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

Heat exchangers, such as radiators, charge air coolers, oil coolers and the like, are used in a variety of applications to transfer heat from one medium to another. Typically, the heat exchanger includes a pair of manifolds, and a plurality of heat exchange tubes stacked between the manifolds to provide a fluid communication between the manifolds. Each manifold includes a header with a plurality of openings to receive the plurality of heat exchange tubes. At least one fin is provided between two adjacent heat exchange tubes. The first manifold includes an inlet port for receiving the first heat exchange fluid and a second manifold includes an outlet port. The first fluid flows from the inlet manifold to the outlet manifold through the plurality of heat exchange tubes. Further, a second fluid flows around the heat exchange tubes across the fins. The first fluid and the second fluid are in heat exchange configuration.

The heat exchanger transfers thermal energy between the fluids as a result of the heating or cooling of the tubes, at different temperatures. The thermal difference may cause non-uniform dimensional changes to the interconnected parts of the heat exchanger. For example, the tubes may increase in length while the ends of the tubes remain in a fixed position relative to the first manifold and the second manifold and the header length may change, which induces thermal and mechanical stresses. Since the tubes are usually rigidly attached to a relatively inflexible header by means of soldering, brazing, welding or the like, the resulting stresses lead to joint fatigue failure or tube fatigue in the area next to the tube to header joint. Ultimately, the heat exchangers suffers limited life because of high stresses at their tube-to-header joints.

Accordingly, there is a need for an improved heat exchanger that reduces stress at the tube to header joints. Further, there is a need for a heat exchanger having a tube to header joint with requisite strength to add reliability and service life to the heat exchanger.

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 comprising a first manifold, a second manifold and a heat exchanger core. The second manifold is arranged in parallel and spaced apart from the first manifold. The heat exchanger core comprises a plurality of heat exchange tubes providing a fluidal communication between the first manifold and the second manifold. Each of the heat exchange tubes comprises an interior surface defined by a sidewall. Further, each of the heat exchange tubes comprises a first end and a second end opposite to that of the first end. Each of the manifolds comprises a tank member and a header plate. The header plate comprises a plurality of apertures to receive the respective end of the heat exchange tubes. The heat exchanger further comprises at least one intermediate plate arranged at least at one end of the plurality of heat exchange tubes. The intermediate plate comprises a plurality of orifices aligning with the arrangement of the plurality of heat exchange tubes and the plurality of apertures of the header plate.

The intermediate plate is at least partially in contact with the end of the plurality of heat exchange tubes and at least partially in contact with the header plate. The heat exchange core further comprises at least one fin within the interior surface of at least one heat exchange tube. Further, a flange extends from at least one orifice towards the heat exchanger core to conform with at least a portion of the sidewall of corresponding heat exchange tube.

In one embodiment, the flange extends from the intermediate plate so as to at least partially surround the orifice. The flange is configured to be in contact with the interior surface of the corresponding heat exchange tube.

In one embodiment, the flange lies at least partially between the fin and the interior surface of the sidewall of the heat exchange tube.

The heat exchange tube comprises a substantially rectangular sidewall defined by a pair of short sidewalls and a pair of long sidewalls.

Each of the orifices comprises a rectangular configuration defining a first side and a second side opposite to the first side. The flange comprises a first flange portion extending from the first side of the orifice and a second flange portion extending from the second side of the orifice.

The flange portions are in contact with the interior surface of the corresponding heat exchange tube.

In one embodiment, the flange portions are brazed to the sidewalls of the corresponding heat exchange tube.

In one embodiment, the first flange portion and the second flange portion extends to conform with at least a part of the long sidewalls of the corresponding heat exchange tube.

In another embodiment, the first flange portion and the second flange portion extends to conform with at least a part of the short sidewalls of the corresponding heat exchange tube.

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 exemplarily illustrates a perspective view of a heat exchanger, according to an embodiment of the present invention.

FIG. 2 exemplarily illustrates a perspective view of a heat exchanger without the shell of FIG. 1.

FIG. 3 exemplarily illustrates an exploded view of the heat exchange tube bundle, and the manifolds of FIG. 1 .

FIG. 4 exemplarily illustrates a perspective view of an intermediate plate of FIG. 3.

FIG. 5 exemplarily illustrates another perspective view of the intermediate plate of FIG. 3.

FIG. 6 exemplarily illustrates the arrangement of intermediate plate at tube to header joint of the heat exchanger of FIG. 1 .

FIG. 7 exemplarily illustrates the flange engaging the end of the heat exchange tube of FIG. 3. DETAILED DESCRIPTION

The present invention discloses a heat exchanger 100 comprising a first manifold 102, a second manifold 108 and a heat exchanger core 105. The heat exchanger core 105 comprises a plurality of heat exchange tubes 1 14 providing a fluidal communication between the first manifold 102 and the second manifold 108. Each of the heat exchange tubes 1 14 comprises an interior surface 1 18 defined by a sidewall 120, a first end 1 16A and a second end 1 16B opposite to the first end 1 16A. Each of the manifolds 102, 108 comprises a tank member 106, 112 and a header plate 104, 1 10 comprising a plurality of apertures 144 to receive the respective end of the heat exchange tubes 1 14. The heat exchanger 100 further comprises at least one intermediate plate 122 arranged at least at one end 1 16A, 1 16B of the plurality of heat exchange tubes 1 14. The intermediate plate 122 comprises a plurality of orifices 128 aligning with the arrangement of the plurality of heat exchange tubes 114 and the plurality of apertures 144 of the header plate 104, 110. A flange 126 extends from at least one orifice 128 towards the heat exchanger core 105 to conform with at least a portion of the sidewall 120 at the interior surface 118 of the heat exchange tube 1 14. The provision of intermediate plate 122 increases the mechanical resistance at the joints between the tubes 1 14 and the header plates 104, 1 10, which adds reliability and life to the heat exchanger 100.

FIG. 1 exemplarily illustrates a perspective view of a heat exchanger 100, according to an embodiment of the present invention. FIG. 2 exemplarily illustrates a perspective view of a heat exchanger 100 of FIG. 1 without the shell 132. The heat exchanger 100 comprises a first manifold 102, a second manifold 108 and a heat exchanger core 105. The heat exchanger 100, for example, may be a charge air cooler or a water charge air cooler. The heat exchanger core 105 comprises a plurality of heat exchange tubes 1 14 providing a fluidal communication between the first manifold 102 and the second manifold 108. The first manifold 102 comprises a first header plate 104 and a first tank member 106, and the second manifold 108 comprises a second header plate 110 and a second tank member 1 12. The header plates 104, 1 10 comprise a plurality of apertures 144 (shown in FIG. 3) and each aperture 144 aligned to one corresponding tube 114. The header plates 104, 110 can be relatively thick plates made of a metallic material like steel or aluminium. Referring to FIG. 3, the plurality of heat exchange tubes 1 14 are arranged substantially in parallel and spaced apart from each other to form a tube bundle. The heat exchange tubes 1 14 are hollow and can be made from thin walled material such as aluminium or another suitable metal. Each heat exchange tube 1 14 comprises a first end 116A and a second end 1 16B opposite to the first end 1 16A. The first end 1 16A of each heat exchange tube 1 14 is received into corresponding apertures 144 of the first header plate 104 of the first manifold 102. The opposing second end 1 16B of the heat exchange tubes 1 14 are received into the corresponding apertures 144 of the second header plate 110 of the second manifold 108. Here, the term heat exchange tubes 1 14 or tubes 1 14 are interchangeably used in the document. The plurality of heat exchange tubes 1 14 are aligned along a longitudinal direction and their lengths are such that the first ends 116A coextensively align together and the second ends 116B coextensively align together. The tube bundle therefore has a generally rectangular shape, with the first and second manifolds 102, 108 being generally perpendicular to the plurality of heat exchange tubes 114 and perpendicular to the longitudinal direction of the heat exchange tubes 1 14. It is contemplated that some embodiments include multiple rows of tubes 1 14.

Referring to FIG. 1 , the heat exchanger 100 further comprises a shell 132 enclosing the heat exchanger core 105 and the manifolds 102, 108. The shell 132 further comprises a first shell portion 132A and a second shell portion 132B. The first shell portion 132A extends between the manifolds 102, 108 and at least a portion of the tube bundle and the second shell portion 132B extends between the manifolds 102, 108 and at least a portion of the tube bundle. The first shell portion 132A and the second shell portion 132B are distinct portions. The first shell portion 132A and the second shell portion 132B together encloses the tube bundle. The first shell portion 132A and the second shell portion 132B are each made of bent metal plates and the plates are brazed together. The heat exchanger 100 further comprises a first inlet port 134 configured on the first manifold 102 and a first outlet port 136 configured on the second manifold 108. The first inlet port 134 adapted to connect with a first external circuit supplying at least one first heat exchange fluid. The shell 132 further comprises a second inlet port 138 and a second outlet port 140 adapted to connect with a second external circuit supplying at least one second heat exchange fluid.

The first fluid may flow from the first inlet port 134 of the first manifold 102, passes through the plurality of heat exchange tubes 1 14 and exits the second manifold 108 via the first outlet port 136. The second heat exchange fluid flows from the second inlet port 138 and flows around the heat exchange tubes 1 14, and reaches the second outlet port 140. The flow of heat exchange fluid in and around the heat exchange core 105 enables heat exchange between the first heat exchange fluid and the second heat exchange fluid.

Referring to FIG. 2, the heat exchanger 100 further comprises heat exchanger fins 142, which are located between the heat exchange tubes 114 to promote the heat transfer between the first heat exchange fluid within the tubes 1 14 and the second heat exchange fluid passing over the tubes 114. According to an exemplary embodiment, the heat exchanger fins 142 are constructed of aluminium, brazed or otherwise joined to the tubes 114. However, according to other exemplary embodiments, the heat exchanger fins 142 may be made of other materials that facilitate heat transfer and may extend in parallel or at varying angles with respect to the flow of the heat exchange fluid. The heat exchanger fins 142 may be louvered fins, corrugated fins, or any other suitable type of fin.

The heat exchanger 100 further comprises at least one intermediate plate 122 disposed between at least one header plate 104, 1 10 and tank member 106, 1 12. In this embodiment, the intermediate plate 122 is disposed between the first header plate 104 and the first tank member 106. Referring to FIG. 3, the intermediate plate 122 comprises a plurality of orifices 128. The orifices 128 align with the arrangement of the plurality of heat exchange tubes 114 and the plurality of apertures 144 of the first header plate 104. In another embodiment, the intermediate plate 122 is arranged between the second header plate 1 10 and the second tank member 1 12, not shown in Figures. In yet another embodiment, at least intermediate plate 122 is arranged between the first header plate 104 and the first tank member 106 and at least one intermediate plate 122 is arranged between the second header plate 1 10 and the second tank member 1 12, not shown in figures. In the assembled configuration, the ends 1 16A of the heat exchange tubes 1 14 are introduced into the corresponding apertures 144 of the header plate 104. Thereafter, the intermediate plate 122 is arranged to receive the ends 1 16A of the corresponding heat exchange tube 114 passing through the header plate 104 at the corresponding orifice 128 of the intermediate plate 122.

Further, in this embodiment, the heat exchange tubes 1 14 are flat tubes. In another embodiment, the heat exchange tubes 1 14 may be multi-channel tubes containing several flow channels or paths. The heat exchange tube 114 comprises an interior surface 118 defined by a sidewall 120, and at least one fin 124 disposed within the interior surface 118 of the heat exchange tube 1 14, shown in FIG. 6. All components of the heat exchanger 100 mentioned above can be made of materials suitable for brazing, for example aluminium, steel and their alloys. In order to obtain the proper fluid tightness of the assembly all components thereof are connected to each other by brazing or any another suitable means.

FIG. 4 exemplarily illustrates a perspective view of the intermediate plate 122 of FIG. 3. FIG. 5 exemplarily illustrates another perspective view of the intermediate plate 122 of FIG. 3. The intermediate plate 122 comprises a first side 130A and a second side 130B opposite to that of the first side 130A. The intermediate plate 122 is arranged such that the first side 130A at least partially contacts at least one end 1 16A of the heat exchange tubes 114 and the first header plate 104, and the second side 130B at least partially contacts the first tank member 106. The intermediate plate 122 comprises a substantially planar surface and the plurality of orifices 128 are formed on the planar surface. The plurality of orifices 128 are arranged at predetermined positions, each of which corresponds to the position of the corresponding heat exchange tube 1 14. The intermediate plate 122 further comprises a flange 126 extending from at least one orifice 128 towards the heat exchanger core 105. In an example, the flange 126 extends from the intermediate plate 122 so as to at least partially surround the orifice 128.

Referring to FIG. 6, the flange 126 extends from at least one orifice 128 towards the heat exchanger core 105 to conform with at least a portion of the sidewall 120 of corresponding heat exchange tube 1 14. The profile of the orifice 128 is complementary to the profile of the heat exchange tubes 1 14. The flange 126 contours the profile of the orifice 128 so that the flange 126 has a profile complementary to the profile of the heat exchange tubes 114 to conform with the sidewall 120 of the corresponding heat exchange tube 1 14. In a preferred embodiment, the flange 126 is configured to be in contact with the interior surface 1 18 of the corresponding heat exchange tube 1 14. In one embodiment, the flange 126 lies at least partially between the fin 124 and the interior surface 1 18 of the sidewall 120 of the heat exchange tube 1 14. The flange 126 contacts the ends 116A of the heat exchange tubes 1 14 and the header plate 104 reinforces the tube to header joints to add reliability and service life to the heat exchanger 100.

The number of orifices 128 corresponds to the number of heat exchange tubes 114 and the apertures 144 of the first header plate 104. Each orifice 128 comprises a rectangular profile, which corresponds to the profile of the apertures 144 of the first header plate 104 and the heat exchange tubes 114. Referring to FIG. 5 and FIG. 6, the orifice 128 comprises a first side 146A and a second side 146B opposite to that of the first side 146A. The orifice 128 further comprises a third side 146C and a fourth side 146D opposite to that of the third side 146C of the orifice 128. The flange 126 extending from the orifice 128 comprises a first flange portion 126A and a second flange portion 126B. The first flange portion 126A extends from the first side 146A of the orifice 128 and the second flange portion 126B extends from the second side 146B of the orifice 128. In another embodiment, the first flange portion 126A extends from the third side 146C of the orifice 128 and the second flange portion 126B extends from the fourth side 146D of the orifice 128, not shown in figures. In yet another, the flange 126 extends from all the sides 146A, 146B, 146C, 146D of the rectangular profile of the orifice 128 and the flange 126 may have a rectangular cross section complementary to the end 116A, 1 16B of the flat heat exchange tube, not shown in figures.

The first header plate 104 is arranged to receive the ends 1 16A of the heat exchange tubes 1 14 into the corresponding apertures 144 of the first header plate 104. Thereafter, the intermediate plate 122 is arranged at least at one end 1 16A of the plurality of heat exchange tubes 1 14. The ends 1 16A of the heat exchange tubes 1 14 passes through the apertures 144 of the first header plate 104 and engages with the corresponding flange 126 of the intermediate plate 122. Thus, the intermediate plate 122 is arranged to be at least partially in contact with the ends 1 16A of the plurality of heat exchange tubes 1 14 and at least partially in contact with the first header plate 104. In other words, the intermediate plate 122 is arranged between the ends 116A of the heat exchange tubes 114 and the first header plate 104, and the first tank member 106.

Referring to FIG. 6 and FIG. 7, the heat exchange tube 1 14 comprises a substantially rectangular sidewall 120 defined by a pair of short sidewalls 120B and a pair of long sidewalls 120A. The first flange portion 126A and the second flange portion 126B extends to conform with at least a part of the long sidewalls 120A of the corresponding heat exchange tube 1 14. In another embodiment, the first flange portion 126A and the second flange portion 126B extends to conform with at least a part of the short sidewalls 120B of the corresponding heat exchange tube 1 14. In yet another embodiment, the flange 126 comprises a profile complementary to the end 1 16A, 1 16B of the heat exchange tubes 144 and the flange 126 conforms with the whole of the sidewall 120 at the interior surface 1 18 of the heat exchange tube 1 14. The configuration and the position of intermediate plate 122 at the tube to header joints provide requisite strength to withstand the stress caused by the thermal expansion and contraction of heat exchange tubes 1 14 discussed in the background section of the document. Consequently, the increase in mechanical resistance at the joints between the tubes 1 14 and the header plates 104, 1 10 adds reliability and increases the life span of the heat exchanger 100.

Even though the description is explained with respect to the arrangement of intermediate plate 122 at the first end 1 16A of the heat exchange tubes 1 14, it should be understood that the intermediate plate 122 could be similarly arranged at the second end 116B of heat exchange tubes 1 14, or both the first and second ends 1 16A, 1 16B of the heat exchange tubes 1 14, and provide same advantages and effects to the tube to header joints of the second manifold 108, or both first manifold 102 and the second manifold 108, respectively.

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.