EP4464965A1

EP4464965A1 - A heat exchanger

Info

Publication number: EP4464965A1
Application number: EP23174121.6A
Authority: EP
Inventors: Michal BELZOWSKI; Damian JURKIEWICZ
Original assignee: Valeo Systemes Thermiques SAS
Current assignee: Valeo Systemes Thermiques SAS
Priority date: 2023-05-17
Filing date: 2023-05-17
Publication date: 2024-11-20

Abstract

A heat exchanger (100) for a motor vehicle comprising a first manifold (102), a second manifold (104), and a plurality of tubes (112, 114) fluidically connected between the first manifold (102) and the second manifold (104) to enable circulation of at least one of a first fluid and a second fluid between the first manifold (102) and the second manifold (104). The plurality of tubes (112, 114) comprises one or more sets of first tubes (112) and one or more sets of second tubes (114). The one or more sets of first tubes (112) and the one or more sets of second tubes (114) are arranged one above another in an alternate manner in at least one row such that at least a portion of neighboring tubes of the corresponding set of first tubes (112) and the set of second tubes (114) abut with each other.

Description

FIELD OF INVENTION

The present invention relates to a heat exchanger. More specifically, the present invention relates to an improved internal heat exchanger (IHX) for a motor vehicle that is able to withstand high fluid pressures.

BACKGROUND OF THE INVENTION

A vehicle is provided with several heat exchangers for example, an internal heat exchanger, an evaporator, a condenser, etc. The evaporator and the condenser are part of an air-conditioning (AC) loop or a part of HVAC system. These heat exchangers are used for heat exchange/transfer between two or more fluids/media. IHX is used to transfer heat between the low side pressure and the high pressure flow circuits. Its function is to improve system performance by further sub-cooling the refrigerant being supplied to the evaporator through the refrigerant control device..
A conventional heat exchanger typically includes a pair of manifolds, including a first manifold and a second manifold, configured at two opposite sides of the heat exchanger, and a heat exchanger core arranged between the pair of manifolds. The heat exchanger core is formed of a plurality of flat tubes (hereinafter, also referred to as tubes for simplicity) and fins arranged between outer surfaces of the adjacent tubes. Each tube has two opposite open ends which are inserted into respective tube insertion slots of a first header and a second header of the respective first manifold and the second manifold. Each of the first header and the second header in conjunction with a corresponding first tank and second tank define the first manifold and the second manifold for receiving and distributing the fluid/coolant to the tubes. One or more of the fluid/coolants flow between the first manifold to the second manifold through the plurality of tubes and the other fluid/air flows around and in a space between the tubes to enable heat exchange between the fluids.
It has been observed that when the one or more fluid/coolants, which flow between the manifolds and in the tubes, are a high-pressure fluid, like R744 (CO2) or R290 (propane), the heat exchanger has to be adapted accordingly. In particular, the high-pressure fluid imposes additional design constrains on the heat exchanger as the high pressure of the fluid necessitates higher mechanical resistance of heat exchanger components. Further, at the same time, efficiency requirements pose further demands on the heat exchanger. In addition, the existing heat exchangers are not capable to operate efficiently for the fluid/coolant operate at the high pressure, which can be up to 260 bar on the low-pressure side and up to 360 bar on the high-pressure side.
Therefore, there is a need of an efficient and cost-effective solution which can overcome abovementioned drawbacks of the conventional heat exchanger.

SUMMARY

The present invention discloses a simple, efficient, light, and economical internal heat exchanger (hereinafter, also referred to as heat exchanger) for a motor vehicle, which is able to withstand high fluid pressures, which can be up to 260 bar on the low-pressure side and up to 360 bar on the high-pressure side, for high-pressure systems. The proposed high-pressure heat exchanger offers efficient operation without sacrificing its mechanical resistance, and which thus is safe to operate.
In accordance with an embodiment of the present invention, the disclosed heat exchanger includes a first manifold, a second manifold configured spaced apart from the first manifold, and a plurality of tubes fluidically connected between the first manifold and the second manifold to enable circulation of at least one of a first fluid and a second fluid between the first manifold and the second manifold. The plurality of tubes comprises one or more sets of first tubes and one or more sets of second tubes. The one or more sets of first tubes and the one or more sets of second tubes are arranged one above another in an alternate manner in at least one row such that at least a portion of neighboring tubes of the corresponding set of first tubes and the set of second tubes abut with each other. In addition, the first manifold comprises at least one channel on an outer side of the first manifold and at least one set of openings on a side opposite to the outer side. At least one set of openings are fluidically connect to at least one channel . The second manifold comprises at least one channel on an outer side of the second manifold and at least one set of openings on a side opposite to the outer side, at least one set of openings being fluidically connect at least one channel.
In an embodiment, the first manifold can include two channels, and the second manifold can also include two channels.
In another embodiment, the first manifold can include three channels, and the second manifold can include one channel.
Each set of tubes of the one or more sets of first tubes and the one or more sets of second tubes includes at least two tubes.
Each tube of the plurality of tubes includes an intermediate flat tube section, two opposite tube end sections, and two tube bend sections between the intermediate flat tube section and the two opposite tube end sections.
At least two tubes of each of the one or more sets of first tubes and the one or more sets of second tubes are configured such that the intermediate flat tube sections of at least two tubes extend substantially in a parallel and spaced manner to each other and the tube end sections are stacked on each other in a corresponding single tube slot of the manifold.
In addition, spacers are provided in a gap between the two tubes of each of the one or more sets of first tubes and the one or more sets of second tubes.
The one or more sets of first tubes and the one or more sets of second tubes are arranged one above another in an alternate manner such that the intermediate flat tube sections of neighboring tubes of the corresponding set of first tubes and the set of second tubes abut with each other.
In an embodiment, a width of each tube of the one or more sets of first tubes can be equal to the width of each tube of the one or more sets of second tubes.
In an embodiment, the one or more sets of first tubes can be arranged in single row and the one or more sets of second tubes can be arranged in two adjacent rows in an alternate manner.
In another embodiment, a width of each tube of the one or more sets of first tubes can be greater than the width of each tube of the one or more sets of second tubes.
In addition, the first manifold can include a first header plate, a first cover, and one or more first internal plates configured between the first header plate and the first cover.
The second manifold can include a second header plate, a second cover, and one or more second internal plates configured between the second header plate and the second cover.
The disclosed heat exchanger can further include two or more connection blocks connected to the first manifold and the second manifold. Each connection block can include one or more ports.
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.

BRIEF DESCRIPTION OF DRAWINGS

Other characteristics, details and advantages of the invention may 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 heat exchanger with two I-flow passages where fluids are flowing in counter flow, in accordance with an embodiment of the present invention;
FIG. 2 illustrates a core of the heat exchanger of FIG. 1;
FIG. 3 illustrates a tube of the heat exchanger of FIG. 1;
FIG. 4 illustrates a set of tubes of the heat exchanger of FIG. 1;
FIG. 5 illustrates an arrangement of a set of first tubes and a set of second tubes of the heat exchanger of FIG. 1;
FIG. 6 illustrates an isometric view of a first manifold with a connecting block of the heat exchanger of FIG. 1;
FIG. 7 illustrates an exploded view of a first manifold with a connecting block of the heat exchanger of FIG. 1;
FIG. 8 illustrates an isometric view of a second manifold with a connecting block of the heat exchanger of FIG. 1;
FIG. 9 illustrates an exploded view of a second manifold with a connecting block of the heat exchanger of FIG. 1;
FIG. 10 illustrates an isometric view of a heat exchanger with one I-flow passage and one U-flow passage where fluids egress the heat exchange through different manifolds, in accordance with an embodiment of the present invention;
FIG. 11 illustrates a core of the heat exchanger of FIG. 10;
FIG. 12 illustrates a first tube of the heat exchanger of FIG. 10;
FIG. 13 illustrates a second tube of the heat exchanger of FIG. 10;
FIG. 14 illustrates an arrangement of a set of first tubes and two sets of second tubes of the heat exchanger of FIG. 10;
FIG. 15 illustrates an isometric view of a first manifold with a connecting block of the heat exchanger of FIG. 10;
FIG. 16 illustrates an exploded view of a first manifold with a connecting block of the heat exchanger of FIG. 10;
FIG. 17 illustrates an isometric view of a second manifold with a connecting block of the heat exchanger of FIG. 10;
FIG. 18 illustrates an exploded view of a second manifold with a connecting block of the heat exchanger of FIG. 10;
FIG. 19 illustrates an isometric view of a heat exchanger with two I-flow passages where fluids flowing in co-flow, in accordance with an embodiment of the present invention; and
FIG. 20 illustrates an isometric view of a heat exchanger with one I-flow passage and one U-flow passage where fluids egress the heat exchange through same manifold, in accordance with an embodiment of the present invention;

DETAILED DESCRIPTION

It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.
The present invention is explained in the forthcoming description and the accompanying drawings with an example of internal heat exchanger for an air conditioning system and/or a cooling system of a motor vehicle. More specifically, the present invention discloses a simple, light, and cost efficient heat exchanger that is able to withstand high fluid pressures, which can be up to 260 bar on the low-pressure side and up to 360 bar on the high-pressure side, for high-pressure systems. In addition, the heat exchanger is adapted to exchange heat between refrigerants from low pressure side and high pressure side of a cooling loop to increase efficiency of the cooling loop of the air conditioning system and/or cooling system.
It is to be appreciated that the concept of the present invention is applicable for any other application in vehicular and non-vehicular environment, where it is required to provide a heat exchanger that can withstand high coolant/fluid pressures flow and perform efficiently.
Referring to FIG. 1, FIG. 2, FIG. 10, and FIG. 11, in accordance with an embodiment, the present invention discloses an internal heat exchanger 100 that includes a first manifold 102, a second manifold 104 configured spaced apart on two opposite sides of a heat exchanger core 150 which fluidically connects the first manifold 102 and the second manifold 104. The heat exchanger core 150 includes a plurality of tubes 112 and 114 fluidically connected between the first manifold 102 and the second manifold 104 to circulate at least one of a first fluid and a second fluid between the first manifold 102 and the second manifold 104. To receive and/or distribute at least one of the first fluid and the second fluid though the plurality of tubes 112 and 114, the first manifold 102 comprises at least one channel, such as channels 106a, 106b, and 106c, and the second manifold 104 comprises at least one channel, such as channels 108a and 108b. For instance, the first fluid and/or the second fluid can be a natural refrigerant such as, but not limited to, R744 (CO2) or R290 (propane).
In addition, the plurality of tubes 112 and 114 comprises one or more sets of first tubes 112 and one or more sets of second tubes 114. The one or more sets of first tubes 112 and the one or more sets of second tubes 114 are arranged one above another in an alternate manner in at least one row such that at least a portion of neighboring tubes of the corresponding set of first tubes 112 and the set of second tubes 114 abut with each other.
In an embodiment, the plurality of tubes 112 and 114 can be extruded tubes with micro ports, i.e., the plurality of tubes 112 and 114 can include micro channels extending along lengths of the tubes.
In an embodiment, extreme upper and lower tubes 112/114, i.e. external tubes, of the core 150 can be a blind tubes to avoid transfer of fluid through the tubes which are not in contact with another tube of adjacent set of tubes.
In an embodiment, each set of tubes of the one or more sets of first tubes 112 and the one or more sets of second tubes 114 comprises two tubes. In addition, the spacers 118 are provided in a gap between the two tubes of each sets of tubes 112/114. The spacers/fillers 118 between tubes of each set of tubes 112/114 are adapted to ensure contact between the tubes 112/114. The spacers/fillers 118 between each set of tubes 112/114 can reinforce the corresponding set of tubes 112/114. The spacers 118 can be of different shapes such as but not limited to corrugated, rectangular, triangular, trapezoidal, and the like. In addition, the spacers 118 can disrupt the air flowing across the core 150 in order to improve the heat exchange of air with the first and/or the second fluids flowing through the tubes 112 and 114.
In addition, FIG. 3 to FIG. 5 and FIG. 12 to FIG. 14, each tube of the plurality of tubes 112 and 114, i.e., each of the first tubes 112 and the second tubes 114, can include an intermediate flat tube section 116a, two opposite tube end sections 116c, and two tube bend sections 116b between the intermediate flat tube section 116a and the two opposite tube end sections 116c. Each of the tube bend sections 116b comprises two opposite turns connected to the respective end of the intermediate flat tube section 116a and the tube end section 116c, which enable offset arrangement of the intermediate flat tube section 116a with respect to the tube end sections 116c. Further, when the two tubes 112/114 of each of the one or more sets of first tubes 112 and the one or more sets of second tubes 114 are configured with concavities of the tubes 112/114 facing each other the intermediate flat tube sections 116a of the two tubes 112/114 extend substantially in a parallel and spaced manner to each other and the tube end sections 116c are stacked on each other. Opposite tube end sections 116c of the two tubes 112/114 of each of the sets of first tubes 112 and the sets of second tubes 114 are configured to be received in the corresponding single tube slot 126/128 of the manifolds 102 and 104. Further, this arrangement of the tubes end sections 116c of the two tubes in single slot 126/128 of the respective manifold 102/104 help to mechanically strengthen the proposed heat exchanger by reducing the number of required slots 126/128 in the manifolds 102 and 104 and increases a gap between two adjacent slots 126/128 of the manifold 102/04 in comparison to number of slots required and a gap between two adjacent slots in the conventional heat exchanger with same number of flat tubes.
In addition, in area between the tubes 112/114 connected to the same slot 126/128 of the manifold 102/104, due to geometry of the tubes 112 /114, free space is created between the intermediate flat tube sections 116a, which can be filled by the spacers 118 to make assembly and brazing process easier. The spacers 118 can be a component help in increasing heat exchange with air and the fluids flowing through the tubes 112 and 114.
In addition, as shown in FIG. 2, FIG. 5, FIG. 11, and FIG. 14, the one or more sets of first tubes 112 and the one or more sets of second tubes 114 are arranged one above another in alternate manner such that the intermediate flat tube sections 116a of neighboring tubes of the corresponding set of first tubes 112 and the set of second tubes 114 abut with each other. This contact between the intermediate flat tube sections 116a of the one or more sets of first tubes 112 and the one or more sets of second tubes 114 allows heat exchange between the fluids, such as the first fluid and/or the second fluid, flowing through the one or more sets of first tubes 112 and the one or more sets of second tubes 114.
In an embodiment, the first fluid and the second fluid can be same refrigerant fluid.
In another embodiment, the first fluid and the second fluid can be different refrigerant fluids.
In another embodiment, the spacers 118 or metallic foils, such as aluminum foils, can be provided between the two adjacent sets of tubes, such as between the sets of first tubes 112 and the sets of second tubes 114. In this case, the neighboring tubes 112 and 114 of the sets of first tubes 112 and the sets of second tubes 114 can be in contact with each other through the spacers 118 or metallic foils indirectly to exchange heat between the fluids flowing though the set of first tubes 112 and the set of second tubes 114.
For instance, the sets of first tubes 112 can be connected to odd number of slots 126/128 of the manifolds 102 and 104, and the sets of second tubes 114 can be connected to even number of slots 126/128 of the manifolds 102 and 104 or vice versa. In addition, the fist fluid can circulate though the sets of first tubes 112 and the second fluid can circulate through the sets of second tubes 114 or vice versa.
In an embodiment, as shown in FIG. 2, the one or more sets of first tubes 112 and the one or more sets of second tubes 114 are arranged one above another in an alternate manner in one row. Opposite ends of the sets of first tubes 112 and the sets of second tubes 114 are received in the respective slots 126 of the manifolds 102 and 104. In addition, a width of each tube of the one or more sets of first tubes 112 can be equal to the width of each tube of the one or more sets of second tubes 114.
In another embodiment, as shown in FIG. 11 and FIG. 14, the one or more sets of first tubes 112 are arranged in single row and the one or more sets of second tubes 114 are arranged in two adjacent rows in an alternate manner. A width of each tube of the one or more sets of first tubes 112 can be greater than the width of each tube of the one or more sets of second tubes 114. For instance, the width of the first tubes 112 can be double to the width of the second tubes 114.
In an embodiment, referring to FIG. 6 and FIG. 7, the first manifold 102 can include a first header plate 120, a first cover 124, and one or more first internal plates 122 configured between the first header plate 120 and the first cover 124. The first header plate 120 can include a plurality slots 126, and the first inner plates 122 can also include a plurality of slots 127 corresponding to the slots 126 of the first header plate 120. In addition, the first cover 124 can include two channels 106a and 106b on an outer side of the first cover 124 and extending along the length of the first cover 124. The first cover 124 can further include a set of openings 107a on a side, i.e. inner side, which is opposite to the outer side and configured along the length of the first cover 124 with a gap between the adjacent openings 107a, and another set of openings 107b on the inner side which is opposite to the outer side and configured along the length of the first cover 124 with a gap between the adjacent openings 107b. The two sets of openings 107a and 107b of the first cover 124 are offset from each other.
In an embodiment, the set of openings 107a are adapted to fluidically connect the channel 106a with the sets of tubes 112/114 fitted to odd number of slots 126 of the first header plate 120, whereas the sets of openings 107b are adapted to fluidically connect the channel 106b with the sets of tubes 112/114 fitted to even number of slots 126 of the first header plate 120. For instance, the openings 107a can be configured to fluidically connect the channel 106a to the one or more sets of first tubes 112 through the corresponding slots 127 and 126 of the first internal plates 122 and the first header plate 120, whereas the openings 107b can be configured to fluidically connect the channel 106b to the one or more sets of the second tubes 114 through the corresponding slots 127 and 126 of the first internal plates 122 and the first header plate 120. This connection between the channels 106a and 106b and the plurality of tubes 112 and 114 enables flow of the first fluid and second fluid separately though the sets of first tubes 112 and the sets of second tubes 114.
Similarly, the second manifold 104 can include a second header plate 130, a second cover 134, and one or more second internal plates 132 configured between the second header plate 130 and the second cover 134, as shown in FIG. 8 and FIG. 9. The second header plate 130 can include a plurality slots 126, and the second inner plates 132 can also include a plurality of slots 127 corresponding to the slots 126 of the second header plate 130. In addition, the second cover 134 can include two channels 108a and 108b on an outer side of the second cover 134 and extending along the length of the second cover 134. The second cover 134 can further include a set of openings 110a on a side, i.e. inner side, opposite to the outer side and configured along the length of the second cover 134 with a gap between the adjacent openings 110a, and another set of openings 110b on the inner side and configured along the length of the second cover 134 with a gap between the adjacent openings 11b. The two sets of openings 11a and 11b are offset from each other.
In an embodiment, the set of openings 110a are adapted to fluidically connect the channel 108a with the sets of tubes 112/114 fitted to odd number of slots 126 of the second header plate 130, whereas the sets of openings 110b are adapted to fluidically connect the channel 108b with the sets of tubes 112/114 fitted to even number of slots 126 of the second header plate 130. For instance, the openings 110a can be configured to fluidically connect the channel 108a to the one or more sets of first tubes 112 through the corresponding slots 127 and 126 of the second internal plates 132 and the second header plate 130, whereas the plurality of second openings 110b can be configured to fluidically connect the channel 108b to the one or more sets of the second tubes 114 through the corresponding slots 127 and 126 of the second internal plates 132 and the second header plate 130. This connection between the channels 108a and 108b and the plurality of tubes 112 and 114 enables flow of the first fluid and/or the second fluid separately though the sets of first tubes 112 and the sets of second tubes 114.
In another embodiment, the first cover 124 and the internal plates 122 can be a single integral part, and the openings 107a and 107b and the slots 127 can be formed on the first cover 124 though machining process. Further, the machined first cover can be connected directly to the first header plate 120. Similarly, the second cover 134 and the second internal plates 132 can be a single integral part, and the openings 110a and 110b and the slots 127 can be formed on the second cover 134 though machining process. Further, the machined second cover can be connected directly to the second header plate 130.
In another embodiment, as shown in FIG. 1, FIG. 6 and FIG. 7, two connection blocks 140 and 142 are connected to the first manifold 102 and the second manifold 104, respectively. The connection block 140 can include two ports 144a and 144b fluidically connected to the channels 106a and 106b of the first manifold 102. Similarly, the other connection block 142 can include ports 144c and 114d fluidically connected to the channels 108a and 108b of the second manifold 104.
In an embodiment, as shown in FIG. 1, the first fluid (indicated by arrow 103a) enters through the port 144d of the connection block 142 into the second manifold 104, travel through the sets of first tubes 112, reach the first manifold 102 and egress the heat exchanger 100 through the port 144b of the connection block 140 connected to the first manifold 102. Whereas, the second fluid (indicated by arrow 103b) enters through the port 144a of the connection block 140 into the first manifold 102, travel through the sets of second tubes 114, reach the second manifold 104 and egress the heat exchanger 100 through the port 144c of the connection block 142 connected to the second manifold 104. Thus, the first fluid and the second fluid can travel through the heat exchanger 100 in counter flow.
In another embodiment, as shown in FIG. 19, the first fluid (indicated by arrow 103a) enters through the port 144b of the connection block 140 into the first manifold 102, travel through the sets of first tubes 112, reach the second manifold 104 and egress the heat exchanger 100 through the port 144d of the connection block 142 connected to the second manifold 104. Whereas, the second fluid (indicated by arrow 103b) enters through the port 144a of the connection block 140 into the first manifold 102, travel through the sets of second tubes 114, reach the second manifold 104 and egress the heat exchanger 100 through the port 144c of the connection block 142 connected to the second manifold 104. Thus, the first fluid and the second fluid can travel through the heat exchanger 100 in co-flow.
In another embodiment, the heat exchanger 100 may comprise more than two connection blocks, for instance three or four connections blacks with ports, which can be connected on one or both top and bottom sides, and/or even on lateral sides, of the respective manifolds 102 and 104.
In another embodiment, referring to FIG. 10, FIG. 15 and FIG. 16, the first manifold 102 can include a first header plate 120, a first cover 124, and one or more first internal plates 122 configured between the first header plate 120 and the first cover 124. The first header plate 120 can include slots 126 and slots 128, which are arranged alternatively along length of the first header plate 120. The slots 126 are arranged in one row, whereas the slots 128 are arranged in two adjacent rows. In addition, the slots 126 are longer than the slots 128. Similarly, the first inner plates 122 can also include a plurality of slots 127a and 127b corresponding to the slots 126 and 128 of the header plate 120. In addition, the first cover 124 can include three channels 106a, 106b and 106c on an outer side and extending along the length of the first cover 124. The first cover 124 can further include three sets of openings, such as openings 107a, openings 107b and openings 107c, on a side, i.e. inner side, facing the first internal plates 122 and configured along the length of the first cover 124. The two sets of openings 107a and 107c can be offset from the other set of openings 107b along length of the first cover 124.
For instance, the set of openings 107b are adapted to fluidically connect the channel 106b with the sets of tubes 112/114 fitted to odd number of slots 126 of the first header plate 120, whereas the sets of openings 107a and 107c are adapted to fluidically connect the channel 106a and 106c with the sets of tubes 112/114 fitted to even number of slots 126 of the first header plate 120. For instance, the plurality of openings 107b are configured to fluidically connect the channel 106b to the one or more sets of first tubes 112 through the corresponding slots 127a and 126 of the first internal plates 122 and the first header plate 120, whereas the plurality of openings 107a and 107c are configured to fluidically connect the channel 106a and 106c to the one or more sets of the second tubes 114, arranged in two adjacent rows, through the corresponding slots 127b and 128 of the first internal plates 122 and the first header plate 120. This enables flow of the first fluid and/or the second fluid separately though the sets of first tubes 112 and the sets of second tubes 114.
Similarly, the second manifold 104 can include a second header plate 130, a second cover 134, and one or more second internal plates 132 configured between the second header plate 130 and the second cover 134, as shown in FIG. 17 and FIG. 18. The second header plate 130 can include slots 126, and 128, which are arranged alternatively along length of the second header plate 130. The second inner plates 132 can also include slots 127 corresponding to the slots 126 and slots 128 of the second header plate 130. In addition, the second cover 134 can include one channels 108a on an outer side and extending along the length of the second cover 134. The second cover 134 can further include a set of openings 110a on the inner side facing the second internal plates 132 and configured along the length of the second cover 134 with a gap between the adjacent openings 110a.
For instance, the set of openings 110a are adapted to fluidically connect the channel 108a with the sets of tubes 112/114 fitted to odd number of slots 126 of the second header plate 130. For instance, the first openings 110a are configured to fluidically connect the channel 108a to the one or more sets of first tubes 112 through the corresponding slots 127 and 126 of the second internal plates 132 and the second header plate 130.
In another embodiment, as shown in FIG. 10, two connection blocks 140 and 142 are connected to the first manifold 102 and the second manifold 104, respectively. The connection block 140 can include three ports 144a, 144b and 144c fluidically connected to the channels 106a, 106b and 106c, respectively, of the first manifold 102. Similarly, the connection block 142 can include a port 144d fluidically connected to the channels 108d of the second manifold 104.
In another embodiment, the heat exchanger 100 can include more than two connection blocks, for instance three or four connections blacks with ports, which can be connected on one or both top and bottom sides, and/or even on lateral sides, of the respective manifolds 102 and 104.
In an exemplary embodiment, the disclosed heat exchanger 100 can be implemented between a low-pressure side, e.g. evaporator, and a high-pressure side, e.g. gas cooler, of a cooling loop of a vehicle. For instance, for the heat exchanger with two I-flow passages, as shown in FIG. 1, any of the low pressure side and the high pressure side of the cooling loop can be connected on any side of the heat exchanger 100 to receive the low pressure refrigerant and the high pressure refrigerant, wherein during the flow in the core 150, the heat exchange occurs between the low pressure refrigerant and the high pressure refrigerant as the temperature of the high pressure refrigerant is more than the temperature of the low pressure refrigerant.
In an embodiment, as shown in FIG. 10, the first fluid (indicated by arrow 103a) enters through the port 144b of the connection block 140 into the first manifold 102, travel through the sets of first tubes 112, reach the second manifold 104 and egress the heat exchanger 100 through the port 144d of the connection block 142 connected to the second manifold 104. Whereas, the second fluid enters through the port 144a of the connection block 140 into the first manifold 102, travel through one row of the sets of second tubes 114, reach the second manifold 104 and then return through another row of the sets of second tubes 114 to the first manifold 102, and further the second fluid egress the heat exchanger 100 through the port 144c of the connection block 140 connected to the first manifold 102. In this case, heat exchange between the first fluid and the second fluid also occurs in the first manifold 102 in addition to heat exchange in the core 150.
In another embodiment, as shown in FIG. 20, the first fluid (indicated by arrow 103a) enters through the port 144d of the connection block 142 into the second manifold 104, travel through the sets of first tubes 112, reach the first manifold 102 and egress the heat exchanger 100 through the port 144b of the connection block 140 connected to the first manifold 102. Whereas, the second fluid (indicated by arrow 103b) enters through the port 144a of the connection block 140 into the first manifold 102, travel through one row of the sets of second tubes 114, reach the second manifold 104 and then return through another row of the sets of second tubes 114 to the first manifold 102, and further the second fluid egress the heat exchanger 100 through the port 144c of the connection block 140 connected to the first manifold 102. In this case, heat exchange between the first fluid and the second fluid also occurs in the first manifold 102 in addition to heat exchange in the core 150.
In an exemplary embodiment, the disclosed heat exchanger 100 can be implemented between a low-pressure side, e.g. evaporator, and a high-pressure side, e.g. gas cooler, of a cooling loop of a vehicle. For instance, the heat exchanger with one U-flow passage and one I-flow passage, as shown in FIG. 10 and 20, the low pressure side of the cooling loop can be connected I-flow passage of the heat exchanger 100 to receive the low pressure refrigerant and the high pressure side of the cooling loop can be connected U-flow passage of the heat exchanger 100 to receive the high pressure refrigerant, wherein during the flow in the core 150, the heat exchange between the low pressure refrigerant and the high pressure refrigerant occurs as the temperature of the high pressure refrigerant is more than the temperature of the low pressure refrigerant.
In an embodiment, the components, such as the tubes 112 and 114, manifolds 102 and 104, and spacers 118, connection blocks 140 and 142, and other elements of the heat exchanger can be joined to each other through one or more joining processes selected from a group of processes including brazing, welding, gluing and the like.
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 heat exchanger (100) for a motor vehicle comprising:
a first manifold (102);

a second manifold (104) configured spaced apart from the first manifold (102); and

a plurality of tubes (112, 114) fluidically connected between the first manifold (102) and the second manifold (104), the tubes (112, 114) being configured to enable circulation of at least one of a first fluid and a second fluid between the first manifold (102) and the second manifold (104);

wherein the plurality of tubes (112, 114) comprises one or more sets of first tubes (112) and one or more sets of second tubes (114), wherein the one or more sets of first tubes (112) and the one or more sets of second tubes (114) are arranged one above another in an alternate manner in at least one row such that at least a portion of neighboring tubes of the corresponding set of first tubes (112) and the set of second tubes (114) abut with each other;

wherein the first manifold (102) comprises at least one channel (106a, 106b, 106c) on an outer side of the first manifold (102) and at least one set of openings (107a, 107b, 107c) on a side opposite to the outer side, at least one set of openings (107a, 107b, 107c) being fluidically connect to at least one channel (106a, 106b, 106c); and

wherein the second manifold (104) comprises at least one channel (108a, 108b) on an outer side of the second manifold (104) and at least one set of openings (110a, 110b) on a side opposite to the outer side, at least one set of openings (110a, 110b) being fluidically connect at least one channel (108a, 106b).
The heat exchanger (100) as claimed in the previous claim, wherein the first manifold (102) comprises two channels (106a, 106b), and wherein the second manifold (104) comprises two channels (108a, 108b).
The heat exchanger (100) as claimed in any of the previous claims, wherein the first manifold (102) comprises three channels (106a, 106b, 106c), and wherein the second manifold (104) comprises one channel (108a).
The heat exchanger (100) as claimed in any of the previous claims, wherein each set of tubes of the one or more sets of first tubes (112) and the one or more sets of second tubes (114) comprises at least two tubes.
The heat exchanger (100) as claimed in any of the previous claims, wherein each tube of the plurality of tubes (112, 114) comprises an intermediate flat tube section (116a), two opposite tube end sections (116c), and two tube bend sections (116b) between the intermediate flat tube section (116a) and the two opposite tube end sections (116c).
The heat exchanger (100) as claimed in any of the previous claims, wherein at least two tubes of each of the one or more sets of first tubes (112) and the one or more sets of second tubes (114) are configured such that the intermediate flat tube sections (116a) of at least two tubes extend substantially in a parallel and spaced manner to each other and the tube end sections (116c) are stacked on each other in a corresponding single tube slot (126, 128) of the manifold (102, 104).
The heat exchanger (100) as claimed in any of the previous claims, wherein spacers (118) are provided in a gap between at least two tubes of each of the one or more sets of first tubes (112) and the one or more sets of second tubes (114).
The heat exchanger (100) as claimed in any of the previous claims, wherein the one or more sets of first tubes (112) and the one or more sets of second tubes (114) are arranged one above another in an alternate manner such that the intermediate flat tube sections (116a) of neighboring tubes of the corresponding set of first tubes (112) and the set of second tubes (114) abut with each other.
The heat exchanger (100) as claimed in any of the previous claims, wherein a width of each tube of the one or more sets of first tubes (112) is equal to the width of each tube of the one or more sets of second tubes (114).
The heat exchanger (100) as claimed in any of the previous claims, wherein the one or more sets of first tubes (112) are arranged in single row and the one or more sets of second tubes (114) are arranged in two adjacent rows in an alternate manner.
The heat exchanger (100) as claimed in any of the previous claims, wherein a width of each tube of the one or more sets of first tubes (112) is greater than the width of each tube of the one or more sets of second tubes (114).
The heat exchanger (100) as claimed in any of the previous claims, wherein the first manifold (102) includes a first header plate (120), a first cover (124), and one or more first internal plates (122) configured between the first header plate (120) and the first cover (124).
The heat exchanger (100) as claimed in any of the previous claims, wherein the second manifold (104) includes a second header plate (130), a second cover (134), and one or more second internal plates (132) configured between the second header plate (130) and the second cover (134).
The heat exchanger (100) as claimed in any of the previous claims, further comprises two or more connection blocks (140, 142) connected to the first manifold (102) and the second manifold (104), wherein each connection block (140, 142) comprises one or more ports (144a, 144b, 144c, 114d).