Patent Application
20100032149
Priority is hereby claimed to German Patent Application No. DE 10 2006 031 653.3, filed on Jul. 8, 2006 and to European Patent Application No. EP06023588.4, filed on Nov. 14, 2006 and to European patent Application No. EP06023987.8, filed on Nov. 19, 2006 and to German Patent Application No. DE 10 2006 058 096.6, filed on Dec. 9, 2006, the entire contents all of which are incorporated herein by reference.
The present invention relates to heat exchangers and a method of manufacturing the same.
A further heat exchanger having at least some of these features is known from European Patent Application No. EP 0 656 517 B1. In this document, in contrast to the first-mentioned reference, the openings are located in the header, and the projections are arranged on a longitudinal partitioning wall in the tank.
Some embodiments of the present invention provide a simplified method for manufacturing and/or assembling a heat exchanger in such a way that a pre-mounting or preassembly of the heat exchanger is more easily soldered, welded, or brazed.
Some embodiments of the present invention provide side parts, which are deformable in their longitudinal direction in order to compensate for fabrication tolerances. The side parts can be compressed, and projections can penetrate somewhat further into the tube ends in order to compensate for changes in the length of the flat tubes. As a result, when the heat exchanger is manufactured, the prefabricated side parts can be more easily secured to the heat exchanger. The closure caps can be soldered, welded, or brazed to the lateral ends of the tanks in a positively engaging and fluid tight manner. The inventive solution of the present invention can be used in motor vehicles, and, in some such applications, can compensate for thermal expansions which occur during operation of the motor vehicle.
It is advantageous that the side parts have at least one elastic region which can be compressed or expanded according to specific requirements. The region can be in the form of at least one expansion gap with at least one expansion web. The width of the expansion gap can have a different dimension before the deformation than after the deformation. In some embodiments, if the side part is compressed, the gap width is correspondingly reduced in size.
In some embodiments, the present invention provides for each side part to have at least two expansion gaps, which are arranged approximately at the junction between a closure cap and a central part. The deformability of the side parts can be made more easily if the expansion gap or gaps extend transversely or obliquely with respect to the longitudinal direction of the side parts.
The elastic region of the present invention can have, for example, a compressible or stretchable bead or the like instead of or in addition to the expansion gaps. In some embodiments, the side parts can bear against the outer fin or directly against the outer flat tube of the heat exchanger core.
Consideration has also been given to the situation in which the closure caps seal the front ends of tanks. Alternatively or in addition, it is possible to attach the closure caps to only one of the headers or to the tanks, as has been provided, for example, in EP 656 517 B1. The closure caps have tabs, which are inserted into holes in the headers and can be soldered, welded, or brazed thereto. In such a construction, separate closure lids can be inserted into the ends of the tanks.
The present invention also provides a method for manufacturing a heat exchanger wherein flat tubes and fins are fitted together to form a heat exchanger core, and wherein headers and/or tanks are secured to one or both of the ends of the flat tubes. Projections can be plugged into openings in the tubes and side parts can be secured onto the core. The side parts can be expanded or compressed in the longitudinal direction of the side parts in order to be able to compensate for fabrication tolerances and thermal expansion.
In some embodiments, the present invention provides a heat exchanger including a number of tubes providing a flow path for a first fluid. A fin can be supported between two of the tubes and positioned along a flow path for a second fluid. Together, the fin and the plurality of tubes can at least partially define a heat exchanger core. First and second tanks can be positioned adjacent to opposite ends of the tubes. An elastically deformable side part can extend across the heat exchanger core and can include a pair of integrally formed caps for closing openings in the first and second tanks.
The present invention also provides a heat exchanger as a soldered, brazed, or welded structure, which includes flat tubes having narrow sides and broad sides, corrugated fins, and tanks formed from two clamshell members. The two tank members can be joined together along a longitudinal plane of the heat exchanger, or alternatively, in a plane which is parallel thereto.
EP 864 839 B1 discloses a conventional heat exchanger, which does not include tanks. The heat exchanger of EP 864 839 B1 does include widened tube ends which are joined to one another to form a heat exchanger core. The terminating edge of each member of the tanks extends around the heat exchanger core and is flush against the tube ends. Conventional heat exchangers have the advantage that less material, such as, for example, sheet aluminum, can be used because, as mentioned above, there are no tanks. However, the weight of the materials used for the heat exchanger is reduced only to an insignificant degree because the widening of the tube ends requires comparatively larger wall thicknesses of the flat tubes, as a result of which the aforementioned savings are at least partially cancelled out. In addition, a considerable degree of extra expenditure is produced during the shaping process being carried out at each individual tube end. It is also possible to assume that the known structures present technical soldering problems which result in excessively high rejection rates or post processing rates unless particularly careful preparations are followed during and prior to soldering. In addition, it is desirable to improve the distribution of the fluid flowing through the tanks between the individual flat tubes.
One object of the present invention is to make available a heat exchanger which permits flat tubes with relatively thin wall thicknesses to be used and/or which can at least partially alleviate one or more of the above-mentioned disadvantages.
Because the two clamshell tank members are equipped with projections which are arranged at intervals and which engage in the ends of the flat tubes in the region of the narrow sides, tubes with relatively thin wall thicknesses can be used because it is not necessary to widen the tube ends. In addition, the present invention includes easily accessible connecting points, which are critical in terms of soldering, brazing, and welding technology. The readily accessible connecting points can be post treated if necessary. In a second soldering, welding, or brazing operation, leaks can be eliminated. However, it has also been found in numerous trials that the soldering, welding, or brazing results are comparatively outstanding so that the need for post treatment is very small. In the functional respect, the heat exchanger according to the present invention has a decidedly advantageous ratio between its overall cross sectional area and the effective heat exchanging area. The available installation space can therefore be utilized satisfactorily.
The ends of the flat tubes can be plugged into openings in headers, and the tube ends can have a protruding portion on each side of the tanks. In contrast to the openings in known tanks, the ends of the flat tubes in the openings of the headers are not embraced around the entire circumference of the opening edge.
It is particularly advantageous here that the clamshell members bear against the edges of the header, that the projections engage in the ends of the flat tubes in the region of the protruding portions, and that they bear on the inside in the narrow sides of the flat tubes.
It is possible that one clamshell tank member is constructed so as to be identical to the other clamshell tank member, and that the connection between the two clamshell tank members is made approximately along the central longitudinal plane of the heat exchanger. This does not take into account the fact that a connector or the like can be formed on one of the clamshell tank members and to this extent the tank members could be different.
One clamshell tank member can have an open shell or cup configuration and the other clamshell tank member can have a substantially planar configuration. The connection between the two parts can be made along a plane which is parallel to the central longitudinal plane. In the present invention, essentially planar parts can therefore also be considered clamshell parts. In the present invention, the central longitudinal plane or a plane which is parallel thereto does not have to be actually planar or entirely planar. As used herein, the term “planar” merely indicates an orientation which extends transversely through the broad sides of the flat tubes. The parts could, for example, be connected along a corrugated portion of the connecting edges of the clamshell tank members.
The present invention also provides clamshell tank members, which are held together in a manner suitable for soldering, brazing, or welding. The connecting structure can include tabs and/or notches or the like, which are arranged along the edge of the clamshell tank members and which engage one another when the clamshell tank members are connected.
The connecting structure of the present invention can also or alternatively include contoured portions which are formed integrally with at least one of the clamshell tank members and are directed inwardly into an interior of the tank. The contoured portions can be constructed in such a way that the clamshell tank members can be connected, for example, by plugging the clamshell tank members together to pre-connect the two clamshell tank members.
The inwardly-directed contoured portions can be constructed in such a way that they have flow directing properties which promote uniform distribution of a working fluid flowing through the flat tubes.
The present invention also provides clamshell tank members which can be joined together to have openings which point toward the ends of the heat exchanger. The heat exchanger of the present invention can also include side parts or caps which close off the openings of the clamshell tank members. Alternatively or in addition, at least one of the clamshell tank members can be shaped in such a way that the parts can be joined together without requiring openings. This eliminates the need to provide side parts or closures.
In some embodiment, the present invention provides a heat exchanger including a number of tubes providing a flow path for a first fluid. The tubes can have narrow sides and broad sides. The heat exchanger can also include a fin supported between two of the tubes and positioned along a flow path for a second fluid and a tank positioned adjacent to ends of the tubes and including first and second tank members joined together along a connection plane. The tank can have outwardly-extending projections engageable in the ends of the tubes adjacent to the narrow sides to secure the tank to the tubes.
The present invention also provides a welded, brazed, or soldered heat exchanger including flat tubes having narrow sides and broad sides, corrugated fins and tanks, and a partitioning wall or the like in at least one of the tanks in order to configure the internal throughflow characteristic of the heat exchanger.
EP 864 840 B1 describes a conventional heat exchanger which does not have any tanks but rather includes widened tube ends which are joined to one another to form a heat exchanger core. The terminating edge of each tank engages around the block of tube ends, in a way which terminates in a flush position. The heat exchanger of EP 864 840 B1 has the apparent advantage of including relatively less material (e.g., sheet aluminum) because the tanks are not included. However, the weight of the materials used for the heat exchanger is reduced only to an insignificant degree because the widening of the tube ends requires comparatively larger wall thicknesses of the flat tubes, as a result of which the aforementioned savings are at least partially cancelled out. In addition, a considerable degree of extra expenditure is produced during the shaping process being carried out at each individual tube end. It is also possible to assume that the known structures present technical soldering problems which result in excessively high rejection rates or post processing rates unless particularly careful preparations are followed during and prior to soldering.
In EP 864 840 B, a partitioning wall is advantageously inserted into one of the tanks in the transverse direction or depth direction of the heat exchanger. The partitioning wall permits a U-shaped flow through the heat exchanger, which is desired for some applications. The embodiment of the partitioning wall with a securing foot plugged onto adjacent flat tube walls proposed in EP 864 840 B1 appears possible but relatively costly.
One object of the invention is to make available a heat exchanger which permits flat tubes with relatively thin wall thicknesses to be used and/or which can at least partially alleviate one of the above-mentioned disadvantages.
In some embodiments of the present invention, it is possible to use tubes with relatively thin wall thicknesses because it is not necessary to widen the tube ends and because the tanks are equipped with projections which are arranged at intervals and which engage in the ends of the flat tubes in the region of the narrow sides. In some embodiments, a partitioning wall extends either transversely or longitudinally between at least two rows of projections. It is to be understood that the terms “transversely” or “longitudinally” also include, for example, “obliquely.”
In addition, the connecting points which are critical in terms of soldering, welding, and brazing technology are easily accessible, and therefore can be post-treated if necessary. In a second soldering, brazing, or welding operation, leakages can be eliminated. However, it has also been found in numerous trials that the soldering, welding, or brazing results are comparatively outstanding so that the need for post-treatment is very limited. In the functional respect, the heat exchanger according to the present invention can have an advantageous ratio between its overall cross sectional area and the effective heat exchanging area. The available installation space can therefore be utilized satisfactorily.
In some embodiments, the present invention provides tubes having a protruding portion on each side of spaced apart headers. In contrast to the openings in conventional heat exchanger tanks, the ends of the flat tubes in the openings of the headers are not embraced around the entire circumference of the opening edge.
It is particularly advantageous here that the tanks bear against the edges of the headers and that the projections engage in the ends of the flat tubes in the region of the protruding portions. It is also advantageous that they bear on the inside in the narrow sides of the flat tubes.
In some embodiments of the present invention, each tank can be composed of two clamshell tank members, which are connected to one another in a central longitudinal plane of the heat exchanger or in a plane which is parallel thereto. Additionally, at least one partitioning wall can be inserted between the two clamshell tank members.
In some embodiments, the present invention provides a header formed of a single part including two edge portions and being open toward the sides of the heat exchanger. The header can include side openings.
In some embodiments, the present invention provides for one clamshell tank member to be identical to the other clamshell member, with the connection between the two clamshell tank members being arranged approximately in the central longitudinal plane of the heat exchanger. In addition, at least one of the clamshell tank members can include a connector.
The invention also provides one clamshell tank member being configured in the manner of a shell, and the other clamshell tank member being configured in an approximately planar fashion such that the connection between the two clamshell tank members is in a plane parallel to the central longitudinal plane of the heat exchanger. The partitioning wall between the clamshell tank members can be planar or be formed with one or more edge portions. This ensures that the connection between the partitioning wall and the header is not in the same plane as the connection between the partitioning wall and the clamshell tank members. Accordingly, the invention provides that planar parts are essentially also clamshell tank members and that the central longitudinal plane or a plane parallel thereto, does not actually have to be planar. The term merely indicates an orientation which extends transversely through the broad sides of the flat tubes. The connection between the parts could, for example, be along a corrugated connecting edge of the parts.
The clamshell tank members have means with which they are held together in a manner which is suitable for soldering, brazing, or welding, with the partitioning wall also being held in a provisional fashion therebetween. The means can be embodied as tabs or notches or the like which are arranged at the edge of one of the clamshell tank members and engage the other clamshell tank member. The means can also be configured as shaped portions which are formed on at least one of the clamshell tank members and are directed inwardly such that the clamshell tank members can be connected together. For example, the clamshell tank members can be plugged together for pre-securing them by joining the clamshell tank members also to the partitioning wall. The partitioning walls can be supported on the surface of the headers. The partitioning walls can also include projections which engage in the flat tubes. The partitioning wall can also be plugged into slits in the edge of the headers.
The present invention also provides an all metal heat exchanger, composed of flat tubes having two narrow sides and two broad sides, and fins which together with the flat tubes form a heat exchanger core such that tanks and projections extending outwardly from the tanks engage in the ends of the flat tubes.
International patent application PCT/EP 2006/001487, which is incorporated herein by reference, describes a heat exchanger embodied as a cooler such that cooling air flows freely through the fins of the heat exchanger core and in doing so cools a working fluid in the flat tubes. Such heat exchangers have proven to be advantageous in terms of their manufacturability and effectiveness. It is possible to achieve comparatively outstanding soldering, welding, or brazing results with heat exchangers which are constructed in such a manner. Furthermore, these heat exchangers are rather compact and thus require relatively little space.
One independent object of the present invention is to provide a heat exchanger that can maintain two different working fluids in separate circuits.
The present invention provides, among other things, an all metal heat exchanger including flat tubes having two narrow sides and two broad sides, and fins which together with the flat tubes form a heat exchanger core such that tanks located at the ends of the flat tubes and projections extending from these first tanks engage the ends of the flat tubes. The heat exchanger of the present invention can also include second tanks which extend in the longitudinal direction of the flat tubes and are fluidly separated from the first tanks.
As a result of the afore mentioned features, the present embodiment of the heat exchanger does not provide free flow of working fluids therethrough but rather both working fluids are conducted in separate circuits through the heat exchanger. In one example, the heat exchanger can include a charge air cooler, cooled with coolant, for motor vehicles or any other application for motor vehicles or can be outside this field.
According to some embodiments of the present invention, the second tanks include projections and are preferably formed of at least two side parts. It is also preferable that the first tanks include openings for receiving the ends of the flat tubes such that the openings do not completely engage around the ends of the flat tubes. This feature causes the ends of the flat tubes to have a protruding portion beyond the first tanks for the projections of the second tanks to engage the ends of the flat tubes in the region of the protruding portion. The projections can bear in the narrow sides of the flat tubes. It is provided that the two parts of the second tanks can be assembled together. Accordingly, the distance defined by the depth which can be plugged together corresponds approximately to the plug-in depth for the projections. The distances between the projections correspond to the distances between the flat tubes allowing the projections to be inserted in the flat tubes.
A serpentine throughflow path through the heat exchanger is provided by means of the seam between the two parts in order to exert a positive influence on the efficiency of the heat exchange. The seams which are present on opposite sides of the heat exchanger are then arranged offset with respect to one another.
Other embodiments of the present invention can include projections arranged on first tanks and for second tanks to be connected to the first tanks but to be fluidly separated therefrom. The connection between the first and second tanks can be configured in different ways. In yet other embodiments, both the first and second tanks can include projections which engage in the ends of the flat tubes. However, it is provided that the first tanks and second tanks do not have a fluid connection with one another.
In some embodiments, the present invention provides a heat exchanger including a number of tubes providing a flow path for a first fluid and a fin supported between two of the tubes and positioned along a flow path for a second fluid. Together, the fin and the tubes can at least partially defining a core. The heat exchanger can also include first and second tanks positioned adjacent to opposite ends of the tubes and a side part extending across the core between the first and second tanks and including outwardly extending projections engageable in the ends of the tubes.
In some embodiments, the present invention provides a heat exchanger including a number of tubes providing a flow path for a first fluid, a fin supported between two of the tubes and positioned along a flow path for a second fluid, and a tank secured to and in fluid communication with the ends of the tubes and including first and second tank members at least partially defining an interior space. A portion of an outer wall of the first tank member can extend inwardly through the interior space and engage a portion of an outer wall of the second tank member.
The present invention also provides a method of assembling a heat exchanger including the acts of stamping a first tank member and depressing a portion of an outer wall of the first tank member, stamping a second tank member and depressing a portion of an outer wall of the second tank member, connecting the first tank member to the second tank member such that the depressed portion of the first tank member extends through an interior space at least partially enclosed by the first and second tank members toward the depressed portion of the second tank member to direct a first fluid through the interior space, and connecting a heat exchanger core to the first and second tank members, the heat exchanger core including a number of tubes providing a flow path for the first fluid and a fin supported between two of the tubes and positioned along a flow path for a second fluid.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
As shown in
When they are assembled, outwardly-extending projections 10, which are arranged on the tanks 4 in the illustrated exemplary embodiment, move past the headers 3 and engage directly in the ends 11 of the flat tubes 1. In order to close the tanks 4 laterally in a fluid tight manner, closure caps 21 are provided at opposite ends of side parts 20. Conventional side parts 20 are in need of improvement because they are each commonly formed of one part, including a central part 22 and two integral closure caps 21. These conventional side parts are therefore relatively rigid and have little or no flexibility to compensate for fabrication tolerances.
In the illustrated embodiment of
The shapes and positions of the webs 25 can be selected as desired. For example, in some embodiments, a single web 25 can be positioned in the approximate center of the expansion gap 23 to divide the expansion gap 23. In still other embodiments, one or more webs 25 can be positioned on one or both sides of a center of an expansion gap 23.
Each expansion gap 23 can have a width b and a length L. In the illustrated embodiment of
A second exemplary embodiment of the heat exchanger of the present invention is shown in
The closure caps 21 of the side parts 20 close the lateral openings in the tanks 4. In this exemplary embodiment, the closure caps 21 are attached to the tanks 4 by the clamps 27, 28 so that they cannot slip. During assembly and when the side parts 20 are secured to the heat exchanger core, the expansion gaps 23 compensate for potential fabrication tolerances by either compressing or expanding the webs 25.
To conclude the operation, the entire heat exchanger or substantially the entire heat exchanger can be soldered, welded, and/or brazed. In some embodiments, the side parts 20 and then the tanks 4 are first fitted onto the heat exchanger core and the entire structure or substantially the entire structure is then pressed together and/or compressed in order to compensate for fabrication tolerances. More specifically, the upper clamp 28 can be configured in such a way that this second manufacturing method can be applied. The two manufacturing methods can be the same for all of the exemplary embodiments.
Two detailed views of the side part 20 are also shown in
A third exemplary embodiment is shown in
As shown in
A fourth exemplary embodiment is shown in
A fifth exemplary embodiment is shown in
Depending on the requirements, it is, however also possible to select a reduced central part 22 which does not have any connections to the closure caps 21. However, it is also possible to use a side part 20 as is known from the other exemplary embodiments, but with the proviso that the outermost fin 2 is eliminated. With very thin walled flat tubes 1, it may be the case that such a side part 20 is required because the clamping aid, which is used during the soldering, brazing, or welding process in order to obtain an optimum connection of the fins 2 to the flat tubes 1, could then damage the outermost flat tubes 1. In this case, the central parts 22 can be positioned precisely at the points at which the clamping aid engages.
The heat exchanger which is illustrated in
The heat exchanger includes an inlet opening 146 located in one of the tanks 104 for receiving charge air to be cooled, and an outlet opening 143 for directing cooled charge air outwardly from the other tank 104. The cooling air flows in the direction of the block arrow through the corrugated fins 102, which are arranged between broad sides 112 of the flat tubes 101. Furthermore, the direction of air flow through the heat exchanger and the air flow referenced herein is presented by way of example only and is not intended to limit the scope of the heat exchanger of the present invention in any manner. As such, the heat exchanger of the present invention can have a number of different configurations and orientations.
The heat exchanger shown in
In some embodiments, the heat exchanger of the present invention can be assembled such that the ends of the flat tubes 101 do not protrude inwardly towards the tank 104. The headers 103 can be fitted in such a way that the headers 103 are pushed onto the ends of the flat tubes 101 transversely with respect to the longitudinal extent of the headers 103. Alternatively or in addition, the tubes 101 can be inserted transversely into the openings 140 in the headers 103.
In the illustrated embodiment of
The tanks 104 can include two clamshell tank members 131 and 132. A first tank member 131 can have an “open” shell or cup configuration and the second tank member 32 can have a substantially planar or flat configuration. In the illustrated embodiment of
In the illustrated embodiment of
As shown in
In the illustrated embodiment of
In addition, in the illustrated embodiment of
Furthermore, the applicant would like to direct the readers' attention to international patent application PCT/EP 2006/001487 which is incorporated herein by reference.
Bumps or contoured portions 165 are formed along the relatively thin outer walls of the first and second members 131, 132 by pressing or deforming the outer walls inward to improve the stability and strength of the tanks 104. These inwardly directed bumps 165 can also or alternatively influence the flow distribution of fluid flowing through the tanks 104. The central pipes of a heat exchanger are often known to have a better flow through them than those which lie at the outer ends of the heat exchanger. As a result, an undesired temperature gradient is caused and the maximum possible cooling power is often not achieved. The bumps 165 of the present invention operate to at least partially counteract these and other disadvantages. The bumps 165 can, as is shown, be located on both tank members 131, 132, or alternatively, can be located on just one of the tank members 131, 132.
The heat exchanger illustrated in
The heat exchanger includes a tank 204 with two inlet/outlet openings 235 for charge air to be cooled. In other embodiments, the tank 204 can include one or more inlet/outlet openings 235. Cooling air flows in the direction of the block arrow through the fins 202 which are arranged between broad sides 212 of the flat tubes 201. Inlet/outlet openings 235 are referred to because very different internal throughflow patterns of the cooler can be set, as is desirable for specific applications, by using one or even more partitioning walls 210 in one or in both tanks 204 to determine whether the openings 235 are either inlet or outlet openings.
Only a few different exemplary throughflow patterns are shown in
The heat exchangers shown in
The tanks 204 include, according to the exemplary embodiment shown in
In the illustrated embodiment, two side openings 233 are formed after the two clamshell tank members 231, 232 have been coupled to each other, thus closure caps or the like (not shown) can be used. The two clamshell tank members 231, 232 forming the tank 204 include projections 230 arranged at intervals and engaging the ends of the flat tubes 201 in the region of the narrow sides 211. The distances between the projections 230 correspond substantially to the distances between the flat tubes 201 such that the tanks 204 can be pushed onto the ends of the flat tubes 201 in their longitudinal direction. Each projection 230 engages an end of a flat tube 201, precisely in the respective protruding portion 205. The projections 230 are present in two rows of projections 230 which have been characterized by A and B (see
A partitioning wall or a longitudinal partitioning wall 210 can be positioned between the two clamshell tank members 231, 232. The partitioning wall 210 can include projections 215 arranged at intervals as a suitable means for holding the longitudinal partitioning wall 210 to the tank members 231, 232 before the heat exchanger is soldered, welded, or brazed (
As illustrated in
As illustrated in
Furthermore, the applicant would like to draw the reader's attention to the international patent application PCT/EP 2006/001487, which is incorporated herein by reference.
Inwardly directed shaped portions or bumps 265 have been formed in the two clamshell tank members 231, 232. The shaped portions 265 provide, on the one hand, improved stability of the heat exchanger. Accordingly, the clamshell tank members 231, 232 can be constructed with extremely thin walls. On the other hand, the shaped portions 265 can influence the flow distribution. The central tubes of a heat exchanger are known often to have a better flow through them than those which lie at the edge of the heat exchanger. As a result, an undesired temperature gradient is caused and the maximum possible cooling power often cannot be achieved. A selective geometry of the shaped portions 265 is intended to counter these disadvantages. The shaped portions 265 further provide provisional securing of the partitioning wall 210 between the clamshell members 231, 232 as shown in
The heat exchanger illustrated in
A tank 304 for a heat exchanger, such as for example, a charge air cooler is illustrated in
The first tank member 331 illustrated in FIGS. 32 and 35-36 includes an exterior wall 372 having an elongated base 373, a first receiving portion 374, and a first connecting flange 375. The first tank member 331 also includes a first bump or contoured portion 377 extending inwardly from the exterior wall 372 into the interior space and, when the heat exchanger is assembled, toward the second tank member 332.
In the illustrated embodiment of
The second tank member 332 is substantially similar to and can be a mirror image of the first tank member 331. In the illustrated embodiment of
As shown in
In the illustrated embodiment of
As mentioned above, the first tank member 331 and the second tank member 332 are preferable each manufactured from a single piece of sheet metal. However, in some embodiments, the first tank member 331 and/or the second tank member 332 can also include welded baffles 379, 389 to add additional structural support and/or improve fluid distribution through the heat exchanger.
The heat exchanger illustrated in
With reference to
In the illustrated embodiment, projections 430 are located at the edge of the second tanks 452, as best shown in
In some embodiments of the present invention, the mounting sequence of the heat exchanger can be as follows. The core 413 is first formed by stacking flat tubes 401 and fins 402. The core 413 with protruding flat tube ends is then introduced into the openings 440 of the first tanks 451. The broad sides of the flat tubes 401 are relatively wider than the tanks 451 such that the openings 440 do not completely surround the ends of the flat tubes 401. For example,
Concurrently with the projections 430 being inserted, the first and second parts 491, 492 are also pushed together at their seam 498. The insertion depth of the projections 430 into the ends of the tubes 401 corresponds approximately to the depth of the seam 498 (
A heat exchanger according to another embodiment of the present invention is illustrated in
The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes are possible.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2006 031 653.3 | Jul 2006 | DE | national |
| 06023588.4 | Nov 2006 | EP | regional |
| 06023987.8 | Nov 2006 | EP | regional |
| 10 2006 058 096.6 | Dec 2006 | DE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US07/72968 | 7/6/2007 | WO | 00 | 9/8/2009 |
