Patent Application
20140262179
This disclosure relates to the field of heat exchangers. More specifically, the present disclosure relates to a tank and plate assembly for a heat exchanger and a method of assembling and securing the same.
A heat exchanger is a device which transfers the heat of one substance to another. Heat exchangers are common in various applications, including industrial, commercial, and domestic applications. For example, heat exchangers are commonly utilized in power plants, processing plants, refrigeration systems, air conditioning systems, vehicles and the like. Heat exchangers may be in the form of evaporators, condensers, and radiators. A heat exchanger includes one or more passages through which a fluid flows to exchange heat with the surrounding environment through which the passages travel.
Heat exchangers in the form of automotive radiators often consist of a composite assembly, including a tank attached to a radiator core, oftentimes with a gasket seal placed therebetween. The tank may include portions thereon that are configured to be crimped to the radiator core to attach the tank to the core. The gasket seal may be placed between the tank and the core to seal the connection therebetween.
However, such an assembly may be inadequate to withstand the elevated temperatures and high operating pressures that a heat exchanger may be subjected to over the course of its operational life. Elevated temperatures and pressures can cause the tank to separate from the core causing leaks and the like, which can diminish or completely hinder the performance of the heat exchanger. Further, separation of the tank from the core could also lead to a “blown gasket,” wherein the gasket escapes from between the tank and the core due to the elevated temperatures and pressures. Such issues damage the performance of the heat exchanger and in some cases render the heat exchanger inadequate for continued use.
Replacing a damaged heat exchanger comes at increased cost and hassle to the consumer and manufacturer alike. Specifically, replacing a damaged heat exchanger is a burden on the consumer's time and budget, and, more often than not, results in an increase in the number of warranty claims made by the consumer to the manufacturer, which in turn increases cost to the manufacturer. In addition, the hassle and expense of replacing the heat exchanger can injure the goodwill and reputation of the manufacturer in the mind of the consumer, leading to decreased market share over time. Thus, there is a need in the field of heat exchangers for an improved heat exchanger assembly that addresses these concerns.
The present invention relates to a tank and plate assembly for a heat exchanger and a method of assembling and securing the same.
An exemplary aspect of the heat exchanger assembly may comprise a core body, a plate fixedly coupled to the core body, the plate defining an aperture therein, and a tank having a foot thereon, wherein under the condition that the plate and the tank are coupled to one another, the aperture functionally engages the foot. The plate can have a sidewall and the aperture can be defined in the plate sidewall. The aperture may have a locking surface thereon, wherein the locking surface is configured to functionally engage the foot. In some cases, the locking surface may have a first shape that is configured to cooperate with and engage an engagement surface having a second shape, the first and second shapes being complimentary. The sidewall of the plate may further comprise a crimping member thereon, the crimping member being positioned between the aperture and a distal edge of the sidewall.
Another aspect of the heat exchanger assembly may comprise a sealing member that can be placed between the plate and the tank and serves to fluidicly seal the plate and the tank together.
Another aspect of the heat exchanger assembly may comprise a first means for coupling the plate and the tank to one another; and a second means for coupling the plate and the tank to one another.
The first means may comprise a crimping member in a distal end of a sidewall of the plate, and a securing surface on a foot of the tank, wherein the crimping member is configured to bend about the foot such that the crimping member and the securing surface functionally engage one another to secure the tank to the plate.
The second means may comprise an aperture in a sidewall of the plate, the aperture defining a locking surface having a first shape, and an engagement surface on a foot of the tank, the engagement surface having a second shape, wherein the first and second shapes are configured to correspond to one another such that the locking surface and the engagement surface functionally engage one another to secure the tank to the plate.
Another aspect of the heat exchanger assembly may comprise a method of producing a heat exchanger, including the operations of providing a plate having an aperture therein, providing a tank having an engagement surface, and coupling the plate and the tank to one another by functionally engaging the engagement surface and the aperture. The method may further include the aperture having a locking surface, wherein the locking surface has a first shape and the engagement surface has a second shape that cooperates with the first shape to lock the plate and the tank to one another. The foot may further comprise a locking surface, and coupling the plate and the tank to one another may further include the operation of bending a portion of a sidewall of the plate about the foot to functionally engage an interior surface of the plate sidewall with the locking surface.
The foregoing and other features, advantages, and construction of the present disclosure will be more readily apparent and fully appreciated from the following more detailed description of the particular embodiments, taken in conjunction with the accompanying drawings.
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures listed above. Although certain embodiments are shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present disclosure will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of embodiments of the present disclosure.
As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
Referring to the drawings,
Embodiments of heat exchanger 10 may comprise heat exchanger core 20, core 20 comprising a body 22 having one or more passages 26 contained therein, passages 26 being configured to allow a fluid to flow therethrough. As the fluid flows through passages 26 of core 20, the fluid may exchange heat with the surrounding environment to cool the fluid. In other words, as the fluid flows through passages 26 of core 20, the fluid dissipates and loses heat to the surroundings. As such, the temperature of the fluid exiting passages 26 of core 20 is lower than the temperature of the fluid entering passages 26 of core 20. The disclosure of the present invention seeks to prolong the longevity and efficiency of this general process within heat exchanger 10.
Embodiments of heat exchanger 10 may further comprise a plate 40. Plate 40 may be configured to be functionally coupled to core 20 at one or more locations on core 20. Plate 40 may be coupled to core 20 or may alternatively be formed as an integral part of core 20. As depicted, plate 40 may be fixedly coupled to core 20 at each of opposing upper and lower ends of core 20. Plate 40 may be configured to receive thereon tank 60, as will be discussed in greater detail herein.
Embodiments of heat exchanger 10 may further comprise plate 40 being configured to provide a rigid, physical connection between core 20 and tank 60 and yet also permit fluidic communication between tank 60 and core 20. As an example, plate 40 may be coupled to the upper end of core 20 and may be referred to herein as an upper plate 42 and plate 40 may also be coupled to the lower end of core 20 and may be referred to herein as a lower plate 44. Additional features of plate 40 will be discussed herein in reference to
Referring still to
Embodiments of heat exchanger 10 may further comprise a tank 60 being configured to be coupled to a corresponding plate 40, such as, for example, upper plate 42 and lower plate 44, so that an upper tank 62 may be coupled to corresponding upper plate 42 and a lower tank 64 may be coupled to corresponding lower plate 44, as shown. Each of upper tank 62 and lower tank 64 may further comprise inlet/outlet member 66 in a portion thereof, and more particularly, in a sidewall thereof. As mentioned herein, inlet/outlet member 66 on each of upper tank 62 or lower tank 64 may function as either an entrance to allow the fluid to enter heat exchanger 10 or as an exit to allow the fluid to exit heat exchanger 10, depending upon the desired direction of flow of the fluid through heat exchanger 10. Tank 60 may further comprise a cap 68 to provide access to a tank interior 61 (see
Referring now to
Embodiments of heat exchanger 10 may further comprise tank 60 having a foot 70 configured on the distal end of sidewall 65. Foot 70 may be configured on the distal end of the entire perimeter of tank 60 defined by sidewall 65, or may alternatively be configured on select portions of the distal end of sidewall 65. Preferably, the entire perimeter of sidewall 65 is configured to have foot 70 configured therein to establish a more secure coupling between tank 60 and plate 40. Foot 70 may be configured to permit tank 60 to couple to corresponding components of plate 40, such that tank 60 may functionally couple to plate 40 to form heat exchanger 10 of the present disclosure.
Referring now to
Referring now to
Embodiments of heat exchanger 10 may further comprise sidewall 46 defining therein one or more crimping members 48. Crimping members 48 may be defined in sidewall 46 by a series of successive gaps 52 in edge portions of sidewall 46, one crimping member 48 being defined between successive gaps 52. Each of crimping members 48 may further comprise a leading edge 56 that may be defined as the edge-most portion of crimping member 48.
In addition thereto, embodiments of heat exchanger 10 may further comprise sidewall 46 defining one or more apertures 50 therein. Apertures 50 may be an opening that extends completely through the entire width of sidewall 46 or may alternatively be a carved-out cavity in interior surface 47 of sidewall 46. As an example of the configuration of aperture 50, the plurality of apertures 50 depicted in the present disclosure are holes extending completely through sidewall 46. Apertures 50 may further comprise a locking surface 54 defined by aperture 50. Apertures 50 may be square-like in shape, as shown, but may also be rectangular in shape or any other shape that provides a locking surface 54 that corresponds to the shape of engagement surface 76 on foot 70. For exemplary purposes, apertures 50 depicted in
Referring now to
Under the condition that tank 60 is to be functionally coupled to plate 40, foot 70 of tank 60 may be brought into proximity with socket portion 58 of plate 40, with sealing member 90 positioned within socket portion 58. Tank 60 and plate 40 may then be advanced toward one another by pressing either or both of tank 60 and plate 40 toward one another to decrease the distance therebetween. As foot 70 advances up into socket 58, leading edge 56 of crimping member 48 may engage, or otherwise contact, tapered surface 74. As a result, the structural configuration of tapered surface 74 may force crimping member 48 to bias, or flex, outwardly to allow foot 70 to continue to advance into socket portion 58. This action may permit tapered surface 74 to pass under inner surface 47 of crimping member 48 until tapered surface 74 has passed completely under crimping member 48 to position tapered surface 74 within aperture 50. Once tapered surface 74 is positioned within aperture 50, crimping member 48 may snap back, or otherwise return, to its unflexed position, placing engagement surface 76 of foot 70 in proximate functional engagement with locking surface 54 of aperture 50. As such, engagement surface 76 of foot 70 is configured to functionally engage locking surface 54 of aperture 50, and vice versa, to prevent foot 70 from retreating out of socket portion 58 and to likewise prevent socket portion 58 from releasing off of foot 70. As a result, foot 70 of tank 60 may be functionally coupled and fixedly secured to aperture 50 of plate 40, and tank 60 may thereby be functionally coupled and fixedly secured to plate 40.
In this configuration, sealing member 90 may be compressed between socket portion 58 and upper surface 72 of foot 70, such that sealing member 90 may seal the union between tank 60 and plate 40. Moreover, sealing member 90 may be fixedly secured within socket portion 58 and may not thereafter escape out from between socket portion 58 and upper surface 72, without undue force.
In addition to engagement surface 76 of foot 70 functionally engaging locking surface 54 of aperture 50 to prevent tank 60 from separating from plate 40, embodiments of heat exchanger 10 may further comprise crimping member 48 being configured to be bent about corner 80 of foot 70 to further secure and fixedly couple tank 60 to plate 40. Specifically, the portion of crimping member 48 that extends beyond securing surface 82 may be configured to be bent, manually or by machine, about corner 80 such that inner surface 47 of crimping member 48 may contact and functionally engage securing surface 82, as depicted by dashed-lines in
Embodiments of heat exchanger 10 may further provide that even under the circumstances where the elevated temperatures and pressures within heat exchanger 10 cause bent crimping member 48 to warp, straighten, twist, or otherwise deform in any way to release crimping member 48 from functional engagement with securing surface 82, locking surface 54 is nevertheless configured to remain in functional engagement with engagement surface 76 to preclude tank 60 and plate 40 from separating and to preclude sealing member 90 from escaping out from therebetween. Embodiments of heat exchanger 10 thus comprise two independent means for coupling tank 60 and plate 40 to one another and for preventing functional disassociation of tank 60 from plate 40 once coupled. The two independent means prevent the disengagement of tank 60 from plate 40, and vice versa, and the escape of sealing member 90 out from between tank 60 and plate 40. A first means for coupling tank 60 and plate 40 to one another may comprise the structural configuration and function, as described herein, of the corresponding features, parts, and components of foot 70 and sidewall 46, and in particular crimping member 48 of sidewall 46 with respect to securing surface 82 of foot 70. A second means for coupling tank 60 and plate 40 to one another may comprise the structural configuration and function, as described herein, of the corresponding features, parts, and components of foot 70 and sidewall 46, and in particular engagement surface 76 of foot 70 with respect to locking surface 54 of aperture 50 in sidewall 46.
In view of the disclosure herein, the configuration of heat exchanger 10 of the present disclosure provides additional means for securing tank 60 to plate 40 over that of conventional heat exchangers. For example, conventional heat exchangers often suffer from poor strength and fail easily when forces from elevated pressures and temperatures are applied to the plate and tank assembly. For example, and without limitation, during normal operation, conventional heat exchangers are subjected to internal forces by elevated temperatures and pressures within the heat exchanger. Failures occur due to structural breakdown between the plate and the tank. Accordingly, the inadequate connection between the tank and plate of conventional heat exchangers limits the life of the conventional heat exchanger. However, embodiments of heat exchanger 10 address the limitations of the conventional heat exchanger by improving the coupling between plate 40 and tank 60. Specifically, not only does heat exchanger 10 provide for the bending of crimping member 48 about corner 80 to allow inner surface 47 of crimping member 48 to functionally engage securing surface 82 of foot 70, but heat exchanger 10 also provides for locking surface 54 of aperture 50 to functionally engage engagement surface 74 of foot 70 once tapered surface 74 is positioned within aperture 50. As a result, the strength and integrity of the union between tank 60 and plate 40 is reinforced, which increases the overall lifespan and efficiency of heat exchanger 10. Moreover, once coupled together, as described herein, it is less likely that tank 60 and plate 40 will separate from one another under the temperatures and stresses that result from normal operating conditions of heat exchanger 10. In addition thereto, once coupled together, as described herein, it is less likely that sealing member 90 will displace from within socket portion 58. Consequently, the frequency with which heat exchanger 10 will need to be repaired or replaced will decrease, resulting in less cost to not only the consumer but also to the manufacturer.
Referring now to
The process may further comprise operation 120 of providing a tank 60 for coupling to plate 40. Tank 60 may comprise a sidewall 65 that defines an interior space 61 therebetween, interior space 61 being in fluidic communication with core 20 of heat exchanger 10, and in particular with passages 26 of core body 20. Sidewall 65 of tank 60 may further comprise foot portion 70 on a distal end of sidewall 65. Foot portion 70 may further comprise an engagement surface 76 and a securing surface 82.
The process may further comprise operation 130 of coupling together tank 60 and plate 40. The operation 130 may comprise engaging sidewall 65 of plate 40 to foot 70 of tank 60. As tank 60 and plate 40 are brought closer together to be coupled together, sidewall 46 of plate 40 may be configured to functionally engage foot 70 in sidewall 65 of tank 60. Specifically, an inside surface 47 of sidewall 46 of plate 40 may be configured to engage a tapered surface 74 of foot 70 as tank 60 and plate 40 are brought together, tapered surface 74 being configured to bias, or otherwise force, sidewall 46 of plate 40 to bend outwardly away from foot 70 to a flexed position. Once tank 60 and plate 40 are brought close enough together, tapered surface 74 passes into aperture 50, at which point sidewall 46 of plate 40 springs back, or otherwise returns, to its unbiased or unflexed position and locking surface 54 of aperture 50 in plate 40 is brought into functional proximity with engagement surface 76 of foot 70. Thereafter, the position of locking surface 54 with respect to engagement surface 76 inhibits, prevents, deters, or otherwise precludes tank 60 and plate 40 from separating from one another due to the elevated temperatures and pressures placed upon tank 60 and plate 40 under normal operating conditions of heat exchanger 10. In other words, should the elevated pressures or temperatures exert force on the coupling between plate 40 and tank 60 to separate plate 40 from tank 60, engagement surface 76 and locking surface 54 functionally engage one another to prevent such separation.
Additionally, once tank 60 and plate 40 are brought close enough together such that tapered surface 74 is positioned within aperture 50 to bring locking surface 54 into functional proximity with engagement surface 76, crimping member 48 of sidewall 46 of plate 40 may protrude below a securing surface 82 of foot 70. Thereafter, crimping member 48 may be bent about foot 70 to bring interior surface 47 of crimping member 48 into functional proximity with securing surface 82. In this way, crimping member 48 may exert force against securing surface 82 to maintain tank 60 and plate 40 coupled together. The force exerted on plate 40 and tank 60 due to crimping member 48 engaging securing surface 82 serves to inhibit, prevent, deter, or otherwise preclude tank 60 and plate 40 from separating from one another due to the elevated temperatures and pressures placed upon tank 60 and plate 40 under normal operating conditions of heat exchanger 10. In other words, should the elevated pressures or temperatures exert force on the coupling between plate 40 and tank 60 to separate plate 40 from tank 60, crimping member 48 and securing surface 82 functionally engage one another to prevent such separation.
The process may further comprise operation 140 of securing a sealing member 90 between tank 60 and plate 40. Specifically, sealing member 90 may be placed within socket portion 58 of plate 40, socket portion 58 being configured on an interior surface of sidewall 46 of plate 40. Thereafter, once plate 40 and tank 60 are brought into close enough proximity with one another such that sidewall 46 of plate 40 begins to functionally engage foot 70, upper surface 72 of foot 70 enters into socket portion 58 and functionally engages sealing member 90. Upper surface 72 forces sealing member 90 into socket portion 58 to seal and lock sealing member 90 within socket portion 58 between plate 40 and foot 70. In this way, sealing member 90 seals the coupling between foot 70 and plate 40. As a result of the positioning of sealing member 90 and the configuration of tank 60 and plate 40 described herein, once sealing member 90 is locked in place within the socket 58 between tank 60 and plate 40, sealing member 90 does not thereafter escape from therebetween without undue force.
Although the preferred embodiments of the invention have been illustrated and described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
