EP4407268A1

EP4407268A1 - A reinforcement insert

Info

Publication number: EP4407268A1
Application number: EP23153261.5A
Authority: EP
Inventors: Damian PAWLAK; Ewelina WODERSKA; Michal FAJKIS
Original assignee: Valeo Systemes Thermiques SAS
Current assignee: Valeo Systemes Thermiques SAS
Priority date: 2023-01-25
Filing date: 2023-01-25
Publication date: 2024-07-31

Abstract

A reinforcement insert (100) includes at least two reinforcement members (10a) and (10b) for reinforcing corresponding adjacent tubular elements (20) and (40) of a heat exchanger (200) disposed in same plane. The first reinforcement member (10a) includes a first connector portion (12a) and two spaced apart first legs (14a) and (14b) depending from the first connector portion (12a) and received and held in a corresponding open end of the first tubular element (20). The first legs (14a) and (14b) are urged against inner side of first tubular element (20). The second reinforcement member (10b) includes a second connector (12a) and two spaced apart second legs (14c) and (14d) depending from the second connector (12b) and received and held in a corresponding open end of the second tubular element (40). The second extreme legs (14c) and (14d) are urged against inner side of the second tubular element (40).

Description

FIELD

The present invention relates to a heat exchanger, particularly, the present invention relates to a multi-core heat exchanger.

BACKGROUND

Generally, there are several heat exchanger in a vehicle for different purposes, for example, a radiator for engine cooling, an evaporator and a condenser being part of an air-conditioning loop, a chiller for battery cooling and a Charged Air Cooler (CAC) for cooling compressed air delivered to a turbo-charged engine. The vehicle heat exchangers are generally single cored, particularly, having a plurality of tubular elements connecting and configuring fluid communication between a pair of header-tank assemblies disposed on opposite sides of the heat exchanger core. However, due to space restrictions in vehicular environment, multiple heat exchangers are configured together to form a hybrid heat exchanger. Particularly, multiple heat exchanger cores are disposed between common headers disposed on both sides of the multiple heat exchanger cores, wherein at least one common header crimped to multiple tank covers or single tank cover with partitions configure distribution and/ or collection manifolds for the different heat exchange cores. The multiple heat exchanger cores include different sets of tubular elements received and held in different sets of apertures arranged along different rows on the common header. The different manifolds distribute and collect different or same heat exchange fluid with respect to the corresponding tubular elements configuring the different heat exchanger cores.
The tubular elements 2 received and held the corresponding apertures 3 are reinforced by reinforcement inserts 1 to avoid any deformation of the tubular elements 2 as illustrated in prior art FIG. 1 corresponding to the US granted Patent US11143463 . Particularly, open ends thereof are reinforced to maintain the open ends of the tubular elements in shape. Also, the tubular elements 2, particularly, the open ends of the tubular elements are reinforced against deformation to ensure unhindered ingress / egress of the heat exchange fluid with respect to the tubular elements 2 to ensure fluid flow through the tubular elements 2. As the tubular elements 2 are for the flow of high temperature fluid there through, the tubular elements 2 are prone to high thermal stresses due to non-uniform distribution of the hot fluid through the tubular elements 2 because of proximity of certain tubular elements 2 to inlet or outlet nozzles. Due to the high thermal stresses and comparatively smaller lateral dimension of the tubular elements 2, the heat exchanger core 4 is prone to core bending, particularly, transverse core bending. Such bending can damage the header 5 and other elements proximal to the heat exchanger, Further, the thermal stresses render the heat exchanger prone to defects, mechanical failures, leakages and frequent maintenance and reduce efficiency and performance of the heat exchanger. The problem is aggravated when multiple tubular elements are arranged in side by side configuration along different rows and coplanar with respect to each other configure hybrid cores as the adjacently disposed tubular elements can intervene with each other due to lack of transverse stiffness. Generally, reinforcement inserts are inserted in the corresponding open ends of the tubular elements with an aim to prevent deformation of the open ends of the tubular elements and ensure unobstructed fluid flow through the open ends of the tubular elements, however, such insert face various challenges. For example, the inserting of the reinforcement inserts in the open ends of the tubular elements is inconvenient and time consuming. Further, the reinforcement inserts are likely to be dislocated, misaligned or dropped inside the corresponding tubular element and fail to perform its function of reinforcing the tubular element, particularly, open ends of the tubular element, due to being loosely held in the respective open ends of the tubular elements in case of being improperly inserted.
Accordingly, there is a need for a reinforcement insert for tubular elements configuring a heat exchanger core that improves transverse stiffness of adjacent tubular elements arranged along different rows on a common header that impart transverse stiffness thereto, prevent damage to the heat exchanger, prevent leakage from the header and increases service life of the heat exchanger. Further, there is a need for a reinforcement insert that enables the tubular elements receiving the reinforcement insert to withstand high thermal stress and avoids transverse bending of the tubular elements due to the thermal stresses. Further, there is a need for a reinforcement insert that enables quick and convenient assembly thereof to reduce the assembly time and render the assembly process convenient. Further, there is a need for a reinforcement insert for tubular elements configuring a heat exchanger core that ensures proper insertion thereof in the corresponding open ends of the tubular elements, thereby preventing misalignment of the reinforcement inserts inside the respective open ends of the tubular elements and maintaining of the reinforcement insert in the open ends of the tubular elements. Furthermore, there is a need for a reinforcement insert for tubular elements of a heat exchanger that can be received and held in the open ends of the tubular elements to provide reinforcement against deformation of the tubular elements, particularly, against deformation of the open ends thereof, to ensure unhindered ingress and egress of the heat exchange fluid with respect to the tubular elements.

OBJECTS

An object of the present invention is to provide a reinforcement insert that obviates the drawbacks related to conventional reinforcement inserts used for reinforcing the tubular elements of a heat exchanger, particularly, the open ends of the tubular elements.
Another object of the present invention is to provide a reinforcement insert that is robust in construction and is securely held and maintained inside an open end of a tubular element.
Still another object of the present invention is to provide a reinforcement insert that ensures proper insertion in the open ends of the tubular elements.
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

A reinforcement insert is disclosed in accordance with an embodiment of the present invention. The reinforcement insert includes at least two reinforcement members for reinforcing corresponding tubular elements of a multi core heat exchanger. Particularly, the reinforcement insert includes the first reinforcement member and the second reinforcement member. The first reinforcement member includes a first connector portion and at least two first legs depending in a spaced apart configuration from the first connector portion. The at least two first legs are received and held in a corresponding open end of the first tubular element with the first legs urged against the first tubular element from inside the first tubular element. Similarly, the second reinforcement member includes a second connector and at least two second legs depending in a spaced apart configuration from the second connector. The at least two second legs are received and held in a corresponding open end of the second tubular element with the second extreme legs urged against the second tubular element from inside the second tubular element. The first connector portion and the second connector portion are connected by a bridge portion.
Generally, at least one first reinforcement member and at least one second reinforcement simultaneously reinforce the at least one first tubular element and the at least one corresponding second tubular element respectively arranged spaced apart from each other in separate rows along longitudinal sides of the common header and co-planar with respect to each other.
Preferably, the first extreme legs are diverging from the fixed ends to the free ends thereof.
Similarly, the second extreme legs are diverging from the fixed ends to the free ends thereof.
Generally, at least a portion of at least one of the first connector portion, the second connector portion and the bridge portion is extending out of the first and second tubular elements.
Further, the first reinforcement member includes at least one additional leg disposed between the first extreme legs.
Similarly, the second reinforcement member includes at least one additional leg disposed between the second extreme legs.
Particularly, the first extreme legs are urged against opposite first lateral walls of the first tubular element.
At least one of second extreme legs are urged against opposite second lateral walls of the second tubular element.
Particularly, at least one of the first extreme legs includes at least one first lip that engages with at least one of the corresponding first lateral wall of the corresponding first tubular element.
Similarly, at least one of the second extreme legs includes at least one second lip that engages with at least one of the corresponding second lateral wall of the corresponding second tubular element.
Generally, the first reinforcement member and the second reinforcement member are symmetrical about the bridge portion in order to be received in corresponding first and second identical tubular elements.
Also is disclosed a heat exchanger in accordance with an embodiment of the present invention. The heat exchanger includes at least one header tank assembly, multiple heat exchanger cores and reinforcement inserts. The at least one header tank assembly includes one common header and a corresponding tank forming crimping connection with the common header for defining multiple manifolds. The common header includes multiple sets of apertures, wherein a first set of apertures corresponding to the first manifold and a second set of apertures corresponding to the second manifold. A first heat exchanger core of the multiple heat exchanger cores includes a first set of tubular elements separated by fins. The first set of tubular elements are received and held in the first apertures. A second heat exchanger core of the multiple heat exchanger cores includes a second set of tubular elements separated by fins. The second set of tubular elements are received and held in the second apertures. Each of the reinforcement inserts includes a first reinforcement member and a second reinforcement member connected by a bridge portion and received and held in the corresponding tubular elements arranged spaced apart from each other and co-planar with respect to each other for reinforcement thereof.

BRIEF DESCRIPTION

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 a schematic representation of a reinforcement insert for reinforcing tubular elements of a heat exchanger.
FIG. 2 illustrates an isometric view of a reinforcement insert in accordance with an embodiment of the present invention;
FIG. 3 illustrates a front view of the reinforcement insert of FIG. 2;
FIG. 4 illustrates a heat exchanger illustrated without a tank cover, also is depicted enlarged view depicting reinforcement members of the reinforcement insert of FIG. 2 received in tubular elements arranged along opposite longitudinal sides of a common header;
FIG. 5 illustrates a top view of the heat exchanger without the tank cover depicted in FIG. 4.
FIG. 6 illustrates a sectional view of the heat exchanger without the tank cover along section plane A-A passing between adjacent apertures arranged on same side of the common header as depicted in FIG. 5;
FIG. 7 illustrates another sectional view of the heat exchanger without the tank cover as illustrated in FIG. 6.

DETAILED DESCRIPTION

The present invention envisages a reinforcement insert configured with at least two reinforcement members for simultaneously reinforcing separate heat exchange tubular elements received in adjacent apertures formed along different rows, particularly, along opposite longitudinal sides of a common header. The first and the second reinforcement members are connected by bridge portion and each of the reinforcement members include a first connector portion and at least two legs depending in a spaced apart configuration from the respective connector portion. The at least two legs are received and held in either one of the open ends of the corresponding tubular elements with the legs urged against inner sides of the corresponding tubular element. Particularly, the legs are urged against lateral walls of the corresponding tubular element to impart transverse stiffness to the tubular element. Although, the present invention is explained with example of reinforcement insert for use in reinforcing the tubular elements of a heat exchanger used in vehicular environment, however, the reinforcement insert of the present invention is also applicable for reinforcing tubular elements of any heat exchanger used in vehicular or non-vehicular environment. The reinforcement insert also finds application in any device involving fluid flow through multiple tubular elements. Particularly, the reinforcement insert of the present invention is applicable for devices involving fluid flow through tubular elements, wherein, it is required to simultaneously reinforce multiple tubular elements, particularly, open ends of the tubular elements that define fluid flow there through. More specifically, the reinforcement insert of the present invention is applicable in devices involving fluid flow through tubular elements, wherein adjacent tubular elements arranged along different rows on a common header and co-planar with respect to each other are required to be simultaneously reinforced by single insert to provide transverse stiffness to the tubular elements. Such reinforcement insert prevents transverse bending of the tubular elements due to thermal stresses induced therein because of non-uniform distribution of hot fluid through the heat exchange tubular elements.
FIG.2 illustrates a reinforcement insert 100 in accordance with an embodiment of the present invention. FIG. 3 illustrates a front view of the reinforcement insert 100. The reinforcement insert 100 includes at least two reinforcement members 10a and 10b for reinforcing corresponding tubular elements 20 and 40 disposed adjacent to each other in the same plane. More specifically, the at least two reinforcement members 10a and 10b reinforces the at least two tubular elements that are disposed adjacent to each other and received in adjacent apertures arranged along different rows along longitudinal sides of a common header 110a.
Particularly, the reinforcement insert 100 includes the first reinforcement member 10a and the second reinforcement member 10b connected by a bridge portion 10c. Generally, at least one first reinforcement member 10a and at least one second reinforcement member 10b simultaneously reinforce the at least one first tubular elements 20 and the at least one corresponding second tubular elements 40 respectively arranged spaced apart from each other in separate rows along longitudinal sides of the common header 110a and co-planar with respect to each other.
Referring to the FIG. 2 and FIG. 3, the first reinforcement member 10a includes a first connector portion 12a and at least two first legs 14a and 14b depending in a spaced apart configuration from the first connector portion 12a. The at least two first legs 14a and 14b are received and held in a corresponding open end of the first tubular elements 20 with the first legs 14a and 14b urged against the first tubular elements 20 from inside the first tubular elements 20 as illustrated in FIG. 6. Preferably, the first extreme legs 14a and 14b are diverging from the fixed ends to the free ends thereof. The first reinforcement member 10a includes at least one additional leg 15 disposed between the first extreme legs 14a and 14b. The first extreme legs 14a and 14b are urged against opposite first lateral walls 20a and 20b of the first tubular elements 20. The first extreme legs 14a and 14b includes at least one first lip 14e that engages with at least one of the corresponding first lateral walls 20a and 20b and prevent over insertion of the first reinforcement member 10a in the corresponding first tubular elements 20. At least one of the first extreme legs 14a and 14b is beveled at extreme end thereof to facilitate insertion of the first reinforcement member 10a in the first tubular elements 20. However, the present invention is not limited to any particular configuration of the first reinforcement member 10a, number, placement, orientation and configuration of the first legs 14a and 14b and the at least one additional leg 15 as far as these elements reinforces the first tubular element 20 and imparts lateral stiffness to the first tubular element 20.
Similarly, the second reinforcement member 10b includes a second connector 12b and at least two second legs 14c and 14d depending in a spaced apart configuration from the second connector 12b. The at least two second legs 14c and 14d are received and held in a corresponding open end of the second tubular elements 40 with the second extreme legs 14c and 14d urged against the second tubular elements 40 from inside the second tubular elements 40. The second extreme legs 14c and 14d are diverging from the fixed ends to the free ends thereof. The second reinforcement member 10b includes at least one additional leg 16 disposed between the second extreme legs 14 c and 14d. The second extreme legs 14c and 14d are urged against opposite second lateral walls 40a and 40b of the second tubular elements 40. The second extreme legs 14c and 14d includes at least one lip 14f that engages with at least one of the corresponding second lateral wall 40a and 40b. Also, at least one of the second extreme legs 14c and 14d is beveled at extreme end thereof to facilitate insertion of the second reinforcement member 10b in the second tubular elements 40. However, the present invention is not limited to any particular configuration of the second reinforcement member 10b, number, placement, orientation and configuration of the second legs 14c and 14d and the at least one additional leg 16 as far as these elements reinforces the second tubular element 40 and imparts lateral stiffness to the second tubular element 20.
The bridge portion 12c connects the first connector portion 12a and the second connector portion 12b and includes at least one slot for imparting flexibility and weight reduction to the reinforcement insert 100. The first reinforcement member 10a and the second reinforcement member 10b are symmetrical about the bridge portion to be received in corresponding first and second identical tubular elements 20 and 40. Generally, at least a portion of at least one of the first connector portion 12a, the second connector portion 10b and the bridge portion 10c is extending out of the first and second tubular elements. Such configuration of the first reinforcement member 10a and the second reinforcement member 10b being connected by the bridge portion 10c has several advantages. Particularly, the reinforcement of such configuration can be conveniently assembled in the multiple adjacent tubular elements 20 and 40 and simultaneously impart lateral stiffness to both the tubular elements 20 and 40 disposed adjacent to each other and co-planar with respect to each other. In accordance with another embodiment the reinforcement insert 100 reinforces tubular elements that are arranged in different planes with respect to each other. Due to being connected, the chances of one of the reinforcement members 10a and 10b being dropped in the respective tubular elements 20 and 40 is eliminated. Further, with such configuration of the reinforcement insert the chances of misalignment of the first and second reinforcement members 10a and 10b with respect to the tubular elements 20 and 40 is reduced. Further such configuration simultaneously enhances transverse stiffness of both the tubular elements disposed adjacent to each other.
The first tubular element 20 and the second tubular element 40 are disposed along separate rows on the common header 110a. For example, the first tubular elements 20 are received in first apertures 112a arranged along first longitudinal side of the common header 110a and the second tubular elements 40 are received in second apertures 112b arranged along second longitudinal side opposite to the first longitudinal side of the common header 110a. Generally, the first apertures 112a and the second apertures 112b are symmetrically arranged about the center line B-B' passing through the center of the header depicted in FIG. 5. Generally, the first apertures 112a and the corresponding second apertures 112b are identical to receive identical tubular elements 20 and 40 respectively.
Also is disclosed a heat exchanger in accordance with an embodiment of the present invention. The heat exchanger includes at least one header tank assembly, multiple heat exchanger cores and reinforcement inserts. The at least one header tank assembly includes one common header and a corresponding tank that forms crimping connection with the common header to define multiple manifolds. The common header includes multiple sets of apertures, wherein a first set of apertures corresponding to the first manifold and a second set of apertures corresponding to the second manifold. A first heat exchanger core of the multiple heat exchanger cores includes a first set of tubular elements separated by fins. The first set of tubular elements are received and held in the first apertures. A second heat exchanger core of the multiple heat exchanger cores includes a second set of tubular elements separated by fins and received and held in the second apertures. Each of the reinforcement inserts includes a first reinforcement member and a second reinforcement member connected by a bridge portion and received and held in the corresponding tubular elements arranged spaced apart from each other and co-planar with respect to each other for reinforcement thereof.
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 reinforcement insert (100) comprising:
- at least two reinforcement members (10a) and (10b) for reinforcing corresponding tubular elements (20) and (40) of a multi core heat exchanger (200), wherein
• the first reinforcement member (10a) comprising:
∘ a first connector portion (12a);

∘ at least two first legs (14a) and (14b) depending in a spaced apart configuration from the first connector portion (12a) and adapted to be received and held in a corresponding open end (22) of the first tubular element (20) with the first legs (14a) and (14b) urged against inner wall of the first tubular element (20),

• the second reinforcement member (10b) comprising:
∘ a second connector (12b);

∘ at least two second legs (14c) and (14d) depending in a spaced apart configuration from the second connector (12b) and adapted to be received and held in a corresponding open end (42) of the second tubular element (40) the second extreme legs (14c) and (14d) urged against inner wall of the second tubular element (40),
characterized in that the first connector portion (12a) and the second connector portion (12b) are connected by a bridge portion (12c).
The reinforcement insert (100) as claimed in the previous claim, wherein at least one first reinforcement member (10a) and at least one second reinforcement member (10b) are adapted to simultaneously reinforce at least one first tubular element (20) and at least one corresponding second tubular (40) respectively arranged spaced apart from each other in separate rows along longitudinal sides of a common header (110a) and co-planar with respect to each other.
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the first extreme legs (14a) and (14b) are diverging from the fixed ends to the free ends thereof.
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the second extreme legs (14c) and (14d) are diverging from the fixed ends to the free ends thereof.
The reinforcement insert (100) as claimed in any of the preceding claims, at least a portion of at least one of the first connector portion (12a), the second connector portion (12b) and the bridge portion (12c) is extending out of the first and second tubular elements (20) and (40).
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the first reinforcement member (10a) further comprises at least one additional leg (15) disposed between the first extreme legs (14a) and (14b).
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the second reinforcement member (10b) further comprises at least one additional leg (16) disposed between the second extreme legs (14c) and (14d).
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the first extreme legs (14a) and (14b) are adapted to be urged against opposite first lateral walls (20a) and (20b) of the first tubular element (20).
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the second extreme legs (14a) and (14b) are adapted to be urged against opposite second lateral walls (40a) and (40b) of the second tubular element (40).
The reinforcement insert (100) as claimed in the claim 8, wherein at least one of the first extreme legs (14a) and (14b) comprises at least one lip (14e) adapted to engage with at least one of the corresponding first lateral wall (20a, 20b).
The reinforcement insert (100) as claimed in the claim 9, wherein at least one of the second extreme legs (14a) and (14b) comprises at least one lip (14f) adapted to engage with at least one of the corresponding second lateral wall (40a, 40b).
The reinforcement insert (100) as claimed in any of the preceding claims, wherein the first reinforcement member (10a) and the second reinforcement member (10b) are symmetrical about the bridge portion (12c) and adapted to be received in corresponding first and second identical tubular elements (20) and (40).
The reinforcement insert (100) as claimed in any of the preceding claims, wherein at least one of the first extreme legs (14a) and (14b) is beveled at extreme end thereof to facilitate insertion of the first reinforcement member (10a) in the open end (22) of the first tubular element (20), also, the at least one of the second extreme legs (14c) and (14d) is beveled at extreme end thereof to facilitate insertion of the second reinforcement member (10b) in the open end (42) of the second tubular element (40).
A multi core heat exchanger (200) comprising:
• at least one header tank assembly (110) comprising a common header (110a) and a corresponding tank (110b) adapted to form crimping connection with the common header (110a) to define multiple manifolds, the common header (110a) comprises multiple sets of apertures (112a, 112b), wherein, a first set of apertures (112a) corresponding to a first manifold and a second set of apertures (112b) corresponding to a second manifold;

• multiple heat exchanger cores (120), wherein,
∘ a first heat exchanger core (120a) comprising a first set of tubular elements (20) separated by fins (24) and adapted to be received and held in the first apertures (112a); and

∘ a second heat exchanger core (120b) comprising a second set of tubular elements (40) separated by fins (44) and adapted to be received and held in the second apertures (112b);

• a plurality of reinforcement inserts (100), wherein each reinforcement insert (100) comprises a first reinforcement member (10a) and a second reinforcement member (10b) connected by a bridge portion (10c) and adapted to be received and held in the corresponding tubular elements (20) and (40) arranged spaced apart from each other and co-planar with respect to each other, for reinforcement thereof.