DE112011103814T5 - Heat exchanger assembly and method - Google Patents

Abstract

A heat exchanger assembly and method for maintenance are described and illustrated, and in some embodiments, includes a pair of core units in an end-to-end configuration and a liquid container disposed between the core units. Each core unit includes air fins arranged in parallel with each other and spaced apart from each other in a core stacking direction, and liquid conveying pipes arranged in parallel and disposed between and connected to adjacent air fins. The first liquid container comprises a first end which is sealingly fixed to a head plate of the one core unit, and a second end which is sealingly fixed to a head plate of the other core unit. The liquid container may be crimped to adjacent units and may be disposed entirely within the outermost boundary of the at least one of the pair of core units in the core-stacking direction.

Description

This application claims the benefit of US Provisional Patent Application No. 61 / 415,588, filed Nov. 19, 2010, the contents of which are hereby incorporated by reference.

BACKGROUND

In general, various heat exchangers are used to transfer heat energy from a first, hotter liquid to a second, cooler liquid. According to an example well known in the art, an internal combustion engine in a motor vehicle or truck continuously runs at a desired temperature using a liquid coolant loop that removes waste heat from the engine and transfers it to a lower temperature air flow into a heat exchanger (i.e., a radiator). Such coolers typically include a plurality of fluid conduits for conveying the coolant through the radiator, ambient air being directed over the outer surfaces of the tubes to convectively remove heat from the exterior surfaces of the fluid conduits.

It should be readily appreciated that the heat transfer rate required in the radiator to maintain such desired engine temperature (sometimes referred to as thermal load) increases in proportion to engine power. Consequently, large, high-performance machines (such as agricultural, construction, and mining machines) require large radiators to provide an adequate heat transfer surface for these thermal loads. The production of such large coolers can be problematic.

Compact and highly efficient radiators for automobiles and trucks are often manufactured in a cost-effective manner by metallurgically bonding at least certain portions of the radiator in an oven brazing operation. However, as the size of the cooler increases, the physical limitations of the furnace can be achieved, and alternative designs that are less cost effective and / or result in less compact and less efficient heat exchangers can be used out of necessity. For example, in some large engines, the radiator is constructed using a large number of individually finned heat exchanger tubes inserted through grommets.

SUMMARY

According to some embodiments of the invention, a heat exchanger assembly comprises a pair of core units in an end-to-end arrangement (butt joint arrangement) and a liquid container disposed between the core units. Each core unit comprises a plurality of air fins arranged parallel to one another and spaced apart in a core stacking direction. Each core unit additionally includes a plurality of parallel fluid delivery tubes disposed between and connected to adjacent ones of the plurality of air ribs. The first and second spaced apart header plates seal the first and second ends of the tubes, respectively. First and second side plates are disposed adjacent to the outermost of the air ribs to define an outermost boundary of the core unit in the core stacking direction. The liquid container includes a first end and a second end opposite the first end, the first end sealingly attached to one of the first and second top plates of one of the pair of core units, and the other end to one of the first and second top plates of the first end another is sealingly attached to the other of the pair of core units. The liquid container is disposed entirely within the outermost boundary of at least one of the pair of core units in the core-stacking direction.

In some embodiments, the liquid container is attached to at least one of the pair of core units by crimping. In some embodiments, a seal is included between the liquid container and a top plate of at least one of the core units.

A heat exchanger assembly according to some embodiments of the invention additionally includes an inlet container and / or an outlet container which is sealingly secured to the other of the first and second head plates of the one of the pair of core units.

In some embodiments, the heat exchanger assembly includes a second pair of core units adjacent to the first pair in the core stacking direction of at least one core unit. Some such embodiments include a structural frame that supports the first and second pairs of core units. In some embodiments, the center tank and fluid delivery tubes of the first pair of core units together define a first fluid flow path, and the center tank and fluid delivery tubes of the second pair of core units together define a second fluid flow path. The first and second liquid flow paths are arranged parallel to each other with respect to a liquid flowing therethrough.

According to some embodiments of the invention, the heat exchanger comprises first and second core units. Each core unit has a set of substantially parallel tubes extending in one direction through the core unit. Each of the tubes has opposed first and second ends. A head is connected to the first ends of the set of substantially parallel tubes to form a liquid-tight seal. A container is disposed between the first and second core units and has opposite ends. A head of each of the first and second core units is crimped in a fluid-tight engagement with a respective one of the opposite ends. The container has at least one interior in fluid communication with interiors of the substantially parallel tubes of the first and second core units.

According to another embodiment of the invention, a method of servicing a heat exchanger comprises separating a first pair of core units from a second pair of core units, the first and second pairs of core units being supported by a common frame. The method may include terminating fluid communication between tubes of the first pair of core units and tubes of the second pair of core units by separating the first pair of core units from the second pair of core units. The method may further include removing the first pair of core units from the frame, wherein the second pair of core units remain in place in the frame.

BRIEF DESCRIPTION OF THE DRAWINGS

1 is a perspective view of a heat exchanger assembly according to an embodiment of the present invention.

2 is a partial perspective view of selected portions of the heat exchanger assembly of 1 ,

3 is a partial perspective detail view of the area III-III of 1 ,

4 is a partial cross-sectional view along the lines IV-IV of 3 ,

5 is a perspective view of a container for use in the heat exchanger assembly of 1 ,

6 is a perspective view of a heat exchanger assembly according to another embodiment of the present invention.

DETAILED DESCRIPTION

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention may have other embodiments and may be practiced or practiced in various ways. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be considered as limiting. The use of "including," "comprising," or "comprising," and variations thereof, is intended herein to include the elements listed thereafter and their equivalents, as well as additional elements. Unless otherwise stated or otherwise limited, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and include both direct and indirect mounts, connections, supports, and couplings. Further, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

A heat exchanger arrangement 1 according to an embodiment of the present invention is in 1 and includes first and second core units 2 in an end-to-end arrangement. Although the exemplary embodiment of 1 represents two such core units, it should be understood that a heat exchanger assembly 1 may also comprise several such core units. Additional core units 2 can equally be arranged in the form of a butt joint or they can be in the form of a butt joint with one of the in 1 illustrated first and second heat exchanger core units 2 or be arranged with both.

Every core unit 2 has a tube and ribbed matrix 3 (in 2 shown in more detail), first and second head plates 5 and first and second side plates 6 on. The tube and rib matrix 3 includes a plurality of air ribs 10 and a plurality of liquid delivery pipes 11 , The air ribs 10 are arranged parallel to each other and are spaced apart from each other in a core-stacking direction (indicated by a double-headed arrow A) so that the tubes 11 between adjacent air ribs 10 may be arranged to produce a nested matrix of tubes and air ribs. The air ribs 10 and pipes 11 may be interconnected at their contact points to provide low resistance to heat transfer between one through the tubes 11 flowing liquid and a flow of air cause during operation of the heat exchanger assembly 1 flows over the surfaces of the air ribs. Such bonding may be accomplished by brazing, welding, brazing, gluing or other methods known in the art of heat exchangers.

The air ribs 10 or pipes 11 or both may be constructed of metal materials including, but not limited to, aluminum, copper, steel, and the like. Alternatively, the air ribs 10 or pipes 11 or both constructed of non-metallic materials such as plastic. Although not shown in the exemplary embodiment, the fluid delivery tubes may 11 In some embodiments, internal tissues, inserts, or other components may be included to increase turbulence and thereby enhance heat transfer to meet specific requirements of an application for which the heat exchanger assembly 1 is determined.

The in 2 illustrated type of air ribs 10 is serpentine, but it should be understood that alternative air rib types known in the art may equally be used. In some embodiments, the air ribs 10 for example, have a rectangular waveform. In further embodiments, the air ribs 10 Be plate ribs. The air ribs may include turbulence components including but not limited to fins, bumps, slots, lances, offsets, and combinations thereof.

The first and second head plates 5 each heat exchanger core 2 are in the tube-axial direction of the tubes 11 the core unit 2 spaced apart. Each of the head plates 5 includes a plurality of tube slots 12 ( 4 ) along the stacking direction A in unambiguous correspondence with the plurality of tubes 11 are arranged. A first end of each of the tubes 11 extends into a corresponding one of the tube slots 12 in a first headstock 5 and is sealingly received therein, and a second end of each of the tubes 11 extends into a corresponding one of the tube slots 12 in a second headstock 5 and is sealed in it. The seal between the head plates 5 and the ends of the pipes 11 can be carried out by brazing, welding, gluing or other known in the art of heat exchangers connection and sealing methods. The head plates 5 may be stamped metal parts in some embodiments. In further embodiments, the top plates 5 Be injection molded plastic parts. In other embodiments, the top plates may be composed of other materials and / or may be made by other methods.

The first and second side pieces 6 each core unit 2 are adjacent to the outermost of the air ribs 10 the core unit 2 arranged around the tube and rib matrix 3 in the core stacking direction A to limit. In other words, the first and second side pieces 6 a core unit 2 the outermost boundaries of the core unit 2 form in the core stacking direction A. The side pieces 6 can during the joining of the tube and rib matrix 3 be used to apply a compressive load in the core stacking direction A, to ensure that contact between adjacent the air ribs 10 and pipes 11 is maintained. In some embodiments, it may be advantageous for the side plates 6 with the outermost air ribs 10 are connected. In some embodiments, the air ribs 10 , the liquid delivery pipes 11 and the side plates 6 For example, all may be composed of aluminum or an aluminum alloy and may be bonded together in one or more brazing operations to form a core unit 2 to build.

The embodiment of 1 further comprises first and second liquid containers 7 that with the head plates 5 at opposite ends of the heat exchanger assembly 1 are connected. These containers 7 may serve as inlet and outlet containers for a liquid passing through the liquid delivery pipes 11 the heat exchanger assembly flows. During operation of the heat exchanger assembly 1 can be a liquid from one of the containers 7 through a connection 8th be included in this container 7 is arranged, and can on the liquid delivery pipes 11 the core unit 2 be distributed, which is the top plate 5 includes, with this container 7 connected is. After flowing through the pipes 11 of at least two of the core units 2 The liquid can be in another of the containers 7 can be recorded and can through the connection 8th who cares about this other container 7 is arranged, from the heat exchanger assembly 2 be removed.

To prevent unwanted liquid leakage from the heat exchanger assembly during operation, a liquid-tight seal between the containers 7 and the corresponding head plates 5 be provided. In exemplary embodiments of 3 and 4 , is such a seal by the use of a seal 13 provided along the entire outer periphery of a corresponding top plate 5 extends and between this headstock 5 and the corresponding container 7 is compressed. The pressure load is by tabs 14 maintained along the whole Circumference of the top plate 5 arranged and deformed to a flange 16 along the entire circumference of the container 7 to be engaged. During assembly of the container 7 on the top plate 5 , a load can be applied to the container and the top plate to seal 13 to squeeze together, and the tabs 14 can be deformed to maintain the pressure load. 3 shows a plurality of such tabs 14 along the circumference of a headstock 5 before being so deformed while 4 one of the tabs 14 in a subsequent, deformed state. Such a connection is often referred to in the art as crimped connection. Such a connection may be particularly desirable when the container 7 is composed of a material that is not suitable for traditional metallurgical bonding processes, such. As welding, soldering or brazing (if the container 7 is formed for example of plastic) is suitable. In addition, other joining methods may not be suitable for many applications. By way of example only, use of bolts, screws or other threaded fasteners, including, but not limited to, in many instances is impractical if access to the fasteners is not possible if localized attachment points are not adequate for a sufficient and reliable pressure connection between the parts. if space and packaging limitations preclude the possibility of using closures and mounting holes, and / or if the use of compressed and crimped connections allows lower heat exchanger production and assembly costs.

The heat exchanger arrangement 1 further comprises a liquid intermediate container 4 that is between the first and second core units 2 is arranged. An embodiment of such an intermediate container 4 is in 5 shown in more detail. The intermediate container 4 has a first open area 15 located at a first end of the container 4 is arranged, and a second open area 15 on, at a second end of the container 4 is arranged opposite the first end. During operation, a liquid is allowed through the first open area 15 from (in relation to the liquid flow) upstream of the intermediate container 4 arranged core unit 2 in the intermediate container 4 to flow and to allow the liquid from the intermediate container 4 through the second open area 15 into a core unit 2 flow out (in relation to the liquid flow) downstream of the intermediate container 4 is arranged.

In the intermediate container 4 can ribs 17 be included. These ribs 17 can be used to reinforce the intermediate container 4 can be used in relation to loads exerted by a liquid pressure acting on the container walls, and can also provide structural support for the heat exchanger assembly 1 (eg against forces that are a core unit 2 with respect to another tending to rotate or tilt). Ribs 17 may additionally or alternatively be used to at least a back-mixing of the liquid in the intermediate container 4 to prevent. In the 5 illustrated ribs 17 are arranged so that a rib 17 between each pair of adjacent pipes 11 is arranged. In further embodiments of the invention, fewer ribs are used 17 used and in some embodiments, the ribs 17 completely removed.

The exemplary intermediate container 4 The illustrated embodiment includes first and second flanges 16 that are alike as the flange 16 of the container 7 in 4 around each of the two open spaces 15 extend. At least one of the flanges 16 of the intermediate container 4 Can be used in conjunction with a seal 13 to be used, a liquid-tight seal between the intermediate container 4 and the top plate 5 that are alongside the adjacent open area 15 is arranged to produce by generating a crimped connection, which was previously with reference to 4 has been described. Such a connection may again be particularly desirable when the intermediate container 4 is made of plastic, and also finds a special use in a variety of applications where other connection methods are not possible or unsuitable.

By such a connection of the intermediate container 4 at a core unit 2 can the intermediate container 4 advantageously within the outermost limits of the core unit described above 2 be arranged in the core stacking direction. By such an arrangement of the intermediate container can have a plurality of heat exchanger assemblies 1 are placed immediately adjacent to each other in the core stacking direction A. It also allows the use of crimp connections between the sub-tank 4 and the neighboring core units 2 (as described above) in one embodiment, a maintenance-free compressed connection that does not require screws, bolts, or other separate fasteners while still providing a strong and stable connection between the core units 2 provided.

In an alternative embodiment 101 a heat exchanger assembly according to the present invention (which is disclosed in US Pat 6 are shown) are a plurality of pairs of core units 2 immediately adjacent to one another in the core Stacking direction A arranged. Each of the pairs of core units 2 includes an intermediate container (such as the intermediate container 4 from 5 ) connected to the core units as described above, and an inlet tank and an outlet tank (such as those in the embodiment of FIG 1 illustrated container 7 ) connected to opposite ends of the pair. A structural framework 107 , the first and second end channels 102 and first and second side channels 103 is used to attach the pair of core units 2 in the heat exchanger assembly 102 used.

The structural framework 107 includes a middle rail 104 extending between the side channels 103 extends to the heat exchanger assembly 101 to reinforce. With reference to the illustrated embodiment are also exemplary fasteners 106 for fixing the middle rail 104 on the side rails 103 and securing the inlet containers and the outlet containers to the end channels 102 used. In the exemplary embodiment of 6 used fasteners 106 are threaded bolts, but it is understood that a variety of fasteners, such. As screws, rivets and the like may be equally suitable. mounting holes 9 in the intermediate tanks 4 and the inlet and outlet tanks (in 1 and 5 shown in detail) are used to receive the fasteners 106 used. In some embodiments, the fasteners extend 106 completely through the mounting holes 9 and are on the opposite surface of the heat exchanger assembly 1 attached, whereas the fasteners 106 in other embodiments directly in the mounting holes 9 be attached. The structural framework 107 can alternatively crossbars 105 have to the heat exchanger assembly 101 continue to strengthen.

By using a heat exchanger assembly as described above 1 . 101 (the at least two core units 2 having, in the form of a butt joint, as also described above, via one or more intermediate containers 4 connected), the entire heat exchanger assembly 1 . 101 have a modular nature. In particular, in some embodiments, a user may partially disassemble the system to remove it, a maintenance, a repair, and / or one or more of the pairs of core units 2 and the intermediate container 4 to be replaced on request. In some embodiments, this process may be without disassembly or removal of the other core units 2 be performed in the system.

With further reference to the heat exchanger assembly 101 from 6 For example, the liquid or the middle container and the liquid delivery tubes of a first pair of core units 2 together form, at least in part, a first fluid flow path and the center reservoir and the fluid delivery tubes of a second pair of core units 2 may at least partially define a second fluid flow path. Likewise, the center tank and the liquid delivery pipes may be a third pair of core units 2 together form at least partially a third fluid flow path. The inlet containers of at least two of the pairs of core units 2 can be joined together so that their respective liquid flow paths are parallel to each other. In some embodiments, at least one of the liquid flow paths is arranged in series with at least one other of the liquid flow paths.

A heat exchanger assembly as described above may be used as engine cooling liquid coolers for use, inter alia, in large machinery such. As agricultural, construction and mining equipment, use. In some embodiments, such a cooler is used to dissipate heat from a flow of cooling fluid passing through the tubes of the core units to an airflow that is directed over the air fins and the other surfaces of the tubes. However, it is self-evident that a heat exchanger assembly according to the present invention may also find application in other applications.

By using a heat exchanger arrangement as described above, several advantages can be realized. As an example, a highly effective brazed tube and finned core design can be used to provide a heat exchanger assembly that has a greater surface area that can be accommodated in an available brazing furnace. The heat exchanger assembly may thus be composed of compact core units that are compactly packed together with a minimum airflow or bypass. As another example, individual core sections of the heat exchanger assembly may be replaced in the event of damage without having to replace the entire heat exchanger assembly, thereby reducing repair and replacement costs.

Various alternatives to certain features and elements of the present invention have been described herein with respect to specific embodiments of the present invention. With the exception of features, elements, and operations that are mutually exclusive or inconsistent with the embodiment described above, it should be understood that the alternative features, elements, and functions described with respect to a particular embodiment are applicable to the other embodiments are.

The embodiments described above and illustrated in the figures have been presented by way of example only and are not intended to limit the concepts and principles of the present invention. One of ordinary skill in the art will recognize that various changes in the elements and their construction and arrangement are possible without departing from the spirit and scope of the present invention.

Various features and advantages of the invention are set forth in the following claims.

Claims (21)

Heat exchanger assembly comprising: a liquid container; and a pair of core units in an end-to-end arrangement, wherein the liquid container is positioned between the pair of core units and has an interior space in fluid communication therewith each of the core units comprises a plurality of air ribs that are parallel to and spaced from each other in a core stacking direction, a plurality of parallel fluid delivery tubes disposed between the plurality of air ribs and connected to adjacent ones thereof; first and second spaced apart header plates sealingly receiving first and second ends of the plurality of parallel fluid delivery tubes, and first and second side plates disposed adjacent to the outermost ones of the plurality of air ribs to define an outermost boundary of each core unit in the core stacking direction; wherein the liquid container includes a first end and a second end opposite the first end, the first end sealingly attached to one of the first and second top plates of one of the pair of core units, and the second end on one of the first and second top plates of the other is sealably mounted from the pair of core units, wherein the liquid container is disposed entirely within the outermost boundary of the at least one of the pair of core units in the core-stacking direction. A heat exchanger assembly according to claim 1, wherein the liquid container is sealingly secured to at least one of the pair of core units by crimping. The heat exchanger of claim 1, further comprising an inlet tank and / or an outlet tank sealingly attached to the other of the first and second header plates of the one of the pair of core units. A heat exchanger according to claim 3, further comprising the other of an inlet tank and / or an outlet tank, which is sealingly secured to the other of the first and second head plates of the other of the pair of core units. The heat exchanger of claim 1, further comprising a gasket positioned between the liquid container and one of the first and second top plates of the one of the pair of core units. A heat exchanger according to claim 1, wherein each core unit is a brazed aluminum core unit. Heat exchanger according to claim 1, wherein the liquid container is made of plastic. The heat exchanger assembly of claim 1, wherein the pair of core units is a first pair of core units and further comprises a second pair of core units adjacent to the first pair of core units in the core-stacking direction. The heat exchanger of claim 8, further comprising a structural frame supporting the first and second pairs of core units. The heat exchanger assembly of claim 8, wherein the liquid container is a first liquid container, the heat exchanger assembly further comprises a second liquid container, wherein the first liquid container and the plurality of parallel liquid delivery tubes of the first pair of core units together at least partially define a first liquid flow path, and wherein the second liquid container and the plurality of parallel fluid delivery tubes of the second pair of core units together at least partially define a second fluid flow path. A heat exchanger assembly according to claim 10, wherein the first and second liquid flow paths are parallel to each other with respect to a liquid passing therethrough. A heat exchanger assembly according to claim 10, wherein the first and second fluid flow paths are arranged in series with respect to a fluid passing therethrough. Heat exchanger comprising: first and second core units, each core unit having a set of substantially parallel tubes extending in one direction through the core unit, each tube having opposed first and second ends and a head connected to the first ends of the set of connected substantially parallel tubes and forms with these a liquid-tight seal; and a container disposed between the first and second core units and having opposite ends, the head of each of the first and second core units is crimped in fluid-tight engagement with a respective one of the opposite ends, the container having at least one interior in fluid communication with interior spaces of the plurality of substantially parallel tubes of the first and second core units. The heat exchanger of claim 13, wherein the heads of the first and second core units are deformed to define crimp connections with the opposite ends of the container. A heat exchanger according to claim 13, further comprising a seal which is pressed between each opposite end of the container and the corresponding head of the first and second core units The heat exchanger of claim 13, wherein the first and second core units are a pair of core units and further comprise a second pair of core units adjacent to the first pair of core units, wherein the set of substantially parallel tubes of the first pair are in substantially the same direction as the set of substantially parallel tubes extends from the second pair of core units. The heat exchanger of claim 16, further comprising a second container that extends across and connects adjacent ends of the first core units in the first and second pairs of core units. 17. The heat exchanger of claim 17, wherein the second container has an interior that provides fluid communication between the set of substantially parallel tubes of the first core units of the first and second pairs of core units. The heat exchanger of claim 13, further comprising first and second side plates disposed adjacent to outermost ones of the set of substantially parallel tubes of each of the first and second core units. The heat exchanger of claim 19, wherein the container and the first and second core units have respective widths that extend across the set of substantially parallel tubes of the first and second core units, and wherein a width of the container is not greater than the widths of the first and second Core units is. A method of servicing a heat exchanger, the method comprising: Separating a first pair of core units from a second pair of core units, the first and second pairs of core units being supported by a common frame, each of the first and second pairs of core units comprising a first core unit and a second core unit; a set of substantially parallel tubes extending in one direction through one of the first and second core units, each tube having a first end and a second end opposite thereto; a head connected to the first end of the set of substantially parallel tubes and forming a fluid-tight seal therewith; and a container disposed between the first core unit and the second core unit, the container having opposite ends each attached in fluid-tight engagement with a respective head of the first and second core units, the container having at least one interior space in fluid communication with interior spaces from the plurality of substantially parallel tubes; Terminating the fluid communication between the set of substantially parallel tubes of the first pair of core units and the set of substantially parallel tubes of the second pair of core units by separating the first pair of core units from the second pair of core units; and Removing the first pair of core units from the frame leaving the second pair of core units in place in the frame.

Images