Heat exchanger comprising a separator element

Abstract

A heat exchanger comprising a first distributor (11) and a second distributor (12) and a plurality of parallel, coplanar tubes (13) interconnecting the first distributor (11) and the second distributor (12). One of the distributors (11) comprises a separator element (30) inserted into a through-hole (18) formed on a side wall (11a) of the distributor (11). The separator element (30) comprises a pair of plates (31, 32), each of which comprises a central portion (31a, 32a) and a peripheral edge (31b, 32b) raised with respect to the central portion (31a, 32a), the plates (31, 32) being joined to each other at their respective central portions (31a, 32a) so as to define an annular gap (G) around the central portions (31a, 32a), interposed between the peripheral edges (31b, 32b) of the plates (31, 32), wherein the peripheral edge (31b, 32b) of each plate (31, 32) has a pair of laterally protruding portions (31c, 32c) arranged on opposite sides of the plate (31, 32), and interposed between opposite edges (18') of the through-hole (18).

Description

[0001] The present invention relates to a heat exchanger, particularly for a motor vehicle, of the type comprising a first distributor and a second distributor and a plurality of parallel, coplanar tubes interconnecting the first distributor and the second distributor, wherein each of said distributors has a tubular body, on a side wall of which a plurality of slits is formed, in each of which an end of a respective tube is inserted, wherein at least one of said distributors, hereinafter partitioned distributor, comprises a separator element which partitions the inside of the partitioned distributor into a first inner space and a second inner space, said separator element being inserted into a through-hole formed in the side wall of the partitioned distributor.

[0002] Heat exchangers of this type are used, for example, in HVAC systems with a heat pump.

[0003] In such heat exchangers, a separator partition is installed to divide the passages inside the heat exchanger. When there is an internal leakage from the separator (i.e., a seepage between the two internal spaces formed inside the partitioned distributor), this results in a significant performance loss. Detecting such leaks during the production process is highly complex, and the available detection systems often lack the sensitivity to identify small leaks that could still negatively affect the performance of the heat exchanger. JP 2016099097 A describes a heat exchanger provided with collectors formed by a plate and a basin assembled together and comprising a separator made up of a pair of plates provided with a protruding structure through a wall of the basin. The plates are joined to each other at the respective central portions so as to define an annular gap around said central portions, interposed between the peripheral edges of the plates. The aforementioned separator improves leak detection by directing any leakage toward the exterior of the heat exchanger, making it detectable through a simple pressure-tightness test.

[0004] One object of the invention is to make a similar solution available for heat exchangers provided with tubular body distributors.

[0005] This object is achieved according to the invention by a heat exchanger of the type defined above, wherein the separator element comprises a pair of plates, each of which comprises a central portion and a peripheral edge raised with respect to the central portion, said plates being joined to each other at the respective central portions so as to define an annular gap around said central portions, interposed between the peripheral edges of the plates, wherein the peripheral edge of each plate has a pair of laterally protruding portions arranged on opposite sides of the plate and interposed between opposite edges of the through-hole.

[0006] Preferred embodiments of the invention are defined in the dependent claims, which are to be understood as an integral part of the present description.

[0007] Further features and advantages of the invention will become clearer with the following detailed description of an embodiment of the invention, made with reference to the accompanying drawings, provided purely by way of illustration and not limitation, in which: Figure 1 is a perspective view of a heat exchanger; Figure 2 is a perspective view of a detail of a distributor of a heat exchanger according to the invention; Figure 3 is a sectional perspective view of the detail of Figure 2; Figure 4 is an exploded view of the detail of Figure 2; Figures 5a and 5b are respectively a cross-sectional view and a longitudinal sectional view illustrating the insertion of a separator element into a through-hole of the distributor; Figures 6a and 6b are respectively a cross-sectional view and a longitudinal sectional view illustrating the separator element completely inserted into the through-hole of the distributor; Figure 7 is a cross-sectional view illustrating a further processing phase; Figures 8 to 11 are respectively a plan view of a first plate of the separator element, a sectional view of the first plate taken along line VIII-VIII of Figure 8, a plan view of a second plate of the separator element, and a sectional view of the second plate taken along line X-X of Figure 10, according to an embodiment; Figures 12 and 13 are respectively a perspective view and a sectional view of the separator element according to another embodiment; Figures 14 and 15 are perspective views of further embodiments.

[0008] With reference to Figure 1, a heat exchanger made of metallic material, particularly aluminum, is shown overall denoted by 1. In the illustrated example, heat exchanger 1 is a heat exchanger for heat transfer fluid-air, particularly an internal condenser of an HVAC system with a heat pump for an electric vehicle.

[0009] Heat exchanger 1 comprises at least a first distributor 11 and at least a second distributor 12 and a plurality of parallel, coplanar tubes 13 interconnecting the first distributor 11 and the second distributor 12. Between adjacent tubes 13, fins 14 are interposed, not shown in detail. Two lateral plates 15 and 16 are fixed to opposite sides of the mass formed by tubes 13.

[0010] The above-described elements are joined together in a manner known per se, for example, by braze-welding.

[0011] Each of the distributors 11, 12 has a tubular body, for example, with a circular cross-section, on a side wall 11a, 12a of which a plurality of slits 17 is formed, in each of which an end of a respective tube 13 is inserted.

[0012] As shown in Figures 1 to 4, inside at least one of the distributors 11, 12, a separator element 30 is arranged, partitioning the inside of partitioned distributor 11 into a first inner space 11' and a second inner space 11". Separator element 30 is inserted into a linear through-hole 18 formed on the side wall 11a of partitioned distributor 11 and parallel to slits 17 for tubes 13. Separator element 30 has an edge abutting against an internal surface of the partitioned distributor 11 and opposite faces contiguous with respective edges 18' of through-hole 18. Separator element 30 is joined to partitioned distributor 11 by material coupling, particularly by braze-welding.

[0013] With reference also to Figures 8 to 11, separator element 30 comprises a pair of plates 31, 32, each of which comprises a central portion 31a, 32a and a peripheral edge 31b, 32b raised with respect to central portion 31a, 32a. As can be seen in Figures 3-4, plates 31, 32 are joined to each other at their respective central portions 31a, 32a so as to define an annular gap G around central portions 31a, 32a. Annular gap G is interposed between peripheral edges 31b, 32b of plates 31, 32 and therefore communicates with the external environment through the portion of through-hole 18 located between peripheral edges 31b, 32b of plates 31, 32. Any fluid seepage between the edges of separator element 30 and the internal surface of partitioned distributor 11 is thus detectable through through-hole 18 via a tightness test.

[0014] The peripheral edge 31b, 32b of each plate 31, 32 has a pair of laterally protruding portions 31c, 32c arranged on opposite sides of plate 31, 32 and interposed between opposite edges 18' of through-hole 18. These laterally protruding portions 31c, 32c are connected to each other by a central protruding portion 31d, 32d of peripheral edge 31b, 32b. Central protruding portions 31d, 32d are also interposed between opposite edges 18' of through-hole 18. As can be seen in Figures 2 and 3, laterally protruding portions 31c, 32c and central protruding portions 31d, 32d of plates 31, 32 extend outward beyond through-hole 18, thus protruding with respect to the outer surface of partitioned distributor 11. Laterally protruding portions 31c, 32c of plates 31, 32 overlap opposite ends 18" of through-hole 18 and are preferably provided with respective crimping appendages 31e, 32e.

[0015] Preferably, plates 31-32 are directly fixed to each other so as to achieve a provisional assembly of plates 31, 32 before their insertion into through-hole 18. In the example illustrated in Figures 8-11, one of plates 31, 32 is provided with a hole 33 formed through its respective central portion 31a, and the other of plates 31, 32 is provided with a button-like protrusion 34 formed on its respective central portion 32a. Hole 33 and button-like protrusion 34 engage with each other to achieve the provisional assembly of plates 31, 32 before their insertion into through-hole 18.

[0016] As shown in Figures 5a-5b and 6a-6b, separator element 30, formed by assembled plates 31, 32, is inserted from the outside of distributor 11 through the through-hole 18, until the edges of plates 31, 32 abut against the internal surface of distributor 11 and the laterally protruding portions 31c, 32c overlap ends 18" of through-hole 18. Subsequently, crimping appendages 31e, 32e are deformed against the external surface of distributor 11, thereby achieving a provisional attachement of separator element 30 to distributor 11. Finally, braze-welding is used to achieve the definitive joining of separator element 30 to distributor 11.

[0017] Figures 12 and 13 show a further embodiment of the invention. Elements corresponding to those of the previous embodiment have been assigned the same reference numbers; these elements will not be further described. The embodiment of Figures 12 and 13 differs from the previous one in the type of engagement between plates 31, 32 of separator element 30. In this embodiment, the engagement between plates 31, 32 is achieved by cold deformation, which creates undercuts in central portions 31a, 32a.

[0018] Figures 14 and 15 show further embodiments of the invention. Elements corresponding to those of the previous embodiments have been assigned the same reference numbers; these elements will not be further described. The embodiments of Figures 14 and 15 differ from the previous ones in that plates 31, 32 of separator element 30 are connected to each other by one or more connection portions 35 made in one piece with plates 31, 32. These connection portions 35 extend between central protruding portions 31d, 32d of peripheral edge 31b, 32b of plates 31, 32. In this embodiment, connection portions 35 are bent before inserting separator element 30 into through-hole 18, so as to arrange plates 31, 32 with central portions 31a, 32a against each other.

Claims

1. Heat exchanger comprising a first distributor (11) and a second distributor (12) and a plurality of parallel, coplanar tubes (13) interconnecting the first distributor (11) and the second distributor (12), wherein each of said distributors (11, 12) has a tubular body, on a side wall (11a, 12a) of which a plurality of slits (17) is formed, in each of which an end of a respective tube (13) is inserted, wherein at least one of said distributors, hereinafter partitioned distributor (11), comprises a separator element (30) which partitions the inside of the partitioned distributor (11) into a first inner space (11') and a second inner space (1177), said separator element (30) being inserted into a through-hole (18) formed in the side wall (11a) of the partitioned distributor (11), characterised in that the separator element (30) comprises a pair of plates (31, 32), each of which comprises a central portion (31a, 32a) and a peripheral edge (31b, 32b) raised with respect to the central portion (31a, 32a), said plates (31, 32) being joined to each other at the respective central portions (31a, 32a) so as to define an annular gap (G) around said central portions (31a, 32a), interposed between the peripheral edges (31b, 32b) of the plates (31, 32), wherein the peripheral edge (31b, 32b) of each plate (31, 32) has a pair of laterally protruding portions (31c, 32c) arranged on opposite sides of the plate (31, 32), and interposed between opposite edges (18') of the through-hole (18).

2. Heat exchanger according to claim 1, wherein, in each plate (31, 32), said laterally protruding portions (31c, 32c) are connected to each other by a central protruding portion (31d, 32d) of the peripheral edge (31b, 32b), and wherein the central protruding portions (31d, 32d) of said plates (31, 32) are interposed between the opposite edges (18') of the through-hole (18).

3. Heat exchanger according to claim 1 or 2, wherein said laterally projecting portions (31c, 32c) of said plates (31, 32) overlap opposite edges (18') of the through-hole (18).

4. Heat exchanger according to claim 3, wherein said laterally protruding portions (31c, 32c) have respective crimping appendages (31e, 32e) provided for attachment to the tubular body of said partitioned distributor (11).

5. Heat exchanger according to any of the preceding claims, wherein said plates (31, 32) are joined to the tubular body of said partitioned distributor (11) by braze-welding.

6. Heat exchanger according to any of the preceding claims, wherein said plates (31, 32) are directly fixed to each other.

7. Heat exchanger according to any of claims 1 to 5, wherein the plates (31, 32) are connected to each other by at least one connection portion (35) made in one piece with the plates (31, 32), said at least one connection portion (35) being bent so as to arrange the plates (31, 32) with the central portions (31a, 32a) against each other.

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