DESCRIPTION

Field of application

[0001] The present invention relates to a heat exchanger .

[0002] In particular, the present invention belongs to the automotive field .

Background art

[0003] Heat exchanger solutions which find speci fic application in a vehicle , having the purpose of managing the temperature of a given fluid circulating in a system of a vehicle , are known from the prior art .

[0004] In further detail , the heat exchanger is suitable for performing a heat exchange operation between two fluids , that is , between a working fluid and an exchange fluid .

[0005] Preferably, the working fluid is an oil , circulating in one or more operating groups of the vehicle , for example a gearbox group, a transmission group, an engine group, to manage the temperature thereof .

[0006] According to an alternative embodiment , the working fluid is a coolant fluid . By way of example , coolant fluid means one of the fluids normally used in a refrigeration cycle such as , for example , R134a, R744 , R290 , R718 , R717 , R1234yfa or R1234yf .

[0007] Preferably, the exchange fluid is a water-based liquid .

[0008] Managing the temperature of an operating group in the best possible manner improves the ef ficiency and lengthens the li fe cycle thereof , improving the performances and li fe cycle of the entire vehicle .

[0009] Therefore , it is increasingly desired to manage the temperature of each operating group in the best possible manner, by providing special components , such as the heat exchangers .

[0010] Heat exchangers are also component systems in which the manufacturing and assembly operations have speci fic complexities , often requiring speci fic ski lls .

[0011] Said complex manufacturing and assembly operations cause the costs of current heat exchangers .

[0012] Obtaining a heat exchanger suitable for performing an ef ficient heat exchange between the working fluid and the exchange fluid, thus simpli fying the manufacturing and assembly operations , is desired in the field . Solution of the invention

[0013] The need is thus strongly felt to provide a heat exchanger which ful fills said desire .

[0014] It is the obj ect of the present invention to provide a heat exchanger which has a layout of the ducts allowing an ef fective heat exchange while simpli fying the manufacturing and assembly operations . [0015] Such an obj ect is achieved by the heat exchanger claimed in claim 1 . The claims dependent thereon show preferred variants resulting in further advantageous aspects .

Description of the drawings

[0016] Further features and advantages of the invention will become apparent from the description provided below of preferred exemplary embodiments thereof , given by way of non-limiting indication, with reference to the accompanying drawings , in which :

[0017] - Figure 1 shows a perspective view of a heat exchanger, according to the present invention, according to a preferred embodiment ;

[0018] - Figure la shows a sectional perspective view of the heat exchanger according to Figure 1 ;

[0019] - Figure 2 shows a front view of the sectional view in Figure la ;

[0020] - Figures 2 ' and 2" show two enlarged views of two areas in Figure 2 ;

[0021] - Figure 3 shows a perspective view with separate parts of the heat exchanger in Figure 1 ;

[0022] - Figures 4a, 4b, 4c, 4d and 4e show top views of some components , a lower plate-like end element , a first and a second intermediate plate-like element , and a working fluid turbulator and an exchange fluid turbulator, comprised in the heat exchanger according to the present invention;

[0023] - Figures 5 and 5a show a top view of a lower platelike end element and of said lower plate-like end element correctly coupled to a working fluid turbulator ;

[0024] - Figures 5b ' and 5b" show a top view of the lower plate-like end element in Figure 5 incorrectly coupled to an exchange fluid turbulator ;

[0025] - Figures 6 and 6a show a top view of a first intermediate plate-like element and of said first intermediate plate-like element correctly coupled to an exchange fluid turbulator ;

[0026] - Figures 6b' and 6b" show a top view of the first intermediate plate-like element in Figure 6 incorrectly coupled to a working fluid turbulator ;

[0027] - Figures 7 and 7a show a top view of a second intermediate plate-like element and of said second intermediate plate-like element correctly coupled to a working fluid turbulator ;

[0028] - Figures 7b' and 7b" show a top view of the second intermediate plate-like element in Figure 7 incorrectly coupled to an exchange fluid turbulator .

Detailed description

[0029] With reference to the accompanying drawings , numeral

1 indicates a heat exchanger of a thermal management system of a vehicle , according to the present invention .

[0030] The heat exchanger 1 is suitable for performing a heat exchange action between a working fluid, preferably oil , and an exchange fluid, preferably a water-based liquid, each circulating in a respective circuit of the vehicle .

[0031] In fact , the heat exchanger 1 is connectable to the two circuits so that both the working fluid and the exchange fluid flow therein .

[0032] Preferably, the working fluid, in the heat exchanger 1 , is cooled by trans ferring heat to the exchange fluid .

[0033] According to the present invention, the heat exchanger 1 comprises a working fluid inlet mouth 2110 and a working fluid outlet mouth 2120 through which the working fluid flows in and out .

[0034] Moreover, according to the present invention, the heat exchanger 1 comprises an exchange fluid inlet mouth 2210 and an exchange fluid outlet mouth 2220 through which the exchange fluid flows in and out .

[0035] The heat exchanger 1 comprises plate-like end elements 3 , 7 and intermediate plate-like elements 4 . The intermediate plate-like elements 4 are divided into first elements 41 and second elements 42 .

[0036] The heat exchanger 1 is obtained by j oining said plate-like elements . In particular, the plate-like elements are packed together along a preferential stacking direction .

[0037] In particular, the heat exchanger 1 extends in height with respect to a vertical axis V-V and longitudinally with respect to a longitudinal axis X-X and transversely with respect to a transverse axis Y-Y, the latter axes lying on the same imaginary plane orthogonal to the axis V-V .

[0038] Preferably, the plate-like elements extend substantially parallel to said vertical axis V-V . That is , the plate-like elements extend longitudinally with respect to the longitudinal axis X-X and transversely with respect to the transverse axis Y-Y .

[0039] It is emphasi zed that the directions of the axes are not limiting to any position of use of the heat exchanger 1 of the present invention in the vehicle .

[0040] Preferably, the plate-like end elements 3 , 7 are axially spaced apart along the vertical axis V-V . According to a preferred embodiment , a plate-like end element 3 is referred to as being upper, while the other plate-like end element 7 is referred to as being lower .

[0041] According to a preferred embodiment , each end platelike element comprises a single plate-like body .

[0042] According to an alternative embodiment , at least one , or both, of the plate-like end elements comprise a plurality, for example two , plate-like bodies aligned along the vertical axis V-V .

[0043] According to the present invention, the inlet mouths and the outlet mouths 2110 , 2120 , 2210 , 2220 are obtained on said plate-like end elements 3 , 7 .

[0044] In a preferred embodiment , all the mouths 2110 , 2120 , 2210 , 2220 are obtained on the upper plate-like element 3 .

[0045] According to a further preferred embodiment , the exchange fluid inlet mouth 2210 and the exchange fluid outlet mouth 2220 are obtained on the upper plate-like element 3 , while the working fluid inlet mouth 2110 and the working fluid outlet mouth 2120 are obtained on the lower plate-like element 7 .

[0046] According to the present invention, the intermediate plate-like elements 4 are specially shaped delimiting, in the stacking thereof between the upper plate-like element 3 and the lower plate-like element 7 , a working fluid region 21 , in which the working fluid flows , and an exchange fluid region 22 , in which the exchange fluid flows .

[0047] According to a preferred embodiment , the intermediate plate-like elements 4 , with features widely described below, are obtained by means of mechanical molding, cutting and/or folding operations carried out from a sheet .

[0048] Preferably, the intermediate plate-like elements 4 and the plate-like end elements 3 , 7 are made of aluminum alloy .

[0049] The working fluid region 21 comprises vertical working fluid segments 211 , 212 , of inlet and outlet , respectively, in fluidic communication with the working fluid inlet mouth 2110 and the working fluid outlet mouth 2120 , as well as transversal working fluid segments 213 . [0050] Preferably, the vertical working fluid segments 211 ,

212 are aligned, along the vertical axis V-V, to the working fluid inlet mouth 2110 and to the working fluid outlet mouth 2120 , respectively .

[0051] Preferably, said transversal working fluid segments

213 extend mutually parallel to each other .

[0052] The exchange fluid region 22 comprises vertical exchange fluid segments 221 , 222 , for inlet and outlet respectively, in fluidic communication with the exchange fluid inlet mouth 2210 and with the exchange fluid outlet mouth 2220 , as well as transversal exchange fluid segments 223 .

[0053] Preferably, the vertical exchange fluid segments 221 , 222 are aligned, along the vertical axis V-V, to the exchange fluid inlet mouth 2210 and to the exchange fluid outlet mouth 2220 , respectively . [0054] Preferably, said transversal exchange fluid segments

223 extend mutually parallel to one another .

[0055] According to the present invention, the transversal exchange fluid segments 223 are positioned alternately with the transversal working fluid segments 213 .

[0056] According to the present invention, in which the heat exchanger 1 comprises :

- a plurality of working fluid turbulators 5 each housed in a respective transversal working f luid segment 213 ;

- a plurality of exchange fluid turbulators 6 each housed in a respective transversal exchange fluid segment 223 .

[0057] Said turbulators have the purpose of increasing the exchange surface available for the heat exchange and at the same time increasing the turbulence of the fluid circulating within each transversal segment .

[0058] According to a preferred embodiment , the working fluid turbulator 5 and the exchange fluid turbulator 6 are respectively shaped to modi fy the flow direction of the working fluid in a di f ferent manner with respect to the modi fication of the flow direction of the exchange fluid .

[0059] For example , the working fluid turbulator 5 is suitable for making the flow of the working fluid tortuous so as to greatly extend the flow time of the working fluid in the heat exchanger 1 with respect to the flow time of the exchange fluid in the heat exchanger 1 .

[0060] According to a preferred embodiment , the working fluid turbulator 5 and the exchange fluid turbulator 6 have a wavy shape oriented with respect to the main circulation direction of the flow of working fluid and exchange fluid within the respective transversal segments 213 , 223 .

[0061] According to the invention, first elements 41 , second elements 42 , working fluid turbulators 5 and exchange fluid turbulators 6 are shaped with a unique shape coupling .

[0062] The working fluid turbulator 5 is only placeable in a transversal working fluid segment 213 . Speci fically, the working fluid turbulator 5 is placeable in a transversal working fluid segment 213 in a single position .

[0063] In other words , each working fluid turbulator 5 is placeable in a single position within the respective housing space identi fied by one of the transversal segments comprised in the plurality of transversal working fluid segments defined by the mutual stacking of the intermediate plate-like elements .

[0064] The exchange fluid turbulator 6 is only placeable in a transversal exchange fluid segment 223 . Speci fically, the exchange fluid turbulator 6 is placeable in a transversal exchange fluid segment 223 in a single position .

[0065] In other words , each exchange fluid turbulator 6 is placeable in a single position within the respective housing space identi fied by one of the transversal segments comprised in the plurality of transversal exchange fluid segments defined by the mutual stacking of the intermediate plate-like elements .

[0066] According to a preferred embodiment , each intermediate plate-like element 4 comprises an inclined peripheral edge suitable for favoring the mutual stacking of intermediate plate-like elements .

[0067] Preferably, the first element 41 comprises a first peripheral edge 418 .

[0068] Preferably, the second element 42 comprises a second peripheral edge 428 .

[0069] According to a preferred embodiment , each turbulator is uniquely placeable , so that the peripheral edges of two consecutive intermediate plate-li ke elements engage each other .

[0070] Preferably, said mutual engagement between elements is tight . Preferably, said mutual tight engagement is obtained by means of the brazing process to which the intermediate plate-like elements are subj ected upon the coupling to the respective turbulators and the mutual stacking .

[0071] According to a preferred embodiment, the transversal working fluid segments 213 have a different height with respect to the transversal exchange fluid segments 223.

[0072] According to a preferred embodiment, the transversal working fluid segments 213 have a greater height than the transversal exchange fluid segments 223.

[0073] Preferably, the turbulators are shaped to occupy the respective space in the best possible manner, therefore the working fluid turbulator 5 has a greater height than the exchange fluid turbulator 6.

[0074] According to a preferred embodiment, the transversal working fluid segments 213 have a greater height than the transversal exchange fluid segments 223 by 20%.

[0075] According to a preferred embodiment, the transversal working fluid segments 213 have a height between 2.2 millimeters and 2.6 millimeters, preferably equal to about 2.4 millimeters.

[0076] According to a preferred embodiment, the transversal exchange fluid segments 223 have a height between 1.8 millimeters and 2.2 millimeters, preferably equal to about 2.0 millimeters.

[0077] According to a preferred embodiment, the working fluid turbulator 5 and the exchange fluid turbulator 6 are shaped as a function of the pressure drop undergone by the respective fluid flowing in the transversal working fluid segments 213 and in the transversal exchange fluid segments 223 , respectively, so as to greatly modi fy the direction of the fluid subj ect to a lower pressure drop .

[0078] According to a preferred embodiment , each first element 41 comprises first element portions protruding at the top 411 and first element portions protruding at the bottom 412 , wherein each second element 42 comprises second element portions protruding at the top 421 and second element portions protruding at the bottom 422 . According to what has been described above , the working fluid turbulator 5 and the exchange fluid turbulator 6 are specially shaped to house said protruding elements .

[0079] According to a preferred embodiment , the first element portions protruding at the top 411 and the first element portions protruding at the bottom 412 are alternating at least along the longitudinal axis X-X or along the transverse axis Y-Y .

[0080] According to a preferred embodiment , the first element portions protruding at the top 411 and the first element portions protruding at the bottom 412 are alternating both along the longitudinal axis X-X and along the transverse axis Y-Y .

[0081] According to a preferred embodiment , the second element portions protruding at the top 421 and the second element portions protruding at the bottom 422 are alternating at least along the longitudinal axis X-X or along the transverse axis Y-Y .

[0082] According to a preferred embodiment , the second element portions protruding at the top 421 and the second element portions protruding at the bottom 422 are alternating both along the longitudinal axis X-X and along the transverse axis Y-Y .

[0083] According to a preferred embodiment , the first element portions protruding at the top 411 face the second element portions protruding at the bottom 422 .

[0084] According to a preferred embodiment , the first element portions protruding at the bottom 412 face the second element portions protruding at the top 421 .

[0085] According to a preferred embodiment , the first element portions protruding at the top 411 engage the second element portions protruding at the bottom 422 . Preferably, said engagement is tight .

[0086] According to a preferred embodiment , the first element portions protruding at the bottom 412 engage the second element portions protruding at the top 421 . Preferably, said engagement is tight .

[0087] According to a preferred embodiment , said engagements allow to delimit and distinguish the working fluid region 21 and the exchange fluid region 22.

[0088] According to a preferred embodiment, each intermediate plate-like element 4 comprises four openings 410a, 410b, 410c, 410d, 420a, 420b, 420c, 420d.

[0089] According to such embodiment, the alignment along the vertical axis V-V of said openings defines the vertical segments 211, 212, 221, 222.

[0090] Preferably, at least two openings 410a, 410b, 410c, 410d, 420a, 420b, 420c, 420d have sections of different mutual shape.

[0091] Preferably, said at least two openings 410a, 410b, 410c, 410d, 420a, 420b, 420c, 420d with sections of different mutual shape are openings intended for circulating the same fluid, preferably the exchange fluid .

[0092] According to a preferred embodiment, at least one opening has an elongated section, for example slotted or elliptical, and the other opening has a circular section. [0093] According to a preferred embodiment, said openings therefore identify, in the alignment thereof, at least two vertical segments, of different shapes. Therefore, each turbulator is objectified in a unique position as a function of the position and shape of said openings, and therefore of said vertical segments.

[0094] Preferably, three openings 410a, 410b, 410c, 410d, 420a, 420b, 420c, 420d have passage sections of different shape .

[0095] According to a preferred embodiment, at least one opening has an elongated section, for example slotted or elliptical, while two openings have a circular section.

[0096] Preferably, the openings with a circular section have respectively different diameters.

[0097] According to a preferred embodiment, said openings therefore identify, in the alignment thereof, three vertical segments with different sections, two of which being vertical segments, for the inlet and outlet of the same fluid, of different shape. Therefore, each turbulator is objectified in a unique position as a function of the position and shape of said openings, and therefore of said vertical segments.

[0098] According to a preferred embodiment, two openings 410b, 410d, 420b, 420d have a circular section and delimit, in the stacking of the intermediate plate-like elements 41, 42 vertical inlet and outlet segments for the same fluid, preferably for the working fluid.

[0099] According to a preferred embodiment, a third opening 410c, 420d has, in turn, a circular shape, but with a section different from the other two.

[00100] According to a preferred embodiment, the fourth opening 410a, 420a has an elliptical shape. [00101] Preferably, the third and fourth openings delimit , in the stacking of the intermediate plate-like elements 41 , 42 , vertical inlet and outlet segments for the same fluid, preferably for the exchange fluid .

[00102] Preferably, the third and fourth openings have the same passage section . Preferably, the third and fourth openings have a larger passage section than the passage section of the first and second openings .

[00103] According to a preferred embodiment , the protruding portions described above are the edges of said openings .

[00104] That is , each intermediate plate-like element 4 is shaped to comprise , about each opening, at the edge , a respective protruding element with the features described above .

[00105] Preferably, the working fluid turbulator 5 comprises working turbulator openings 50 , through which the respective protruding portions extend, thus defining the vertical working fluid segments .

[00106] Preferably, the working fluid turbulator 5 comprises working turbulator openings 50 , through which the respective portions protruding at the top and at the bottom, provided on two adj acent intermediate plate-like elements , extend, thus defining at least one portion of the vertical working fluid inlet segments and of the vertical working fluid outlet segments within a transversal exchange fluid segment .

[00107] Preferably, the exchange fluid turbulator 6 comprises exchange turbulator openings 60 , through which the respective protruding portions extend, thus defining the vertical exchange fluid segments .

[00108] Preferably, the exchange fluid turbulator 6 comprises exchange turbulator openings 60 , through which the respective portions protruding at the top and at the bottom, provided on two adj acent intermediate plate-like elements , extend, thus defining at least one portion of the vertical exchange fluid inlet segments and of the vertical exchange fluid outlet segments within a transversal working fluid segment .

[00109] Preferably, the working turbulator openings 50 and the exchange turbulator openings 60 are shaped to be coupled to the respective openings 410a, 410b, 410c, 410d, 420a, 420b, 420c, 420d so as to uniquely define the position of the working fluid turbulator 5 and of the exchange fluid turbulator 6 within the respective transversal segment . In other words , as a function of the speci fic transversal segment , the working turbulator openings 50 and the exchange turbulator openings 60 have a shape corresponding to that of the openings 410a, 410b, 410c, 410d, 420a, 420b, 420c, 420d . I f the respective turbulator is to receive the respective protruding portions , the shape of the working turbulator openings 50 or of the exchange turbulator openings 60 are such as to receive said protruding portions .

[00110] According to a preferred embodiment , the protruding edge portions of the opening with elongated section mutually engage in a centerline region defined between two intermediate plate-like elements . Preferably, therefore , said engagement is housed in the opening of a respective turbulator .

[00111] Preferably, the protruding edge portions of the openings with circular section mutually engage by overlapping along the vertical axis V-V.

[00112] In further other words , the coupling and stacking of plate-like end elements 3 , 7 , intermediate plate-like elements 4 , working fluid turbulators 5 and exchange fluid turbulators 6 , are only and exclusively possible i f performed in the correct order and in the correct manner . The turbulators are insertable into the respective housing in only one position : when inserting the turbulator in an incorrect position, the latter has the openings thereof misaligned or it appears to be li fted from the nominal installation position provided in the proj ect , since it interferes with a respective protruding portion which does not find the housing space necessary to allow the complete insertion of the turbulator into the intermediate plate-like element . [00113] According to a preferred embodiment , the lower plate-like end element 7 and/or the upper plate-like end element 3 comprises/comprise portions , protruding at the top or at the bottom, suitable for facilitating the correct positioning of the respective turbulator element in the transversal segment defined between the end element 3 , 7 and the adj acent intermediate plate-like element 4 .

[00114] Preferably, said protruding portions formed on the plate-like end element are configured in the form of protrusions . Preferably, said protrusions are positioned at the opening with an elongated passage section .

[00115] A preferred embodiment of said protrusions , in this case provided on the lower plate-like end element , is shown in Figure 5 . Figure 5a shows how the position of said protrusions contributes to defining the unique positioning of the respective turbulator element in the speci fic housing space .

[00116] According to a preferred embodiment , the platelike end elements 3 , 7 , the intermediate plate-like elements 4 , the working fluid turbulators 5 and the exchange fluid turbulators 6 are mutually j oined by means of a brazing operation, preferably in a vacuum furnace . [00117] According to a preferred embodiment , the heat exchanger 1 comprises at least one connection member 8 operatively connected to at least one plate-like end element 3 , 7 at least one fluid inlet or outlet mouth .

[00118] Preferably, said connection member 8 is engageable by a respective duct for the fluid connection of the heat exchanger 1 .

[00119] According to a preferred embodiment , at each mouth, the heat exchanger 1 comprises a respective connection member 8 .

[00120] Preferably, the plate-like end element 3 , 7 in correspondence with at least one mouth comprises a protruding connection collar 38 being engageable by the respective connection member 8 .

[00121] According to a preferred embodiment , the connection member 8 , the plate-like end elements 3 , 7 , the intermediate plate-like elements 4 , the working fluid turbulators 5 and the exchange fluid turbulators 6 are mutually j oined each other by means of a single brazing operation, preferably in a vacuum furnace .

[00122] Innovatively, the heat exchanger largely achieves the purpose of the present invention, overcoming issues which are typical of the prior art .

[00123] Advantageously, in fact , the heat exchanger has fluidic passages suitable for making the heat exchange particularly ef ficient , but at the same time it has simpli fied manufacturing and assembly operations .

[00124] Advantageously, the plate-like elements and the turbulators comprised in the heat exchanger are assemblable with a reliable assembly sequence suitable for ensuring the correct positioning of the turbulators within the respective transversal segments and the mutual connection of the components included in the exchanger by brazing .

[00125] Advantageously, the stacking of plate-like elements and turbulators is possible in a certain order . Advantageously, any attempt by an operator to proceed with a stacking order di f ferent from the pre-set one is prevented : advantageously, plate-like elements and/or turbulators inserted in the wrong manner are not stackable but remain mutually raised .

[00126] Advantageously, the heat exchanger has speci fic turbulators for the physical features of the fluid, for example the viscosity thereof , and/or for the features of the flow, for example the pressure drop . Advantageously, speci fic turbulators are speci fically placeable to be uniquely used for the intended purpose .

[00127] Advantageously, vertical segments of di f ferent section and shape are used to uniquely obj ecti fy the position of the working turbulators and of the exchange turbulators within the respective housing spaces .

[00128] Advantageously, any possible error in the stacking sequence of the components i s minimized .

[00129] Advantageously, in case of an incorrect arrangement of the components , the heat exchanger is not correctly assemblable by means of the subsequent brazing process . Advantageously, the obj ecti fication system of fers an economic solution capable of identi fying any defective exchangers .

[00130] Advantageously, the heat exchanger has improved manufacturing and assembly, thus having a lower cost .

[00131] Advantageously, the heat exchanger is a single component .

[00132] Advantageously, the recognition solutions described for the intermediate plate-like elements suitable for delimiting the transversal segments , comprised the edges of the openings , can be easily reversed between elements for the working fluid and elements for the exchange fluid according to the operating needs .

[00133] It is apparent that , in order to meet contingent needs , a person skilled in the art may make changes to the above-described heat exchanger, all contained within the scope of protection as def ined by the following claims . List of reference signs :

[00134]

1 heat exchanger

21 working fluid region

211 vertical working fluid ( inlet ) segment

212 vertical working fluid ( outlet ) segment

213 transversal working fluid segments

2110 working fluid inlet mouth

2120 working fluid outlet mouth

22 exchange fluid region

221 vertical exchange fluid ( inlet ) segment

222 vertical exchange fluid ( outlet ) segment

223 transversal exchange fluid segments

2210 exchange fluid inlet mouth

2220 exchange fluid outlet mouth

3 upper plate-like end element

38 protruding connection collar

4 intermediate plate-like element

41 first element

410a, 410b, 410c, 410d openings

411 first element portions protruding at the top

412 first element portions protruding at the bottom

418 first peripheral edge

42 second element

420a, 420b, 420c, 420d openings 421 second element portions protruding at the top

422 second element portions protruding at the bottom

428 second peripheral edge

5 working fluid turbulator 50 working turbulator openings

6 exchange fluid turbulator

60 exchange turbulator openings

7 lower plate-like end element

X-X longitudinal axis Y-Y transverse axis

V-V vertical axis