The present disclosure relates to a tank for a heat exchanger. The present disclosure further relates a method for manufacturing the tank.
A vehicle is generally equipped with a heat exchanger for a thermal system. A heat exchanger generally includes a tank for receiving thermal medium.
According to an aspect of the disclosure, a tank for a heat exchanger includes a tank part and a core plate. The tank part is affixed to the core plate.
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
According to one aspect of the disclosure, a tank has a slide-in configuration where a tank part is inserted along holders of a core plate. The holders are continuous along long lateral sides of the core plate, respectively. This configuration may enable consistent sealing and may require less manufacturing process.
As follows, a first embodiment of the present disclosure will be described with reference to drawings.
(Coolant System)
(Radiator)
The radiator 100 includes a core 110, an inlet tank 120, and an outlet tank 130. The core 110 is interposed between the inlet tank 120 and the outlet tank 130. The core 110 includes tubes 114 and fins 116. The tubes 114 and fins 116 are stacked one another and brazed together. The tubes 114 are connected with the inlet tank 120 and the outlet tank 130. Each of the tubes 114 is in a planar shape and defines a coolant passage to conduct coolant therethrough. Each of the fins 116 is in a wave shape. The fins 116 and the tubes 114 form airflow passages. The airflow passages are directed toward a front grill of the vehicle. As the vehicle travels, ram air flows through the airflow passages. In addition, a fun device (not shown) is installed to the radiator 100 to generate airflow through the radiator 100. The fins 116 and tubes 114 conduct heat exchange between the air passing through the airflow passages and coolant flowing through the tubes 114.
The inlet tank 120 has an inlet port 122 connected with a coolant outlet port of the engine 180 through the conduit. The outlet tank 130 has an outlet port 132 connected with a coolant inlet port of the engine 180 through the conduit. In the present example, the radiator 100 has a single pass structure to conduct coolant from the inlet tank 120 through the core 110 to the outlet tank 130.
While the coolant passes through the core 110, the coolant and the ram air conduct heat exchange therebetween to cool the coolant. In this way, the coolant system is configured to cool the engine 180 by using circulating coolant.
The radiator 100 may be used in a low-temperature radiator system (LTR system) for cooling a battery and/or a power electronics device.
(Construction of Tank)
As follows, a construction of the tank will be described in detail. In the following description, the inlet tank 120 will be described as an example. In the following description and related drawings, the inlet port 122 is omitted.
As shown in
A seal member 8 is interposed between the tank part 2 and the core plate 4. The seal member 8 is formed of an elastomer such as EPDM rubber.
The tank part 2 and the core plate 4 form a tank cavity 120a. The seal member 8 liquid-tightly seals the interface between the tank part 2 and the core plate 4. The tank cavity 120a communicates with an exterior of the tank 120 through the openings 4a.
The tank part 2 has a tank portion 20 and a foot portion 30. The foot portion 30 extends radially outward from a bottom end of the tank portion 20. In the present example, the foot portion 30 has a recess 32 at its underneath. The recess 32 accommodates an upper portion of the seal member 8.
The core plate 4 has a base portion 40 and a holder portion 50 which are integrally formed as one piece. The base portion 40 is in a plate shape having a flat bottom surface. The holder portion 50 has a U-shaped cross section on each side. The holder portion 50 grips the foot portion 30 and the seal member 8.
The tank cavity 120a is configured to receive pressurized coolant and is exerted with internal pressure. In the present configuration, the holder portion 50 of the core plate 4 rigidly holds the foot portion 30. In addition, the seal member 8 restricts leakage of the coolant from the tank cavity 120a to the outside of the tank 120.
(Components of Tank)
(Tank Part)
In
(Seal Member)
The seal member 8 is in an annular shape. The seal member 8 has an outer periphery slightly smaller than an outer periphery of the foot portion 30 of the tank part 2. The seal member 8 has an inner periphery slightly larger than an inner periphery of the foot portion 30.
(Core Plate)
In
The holder portion 50 includes a first holder 52, a second holder 54, and a third holder 56. The first holder 52 and the second holder 54 are located at the two long lateral sides, respectively. Each of The first holder 52 and the second holder 54 is one piece continuously extending linearly along corresponding one of the long lateral sides. The third holder 56 is located at the one short lateral side. The third holder 56 is one piece continuously extending linearly along the other short lateral side.
The first holder 52 and the second holder 54 have a U-shaped cross section forming a first linear channel 52a and a second linear channel 54a, respectively. The first linear channel 52a and second linear channel 54a continuously extend linearly along the long lateral sides of the base portion 40. The third holder 56 has a U-shaped cross section forming a third linear channel 56a. The third linear channel 56a continuously extends linearly along the other short lateral side.
The holder portion 50 and the base portion 40 form a slot 50a at the one short lateral side. The slot 50a linearly extends along the bottom surface of the base portion 40. The slot 50a serves as an insertion opening for the tank part 2.
The core plate 4 further has tabs 58 integrally formed with the base portion 40. The tabs 58 extend radially outward from the one short lateral end of the base portion 40. Each of the tabs 58 is in a rectangular shape. In the present example, the core plate 4 has two tabs 58.
(Assemble Process)
As follows, an assembling process of the tank 120 will be described with reference to
In
Subsequently, in
The foot portion 30 is further inserted until the foot portion 30 abuts against the inner periphery of third holder potion 56. Thus, the tank part 2 is assembled to the core plate 4.
Before inserting the tank part 2 into the slot 50a, the lower surface of the seal member 8 may be applied with lubricant such as grease. The lubricant may mitigate friction between the seal member 8 and the core plate 4 to enable smooth insertion of the tank part 2 through the slot 50a.
In
In
(Forming Process of Core Plate)
As follows, a forming process of the core plate 4 will be described with reference to
In
In
Subsequently, as shown by the arrows, three cores 830, 840, and 850 are moved horizontally toward the tilted first margin 520, the tilted second margin 540, and the tilted third margin 560, respectively. Each of the cores 830, 840, and 850 bends the corresponding margin along the surface of the punch 820 while being moved toward the center of the punch 820. During the present process, as the first margin 520, the second margin 540, and the third margin 560 are bent, the adjacent two margins are, at the boundary, further deformed and fused together, and the notches 500a are further reduced in size.
In
In
Through the deep drawing process of the blank 500 and the bending process of the first margin 520, the second margin 540, and the third margin 560 in
(Effect)
According to the present embodiment, each of the first holder 52 and the second holder 54 is one piece continuously extending linearly along the corresponding long lateral side. Therefore, the first holder 52 and the second holder 54 may enable consistent seal between the tank part 2 and the core plate 4.
The first holder 52 and the second holder 54 have the U-shaped cross section forming the first linear channel 52a and second linear channel 54a, respectively. The first linear channel 52a and second linear channel 54a continuously extend linearly along the long lateral sides, respectively. The holder portion 50 and the base portion 40 enable insertion of the tank part 2 therethrough. The first linear channel 52a and second linear channel 54a, which are opposed across the base portion 40, may serve as the guiderails to guide insertion of the foot portion 30 of the tank part 2.
The third holder 56 has the U-shaped cross section forming the third linear channel 56a. The third linear channel 56a continuously extends linearly along the short lateral side. The third holder 56 serves as a stopper defining an end position of the insertion.
In the present example, the first holder 52 and the second holder 54 extend continuously throughout the lateral sides of the core plate 4 in the longitudinal length. One of the long lateral sides has only the first holder 52 for gripping the foot portion 30. The other of the long lateral sides has only the second holder 54 for gripping the foot portion 30. The present configuration does not require a manufacturing process to crimp a large number of tabs. The continuously formed holder portion 50 may have extensive rigidity to securely grip the foot portion 30 of the tank part 2 and the seal member 8.
In addition, in the present example, the holder portion 50 is seamless at the corners. Therefore, the holder portion 50 may enable to seal extensively between the tank part 2 and the core plate 4.
As shown in
As shown in
During insertion of the foot portion 330 through the slot 50a of the core plate 4, friction may occur between the seal member 308 and the core plate 4. The seal member 308 would potentially deform due to the friction during the insertion. The present configuration may fortify the interface between the seal member 308 and the foot portion 330 and may avoid deformation of the seal member 308 caused by the friction.
The tabs 58 are optional. Provided that the holder portion 50 grips the foot portion 30 and the seal member 8 with sufficient rigidity, the tabs 58 may be omitted.
The cap 200 may be provided to an end of the tank 120 instead of or in addition to the third holder 56.
The tank part 2 may be formed of a metallic material such as an aluminum alloy by die-casting or press working.
The tank may be used for a heat exchanger for various thermal system such as a thermal recovery cycle for a power source and/or a refrigerant cycle.
While the present disclosure has been described with reference to preferred embodiments thereof, it is to be understood that the disclosure is not limited to the preferred embodiments and constructions. The present disclosure is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, which are preferred, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the present disclosure.