The present invention relates to a heat exchanger. In particular, the present invention relates to a heat exchanger for a motor vehicle.

Generally, a vehicle may have heat exchangers including a radiator and a condenser. The condenser is a part of an air-conditioning loop whereas the radiator is part of an engine-cooling loop. The term engine-cooling loop may refer both to vehicles powered by internal combustion engines, hybrid vehicles and electric vehicles. The radiator and condenser are both disposed at front of a vehicle to be impinged by ram air acting as cooling fluid, the operating heat exchange fluids flowing through the radiator and the condenser undergo heat exchange with the cooling air flowing there across, as the vehicle traverses. More specifically, coolant flowing through the radiator rejects heat picked up from a power unit to the environment, particularly, air flowing across the radiator. The refrigerant flowing through the condenser rejects heat to the outside air, particularly, ram air for causing the phase change of the refrigerant from vapor to liquid state.

Generally, the radiator and the condenser are disposed overlapping with respect to one other in the direction of the ram air. In case, the radiator is disposed downstream of the condenser in the direction of ram air. With such arrangement of the radiator and the condenser, the air reaches the radiator after picking heat rejected by the condenser as such the air reaching the radiator is at elevated temperature than the ambient air. Accordingly, the heat rejecting performance of the radiator is substantially reduced. Similarly, in case the condenser is disposed downstream of the radiator in the direction of ram air, the air reaches the condenser after picking heat rejected by the radiator and the air reaching the condenser is at elevated temperature than the ambient air. Accordingly, the efficiency and performance of the condenser is substantially reduced.

Further, the radiator and the condenser are required to be disposed sufficiently spaced apart to achieve sufficient and proper air-flow there across. Such an overlapping arrangement of the radiator and the condenser occupies more space thereby resulting in packaging issues.

Accordingly, there is a need for a heat exchanger that exhibits improved performance, reduces overall weight, and addresses the packaging issues.

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.

SUMMARY OF THE INVENTION

The present invention discloses a heat exchanger for a motor vehicle. The heat exchanger comprises at least one first manifold, at least one second manifold and a plurality of first tubes. Each first tube comprises an axis of elongation, and each tube extends between the first manifold and the second manifold for configuring fluid communication between the first manifold and the second manifold. The first tubes are separated by fins. The first tube is configured for circulation of a first fluid and a second fluid. The first tube comprises an outer wall and an inner wall, both extending along the axis of elongation of the first tube, and at least one first partition located in-between the outer wall and the inner wall. The first partition extends along the axis of elongation, and is configured to fix the inner wall to the outer wall.

The first tube comprises a first zone delimited between the inner and the outer walls. The first zone adapted for circulation of the first fluid. The first tube further comprises a second zone delimited by the inner wall. The second zone is configured for circulation of the second fluid.

The inner wall comprises at least one second partition extends along the axis of elongation and connects at least two inner faces of the inner wall. The first partition located in-between the inner wall and the outer wall defines one or more first microchannels for flow of the first fluid. The second partition located in-between the inner wall defines one or more second micro-channels for flow of the second fluid. The heat exchanger further comprises a tubular insert inserted at each open end delimited by the inner wall.

Further, each manifold comprises a first header, a second header and a cover. The second header is received in an open end of the first header and defines a first tank. The first header along with the second header is received in a first opening of the corresponding cover to define a second tank.

The first header comprises a first set of apertures adapted to receive the first tubes that configure fluid communication between the spaced apart first tanks of the manifolds for flow of the first fluid and defines a first fluid circuit. The second header comprises a second set of apertures adapted to receive tubular insert that configure fluid communication between the second tanks of the manifolds for flow of the second fluid and defines a second fluid circuit. The first fluid circuit is for coolant flow with a radiator being part of the second fluid circuit and the second fluid circuit is for refrigerant flow with a condenser being part of the second fluid circuit.

The heat exchanger further comprises a first inlet and a first outlet configured on the first tank of the first manifold to configure U-flow of the first fluid through the first zone of the first tubes. The heat exchanger further comprises a second inlet and a second outlet configured on the second tank of the second manifold to configure U-flow of the second fluid through the second zone of the first tubes, and also configure counter flow between the second fluid and the first fluid.

The first tubes comprises at least a first set of tubes and a second set of tubes in fluidal communication with the first set of tubes via the second manifold. The first fluid and the second fluid flowing through the first set of tubes defines a first pass, and the first fluid and the second fluid flowing through the second set of tubes defines a return pass. The heat exchanger further comprises a receiver drier comprising a first opening and a second opening. The receiver drier receives the second fluid through the first opening to remove incompressible moisture and debris therefrom and delivers the second fluid to the second set of tubes through the second opening in fluid communication with the second manifold. BRIEF DESCRIPTION OF DRAWINGS

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 perspective view of a heat exchanger in accordance with an embodiment of the present invention;

FIG. 2 illustrates an exploded view of the heat exchanger of FIG. 1 ;

FIG. 3 illustrates a cross-sectional view of a first tube of FIG. 1 in one embodiment of the present invention.

FIG. 4 illustrates a cross-sectional view of a first tube, in another embodiment of the present invention.

FIG. 5 illustrates a partial cross-sectional view of the first and second manifolds of FIG. 1.

FIG. 6 illustrates a perspective view of a tubular insert passing through the second header of heat exchanger of FIG. 1

FIG. 7 illustrates a perspective view of a first tube passing through the first header of the heat exchanger of FIG. 1 .

FIG. 8 illustrates an exploded view of the first and second manifolds of FIG. 1 .

FIG. 9 to FIG. 12 illustrates different configurations of the heat exchanger with different positioning of the first inlet and first outlet for coolant, second inlet and second outlet for refrigerant and receiver drier inlet and outlet on at least one of first manifold and second manifold. DETAILED DESCRIPTION

Although, the present invention is explained in the forthcoming description and the accompanying drawings with an example of heat exchanger for a motor vehicle, particular a heat exchanger that combines functions of two heat exchangers in one heat exchanger. More specifically, combines functions of a radiator and a condenser for a vehicle, thereby eliminating the need for multiple heat exchangers and problems associated with multiple heat exchangers arranged in overlapping configuration, for example packaging issues and performance and efficiency issues. However, the present invention is applicable for any heat exchanger for use in vehicular and non-vehicular environment where it is required to combine functions of two heat exchangers into one to address packaging issues, and other problems faced with overlapping arrangement of multiple heat exchangers.

Referring to FIG. 1 and FIG. 2, the heat exchanger 100 comprises at least one first manifold 102, at least one second manifold 104, and a plurality of first tubes 106. Each first tube 106 comprises an axis of elongation and extends between the first manifold 102 and the second manifold 104 configuring fluid communication between the first manifold 102 and the second manifold 104. The first tubes 106 are separated by fins 154 (shown in FIG. 6). Each manifold 102, 104 may comprise a first header 124A, 124B, a second header 126A, 126B and a cover 128A, 128B. The first header 124A, 124B comprises a first set of apertures 134A, 134B, and the second header 126A, 126B comprises a second set of apertures 136A, 136B.

Referring to FIG. 3, each first tube 106 comprises an outer wall 108 and an inner wall 110. The inner wall 1 10 and the outer wall 108 extends along the axis of elongation of the first tube 106. Further, at least one first partition 1 12 is located in-between the outer wall 108 and the inner wall 1 10. The first partition 1 12 extends along the axis of elongation and fixes the inner wall 1 10 to the outer wall 108. The first partition 1 12 location inbetween the inner wall 1 10 and the outer wall 108 defines one or more first microchannels 120 for flow of a first fluid. FIG. 4 illustrates the cross-section of the first tube 106 according to another embodiment of the present invention. Each first tubes 106 comprises an axis of elongation. Each first tube 106 comprises the outer wall 108 and the inner wall 1 10. The inner wall 1 10 and the outer wall 108 extends along the axis of elongation of the first tube 106. Further, at least one first partition 1 12 is located in-between the outer wall 108 and the inner wall 1 10. The first partition 1 12 extends along the axis of elongation and fixes the inner wall 1 10 to the outer wall 108. Further, at least one second partition 1 16 extends along the axis of elongation and connects at least two inner faces of the inner wall 1 10. The second partition 1 16 located in-between at least two inner faces defines one or more second micro channels 122 for flow of a second fluid.

Referring to FIG. 3 and FIG. 4, the first tube 106 comprises a first zone 1 14 delimited between the inner and the outer walls 1 10, 108. The first zone 1 14 is adapted for circulation of the first fluid. The first tube 106 further comprises a second zone 1 18 delimited by the inner wall 1 10. The second zone 1 18 is adapted for circulation of the second fluid.

In one embodiment, the micro-channels 120, 122 may have square, circular or triangular cross section. In one embodiment, the first tube 106 may have square, circular or triangular cross section. However, the present invention is not limited to any particular cross section of the micro-channels 120, 122 and first tubes 106. Further, each tube 106 comprises a tubular insert 124 (shown in FIG. 5) extending from the inner wall 1 10. In other words, the tubular insert 124 is inserted at each open end delimited by the inner wall 1 10 of the first tubes 106.

Referring to FIG. 5, each manifold 102, 104 is formed by assembly of a first header 124A, 124B, a second header 126A, 126B and a cover 128A, 128B. The first header 124A, 124B in conjugation with the second header 126A, 126B defines a first tank 130A, 130B and second header 126A, 126B in conjugation with the cover 128A, 128B defines a second tank 132A, 132B. The first header 124A, 124B comprises a first set of apertures 134A, 134B to receive the first tubes 106 and configure fluid communication between the first zone 1 14 and the first tanks 130A, 130B of the manifolds 102, 104.

The second header 126A, 126B comprises a second set of apertures 136A, 136B to receive the tubular insert 124 and configure fluid communication between the second zone 1 18 and the second tanks 132A, 132B of the manifolds 102, 104. In another embodiment, instead of tubular insert 124, the inner wall 1 10 may have a length longer than the outer wall 108, which enables the second set of apertures 136A, 136B to receive the inner wall 1 10 or second zone 1 18 delimited by the inner wall 1 10 and configure fluid communication between the second zone 118 and the second tanks 132A, 132B of the manifolds 102, 104.

Referring to FIG. 2 to FIG. 4, further, the first tubes 106 comprises a first set of tubes 106A and a second set of tubes 106B is in fluid communication with the first set of tubes 106A via the second manifold 104. Specifically, the first zone 1 14 of the first set of tubes 106A are in fluid communication with the first zone 1 14 of the second set of tubes 106B via the first tank 130A of the second manifold 104. Further, the second zone 1 18 of the first set of tubes 106A are in fluid communication with the second zone 118 of the second set of tubes 106B via the second manifold 104.

FIG. 6 illustrates a perspective view of the tubular insert 124 passing through the second header 126A, 126B of heat exchanger 100 of FIG. 1. FIG. 7 illustrates a perspective view of a first tube 106 passing through the first header 124A, 124B of the heat exchanger 100 of FIG. 1 . Even though FIG. 6 and FIG. 7 illustrates the first tube 106 arrangement with respect to FIG. 4, it should be understood the first tube 106 arrangement with respect to FIG. 3 have a similar representation.

Referring to FIG. 5 and FIG. 8, the first header 124A, 124B and the cover 128A, 128B are assembled to each other with the corresponding second header 126A, 126B received in either one of the first header 124A, 124B and the cover 128A, 128B to define the first manifold 102 and the second manifold 104. The cover 128A, 128B is in the form of an enclosure with a stepped configuration that includes a first portion with a first opening and a second portion with a second opening. The first opening is wider than the second opening to form an intermediate neck portion 152A, 152B at the interface between the first portion and the second portion of the cover 128A, 128B.

The first header 124A, 124B may be also in the form of an enclosure having a closed end and an open end. The second header 126A, 126B is received in the open end of the first header 124A, 124B. The first header 124A, 124B with the second header 126A, 126B received in the first opening of the corresponding cover 128A, 128B. The neck portion 152A, 152B formed on the cover 128A, 128B prevents further advance of the first header 124A, 124B along with the second header 126A, 126B within the cover 128A, 128B to define the first tank 130A, 130B and the second tank 132A, 132B of the manifolds 102, 104. More specifically, the second header 126A, 126B separates the first tank 130A, 130B with respect to the second tank 132A, 132B. Alternatively, the second header 124A, 124B is received in the first opening of the corresponding cover 128A, 128B and thereafter, the first header 128A, 128B is received in the first opening of the corresponding cover 128A, 128B to define the first tank 130A, 130B and the second tank 132A, 132B. However, the present invention is not limited to any particular configuration and sequence of connections between the first header 124A, 124B, the second header 126A, 126B and the cover 128A, 128B to form the first tank 130A, 130B and the second tank 132A, 132B.

The first tank 130A, 130B is for circulation of the first fluid within the first zone 114 to define at least a portion of a first fluid circuit. The second tank 132A, 132B is for circulation of the second fluid within the second zone 118 to define at least a portion of a second fluid circuit. In accordance with an embodiment of the present invention, the first fluid circuit is an engine cooling circuit for coolant flow with a radiator being part of the first fluid circuit. In accordance with an embodiment of the present invention, the second fluid circuit is an air conditioning loop for refrigerant flow with a condenser being part of the second fluid circuit.

In another embodiment, the heat exchanger 100 may comprise a first tank 130Aof the first manifold 102 and a first tank 130B of the second manifold 104 to configure l-flow of the coolant. The first tank 130A of the first manifold 102 is configured to distribute heated coolant from the first fluid circuit, particularly, the engine cooling circuit, to the first zone 130A of the first tubes 106. The first tank 130B of the second manifold 104 collects coolant from the first set of tubes 106A after the heated coolant had rejected heat to the refrigerant flowing through the second zone 1 18 defined in the first tubes 106.

Referring to FIG. 1 and FIG. 2, the first manifold 102 is divided into a first section and a second section by an internal baffle. The heat exchanger 100 further may comprise a first inlet 138 and a first outlet 140 configured on the first tank 130A of the first manifold 102. The heat exchanger 100 further may comprise a second inlet 142 and a second outlet 144 configured on the second tank 132A of the first manifold 102.

The first fluid ingresses through the first inlet 138 of the first manifold 102. The first fluid flows through the first zone 118 of the first set of tubes 106A and reaches the first tank 130A of the second manifold 104. Further, the first tank 130B of the second manifold 104 redirects the first fluid to the second set of first tubes 106B and exits via the first outlet 140 of the first manifold 102. Thereby, the heat exchanger 100 facilitates U-flow of the first fluid. The flow of the first fluid from the inlet 138 to the second manifold 104 defines a first coolant pass, or a first pass, and the flow of second fluid from the second manifold 104 to the outlet 140 defines a second coolant pass or a return pass.

The second fluid ingresses through the second inlet 142 formed on the second tank 132B of the first manifold 102. The second fluid flows through the second zone 1 18 of the first set of tubes 106A and reaches the second tank 132B of the second manifold 104. Further, the second tank 132B of the second manifold 104 redirects the second fluid to the second zone 118 of the second set of tubes 106B and exits via the second outlet 144 configured at the outlet section of the first manifold 102.

In a first embodiment, the first fluid may be a coolant and the second fluid may be a refrigerant. The flow of the second fluid from the second inlet 142 to the second manifold 104 defines a first refrigerant pass or first pass, and the flow of second fluid from the second manifold 104 to the second outlet 144defines a second refrigerant pass or a return pass. The fluid communication between the first refrigerant pass and the second refrigerant pass is configured via a receiver drier 146. At least one inlet 148 and at least one outlet 150 are configured on the receiver drier 146 is in fluid communication with the second tank 132B of the second manifold 104.

In a second embodiment, the first fluid may be a refrigerant and the second fluid may be a coolant. According to the second embodiment, the receiver drier 146 may be in fluid communication with the first tank 130B of the second manifold 104 to receive the refrigerant. In a third embodiment, the first fluid may be a refrigerant having a first temperature and the second fluid may be a refrigerant having a second temperature. In a fourth embodiment, the first fluid may be a coolant having a first temperature and the second fluid may be a coolant having a second temperature.

The flow of the coolant and the refrigerant through the first zone 1 14 and the second zone 1 18 of the first tubes 106 can be either parallel flow or counter flow based on the positioning of the first inlet 138 and the first outlet 140 for the coolant, the second inlet 142 and the second outlet 144 for the refrigerant, and the receiver drier inlet 148 and the receiver drier outlet 150 on at least one of the first manifold 102 and the second manifold 104. FIG. 9 - FIG. 14 illustrates different configurations of the heat exchanger 100 based on different combinations of the positioning of the first inlet 138 and the first outlet 140 for coolant, the second inlet 142 and the second outlet 144 for refrigerant and the receiver drier inlet 148 and the receiver drier outlet 150 on at least one of first manifold 102 and second manifold 104.

Generally, the first inlet 138 and the first outlet 140 are configured either on the same manifold, for example, the first manifold 102, or on different manifolds, for example, the first manifold 102 and the second manifold 104. In accordance with an embodiment as illustrated in FIG. 9, 10, 12-14, the first inlet 138 and the first outlet 140 are formed on the first manifold 102. In accordance with another embodiment of the present invention as illustrated in FIG. 1 1 , the first inlet 138 and the first outlet 140 are formed on different manifolds 102, 104.

Further, the second inlet 142 and the second outlet 144 are configured on the same first manifold 102 to configure U-flow of the second fluid through the second zone 1 18. Furthermore, such configuration of the first inlet 138 and the first outlet 140 formed may be revered to the second inlet and outlet 142 and 144 configures counter flow between first fluid flowing through the first zone 1 14 and second fluid flowing through the second zone 1 18. In accordance with an embodiment, some tubes of the first tubes 106 define a first pass that is a condensing pass while the remaining tubes of the first tubes 106 define a return pass that is the sub-cooling pass. Generally, the condensing pass includes more number of tubes than the second heat exchange tubes in the sub-cooling pass. The condensing pass is in fluid communication with the sub-cooling pass via the receiver drier 146. The receiver drier 146 is disposed along and in fluid communication with the second manifold 104, specifically second tank 132A, 132B on which the second inlet and outlet 142, 144 are formed.

The receiver drier 146 may comprise the inlet 148 and the outlet 150 formed thereon. The receiver drier 146 receives condensed second fluid from the condensing pass defined by few of the tubes 106 through the inletl 48 to remove incompressible moisture and debris therefrom. The receiver drier 146 delivers the condensed second fluid substantially free of debris and incompressible moisture to the sub-cooling pass defined by the remaining of the first tubes 106 through the outlet 150. The heat exchanger 100 can be incorporated in any cooling loop configured in a vehicle, wherein the heat exchanger functioning as radiator supplies coolant to any of the vehicle heat exchangers to extract heat from any of the heat-generating component in the vehicle. Specifically, the vehicle heat exchangers can be any one of radiator, water charged air cooler, chiller and the heat-generating means can be any one of engine, e-motor and battery in a vehicle that is either one of internal-combustion engine driven, electric motor driven or any hybrid vehicle.

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.