The present disclosure relates to a heat exchanger system, particularly, the present disclosure relates to a protective grid system for protecting a heat exchanger system of a vehicle and maintaining proper performance and efficiency thereof.

A vehicle includes several heat exchanger elements. Conventionally, an engine cooling system of a vehicle includes a heat exchanger in form of a radiator to facilitate cooling of an engine of the vehicle. Specifically, a coolant in form of glycol or water- glycol mixture is passed through the engine, from where the coolant absorbs heat and becomes hot. The hot coolant is then fed into an inlet tank of the radiator that is located preferably on top of the radiator, or along one side of the radiator, from the inlet tank the hot coolant is distributed across a radiator core through radiator tubes to another tank on an opposite end of the radiator. As the hot coolant passes through the radiator tubes to the opposite tank, the coolant transfers heat to tubes of the radiator core, which in turn, transfers the heat to fins that are lodged between each row of radiator tubes. The fins then release the heat to the ambient air that flows across the radiator core. For effective and efficient performance of the radiator, there should be unhindered supply of ambient air to the radiator core. In order to save the power consumption in the vehicle, natural draft of air across the radiator core is utilized. For achieving natural draft of air across the radiator core, the radiator core is disposed behind a front grill of the vehicle, wherein the front grill is disposed between a front hood and a front bumper of the vehicle such that the ram air impinges on the front grille of the vehicle as the vehicle moves in forward direction. Such strategic placement of the radiator core enables the ram air to impinge on and pass through the radiator core disposed behind the front grille, thereby creating natural draft of air across the radiator core as the vehicle moves ahead in the forward direction. The engine cooling system often incorporates one or more fans disposed behind the radiator core to generate a forced draft of air that facilities passage of air through the radiator core. The forced draft generated by the fans improves the performance and efficiency of the radiator by improving the air flow rate through the radiator by increasing the air speed. The radiator may be disposed either alone or in series with other heat exchange elements such as for example, a condenser and a chiller that require draft of air for efficient operation thereof. Also, the sequence in which the radiator, condenser and chillers are disposed may vary, for example, sometimes the radiator is at the front to first receive the ram air and in other cases the condenser is at the front to first receive the ram air. The position of the radiator and the condenser can interchange.

However, such high speed ram air often carries therewith lighter articles such as paper, empty polythene bags, leaves and the likes, that may reach a front face of the heat exchanger core, such as for example, radiator core or condenser core and may get struck over there due to draft of air created by the fan or the ram air. Most often, these lighter articles accumulate in the space behind the front grille and in front of the radiator or condenser core causing hindrance to air flow and preventing ram air from reaching and entering the radiator or condenser core, thereby deteriorating efficiency and performance of the radiator or condenser. Certain prior art suggest placing a grid over the front face of the radiator or the condenser core. Such arrangement may still prevent all the ram air from reaching and entering the radiator or condenser core for achieving cooling of the hot coolant flowing through the radiator or condensing of the refrigerant in gaseous state flowing through condenser, thereby under utilizing the ram air and deteriorating the efficiency and performance of the radiator or the condenser respectively. Inefficient performance of the radiator may in extreme conditions lead to complications such as for example, the radiator failing to remove heat from the engine and resulting in engine seizure due to excessive heat. In case of a condenser, inefficient performance of the condenser may cause inefficient operation of the Heating Ventilation and Air Conditioning system, thereby causing inefficient cooling in the cabin and causing discomfort to the occupants.

Accordingly, there is a need for a protective system that not only protects the heat exchanger core such as radiator and/or condenser core but also ensures ram air reaches the radiator and/or condenser core to maintain proper efficiency and performance of the radiator and/or condenser respectively. Also, there is a need for a protective grid system that prevents lighter articles such as paper, polythene bags and leaves from getting in to path of ram air approaching the radiator or condenser core and deteriorating efficiency and performance of the radiator or condenser respectively, while still not compromising air flow through the radiator or condenser core. Still further, there is a need for a protective system that acts as a barrier in front of the radiator or condenser core and prevents heavier article such as stones from impacting and damaging the radiator and/or condenser core, while still not compromising air flow through the radiator or condenser core.

An object of the present invention is to provide a protective grid system configured with sealing elements for sealing a gap between a grid of the protective grid system and /or a heat exchanger core, particularly, a radiator core or condenser core to prevent escape of air through the gap and achieve proper utilization of the ram air.

Another object of the present invention is to provide a protective grid system that maintains efficiency and performance of a heat exchanger, particularly, a radiator and/or a condenser by directing most of the ram air thereto.

Still another object of the present invention is to provide a protective grid system that protects a heat exchanger core, particularly, a radiator core and/or condenser core against damage from impact of heavier articles such as stones.

Yet another object of the present invention is to provide a protective grid system that prevents lighter articles such as paper, polythene bags and leaves from getting in to path of ram air approaching a heat exchanger core such as for example, a radiator core and /or condenser core.

Still another object of the present invention is to provide a protective system that can be easily retrofitted over current radiators and /or condensers without requiring many modifications. Another object of the present invention is to provide a protective system that enhances service life of a heat exchanger such as a radiator and/or condenser and reduces maintenance thereof.

Yet another of the present invention is to provide a protective system that is inexpensive and also convenient to manufacture, assemble and use.

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.

In accordance with an embodiment of the invention, a protective grid system is disclosed. The protective grid system includes at least one grid mounted over a face of at least one heat exchanger core such that at least one lateral edge of the grid configures sealing engagement with the heat exchanger core. The grid includes at least one sealing element configured along at least a part of the at least one longitudinal edge thereof and extending in direction of the face of the heat exchanger core. The sealing element contacts the face of the heat exchanger core to configure at least a partial sealing of gap between the grid and the heat exchanger core.

In accordance with another embodiment of the invention, the grid includes an array of elements defining restricted air passages.

In accordance with an embodiment of the invention, the elements are horizontally and vertically disposed beams that cross each other to configure the restricted air passages. Alternatively, the elements are honeycomb structures that configure the restricted air passages.

In accordance with an embodiment of the invention, the grid is of metal and is configured by stamping process.

Alternatively, the grid is of plastic material and is configured by molding process.

Further, the grid includes first engagement elements that engage with complimentary second engagement elements configured on a housing receiving the heat exchanger core.

In accordance with an embodiment, at least a portion of the lateral edges of the grid is configured with guide- ways that receive protrusions configured along at least a portion of the lateral sides of the heat exchanger core for configuring lateral sealing between the grid and the heat exchanger core.

Alternatively, a portion of the lateral edges of the grid is configured with protrusions that are received within guide-ways configured along at least a portion of the lateral sides of the heat exchanger core for configuring lateral sealing between the grid and the heat exchanger core.

In accordance with an embodiment, the grid is so mounted on the heat exchanger core that at least some relative movement is permitted between the grid and the heat exchanger core. In accordance with an embodiment of the invention, the sealing elements are further pressed by the grid against the heat exchanger core and get deformed when ram air pushes the grid towards the heat exchanger core.

In accordance with an embodiment of the invention, the sealing elements are integrally formed on the longitudinal edges of the grid.

Alternatively, the sealing elements are detachably mounted on the longitudinal edges of the grid.

Preferably, the sealing element is of a resilient material such as rubber and is configured by either one of over- molding and extrusion process.

In accordance with an embodiment of the present invention, the sealing elements are located in front of tubes of the heat exchanger core.

Also is disclosed a heat exchanger module that includes a protective grid system as claimed in any of the preceding claims.

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:

FIGURE 1 illustrates a schematic representation of a protective grid system in accordance with an embodiment of the present invention that includes at least one grid mounted over a heat exchanger core and sealing elements configured along longitudinal edges of the at least one grid, also is illustrated an enlarged view depicting a sealing element for sealing the gap between the at least one grid and the heat exchanger core;

FIGURE 2 illustrates a front view of the protective grid system of FIGURE 1;

FIGURE 3 illustrates an exploded view of the protective grid system of FIGURE 1 along with the heat exchanger, wherein the grids are depicted separate from the heat exchanger core;

FIGURE 4 illustrates sectional view of the protective grid system mounted on the heat exchanger core along section line A-A depicted in FIGURE 2, also is depicted enlarged view of the sealing element configured along longitudinal edge of the grid for sealing the gap between the grid and the heat exchanger core;

FIGURE 5 illustrates sectional view of the protective grid system mounted on the heat exchanger core along section line B-B depicted in FIGURE 2, also is depicted enlarged view of engagement between guide ways configured on the grid and protrusions configured on lateral sides of the heat exchanger core for configuring lateral sealing between the grid and the heat exchanger core;

FIGURE 6 illustrates sealing elements configured along longitudinal edges of a corresponding grid in accordance with one embodiment of the present invention, wherein the sealing elements are converging away from the grid; and

FIGURE 7 illustrates sealing elements configured along longitudinal edges of a corresponding grid in accordance with another embodiment of the present invention, wherein the sealing elements are diverging away from the grid. A protective grid system disclosed herein includes at least one grid mounted on at least one heat exchanger core, such as for example, a radiator core and/or condenser core. The at least one grid is configured with sealing elements disposed along longitudinal edges thereof. The sealing elements seal the gaps between the grid and the heat exchanger core, thereby preventing escape of air through the gaps between the grid and the heat exchanger core and achieving proper utilization of the ram air for maintaining efficiency and performance of the heat exchanger. Although, the protective grid system of the present invention is used in heat exchangers, such as radiators, condensers and evaporators that are used in vehicles, however, the protective grid system of the present invention is also applicable to any other heat exchangers used in non-vehicular systems such as generators that also involve air draft for achieving better performance of the heat exchanger.

Referring to FIGURE 1, a schematic representation of a protective grid system 100 in accordance with an embodiment of the present invention is illustrated. The protective grid system 100 includes at least one grid, FIGURE 1 illustrates two grids, referred to as a first grid 10a and a second grid 10b, also simply referred to as grids 10a and 10b mounted over a heat exchanger core 20, such as for example, radiator or condenser core and sealing elements 12a and 12b configured along at least a part of at least one longitudinal edge of the respective first and second grids 10a and 10b. Also, is illustrated an enlarged view depicting the sealing element 12a sealing, at least partially, the gap between the grid 10a and the heat exchanger core 20, thereby preventing escape of air crossing the grid 10a through the gap between the grid 10a and the heat exchanger core 20. With such configuration, most of the air that crosses the grid 10a reaches the heat exchanger core 20, thereby resulting in better utilization of the air for cooling in the heat exchanger and maintaining the performance and efficiency of the heat exchanger. As the first and the second grids 10a and 10b respectively are almost identical to each other, every embodiment disclosed henceforth in relation to the first grid 10a configured with the sealing element 12a and ways of mounting thereof on the heat exchanger core 20 may also be applicable for the second grid 10b configured with the sealing element 12b. For sake of brevity of present document, enlarged view depicting only the first grid 10a mounted over the heat exchanger core 20 with the sealing element 12a sealing the gap between the first grid 10a and the heat exchanger core 20 is illustrated in the FIGURE 1 and is described in the forthcoming description. Referring to the FIGURE 2 - FIGURE 5, the first grid 10a is mounted over a front face of the heat exchanger core 20 such that lateral edges of the first grid 10a configure sealing engagement with the heat exchanger core 20. The front face of the heat exchanger core 20 is the face facing a rear of a front grille mounted at front of the vehicle. In accordance with an embodiment, the first grid 10a is detachably mounted over the front face of the heat exchanger core 20. In accordance with still another embodiment of the present invention, the first grid 10a includes at least one sealing element 12a configured along at least a part of at least one longitudinal edge thereof. Specifically, the sealing element can be configured along only one longitudinal edge or both longitudinal edges of the first grid 10a, and only on a portion of the longitudinal edge(s) or on all the longitudinal length of the longitudinal edge(s).

In accordance with an embodiment, the first grid 10a includes an array of elements 14a defining restricted air passages 16a that restrain passage of articles of a predetermined size but facilitate air flow there through. Specifically, in accordance with a preferred embodiment, the elements 14a configuring the passages 16a are aligned with respect to at least few of the tubes of the heat exchanger core 20. As a result, the elements 14a configuring the first grid 10a either not at all obstruct or do partial obstruct air flowing towards the heat exchanger core 20 and as such do not prevent the air from reaching and entering the heat exchanger core 20. In accordance with a preferred embodiment, the elements 14a are horizontally and vertically disposed beams that cross each other to configure the restricted air passages 16a. In accordance with another embodiment, the elements 14a are honeycomb structures that configure the restricted air passages 16a. In accordance with still another embodiment, the first grid 10a is formed of woven wires. In accordance with an embodiment, the first grid 10a is of metal and is configured by stamping process. In accordance with another embodiment, the first grid 10a is of plastic material and is configured by molding process with the beams integrally configured thereon during single step molding process. However, the first grid 10a of the present invention is not limited to any particular configuration of the elements 14a configuring the first grid 10a and any particular material or process used for configuring the first grid 10a as far as the first grid 10a prevents lighter articles such as paper, polythene bags and leaves from getting in to path of ram air approaching the heat exchanger core 20 while still not compromising air flow through the heat exchanger core 20. The first grid 10a is so mounted over the front face of the heat exchanger core 20 that lateral edges of the first grid 10a configure sealing engagement with the heat exchanger core 20. Generally at least one of the lateral edges of the first grid 10a configures sealing engagement with the heat exchanger core 20. Specifically, either one or both of the lateral edges of the first grid 10a configures sealing engagement with the heat exchanger core 20. In accordance with an embodiment of the present invention as illustrated in FIGURE 5, at least a portion of the lateral edges of the first grid 10a is configured with guide-ways 19a that receive protrusions 22 configured along at least a portion of lateral sides of the heat exchanger core 20 for configuring sliding engagement and lateral sealing between the first grid 10a and the heat exchanger core 20. In accordance with another embodiment of the present invention (not illustrated on figures), at least a portion of the lateral edges of the first grid 10a is configured with protrusions 22 that are received within guide-ways 19a configured along at least a portion of lateral sides of the heat exchanger core 20 for configuring sliding engagement and lateral sealing between the first grid 10a and the heat exchanger core 20. With such lateral sealing between the first grid 10a and the heat exchanger core 20, escape of air through the gap between the lateral edges of the first grid 10a and the lateral sides of the heat exchanger core 20 is prevented, or at least significantly reduced. With such configuration, most of the air that crosses the first grid 10a reaches the heat exchanger core 20, thereby resulting in better utilization of the air for cooling in the heat exchanger and maintaining the performance and efficiency of the heat exchanger.

In accordance with an embodiment, the first grid 10a is so mounted on the heat exchanger core 20 that at least some relative movement is permitted between the first grid 10a and the heat exchanger core 20. Once the first grid 10a is disposed in the desired position with respect to the heat exchanger core 20, complementary engagement elements configured on the first grid 10a and a housing 30 receiving the heat exchanger core 20 facilitate mounting of the first grid 10a over the heat exchanger core 20. In accordance with an embodiment of the present invention, the first engagement elements 18a configured on the first grid 10a engages with complimentary second engagement elements 32 configured on the housing 30 receiving the heat exchanger core 20 to facilitate secure mounting of the first grid 10a over the front face of the heat exchanger core 20. However, the first grid 10a of the present invention is not limited to any particular configuration of the elements configuring lateral sealing between the first grid 10a and the heat exchanger core 20. Also, the first grid 10a of the present invention is not limited to any particular configuration of the elements used for securely mounting of the first grid 10a over the front face of the heat exchanger core 20.

FIGURE 1 and FIGURE 4 depict the sealing elements 12a configured along longitudinal edges of the first grid 10a. In accordance with an embodiment of the present invention, the sealing element 12a is integrally formed on the longitudinal edges of the first grid 10a. Alternatively, the sealing element 12a is detachably mounted on the longitudinal edges of the first grid 10a. As, detachable engagement means for detachably mounting the at least one sealing element 12a on the longitudinal edges of the first grid 10a is well known therefore such detachable engagement means are not disclosed in details for the sake of brevity of the present document. In accordance with an embodiment of the present invention, the sealing elements 12a configured along opposite longitudinal edges of the first grid 10a are converging away from the first grid 10a as illustrated in FIGURE 6. Alternatively, the sealing elements 12a configured along opposite longitudinal edges of the first grid 10a are diverging away from the first grid 10a as illustrated in FIGURE 7. In accordance with an embodiment of the present invention, the sealing elements 12a are located in front of tubes of the heat exchanger core 20. Specifically, the sealing elements 12 are aligned with respect to at least few of the tubes of the heat exchanger core 20. As a result, the sealing elements 12 do not obstruct air flowing towards the heat exchanger core 20 and as such do not prevent the air from reaching and entering the heat exchanger core 20. The sealing element 12a is of a resilient material such as rubber and is configured by either one of over-molding and extrusion process. However, the present invention is not limited to any particular configuration, material and method of manufacturing the sealing element 12a. In accordance with an embodiment of the present invention, the sealing element 12a extends in the direction of or towards the front face of the heat exchanger core 20 and contacts the front face of the heat exchanger core 20 only when ram air or any external air flow pushes the first grid 10a towards the heat exchanger core 20. The sealing element 12a as per such embodiment remains in contact with the front face of the heat exchanger core 20 as far as the ram air or any external air flow pushes the grid 10a towards the heat exchanger core 20 and the sealing element 12a does not necessarily remain in contact with the front face of the heat exchanger core 20 at all the time, such as at times when ram air or any external air flow is not pushing the grid 10a towards the heat exchanger core 20. With such configuration of the sealing elements, the sealing elements 12a seals the gap between the first grid 10a the heat exchanger core 20 for preventing escape of air through the gap before reaching the heat exchanger core 20, only when ram air or any external air flow pushes the grid 10a towards the heat exchanger core 20.

In one embodiment of the present invention, the sealing element 12a gets deformed and is further pressed against the heat exchanger core 20 by the first grid 10a when ram air pushes the first grid 10a towards the heat exchanger core 20, thereby enhancing the sealing between the first grid 10a and the heat exchanger core 20. In accordance with an embodiment of the present invention, the sealing element 12a is bifurcated at a distal end thereof, and two arms forming the bifurcated portion of the sealing element 12a spread away from each other and get pressed against the heat exchanger core 20. Such configuration of the sealing element 12a facilitates in achieving better longitudinal sealing between the first grid 10a and the heat exchanger core 20. Such configuration ensures better utilization of ram air by directing most of the ram air to the heat exchanger core 20, thereby maintaining efficiency and performance of the heat exchanger.

In accordance with another embodiment of the of the present invention, the sealing element 12a extends in the direction of or towards the front face of the heat exchanger core 20 and always remains in contact therewith. With such configuration, the sealing elements 12a seals the gap between the first grid 10a the heat exchanger core 20 for preventing escape of air through the gap before reaching the heat exchanger core 20 at all times irrespective of whether ram air or any external air flow is pushing the grid 10a towards the heat exchanger core 20.

Several modifications and improvement might be applied by the person skilled in the art to the protective grid system as defined above, as long as it comprises at least one grid mounted over a face of at least one heat exchanger core such that at least one lateral edge of the grid configures sealing engagement with the heat exchanger core, the grid includes at least one sealing element configured along the at least one longitudinal edge thereof and extending till in direction of the face of the heat exchanger core, the sealing element contacts the face of the heat exchanger core to configure at least a partial sealing of the gap between the grid and the heat exchanger core.

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.