EP4317896A1

EP4317896A1 - A tank assembly

Info

Publication number: EP4317896A1
Application number: EP22188338.2A
Authority: EP
Inventors: Jiri Volf; Jan Forst; Jakub JIRSA; Lukas BERANEK
Original assignee: Valeo Systemes Thermiques SAS
Current assignee: Valeo Systemes Thermiques SAS
Priority date: 2022-08-02
Filing date: 2022-08-02
Publication date: 2024-02-07

Abstract

A tank assembly (100) includes a tank cover (10) and a tank header (20). The tank cover (10) includes first channels (10a) and (10b). The tank header (20) includes portions (20a) and (20b) that in conjunction with the first set of channels (10a) and (10b) defines a first and a second manifold (30a) and (30b). The tank header (20) includes apertures (22a) and (22b) that receive the corresponding first set of tubular elements (42a) and second set of tubular elements (42b). At least one of an intermediate plate (60) and an end cover (70) orthogonally assembled with respect to longitudinal axis of the first and second manifolds (30a) and (30b) forms a connection system (80). The connection system (80) formed with an inlet (50a), an outlet (50b) and fluid flow passages (30c) and (30d) configuring fluid communication between the inlet (50a) and the outlet (50b) and the respective first and second manifolds (30a) and (30b).

Description

The present invention relates to a tank assembly. In particular, the present invention relates to a tank assembly for a vehicle heat exchanger.
Generally, a vehicle heat exchanger,i such as for example, an inner condenser. The inner condenser is a heat exchanger used in the heat pump systems for electric vehicles. It may be used for the heating of the passenger cabin and this heating system allows to prolong the driving distance of the electric vehicle. The inner condenser may use tetrafluoropropene (R1234yf) as refrigerant. The heat exchanger includes tank assemblies configuring a first manifold and a second manifold disposed on opposite sides of a heat exchanger core defined by tubular elements separated by fins. The tubular elements configure fluid communication between the first manifold and the second manifold. Separate connection conduits connected to the first manifold and the second manifold respectively supply heat exchange fluid to and collect heat exchange fluid therefrom. However, such configuration of the heat exchanger with connection conduits faces packaging, connection, routing issues, as the connection conduits are disposed on both sides of the heat exchanger.
To address the above issues, prior art suggests a heat exchanger 1, for example, a condenser for a vehicle that includes a tank assembly, a heat exchanger core 4 and a connector block 6 as illustrated in FIG. 1. The tank assembly includes a tank cover 2 and a tank header 3. The tank cover 2 includes channels 2a and 2b formed thereon that are longitudinally extending along length of the tank cover 2. The tank header 3 includes portions with apertures formed thereon. The tank cover 2 and the tank header 3 are assembled together by crimping and brazing so that the channels 2a and 2b of the tank cover 2 aligned to and in conjunction with the corresponding tank header portions define a first manifold, particularly, an inlet manifold and a second manifold, particularly, an outlet manifold. The first manifold and the second manifold are disposed on same side of the heat exchanger core 4. The heat exchanger core 4 includes tubular elements 4a separated by fins 5a. The first set of adjacent tubular elements 4a are separated by first set of fins 5a whereas the second set of adjacent tubular elements are separated by second set of fins. For ingress of the first heat exchange fluid into the heat exchanger 1, the first manifold is supplied heat exchange fluid from an inlet port 6a of the connector block 6 via by an inlet conduit 7a. For egress of the first heat exchange fluid from the heat exchanger after heat exchange with air surrounding the tubular elements 4a while passing through the tubular elements 4a, the second manifold delivers the first heat exchange fluid to an outlet port 6b of the connector block 6 via an outlet conduit 7b. Further, the tubular elements 4a are divided into a first set of tubular elements 4a and a second set of tubular elements that are disposed adjacent to each other, wherein the second set of tubular elements are disposed behind the first set of tubular elements 4a, more specifically, downstream of the first set of tubular elements in second flow direction. The first set of tubular elements 4a and the second set of tubular element are interconnected and in fluid communication with each other via an intermediate manifold 2c to define a first pass and a second pass respectively. Also, the connector block 6 with the inlet port 6a and the outlet port 6b is disposed proximal to the first and second manifolds. Accordingly, shorter lengths of inlet and outlet conduits 7a and 7b can be used for configuring fluid communication between the inlet port 6a and the first manifold and between the second manifold and the outlet port 6b respectively. The first manifold distributes the heat exchange fluid received thereby to the first set of tubular elements 4a. The heat exchange fluid undergoes heat exchange with a second heat exchange fluid, particularly, air around the first set of tubular elements 4a as the first heat exchange fluid flows through the first set of tubular elements 4a. The second set of tubular elements receive the heat exchange fluid from the first set of tubular elements 4a via the intermediate manifold 2c configuring fluid communication between the tubular elements 4a, and the second heat exchange fluid undergoes further heat exchange as it passes through the second set of tubular elements. The second manifold collects the first heat exchange fluid from the second tubular elements, after the first heat exchange fluid had rejected heat to the air flowing across the tubular elements as it passes through the tubular elements. The second manifold delivers the first heat exchange fluid collected thereby to the outlet conduit 7b for egress of the first heat exchange fluid from the heat exchanger 1 via the outlet port 6b. The first set of tubular elements 4a are separated by first set of fins 5a disposed there-between and the second set of tubular elements are separated by second set of fins disposed there-between. The fins retard flow of the second heat exchange fluid, particularly, the air outside the tubular elements to improve the heat exchange between the heat exchange fluid flowing inside and air flowing outside the tubular elements.
The connector block 6 with the inlet port 6a and the outlet port 6b for ingress and egress of fluid with respect to the heat exchanger 1 is generally mounted on a vehicle frame proximal to the first and second manifolds. The inlet and outlet conduits 7a and 7b configures fluid communication between the inlet port 6a and the first manifold and between the second manifold and the outlet port 6b respectively. However, use of inlet and outlet conduits 7a and 7b involves routing of the connecting inlet and outlet conduits 7a and 7b in limited space, particularly, in areas proximal to the lateral side of the heat exchanger 1. Moreover, the inlet an outlet conduits 7a and 7b inherently cause an unutilized space "X" along lateral side of the heat exchanger 1. The inlet and outlet conduits 7a and 7b and connections thereof with manifolds on one side and with the connector block 6 on the other side cause packaging issues and pressure losses due to length of the inlet and outlet conduits 7a and 7b and bends in the inlet and outlet conduits 7a and 7b.
Accordingly, there is a need of a tank assembly for a heat exchanger that eliminates connection conduits and renders the heat exchanger compact and addresses the packaging issues, particularly, along lateral sides of the heat exchanger and longitudinal direction of the first and second manifolds. Further, there is a need of a tank assembly for a heat exchanger that eliminates inlet and outlet conduits, thereby preventing problems such as energy losses and pressure drop between the inlet / outlet ports and corresponding first / second manifolds due to lengthy inlet and outlet connection conduits and bends in the inlet and outlet connection conduits. Further, there is a need for a tank assembly for a heat exchanger that improves efficiency and reliability of the heat exchanger by preventing fluid flow losses by eliminating connection conduits. There is a need of a tank assembly for a heat exchanger that reduces the number of parts, thereby reducing maintenance and enhancing reliability of the heat exchanger.
An object of the present invention is to obviate the problems associated with conventional tank assembly for heat exchanger that requires inlet and outlet connection conduits.
Another object of the present invention is that the tank assembly renders the heat exchanger compact and addresses the packaging issues, particularly, along lateral sides of the heat exchanger and longitudinal direction of the first and second manifolds.
Yet another object of the present invention is to provide a tank assembly for a heat exchanger that improves efficiency of the heat exchanger by reducing the pressure losses by eliminating the connection conduits.
In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

SUMMARY OF THE INVENTION

A tank assembly for a heat exchanger is disclosed in accordance with an embodiment of the present invention includes an axis of elongation. The tank assembly further includes a tank cover and a tank header. The tank cover extends along the axis of elongation of the tank assembly and is formed with first set of channels. The tank header includes portions that in conjunction with the first set of channels formed on tank cover defines a first manifold and a second manifold, when the tank header and the tank cover are aligned and assembled with respect to each other. The tank header further includes apertures configured on the respective portions thereof. At least one of an intermediate plate and an end cover is orthogonally assembled with respect to longitudinal axis of the first and second manifolds to form a connection system. The connection system is formed with an inlet, an outlet and fluid flow passages configuring fluid communication between the inlet and the outlet and the respective first and second manifolds.
Preferably, the intermediate plate in conjunction with the end cover when assembled together define a first fluid flow passage and a second fluid flow passage. The first fluid flow passage defines fluid flow trajectory and fluid communication between the inlet and the first manifold. The second fluid flow passage defines fluid flow trajectory and fluid communication between the second manifold and the outlet.
Generally, the first set of channels longitudinally extend along the length of the tank cover to free end thereof to define a first set of concave profiles at free end thereof. Further, the tank header includes extension portions with a second set of concave profiles at the free end thereof. The profiles of the second set of concave profiles at free end thereof, the profiles of the second set of concave profiles being complementary to the respective profiles of the first set of concave profiles.
Generally, the extension portions with the second set of concave profiles are integrally formed with the header, whereas the first set of profiles are inherently formed at the free end of the respective first channels integrally formed with the tank cover.
Particularly, the first set of concave profiles get aligned to the second set of concave profiles to define respective manifold inlet and outlet as the tank cover is assembled to the tank header.
Generally, the intermediate plate is of rectangular configuration and includes a first set of sleeves, a third set of concave profiles and either one of tabs and notches. The first set of sleeves disposed along a first side thereof being aligned to receive and hold respective manifold inlet and outlet. The third set of concave profiles are configured along a second side orthogonal to the first side. Either one of tabs and notches formed on the sides thereof for configuring crimping connection with the heat exchanger core.
Further, the end cover includes a second set of channels and either one of tabs and notches. The second set of channels are spaced apart from each other and emanating from portions of the end cover corresponding to and aligned with sleeves formed on the intermediate plate and extending along plane of the end cover to one side of the end cover for configuring fourth set of concave profiles. Either one of tabs and notches for configuring crimping connection with the heat exchanger core. As the end cover is assembled to the intermediate cover, the fourth set of concave profiles get aligned with the third set of concave profiles and are held together within a second set of sleeves to define the inlet and outlet respectively.
Still further, the second set of channels form fluid flow passages when the end cover is assembled to the intermediate cover. Particularly, the first fluid flow passage configures fluid communication between the inlet and the corresponding first manifold and the second fluid flow passage configures fluid communication between the second manifold and the outlet.
The inlet and the outlet are disposed along an axis extending orthogonally to the longitudinal axis of the first and second manifold and the longitudinal axis of the tubular elements, either one of the inlet and outlet is disposed underneath the other.
Generally, the first set of channels are separated by a first intermediate gap.
Further, the second set of channels are separated by a second intermediate gap.
In accordance with an embodiment, at least a portion of the second set of channels about the diameter is formed on the intermediate plate.
Preferably, at least one channel of the second set of channels follows a curved profile while the other follows a straight profile.
Generally, the inlet and outlet are symmetrical about a plane passing through center of the second intermediate gap at extreme end of the second intermediate gap.
Alternatively, the inlet and outlet are asymmetrical about a plane passing through center of the second intermediate gap at extreme end of the second intermediate gap.
Particularly, the first and second fluid flow passages are of varying cross section along the length thereof.
In accordance with an embodiment of the present invention, substantial portions of the channels of the second set of channels are parallel to each other with substantial portion of one channel being disposed underneath the other and the outlet being disposed underneath the inlet.
A heat exchanger is disclosed in accordance with an embodiment of the present invention. The head exchanger includes a heat exchanger core, a tank assembly, an intermediate manifold and at least one of an intermediate plate and an end cover forming a connection system. The heat exchanger core includes a first set of tubular elements and a second set of tubular element disposed adjacent to the first set of tubular elements and respectively defining a first pass and a second pass. The tank assembly is as disclosed above and forms a first manifold and a second manifold disposed on same side of the heat exchanger core. The first manifold delivers fluid to the first set of tubular elements and the second manifold collects fluid from the second set of tubular elements after the fluid had undergone heat exchange while passing through the first and the second set of tubular elements. At least one of an intermediate plate and an end cover orthogonally assembled with respect to longitudinal axis of the first and second manifolds to form the connection system. The connection system is formed with an inlet, an outlet and fluid flow passages. The first fluid flow passage configures fluid communication between the inlet and the first manifold and the second fluid flow passage configures fluid communication between the second manifold and the outlet. The intermediate manifold configures fluid communication between the first set of tubular elements and the second set of tubular elements to define U-flow trajectory of the fluid there-between to enable configuring of the first and second manifolds on the same side of the heat exchanger core.

BRIEF DESCRIPTION OF DRAWINGS

Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

FIG. 1 illustrates an isometric view of a conventional tank assembly for heat exchanger forming first and second manifolds, wherein a separate connector block is connected to and in fluid communication with the manifolds by means of inlet an outlet conduits;
FIG. 2 illustrates a front view of the conventional tank assembly, depicting unutilized space "X" inherently created at the lateral side of the heat exchanger core because of the inlet and outlet conduits;
FIG. 3 illustrates an exploded view of a heat exchanger configured with a tank assembly of the present invention along with a connection system;
FIG. 4 illustrates another isometric view of the heat exchanger of FIG. 3;
FIG. 5 illustrates an isometric view of the tank assembly of the FIG. 3 in an assembled configuration;
FIG. 6 illustrates an isometric view of a tank cover of the tank assembly of FIG. 5;
FIG. 7 illustrates an isometric view of a tank header of the tank assembly of FIG. 5;
FIG. 8 illustrates a front view of the tank assembly of FIG. 5;
FIG. 9 illustrates a cross sectional view of the tank assembly of the FIG. 8 along a sectional plane A-A' passing through a crimping tab disposed between adjacent apertures formed on the tank header;
FIG. 10a - 10d illustrate different views of the connection system formed by orthogonally assembling an intermediate plate and a cover plate with respect to longitudinal axis of the first and second manifolds;
FIG. 11 illustrates an isometric view of an intermediate plate forming a part of the connection system of FIG 10a;
FIG. 12 illustrates an isometric view of a cover plate forming a part of the connection system of FIG. 10a: and
FIG. 13 illustrates another isometric view of the cover plate of FIG. 12.

DETAILED DESCRIPTION

The present invention envisages a tank assembly for a vehicle heat exchanger. The tank assembly includes a tank cover and a tank header. The tank cover separately covers two separate sections of the tank header formed with individual apertures, thereby configuring a first manifold and a second manifold on same side of the heat exchanger to render the heat exchanger compact. Further, the heat exchanger includes a connection system to avoid connection conduits, thereby rendering further compactness to the heat exchanger, particularly, along the lateral side thereof. Specifically, the tank cover and the tank header are assembled to configure the manifolds formed with a manifold inlet and a manifold outlet. The tank header and the tank cover aligned with respect to the heat exchanger core are secured to each other by crimping and brazing to configure the manifolds with the manifold inlet and the manifold outlet. Further at least one of an intermediate plate and an end cover is orthogonally assembled with respect to longitudinal axis of the first and second manifolds to form the connection system. The connection system is formed with an inlet, an outlet and fluid flow passages. The first flow passage configures a curved fluid flow trajectory and fluid communication between the inlet and the first manifold. The second fluid flow passage also configures flow trajectory and fluid communication between the second manifold and the outlet. Accordingly, the inlet and the outlet extend orthogonally to the longitudinal axis of the manifold and the longitudinal axis of the tubular elements, wherein either one of the inlet and outlet is disposed underneath the other, thereby rendering the heat exchanger compact, particularly, along longitudinal side of the manifolds, thereby addressing packaging issues. Such configuration of fluid flow passages avoids inlet and outlet conduits and packaging, connection and routing issues faced due to the inlet and outlet conduits. Although, the present invention is explained in the forthcoming description and accompanying drawings with example of tank assembly for a condenser for use in vehicle air conditioning, however, the tank assembly of the present invention is also applicable in any other heat exchanger used in vehicular or non-vehicular applications, where the first and the second manifold are required to be on same side of the heat exchanger and the heat exchanger is required to be compact, particularly, along longitudinal side of the manifold by eliminating connection conduits to address packaging issues.
A tank assembly 100 configured on a vehicle heat exchanger 200, particularly, an air-conditioning gas cooler, condenser, gas cooler or evaporator is disclosed. FIG. 3 illustrates an exploded view of the vehicle heat exchanger 200, hereinafter simply referred to as heat exchanger 200 configured with the tank assembly 100 of the present invention along with a connection system 80. FIG. 4 illustrates another isometric view of the heat exchanger 200 configured with the tank assembly 100 of the present invention.
Referring to the FIG. 5, the tank assembly 100 includes an axis of elongation. The tank assembly 100 incudes a tank cover 10 as illustrated in FIG. 6 and a tank header 20 as illustrated in FIG. 7. The tank cover 10 extends along the axis of extension of the tank assembly 100 and is formed with longitudinally extending first set of channels 10a and 10b. The first set of channels 10a and 10b longitudinally extend along the length of the tank cover 10 to free end thereof to define a first set of concave profiles 12a and 12b at free end thereof. The first set of channels 10a and 10b are separated by a first intermediate gap 10c. The intermediate gap 10c provides thermal insulation between fluid flowing through the respective channels of the first set of channel 10a and 10b.
Further, referring to the FIG. 7, the tank header 20 includes portions 20a and 20b disposed along opposite longitudinal sides of the tank header 20. The portions 20a and 20b in conjunction with the first set of channels 10a and 10b formed on the tank cover 10 define a first manifold 30a and a second manifold 30b when the tank header 20 and the tank cover 10 are assembled with respect to each other as illustrated in FIG. 5. FIG. 8 also depicts the side view of the tank assembly 100. The first and the second manifolds 30a and 30b are depicted in the sectional view of the tank assembly 100 depicted in the FIG. 9. The first and the second manifolds 30a and 30b are disposed side by side to each other and on one side of a heat exchanger core 40 of the heat exchanger 200. Generally, the tank cover 10 and the tank header 20 are secured to each other by crimping and brazing. Particularly, the first set of channels 10a and 10b of the tank cover 10 and the portions 20a and 20b of the tank header 20 aligned with respect to the heat exchanger core 40 and secured to each other configure the manifolds 30a and 30b. More specifically, at least one of the tank cover 10 and the tank header 20 forming the manifolds 30a and 30b is formed with tabs 24 disposed along longitudinal sides thereof to configure crimping connection between the tank cover 10 and the tank header 20. The tank cover 10 and the tank header 20 forming the manifolds are further secured to each other by brazing. However, the tank cover 10 and the tank header 20 can be secured to each other by any other means that can form secure connection between the tank cover 10 and the tank header 20.
The tank header 20 includes a second set of concave profiles 26a and 26b at the free end thereof. The profiles of the second set of concave profiles 26a and 26b being complementary to the respective profiles of the first set of concave profiles 12a and 12b. Particularly, the tank header 20 includes the extension portions 23a and 23b with the second set of concave profiles 26a and 26b are integrally formed with the header 20. The extension portions are extending beyond the heat exchanger core. Whereas the first set of profiles 12a and 12b are inherently formed at the free end of the respective first channels 10a and 10b integrally formed with the tank cover 10. As the tank cover 10 is assembled to the tank header 20, the first set of concave profiles 12a and 12b get aligned to the second set of concave profiles 26a and 26b as the free end of the respective first channels 10a and 10b are aligned to the extension portions 23a and 23b to define respective manifold inlet and outlet 32a and 32b as illustrated in FIG. 5. The manifold inlet 32a is for ingress of fluid into the first manifold 30a and the manifold outlet 32b is for egress of fluid from the second manifold 30b. The tank header 20 further includes apertures 22a and 22b configured on the respective portions 20a and 20b thereof. The apertures 22a and 22b receive respective tubular elements 42a and 42b of the heat exchanger core 40 therein to configure fluid communication between the first manifold 30a and the first set of tubular elements 42a and fluid communication between the second set of tubular elements 42b and the second manifold 30b,
Such configuration of the heat exchanger 200 with the first manifold 30a and the second manifold 30b disposed adjacent to each other and on same side of the heat exchanger core 40 provides certain advantages. For example, such configuration renders the heat exchanger 200 compact and addresses the packaging issues, connection issues and prevents clutter due to manifolds being disposed on opposite sides and connection conduits connected to opposite sides of the heat exchanger core. However, such configuration requires the heat exchange fluid entering the heat exchanger to follow a U-turn trajectory within the heat exchanger core 40 that is achieved by providing the first and second set tubular elements 42a and 42b disposed side by side and an intermediate manifold 30e configuring fluid communication between the first and the second set of tubular elements 42a and 42b. More specifically, the intermediate manifold 30e interconnects and configures fluid communication between the first set of tubular elements 42a defining the first pass and the second set of tubular elements 42b defining the second pass or return pass.
At least one of an intermediate plate 60 and an end cover 70 is orthogonally assembled with respect to longitudinal axis of the first and second manifolds 30a and 30b to form the connection system 80 as illustrated in FIG. 10a-10d. The connection system 80 is formed with an inlet 50a, an outlet 50b and fluid flow passages 30c and 30d configuring fluid communication between the inlet and the outlet 50a and 50b and the respective first and second manifolds 30a and 30b. The connection system 80 can be configured by the intermediate plate 60 alone, the end cover 70 alone or by assembling together the intermediate plate 60 and the end cover 70.
According to a preferred embodiment as illustrated in FIG. 3 and FIG. 10a-10d, the intermediate plate 60 in conjunction with the end cover 70 when assembled together form the connection system 80. The connection system 80 is formed with the inlet 50a, the outlet 50b, the first fluid passage 30c and the second fluid flow passage 30d. The first fluid flow passage 30c defines fluid flow trajectory and fluid communication between the inlet 50a and the first manifold 30a, whereas the second fluid flow passage 30d defines fluid flow trajectory and fluid communication between the second manifold 30b and the outlet 50b. With the intermediate plate 60 and the end cover 70 forming the connection system 80, the need for connection conduits is eliminated and pressure losses are avoided, thereby improving the efficiency and performance of the heat exchanger 200. Further, with the elimination of the connection conduits, compactness of the heat exchanger 200 is achieved. With compact configuration of the heat exchanger of the present invention, more number of heat exchange tubes can be configured in same space occupied by the conventional heat exchanger, thereby improving the heat exchange capacity of the heat exchanger 200 of the present invention compared to the conventional heat exchanger.
In accordance with an embodiment of the present invention, the intermediate plate 60 is of rectangular configuration and includes a first set of sleeves 62a and 62b, a third set of concave profiles 64a and 64b and either one of tabs and notches 66 as illustrated in FIG. 11. The first set of sleeves 62a and 62b are disposed along a first side of the intermediate plate 60. The intermediate plate 60 is so positioned with respect to the manifolds 30a and 30b that the first set of sleeves 62a and 62b are aligned to receive and hold respective manifold inlet 32a and outlet 32b. The third set of concave profiles 64a and 64b are configured along a second side of the intermediate plate 60 orthogonal to the first side. Either one of tabs and notches 66 are formed on the sides of the intermediate plate 60 for configuring crimping connection of the intermediate plate 60 with the heat exchanger core 40.
Further, the end cover 70 includes a second set of channels 70a and 70b and either one of tabs and notches 76. The second set of channels 70a and 70b are spaced apart from each other and emanating from portions of the end cover 70 corresponding to and aligned with first set of sleeves 62a and 62b formed on the intermediate plate 60. The second set of channels 70a and 70b extend along the plane of the end cover 70 to one side of the end cover 70 for configuring a fourth set of concave profiles 74a and 74b. Either one of tabs and notches 76 formed on the sides of the end cover 70 for configuring crimping connection with the heat exchanger core 40. The end cover 70 is secured to the heat exchanger core 40 with the intermediate plate 60 disposed between the end cover 70 and the manifolds 30a and 30b. As the end cover 70 is assembled with respect to the intermediate plate 60, the fourth set of concave profiles 74a and 74b get aligned with the third set of concave profiles 64a and 64b and are held together within a second set of sleeves 72a and 72b to define the inlet and outlet 50a and 50b respectively. Still further, in the aligned and assembled configuration of the intermediate plate 60 and the end cover 70, the second set of channels 70a and 70b form the fluid flow passages 30c and 30d along the plane of the end plate 70. The first fluid flow passage 30c configures fluid communication between the inlet 50a and the first manifold 30a and the second fluid flow passage 30d configures fluid communication between the second manifold 30b and outlet 50b. The first and second fluid flow passages 30c and 30d are of varying cross section along the length thereof. Alternatively, cross section of the first and second fluid flow passages 30c and 30d is uniform along the length thereof. The channels of the second set of channels 70a and 70b are separated by a second intermediate gap 70c. The second intermediate gap 70c provides thermal insulation between fluid flowing through the channels of the second set of channels 70a and 70b. Preferably, the second set of channels 70a and 70b are entirely formed on the end cover 70. In accordance with another embodiment of the present invention, the second set of channels 70a and 70b are partially formed on the end plate 70 and partially formed on the intermediate plate 60. Particularly, at least a portion of the second set of channels 70a and 70b is formed on the intermediate plate 60 and the fluid flow passages 30c and 30d are formed when the end plate 70 is assembled to the intermediate plate 60. However, the present invention is not limited to any particular configuration and placement of the second set of channels 70a and 70b as far as the second set of channels are configuring the fluid flow passages 30c and 30d for configuring fluid communication between the inlet and the outlet 50a and 50b and the respective first and second manifolds 30a and 30b.
The connection system 80 formed by assembling the intermediate plate 60 and the end plate 70 is disposed orthogonally with respect to the longitudinal axis of the manifold 30a and 30b and is in fluid communication with the manifolds 30a and 30b. The first and the second fluid flow passages 30c and 30d are disposed along the plane of the connection system 80. At least one channel of the second set of channels 70a and 70b follows a curved profile while the other channel follows a straight profile. The first flow passage 30c formed by the channel 70a follows a curved profile between the inlet 50a and the manifold inlet 32a. The second fluid flow passage 30d formed by the channel 70b follows a straight path between the manifold outlet 32b and outlet 50b. Further, substantial portions of the channels of the second set of channels 70a and 70b are parallel to each other, with substantial portion of one channel being disposed underneath the other and the outlet 50b being disposed underneath the inlet 50a. With such configuration, the inlet 50a and the outlet 50b are disposed along an axis extending orthogonally to the longitudinal axis of the first and second manifold 30a and 30b and the longitudinal axis of the tubular elements 42a and 42b.
Preferably, the inlet and outlet 50a and 50b are symmetrical about a plane passing through center of the second intermediate gap 70c at extreme end of the second intermediate gap 70c. Alternatively, the inlet and outlet 50a and 50b are asymmetrical about a plane passing through center of the second intermediate gap 70c at extreme end of the second intermediate gap 70c, wherein the inlet 50a is larger than the outlet 50b.
A heat exchanger 200 is disclosed in accordance with an embodiment of the present invention. The heat exchanger 200 includes a heat exchanger core 40, a tank assembly 100, an intermediate manifold 30e and a connection system 80 formed by at least one of an intermediate plate 60 and an end cover 70. The heat exchanger core 40 includes a first set of tubular elements 42a and a second set of tubular elements 42b disposed adjacent to the first set of tubular elements 42a and respectively defining a first pass and a second pass. The tank assembly 100 is as disclosed above and forms a first manifold 30a and a second manifold 30b disposed on same side of the heat exchanger core 40. The first manifold 30a delivers fluid to the first set of tubular elements 42a and the second manifold 30b collects fluid from the second set of tubular elements 42b after the fluid had undergone heat exchange while passing through the first and the second set of tubular elements 42a and 42b. At least one of the intermediate plate 60 and the end cover 70 orthogonally assembled with respect to longitudinal axis of the first and second manifold 30a and 30b to form the connection system 80. The connection system 80 formed with an inlet 50a, an outlet 50b and fluid flow passages 30c and 30d. The first fluid flow passage 30c configures fluid communication between the inlet 50a and the first manifold 30a and the second fluid flow passage 30d configures fluid communication between the second manifold 30b and the outlet 50b. The intermediate manifold 30e configures fluid communication between the first set of tubular elements 42a and the second set of tubular elements 42b to define U-flow trajectory of the fluid there-between to enable configuring of the first and second manifolds 30a and 30b on the same side of 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.

Claims

A tank assembly (100) comprising an axis of elongation, wherein the tank assembly (100) further comprising:
• a tank cover (10) extending along the axis of elongation of the tank assembly (100) and formed with first set of channels (10a) and (10b);

• a tank header (20) comprising portions (20a) and (20b) that in conjunction with the first set of channels (10a) and (10b) formed on the tank cover (10) are adapted to define a first manifold (30a) and a second manifold (30b) when the tank header (20) and the tank cover (10) are assembled with respect to each other, the tank header (20) further comprising apertures (22a) and (22b) configured on the respective portions (20a) and (20b) thereof,
characterized in that at least one of an intermediate plate (60) and an end cover (70) is orthogonally assembled with respect to longitudinal axis of the first and second manifolds (30a) and (30b) to form a connection system (80), the connection system (80) is formed with an inlet (50a), an outlet (50b) and fluid flow passages (30c) and (30d) configuring fluid communication between the inlet and the outlet (50a) and (50b) and the respective first and second manifolds (30a) and (30b).
The tank assembly (100) as claimed in the previous claim, wherein the intermediate plate (60) in conjunction with the end cover (70) when assembled together define a first fluid passage (30c) and a second fluid flow passage (30d), the first fluid flow passage (30c) defines fluid flow trajectory and fluid communication between the inlet (50a) and the first manifold (30a), whereas the second fluid flow passage (30d) defines fluid flow trajectory and fluid communication between the second manifold (30b) and the outlet (50b).
The tank assembly (100) as claimed in any of the preceding claims, wherein,
• the first set of channels (10a) and (10b) longitudinally extend along the length of the tank cover (10) to free end thereof to define a first set of concave profiles (12a) and (12b) at free end thereof;

• the tank header (20) comprises a extension portions (23a) and (23b) with second set of concave profiles (26a) and (26b) at the free end thereof, the profiles of the second set of concave profiles (26a) and (26b) being complementary to the respective profiles of the first set of concave profiles (12a) and (12b).
The tank assembly as claimed in Claim 3, wherein the extension portions (23a) and (23b) with the second set of concave profiles (26a) and (26b) are integrally formed with the header (20), whereas the first set of profiles (12a) and (12b) are inherently formed at the free end of the respective first channels (10a) and (10b) integrally formed with the tank cover (10).
The tank assembly (100) as claimed in claim 3, wherein the first set of concave profiles (12a) and (12b) are aligned to the second set of concave profiles (26a) and (26b) to define respective manifold inlet and outlet (32a) and (32b) as the tank cover (10) is assembled to the tank header (20).
The tank assembly (100) as claimed in any of the preceding claims, wherein the intermediate plate (60) of rectangular configuration comprises:
• a first set of sleeves (62a) and (62b) disposed along a first side thereof being aligned to and adapted to receive and hold respective manifold inlet and outlet (32a) and (32b);

• a third set of concave profiles (64a) and (64b) configured along a second side orthogonal to the first side; and

• either one of tabs and notches (66) formed on the sides thereof for configuring crimping connection with the heat exchanger core (40).
The tank assembly as claimed in any of the preceding claims, wherein the end cover (70) comprises:
• a second set of channels (70a) and (70b) spaced apart from each other, emanating from portions of the end cover (70) corresponding to and aligned with the first set of sleeves (62a) and (62b) formed on the intermediate plate (60) and extending along plane of the end cover (70) to one side of the end cover (70) for configuring a fourth set of concave profiles (74a) and (74b);

• one of tabs and notches (76) for configuring crimping connection with the heat exchanger core (40),
as the end cover (70) is assembled to the intermediate cover (60), the fourth set of concave profiles (74a) and (74b) get aligned with the third set of concave profiles (64a) and (64b) and are held together within a second set of sleeves (72a) and (72b) to define the inlet and outlet (50a) and (50b) respectively,
The tank assembly (100) as claimed in the claim 7, wherein the second set of channels (70a) and (70b) form the fluid flow passages (30c) and (30d) when the end cover (70) is assembled to the intermediate cover (60), the first fluid flow passage (30c) configures fluid communication between the inlet (50a) and the corresponding first manifold (30a) and the second fluid flow passage (30d) configures fluid communication between the second manifold (30b) and outlet (50b).
The tank assembly (100) as claimed in any of the preceding claims, wherein the inlet (50a) and the outlet (50b) are disposed along an axis extending orthogonally to the longitudinal axis of the first and second manifold (30a) and (30b) and the longitudinal axis of the tubular elements (42a) and (42b), either one of the inlet (50a) and outlet (50b) is disposed underneath the other.
The tank assembly (100) as claimed in any of the preceding claims, wherein the first set of channels (10a) and (10b) are separated by a first intermediate gap (10c).
The tank assembly (100) as claimed in claim 7, wherein the second set of channels (70a) and (70b) are separated by a second intermediate gap (70c).
The tank assembly (100) as claimed in claim 7, wherein at least a portion of the second set of channels (70a) and (70b) is formed on the intermediate plate (60).
The tank assembly (100) as claimed in claim 7, wherein at least one channel of the second set of channels (70a) and (70b) follows a curved profile while the other follows a straight profile.
The tank assembly (100) as claimed in claim 11, wherein the inlet and outlet (50a) and (50b) are symmetrical about a plane passing through center of the second intermediate gap (70c) at extreme end of the second intermediate gap (70c).
The tank assembly (100) as claimed in claim 11, wherein the inlet and outlet (50a) and (50b) are asymmetrical about a plane passing through center of the second intermediate gap (70c) at extreme end of the second intermediate gap (70c).
The tank assembly (100) as claimed in claim 2, wherein the first and second fluid flow passages (30c) and (30d) are of varying cross section along the length thereof.
The tank assembly (100) as claimed in any of the preceding claims, wherein substantial portions of the channels of the second set of channels (70a) and (70b) are parallel to each other with substantial portion of one channel being disposed underneath the other and the outlet (50b) being disposed underneath the inlet (50a).
A heat exchanger (200) comprising :
• a heat exchanger core (40) comprising a first set of tubular elements (42a) and a second set of tubular element (42b) disposed adjacent to the first set of tubular elements and respectively defining a first pass and a second pass;

• a tank assembly (100) as claimed in any of the preceding claims forming a first manifold (30a) and a second manifold (30b) disposed on same side of the heat exchanger core (40), the first manifold (30a) adapted to deliver fluid to the first set of tubular elements (42a) and the second manifold (30b) adapted to collect fluid from and the second set of tubular elements (42b) after the fluid had undergone heat exchange while passing through the first and the second set of tubular elements (42a) and (42b),

• at least one of an intermediate plate (60) and an end cover (70) orthogonally assembled with respect to longitudinal axis of the first and second manifolds (30a) and (30b) to form a connection system (80), the connection system (80) formed with an inlet (50a), an outlet (50b) and fluid flow passages (30c) and (30d), the first fluid flow passage (30c) adapted to configure fluid communication between the inlet (50a) and the first manifold (30a) and the second fluid flow passage (30d) adapted to configure fluid communication between the second manifold (30b) and the outlet (50b); and

• an intermediate manifold (30e) configuring fluid communication between the first set of tubular elements (42a) and the second set of tubular elements (42b) to define U-flow trajectory of the fluid there-between to enable configuring of the first and second manifolds (30a) and (30b) on the same side of the heat exchanger core (40).