The present invention relates to a heat exchanger assembly, more particularly, the present invention relates to an assembly between a condenser and a radiator for a vehicle.

Generally, vehicles include several heat exchanger elements. Conventionally, an engine cooling system of a vehicle includes a heat exchanger in the form of a radiator to facilitate cooling of an engine of the vehicle. Further, Heating Ventilation and Air-Conditioning (HVAC) system of the vehicle also includes another heat exchanger such as for example, a condenser. The radiator and the condenser are disposed at the front of the vehicle, so that air impinges on and passes through the radiator and the condenser arranged parallel to each other, as the vehicle traverses in a forward direction. The sequence in which the radiator and the condenser or any other heat exchanger are disposed may vary, for example, sometimes the radiator is at the front to first receive the air and in other cases the condenser is at the front to first receive the air. The position of the radiator and the condenser configuring a radiator-condenser assembly can interchange. However, considering packaging, serviceability, pricing and other factors, the radiator and the condenser of the radiator- condenser assembly are arranged to attain a compact configuration, reduced number of fixation points, reduced interface size and achieve proper routing of the fluid flow lines for minimum flow and pressure losses. Often, with use of jumper lines, more fixation points, longer fluid flow lines and larger connector interface size, the packaging of the heat exchange assembly in a confined space becomes complicated and the overall cost of the heat exchanger assembly increases.

In case of a conventional heat exchanger assembly, such as for example, a radiator-condenser assembly 01 as illustrated in FIG. 1 , a radiator 10 and a condenser 20 are arranged sequentially parallel to each other. The condenser 20 includes inlet and outlet blocks 2a, 2b configured on at least one manifold thereof, also simply referred to as at least one condenser manifold 24. The inlet and outlet blocks 2a, 2b are connected to heat exchange fluid flow lines, particularly, refrigerant flow lines 40 and deliver vapour refrigerant to and collects condensed refrigerant from the at least one condenser manifold 24, i.e. performs fluid connection function. The at least one condenser manifold 24 in turn distributes vapour refrigerant to the condenser core 22 and collects condensed refrigerant from the condenser core 22. The radiator- condenser assembly 01 further includes separate brackets 4a, 4b for mounting or fixing the condenser 20 over the radiator 10. One end of each bracket 4a, 4b is secured to the at least one condenser manifold 24 while the other end of each bracket 4a, 4b is secured to at least one radiator tank 14. Such configuration of using separate dedicated elements, particularly, inlet and outlet blocks 2a, 2b for fluid connection function and brackets 4a, 4b for fixing function, increases the total number of parts, increases inventory and inventory costs, overall size of the assembly, assembly time and efforts and reduces reliability. Further, such configuration increases assembly time. Also, in case the condenser 20 is disposed downstream of the radiator 10 and the refrigerant flow lines 40 are emanating from upstream of the radiator 10 in the direction of air depicted by arrow R, the refrigerant flow lines 40 are required to go around the at least one radiator tank 14 to reach the at least one condenser manifold 24. Such configuration, increases bends along the refrigerant flow lines 40 and overall length of the refrigerant flow lines 40, thereby causing pressure losses in the refrigerant flow lines 40.

Accordingly, there is a need for a heat exchanger assembly, particularly, a radiator-condenser assembly that involves comparatively fewer fixation points and reduced interface size. Further, there is a need for a radiator-condenser assembly that is compact in configuration. Furthermore, there is a need for a radiator-condenser assembly that achieves proper routing of the refrigerant flow lines such that the number of bends along the refrigerant flow lines and length of the refrigerant flow lines is reduced. Still further, there is a need for a radiator-condenser assembly that prevents or reduces pressure losses due to longer refrigerant flow lines or refrigerant flow lines following torturous path. Further, there is a need for a radiator -condenser assembly that provides better serviceability while still addressing packaging issues. Furthermore, there is a need for a radiator-condenser assembly that involves fewer parts, reduced inventory and inventory costs, reduced assembly efforts and assembly time as compared to conventional radiator-condenser assembly and exhibits improved reliability as compared to conventional radiator-condenser assembly. An object of the present invention is to provide a heat exchanger assembly, particularly, a radiator-condenser assembly that obviates drawbacks associated with the conventional radiator-condenser assembly.

Another object of the present invention is to provide a radiator-condenser assembly that involves comparatively fewer fixation points and reduced interface size.

Still another object of the present invention is to provide a radiator-condenser assembly that is of compact configuration.

Yet another object of the present invention is to provide a radiator-condenser assembly that achieves proper routing of the refrigerant flow lines such that the length of and bends along the refrigerant flow lines is reduced and pressure losses due to longer refrigerant flow lines or refrigerant flow lines following torturous path is reduced.

Another object of the present invention is to provide a radiator-condenser assembly that provides better serviceability while still addressing packaging issues.

Still another object of the present invention is to provide a radiator-condenser assembly that involves fewer parts, reduced inventory, inventory costs, reduced assembly efforts and assembly time as compared to conventional radiator-condenser assembly.

Yet another object of the present invention is to provide a radiator-condenser assembly that exhibits improved reliability as compared to conventional radiator- condenser assembly.

In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention. A heat exchanger assembly is disclosed in accordance with an embodiment of the present invention. The heat exchanger assembly includes a first heat exchanger, a second heat exchanger and at least one connector. The first heat exchanger includes at least one first manifold. The second heat exchanger includes at least one second manifold. The at least one connector is formed on at least one of the first manifold and the second manifold and facilitates connection between the second heat exchanger and the first heat exchanger. The at least one connector includes a fluid flow passage to form fluid communication between heat exchange fluid flow lines and the at least one second manifold. The fluid flow passage is fluidically isolated from the at least one first manifold.

Specifically, each connector includes a first portion and a second portion. The first portion is secured to at least one first manifold. The first portion includes a first section of the fluid flow passage that is in fluid communication with heat exchange fluid flow lines and is in fluidically isolated from the at least one first manifold. The second portion is secured to the first portion and the at least one second manifold. The second portion includes a second section of the fluid flow passage that is in fluid communication with the first section and the at least one second manifold.

Generally, the first portion and the second portion of each connector are integrally formed with respect to each other.

Alternatively, the first portion and the second portion of each connector are connected by at least one threaded connection element.

Generally, the first portion is integrally formed with the at least one first manifold.

Alternatively, the first portion is secured to the at least one first manifold by at least one of the connection methods selected from a group comprising of brazing, soldering and welding. Specifically, the first portion is connected to and in fluid communication with the heat exchange fluid flow lines by means of complimentary connection elements formed on the heat exchange fluid flow lines and the first portion.

Generally, the second portion is integrally formed with the at least one second manifold.

Alternatively, the second portion is secured to the at least one second manifold by at least one of the connection methods selected from a group comprising of brazing, soldering and welding.

Generally, the heat exchanger assembly includes two connectors disposed at a single second manifold, wherein a first connector is for inlet of heat exchange fluid into the single second manifold and a second connector is for outlet of the heat exchange fluid from the single second manifold.

Alternatively, the heat exchanger assembly includes two connectors disposed at two second manifolds at opposite sides of the second core, wherein a first connector is for inlet of heat exchange fluid into one of the two second manifolds and a second connector is for outlet of the heat exchange fluid from the other of the two second manifolds.

In accordance with an embodiment of the present invention, the heat exchanger assembly includes a single collector for inlet of heat exchange fluid into the second manifold and outlet of heat exchange fluid out of the second manifold.

Generally, the first heat exchanger is a radiator and the second heat exchanger is a condenser.

Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein: FIG. 1 illustrates a schematic representation of a conventional heat exchanger assembly;

FIG. 2 illustrates a schematic representation of a heat exchanger assembly, particularly, a radiator-condenser assembly, in accordance with an embodiment of the present invention;

FIG 3a illustrates an isometric view of a radiator-condenser assembly as viewed from one side for assembling together a radiator and a condenser in compact configuration, also illustrated is an enlarged view of a pair of connectors;

FIG. 3b illustrates an isometric view of the radiator-condenser assembly of FIG. 3a as viewed from another side, also illustrated is an enlarged view of the pair of connectors;

FIG. 4 illustrates an exploded view of the pair of connectors of FIG. 3b forming connection and fluid communication between at least one tank and at least one manifold of the radiator and the condenser respectively;

FIG. 5a illustrates an isometric view of at least one tank with first portions of the pair of connectors of FIG. 4 integrally formed thereon and as viewed from one side;

FIG. 5b illustrates an isometric view of the at least one tank of FIG. 5a as viewed from another side;

FIG. 6a illustrates an isometric view of a second portion of the connector of the pair of connectors of FIG. 3a, as viewed from one side;

FIG. 6b illustrates an isometric view of the second portion illustrated in FIG. 6a as viewed from another side;

FIG. 6c illustrates an isometric view of a threaded connection element, particularly, a threaded bolt for configuring connection between the first portion illustrated in FIG. 5a and FIG. 5b and the second portion of the connector illustrated in FIG. 6a and FIG. 6b;

FIG. 7 illustrates a cross sectional view depicting connection and fluid communication between the first portion and the second portion by means of bolt and plug respectively;

FIG. 8a and FIG. 8b illustrates isometric views of the first portion and the second portion of the connector of FIG. 3a;

FIG. 9a illustrates a front view of the second portion of the connector of FIG. 3a; and

FIG. 9b illustrates a sectional view of the second portion along section line A- L’ depicted in FIG. 9a.

It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

Disclosed is a radiator-condenser assembly that utilizes a single component that performs mounting and fluid connection functions, particularly, the condenser - radiator assembly uses a common connector that not only forms connection between the radiator and the condenser but also establishes fluid communication between refrigerant flow lines and at least one condenser manifold. Further, the common connector allows refrigerant to pass through at least one radiator tank while bypassing the same. Such configuration of the radiator-condenser assembly, eliminates the drawbacks associated with the conventional assembly, wherein the refrigerant flow lines encounter increased number of bends and increase in length due to the refrigerant flow lines being routed around the at least one radiator tank to reach the at least one condenser manifold. Although, the heat exchanger assembly is explained with an example of the radiator-condenser assembly in the forthcoming description and the accompanying drawings, however, the heat exchanger assembly is also applicable for assembly between any heat exchangers used in vehicle, such as for example, evaporator, condenser, radiator, chiller and the likes. Particularly, the present invention is applicable for heat exchanger assemblies that are required to be compact in configuration, require fewer number of fixation points, reduced interface size and proper routing of the refrigerant flow lines for reduced pressure loss.

A heat exchanger assembly, particularly, a radiator-condenser assembly 100 is disclosed in accordance with an embodiment of the present invention. FIG. 2 illustrates a schematic representation of the radiator-condenser assembly 100. FIG 3a illustrates an isometric view of the radiator-condenser assembly 100 as viewed from one side, whereas FIG 3b illustrates an isometric view of the radiator-condenser assembly 100 as viewed from another side, also is illustrated an enlarged view depicting a pair of connectors 30.

The radiator-condenser assembly 100 includes a first heat exchanger, particularly, a radiator 10, a second heat exchanger, particularly, a condenser 20 and at least one connector 30. The first heat exchanger includes a first heat exchanger core and either one of at least one first manifold and tank, particularly, the radiator 10 includes a radiator core 12 and at least one radiator tank, simply referred to as at least one tank 14. The second heat exchanger includes a second heat exchanger core and at least one second manifold, particularly, the condenser 20 includes a condenser core 22 and at least one condenser manifold, simply referred to as at least one manifold 24. The at least one connector 30 is formed on at least one of the tank 14 and the manifold 24.

The at least one connector 30 facilitates connection between the condenser 20 and the radiator 10. Further, the at least one connector 30 also forms a refrigerant flow passage 32 to establish fluid communication between the refrigerant flow lines 40 and the at least one manifold 24. However, the refrigerant flow passage 32 is fluidically isolated from the at least one tank 14. More specifically, the at least one connector 30 configures fluid communication between the refrigerant flow lines 40 and the at least one manifold 24, while bypassing the at least one tank 14. Such configuration of the at least one connector 30 performs dual functions, firstly, the at least one connector 30 performs fluid connection function, i.e. either the at least one connector 30 delivers vapour refrigerant to or collects condensed refrigerant from the at least one manifold 24. Secondly, the at least one connector 30 also configures connection between the at least one tank 14 and the at least one manifold 24, and as such connection between the radiator 10 and the condenser 20 to reduce the number of fixation points. The radiator-condenser assembly 100 configured with such a configuration of the at least one connector 30 has several advantages. Particularly, the radiator-condenser assembly 100 configured with such a configuration of the at least one connector 30, involves fewer parts, reduced inventory and inventory costs, reduced assembly time and efforts and improved reliability. Further, the radiator-condenser assembly 100 configured with such a configuration of the at least one connector 30 is compact.

FIG. 4 illustrates an exploded view of the pair of connectors 30 forming connection and fluid communication between the at least one tank 14 and the at least one manifold 24 of the radiator 10 and the condenser 20 respectively. Each connector 30 includes a first portion 30a and a second portion 30b. The first portion 30a is secured to the at least one tank 14. Specifically, the first portion 30a is integrally formed with the at least one tank 14 as illustrated in FIG. 5a and FIG. 5b. More specifically, the at least one tank 14 is of plastic material and the first portion 30a is integrally formed on the at least one tank 14 during manufacturing of the at least one tank 14 by moulding. In case, the at least one tank 14 is of metal, the first portion 30a is secured to the at least one tank 14 by at least one of the connection methods selected from a group comprising of brazing, soldering and welding. However, the present invention is not limited to any particular configuration of the first portion 30a and method of securing the first portion 30a over the at least one tank 14 as far as a first section 32a of the refrigerant flow passage 32 formed in the first portion 30a is by passing the at least one tank 14. Specifically, the first portion 30a includes the first section 32a of the refrigerant flow passage 32 that is in fluid communication with the refrigerant flow lines 40 and is fluidically isolated from the at least one tank 14. Specifically, the first portion 30a includes a through aperture 31a defining the first section 32a of the refrigerant flow passage 32, wherein a first end of the through aperture 31a is connected to the refrigerant flow lines 40 whereas an opposite second end of the through aperture 31a is connected to a second section 32b of the refrigerant flow passage 32 formed on the second portion 30b via a complimentary, hollow plug, simply referred to as plug 31b formed on the second portion 30b. Specifically, the first portion 30a is connected to and in fluid communication with the refrigerant flow lines 40 by means of complimentary connection elements formed on the refrigerant flow lines 40 and the first end of the through aperture 31a formed on the first portion 30a. The first portion 30a further includes a first hole 33a, either through or blind for passage of a threaded connection element there through, particularly, a bolt 34 there through for facilitating threaded connection between the respective first portion 30a and the second portion 30b of the respective connector 30. Furthermore, the first section 32a of the refrigerant flow passage 32 formed on the first portion 30a is in fluid communication with the second section 32b of the refrigerant flow passage 32 formed on the second portion 30b.

FIG. 6a illustrates an isometric view of the second portion 30b of the connector 30 as viewed from one side. FIG. 6b illustrates an isometric view of the second portion 30b of the connector 30 as viewed from another side. The second portion 30b is secured to the first portion 30a and the at least one manifold 24. Specifically, the second portion 30b is integrally formed with the at least one manifold 24. More specifically, the at least one manifold 24 is of plastic material and the second portion 30b is integrally formed on the at least one manifold 24 during manufacturing of the at least one manifold 24 by moulding. In case the at least one manifold 24 is of metal, the second portion 30b is secured to the at least one manifold 24 by at least one of the connection methods selected from a group comprising of brazing, soldering and welding. However, the present invention is not limited to any particular configuration of connection between the second portion 30b and the at least one manifold 24 as far as the second portion 30b and the at least one manifold 24 are in fluid communication with each other. With such configuration, the refrigerant received in the second section 32b from the first section 32a of the refrigerant flow passage 32 passes through the second section 32b along flow direction depicted by arrow B and is delivered to the manifold 24. The second portion 30b includes the second section 32b of the refrigerant flow passage 32 that is in fluid communication with the first section 32a of the refrigerant flow passage 32 and the at least one manifold 24. Specifically, the second portion 30b includes the plug 31b that is complimentary to and connected to the second end of the through aperture 31a to configure fluid communication between the first section 32a formed in the first portion 30a and the second section 32b formed in the second portion 30b. More specifically, as illustrated in FIG. 7, the plug 31b is received in the second end of the through aperture 31a and includes threads for configuring connection between the plug 31b and the second end of the through aperture 31a formed on the first portion 30a. The plug and the hole can be interchangeable disposed on the first part 30a and the second part 30b. Specifically, the plug is in fluid communication with the first section 32a formed on the first portion 30a and can extends from the first portion 30a instead of extending from the second portion 30b and is received in a hole configured on the second portion 30b, wherein the hole is in fluid communication with the second section 32b formed in the second portion 30b. However, the present invention is not limited to whether the plug and the hole are configured the first portion 30a or the second portion 30b of the connector 30, as far as the plug and the hole forms fluid communication between the first section 32a and the second section 32b of the refrigerant flow passage 32 formed on the first part 30a and the second part 30b of the connector 30 respectively.

Again referring to FIG.7, the second portion 30b further includes a second hole 33b, particularly a through hole that is aligned with the first hole 33a formed on the first portion 30a for passage of the threaded connection element, particularly, the bolt 34 as illustrated in FIG. 6c there-through for facilitating threaded connection between the respective first portion 30a and the second portion 30b of the connector 30. Alternatively, the first portion 30a and the second portion 30b of each connector 30 can be integrally formed with respect to each other. FIG. 8a and FIG. 8b illustrates isometric views of the first portion 30a and the second portion 30b of the connector 30. FIG. 9a illustrates a front view of the second portion 30b of the connector 30. FIG. 9b illustrates a sectional view of the second portion 30b along section line A-A’.

The at least one connector 30 performs dual function of forming connection between the at least one tank 14 of the radiator 10 and the at least one manifold 24 of the condenser 20 and establishing fluid connection between the refrigerant flow lines 40 and the at least one manifold 24. Accordingly, such configuration of the at least one connector 30 of the radiator-condenser assembly 100 reduces the fixation points of the radiator-condenser assembly 100. Particularly, with such configuration, either one of the radiator 10 and the condenser 20 of the radiator-condenser assembly 100 can be mounted on a vehicle frame as against conventional assembly that requires the radiator as well as the condenser to be mounted on the vehicle frame. Further, in case the refrigerant flow lines are emanating from upstream the radiator in the direction of air, such configuration of the at least one connector 30 of the radiator-condenser assembly 100 allows the refrigerant from the refrigerant flow lines 40 to pass through the at least one tank 14 while bypassing the same. Such configuration is advantageous over conventional arrangement of the radiator-condenser assembly, wherein the refrigerant flow lines 40 are required to go around the at least one tank 14 to reach the at least one manifold 24. Such configuration of the at least one connector 30 achieves proper routing of the refrigerant flow lines 40 as the number of bends along the refrigerant flow lines 40 and length of the refrigerant flow lines 40 is reduced and pressure losses due to the refrigerant flow lines 40 being longer or the refrigerant flow lines 40 following torturous path is also reduced.

In accordance with an embodiment of the present invention as illustrated in FIG. 3a - FIG. 5b, the radiator-condenser assembly 100 includes two connectors 30 disposed at a single manifold 24 disposed at one side of the radiator 10 and the condenser 20. The first connector 30 is for inlet of refrigerant vapour into the single manifold 24 and the second connector 30 is for outlet of the condensed refrigerant from the single manifold 24 after the refrigerant vapour undergoes condensation in the condenser core 22.

In accordance with an embodiment of the present invention, the radiator- condenser assembly 100 includes two connectors, each disposed at two separate manifolds 24 disposed at opposite sides of the condenser core 22. Specifically, a first connector is for inlet of refrigerant vapour into one of the two manifolds and a second connector 30 is for outlet of the condensed refrigerant from the other of the two separate manifolds 24.

In accordance with an embodiment of the present invention, the radiator- condenser assembly 100 includes a single collector disposed at the single manifold 24. The single collector is for inlet of refrigerant vapour into the single manifold and outlet of condensed refrigerant out of the single manifold 24.

Several modifications and improvement might be applied by the person skilled in the art to the heat exchanger assembly 100 as defined above, and such modifications and improvements will still be considered within the scope and ambit of the present invention, as long as the heat exchanger assembly comprises_a first heat exchanger that includes at least one first manifold, a second heat exchanger that includes at least one second manifold and at least one connector formed on at least one of the first manifold and the second manifold. The at least one connector facilitates connection between the second heat exchanger and the first heat exchanger. The at least one connector includes a fluid flow passage that forms fluid communication between heat exchange fluid flow lines and the at least one second manifold. The fluid flow passage is fluidically isolated from the at least one first manifold.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein.

In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means.