 13. The first column 13a of the heat exchanger tubes 13 comprises the same configuration as shown in relation to the second column 13b at a lateral position, while extending between the opposing tank chambers 83 and 85 in the manner described above.

[0035] Fig. Figure 8 illustrates the heat exchanger tubes 13 of each of the columns 13a, 13b as a multi-channel configuration in which the surface area of ​​each of the heat exchanger tubes 13 exposed to the refrigerant flowing through it is maximized to increase the heat exchange capacity of each of the heat exchanger tubes 13. In the present embodiment, each of the heat exchanger tubes 13 can be extruded and comprise a plurality of fluid conveying channels in a laterally oriented row with wall segments separating the adjacent channels. However, the heat exchanger tubes 13 can essentially comprise any heat exchange or fluid conveying configuration while remaining within the scope of the present invention.

[0036] As in Fig. 6 and Fig. As shown in Figure 8, the base wall structure 80 of the first distribution tank 12 further comprises a plurality of tube openings 87 formed therein, each of the tube openings 87 accommodating an end section of one of the heat exchanger tubes 13 therein. In particular, the first connecting wall 80d comprises a plurality of first tube openings 87a formed therein, and the second connecting wall 80e comprises a plurality of second tube openings 87b formed therein. Each of the first tube openings 87a is configured to accommodate one of the heat exchanger tubes 13 of the first column 13a, while each of the second tube openings 87b is configured to accommodate one of the heat exchanger tubes 13 of the second column 13b. The base wall structure 80 can further have corresponding connecting openings 88 for receiving sections with a tab of one of the described connecting plates 17, 18 therein at one of the ends of the columns 13a, 13b of the heat exchanger tubes 13.As already mentioned, the corresponding features of the second distribution tank 14, which are identical and arranged opposite each other, have similar openings for receiving opposite ends of the heat exchanger tubes 13 and / or the connecting plates 17, 18 therein in order to couple the opposite distribution tanks 12, 14 together, so that a further description is not included here.

[0037] The internal condenser 10 comprises only one of the tank chambers 83, 86 of each of the respective distribution tanks 12, 14, which is in direct fluid communication with the interior of a corresponding pipe connection structure 11, 15 via a corresponding first coupling element 40 in which one of the through-holes 45 is formed, while the other of the tank chambers 84, 85 assigned to each of the respective distribution tanks 12, 14 is aligned with a corresponding blind hole, which is connected to the reinforcement of a connection between the corresponding distribution tank 12, 14 and the pipe connection structure 11, 15. Thus, at least one of the distribution tanks 12, 14 must have a corresponding structure for fluid communication of the refrigerant between the adjacently located tank chambers 83, 84 and 85, respectively.Tank chambers 85, 86 are provided to utilize the two different columns 13a, 13b of the heat exchanger tubes 13 in the heat exchange between the refrigerant and the ambient air.

[0038] Fig. Figures 9-12 show a possible flow configuration through the inner condenser 10, wherein the wall segments 81, 82 are located away from the base wall structure 80 of each of the respective distributor tanks 12, 14, and wherein the second shell 31 of each of the respective pipe connection structures 11, 15 is located away from the corresponding first shell 21 to more easily show the internal structure of the inner condenser 10. In contrast to the first distributor tank 12, the second distributor tank 14 includes at least one fluid connection opening 92 ( Fig. 10), which is formed by the corresponding central wall 80b of the base wall structure 80 thereof, to allow a fluid connection between the third and fourth tank chambers 85, 86, wherein the fluid connection openings 92 may be formed at positions by a section of the central wall 80b that is spaced apart from or opposite the second pipe connection structure 15. The second distribution tank 14 also differs from the first distribution tank 12 by the addition of an inner baffle plate 93, which is substantially identical in construction to each of the baffle plates 60, 70, except for the removal of a central opening to receive a projecting section of one of the coupling elements 40, 50 passing through it.Instead, the inner baffle plate 93 divides the fourth tank chamber 86 into an upstream section 86a and a downstream section 86b with respect to the flow of refrigerant through the inner condenser 10, as will be explained in more detail below. As shown in the figures, each of the distribution tanks 12, 14 can further utilize end baffle plates 94 having the same structure as the disclosed inner baffle plate 93, each of the end baffle plates 94 restricting the flow of refrigerant within the corresponding tank chamber in a direction away from the corresponding pipe connection structure 11, 15.

[0039] As in Fig. As shown in Figure 9, the refrigerant enters the interior of the first pipe connection structure 11 via its cylindrical opening 38, before rotating to flow through the through-bore 45 of the first coupling element 40. The refrigerant enters the first tank chamber 83 of the first distribution tank 12 and flows axially through it for distribution to each of the first columns 13a of the heat exchanger tubes 13, which lead to the third tank chamber 85 of the second distribution tank 14.

[0040] As in Fig. As shown in Figure 10, the refrigerant, as soon as it enters the third tank chamber 85, is caused to flow axially towards the fluid connection openings 92 of the second distribution tank 14 (in a direction perpendicular to the axial direction of the third tank chamber 85) and then laterally through it into the adjacent fourth tank chamber 86. The inner baffle plate 93 limits the axial flow of the refrigerant in a direction towards the second pipe connection structure 15 as it flows through the upstream section 86a of the fourth tank chamber 86, and therefore causes the refrigerant instead to flow through a first section of the second column 13b of the heat exchanger tubes 13 in a direction back towards the second tank chamber 84 of the first distribution tank 12. As shown in Fig. As shown in Figure 11, the refrigerant can then flow back through a second section of the second column 13b of the heat exchanger tubes 13 to the downstream section 86b of the fourth tank chamber 86, after flowing axially within the second tank chamber 84 in a direction towards the first pipe connection structure 11. The downstream section 86b is in fluid communication with the corresponding through-hole 45, which leads to the interior of the second pipe connection structure 15, allowing the refrigerant to exit the second pipe connection structure 15 while flowing in a lateral direction opposite to that in which the refrigerant enters the first pipe connection structure 11, as shown in Figure 11. Fig. 12 shown.

[0041] It is understood that the distribution tanks 12, 14 and each of the respective tank chambers 83, 84, 85, 86 may include alternative flow configurations formed through them while remaining within the scope of the present invention, such as including additional fluid connection openings 92 and / or internal baffle plates 93 to cause the refrigerant to undergo additional changes in flow direction as desired.It should also be evident that each of the distribution tanks 12, 14 can be configured to include additional tank chambers by modifying the base wall structure 80 to include additional inner walls (corresponding to the central wall 80b) between the outermost walls (corresponding to the first and second side walls 80a, 80c), each with a wall element (corresponding to one of the wall segments 81, 82) spanning the space between the walls of the modified base wall structure 80, to form three or more tank chambers in a lateral direction of the modified base wall structure 80. In such a modified distribution tank, one or more of the resulting additional tank chambers can be aligned with one of the disclosed coupling elements 40, 50, where a fluid connection between the respective tank chambers and an interior of the corresponding pipe connection structure 11, 15 is to be effected or prevented.Such a modified distribution tank would also lead to corresponding modifications to the aligned pipe connection structure 11, 15, such as one of the coupling elements 40, 50 aligned with each of the resulting tank chambers. For example, a distribution tank with three tank chambers can include one of the coupling elements 40 with the through-hole 45 and two of the coupling elements 50 with the barrier wall 56 and the at least one blind hole 55, 57 formed therein, each of the coupling elements 50 assisting in providing structural reinforcement for the connection formed between the pipe connection structure 11, 15 and the aligned distribution tank 12, 14.

[0042] Each of the disclosed structures can further be coupled to one another by a suitable aggressive joining process to form a fluid-tight seal at each of the disclosed connections present between their structural elements. For example, each of the connections at which the pipe connection structures 11, 12, the coupling elements 40, 50, the baffle plates 60, 70, 93, 94, the base wall structures 80, the wall segments 81, 82, and the heat exchanger tubes 13 engage with one another can be sealed by a soldering process once the internal capacitor 10 has been assembled into the configuration shown in the drawings. However, alternative joining processes, which remain within the scope of the present invention, such as press-fit couplings or mechanical deformation of one or more engagement components (such as crimping), can also be used to form a desired connection between the engagement components.

[0043] The present disclosure comprises the first coupling element 40 with the through-hole 45, which is provided distal to the cylindrical opening 38 to a closed end of the corresponding pipe connection structure 11, and the second coupling element 50 with the fluid barrier wall 56, which is provided proximal to the cylindrical opening 38. However, it is readily apparent to those skilled in the art that the positioning of the coupling elements 40, 50 can be changed to specify a different flow configuration through the tank chambers 83, 84, 85, 86 of the distribution tanks 12, 14 without departing from the scope of the present invention.That is, the proximally positioned one of the coupling elements 40, 50 adjacent to the cylindrical opening 38 can instead be the first coupling element 40 with the through-hole 45, and the distally positioned one of the coupling elements 40, 50, which is placed towards the closed end of the pipe connection structure 11, can be the second coupling element 50 with the fluid barrier wall 46 formed by the presence of the blind hole 57, the flow configuration through the distributor tanks 12, 14 being different from that disclosed to take into account that the coolant enters and / or exits each respective distributor tank 12, 14 at positions aligned with the tank chambers 84, 85 instead of the tank chambers 83, 86. An example of such an alternative pipe connection structure 111, in which the coupling elements 40, 50 are switched into position, is shown in . Fig.13. As previously noted, the pipe connection structure 11 can also be modified to include three or more of the coupling elements 40, 50 for alignment with three or more of the tank chambers forming modified versions of the distribution tanks 12, 14, wherein any sequence of the different coupling elements 40, 50 can be used in the proximal to distal direction away from the cylindrical opening 38, while remaining within the scope of the present invention.

[0044] Exemplary embodiments are provided in such a way as to ensure that this disclosure is comprehensive and will fully convey its scope to all those skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It is understood by those skilled in the art that specific details need not be used, that exemplary embodiments can be implemented in many different forms, and that none should be designed to limit the scope of the disclosure. In some exemplary embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.Equivalent changes, modifications and variations of some embodiments, materials, compositions and processes can be made within the scope of the present technology with substantially similar results. Industrial applicability

[0045] The disclosure relates to a heat exchanger and in particular an inlet pipe connection structure and an outlet pipe connection structure for a condenser of a heating, ventilation and air conditioning (HVAC) system of a vehicle, wherein the condenser and pipe connection structures occupy a minimized packing space within the vehicle.

Claims

[1] A heat exchanger which has the following features: a first pipe connection structure comprising a first outer wall defining at least a section of an interior of the first pipe connection structure, wherein the interior of the first pipe connection structure accommodates a first fluid therein; a first coupling element received in a first opening formed by the first outer wall of the first pipe connection structure, wherein the first coupling element comprises a first through-hole formed by the latter; a second coupling element that is received in a second opening formed by the first outer wall of the first pipe connection structure; and a first distribution tank coupled to each of the first coupling element and the second coupling element, the first distribution tank comprising a first tank chamber extending longitudinally from the first coupling element and a second tank chamber extending longitudinally from the second coupling element, the first through-hole of the first coupling element providing a fluid connection of the first fluid between the interior of the first pipe connection structure and the first tank chamber, and the second coupling element forming a first fluid barrier wall to prevent a fluid connection of the first fluid between the interior of the first pipe connection structure and the second tank chamber via the second coupling element. [2] The heat exchanger according to claim 1, wherein the second coupling element comprises at least one blind hole formed therein. [3] The heat exchanger according to claim 2, wherein the at least one blind hole has a cylindrical shape. [4] The heat exchanger according to claim 2, wherein the at least one blind hole is formed in one or both by a first axial end of the second coupling element facing the interior of the first pipe connection structure and / or a second axial end of the second coupling element facing away from the interior of the first pipe connection structure. [5] The heat exchanger according to claim 2, wherein the at least one blind hole comprises a first blind hole formed in a first axial end of the second coupling element and a second blind hole formed in a second axial end of the second coupling element. [6] The heat exchanger according to claim 5, wherein the first blind hole is formed directly opposite the second blind hole, wherein the first blind hole is axially aligned with the second blind hole. [7] The heat exchanger according to claim 5, wherein the first fluid barrier wall is formed by a section of the second coupling element which is placed directly between the first blind hole and the second blind hole. [8] The heat exchanger according to claim 2, wherein the first fluid barrier wall is placed at an inner axial end of the at least one blind hole. [9] The heat exchanger according to claim 8, wherein the first fluid barrier wall comprises a concave surface formed therein at the inner axial end of the at least one blind hole. [10] The heat exchanger according to claim 1, wherein the first through-hole extends through an assembly of the first coupling element in an axial direction thereof. [11] The heat exchanger according to claim 10, wherein the axial direction of the first coupling element is parallel to a longitudinal direction of the first tank chamber. [12] The heat exchanger according to claim 10, wherein a first axial end of the first through-hole is placed inside the interior of the first pipe connection structure and a second axial end of the first through-hole is placed inside the first tank chamber. [13] The heat exchanger according to claim 1, wherein the first distribution tank comprises a central wall that divides the first distribution tank laterally into the first tank chamber and the second tank chamber, and wherein the central wall comprises at least one fluid connection opening formed through it to provide a fluid connection of the first fluid between the first tank chamber and the second tank chamber. [14] The heat exchanger according to claim 1, wherein the first distribution tank comprises a first baffle plate placed around the first coupling element and a second baffle plate placed around the second coupling element. [15] The heat exchanger according to claim 14, wherein the first baffle plate forms an axial end surface of the first tank chamber, which surrounds the first coupling element to limit a flow of the first fluid in an axial direction of the first tank chamber towards the interior of the first pipe connection structure, and wherein the second baffle plate forms an axial end surface of the second tank chamber, which surrounds the second coupling element to limit a flow of the first fluid in an axial direction of the second tank chamber towards the interior of the first pipe connection structure. [16] The heat exchanger according to claim 14, wherein the first baffle plate comprises a first coupling tab projecting outwards therefrom, and the second baffle plate comprises a second coupling tab projecting outwards therefrom, wherein the first coupling tab is received in a first opening formed by a first wall of the first distribution tank, which partially defines the first tank chamber, and wherein the second coupling tab is received in a second opening formed by a second wall of the first distribution tank, which partially defines the second tank chamber. [17] The heat exchanger according to claim 1, which further comprises the following features: a second distribution tank, which is spaced apart from the first distribution tank and comprises a third tank chamber and a fourth tank chamber formed therein; and a plurality of heat exchanger tubes extending between the first distribution tank and the second distribution tank, wherein the plurality of heat exchanger tubes constitute a first set of heat exchanger tubes providing a fluid connection of the first fluid between the first tank chamber of the first distribution tank and the third tank chamber of the second distribution tank, and include a second set of heat exchanger tubes that provide a fluid connection of the first fluid between the second tank chamber of the first distribution tank and the fourth tank chamber of the second distribution tank. [18] The heat exchanger according to claim 17, wherein the first tank chamber is in fluid communication with the second tank chamber via the first fluid which flows through the first set of heat exchanger tubes, the third tank chamber, the fourth tank chamber and the second set of heat exchanger tubes. [19] The heat exchanger according to claim 17, which further comprises the following features: a second pipe connection structure comprising a second outer wall defining at least a section of an interior of the second pipe connection structure, wherein the interior of the second pipe connection structure receives the first fluid therein; a third coupling element that is received in a third opening formed by the second outer wall of the second pipe connection structure; and a fourth coupling element which is received in a fourth opening formed by the second outer wall of the second pipe connection structure, wherein the fourth coupling element comprises a second through-hole formed by the latter; wherein the second distribution tank is coupled to each of the third coupling element and the fourth coupling element, wherein the third tank chamber extends longitudinally from the third coupling element and the fourth tank chamber extends longitudinally from the fourth coupling element, wherein the second through-hole of the fourth coupling element provides a fluid connection of the first fluid between the interior of the second pipe connection structure and the fourth tank chamber, and wherein the third coupling element forms a second fluid barrier wall to prevent a fluid connection of the first fluid between the interior of the second pipe connection structure and the third tank chamber via the third coupling element. [20] The heat exchanger according to claim 19, wherein the second pipe connection structure is structurally identical to the first pipe connection structure, wherein the orientation of the second pipe connection structure is rotated by 180 degrees relative to the first pipe connection structure.

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