LU500400B1

LU500400B1 - Heat exchanger assembly

Info

Publication number: LU500400B1
Application number: LU500400A
Authority: LU
Inventors: Chris Calhoun; Jérome POMMAY
Original assignee: Estra Automotive Systems Luxembourg S A R L
Priority date: 2021-07-07
Filing date: 2021-07-07
Publication date: 2023-01-10

Abstract

A heat exchanger assembly (10) comprises a heat exchanger (12) including a core (20) with a plurality of heat exchanger tubes (26) for carrying a coolant fluid, the core (20) extending between two opposite manifolds (16, 18), a first reinforcement member (30) extending along a lateral side (24) of the core between the manifolds (16, 18). At least one plastic mounting bracket (14) is installed to a corner of the heat exchanger (12) and comprises: a body (42) with a socket portion (44) closely fitted around a manifold end and a profiled portion (50) extending from the socket portion (44) and embracing the first reinforcement member (30), the profiled portion (50) including a central wall (56) extending along the reinforcement member (30, 32) and two opposite lateral walls (52, 54) projecting from the central wall on opposite sides of the core (20); at least one retention finger (60, 62, 64, 66) arranged on one of the lateral walls (52, 54) and configured to lock on the first reinforcement member (30); a locking pin (68) protruding from the central wall (56) and inserted into a hole (40) in the first reinforcement member (30); and a mounting feature (70) extending from the body (42).

Description

Heat exchanger assembly LU500400 Technical Field

[0001] The invention generally relates to the field of heat exchangers, and specifically to a heat exchanger assembly comprising a mounting bracket. Background Art

[0002] In vehicles such as passenger cars or trucks, heat exchangers are used as part of cooling circuits, which in turn are needed for cooling vehicle components like the engine, the transmission etc. Some of these cooling circuits employ a liquid heat exchange medium, which receives heat from the vehicle components and transfers heat to ambient air at the main heat exchanger, like a radiator, installed in the front of the vehicle. In other cases, the heat exchanger is a condenser, wherein the heat exchange medium (or fluid) enters the condenser in gaseous state, is condensed and cooled in the condenser and exits the condenser in liquid state.

[0003] Automotive heat exchangers generally include a central core made of regularly spaced tubes and featured with corrugated air fins. The tubes extend between a pair of tanks (or manifolds) at opposite ends of the core. A pair of reinforcement members extend along opposite edges of the core between the tanks. Two configurations are conventionally used for the heat exchangers: in the so-called crossflow configuration, the tanks are vertically oriented and the tubes forming the central core are horizontally oriented; alternatively, the heat exchanger tanks are horizontally oriented, and the tubes forming the central core are vertically oriented, which is referred to as downflow configuration.

[0004] A heat exchanger may be mounted directly into a vehicle but generally, two or more heat exchangers are used in combination. Such assemblies of multiple heat exchangers generally comprise a condenser, a radiator and a fan unit, thereby forming a cooling module, commonly referred to as CRFM, standing for Condenser Radiator and Fan Module. The condenser and radiator are rectangularly shaped of more or less comparable dimensions and placed in a closely-spaced, stacked relationship at a vehicle location where air flow therethrough is facilitated. In this regard, the fan unit is placed adjacent the condenser/radiator pair so as to assure air flow therethrough even in situations where the motor vehicle is stationary. The condenser is commonly mounted to the radiator by bracket(s) extending either from the header tanks or from LU500400 the reinforcement members, wherein the bracket(s) accepts a fastener such as a bolt.

[0005] Conventionally, most of the brackets are metal pieces that are somehow held in place before the brazing operation and then are brazed into a fixed attachment. Such brackets are, e.g., disclosed in US 5,570,737. The bracket clamps on to the header tank prior to the furnace brazing of the heat exchanger assembly. The addition of the bracket during the furnace brazing introduces irregularities to the braze temperature profile. In addition, such brackets are limited to locations on the pre- brazed heat exchanger that are able to receive and retain the bracket until after the brazing joins the components. Moreover, such brackets are meant to be fastened to manifolds of a second heat exchanger and cannot be fastened to reinforcement members. Therefore, such brackets are not compatible with downflow cooling modules.

[0006] To avoid such drawbacks, a plastic bracket may be snapped onto the heat exchanger, such as disclosed in US 6,513,579. These plastic brackets are light molded pieces that are attached to the corners of the heat exchanger entirely post braze, in a press fit operation that requires no additional fasteners. However, they are shaped to be used only with rectangle or square-shaped tanks. Furthermore, they include rigid snap on features that tend to damage the reinforcement members.

[0007] An alternative design for mounting brackets is disclosed in US 7,117,927. Such brackets have a U-shape and are merely clamped on the heat exchanger around the reinforcement members post-braze. However, such a design of mounting brackets presents enough robustness only because it uses the surface of the core like a clamp load, which gives rise to tube damage and center debonding. The design may also cause localized corrosion as the legs of the U-shaped bracket must be in close contact with the surface of the heat exchanger to prevent the bracket from slipping along the reinforcement members. Moreover, such brackets may rotate or at least tilt around the reinforcement members, thereby complicating the assembly of heat exchangers or the mounting of CRFM.

Technical Problem LU500400

[0008] It is thus an object of the present invention to provide an alternative, improved design of a heat exchanger mounting bracket that does not comprise the above- mentioned drawbacks.

[0009] This problem is solved by a heat exchanger assembly as claimed in claim 1. Summary of the Invention

[0010] According to the present invention, a heat exchanger assembly comprises a heat exchanger having a core with a plurality of heat exchanger tubes for carrying a coolant fluid. The core extending between two opposite manifolds. The tubes are generally flat tubes arranged in parallel to be in fluid communication with the manifolds. A first reinforcement member extends along a lateral side of the core between the manifolds. Generally, a second reinforcement member is provided on the opposite side of the core, also extending between the manifolds. Conventionally, the reinforcement members are rigidly connected to the manifolds. The heat exchanger thus has core with opposite front and rear sides, and the lateral sides of the core are surrounded by the manifolds and reinforcement members, forming a kind of frame.

[0011] At least one plastic mounting bracket is installed to a corner of the heat exchanger. The mounting bracket comprises a body with a socket portion closely fitted around a manifold end and a profiled portion extending from the socket portion and embracing the first reinforcement member, the profiled portion including a central wall extending along the reinforcement member and two opposite lateral walls projecting from the central wall on opposite sides of the core.

[0012] At least one retention finger is arranged on one of the lateral walls and configured to lock on the first reinforcement member.

[0013] A locking pin protrudes from the central wall and is inserted into a hole in the first reinforcement member. The locking pin may e.g. be arranged at equal distance from the lateral walls.

[0014] The mounting bracket further includes a mounting feature extending from the body.

[0015] The inventive mounting bracket can be easily manufactured by injection LU500400 molding and allows for rapid, firm and secure mounting onto the heat exchanger. The mounting feature extending from the body of the mounting bracket, generally away from the core, can take various forms and allows fixing the heat exchanger to any structure, in particular to another heat exchanger. For example, the mounting feature may be formed as a flange, in particular a flat flange with an opening therein for a fastening member. Alternatively, the mounting feature may be designed as a pin, or as tab, in particular a reinforced tab, that cooperates with a receiving portion of the structure / heat exchanger to which the heat exchanged with the present mounting brackets is mounted.

[0016] The present invention is of particular interest where the heat exchanger is a condenser with vertical manifolds, which is to be mounted on a downflow-type radiator with horizontal plastic manifolds.

[0017] Advantageously, the socket portion of the mounting bracket comprises an inner surface with crush ribs that are plastically deformed during assembly of the mounting bracket, in order to provide a press fit mounting onto the manifold end.

[0018] In embodiments, the retention finger comprises a resilient tab disposed in the respective lateral wall to extend from a connection end; and a protrusion extending inward toward the opposite lateral wall and configured to lockingly engage a respective edge portion of the first reinforcement member. The protrusion may be disposed on a free end of the resilient tab and present a ramp to allow the finger to move over the first reinforcement member as the resilient tab flexes outward from said lateral wall until the ramp snaps over the edge portion.

[0019] Depending on embodiments, the edge portion may be a portion of a longitudinal edge of the first reinforcement member or an edge defined by an aperture in the first reinforcement member.

[0020] In embodiments, the mounting bracket may comprise four retention fingers, two on each lateral wall.

[0021] One, preferably both, of the manifolds of the heat exchanger may be a round, one-piece manifold.

[0022] According to another aspect, the present invention relates to a cooling module LU500400 as claimed in claim 12 or 13. Brief Description of the Drawings

[0023] Embodiments of the invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which: Fig.1 is a perspective view of a heat exchanger assembly according to the invention; Fig.2 is a perspective view of a detail of the heat exchanger assembly of Fig.1; Fig.3 is a first perspective view of a mounting bracket of the heat exchanger assembly of Fig.1; Fig.4 is a second perspective view of a mounting bracket of the heat exchanger assembly of Fig.1; Fig.5 is a cross-sectional view in the Y-Z plan of the heat exchanger assembly of Fig.2; Fig.6 is a cross-sectional view in the X-Z plan of the heat exchanger assembly of Fig.2; Fig.7 is a cross-sectional view in the X-Y plan of the heat exchanger assembly of Fig.2; and Fig.8 is a perspective view of a cooling module comprising the heat exchanger assembly of Fig.1. Description of Preferred Embodiments

[0024] Referring to the Figures, a heat exchanger assembly 10 generally comprises a heat exchanger 12 e.g. a condenser, radiator, or the like and at least one mounting bracket 14, 114.

[0025] The heat exchanger 12 comprises a basic core 20 of conventional design with flow tubes 26 and intervening air centers or air fins, which are not shown in detail. The exchanger core 20 extends along a first axis Z as well as along a second axis Y, which in the exemplary embodiments of Fig.1 and 8 are respectively a vertical axis and a lateral axis of the vehicle. The heat exchanger core 20 therefore presents faces 22.1,

22.2 inthe Y-Z plan. The exchanger core thickness then extends along the third axis LU500400 X. The heat exchanger 12 offers a crossflow configuration, whereby the tubes 26 extend along the Y axis.

[0026] The core (or exchanger core) 20 is surrounded by a four sided, generally rectangular frame. Two sides of the frame are comprised of a pair of manifolds 16, 18, also referred to as header tanks, typically metal (e.g. brazeable aluminum alloy) or plastic, and the other two sides are a pair of reinforcement members (or core reinforcements) 30, 32. The reinforcement members 30, 32 extend along the edges of the core (Y direction) and are fixed at both ends to the manifolds 16, 18, thereby forming four right angle corners.

[0027] The first manifold 18 is connected by the exchanger core 20 (or simply core) to the second manifold 16. The first manifold 18 and the second manifold 16 each have a roughly circular shape and are elongate along the first axis Z, which is a vertical axis of the vehicle when the heat exchanger 12 is in the embodiment of Fig.1. Both manifolds 16, 18 are identically shaped. It should be noted that the shape of the manifolds is roughly circular in the embodiment presented in the figures, but they may be generally cylindrical with various kinds of cross-section, including prismatic shapes.

[0028] The fluid to be cooled enters the heat exchanger via the first manifold 18 and flows through the tubes of the exchanger core 20, where it is cooled by ambient air, to the second manifold 16. The first and second manifolds can be respectively inlet and outlet manifolds. However, according to the non-limiting exemplary embodiment of the figures, the first manifold 18 can present an inlet fluid portion and an outlet fluid portion. The inlet portion receives a fluid through an inlet port during operation of the heat exchanger. The fluid is then distributed to a lower part of the exchanger core 20 and guided to the second manifold 16. From there, it is distributed to an upper part of the exchanger core 20 and guided to the outlet portion of the first manifold, which communicates with an outlet port to evacuate the fluid. A first block fitting 28 is connected to the inlet port of the inlet portion of the first manifold 18, while a second block fitting 28’ is connected to the outlet port of the outlet portion of the first manifold

18. When installed in the vehicle, additional pipes (not shown) of a cooling circuit are connected to the block fittings 28, 28’.

[0029] The reinforcement members 30, 32, which are typically metal bars with L or U- LU500400 shaped cross section, rest over and protect the outermost pair of air centers, thereby allowing the core to be banded together prior to brazing. Each reinforcement member 30, 32 presents at least one edge 34 extending between a first and a second end. As shown in Fig.6 the reinforcement member presents a U-shape with two legs 36.1, 36.2 extending along the faces 22.1, 22.2 of the core 20 and a central portion 38 extending over a side 24 of the core. Each leg 36.1, 36.2 forms an edge 34 along one face 22.1,

22.2. of the core 20. The reinforcement member 30, 32 can be generally manufactured by any known method, such as stamping, extrusion or machining. It should be noted that the reinforcement members may also present an L-shape having a short leg extending along one face of the core and a longer leg perpendicular to the short leg extending along the side of the core. Or one reinforcement member may present an L-shape while the other presents a U-shape.

[0030] The reinforcement member 30, 32 has at least one opening 40, e.g. a through hole, in the central portion 38. As will become clear below, the opening 40 is arranged to stably assemble the bracket 14 to the heat exchanger 12 by preventing tilting of the bracket 14 around the Y-axis.

[0031] Referring to Fig.1 and Fig.8, the heat exchanger 12 is shown with four corner brackets 14, 114 so that the heat exchanger assembly 10 comprises four mounting brackets, namely two upper mounting brackets 14 and two lower mounting brackets

114. Each bracket 14, 114 is an injection molded, hollow plastic part, attached to the corners of heat exchanger 12 post braze and without the use of any separate fasteners.

[0032] Turning now to Fig.3 to Fig.7, the mounting brackets 14 will be described in details.

[0033] Each mounting bracket 14 has a body 42 comprising a socket portion 44 with an integral profiled portion 50. The socket portion 44 is designed to closely match the shape of the manifolds 16, 18 and configured to tightly enclose one end of a manifold. In other words, the socket portion 44 acts as a closely-fitted cap above one end of a manifold 16. The socket portion comprises a peripheral wall 44.2 extending around the manifold from one side to the other, and closed at the top by a cover 44.3.

[0034] The socket portion 44 comprises a plurality of crush ribs 46. The crush ribs 46 LU500400 are formed as protrusions on the inner surface 44.1 of the peripheral wall 44.2, each rib 46 extending axially along the Z-axis and protruding radially inwardly (Fig.4). The ribs are preferably integrally formed with the socket portion 44 during the molding of the mounting bracket 14.

[0035] Each rib 46 presents a width W (in circumferential direction), which can be identical for all ribs or can vary from rib to rib. As shown in the embodiment of Fig.7, all ribs 46 have the same width W, which width W is smaller than the space S between two adjacent ribs 46. It is however possible, and still within the scope of the present invention, to reduce the space S between adjacent ribs, e.g. either by providing more ribs 46 or by increasing the width W of each rib. The ribs 46 of the plurality of crushed ribs may be regularly provided on the whole inner surface 44.1 of the socket portion 44 (Fig. 4 and Fig.7), but alternatively ribs may be formed in a random way on the inner surface 44.1, ribs may be formed on only one portion of the inner surface 44.1, or ribs may be formed as groups of two, three or more ribs, each group being arranged on the inner surface 44.1 of the socket portion 44 so that the space between two distinct groups of ribs is larger than the space between two adjacent ribs of the same groups.

[0036] The plurality of crush ribs allows firmly securing the mounting bracket around the manifold (Fig.7) in a press-fitting manner. In other words, the crush ribs 46 maintain the mounting bracket 14 in place around the manifold 16 by firmly and entirely griping the end of the manifold. In other words, the plurality of crush ribs 46 provide strong resistance to pulling off the socket portion 44 (and thereby the mounting bracket 14) of the end of the manifold 16.

[0037] The profiled portion 50 of the mounting bracket 14 extends from the socket portion 44 and comprises a pair of opposite lateral walls 52, 54 extending from a central wall 56. In the assembled position, the central wall extends along the reinforcement member, in contact or close vicinity thereof, and the first and second lateral walls 52, 54 extend along the faces 22.1, 22.2 of the heat exchanger 12.

[0038] The lateral wall 52, 54 with central walls 56 form a channel 58 which tightly embraces (fits around) the upper side 24 and reinforcement member of the heat exchanger 12 in the assembled state of the heat exchanger assembly 10. The channel

58, along with the crush ribs 46 in the socket 44 permit aligning the mounting bracket LU500400 14 onto the heat exchanger 12 during assembly.

[0039] Retention fingers 60, 62, 64, 66 are integrated in the lateral walls 52, 54. Here the retention fingers are arranged by pairs 60, 62 and 64, 66, on each wall. They are spaced apart from each other, so that a plain portion of the respective wall is formed between two retention fingers.

[0040] In this embodiment, the retention fingers are arranged in facing relationship. They may alternatively be arranged in a staggered manner, so that each finger would be facing a plain portion of the opposite wall.

[0041] Each one of the four retention fingers is formed as a resilient tab disposed to extend from a connection in a cantilever fashion within the lateral wall, whereby the tab is surrounded by a gap except at the connection. The tab presents a protrusion

60.1, 62.1, 64.1 disposed on a free end of the resilient tab (opposite the connection) and extending inward toward the opposite wall.

[0042] The protrusion 60.1, 62.1, 64.1 presents a ramp or inclined surface 60.2, 62.2,

64.2, which allows the retention finger 60, 62, 64 to flex outward for snapping over and engaging with the reinforcement member 30, 32 of the heat exchanger 12. As shown in Fig.6, the ramp 60.2, 62.2 of the protrusion 60.1, 62.1 snaps over and engages the edge 34 of the reinforcement member 30 to secure the bracket 14 to the reinforcement member and to prevent removal of the bracket from the reinforcement member.

[0043] A locking pin 68 is formed as a protrusion extending from the center wall 56 of the profiled portion 50 in the same direction as the lateral walls 52, 54. The pin 68 is preferably centered between the two lateral walls 52, 54, i.e. the locking pin 68 is arranged at equal distance from the walls 52, 54. The pin 68 presents a rounded shape to match and easily engage through a round opening 40 in the reinforcement member

30. It should be noted that the pin 68 and opening 40 may present different shapes, e.g. prismatic shapes, but complementary to each other in order to facilitate the insertion of the pin through the opening.

[0044] In the assembled stated of the heat exchanger assembly 10, the locking pin 68 thus extends into the opening 40 of the reinforcement member 30, 32 to retain the mounting bracket 14 and prevents its slipping along or its tilting around the Y-axis.

[0045] The mounting bracket 14 further comprises an integral mounting feature 70 LU500400 extending from the base wall 56 of the flange section 50 in the direction opposite to the first 52 and second 54 walls. The mounting feature 70 is here a flat flange provided with a through hole 72 to allow the mounting bracket 14 to be secured to a structure in the vehicle, or to another heat exchanger or heat exchanger assembly. The dimensions of the through hole 72 will be adapted in practice depending in the type/size of the matching fixing member, such as e.g. a screw, pin, rivet, etc.

[0046] Mounting brackets 114, arranged on the lower side of heat exchanger 12, are similar to mounting brackets 14, and include identical socket and profiled sections, however the mounting feature is different. Indeed, the mounting feature 174 of mounting bracket 114 is designed as fixing tab that is mounted by engagement into a mating feature on the vehicle or on another heat exchanger, or for mating with other components or insulators. The fixing tab is advantageously reinforced by ribbing for increased stiffness

[0047] As visible in the embodiment of Fig.1, the heat exchanger assembly comprises four mounting brackets 14, 114, wherein the two upper brackets 14 along the Z-axis comprise a mounting flange 70 including a through hole 72, while the two lower brackets 114 comprise a tab-like mounting flange 174.

[0048] In the context of CRFM applications, the heat exchanger 12 can be mounted to a second heat exchanger 80 as shown in Fig.8. The present assembly is of particular interest where the heat exchanger 12 is a crossflow condenser equipped with the present mounting brackets 14, 114 (as presented in Fig.1 to Fig.8) and the second heat exchanger 80 is a downflow type radiator. The condenser and radiator thus form a condenser radiator cooling module 82. In the assembled state of the cooling module 82, the condenser 12 and the radiator 80 are arranged in a parallel (or layered) manner, in front of one another.

[0049] The radiator comprises two horizontal (Y-axis) manifolds 84, 86 and a core 88 extending between the two manifolds with two reinforcement members 90 extending in the Z-direction. The mounting brackets 14, 114 mounted at the corners of the condenser 12 allow fastening of the condenser to the manifolds 84, 86 of the radiator 80 by means of the mounting features 70, 174. In practice, the tab-like mounting features of the lower mounting brackets 114 are first engaged in corresponding receiving members 92 of the lower manifold 86. Then screws (not shown) are inserted LU500400 through holes 72 in flanges 70 of the upper mounting brackets 14, which engage into threaded bores (not visible) in the upper manifold 84.

[0050] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments.

Claims

Claims LU500400

1. A heat exchanger assembly (10) comprising: a heat exchanger (12) comprising a core (20) with a plurality of heat exchanger tubes (26) for carrying a coolant fluid, the core (20) extending between two opposite manifolds (16, 18), a first reinforcement member (30) extending along a lateral side (24) of the core between the manifolds (16, 18); at least one plastic mounting bracket (14) installed to a corner of the heat exchanger (12), the mounting bracket (14) comprising: - a body (42) with a socket portion (44) closely fitted around a manifold end and a profiled portion (50) extending from the socket portion (44) and embracing said first reinforcement member (30), the profiled portion (50) including a central wall (56) extending along the reinforcement member (30, 32) and two opposite lateral walls (52, 54) projecting from the central wall on opposite sides of the core (20); - at least one retention finger (60, 62, 64, 66) arranged on one of the lateral walls (52, 54) and configured to lock on the first reinforcement member (30); - a locking pin (68) protruding from the central wall (56) and inserted into a hole (40) in the first reinforcement member (30); and - a mounting feature (70) extending from the body (42).

2. The heat exchanger assembly (10) according to claim 1, wherein the locking pin (68) of the mounting bracket (14) is arranged at equal distance from the lateral walls (52, 54).

3. The heat exchanger assembly (10) according to claim 1 or 2, wherein the retention finger (60, 62, 64, 66) comprises aresilient tab disposed in the respective lateral wall to extend from a connection end; and a protrusion (60.1, 62.1, 64.1) extending inward toward the opposite lateral wall and configured to lockingly engage a respective edge portion of the first reinforcement member (30).

4. The heat exchanger assembly (10) according to claim 3, wherein the protrusion LU500400 (60.1, 62.1, 64.1) is disposed on a free end of said resilient tab and presents a ramp (60.2, 62.2, 64.2) to allow the finger to move over said first reinforcement member as said resilient tab flexes outward from said lateral wall (52, 54) until said ramp (60.2, 62.2, 64.2) snaps over said edge portion.

5. The heat exchanger assembly (10) according to claim $ or +, wherein said edge portion is part of a longitudinal edge (34) of said first reinforcement member (30) or an edge defined by an aperture in said first reinforcement member.

6. The heat exchanger assembly (10) according to any one of the preceding claims, wherein the mounting bracket (14) comprises four retention fingers (60, 62, 64, 66), two on each lateral wall (52, 54).

7. The heat exchanger assembly (10) according to any one of the preceding claims, wherein the socket portion (44) of the mounting bracket (14) comprises an inner surface (44.1) with crush ribs (46) that are plastically deformed during assembly of the mounting bracket (14), in order to provide a press fit mounting.

8. The heat exchanger assembly (10) according to any one of the preceding claims, wherein the mounting feature (70) is formed as a flange, in particular a flat flange (70) with an opening (72) therein for a fastening member, as a pin, or as tab, in particular a reinforced tab.

9. The heat exchanger assembly (10) according to any one of the preceding claims, wherein the mounting bracket (14) is formed by injection molding.

10. The heat exchanger assembly (10) according to any one of the preceding claims, wherein at least one, preferably both, of the manifolds (16, 18) of the heat exchanger is a round, one-piece manifold.

11. The heat exchanger assembly (10) according to any one of the preceding claims, wherein the heat exchanger (12) is a condenser.

12. A cooling module comprising: - an assembly of a first heat exchanger (12) with mounting brackets (14, 114) as claimed in any one of the preceding claims; and - at least a second heat exchanger (80) comprising two manifolds (84, 86), a core with a plurality of parallel tubes extending between the two manifolds; wherein the first heat exchanger (12) is mounted to the second heat exchanger (80) by way of the mounting features (70, 174) of the mounting brackets (14, 114) installed to the corners of the first heat exchanger (12).

13. The cooling module according to claim 12, wherein the first heat exchanger (12) LU500400 is a condenser and the second heat exchanger (80) is a radiator, preferably a downflow radiator.