BLOCKING TABS

FIELD

[0001] The specification relates to a heat exchanger having an air bypass blocking tabs, and a heat exchanger assembly having a housing and the heat exchanger described herein.

BACKGROUND

[0002] Charge air cooler heat exchangers are well known in the art for mounting along the flow path of charge air supplied to a combustion engine. This charge air typically comprises ambient air which has been compressed by apparatus such as a supercharger or turbocharger to provide an increased mass flow of air to the engine to permit the engine to combust increased quantities of fuel and thereby operate at an increased level of power and performance. However, compression of ambient air also elevates the air temperature such that the charge air has a relatively high temperature which, if not reduced, undesirably increases total engine heat load . It is therefore desirable to cool the charge air prior to supply thereof to the engine, and charge air coolers are provided for this purpose.

[0003] In general, the charge air cooler is constructed from a plurality of lightweight heat transfer elements of a heat conductive material, such as copper or aluminum, shaped to provide extended heat transfer surfaces and defining a flow path for the charge air in heat transfer relation with a suitable coolant, such as ambient air or a liquid coolant. More specifically, the charge air cooler may be constructed from a network of finned tubes such that charge air flowing over the fins is associated with a coolant flowing through the tubes resulting in adequate heat transfer for some engine system applications. Alternatively, when improved heat transfer capacity is required, the charge air cooler is constructed from a stacked array of plates and fins which cooperate to define a heat exchanger core having separate flow paths for passage of the charge air and the coolant in close heat transfer relation with each other. In either case, however, the charge air cooler is desirably mounted directly into the intake manifold of the engine wherein charge air passing through the intake manifold is reduced in temperature by flow through the charge air cooler immediately prior to ingestion by the engine.

[0004] The current heat exchanger products can allow air bypass past the ends of the fins (the plate lap joints extend beyond the end of the fins, or extend beyond the liquid fluid manifold, leaving unintended air bypass channels), or require additional brazed on components to compensate by blocking off these regions, which adds significant cost and/or may be impossible for certain cooler configurations. To address the above problem, wide elastomer seals can be provided, such as adhesively bonded or mechanically trapped seals, as part of the ducting installation - to minimize such bypass. But these seal materials are expensive, add assembly complexity, and have service durability limitations.

Another compensating alternative is to overdesign the heat exchanger, either by over-sizing or adding much higher fin density (pressure drop penalty) so that performance is maintained even with bypass flow, which can have other

disadvantages.

[0005] There is a need in the art for a heat exchanger and a heat exchanger assembly, where the heat exchanger can reduce or prevent air bypass around the ends of the heat exchanger.

SUMMARY OF THE INVENTION

[0006] In one aspect, the specification discloses a heat exchanger, containing : a plurality of spaced-apart plate pairs, where each plate pair defines a flow passage for the flow of a first fluid;

one or more fins thermally coupled and sandwiched by the spaced-apart plate pairs for flow of a second fluid; a fluid manifold being fluidly coupled to the spaced-apart plate pairs at a manifold end of the spaced-apart plate pairs; and

a tab extending from a flange end of a first plate of a first plate pair and being in contact with a second tab extending from a flange end of a second plate of a second plate pair for providing a fluid flow blocker.

[0007] In another aspect, the specification discloses a heat exchanger containing

a plurality of spaced-apart plate pairs, where each plate pair defines a flow passage for the flow of a first fluid;

one or more fins thermally coupled and sandwiched by the spaced-apart plate pairs for flow of a second fluid;

a fluid manifold being fluidly coupled to the spaced-apart plate pairs at a manifold end of the spaced-apart plate pairs; and

a tab extending from a flange end of a first plate of the first plate pair and being in contact with a second plate of a second plate pair for providing a fluid flow blocker.

[0008] In a further aspect, the specification discloses a heat exchanger assembly containing

a housing having a cavity in communication with an opening; and

a heat exchanger, as described herein, receivable in the cavity of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which : [0010] Figure 1 shows an air intake manifold for receiving a heat exchanger in accordance with an embodiment of the specification;

[0011] Figure 2 shows a front elevational view of a heat exchanger in accordance with a first embodiment of the specification;

[0012] Figure 3 shows a side elevational view of a heat exchanger in accordance with a first embodiment of the specification;

[0013] Figure 4 shows a perspective view of an expanded portion of the heat exchanger in accordance with a first embodiment of the specification;

[0014] Figure 5 shows a perspective view of an expanded portion of a single plate of a plate pair in accordance with a first embodiment of the specification;

[0015] Figure 6 shows a perspective view of an expanded portion of a single plate of a plate pair in accordance with a second embodiment of the specification;

[0016] Figure 7 shows a perspective view of an expanded portion of a single plate of a plate pair in accordance with a third embodiment of the specification; and

[0017] Figure 8 shows a side elevational view of an expanded portion of a plate pair in accordance with a fourth embodiment of the specification.

[0018] Similar reference numerals may have been used in different figures to denote similar components.

DESCRIPTION

[0019] The specification generally relates to heat exchanger (2), such as a charge air cooler for reducing the temperature of air inflow to a combustion engine.

[0020] The heat exchanger (2) is typically placed in an air intake manifold (4), as shown in Figure 1, which has a cavity (6) for placing the heat exchanger (2) through an opening (8) . Incoming air enters the manifold (4) through an air intake aperture (10) and passes the heat exchanger (2) before being directed to the combustion engine. [0021] The heat exchanger (2) used in accordance with the disclosure is not particularly limited. In one example embodiment, as shown in Figures 2 and 4, the heat exchanger (2) has a plurality of spaced-apart plate pairs (12), where each plate pair defines a flow passage for the flow of a first fluid, such as a coolant. A fluid manifold (14) having an inlet (16) and outlet (18) (Figures 2 and 3) is also provided; where the fluid manifold (14) is connected to the flow passage of each plate pair (12) to allow fluid, such as the coolant, to enter through the inlet (16) pass through the flow passages of the plate pairs (12) and exit through the outlet (18) . The position of the fluid manifold (14) and the inlet (16) and outlet (18) are not particularly limited . In one embodiment, as shown in Figures 2 and 3, the inlet and outlet can be present on a top plate (20) . While in another embodiment (not shown), the inlet (16) and outlet (18) can be present on a side face (22) of the heat exchanger (2) .

[0022] The space between each spaced-apart plate pair (12) is provided with a fin (24). The fins (24) can provide for a second fluid flow passage, generally the air entering through the air intake aperture (10); and where the second flow passage is perpendicular to the flow passage defined by the plate pairs (12) to allow for heat exchange.

[0023] The heat exchanger (2) as disclosed herein, has a front face (26) such that when the heat exchanger (2) is positioned in the air intake manifold (4), the front face (26) is positioned at the air intake aperture (10) and allows for the second fluid, the air, to pass through the fins (24) and undergo heat exchange before entering the combustion engine.

[0024] In addition, each plate of the heat exchanger (2), as disclosed herein, has a manifold end (28) and an opposing end (30), denoted herein as the flange end (30) . The manifold end (28) of the heat exchanger plates have the fluid manifold (14) coupled to the plates, while the flange end (30) have one or more tabs (32) for blocking air bypass. The heat exchanger (2), as disclosed herein, are provided with side faces (22). In the embodiment shown in Figure 2, one of the side faces is formed by the fluid manifold (14) while the other side face is formed by the flange ends (30) of the plate pairs (12) along with the ends of the fins (24) (Figure 4). [0025] In the embodiment shown in Figures 2-5, each plate of the heat exchanger (2) is provided with a tab (32) at the flange end. The tab (32) in each plate can be formed by creating a cut at the flange end (30) of the plates and folding up the cut section of the flange end (30), to create a face of the tab (34) (Figures 4 and 5) that is essentially perpendicular to the air flow direction . [0026] The length of the tabs (32) in accordance with the specification is not particularly limited. In the embodiments disclosed in Figures 2-7, the length of the tabs (32) in each plate of the heat exchanger (2) can be set such that in the assembled heat exchanger (2), a tab (32) extending from a flange end (30) of a first plate of a first plate pair is in contact with a second tab extending from a second plate of a second (or adjacent) plate pair, in the heat exchanger (2) . In another embodiment, as shown in Figure 8, a tab (32) extending from the flange end (30) of a first plate is in contact with a second plate of an adjacent (or second) plate pair. By adjusting the size and position of the tabs (32), air that bypasses at the flange end (30) of the heat exchanger (2) can be blocked. [0027] The number of tabs (32) in accordance with the specification is not particularly limited. In the embodiments shown in Figures 2-5 and 7, each plate of the heat exchanger (2) is provided with a single tab (32). While in the

embodiment shown in Figure 6, each plate of the heat exchanger (2) is provided with a pair of tabs (32). [0028] The position of the tabs (32) in each plate of the heat exchanger (2) is not particularly limited . In one embodiment in accordance with the specification, as shown Figures 2-5, the tab (32) in each plate is centrally positioned at the flange end (30) of the heat exchanger. While in other embodiments in accordance with the specification, and as shown in Figures 6-8, the tabs (32) in each plate are positioned at a corner of the flange end (30). When the tabs (32) are positioned near a corner of the flange end (30), in the assembled heat exchanger (2), the tabs (32) can be proximate to the front face (26) or back face (36) (i .e., the face away from the air intake aperture (10) of the manifold (4)), depending upon the design and other requirements.

[0029] In the embodiments shown in the figures, the tabs (32) project nearly perpendicularly from the plates of the heat exchanger (2). However, it should be understood that the tabs (32) can be at an angle relative to the plane of the plates of the heat exchanger (2). Further, in the embodiments as shown in the figures, the tabs (32) can be provided with a bent neck (38) that can help with aligning of the tabs (32) in adjacent plate pairs. Alternatively, the bent neck (38) can be used for contacting a plate of the adjacent plate pair in the heat exchanger (2). [0030] The method of maintaining contacts between the tabs (32) or tab (32) and plate in a heat exchanger (2) is not particularly limited in accordance with specification . In one embodiment, the tabs (32) can be contact with adjacent tabs (32) or plate of a plate pair in the heat exchanger (2) . In an alternate

embodiment, the tabs (32) can be brazed to tabs (32) on a plate in an adjacent plate pair or to a plate in an adjacent plate pair to prevent air bypass.

[0031] In another aspect, the specification discloses a heat exchanger assembly containing the housing (4) and the heat exchanger (2), as described herein . The presence of the tabs (32) in the heat exchanger (2) and the heat exchanger assembly can help to reduce the air bypass and improve the efficiency of the heat exchange.

[0032] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.