Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
  • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
  • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
  • F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
  • F28D1/0535—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight the conduits having a non-circular cross-section
  • F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F1/00—Tubular elements; Assemblies of tubular elements
  • F28F1/02—Tubular elements of cross-section which is non-circular
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0084—Condensers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0085—Evaporators
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0089—Oil coolers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0091—Radiators
  • F28D2021/0094—Radiators for recooling the engine coolant
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F1/00—Tubular elements; Assemblies of tubular elements
  • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
  • F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
  • F28F1/126—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins

Definitions

• the present teachings generally relate to heat exchangers.
• the present teachings relate to cooling systems for internal combustion engines.
• a conventional radiator cools an internal combustion engine by passing a coolant through the engine block where it is heated.
• the coolant is fed into an inlet tank of the radiator which distributes the coolant through radiator tubes to an outlet tank.
• An airflow pulled by a cooling fan circulates across the radiator using the air to extract heat from the radiator and transfer it to the atmosphere.
• the colder coolant is fed back to the engine and the cycle repeats.
• the coolant is usually water-based, with addition of glycol to prevent freezing and other additives to limit corrosion.
• radiators Because air has a lower heat capacity and density than liquid coolants, a fairly large volume flow rate must pass through the radiator core to sufficiently extract heat from the coolant. Radiators have one or more fans that draw air through the radiator. To save fan power consumption in vehicles, radiators are often behind the grille at the front end of a vehicle. Ram air provides a portion of the necessary cooling air flow.
• the channels of the plurality of channels are operative for directing a flow of air through the core such that a flow of air enters a front face of the core in a first direction and exits the core in a different direction.
• the change of direction causes air turbulence and direct impingement of the air upon the core, resulting in a substantially higher heat transfer efficiency.
• the change of direction is achieved by tubes made with a non-straight shape, in some cases shaped like a V, or like a curve, or other non-straight shapes.
• FIG. 5 is a simplified front view of another heat exchanger constructed in accordance with the present teachings.
• FIG 8 is a simplified front view of another heat exchanger constructed in accordance with the present teachings.
• Figure 9 is a simplified side view of the heat exchanger of
• Figure 1 1 is a side view similar to Figure 10, illustrating the fin after shaping to conform with the tubes.
• Figure 13 illustrates the general steps of a method of manufacturing a fin in accordance with the present teachings.
• Figure 14 is a top view of a metal strip for making a fin in accordance with the method of the present teachings.
• Figure 15 is a top view of the metal strip of Figure 14 after stamping.
• Figure 16 is a simplified prior art view illustrating airflow through a typical heat exchanger.
• Figure 17 is a simplified view illustrating airflow through a heat exchanger constructed in accordance with the present teachings to include angled tubes.
• Figure 18 is a simplified view similar to Figure 17 illustrating a "cloud" of air molecules that may form on a front side of the heat exchanger.
• Figure 19 is another simplified view illustrating airflow through a heat exchanger constructed in accordance with the present teachings to include angled tubes.
• Figure 20 is another simplified view illustrating airflow through a heat exchanger constructed in accordance with the present teachings to include angled tubes. In the embodiment illustrated, the angling of the tubes is achieved through a gradual curve shape.
• Figure 23 is a simplified front view of another heat exchanger in accordance with the present teachings.
• Figure 24 is a simplified top view of the heat exchanger of Figure 23.
• Figure 26 is a simplified top view of the heat exchanger of Figure 25.
• Figure 2 uses an engine-mounted cooling fan configuration as an example. This configuration is typically used for trucks. An alternative configuration would be a radiator-mounted electric fan assembly, which is typically used in passenger cars. It will be understood that the present teachings apply to both of these possible configurations.
• a shroud 14 is positioned between the heat exchanger 10 and the engine/transmission 12.
• the shroud 14 functions to collect and direct air passing through the heat exchanger 10 toward a fan assembly 18.
• the shroud 14 conventionally tapers from a front side to a rear side.
• the fan assembly 18 operates to draw air through the heat exchanger 10.
• the fan assembly includes a fan drive 20 driven by a shaft 22 extending from the engine 12.
• the fan drive 20 holds and drives the fan24.
• air molecules are impinged against the fan drive 20 and the root of the fan blade hub. This impingement creates a boundary layer of stagnant air that may impede or constrain the flow of air 16 through the heat exchanger 10.
• the heat exchanger 10 is illustrated to generally include first and second tanks 26 and 28 and a core 29.
• the core 29 includes a plurality of tubes 30 and a plurality of fins 32.
• the first tank 26 receives a medium to be cooled from the engine/transmission 12 in the direction of arrow A.
• the medium may be coolant.
• the medium to be cooled enters the first tank 26 through an input port 34.
• the second tank 28 defines an output port 36 through which cooled medium is directed to the engine/transmission 12 in the direction of arrow B.
• the plurality of tubes 30 extends between the first and second tanks 26 and 28.
• the tubes 30 fluidly connect the first and second tanks 26 and 28 for transferring the medium to be cooled there between.
• the tubes 30 are oriented horizontally between the vertically oriented header tanks 26 and 28.
• the tubes are in direct contact with the coolant and therefore serve as the primary structure for removing heat from the coolant.
• the fins 32 and tubes 30 cooperate to generally direct the air 16 through the heat exchanger 10 such that a flow of air enters a front face of the core 29 in a first direction (i.e., in the direction indicated by the arrow associated with reference character 16) and is biased in at least a second direction.
• the airflow may be generally directed toward an imaginary plane 40.
• the plane 40 may be parallel to the direction 16.
• the plane 40 toward which the air 16 is generally directed is horizontally oriented and intersects the fan drive 20.
• the plane 40 toward which the air 16 is directed may be horizontally oriented.
• the first and second groups of air channels 42 and 44 both generally converge toward the first imaginary plane 40 as the air channels 42 and 44 extend from a front side 46 of the heat exchanger 10 to a rear side 48 of the heat exchanger 10.
• the geometry of the tubes 30 serves to generally converge the flow of air toward the plane 40.
• the configuration of the fins may generally converge the flow of air toward a plane.
• air 16 enters the front side 46 of the heat exchanger 10 in a direction generally perpendicular thereto.
• the angled channels 42 and 44 function to increase contact between the air 16 and the tubes 30 and further function to generally direct the flow of the air 16 toward the plane 40.
• turbulence is created to break away the thermal boundary layer of air molecules adjacent the fan drive 20.
• heat transfer and thus heat dissipation
• Fan performance may be improved as turbulent air is pulled along the roots of the radial flow fan blades.
• FIG. 5-7 another heat exchanger constructed in accordance with the present teachings is illustrated and identified at reference character 10'.
• the heat exchanger 10' differs from the heat exchanger 10 in that the flow of air 16 is generally directed toward a first plane 40' that is vertically oriented and that the geometries of the fins 32 function to generally divert the flow of air 16. Given the similarities between the heat exchangers 10 and 10', like reference characters will be used to identify similar elements.
• the plane 40' generally bisects the core 29 of the heat exchanger 10' in a vertical direction.
• a first group of channels 42' defined by the plurality of fins 32 and plurality of tubes 30 are disposed on a first side of the plane 40' (i.e., to the left of the plane 40 as illustrated in Figure 1 ).
• a second group of channels 44' defined by the plurality of fins 32 and the plurality of tubes 30 are disposed on a second, opposite side of the plane 40' (i.e., to the right as illustrated in Figure 1 ).
• the channels 42 and 44 defined by the fins 32 and tubes 30 linearly converge toward plane 40'.
• the channels 42 and 44 may non-linearly converge in alternative embodiments. Any fin shape suitable for generally directing the air 40' toward the plane 40' may be utilized within the scope of the present teachings.
• air 16 enters the front side 46 of the heat exchanger 10 in a direction generally perpendicular thereto.
• the angled channels 42 and 44 function to increase contact between the fins 32 and further function to generally direct the flow of the air 16 toward the plane 40'.
• turbulence is created to break away the thermal boundary layer of air molecules adjacent the fan drive 20.
• a third group of channels 106 is disposed on a first side of the first plane 40 and on a second side of the second plane 102 (i.e., below the plane 1 10 in Figure 4).
• a fourth group of channels 108 is disposed on the second side of the first plane 40 (i.e., to the right of plane 40 in Figure 4) and on the second side of the second plane 102.
• the first, second, third, and fourth groups of channels 102- 108 all converge toward the plane 40 as the channels extend from the front side 46 of the heat exchanger 100 to the rear side 48 of the heat exchanger 100.
• FIG. 12 Another side view of a fin 210 in accordance with the present teachings is illustrated.
• This fin 210 may be used with such an alternative arrangement in which the tubes define a lead-in.
• the fin 210 differs from the fin 32 discussed above in that the fin 210 includes three generally planar segments.
• a method of manufacturing the fin 210 in accordance with the present teachings will be described below with reference to Figure 13.
• a metal strip 214 is provided having a length I and a width w.
• the metal strip is illustrated in Figure 9.
• the stamped metal strip 214 is pleated to define a plurality of fold lines perpendicular to the length I of the metal strip 214.
• the step of pleating may be carried out in a conventional manner with rollers.
• a first portion 220 of the metal strip 214 is bent relative to a second portion 222 of the metal strip 214 about the first hinge axis.
• the reduced material between adjacent slots facilitates bending of the metal strip 214 about the first hinge axis.
• a third portion 224 is bent relative to the second portion 222 about the second hinge axis.
• the reduced material between adjacent diamond shaped openings facilitates bending of the metal strip 214.
• the openings permit downward bending of the third portion 224 (as shown in Figure 7).
• the present teachings provide a heat exchanger with features that can individually or in combination provide a significant increase in heat transfer performance. Such an increase in thermal performance can be used to design a heat exchanger with reduced frontal area, radiator thickness, weight, and cost. Additionally or alternatively, a smaller fan drive may be utilized and/or a smaller fan may be used. Smaller components may provide for improved styling flexibility.
• the angled tube heat exchanger of the present teachings seeks to enhance heat exchange by making the airflow through a heat exchanger non-straight by shaping the tubes 30 in a way that the air paths through the heat exchanger force the air to impinge on the heat exchange areas of the heat exchanger (fins and tubes) as opposed to just flow mostly parallel to these heat exchange areas.
• Figure 16 shows that in a conventional heat exchanger the air molecules 300 have a very low probability of actually touching the tubes 30. Most of the airflow can go relatively undisturbed between the tubes 30 and the fins 32 of the core. This situation creates inefficient heat transfer.
• Figure 17 shows that by slanting the tubes 30 by a certain angle, an angled airflow path is created that forces the air molecules 300 to collide against the tubes 30 and the fins 32 of the channels, destroying laminar flow boundaries, bouncing around and creating turbulence that enhances heat transfer.
• the arrow 302 shows the direction of travel of the vehicle.
• Figure 18 illustrates an unintended consequence: a "cloud" 304 of air molecules forms in front of the vehicle because of air molecules being bounced back by the movement of the vehicle when they collide against the radiator. Not all molecules are bounced in an angle toward the inside of the radiator. Many molecules are just thrown back out of the radiator, creating the cloud of air molecules 304, which represents an obstacle to the air getting into the radiator. The vehicle pushes this cloud in front of it, which is undesirable because it acts like a brake on the vehicle and also makes it harder for air to enter the radiator, increasing the pressure drop across the radiator.
• Figures 21 and 22 illustrate another embodiment of the present invention.
• all the tubes 30 have the same angle. Therefore, the airflow is deflected laterally which is desirable in some situations. In other situations it may be desirable to orient the airflow toward the center of the cooling fan (instead of a laterally shift of the airflow). In all those cases, the angled tube heat exchanger allows a degree of airflow management heretofore not available.
• FIGs 23 and 24 illustrate a radiator in accordance with the present teachings that has two portions, each with tubes 30 oriented in opposite directions. Therefore, one portion of the radiator deflects the air toward the right side, while the other portion deflects the air toward the left side. The result is a focused and centered airflow, which can substantially increase the efficiency of the cooling fan.
• Figures 25 and 26 illustrate another radiator in accordance with the present teachings. In this embodiment, the radiator includes four sections. Two of the sections center the airflow in horizontal direction, while the two other sections orient the airflow in vertical direction. The result is airflow focused on the fan from all directions, which further increases fan efficiency.
• the tube angle does not have to be constant. This figure shows a variable angle, with the angle almost zero near the center and becoming much more larger in the periphery. This variable tube geometry may achieve an even better focusing of the airflow.
• the radiator has a circular shape to closely match the shape of the cooling fan.
• the core of the radiator may be constructed to include any of the angled tube and/or angled fin constructions discussed above.
• the inlet and outlet tubes are curved.
• the length of the tubes has a maximum dimension at a horizontal center of the radiator and decreases in both upper and lower directions.

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• Engineering & Computer Science (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Geometry (AREA)
• Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Applications Claiming Priority (2)

Publications (2)

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ID=49783733

Family Applications (1)

Country Status (3)

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• 2013
  • 2013-03-29 CA CA2879828A patent/CA2879828A1/en not_active Abandoned
  • 2013-03-29 WO PCT/US2013/034535 patent/WO2014003865A1/en not_active Ceased
  • 2013-03-29 EP EP13808627.7A patent/EP2906896A4/de not_active Withdrawn

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