WO2003056264A1 - Echangeur de chaleur avec collecteur interne a fentes - Google Patents

Echangeur de chaleur avec collecteur interne a fentes Download PDF

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Publication number
WO2003056264A1
WO2003056264A1 PCT/CA2002/001999 CA0201999W WO03056264A1 WO 2003056264 A1 WO2003056264 A1 WO 2003056264A1 CA 0201999 W CA0201999 W CA 0201999W WO 03056264 A1 WO03056264 A1 WO 03056264A1
Authority
WO
WIPO (PCT)
Prior art keywords
manifold
tube
manifold tube
heat exchanger
wall
Prior art date
Application number
PCT/CA2002/001999
Other languages
English (en)
Inventor
Thomas F. Seiler
Brian E. Cheadle
Original Assignee
Dana Canada Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CA002366227A external-priority patent/CA2366227C/fr
Priority claimed from CA 2366332 external-priority patent/CA2366332A1/fr
Application filed by Dana Canada Corporation filed Critical Dana Canada Corporation
Priority to EP02787290A priority Critical patent/EP1461579A1/fr
Priority to AU2002351617A priority patent/AU2002351617A1/en
Publication of WO2003056264A1 publication Critical patent/WO2003056264A1/fr

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02Header boxes; End plates
    • F28F9/0246Arrangements for connecting header boxes with flow lines
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00Making other particular articles
    • B21D53/02Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/08Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal
    • B21D53/085Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal with fins places on zig-zag tubes or parallel tubes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/26Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/03Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits
    • F28D1/0308Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits the conduits being formed by paired plates touching each other
    • F28D1/0325Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits the conduits being formed by paired plates touching each other the plates having lateral openings therein for circulation of the heat-exchange medium from one conduit to another
    • F28D1/0333Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits the conduits being formed by paired plates touching each other the plates having lateral openings therein for circulation of the heat-exchange medium from one conduit to another the plates having integrated connecting members
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/02Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
    • F28D1/03Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits
    • F28D1/0391Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits a single plate being bent to form one or more conduits
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F3/00Plate-like or laminated elements; Assemblies of plate-like or laminated elements
    • F28F3/02Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
    • F28F3/025Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements
    • F28F3/027Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements with openings, e.g. louvered corrugated fins; Assemblies of corrugated strips
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/001Casings in the form of plate-like arrangements; Frames enclosing a heat exchange core
    • F28F9/002Casings in the form of plate-like arrangements; Frames enclosing a heat exchange core with fastening means for other structures
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02Header boxes; End plates
    • F28F9/0202Header boxes having their inner space divided by partitions
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02Header boxes; End plates
    • F28F9/026Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits
    • F28F9/0278Header boxes; End plates with static flow control means, e.g. with means for uniformly distributing heat exchange media into conduits in the form of stacked distribution plates or perforated plates arranged over end plates
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02Header boxes; End plates
    • F28F9/04Arrangements for sealing elements into header boxes or end plates
    • F28F9/16Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F28F9/182Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding the heat-exchange conduits having ends with a particular shape, e.g. deformed; the heat-exchange conduits or end plates having supplementary joining means, e.g. abutments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/0049Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for lubricants, e.g. oil coolers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/4935Heat exchanger or boiler making

Definitions

  • This invention relates to heat exchangers, and in particular to stacked plate heat exchangers using slotted manifold tubes.
  • the core elements are secured together by bolts, independently of the manifolds.
  • a heat exchanger that includes a manifold tube having a wall defining a flow passage therethrough and having a plurality of spaced apart openings formed through the wall in flow
  • the openings formed through the manifold tube wall may vary in size along a length of the manifold tube.
  • a method of assembling a stacked plate heat exchanger including steps of (a) providing a
  • -0 manifold tube having a wall defining a flow passage therethrough and having a plurality of spaced apart openings formed through the wall in flow communication with the flow passageway; (b) providing a plurality of flat tube elements each including a first plate and a second plate defining a flow channel therebetween, the plates each being provided with an aperture therethrough, the apertures in the first
  • a heat exchanger comprising a manifold tube having a wall defining a fluid flow passage therethrough and a stack of flat tube elements connected to the manifold tube and each having a flow channel therethrough in fluid communication with the fluid flow passage.
  • a baffle cup having a wall engages an inner surface of the manifold tube wall, the manifold tube wall having an error proofing hole formed therethrough at a location where the baffle cup wall is positioned, the hole being sized such that a visual check can be performed to ensure that the baffle cup is in place.
  • the error proofing hole is sealably covered by the wall of the baffle cup.
  • a heat exchanger comprising a manifold tube having a wall defining a fluid flow passage therethrough, a stack of flat tube elements connected to the manifold tube and each having a flow channel therethrough in flow communication with the fluid flow passage, and a port fixture having a collar providing an annular flow way surrounding an annular area of the manifold tube wall having a plurality of radially spaced openings formed therethrough.
  • the annular flow way is in flow communication with the fluid flow passage through the radially spaced openings
  • the port fixture having a connecting member extending from the collar and defining a fluid passageway in flow communication with the annular flow way.
  • Figure 1 is an elevational view of a preferred embodiment of a flat plate heat exchanger according to the present invention
  • Figure 2 is a perspective view of the heat exchanger of Figure 1 ;
  • Figure 3 is a partial sectional perspective view of the heat exchanger of Figure 1 ;
  • Figure 3A is a partial sectional elevational view showing an inlet port mounted to a manifold tube of the heat exchanger;
  • Figure 4 is a plan view of a plate pair tube element of the heat exchanger of Figure 1 ;
  • Figure 5 is an exploded elevational view of a plate pair tube element;
  • Figure 6 is a perspective view of a turbulizer of the plate pair tube element
  • Figure 7 is an elevational view of a manifold tube of the heat exchanger
  • Figure 8 is a plan view of the manifold tube
  • Figure 9 is a perspective view of a bracket for the heat exchanger according to one embodiment of the invention.
  • Figure 10 is a schematic illustration of an assembly process for the heat exchanger
  • Figure 11 is a partial sectional perspective view of the heat exchanger of Figure 1 , showing a hydraulic bladder being used to expand a manifold tube;
  • Figures 12A and 12B illustrate, in elevational view, the use of a tapered pin mandrel to expand a manifold tube
  • Figure 13 is a partial elevational view showing a manifold tube having slot openings in accordance with a further embodiment of the invention.
  • Figure 14 is a partial elevational view showing a manifold tube having slot openings 5 in accordance with still a further embodiment of the invention.
  • Figure 15 is a partial elevational view showing a flat tube element mounted on a manifold tube in accordance with a further embodiment of the invention.
  • Figure 16 is a partial elevational view showing a manifold tube having slot openings in accordance with a further embodiment of the invention.
  • FIG. 17 is a simplified elevational view showing a further embodiment of a heat exchanger in which a baffle cup is used to separate the manifold tubes;
  • Figure 18 is a sectional perspective view of a baffle cup
  • Figure 19 is a partial elevational view showing an error proofing hole for the baffle cup
  • FIG. 20 is a simplified elevational view of yet a further embodiment of a heat exchanger according to the present invention.
  • Figure 21 is a plan view of the heat exchanger of Figure 20;
  • Figure 22 is a partial sectional perspective view of a heat exchanger according to another embodiment of the invention.
  • Figure 23 is a plan view of a bracket of the heat exchanger of Figure 22;
  • Figure 24 is a plan view of a further bracket configuration
  • Figure 25 is a plan view of yet a further bracket configuration
  • Figure 26 is a sectional plan view of a further port fitting mounted on a tube manifold;
  • Figure 27 is an elevational view of the further port fitting;
  • Figure 28 is an elevational view of yet another port fitting
  • Figures 29 and 30 are partial sectional perspective views of further flat tube element embodiments.
  • Figure 31 is a elevational view of still a further embodiment of a heat exchanger according to the present invention.
  • the heat exchanger 10 is a single pass heat exchanger which may be used in an automotive application such as a transmission oil cooler or power steering fluid cooler, however the features of the present invention can be applied to a wide range of heat exchangers for different applications and the heat exchanger 10 of Figure 1 is provided as just one example of a heat exchanger according to the present invention.
  • the heat exchanger 10 includes a first manifold tube 12 and second manifold tube 14, which in the single pass configuration illustrated function as an intake manifold tube and an out take manifold tube respectively.
  • a plurality of elongate flat tube elements 16 are arranged in parallel fashion on the manifold tubes 12,14.
  • the flat tube elements 16 each include a first plate 18 and a second plate 20 sealed together to form a flow passage way 21 there between.
  • Air passages 22 are located between adjacent flat tube elements 16, and corrugated fins 24 are located in air passages 22, fins 24 being in thermal contact with adjacent flat tube elements 16 for providing a high surface area for heat exchange between the fins 24 and air flowing through the air passages 22.
  • the manifold tube 12 includes a series of slots 42 that are longitudinally spaced along and extend through the cylindrical wall of the manifold
  • the slots 42 are arranged so that their length runs transverse to the longitudinal axis of the manifold tube 12.
  • the flat tube elements 16 are each arranged along the manifold 12 so that each of the tube elements 16 is aligned with a respective one of the tube slots 42, and more particularly, so that the fluid passage 21 provided through each of the tube elements 16 is in flow communication with the
  • Similar slots are provided along the cylindrical wall of the out take manifold tube 14, and the out take ends of the flat tube elements 16 are arranged on the out take manifold 14 such that an out take end of each of the fluid passages 21 provided 15 through the flat plate tube elements 16 communicates with the flow passage 34 provided through the out take manifold tube 14 by way of the slots provided along the out take manifold tube 14.
  • a fluid inlet port 26 is provided on the intake manifold tube 12 and a fluid outlet port 28 is provided on the out take manifold tube 14.
  • the inlet and outlet ports 26, 28 are
  • the inlet port 26 defines a passage that is in flow communication with a fluid flow passage 30 provided through the interior of intake manifold tube 12 such that a fluid can flow through the inlet port 26 into the interior of the manifold tube 12 as illustrated by arrow 32 in Figure 3.
  • the outlet port 28 defines a flow
  • end plates 36 and 38 without flow passages there through are provided as the first and last plate on the heat exchanger 10.
  • End caps 40 which are shown in exploded view in Figures 1 and 2, can conveniently 30 be used to seal the ends of the intake and out take manifold tubes 12, 14. Brackets 43 may be positioned along the manifold tubes 12, 14 to permit the heat exchanger 10 to be secured in position.
  • the fluid to be cooled enters the heat exchanger 10 through the inlet port 26 and flows into the passage 30 in the intake manifold tube 12. From the intake manifold tube 12, the fluid is dispersed through slots 42 into the plurality of fluid passages 21 that are provided through the
  • the flat tube elements 16 each include openings at
  • each of the first and second plates 18,20 includes a elongate substantially planar central portion 56. Inwardly offset flanges 58 are located along
  • first and second plates 18, 20 are sealably connected along the longitudinal edges and end edges thereof through a brazing process.
  • the longitudinal flow passage 21 is defined between the central planar portions 58 of the first and second plates 18, 20.
  • a turbulizer or turbulator 62 is, in a preferred embodiment, located within the fluid channel 21 that is formed between the planar portions 56. Greater detail of one possible turbulizer 62 configuration is shown in Figure 6.
  • the turbulizer 62 includes a series of undulations or convolutions formed therein to create turbulence in the fluid flow and in this way increase heat transfer in the heat exchanger. In some embodiments, turbulizers may not be used, or could be 5 replaced by dimples, ribs or ripples formed on the plates 18,20.
  • an opening 44 is provided through one end of the flat tube element 16 for receiving the intake manifold tube 12, and a second spaced- apart opening 46 is located at the other end of the flat tube element 16 for receiving the out take manifold tube 14.
  • the opening 44 is provided
  • opening 46 is provided by aligned apertures 50 that are pierced through opposite ends of the plates 18, 20.
  • the apertures 48 and 50 are pierced through end portions of the outwardly offset planar portions 56 such that when the flat tube elements are assembled, the openings 44 and 46 are both in flow
  • the apertures 44,46 are, in a preferred embodiment, arranged such that an annular portion 23 of the flow channel 21 extends around the circumferences of the manifold tubes.
  • a peripheral flange 64 defines an inner circumference of each of the apertures 48. !0
  • the flange 64 extends outward (i.e. away from the flow channel) from the outer surface of the central planer portion 56.
  • the peripheral flanges 64 are integrally formed on their respective plates, and provide an overlap joint between the flat tube elements 16 and the respective manifold tubes 12,14, as can best be seen in Figure 3A.
  • the plates 18, 20, are roll formed to form the central planar portion 56 and longitudinal flanges 58, after which the roll formed raw plate is lanced at a desired length and peripheral end flanges 60 are end formed.
  • the apertures 48 and 50 are formed by piercing and subsequently extruding the peripheral flange 64.
  • the longitudinal flanges 58 can extend
  • Plates 18,20 could also be 5 formed using other techniques, including for example, stamping, however such alternatives may not be as flexible as roll forming for permitting changes in plate length.
  • Figure 7 shows an elevational view of a preferred embodiment of the intake manifold tube 12, which is basically a cylindrical wall having manifold tube slots 42 spaced
  • an inlet opening 68 is provided for the inlet port 26.
  • An outwardly extending flange 70 which in the illustrated embodiment is annular, is optionally provided at one end of the manifold tube 12 in order to provide a stop for the end plate 36 or 38 during assembly of the heat exchanger.
  • the slots 42 are preferably formed by using a die punch with internal die
  • slot forming methods could be used, for example, saw cutting, milling, piercing, laser cutting, or lancing.
  • an outer diameter of the manifold tube 12 is illustrated as having a dimension D1. Prior to assembly of the heat exchanger 10, the outer diameter D1 is less than an inner diameter D2 (see Figure 4) of the opening 44 .0 through the plate pair 16, in order to allow the plate pair 16 to be slidably mounted on the manifold 12.
  • the out take manifold tube 14 is basically identical to the intake manifold tube 12, and has an outer diameter D1 that, prior to assembly, is less than an inner diameter D2 of the opening 46 through each of the flat tube element 16 so that the plate pair elements can be mounted thereon.
  • the inlet port 26 includes a cylindrical collar 98 through which the intake manifold tube 12 can pass.
  • a cylindrical connecting wall 100 defining an inlet passage extends transversely from the collar 98.
  • the collar 98 can be supported by the peripheral flanges 64 of opposing flat tube elements as illustrated in Figure 3A in such a manner that it can
  • FIG. 30 shows in greater detail a mounting bracket 43 according to one embodiment of the invention for use on the intake or out take manifold tube 12,14 side of the heat exchanger 10.
  • Each mounting bracket 43 has first clip part 146 including spaced- apart C-shaped clips 148, 149, each of which defines respective contacting surfaces 150, and a central portion or spacer member 152 extends between and connects the clips 148,149.
  • a second clip part 154 has spaced apart C-shaped clips 156,157. Each clip 156,157 defines a respective contacting surface 158.
  • a central portion or spacer member 160 extends between and connects the clips 156,157.
  • the C- shaped clips 148, 149 are dimensioned to receive one flat tube element 16, and the C-shaped clips 156, 157 a second flat tube element 16.
  • the C-shaped clips are dimensioned to frictionally engage their respective flat tube element with sufficient force to hold the bracket in place until brazing occurs.
  • inlet and outlet ports 26, 28 and brackets 43 as described above are only one example of several different inlet and outlet port and bracket configurations that can be used with the present invention, and examples of further alternatives will be provided further below.
  • Alternative manifold tube and flat tube element configurations to those described above can be used as well, and examples of further alternatives will also be provided below. But first, a description of the elements of a preferred embodiment of the heat exchanger 10 having been provided, assembly of the elements to form the heat exchanger 10 will now be described.
  • a core heat exchanger stack (indicated by reference numeral 108 in Figure 11 ) is assembled from end plates 36,38, first and second plates 16, 18, turbulizers 62 and fins 24.
  • the end plate 38 is positioned (step 90-1 ) and a fin 24 placed along it (step 90-2), after which a first plate 16 is added (step90-3), followed by a turbulizer 62 (step 90-4), followed by a second plate 18 (step 90-5) such that the first and second plates 16,18 define fluid flow channel 21 therebetween in which the turbulizer 62 is positioned.
  • fittings namely the inlet and outlet ports 26,28 and brackets 43 are then 5 positioned on the core stack 108 as required (step 90-7).
  • the manifold tubes 12 and 14 are slidably inserted through the corresponding aligned apertures in the assembled core stack (step 90-8).
  • the annular flanges 70 on the ends of the manifold tubes 12 and 14 act as stop members to assist in positioning the manifold tubes.
  • the core I0 stack 108 is then compressed (step 90-9) until the slots 42 in the manifold tubes 12 and 14 are each aligned with a respective flow channel 21 through a corresponding flat tube element 16.
  • the manifold tubes 12 and 14 are each then internally expanded to increase their respective outer circumferences so that they each securely engage an inner
  • the manifold tubes 12 and 14 each have a respective outer diameter D1 ( Figure 8) that is less that an inner diameter D2 ( Figure 4) of the corresponding plate apertures 48 and 50, in order to facilitate assembly of the heat
  • the enlarged manifold tubes 12 and 14 each engage substantially the entire circumference of the plate apertures 48 and 50, respectively (in the preferred embodiment that is shown in
  • annular flange 64 is formed between each of annular flange 64 and the manifold tubes that it surrounds), preventing any further movement of the plates 16,18 relative to the enlarged manifold tubes 12 and 14.
  • a hydraulic bladder 102 is placed inside each of the manifold tubes 12 and 14, and expanded by pumping 30 hydraulic fluid through an inlet 106 to radially enlarge the manifold tubes in a substantially uniform manner along their entire lengths through radial pressure applied uniformly throughout the manifold tubes in the direction indicated by arrows 104.
  • the use of a uniform radial pressure along the length of the manifold tubes decreases any axial loading during the expansion process. Axial loading is generally not desired, especially in longer manifold tubes, as it can result in deformation that is exacerbated by the slotted nature of the manifold tubes.
  • FIGS 12A and 12B show pre-expansion and post-expansion, respectively, views illustrating the use of a stepped tapered pin mandrel 106 to radially expand the manifold tube 14 in the vicinity of each of the slots 42 to achieve locally pronounced expansion at the points along the manifold tube 14 where the flat tube elements (not shown in Figures 12A and 12B) are engaged by the manifold tube.
  • bands could be provided around the bladder to localize expansion at the points along the manifold tubes in the manner shown in Figure 12B.
  • end caps 40 are placed on the manifold tubes 12 and 14, for example by a swage or press-fit operation (step 90-11 ), after which the entire heat exchanger 10 assembly is sent to a brazing oven (step 90-12).
  • At least the first and second plates 18, 20 of the heat exchanger are preferably braze clad such that in the brazing oven, the flat tube elements are sealaby brazed along their respective edges, the peripheral flanges 64 about the plate apertures 48, 50 are sealably brazed about their entire circumferences to the manifold tubes 12,14, respectively, the end caps 40 are sealably brazed in place, and the fins 24 and end plates 36,38 are all secured by brazing. Compression of the core stack 108 (step 90-9) prior to radial expansion of the manifold tubes is performed in the preferred assembly method to compensate for shrinkage of the core stack that occurs during brazing.
  • the centre area of the core stack may bow inwards due to shrinkage in the brazing oven.
  • compression of the core stack is applied preferentially to the core plate stack 108 in the areas closer to the manifold tubes 12,14, where the greatest resistance to compression will generally be experienced.
  • the core plate stack 108 could be assembled using methods differing from that shown in Figure 10.
  • the manifold tubes 12,14 are loaded into a fixture, and the core plate stack 108 built up by sliding the plates onto the manifold tubes one at a time, or in groups, along with 5 alternating fins and turbulizers, rather than assembling the entire core plate stack 108 and then inserting the manifold tubes as described above in respect of Figure 10.
  • the configuration of the present invention provides a heat exchanger with a relatively high burst strength as the slotted manifold tubes 12,14 are supported internally
  • heat exchanger configuration and assembly method of the present invention can be used to produce a number of variations of the heat exchanger.
  • heat exchangers of different heights can be produced by using longer or shorter manifold tubes (for taller and shorter
  • Heat exchangers of different lengths can be produced by roll forming longer or shorter first and second plates 18, 20, and longer or shorter end plates 36,38, and using longer or length-wise shorter fins 24. Heat exchangers
  • inlet and outlet ports 26, 28 can be varied relatively easily by using manifold tubes with inlet and outlet openings 68 in a different location, and then adding the inlet and/ or outlet ports 26, 28 to the core stack 108 at a location corresponding to the different inlet and/or outlet openings.
  • the positions of the fittings in this invention can easily be adjusted to suit heat exchanger flow distribution constraints or to correspond to preferred fluid supply connector locations.
  • One or both of the manifold tubes 12,14 could also be configured without side inlets or outlets, and instead have an inlet or outlet, respectively, at a manifold tube end rather than an end cap 40.
  • the slots 42 may be replaced by openings of a different configuration, for example circular or oval, or each individual slot 42 could be replaced with a plurality of openings.
  • Figure 13 shows a manifold tube 14 having radial rows of circular openings 172 and radial rows of square openings 174 in place of slots 42. Such openings may be radially located about part of or the entire circumference of the manifold tube.
  • the sizes of the slots 42 along one or both of the manifold tubes 12, 14 are varied along the length thereof.
  • the opening defined by the slot 42 designated by S2 is larger than the opening defined by the slot 42 designated by S1.
  • the larger size of slot 42-S2 may be the result of slot 42-S2 having a greater height than slot 42-S1 (slot height being parallel to the longitudinal axis of the manifold tube 14), or may be the result of slot 42-S2 having a greater length than slot 42-S1 ( slot length being transverse to the longitudinal axis of the manifold tube), or may be a result of both of these factors.
  • the same effect can be achieved by using more openings to communicate with the flow channels of flat tube elements where a larger opening area is desired.
  • Varying the size of the slot openings along the manifold tubes may be used to improve flow distribution through the heat exchanger 10.
  • the slot openings become progressively larger from the bottom to the top of the manifold tube 14.
  • the slots may be grouped with slot size increasing progressively for groups of slots, with for example a group of three longitudinally adjacent slots having the same size, and then the next three slots having a different size and so on.
  • FIG. 15 shows an embodiment of the invention in which the spacing between first and second plates 18 and 20 of tube element 16 is increased in an annular area 110 surrounding the manifold tube 14 to accommodate a slot 42 having a height greater 5 than the flow channel defined by planar portions 56.
  • the slots 42 along the manifold tubes 12,14 may, in some embodiments of the present invention, be directed in some other manner than inward towards the centre of the heat exchanger.
  • Figure 16 shows an out take tube manifold 14 in which the slots 42 face the ends 60 of the plates making up flat tube elements 16, !0 rather than facing towards the centre of the heat exchanger. Such a configuration forces the fluid flowing through the flat tube elements 16 into the ends of such elements.
  • spacing of the slots 42, and the corresponding spacing of the flat tube elements 16 may be varied along the length of !5 the manifold.
  • spacing H1 could be different than spacing H2.
  • FIG. 111 Another embodiment of a heat exchanger according to the present invention is shown in a simplified view indicated by reference number 111 in Figure 17.
  • the heat exchanger 111 is similar in construction and operation to the heat exchanger 10 as 10 described above except for the differences noted below.
  • the heat exchanger 111 includes a stack of alternating fins 24 and flat tube elements 16 that extend between a first manifold tube 12' and a second manifold tube 14'.
  • the manifold tubes 12' and 14' each have spaced apart slots along their respective lengths that connect flow passages inside the manifold tubes 12' and 14' with flow channels in the flat tube elements 16.
  • cup baffles 112 are sealably secured inside each of the manifold tubes 12' and 14', effectively turning the heat exchanger into two separate heat exchangers, as identified by reference numbers 114 and 116, for two different fluids.
  • a first fluid flows into the portion of the manifold tube 12 ' above the cup baffle 112.
  • the first fluid then flows through slots in the upper portion of manifold tube 12', through corresponding plate pair flow tubes 16, and subsequently into the out take manifold tube 14', and then out of the manifold tube 14' as indicated by arrow 120.
  • a second fluid flows into the portion of the manifold tube 12' below the cup baffle 112.
  • the second fluid then flows through slots in the lower portion of manifold tube 12', through corresponding plate pair flow tubes 16, and subsequently into the out take manifold tube 14', and then out of the manifold tube 14' as indicated by arrow 124.
  • the first and second fluids are kept separated in the heat exchanger 111.
  • Various features could be varied between the two sub-heat exchangers 114, 116 depending on the desired treatment for the first and second fluids. For example, higher flat tube element 16 spacing could be used for one sub- heat exchanger than the other and/or larger manifold slots could be used in one sub- heat exchanger than in the other.
  • baffle cup 112 having a calibrated opening therethrough may be located in either one or both of the intake or out take manifold tubes 12' and 14' to control fluid flow therein.
  • baffle cups may divide only one of the manifold tubes 12', 14', and only a single fluid be used in the heart exchanger, which then assumes a double pass configuration.
  • a baffle cup 112 could be used only in the first manifold tube 12' to divide it in two chambers as indicated in Figure 17, the baffle cup 112 in second manifold tube 14' omitted, and the second manifold tube 14' capped with no outlet or inlet ports provided therein.
  • fluid would flow into the portion of first manifold tube 12' above the baffle cup 112 as indicated by arrow 118, through the upper three flat tube elements 16 shown in Figure 17 and into the second manifold tube 14', then into the three lower flat tube elements 16, and back into the first manifold tube 12' below the baffle cup 112, and out of the manifold tube 12' in the opposite direction of arrow 122.
  • baffle cups could be used to configure the heat exchanger as a multi-pass exchanger.
  • the baffle cups 112 can each be stamped from a brazing sheet, and will typically be installed after manifold tube expansion has been carried out.
  • An example of one possible configuration of a baffle cup 112 is shown in greater detail in Figure 18, in which the baffle cup 112 includes a circular disc like member 113 having an cylindrical wall 115 formed about its outer peripheral edge. Wall 115 provides an overlap joint with the wall of the manifold tube 12' or 14' in which the baffle cup 112 is inserted.
  • the baffle cup is sized so that the circumference of the outer surface of wall 115 is small enough to slidably fit into the expanded manifold tube 12' or 14', but large enough to frictionally engage the inner surface of the wall of the manifold tube 12' or 14' so that the baffle cup 112 does not move unintentionally prior to brazing once positioned in place.
  • the baffle cup 113 is inserted into its respective manifold tube using a rod fixture of calibrated length to correctly position the baffle cup.
  • an error proofing hole 117 is provided through the wall of the manifold tubes 12', 14' in alignment with the location where the baffle cup 12 should be positioned once installed.
  • the error proofing hole 117 is positioned to align with and be covered by the baffle cup wall 115 when the baffle cup is mounted in the manifold tube 12', 14'.
  • the error proofing hole 117 provides for a visual check to ensure the baffle cup is in place as an operator can look into the hole to ensure that it is blocked by wall 115.
  • the error proofing hole 117 also provides a functional check as a test fluid fed into the manifold tube will leak out of the hole if the baffle cup 112 is not sealably in place. It will be appreciated that the baffle 112 and error proofing hole 117 combination could be used for flat plate tube heat exchanger configurations other than the expanded manifold tube configuration of the present invention.
  • FIG. 20 and 21 illustrate yet another embodiment of a heat exchanger 126 of the present invention.
  • the heat exchanger 126 is similar to the heat exchanger 10 described above, except for the differences noted below.
  • the heat exchanger 126 includes a stack of alternating flat tube elements 16(1 )-16(4) and fins 24.
  • the heat exchanger includes a pair of intake manifold tubes 12A and 12B, and a pair of out take manifold tubes 14A and 14B.
  • the manifold tubes 12A.12B, 14A and 14B are each internally received through openings provided through each of the flat tube elements 16(1 )-16(4).
  • the intake manifold tubes 12A and 12B are slotted so that neither intake manifold tube is in flow communication with the same flow channel 21 through the same flat tube element, and similarly the out take manifold tubes 14A and 14B are slotted so that neither out take manifold tube is in flow communication with the same flow channel 21 through the same flat tube element.
  • the first intake manifold 12A receives a first fluid through an inlet port as indicated by arrow 128.
  • the first intake manifold 12A has slots in communication with the flow channels through flat tube elements 16(1 ) and 16(3), but does not include slots along the portions of its length that pass through flat tube elements 16(2) or 16(4).
  • the first out take manifold tube 14A has slots in communication with the flow channels through flat tube elements 16(1 ) and 16(3), but does not include slots along the portions of its length that pass through flat tube elements 16(2) or 16(4), such that the first fluid passes from the first intake tube manifold 12A through flat tube elements 16(1 ) and 16(3) to the first out take manifold 14A, and out of the heat exchanger through an outlet port as indicated by arrow 134.
  • Each of the second intake manifold tube 12B and the second out take manifold tube 14B have manifold slots 42 in communication with the flow channels through flat tube elements 16(2) and 16(4), but not with alternating flat tube elements 16(1 ) and 16(3).
  • a second fluid can flow into the second intake manifold tube 12B as indicated by arrow 130, through the flat tube elements 16(2) and 16(4) into second out take tube manifold 14B, and then out of the heat exchanger as indicated by arrow 132.
  • the inner manifold tubes 12B and 14B preferably have smaller diameters than the outer manifold tubes 12A and 14A in order to facilitate flow of the first fluid by the inner manifolds as indicated by arrows 136 and 138.
  • manifold slots 42 on the inner manifold tubes 12B and 14B can be outwardly directed (i.e. towards the outer manifold tubes 12A and 14A) in order to force the second fluid to travel closer to the outer ends of the heat exchanger.
  • FIG. 22 illustrates yet another embodiment of a heat exchanger 178 of the present invention.
  • the heat exchanger 178 is similar to the heat exchanger 10 described above, except that inlet and outlet ports 26 and 28 are replaced by differently configured inlet and outlet ports 182 (inlet port not shown in Figure 22), and brackets 43 have been replaced by differently configured mounting brackets 180.
  • the bracket 180 includes an L-shaped mounting plate 184 that is connected to a cylindrical wall forming a closed collar 186 that is sized to receive wall of a manifold tube 12 or 14 therein.
  • Figure 23 shows a plan view of the bracket 180 having closed collar 186.
  • Bracket configurations can be used in which an open snap-on style collar is used.
  • Figure 24 shows a further bracket 188 having a hook shaped open collar 190 for engaging the manifold tube between two flat tube elements
  • Figure 25 shows a bracket 192 having a Y-shaped open collar having opposed semi-circular portions 194 for engaging the manifold tube.
  • the hook shaped collar 190 and collar portions 194 are preferably braze clad and appropriately dimensioned and sufficiently resilient so that the brackets 188, 192 can be snapped on the manifold tube at a desired location and will stay in place until brazing.
  • the collar 190 and collar portions 194 could be crimped to secure them in place.
  • Fitting 182 includes an annular collar 200 for receiving the manifold tube 12 or 14.
  • the collar 200 includes a cylindrical wall 202 that is capped on opposite ends thereof by disk-like end plates 204 and 206, each of which has a circular opening 208 therethrough for receiving the manifold tube 12 or 14.
  • the inner surfaces of the cylindrical wall 202 and end plates 204, 206 collectively define an internal cavity 210 through which the manifold 12 or 14 passes.
  • the internal cavity 210 has diameter, transverse to the longitudinal axis of tube manifold 12, 14, that, is greater than the diameter of the tube manifold 12, 14 such that an annular flow passage 212 is defined between the tube manifold 12,14 and the inner surface of wall 202.
  • a cylindrical connecting member 214 extends radially from the outer surface of the collar wall 202, and the connecting member 214 defines an fluid flow passage 216 that is in flow communication, through an opening 218 provided in the wall 202, with the annular flow passage 212.
  • a frustal-conical flange is provided at an extending end of the connecting member 216 for internally engaging a connector hose or like flow passage connected to the connecting member 216.
  • the port fitting 182 is intended to be used in conjunction with a manifold tube 12,14 having a plurality of radially spaced flow openings 222 provided therethrough which are each in flow communication with the annular passage 212.
  • the port fitting and manifold tube combination of Figures 22, 26 and 27 permits fluid to be forced into or drawn from multiple locations about the radius of the manifold tube, providing improved flow management in some heat exchanger applications.
  • the annular collar 200 preferably has a height that corresponds to the spacing between two flat tube elements 16 so that it can fit between adjacent tube elements as shown in Figure 22.
  • Figure 28 shows a further embodiment of a port fitting, indicated generally by reference 224, that is similar to port fitting 182 except that it is a banjo-type fitting adapted for use at the end of a manifold tube 12,14.
  • a port fitting indicated generally by reference 224
  • an opening 208 for receiving the tube manifold 12 or 14 is only provided at an one end plate (plate 204 in the Figure 28), and the other end plate (end plate 206 in Figure 28) is sealed and acts as a stop for engaging an end of the manifold tube 12,14.
  • openings 22 could be spaced apart from the end of the manifold tube as shown in Figure 28, or could be notches formed about the radius of the bottom of the tube.
  • integral top plates 204 and 206 may be omitted from the collar 200, and functionally replaced by the facing surfaces of the two adjacent flat tube elements 16.
  • the collar 200 and passage 212 may extend only partially around the manifold tube.
  • the collar 200 could be secured in place prior to brazing by radial expansion of the manifold tube.
  • the collar could be formed from a non-metal such as a polymer material and secured by epoxy or other adhesive. It will be appreciated that the collar fitting and manifold tube combination of Figures 26 and 27 could be used in heat exchangers having a variety of different configurations, including for example conventional stacked plate exchangers in which the plate ends are received within the manifold tubes.
  • the flat tube elements 16 have been described as comprising two separate opposing plates 18, 20 that are joined together by brazing along their respective edges. It will be appreciated that flat tube elements in which the opposing plates are formed in another manner can be used in the present invention.
  • Figures 29 and 30 illustrate partial sectional perspective views of two further flat tube elements 16A and 16B, respectively, each of which defines a flow channel 21.
  • the first and second plates 18 and 20 of flat tube element 16A are preferably roll formed longitudinally together as a single sheet with longitudinal flanges 252 and 254 provided along opposite side edges thereof.
  • Apertures 48, 50 for the manifold tubes are then pierced through each of the plates 18, 20, and the flange about the apertures extruded, after which the plates 18, 20 are folded together about a common longitudinal edge 250 until the flanges 252 and 254 contact each other. With respect to the flat tube element 16B, in such configuration the edges 256, 258 joining the first and second plates 18, 20 are seamless.
  • the heat exchanger 10 has been shown in its preferred embodiment as including a flange 64 about the apertures 48, 50 in first and second plates 18, 20, in some applications a flangeless aperture may suffice, in which case a somewhat weaker butt joint rather than an overlap joint would be formed between the plates 18, 20 and each of the manifold tubes 12, 14.
  • the annular flow path 23 may not be present about the entire circumference of the manifold tubes.
  • the heat exchangers of the present invention as described above have each included corrugated fins 24 located between adjacent flat tube elements 16.
  • such fins may be omitted, or replaced with ribs or other protrusions formed on the flat tube elements 16.
  • spacing between the adjacent flat tube elements 16 may be provided by enlarged bosses around the apertures, such as the enlarged annular area 110 as shown in Figure 15.
  • removable spacers may be positioned between adjacent tube elements 16 to support them during assembly.
  • FIG. 31 Another embodiment of a heat exchanger according to the present invention is shown in a simplified view indicated by reference number 270 in Figure 31.
  • the heat exchanger 270 is similar in construction and operation to the heat exchanger 10 as described above except for the differences noted below.
  • the manifold tubes 21 and 14 are connected by a bypass tube 272 through which fluid can flow directly from one manifold tube to the other, bypassing the core stack 108.
  • a calibrated baffle 274 or other flow control means such as a thermostatically actuated valve can be located in the bypass tube 272 to control flow therethrough.
  • the tubes 12, 14, and 272 may be integrally formed as a single U-shaped unit.
  • manifold tubes may be thermally expanded rather than or in addition to being pressure expanded.
  • the manifold tube may not be expanded, but a friction fit between the flat plate tube element and the manifold tubes used in combination with bonding effected, for example, thermally, ultrasonically, or through the use a bonding agent or adhesive.
  • the heat exchanger of the present invention can be adapted for a number of different applications for use, among other things, in automobiles, recreational vehicles, and fuel cell thermal management systems.
  • the present invention can be adapted for use in, among other things, engine oil cooling, hydraulic fluid cooling (which requires high pressure strength) and air conditioning applications (for both evaporator and condenser applications).
  • Selective variable manifold tube slot size and positioning can be particularly helpful in evaporator applications where flow distribution sensitivity is high.

Abstract

Cette invention concerne un échangeur de chaleur comprenant un tube collecteur qui comporte dans sa paroi une pluralité d'ouvertures espacées les unes des autres, en communication fluidique avec un passage d'écoulement, et une pluralité d'éléments tubulaires plats empilés comprenant chacun une première et une seconde plaques définissant entre elles un canal d'écoulement, chaque plaque présentant une ouverture traversante. Le tube collecteur traverse les ouvertures des première et seconde plaques de chacun des éléments tubulaires plats. Au moment de l'assemblage, la paroi du tube collecteur est élargie dans le sens radial pour que chacune des première et seconde plaques puisse assurer la fixation des éléments tubulaires plats sur le tube collecteur. L'invention concerne également un échangeur de chaleur à empilement de plaques, avec tube collecteur à trou de localisation garantissant que la cuvette de déflection est bien positionnée dans le tube collecteur, et un échangeur de chaleur à empilement de plaques avec un porte-orifice dont le chemin d'écoulement est en communication avec un passage d'écoulement dans le tube collecteur via une pluralité d'ouvertures espacées radialement au travers dudit tube.
PCT/CA2002/001999 2001-12-27 2002-12-23 Echangeur de chaleur avec collecteur interne a fentes WO2003056264A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP02787290A EP1461579A1 (fr) 2001-12-27 2002-12-23 Echangeur de chaleur avec collecteur interne a fentes
AU2002351617A AU2002351617A1 (en) 2001-12-27 2002-12-23 Heat exchanger with internal slotted manifold

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
CA2,366,227 2001-12-27
CA002366227A CA2366227C (fr) 2001-12-27 2001-12-27 Support de fixation pour faisceaux d'echangeur de chaleur
CA 2366332 CA2366332A1 (fr) 2001-12-31 2001-12-31 Echangeur thermique a collecteur a fentes interne
CA2,366,332 2001-12-31

Publications (1)

Publication Number Publication Date
WO2003056264A1 true WO2003056264A1 (fr) 2003-07-10

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US (1) US20030121649A1 (fr)
EP (1) EP1461579A1 (fr)
CN (1) CN1620588A (fr)
AU (1) AU2002351617A1 (fr)
WO (1) WO2003056264A1 (fr)

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GB2417308B (en) * 2003-06-27 2006-10-11 Dana Canada Corp Vibration-resistant mounting bracket for heat exchangers
ES2279713A1 (es) * 2005-12-23 2007-08-16 Valeo Termico, S.A. Intercambiador de calor de placas apiladas.
CN102161060A (zh) * 2010-12-09 2011-08-24 中山市奥美森工业有限公司 折弯机
CN102161060B (zh) * 2010-12-09 2013-03-20 中山市奥美森工业有限公司 折弯机
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FR3086042A1 (fr) * 2018-09-13 2020-03-20 Valeo Systemes Thermiques Echangeur thermique et installation de chauffage et/ou ventilation et/ou climatisation correspondante

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US20030121649A1 (en) 2003-07-03
AU2002351617A1 (en) 2003-07-15
EP1461579A1 (fr) 2004-09-29

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