Patent Grant
10962295
A heat exchange apparatus having a plurality of modular flow path assemblies, encased in a core body with a plurality of corresponding flow path assembly seats, providing means for independent positioning and axial alignment for a desired effect.
In a typical heat exchanger, a core body comprising of a plurality of tube sections is provided wherein at least two heat exchange mediums are utilized to facilitate heat exchange between the two heat exchange mediums. A first heat exchange medium is generally contained inside the plurality of tube sections while a second heat exchange medium flows outside the plurality of tube sections. The purpose of using a typical heat exchanger is to generally transfer heat from the first heat exchange medium to the second heat exchange medium. The heat can be transferred from inside the heat exchanger to the outside, or vice versa. With the desire to effectively utilize a limited amount of packaging space provided for a heat exchanger in an application, the heat exchanger may not be provided with an environment that optimizes heat transfer performance. Namely, when free flowing external heat exchange medium such as air is used as an external heat exchange medium, it is vital that the heat exchanger is provided with an optimal flow path for the external heat exchange medium, facilitating effective transfer of heat between the first and the second heat exchange medium. In an automotive application, for example, heat exchangers vital for proper operation of a vehicle are typically located at the very front of the vehicle, to facilitate means to provide the heat exchangers with as much flow of air as possible to achieve optimum heat transfer. The location at the front of the vehicle is desirable, as the location generally provides the heat exchangers with the optimum flow of the external heat exchange medium, which in the automotive radiator application may generally be air.
However, as the desire to design a smaller, more compact vehicle is pursued, the traditional space at the front of the vehicle may no longer be available for the purpose of locating heat exchangers. As such, need arises to position the heat exchangers at non-traditional positions, such as to a side of a vehicle engine compartment, on a side fender panel, or on a bonnet of a vehicle, for example. As the alternative heat exchanger locations typically do not provide for optimum external heat exchange medium flow, a solution must be devised to provide the heat exchanger with an optimum external heat exchange medium flow regardless of the positioning of the heat exchanger within the vehicle, which may include space or shape limitations, for example. Similar constraints impacting optimal heat transfer efficiency is not only limited in an automotive application, therefore, a solution provided herein may be applied to a variety of heat exchanger applications. Similar constraints may be observed in other applications of heat exchangers, such as in general electronics, appliances, and industrial cooling systems, for example. The present invention relates to optimization of the external heat exchange medium flow, wherein individual flow paths provided within the heat exchanger for the external heat exchange medium are optimized for positioning as well as horizontal and vertical axial orientation to enhance the overall heat exchange performance, while achieving the desired effect in a cost effective manner along with enhancements made to the heat conduction effectiveness, yielding higher heat transfer performance in a smaller heat exchanger package.
A prior art heat exchanger, commonly called a tube and fin heat exchanger, is typically comprised of a plurality of tubular sections and fin sections stacked interchangeably together as an assembly to generally optimize ease of assembly. The tubular sections are used to transport the internal heat exchange medium as well as to transfer heat between the internal heat transfer medium and the external heat transfer medium. The fin sections are attached to the exterior surface of the tube sections to supplement the tubes in transferring heat between the internal heat exchange medium and the external heat exchange medium. The assembly comprising the tube sections and the fin sections, commonly referred to as a core, is designed primarily for minimizing assembly cost, in turn, generally not given any provisions for cost effective means for minute adjustments of individual tubular section and fin section orientation to optimally align the individual components to the expected flow pattern of the external heat exchange medium.
The core section of the prior art heat exchanger generally is designed for a simplified uniform flow of the external heat exchange medium, wherein the assumption is that the flow of the external heat exchange medium is uniform throughout the core surface, even though in actual application, it is typically not the case. Similarly, in some instances where space is restricted for positioning of a heat exchanger, the heat exchanger may be bent or contorted to fit in a space available in an application. For example, a radiator for a motorcycle is generally placed in front of an engine of the motorcycle. Due to the size restriction of the space generally available for the radiator, the radiator core is commonly provided with a tapered core shape that is generally concave convexo in appearance, when observed from the frontal plane of the radiator.
As the core is formed to fit in the required package space, the tube sections and fin sections provided within the core may no longer align in the most desirable way with the expected flow pattern of the external heat exchange medium, which may negatively affect the performance of the heat exchanger. Namely, when the flow path for the external heat exchange medium is not ideally aligned to the expected flow pattern of the external heat exchange medium, the external heat exchange medium may be required to make flow directional changes within the core of the heat exchanger, thereby hampering heat transfer effectiveness by increasing pressure drop effect to the external heat exchange medium, generally known in the art to adversely affect the performance of the heat exchanger. As the performance of the heat exchanger is negatively affected, the heat exchanger may need to be larger in physical size, which generally results in need for additional raw material, which in turn results in additional weight and cost as well as requiring additional packaging space for the heat exchanger placement.
Generally, in a prior art heat exchanger, a first lateral side of the core is terminated with a first header plate while a second lateral side of the core is terminated with a second header plate. The first and the second header plates are laterally space apart, positioned generally parallel to each other. Coupled between the first and the second header plates are a plurality of tubes and fin structures, positioned transversely in relation to the pair of header plates. First leading longitudinal edge of the plurality of tubes and fin structures form a frontal plane of the core, generally facing the flow of the external heat exchange medium, wherein space provided between the plurality of tubes and fins act as an inlet for the external heat exchange medium of the heat exchanger. Second trailing longitudinal edge of the plurality of tubes and fin structures form a backward facing plane of the core, wherein space provided between the plurality of tubes and fins act as an outlet for the external heat exchange medium to facilitate discharge of the external heat exchange medium out of the heat exchanger.
In a prior art heat exchanger, as the first lateral end of the plurality of tubes are affixed to the first header plate while the second lateral end of the plurality of tubes are affixed to the second header plate, when a heat exchanger application calls for the heat exchanger core surface to be formed or contorted in shape to fit within a given package space, the external heat exchange medium flow paths provided within the core generally obtains similarly contorted flow path arrangement. Therefore, the flow path provided for the external heat exchange medium within the heat exchanger core may no longer align with the expected flow path of the external heat exchange medium, negatively affecting the heat transfer effectiveness of the heat exchanger as a result. As the orientation of the individual tubes and fins are dictated by the corresponding mating holes for the tubes provided on the first and the second header plates, the only adjustment available for the tubes and fins are vertical angulation at best. As a result, it is difficult if not impossible to align individual flow paths provided within the core for the external heat exchange medium in a desired way to optimize external heat exchange medium flow to maintain heat transfer effectiveness in a cost-effective manner.
In an embodiment of the present invention, the flow paths for the external heat exchange medium within a core body are provided by a plurality of flow path assemblies, which are independent, modular, and self-contained units permitting means to independently align the individual flow path assemblies, in an easy, cost effective manner within the core body of the heat exchanger. The internal heat exchange medium for the heat exchanger flow within the core body, contained within a vessel comprised of a plurality of core body panels, which can be easily separately designed without adversely affecting the locating means or axial orientation of the plurality of flow path assemblies, thereby permitting means to obtain desirable heat transfer performance for any given application of the heat exchanger. A frontal plane of the heat exchanger core body is established by a first core surface while a backward facing plane of the heat exchanger core body is established by a second core surface. The positioning and axial orientation of the individual flow path assemblies within the core body are accomplished by the corresponding individual flow path assembly seats provided on the first core surface and individual flow path assembly seats provided on the second core surface, which together provides for means to independently align and locate within the core body the individual flow path assemblies, regardless of the general planar characteristics established by the first core surface and the second core surface. Such feature allows for heat exchanger design maximizing flow of the external heat exchange medium into the core body of the heat exchanger, minimizing pressure drop effect to the external heat exchange medium flow, vastly improving heat transfer effectiveness as a result. Furthermore, as individual flow path assemblies are modular units, flow path assemblies of various configurations may be coupled within the core body for a desired effect in a cost-effective manner. Improved performance as a result permits designing smaller heat exchanger of equal or higher heat transfer performance compared to a conventional heat exchanger, permitting means for significant cost savings in usage of raw materials and assembly cost, which by extension permits designing heat exchanger of lighter weight, generally a desirable feature in many heat exchanger applications.
In an embodiment of the present invention, a heat exchanger is provided with a core body. Exterior structure of the core body is a fluid containing vessel, comprising of at least one component, having a first core surface having a thickness, a second core surface having a thickness set at a predetermined longitudinal spacing away from the first core surface, a first lateral core wall having a thickness sealingly mating the first lateral side edge respectively of the first core surface and the second core surface, a second lateral core wall having a thickness sealingly mating the second lateral side edge respectively of the first core surface and the second core surface, a top core wall having a thickness longitudinally sealingly mating the top vertical edge respectively of the first core surface and the second core surface while laterally sealingly mating the top vertical edge respectively of the first lateral core wall and the second lateral core wall, and a bottom core wall having a thickness longitudinally sealingly mating the bottom vertical edge respectively of the first core surface and the second core surface, while laterally sealingly mating the bottom vertical edge respectively of the first lateral core wall and the second lateral core wall.
Coupled within the fluid containing vessel comprising the first and second core surface, the first and second lateral core wall, and the top and bottom core wall are a plurality of flow path assemblies completing the core body. A first heat exchange medium flow within the fluid containing vessel, while flowing externally of the plurality of flow path assemblies coupled within the core body. A second heat exchange medium flow within the plurality of flow path assemblies coupled within the core body, facilitating heat transfer between the first heat exchange medium and the second heat exchange medium by conduction generally through the material comprising the plurality of flow path assemblies.
The top core wall may be provided with at least one inlet to introduce the first heat exchange medium into the heat exchanger. The bottom core wall may be provided with at least one outlet to discharge the first heat exchange medium out of the heat exchanger. In an embodiment of the present invention, the top core wall may be sealingly coupled to an inlet tank. In another embodiment of the present invention, the bottom core wall may be sealingly coupled to an outlet tank. In yet another embodiment of the present invention, the top core wall and the bottom core wall may both be individually coupled to a respective tank.
The core body is provided with the first core surface having a plurality of throughholes, which are orifices extending the thickness of the first core surface. The first core surface may be rectangular, square or any other geometric shape, such as trapezoidal shape, for example. The first side of the first core surface may be of generally flat planar surface, or it may have a contour to give the surface a convex or a concave shape. In yet another embodiment of the present invention, the first side of the first core surface may feature a right angle, providing the first core surface with more than one distinct planar surfaces. Furthermore, the contour provided on the first side of the first core surface may be of a singular moderate radius, a combination of a plurality of moderate radii, one or more of an obtuse or an acute angle, or a combination of one or more radii and angles. The opposite side of the first side of the first core surface is a second side of the first core surface. On the second side of the first core surface, the plurality of throughholes provided on the first core surface are individually mated with a flow path assembly seat surrounding the individual throughholes for the purpose of coupling a first longitudinal end of the plurality of individual flow path assemblies to the first core surface. The flow path assembly seat surfaces provided on the first core surface may be set at a parallel angle relative to the plane established by the respective second side of the first core surface in the immediate vicinity surrounding the individual flow path assembly seat surfaces, or in other embodiment of the present invention, the flow path assembly seat surfaces may not be parallel to the plane established by the respective second side of the first core surface in the immediate vicinity surrounding the flow path assembly seat surfaces.
Longitudinally spaced apart from the second side of the first core surface is the second core surface, wherein a first side of the second core surface faces the second side of the first core surface. In an embodiment of the present invention, the contour of the first side of the second core surface may generally mirror the shape of the second side of the first core surface. In other embodiment of the present invention, however, the first side of the second core surface may not mirror the contour of the second side of the first core surface. The second core surface is provided with a plurality of throughholes, which are orifices extending the thickness of the second core surface. The quantity of throughholes provided on the second core surface generally correspond to the quantity of throughholes provided on the first core surface.
The plurality of throughholes provided on the second core surface are individually mated with the flow path assembly seat surface surrounding the individual throughholes for the purpose of individually coupling a second longitudinal end of the plurality of individual flow path assemblies to the second core surface. The flow path assembly seat surfaces on the second core surface may be parallel relative to the plane established by the first side of the second core surface in the immediate vicinity surrounding the individual flow path assembly seat surface, or in other embodiments of the present invention may not be parallel to the plane established by the respective first side of the second core surface in the immediate vicinity surrounding the flow path assembly seat surface.
In an embodiment of the present invention, the second heat exchange medium is introduced into the heat exchanger through the plurality of throughholes provided on the first core surface, travel through the plurality of flow path assemblies provided in the core body, then discharged out of the plurality of throughholes provided on the second core surface.
The flow path assembly seats on the first core surface and the second core surface provide for means for independent adjustment of the horizontal and the vertical axial orientation of the individual flow path assemblies, regardless of the plane established by the first and the second core surface. The flow path assembly seats further provide locating means of the individual flow path assemblies within the core body.
In an embodiment of the present invention, flow path assembly seats populated on the second side of the first core surface may set flush with the plane established by the second side of the first core surface. In other embodiments of the present invention, a first longitudinal end of the flow path assembly seats may be set at a plane that is outwardly extending from the plane established by the first side of the first core surface, or yet in another embodiment a second longitudinal end of the flow path assembly seats may be set inward from the plane established by the second side of the first core surface. Similarly, flow path assembly seats populated on the first side of the second core surface may set flush with the plane established by the first side of the second core surface. In other embodiments of the present invention, a first longitudinal end of the flow path assembly seats populated on the first side of the second core surface may be set at a plane that is inward from the plane established by the first side of the second core surface or the second longitudinal end of the flow path assembly seats may extend outward from the plane established by a second side of the second core surface.
The second heat exchange medium introduced into the plurality flow path assemblies encounter a plurality of obstacles that force fluid flow directional changes that disrupt heat transfer boundary layer formation, which in turn improves heat transfer effectiveness of the heat exchange medium. In a preferred embodiment of the present invention, the flow paths provided are void of secondary surface features, such as an offset fin or other structures known in the art. However, in other embodiment of the present invention, secondary surface features know in the art may be populated within or outside of the flow path assembly.
In an embodiment of the present invention, a first longitudinal end of the plurality of flow path assemblies are individually provided with the first tubular section. The first tubular section is a hollow member, permitting flow of the second heat exchange medium therethrough, while providing coupling means for the plurality of flow path assemblies to a corresponding first panel flow path assembly seats provided on the first core surface. In an embodiment of the present invention, the diameter of the first tubular section may be smaller than the diameter of the chamber section. In other embodiment of the present invention, the diameter of the first tubular section may generally be the same as the diameter of the chamber section. A second longitudinal end of the plurality of flow path assemblies are individually provided with the second tubular section. The second tubular section is a hollow member, permitting flow of the second heat exchange medium therethrough, while also providing coupling means for the plurality of flow path assemblies to the plurality of corresponding second panel flow path assembly seats provided on the second core surface. In an embodiment of the present invention, the diameter of the second tubular section may be shown smaller than the diameter of the chamber section. In yet another embodiment of the present invention, the diameter of the second tubular section may generally be the same as the diameter of the chamber section. In an embodiment of the present invention, the first tubular section is coupled to a first longitudinal end of the chamber section while the second tubular section is coupled to a second longitudinal end of the chamber section.
Longitudinally disposed between the first tubular section and the second tubular section is the chamber section. The chamber section is a hollow member, permitting flow of the second heat exchange medium therethrough. The first tubular section, the chamber section, and the second tubular section are fluidly connected to each other, permitting flow of the second heat exchange medium between respective components comprising the flow path assembly.
Disposed within the chamber section is the medium directing component. The medium directing component generally functions to longitudinally partition the heat exchange medium flow space provided within the chamber section into two distinct longitudinal zones, an anterior chamber section longitudinally spaced between the first core surface and the medium directing component and a posterior chamber section longitudinally spaced between the medium directing component and a medium directing component base, a planar member, which in an embodiment of the present invention, may be provided as part of the posterior chamber wall of the chamber section. In another embodiment of the present invention, the posterior chamber section may be longitudinally spaced between the medium directing component and a seat interior base, a planar panel member, coupled to the second core surface to maximize the flow space available for the second heat exchange medium to further mix and agitate within the flow path assembly to enhance overall heat transfer efficiency.
The medium directing component, having an inlet medium directing panel, a generally planar member facing towards the first core panel throughholes, further functions to disperse as well as divert the flow of the second heat exchange medium collected in the anterior chamber section. The inlet medium directing panel having a planar surface set at an inclined angle relative to the longitudinal axial orientation of the chamber section induces great amount of swirling and mixing effect to the second heat exchange medium within the chamber section as the second heat exchange medium is directed towards the inlet medium directing panel, while the inclined face of the inlet medium directing panel functions to simultaneously divert the flow of the second heat exchange medium in a generally vertical direction, generally following the slope of the angled face of the inlet medium directing panel. The inlet medium directing panel is generally free of any heat exchange medium flow restricting obstructions on its lateral edges that may restrict the amount of swirling and mixing effect occurring to the second heat exchange medium within the chamber section. Minimizing presence of obstruction on the inlet medium directing panel further lends itself to reduce potential pressure drop effect to the flow of the second heat exchange medium, which may be detrimental to the heat transfer performance, while maintaining the beneficial effect of swirling and mixing effect to the second heat exchange medium.
After the second heat exchange medium is directed into the vertical direction of flow within the interior of the chamber section by the inlet medium directing panel, the second heat exchange medium is further diverted into two divergent flow patterns within the chamber section in a semi-circular manner, generally symmetrical to one another. The two semi-circular flow patterns generally flow away from each other, while generally vertically axially aligned to one another, following the contour of the interior of the chamber section within the posterior chamber section, the respective flows longitudinally located between the medium directing component and the medium directing component base. In another embodiment of the present invention, the two semi-circular flow of the second heat exchange medium may be located between the medium directing component and the seat interior base coupled to the second core surface, located at the terminal edge of a second longitudinal end of the second tubular section, thereby maximizing the interior space available within the flow path assembly to facilitate further swirling and mixing effect to the second heat exchange medium, enhancing the overall heat transfer performance of the heat exchanger. In an embodiment of the present invention, the seat interior base may be an independent component coupled to the medium directing component or to the second core surface. In other embodiment of the present invention, the seat interior base may be provided as an integral component of the second core surface or the medium directing component.
The configuration of the interior contour of the chamber section along with a first lateral directing panel, a top directing panel, and a second lateral directing panel coupled to the medium directing component channels the flow of the two semi-circular flow of the second heat exchange medium originated on the anterior section of the chamber section towards an outlet medium directing panel. The outlet medium directing panel is an inclined planar surface provided on the medium directing component, generally on the opposite side of the inlet medium directing panel. The outlet medium directing panel is partially laterally abutted by the first lateral directing panel and the second lateral directing panel while a top vertical end of the outlet medium directing panel is terminated with the top directing panel, obstructing the second heat exchange medium introduced towards the outlet medium directing panel located within the posterior section of the chamber section from flowing back towards the anterior section of the chamber section, located forward of the medium directing component. Minimizing flow back of the second heat exchange medium prevents pressure drop effect to the second heat exchange medium, thereby enhancing the heat transfer effectiveness of the heat exchanger by extension.
Furthermore, when the second heat exchange medium is directed towards the outlet medium directing panel, the medium directing component having the first lateral directing panel, the second lateral directing panel and the top directing panel acting as a barrier, generally merge the two semi-circular flow of the second heat exchange medium into a singular flow, while simultaneously directing the flow of the second heat exchange medium in a new longitudinal flow direction, wherein the angle of attack of the new flow direction is substantially divergent from the respective lines of flow of each semi-circular flow paths. The outlet medium directing panel of the medium directing member has an inclined surface, generally diverting the flow of the second heat exchange medium to nearly a perpendicular flow pattern in relation to the two semi-circular flow paths, now generally axially aligned to the longitudinal axial orientation of the chamber section, where the flow of the second heat exchange medium is further directed towards the throughholes provided on the second core surface.
In an embodiment of the present invention, a first longitudinal end respectively of the first lateral directing panel, the second lateral directing panel, and the top vertical directing panel are coupled to the outlet medium directing panel, while a second longitudinal end respectively of the first lateral directing panel, the second lateral directing panel, and the top vertical directing panel are coupled to the seat interior base. In other embodiment of the present invention, the second longitudinal end of the respective components may be coupled to the medium directing component base. The configuration comprising of the outlet medium directing panel, the first lateral directing panel, the second lateral directing panel, and the top vertical directing panel acts as a channel for the second heat exchange medium, fully directing the flow of the second heat exchange medium towards the throughholes provided on the second core surface, enhancing the heat transfer effectiveness by minimizing pressure drop effect to the second heat exchange medium. The arrangement also generally prevents the second heat exchange medium to flow directly from the anterior section of the chamber section to the throughholes provided on the second core surface, thereby enhancing the performance of the heat exchanger by forcing the second heat exchange medium to flow through the stirring and mixing effect afforded by the medium directing component feature placed in the posterior section of the chamber section.
The flow path assembly may comprise the first tubular section, the chamber section, the second tubular section, and the medium directing component disposed within the chamber section. In other embodiment of the present invention, a plurality of flow path assemblies as described herein may be coupled together in a serial manner. As such, the flow pattern described herein may be repeated dependent upon the number of the first tubular sections, the chamber sections, the second tubular section, and medium directing component packaged within an embodiment of the flow path assembly coupled within an embodiment of the heat exchanger.
In an embodiment of the present invention, various components comprising the heat exchanger may be produced of ferrous or non-ferrous material. Similarly, the components may be made of plastics or composite materials. The components may be produced of the same material or may be produced of dissimilar materials. Various coupling means may be utilized, which may include but not limited to adhesives, epoxy, mechanical means, or brazing and soldering, for example. In another embodiment of the present invention, various components may be welded without additional bonding material, such as in the case of laser welding. In yet another embodiment of the present invention, a portion or all of the components may be manufactured by means of 3D printing technology, known in the art.
Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.
Referring to the drawings and in particular
In an embodiment of the present invention, the first core surface 105, the second core surface 110, the first lateral core wall 115, and second latera core wall 120 may be shown generally as rectangular in shape. However, in other embodiments of the present invention, respective components may be in other geometric shape such as a square or trapezoidal shape, for example.
Coupled within the fluid containing vessel comprising the first core surface 105, the second core surface 110, the first lateral core wall 115, the second lateral core wall 120, the top core wall 125, and the bottom core wall 130 are a plurality of flow path assemblies 155, completing the core body 101. In an embodiment of the present invention, a first heat exchange medium flow internally within the fluid containing vessel established by the core body 101 exterior body, while flowing externally of the plurality of flow path assemblies 155 coupled within the core body 101. A second heat exchange medium flow within the plurality of flow path assemblies 155 coupled within the core body 101, facilitating heat transfer between the first heat exchange medium and the second heat exchange medium by conduction generally through the material comprising the plurality of flow path assemblies 155 coupled within the core body 101.
Now referring to
In yet another embodiment of the present invention, the heat exchanger 100 may have both the inlet tank 135 and the outlet tank 140 coupled to the core body 101 for a desired effect. In an embodiment of the present invention, the inlet tank 135 may be mated to an inlet pipe 145, a tubular member, in fluid communication with the interior of the inlet tank 135 to facilitate introduction of the first heat exchange medium into the inlet tank 135. In a similar fashion, the outlet tank 140 may be mated to an outlet pipe 150, a tubular member, in fluid communication with the interior of the outlet tank 140 to facilitate discharge of the first heat exchange medium out of the outlet tank 140.
Referring to
In an embodiment of the present invention, the first heat exchange medium may be provided by a reservoir or by means of a cooling loop or a heat source to supply the first heat exchange medium into the heat exchanger 100. In yet another embodiment of the present invention, the heat exchanger 100 may be coupled with the inlet tank 135 and the outlet tank 140 to facilitate supply and discharge means of the first heat exchange medium to the heat exchanger 100. In such an embodiment of the present invention, the inlet tank 135 may be coupled to the reservoir or coupled to the cooling loop or the heat source to supply the inlet tank 135 with the first heat exchange medium, while the outlet tank 140 may be coupled to the reservoir or coupled to the cooling loop or the heat source to discharge the first heat exchange medium out of the outlet tank 140. In an embodiment of the present invention, the second heat exchange medium may be air, directed to the heat exchanger from atmosphere, for example.
Now referring to
Referring now to
As the curvature is provided to the first core surface 105C and a second core surface 110C, the flow path assemblies 155 provided within the core body 101C may no longer align with the expected flow pattern of the second heat exchange medium in a desirable manner. However, with the present invention, with the modular flow path assembly design along with flexible flow path assembly seat orientation means, the flow path assemblies 155 may be independently located and angulated horizontally as well as vertically to achieve a desired effect, maximizing the flow of the second heat exchange medium through the core body with minimal pressure drop effect. In such an embodiment of the present invention, the lateral planes of the core body 101C established by a first lateral core wall 115C and a second lateral core wall 120C may not be parallel to each other.
Furthermore, the first lateral core wall 115C and the second lateral core wall 120C may not be perpendicular to the surface established by the first core surface 105C, the second core surface 110C, or both the first core surface 105C and the second core surface 110C. Furthermore, a top core wall 125C may be coupled to a top vertical edge respectively of the first core surface 105C, the second core surface 110C, the first lateral core wall 115C, and the second lateral core wall 120C, while a bottom core wall 130C may be coupled to a bottom vertical edge respectively of the first core surface 105C, the second core surface 110C, the first lateral core wall 115C, and the second lateral core wall 120C. The top core wall 125C as well as the bottom core wall 130C may generally feature a concave convexo shape to sealingly couple to the first core surface 105C and the second surface 110C of the core body 101C. In yet another embodiment of the present (Not shown), the core body may be provided with a convex shape when observed from the frontal plane of the core body, giving the core body a convexo concave shape.
Now referring to
The flow path assemblies 155 populated within a first region of the first core surface 105D may be arranged with a uniform angulation as well as spatial positioning for a desired effect, while the flow path assemblies populated within a second region of the first core surface 105D may be arranged with a uniform angulation as well as spatial positioning within the second region. In such an embodiment of the present invention, positioning and angulation arrangement of the flow path assemblies 155 utilized in the first region of the first core surface 105D may be different from the positioning and angulation arrangement of the flow path assemblies 155 utilized in the second region of the first core surface 105D. In an embodiment of the present invention, the respective planar surfaces provided within the first core surface 105D may be paired with a corresponding second core surface 110D which generally mirrors the shape of the first core surface 105D. A first lateral side of the core body 101D may be provided by a first lateral core wall 115D, while a second lateral side of the core body 101D may be provided by a second lateral core wall 120D. The planar surfaces established by the first lateral core wall 115D may be generally perpendicular to the planar surfaces established by the second lateral core wall 120D. In other embodiment of the present invention, the plurality of flow path assemblies 155 populated within a region may not be uniform in spatial positioning or axial orientation. In yet another embodiment of the present invention, the plurality of flow path assemblies 155 populated within a region may comprise of one or more configurations.
In an embodiment of the present invention, referring now to
In an embodiment of the core body 101E, the flow path assemblies 155 populated within a first region may be arranged with a uniform angulation as well as spatial positioning for a desired effect, while the flow path assemblies populated within a second region may be arranged with a uniform angulation as well as spatial positioning within the second region differing from orientation and arrangement utilized in the first region. The flow path assemblies 155 populated within a third region may be arranged with a uniform angulation as well as spatial positioning for a desired effect, which may differ in orientation and arrangement from the first region as well as from the second region. In such an embodiment of the present invention, positioning and angulation arrangement of the flow path assemblies 155 utilized in the first region of the first core surface 105E, the second region of the first core surface 105E, and the third region of the first core surface 105E may be dissimilar from one another. In other embodiment of the present invention, the plurality of flow path assemblies 155 populated within a region may not be uniform in spatial positioning or axial orientation. In yet another embodiment of the present invention, the plurality of flow path assemblies 155 populated within a region may comprise of one or more configurations.
In an embodiment of the present invention, the respective planar surfaces provided within the first core surface 105E may be paired with a corresponding second core surface 110E which may generally mirror the shape of the first core surface 105E. In an embodiment of the present invention, positioning and angulation arrangement means of the plurality of flow path assemblies 155 within the first, the second, and the third regions of the first core surface 105E are accomplished by flow path assembly seats provided on the first core surface 105E as well as corresponding flow path assembly seats provided on the second core surface 110E.
A first lateral side of the core body 101E may be provided by a first lateral core wall 115E, while a second lateral side of the core body 101E may be provided by a second lateral core wall 120E. In an embodiment of the present invention, the planar surface established by the first lateral core wall 115E may be generally perpendicular to the planar surface established by the second lateral core wall 120E. A top core wall 125E may be coupled to a respective top vertical edge of the first core surface 105E, the second core surface 110E, the first lateral core wall 115E, and the second lateral core wall 120E, while a respective bottom vertical edge of the first core surface 105E, the second core surface 110E, the first lateral core wall 115E, and the second lateral core wall 120E may be coupled to a bottom core wall 130E, completing the core body 101E.
In yet another embodiment of the present invention, the core body may be provided with a singular obtuse angle provided on a first core surface 105F. Referring to
The flow path assemblies 155 populated within a first region may be arranged with a uniform angulation as well as spatial positioning for a desired effect, while the flow path assemblies 155 populated within a second region may be arranged with a uniform angulation as well as spatial positioning within the second region. In such an embodiment of the present invention, positioning and angulation arrangement of the flow path assemblies 155 utilized in the first region of the first core surface 105F and the second region of the first core surface 105F may be dissimilar from each other to obtain a desired effect. In an embodiment of the present invention, the respective planar surfaces provided within the first core surface 105F may be paired with a corresponding second core surface 110F which generally mirrors the shape of the first core surface 105F. In other embodiment of the present invention, the plurality of flow path assemblies 155 populated within a region may not be uniform in spatial positioning or axial orientation. In yet another embodiment of the present invention, the plurality of flow path assemblies 155 populated within a region may comprise of one or more configurations.
A first lateral side of the core body 101F may be provided by a first lateral core wall 115F, while a second lateral side of the core body 101F may be provided by a second lateral core wall 120F. The planar surfaces established by the first lateral core wall 115F may generally not be perpendicular nor parallel to the planar surface established by the second lateral core wall 120F. Top vertical edge respectively of the first core surface 105F, the second core surface 110F, the first lateral core wall 115F, and the second lateral core wall 120F may be engagingly coupled to a top core wall 125F, while bottom vertical edge respectively of the first core surface 105F, the second core surface 110F, the first lateral core wall 115F, and the second lateral core wall 120F may be engagingly coupled to a bottom core wall 130F, completing the core body 101F. In an embodiment of the present invention, desired positioning and axial angulation of the corresponding flow path assemblies 155 populated in the first region as well as the second region of the first core surface 105F are accomplished by the flow path assembly seats provided for the individual flow path assemblies on the first core surface 105F as well as by corresponding flow path assembly seats provided on the second core surface 110F.
Reference is now made to
As the alternative heat exchanger locations typically do not provide for optimum external heat exchange medium flow, a solution must be devised to provide the heat exchanger with an optimum external heat exchange medium flow regardless of the positioning of the heat exchanger 100 within a vehicle 300, which may include space or shape limitations, for example. Similar constraints impacting optimal heat transfer efficiency is not only limited in an automotive application, therefore, a solution provided herein may be applied to a variety of heat exchanger applications. Similar constraints may be observed in other applications of heat exchangers, such as in general electronics, appliances, and industrial cooling systems, for example. Referring to
Furthermore, the modular flow path assemblies 155 provides for optimization of the external heat exchange medium flow, wherein individual external heat exchange medium flow paths provided within the heat exchanger 100 in the form of the first core panel throughholes 175 and a second core panel throughholes 176 may be optimally aligned in horizonal and vertical axial orientation with inlet orifices provided on the bonnet 320 in the form of a plurality of bonnet air intakes holes 325, whereby the external heat exchange medium flow are optimized for positioning and horizontal and vertical axial orientation to enhance the overall heat exchange performance. The individual flow path assemblies 155 coupled within the core body 101 are positioned as well as horizontally and vertically angled in a desired effect by a first panel flow path assembly seats 170 provided on the first core surface 105, along with a corresponding second panel flow path assembly seats 171 provided on the second core surface 110.
Now referring to
Referring to
Referring again to
The plurality of second core panel throughholes 176 provided on the second core surface 110 are individually mated with the second panel flow path assembly seat 171 surrounding the individual throughholes 176 for the purpose of coupling a second longitudinal end of the plurality of individual flow path assemblies 155 to the second core surface 110. The second panel flow path assembly seats 171 populated on the second core surface 110 may be parallel relative to the plane established by the first side of the second core surface 110 in the immediate vicinity surrounding the individual second panel flow path assembly seat 171, or in other embodiments of the present invention may not be parallel to the plane established by the respective first side of the second core surface 110 in the immediate vicinity surrounding the individual second panel flow path assembly seat 171.
In an embodiment of the present invention, the second heat exchange medium is introduced into the heat exchanger 100 through the plurality of first core panel throughholes 175 provided on the first core surface 105, travel through the plurality of flow path assemblies 155 provided in the core body 101, then discharged out of the plurality of second core panel throughholes 176 provided on the second core surface 110. For each of the flow path assemblies 155 coupled within the core body 101, one first core panel throughhole 175 is individually assigned exclusively as an inlet means of the second heat exchange medium into the one particular flow path assembly 155. In a similar fashion, one second core panel throughhole 176 is individually assigned exclusively as an outlet means of the second heat exchange medium for the one particular flow path assembly 155.
The plurality of first panel flow path assembly seats 170 populated on the first core surface 105 and the plurality of second panel flow path assembly seats 171 populated on the second core surface 110 provide for means of independent horizontal and vertical axial orientation of the individual flow path assemblies 155, regardless of the plane established by the first core surface 105 and the second core surface 110. The first panel flow path assembly seats 170 and the second panel flow path assembly seats 171 further provide locating means of the individual flow path assemblies 155 within the core body 101.
Now referring to
In an embodiment of the present invention, referring to
Referring now to
Referring now to
Referring to
The first panel flow path assembly seat 170A is provided with a seat lateral wall 225A, a cylindrical exterior surface of the outwardly extending first panel flow path assembly seat 170A, longitudinally terminating at the outward facing surface of the seat exterior base 230A. On an inside wall of the first panel flow path assembly seat 170A, opposite of the seat lateral wall 225A, is provided with a seat interior side wall 235A, a tubular surface extending longitudinally outwardly terminating at the seat interior base 240A. In order to facilitate coupling of the flow path assembly 155A to the first panel flow path assembly seat 170A, a coupling material 245A may be provided on the surface of the seat interior side wall 235A and the seat interior base 240A of the first panel flow path assembly seat 170A to couple the first longitudinal end of the flow path assembly 155A to the first core surface 105A. The coupling material may be an epoxy, adhesive, or brazing material, for example. In an embodiment of the present invention, the second core surface 110A may be provided with a plurality of second panel flow path assembly seats 171A to facilitate coupling individually a plurality of second longitudinal end of the flow path assembly 155A to the second core surface 110A, configuration of which may generally be symmetrically mirrored from the first panel flow path assembly seat 170A provided on the first core surface 105A.
Reference is now made to
In an embodiment of the present invention, the plurality of first panel flow path assembly seat 170C provided on the first core surface 105C are individually paired with a first core panel throughholes 175C, an orifice extending the thickness of the first core surface 105C. The plurality of second panel flow path assembly seat 171C provided on the second core surface 110C are similarly individually paired with a second core panel throughholes 176C, an orifice extending the thickness of the second core surface 110C. Referring in particular to
The first panel flow path assembly seat 170C is provided with the seat lateral wall 225C, a first lateral side of the first panel flow path assembly seat 170C, a cylindrical surface facing the interior of the core body of the heat exchanger. A second lateral side of the first panel flow path assembly seat 170C is provided with the seat interior side wall 235C, a tubular surface, on an opposite lateral side from the seat lateral wall 225C. A tubular surface provided by the seat interior side wall 235C may be sized to matingly couple a first longitudinal end of a flow path assembly 155C. In an embodiment of the present invention, a coupling material 245C may be provided between the surface of a seat interior side wall 235C and the first longitudinal end of the flow path assembly 155C to sealingly couple the flow path assembly 155C to the first core surface 105C. The coupling material may be an epoxy, adhesive, or brazing material, for example.
Referring now to
Referring in particular to
The seat interior side wall 235D terminates with a planar surface having a first side, a seat exterior base 230D, facing the outside of the heat exchanger, and a second side, a seat interior base 240D, facing the inside of the heat exchanger. A tubular surface provided by the seat interior wall 235D may be sized to matingly couple a first longitudinal end of a flow path assembly 155D. In an embodiment of the present invention, a coupling material 245D may be provided between the surface of the seat interior side wall 235D and the seat interior base 240D provided on the first panel flow path assembly seat 170D and the first longitudinal end of the flow path assembly 155D to sealingly couple the flow path assembly 155D to the first core surface 105D. The coupling material may be an epoxy, adhesive, or brazing material, for example.
Now referring to
In an embodiment of the present invention, a first longitudinal end of the plurality of first panel flow path assembly seats 170 may be coupled to the second side of the first core surface 105, while a second longitudinal end of the first panel flow path assembly seats 170 may be set at a plane that is extended inward from the plane established by the second side of the first core surface 105. In other embodiment of the present invention, a first longitudinal end of the plurality of first panel flow path assembly seats 170 may extend longitudinally outwardly out of the plane established by the first side of the first core surface 105, while the second longitudinal end of the first panel flow path assembly seats 170 may be coupled to the first side of the first core surface 105. In a similar fashion, the first longitudinal end of the second panel flow path assembly seats 171 populated on the first side of the second core surface 110 may extend inwardly from the plane established by the first side of the second core surface 110, while a second longitudinal end of the second panel flow path assembly seats 171 may be coupled to the first side of the second core surface 110. In other embodiment of the present invention, the first longitudinal end of the second panel flow path assembly seats 171 may be coupled to the second side of the second core surface 110, while the second longitudinal end of the second panel flow path assembly seats 171 extend longitudinally outwardly out of the second side of the second core surface 110.
Reference is now made to
Now referencing to
Longitudinally disposed between the first tubular section 185 and the second tubular section 195 is the chamber section 190. The chamber section 190 is a hollow member, permitting flow of the second heat exchange medium therethrough. The first tubular section 185, the chamber section 190, and the second tubular section 195 are fluidly connected to each other, permitting flow of the second heat exchange medium between respective components comprising the flow path assembly 155.
Referring to
Referring again to
The inlet medium directing panel 205 is generally free of any heat exchange medium flow restricting obstructions on its lateral edges that may restrict the amount of swirling and mixing effect occurring to the second heat exchange medium within the chamber section 190. Minimizing presence of obstruction on the inlet medium directing panel 205 further lends itself to reduce potential pressure drop effect to the flow of the second heat exchange medium, which may be detrimental to the heat transfer performance, while maintaining the beneficial effect of swirling and mixing effect to the second heat exchange medium.
After the second heat exchange medium is directed into the vertical direction within the interior of the chamber section 190 by the inlet medium directing panel 205, the second heat exchange medium is further diverted into two divergent flow patterns within the chamber section 190 in a semi-circular manner, generally symmetrical to one another (See
Referencing back to
Furthermore, when the second heat exchange medium is directed towards the outlet medium directing panel 220, the medium directing component 200 having the first lateral directing panel 210, the second lateral directing panel 215 and the top directing panel 335 acting as a barrier, generally merge the two semi-circular flow of the second heat exchange medium into a singular flow, while simultaneously directing the flow of the second heat exchange medium in a new longitudinal flow direction, wherein the angle of attack of the new flow direction is substantially divergent from the respective lines of flow of each semi-circular flow paths. The outlet medium directing panel 220 of the medium directing member 200 has an inclined surface, angle of which is divergent from the longitudinal axial characteristics established by the chamber section 190, generally diverting the flow of the second heat exchange medium to nearly a perpendicular flow pattern in relation to the two semi-circular flow paths, now axially aligned to the longitudinal axial characteristics of the chamber section 190, where the flow of the second heat exchange medium is further directed towards the second core panel throughholes 176 provided on the second core surface 110, where the second heat exchange medium is then discharged out of the heat exchanger 100.
In an embodiment of the present invention, a first longitudinal end respectively of the first lateral directing panel 210, the second lateral directing panel 215, and the top directing panel 335 are coupled to the outlet medium directing panel 220, while a second longitudinal end respectively of the first lateral directing panel 210, the second lateral directing panel 215, and the top directing panel 335 are coupled to the medium directing component base 340. The configuration comprising of the outlet medium directing panel 220, the first lateral directing panel 210, the second lateral directing panel 215, and the top directing panel 335 forms a channel for the second heat exchange medium, fully directing the flow of the second heat exchange medium towards the second core panel throughholes 176 provided on the second core surface 110 once the second heat exchange medium is introduced towards the posterior section of the chamber section 190, enhancing the heat transfer effectiveness by minimizing pressure drop effect to the second heat exchange medium as the second heat exchange medium is introduced within the posterior section of the chamber section 190 from the anterior section of the chamber section 190. Furthermore, the arrangement also generally prevents the second heat exchange medium to flow directly from the anterior section of the chamber section 190 to the second core panel throughholes 176 provided on the second core surface 110, thereby enhancing the performance of the heat exchanger by forcing the second heat exchange medium to flow through the stirring and mixing effect afforded by the medium directing component 200.
In an embodiment of the present invention, the flow path assembly 155 may comprise the first tubular section 185, the chamber section 190, the second tubular section 195, and the medium directing component 200 disposed within the chamber section 190. In other embodiment of the present invention, a plurality of flow path assemblies 155 as described herein may be coupled together in a serial manner. As such, the flow pattern described herein may be repeated several times dependent upon the number of the first tubular sections 185, the chamber sections 190, the second tubular section 195, and the medium directing component 200 packaged within an embodiment of the flow path assembly 155 coupled within an embodiment of a heat exchanger.
Now, reference is made to
Referring now to
In an embodiment of the present invention, the leading edge of the first longitudinal end of the medium directing component 200F is matingly coupled to the interior surface of the chamber section 190F. As a result, the bottom vertical section of the inlet medium directing panel 205F as well the outlet medium directing panel 220F is generally terminated by the interior surface of the chamber section 190F, restricting flow of the second heat exchange medium on the bottom vertical edge of the respective panels. Coupled on the outlet medium directing panel 220F is a plurality of longitudinally extended panel members having a thickness, comprising, a first lateral directing panel 210F, a second lateral directing panel 215F, and a top directing panel 335F. A first longitudinal end of the first lateral directing panel 210F is coupled to a first lateral side of the outlet medium directing panel 220F, while a second longitudinal end of the first lateral directing panel 210F is coupled to the seat interior base 240F. A first longitudinal end of the second lateral directing panel 215F is coupled to a second lateral side of the outlet medium directing panel 220F, while a second longitudinal end of the second lateral directing panel 215F is coupled to the seat interior base 240F.
The first lateral directing panel 210F and the second lateral directing panel 215F are laterally space apart, leaving a space between the respective components. A first longitudinal end of the top directing panel 335F is coupled to the top vertical end of the outlet medium directing panel 220F while a second longitudinal end of the top directing panel 335F is coupled to the seat interior base 240F. The top directing panel 335F is laterally coupled on a first lateral side by a top vertical edge of the first lateral directing panel 210F, while laterally coupled on a second lateral side by a top vertical edge of the second lateral directing panel 215F. A bottom vertical edge respectively of the first lateral directing panel 210F and the second lateral directing panel 215F extend vertically downwardly, while the leading bottom vertical leading edge of the respective panels are disconnected from the interior surface of the chamber section 190F. As a result, a flow space for the second heat exchange medium is provided between the bottom vertical edge of the first lateral directing panel 210F and the interior surface of the chamber section 190F as well as between the bottom vertical edge of the second lateral directing panel 215F and the interior surface of the chamber section 190F, forming as a result two distinct pathways for the second heat exchange medium between the interior surface of the chamber section 190F and the medium directing component 200F. The space provided between the bottom vertical edge of the first lateral directing panel 210F and the chamber section 190F interior surface as well as the space provided between the bottom vertical edge of the second lateral directing panel 215F and the chamber section interior surface provide the two semi-circular flow paths for the second heat exchange medium originating from the chamber section 190F anterior section, located forward of the medium directing component 200F.
Referring to
The inlet medium directing panel 205F having a planar surface set at an inclined angle relative to the longitudinal axial orientation of the chamber section 190F induces great amount of swirling and mixing effect to the second heat exchange medium within the chamber section 190F as the second heat exchange medium is directed towards the inlet medium directing panel 205F, while the inclined face of the inlet medium directing panel 205F functions to simultaneously divert the flow of the second heat exchange medium in a generally vertical direction, generally following the slope of the angled face of the inlet medium directing panel 205F. The inlet medium directing panel 205F is generally free of any heat exchange medium flow restricting obstructions on its lateral edges in order to maximize the amount of swirling and mixing effect occurring to the second heat exchange medium within the chamber section 190F.
Referring to
The configuration of the interior contour of the chamber section 190F along with the first lateral directing panel 210F, the top directing panel 335F, and the second lateral directing panel 215F directs and channels the flow of the two semi-circular flow of the second heat exchange medium originated on the anterior section of the chamber section 190F towards the outlet medium directing panel 220F. As the first longitudinal end of the first lateral directing panel 210F, the top directing panel 335F, and the second lateral directing panel 215F are coupled to the outlet medium directing panel 220F, while the second longitudinal end of the respective panels are coupled to the seat interior base 240F (See
As the second heat exchange medium is directed towards the outlet medium directing panel 220F, the medium directing component 200F having the first lateral directing panel 210F, the second lateral directing panel 215F and the top directing panel 335F acting as a barrier, generally merge the two semi-circular flow of the second heat exchange medium into a singular flow, while simultaneously directing the flow of the second heat exchange medium in a new longitudinal flow direction, wherein the angle of attack of the new flow direction is substantially divergent from the respective lines of flow of each semi-circular flow paths. The outlet medium directing panel 220F of the medium directing member 200F has an inclined surface, angle of which is divergent from the longitudinal axial characteristics established by the chamber section 190F, generally diverting the flow of the second heat exchange medium to nearly a perpendicular flow pattern in relation to the two semi-circular flow paths, now axially aligned to the longitudinal axial characteristics of the chamber section 190F, where the flow of the second heat exchange medium is further directed towards the second core panel throughholes 176F (See
Now referring to
Now referring to
The heat exchanger 100 may be utilized as a cooler, a condenser, an evaporator, a radiator, an oil cooler or any other application requiring heat to be transferred from one heat exchange medium to another heat exchange medium. The first heat exchange medium as well as the second heat exchange medium may be air, liquid, or gas, known in the art. In an embodiment of the present invention, more than one type of heat exchange medium may be utilized. Furthermore, in some embodiments of the present invention, heat exchange medium may be combined with more than one type of material, such as with air and silica gel solids to obtain additional desired features, for example.
In an embodiment of the present invention, various components comprising the heat exchanger 100 may be produced of ferrous or non-ferrous material. Similarly, the components may be made of plastics or composite materials. The various components may be produced of the same material or may be produced of dissimilar materials. Various bonding and brazing means may be utilized, which may include but not limited to adhesives, epoxy, mechanical means, or brazing and soldering, for example. In another embodiment of the present invention, various components may be welded without additional bonding material, such as in the case of laser welding. In yet another embodiment of the present invention, a portion or all the components may be manufactured by means of 3D printing technology, known in the art.
In an embodiment of the present invention, the heat exchanger 100 conducts mainly all its heat transfer between the first heat exchange medium and the second heat exchange medium by conduction means through the material comprising the plurality of flow path assemblies 155 coupled within the core body 101. As such, to facilitate excellent heat transfer effectiveness while maintaining low assembly costs, the core body 101 may be fabricated of composites or plastics material, especially desirable when utilizing manufacturing process such as with a carbon graphite composites molding technology, for example, reducing overall weight substantially with a dramatic effect while maintaining excellent heat transfer characteristics. The of plurality of flow path assemblies 155, being the main body offering heat transfer between the first heat exchange medium and the second heat exchange medium, may be produced of highly heat conductive material such as aluminum, copper, or silver, for example. Insert molding techniques know in the art may be combined with injection molding technology known in the art to manufacture the heat exchanger 100 in a cost-effective manner. Furthermore, as the plurality of flow path assemblies 155 coupled within the core body 101 act individually as longitudinal as well as vertical structural support to the heat exchanger 100, the core body 101 may be made of extremely thin material while maintaining excellent structural rigidity, offering significant weight savings as well as cost savings in raw material.
In an embodiment of the present invention, the flow path assembly seats provided on the first core surface 105 may be a simple recess or an indentation provided on a second side of the first core surface 105 to couple the first longitudinal end of the flow path assembly 155. In a similar fashion, the flow path assembly seats provided on the second core surface 110 may be a simple recess or an indentation similar to those found on the first core surface 105 to couple the second longitudinal end of the flow path assembly 155.
Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced other than as specifically described.
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| Number | Date | Country | |
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| 20200271386 A1 | Aug 2020 | US |
