Patent Application
20190063849
The invention relates to a heat exchanger for a vehicle, and more particularly, to a housing configuration for a heat exchanger.
As is commonly known, it is desirable for air entering an engine of a vehicle to be cooled, especially after exiting a turbocharger or a supercharger, because cooler air will have an increased density that maximizes an efficiency of the engine. In certain situations, the cooling of the air may also facilitate engine management and eliminate pre-detonation of the air and a fuel prior to a timed spark ignition. Additionally, the cooling of the air militates against excessive wear or heat damage to an engine block of the engine.
Heat exchangers such as water-cooled charge air coolers (WCAC) can be used in the vehicle to cool the air that has been compressed by the turbocharger or the supercharger prior to entering the engine. Typically, for application specific needs such as space constraints in a vehicle, for example, WCACs utilize a coolant from one or more sources and may include a heat exchange core with plates interposed between fins.
Typically, the core of the heat exchanger is disposed within a housing. The housing is coupled to an inlet tank configured for receiving air to be cooled within the heat exchanger and an outlet tank configured for conveying the cooled air from the heat exchanger. Disadvantageously, however, the housing may be complex or formed from multiple components such as greater than or equal to three components. The numerous components increase manufacturing and assembly costs. Additionally, the multiple components are susceptible to leakage at the joints of the multiple components forming the housing.
Accordingly, there exists a need in the art for a simple housing for a heat exchanger formed from minimal components that minimizes manufacturing and assembly costs and minimizes leakage.
In concordance with the instant disclosure, a simple housing for a heat exchanger formed from minimal components that minimizes manufacturing and assembly costs and minimizes leakage is discovered
According to a first embodiment of the disclosure, a housing for a heat exchanger is disclosed. The housing has a first housing portion having a U-shaped cross-section and a second housing portion cooperating with the first housing portion to define a chamber receiving a heat exchange assembly. The second housing portion is configured as a plate.
According to another embodiment of the disclosure, a core assembly for a heat exchanger is disclosed. The core assembly includes a two-component housing including a first housing portion and a second housing portion cooperating to define a chamber with a first open end and a second open end. A heat exchange assembly is received in the chamber.
According to yet another embodiment of the disclosure, a heat exchanger for a vehicle is disclosed. The heat exchanger includes a core assembly having a first open end and a second open end. The core assembly includes a housing receiving a heat exchange assembly. The housing is formed from a substantially U-shaped first housing portion and a substantially planar second housing portion. A first tank is coupled to the first open end of the core assembly. A second tank is coupled to the second open end of the core assembly.
The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical. As used herein, the term “substantially” means “mostly, but not perfectly” or “approximately” as a person skilled in the art would recognize in view of the specification and drawings.
As shown in
The heat exchange assembly 16 is disposed in a housing 18 of the core assembly 15. The heat exchange assembly 16 includes a plurality of stacked, substantially parallel plate assemblies 22. The plate assemblies 22 are interposed between a plurality of substantially parallel fins 20. Each of the plate assemblies 22 defines at least one flow channel (not shown) for receiving the fluid from at least one external source. It is understood, other fluid conveying mechanisms can be employed instead of the plate assemblies 22. For example, tubes can be employed instead of the plate assemblies 22. Other fluid conveying mechanisms can be employed as desired.
The housing 18 shown is a multi-component housing formed from a pair of components designated as a first housing portion 24 and a second housing portion 26. The first housing portion 24 and the second housing portion 26 cooperate with each other to define a chamber for receiving the heat exchange assembly 16. It is understood other housing configurations can be used to enclose and receive the heat exchange assembly as desired. The first housing portion 24 has a substantially U-shaped cross-section including a first wall 28 and a pair of second walls 30. The second walls 30 extend outwardly from an inner surface 54 of the first wall 28 at opposing sides of the first wall 28 and substantially perpendicular to the first wall 28. The second walls 30 extend substantially parallel to a direction of flow of the air through the heat exchanger 10, as indicated by an arrow. The second walls 30 form closed sides of the core assembly 15.
A pair of flanges 34 is coupled to the first housing portion 24 of the housing 18, wherein a first one of the flanges 34 is formed at the first open end 15a and a second one of the flanges 34 is formed at the second open end 15b. The flanges 34 frame or define a portion of the openings at the respective one of the first open end 15a and the second open end 15b. In the embodiment illustrated, the flanges 34 are substantially U-shaped to correspond in shape with the first housing portion 24. The flanges 34 can be formed separate from and coupled to the first housing portion 24 by attachment means such as a brazing or welding process, for example, or the flanges 34 can be integrally formed with the first housing portion 24. Each of the flanges 34 cooperates with a respective lip 46 formed on the second housing portion 26 of the housing 18, which will be described in further detail hereinbelow, to form a frame or support 48 configured for engagement with the header 19 or one of the tanks 12, 14.
The flanges 34 have a substantially flat engagement surface 36 to facilitate engagement of the flanges 34 to the header 19 or one of the tanks 12, 14 for a welding or a brazing operation, for example. In the embodiment illustrated, the outer perimeter 38 of the flanges 34 extends outwardly from an outer surface 25 of the first housing portion 24 of the housing 18. Tabs 40 are formed along the perimeter 38 of the flanges 34 to facilitate alignment and positioning of the header 19 or one of the tanks 12, 14 to the housing 18 prior to the welding or the brazing operation. The tabs 40 extend substantially perpendicular to and outwardly from the engagement surface 36 of the flanges 34. Three of the tabs 40, one at each lateral side of each of the flanges 34 and one at a portion of each of the flanges 34 extending from the first wall 28 of the first housing portion 24, are shown. However, more than three or fewer than three tabs 40 can be included if desired.
A plurality of apertures 32 is formed through the first wall 28 of the first housing portion 24. The apertures 32 are configured for providing fluid communication between the conduits and the heat exchanger 10. The apertures 32 provide fluid communication of the fluid from the external fluid source to the chamber formed by the first housing portion 24 and the second housing portion 26. It is understood the apertures 32 can be formed in other portions of the housing 18, as desired, such as in the second walls 30 or the second housing portion 26, for example.
The second housing portion 26 of the housing 18 is configured as a substantially planar plate with the lip 46 disposed at each of opposing ends of the second housing portion 26. Each of the lips 46 extends outwardly from a surface 50 of the second housing portion 26 substantially perpendicular to the surface 50. As mentioned hereinabove, each of the lips 46 cooperates with a respective one of the flanges 24 to form the frame 48. The second housing portion 26 has a width slightly less than the width between the inner surfaces 54 of the second walls 30 of the first housing portion 24, wherein side edges of the second housing portion 26 abut the inner surfaces 54 of the second walls 30 of the first housing portion 24. The first housing portion 24 has a length substantially equal to a length of the second housing portion 26.
The frame 48 is substantially rectangular to engage the header 19 that is substantially rectangular or the tank 12, 14 that is substantially rectangular. However, the frame 48 can have other shapes as desired to facilitate engaging with the header 19 and/or tank 12, 14 having alternate shapes.
The tabs 40 facilitate alignment and engagement of the header 19 or the tank 12, 14 to the frame 48, and consequently to the core assembly 15. Once aligned and engaged with the core assembly 15, the header 19 or the tank 12, 14 is secured to the frame 48 by a coupling means such as a brazing process, a welding process, or a crimping process. Although, other coupling means such as fasteners, bolts, screws, clamps, or other coupling means can be contemplated, if desired.
The components of the housing 18 (i.e. the first housing portion 24 and the second housing portion 26) can be formed from any material or process as desired. In one example, the first housing portion 24 and the second housing portion 26 are formed from aluminium by a stamping or casting process. In another example, the first housing portion 24 and the second housing portion 26 of the housing 18 are formed from a plastic material by a plastic forming process such as a molding process or extrusion process. Although, it is understood the first housing portion 24 and the second housing portion 26 of the housing 18 can be formed from any material or any process as desired. The first housing portion 24 is coupled to the second housing portion 26 by coupling means such as a brazing process, a welding process, or a crimping process. Although bolts, screws, clamps, or other coupling means can be contemplated, if desired.
To assemble the core assembly 15, the heat exchange assembly 16 is received in the first housing portion 24, wherein the first housing portion 24 partially covers the heat exchange assembly 16. The second housing portion 26 cooperates with the first housing portion 24 to form the housing 18 to enclose the heat exchange assembly 16 to form the housing 18 and define the first open end 15a and the second open end 15b of the core assembly 15. The side edges of the second housing portion 26 engage respective ones of the inner surfaces 54 of the second walls 30 of the first housing portion 24. The lips 46 of the second housing portion 26 align with the flanges 34 to form the frames 48. Once the second housing portion 26 is positioned in cooperation with the first housing portion 24, the first housing portion 24 is coupled to the second housing portion 26 by the coupling means.
According to one embodiment of the disclosure, the tanks 12, 14 are directly coupled to the core assembly 15 by the coupling means. In another embodiment, the headers 19 are directly coupled to the core assembly 15 by the coupling means and disposed intermediate the tanks 12, 14 and the core assembly 15. The tabs 40 are configured to align and engage the tanks 12, 14 or the headers 19 prior to coupling. Once aligned and engaged, the tanks 12, 14 or the headers 19 can then be brazed, welded, or otherwise coupled by the coupling means to the frames 48.
Advantageously, the heat exchanger 10 according to the present disclosure minimizes the number of components required to form the housing 18 of the heat exchanger 10, such as less than four components, and more specifically, such as two components as described herein. Additionally, because only two components form the housing 18, there is less brazing, welding, or coupling interfaces between the components of the housing 18 than prior art housings for heat exchangers. Consequently, there are less coupling interfaces leading to possible leakage. Furthermore, the heat exchanger 10 of the present disclosure minimizes manufacturing costs and complexity.
From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.
