This specification relates to heat exchangers, and in particular to stacked plate heat exchangers, as used particularly in the automotive industry.
Stacked plate heat exchangers typically comprise a plurality of plate pairs stacked one on top of the other with each plate pair having opposed inlet and outlet openings such that when the plate pairs are stacked together, the inlet and outlet openings align to form inlet and outlet manifolds and thereby establish communication between fluid channels formed inside each plate pair. The plate pairs are usually joined together by brazing. However, as the plate pairs tend to be unsupported in the area of the manifolds, the heat exchanger in the area of the inlet and outlet openings tends to distort under the pressure of the fluid flowing therethrough and will often expand like an accordion or “bellows” in the manifold region. The distortion that occurs in the manifold regions of the heat exchanger tends to lead to premature failure or cracking and leaking in the heat exchanger.
Similarly, in in-tank oil coolers (ITOC) (cross-section of a portion of an ITOC is shown in
For applications that require higher durability, the core plate bubbles are replaced with washers (also referred to as spacers) as shown
Another approach used to reinforce the inlet and outlet areas of a heat exchanger is to use exterior clamps or brackets that are brazed to the outside of the heat exchanger to keep it from expanding under pressure. Another further approach is to insert perforated or slotted tubes through all of the aligned inlet and outlet openings of each plate, the tubes being brazed to the peripheries of the respective inlet and outlet openings. However, such approaches as described above, can be costly and can increase overall manufacturing process and costs associated with the particular heat exchanger.
U.S. Pat. No. 5,794,691 (Evans et al.) discloses a heat exchanger made from a plurality of stacked plate pairs wherein the inlet and outlet openings that form the manifolds include opposed flange segments formed on the inner peripheral edges of the openings. The flange segments extend inwardly and are joined together when the plates are stacked together to prevent expansion of the manifolds when under pressure.
U.S. Pat. No. 8,678,076 B2 (Shore et al.) discloses a plate type heat exchanger having a plurality of stacked plate pairs. Each plate pair has opposed manifold members with respective inlet and outlet openings that are in registration to form respective inlet and outlet manifolds for the flow of a first fluid through a first set of fluid channels formed by the plate pairs. The manifold members spacing the plate pairs apart to form a second set of transverse flow channels for the flow of a second fluid. Each plate has a peripheral edge portion which seals the plates together to form the first set of fluid channels therebetween. A protrusion member is formed proximal to each of the manifold members, each protrusion member having a mating surface such that the protrusion members on the second plate of one plate pair align and abut with the protrusion members on the first plate of an adjacent plate pair thereby reinforcing and strengthening the manifold region of the heat exchanger to prevent the deformation or accordion of the manifold under pressure.
There is a need in the art for heat exchanger plates that can help to form a rigid structure along the height of the heat exchanger that allows the bottom and top core plates to better withstand the pressure load of a fluid flowing therethrough. In addition, there is a need in the art for a heat exchanger plate that can to eliminate the need to use washers between core plates in the header region and to increase the burst strength of the heat exchanger. Further, there is a need in the art for a heat exchanger having such heat exchanger plates.
Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:
Similar reference numerals may have been used in different figures to denote similar components.
In one aspect, a reinforcing rib is formed in the header portion (inlet and outlet manifolds) of the heat exchanger plate. In particular, the reinforcing rib is positioned between a boss having the inlet (or outlet) and the peripheral edge of the heat exchanger plate. Preferably, the reinforcing rib extends from the central planar portion of the heat exchanger plate around the boss having the inlet (or outlet) to the peripheral edge portion of the heat exchanger plate, with the reinforcing rib being in contact with the peripheral edge portion.
In another aspect, a heat exchanger plate pair is disclosed having the reinforcing rib as described above.
In another further aspect, the heat exchanger plate pair is disclosed having the reinforced rib as described herein and a turbulizer positioned in a fluid channel defined by the plate pair. The turbulizer extending from one peripheral edge portion of the heat exchanger plate having the inlet (from the narrow edge of the longitudinal heat exchanger plate) to the opposing peripheral edge portion of the heat exchanger plate (to the other the narrow edge of the longitudinal plate) having the outlet. In a particular embodiment, the turbulizer has an aperture, with the edge of the aperture being generally aligned with the edge of the inlet (or outlet).
In still another aspect, the specification relates to a heat exchanger having a heat exchanger plate pair with the plate having the reinforcing rib as described above. The heat exchanger is also provided with a fitting that engages the inlet and outlet of the heat exchanger. Further, the peripheral edge portion of the fitting also engages the reinforcing rib of the top heat exchanger plate to help provide a more rigid structure along the height of the heat exchanger.
The heat exchanger plate 2 is also provided with a peripheral edge portion 14 that extends from the longitudinal central portion 4 on all sides of the heat exchanger plate 2. Hence, the peripheral edge portion 14 extends from the first end 6, the second end 8, the third end 10 and the fourth end 12 of the longitudinal central planar portion 4. As is described herein, the peripheral edge portions 14 of two plates come in contact to form a plate pair, when the plates 2 are positioned in a face-to-face relationship, and help define a fluid channel. To achieve this, the peripheral edge portion 14 is present in a different plane than the central planar portion 4 of the heat exchanger plate 2. For instance, the peripheral edge portion 14 can be considered to be below the central planar portion 4. For purposes of description, the central planar portion is present in first plane, while the peripheral edge portion 14 is present in a second plane.
The heat exchanger plate 2 has a first boss (or bubble) 16 near the first end 6 of the central planar portion 4. The first boss 16 extends in a direction opposite to the peripheral edge portion 14. In one embodiment, as shown in the figures, the first boss 16 has a generally flat surface, denoted herein as a first boss contact surface 18, which lies in a different plane (third plane) than the central planar portion 4 and the peripheral edge portion 14. When viewed from the side, in one view of the heat exchanger plate 2, the central planar portion 4 (that lies in the first plane) is in between the peripheral edge portion 14 (that lies in the second plane) and the first boss contact surface 18, which lies in the third plane. The first boss contact surface 18 has inlet opening 20 to permit fluid to enter into the heat exchanger 22. As described herein, the first boss contact surface 18 engages the contact surface of a boss on an adjacent plate pair to form the inlet manifold.
In addition to the above, the heat exchanger plate 2 also has a second boss (or bubble) 24 near the second end 8 of the central planar portion 4. Like the first boss 16, the second boss 24 extends in a direction opposite to the peripheral edge portion 14 (and in the same direction as the first boss 16). Similar to the first boss 16, the second boss 24 has a generally flat surface, denoted herein as a second boss contact surface 26, which also lies the third plane (same as the first boss contact surface 18). The second boss contact surface 26 has outlet opening 28 to permit fluid to exit from the heat exchanger 22. As described herein, the second boss contact surface 26 engages the contact surface of a boss on an adjacent plate pair to form the outlet manifold.
In accordance with an embodiment disclosed in
The first end first reinforcing rib 30 is also provided with a first end first rib mating surface 32. The first end first rib mating surface 32 also lies in the third plane, with the first boss contact surface 18 and the second boss contact surface 26. When the heat exchanger 22 is assembled, the rib 30 on one plate engages a rib 30 on another plate in an adjacent plate pair. This can help to reinforce the header section of the heat exchanger 22.
Also provided (as shown in
In a particular embodiment, as shown in
As described herein, particularly with respect to
As more clearly shown in
In one embodiment, as shown in
The heat exchanger 22 also has a fitting 50 that couples to a top heat exchanger plate 2. In one embodiment, the top plate and/or the bottom plate of the heat exchanger is a flat plate. In other words, a plate lacking the reinforcing ribs disclosed herein. Alternatively, in another embodiment, the top plate and/or the bottom plate of the heat exchanger can have the reinforcing ribs as disclosed herein. The fitting 50 has an orifice 54 that is in fluid communication with the inlet 20 (or outlet 28) of the top heat exchanger plate 2. In one embodiment, as shown in
In another embodiment, the peripheral edge portion 52 of the fitting 50 overlays the reinforcing ribs 30 on the first end, the third end and the fourth end of heat exchanger plates (with or without the flat heat exchanger plate in between).
In an alternate embodiment, as shown in
The reinforcing rib 30 can be formed as a single rib as shown in
The heat exchanger disclosed herein helps to increase the vertical rigidity of the header region, making is less susceptible to vertical expansion under pressure; while also helping to avoid use of washers.
In addition, the extended turbulizer can help to increase the oil side stiffness of the channels. The rib can help to increase the coolant side stiffness with the additional braze contact around the perimeter of the core plate under the fitting, eliminating the forcing moment that is applied to the core plate bubble as the bottom plate is pushed downwards by the oil pressure. The reaction force from the downward force of the oil is now transmitted up through the header to the fitting, and the overall effect is to reduce the deformation in the heat exchanger (as shown in
Another benefit of this design is that it can help to reduce the oil side pressure drop. With the additional support provided by the rib, the internal diameter (ID) of the header bubble can be reduced as well. Having this diameter match the fitting diameter eliminates the pressure loss associated with sudden changes in cross sectional area of the flow path. Therefore, such heat exchangers 22 can also have a lower oil side pressure drop than conventional designs for the same turbulizer design.
Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.
Number | Date | Country | |
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62403389 | Oct 2016 | US |