EP3786563A1

EP3786563A1 - A connection system

Info

Publication number: EP3786563A1
Application number: EP19382727.6A
Authority: EP
Inventors: Guillermo SÁNCHEZ SIERRA; Reyes TORRUBIA; Iñigo Tolosa Echarri; Julián GÓMEZ CLERENCIA
Original assignee: Valeo Termico SA
Current assignee: Valeo Termico SA
Priority date: 2019-08-26
Filing date: 2019-08-26
Publication date: 2021-03-03

Abstract

A connection system for forming connection between a flange and a tank of a heat exchanger is disclosed in accordance with an embodiment of the present invention. The connection system includes a first neck portion configured along a first opening formed on the flange and a second neck portion configured along a second opening formed on the tank, wherein the first neck portion and the second neck portion engage with each other to form connection between the flange and the corresponding tank at interface between the first neck portion of the flange and the second neck portion of the tank.

Description

The present invention relates to a connection system to configure connection between elements subjected to vibrations without generating any stresses, particularly, the present invention relates to a connection system to configure connection between elements of a heat exchanger used in a vehicle and subjected to engine vibration.

Background of the invention:

A heat exchanger, such as for example, an Exhaust Gas Re-circulation cooler, hereinafter referred to as "EGR cooler", with heat exchange tubes configuring I-shaped fluid circulation path, generally includes a pair of spaced apart headers connected to two distant and opposite end portions of a housing receiving a heat exchanger core. The housing receives a first heat exchange fluid, particularly coolant. The heat exchanger core is configured of plurality of heat exchange elements, particularly, heat exchange tubes and a plurality of fin elements lodged between the adjacent heat exchange tubes. The heat exchanger further includes a pair of heat exchanger tanks, hereinafter simply referred to as tanks, wherein each tank is joined to the corresponding header for configuring a sealed connection between the headers and the corresponding tanks. The tanks are capable of receiving second heat exchange fluid, often pressurized heat exchange fluid such as exhaust gases. The tanks in conjunction with the corresponding headers distribute second heat exchange fluid to and collect second heat exchange fluid from the heat exchange tubes of the heat exchanger core respectively. The tanks are further connected to respective flanges that configure a connection and fluid communication between the tanks and the inlet and outlet pipes respectively. The inlet pipe supplies exhaust gases from the engine to the EGR cooler. As the EGR cooler is coupled to an engine of the vehicle via the inlet pipe, the EGR cooler may experience some vibration due to engine vibrations being transmitted to the EGR cooler. The engine vibration applies high acceleration on the components fixed to an engine block of the engine and causes twisting and high stress peaks that detrimentally impact the endurance of the EGR cooler. The detrimental impact of engine vibration is more evident on components and joints between the components that are in any way coupled to the engine block such as for example, joint between the tanks and the flanges of the EGR cooler that are connected to the engine via the inlet pipes. Further, detrimental impact of the engine vibration on the components and the joint between the components of the EGR cooler is aggravated, in case the components are thin-sectioned to achieve cost and weight reduction of the EGR cooler. Further, the connection between the components such as for example flanges and tanks of the EGR cooler cannot be modified substantially considering space limitation and limitation of modifying the connection interface between the components being joined.
Accordingly, there is a need for a connection system and a method for connecting components of a heat exchanger, particularly, an EGR cooler that ensures secure connection between the various components that are subjected to engine vibration. More specifically, there is a need for a connection system and a method for connecting components such as tanks and flanges of an EGR cooler that reduces stresses, and stress peaks on these components arising due to the components being subjected to any vibration such as engine vibration during operation of the engine or otherwise. Furthermore, there is a need for a connection system that configures secure connection between the components without requiring much modification of the connection interface between the components being joined. Furthermore, there is a need for a connection system and a method for connecting components that simplifies the manufacturing process for manufacturing the heat exchanger and leads to cost savings.

Description of the invention:

An object of the present invention is to provide a connection system and a method for connecting components of a heat exchanger that obviates the drawbacks associated with conventional connection systems that fail to reduce stresses or stress peaks arising due to engine vibrations reaching the components or joints between the components.
Another object of the present invention is to provide a connection system and a method for connecting components of a heat exchanger that ensures secure connection between the various components that are subjected to vibration such as engine vibration during operation of the engine or any other vibration.
Still another object of the present invention is to provide a connection system and a method for connecting components that reduce stresses on these components arising due to the components being subjected to vibration such as engine vibration during operation of the engine or any other vibration.
Yet another object of the present invention is to provide a connection system and a method for connecting components that configure secure connection between the components without requiring much modification of the connection interface between the components being joined.
Another object of the present invention is to provide a connection system and a method for connecting components that simplifies the manufacturing process for manufacturing the heat exchanger and leads to cost savings.
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.
A connection system for forming connection between a flange and a tank of a heat exchanger is disclosed in accordance with an embodiment of the present invention. The connection system includes a first neck portion configured along a first opening formed on the flange and a second neck portion configured along a second opening formed on the tank, wherein the first neck portion and the second neck portion are adapted to engage and be joined with each other to form a connection between the flange and the corresponding tank at interface between the first neck portion and the second neck portion.
In accordance with an embodiment of the present invention, the connection system further includes a groove configured along a periphery of the first opening and disposed at bottom of the first neck portion.
Alternatively, the connection system includes a groove configured along a periphery of the first opening to inherently form the first neck portion around the first opening.
Generally, the second neck portion extends till extreme end of the groove.
In accordance with an embodiment of the present invention, at least a portion of at least one of the first neck portion and the second neck portion is reinforced with additional material.
A method of configuring connection between a flange and a tank of an EGR cooler is disclosed in accordance with an embodiment of the present invention. The method includes the steps of aligning a first opening formed on the flange with the second opening formed on the corresponding tank. Thereafter, engaging a first neck portion configured along the first opening formed on the flange with the second neck portion configured along the second opening formed on the corresponding tank. Finally, joining the first neck portion to the second neck portion at interface there between for configuring connection between the flange and the corresponding tank.
An EGR cooler is disclosed in accordance with an embodiment of the present invention. The EGR cooler includes housing, at least one tank, a heat exchanger core, and at least one flange. The housing receives first heat exchange fluid. The at least one tank receives second heat exchange fluid. The heat exchanger core is disposed inside the housing and includes a plurality of heat exchange tubes that receive second heat exchange fluid. The at least one flange is connected to the at least one tank by a joining process. A first neck portion configured along a first opening formed on the at least one flange and a second neck portion configured along a second opening formed on the at least one tank engage and get joined with each other to form connection between the at least one flange and the at least one tank at the interface between the first neck portion and the second neck portion.
Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

Brief description of the drawings:

FIG. 1 illustrates an isometric view of an EGR cooler in accordance with an embodiment of the present invention;
FIG. 2a illustrates a schematic representation of a connection system in accordance with an embodiment of the present invention, wherein a groove along with a first neck portion engaging with a second neck portion forms a secure connection between a flange and a corresponding tank of the EGR cooler of FIG.1 ;
FIG. 2b illustrates a schematic representation of the flange of FIG. 2a configured with the first neck portion along with the groove having a radius configured at bottom of the first neck portion;
FIG. 3a illustrates a schematic representation of a connection system in accordance with yet another embodiment of the present invention, wherein yet another groove inherently forming a first neck portion engaging with a second neck portion forms a secure connection between the flange and the corresponding tank of the EGR cooler of FIG.1 ;
FIG. 3b illustrates a schematic representation of the flange of FIG. 3a , depicting the groove of a certain configuration along the neck portion inherently formed along the groove;
FIG. 4a - FIG. 4b illustrates a schematic representation of a connection system in accordance with yet another embodiment of the present invention, wherein entire periphery of the first neck portion is reinforced with an additional material;
FIG. 5a - FIG. 5c illustrates a schematic representation of a connection system in accordance with another embodiment of the present invention, wherein at least a portion of the periphery of the first neck portion is reinforced with additional material; and
Fig. 6 illustrates a flow diagram depicting the steps involved in configuring a connection between a flange and a tank of an Exhaust Gas Re-circulation cooler in accordance with an embodiment of the present invention.

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.

Detailed description of the preferred embodiments:

A connection system and a method for connecting components of a heat exchanger, particularly, an EGR cooler that are subjected to vibrations, is disclosed in accordance with an embodiment of the present disclosure. The connection system and the method for connecting the components configure secure connection between the various components of the EGR cooler that are subjected to vibration such as engine vibration during operation of the engine or any other vibration. The connection system and the method for connecting the components, particularly, the flanges and the corresponding tanks of the EGR cooler of the present invention reduce stresses or occurrence of peak stresses on these components arising due to the components being subjected to vibration such as engine vibration during operation of the engine. The connection system is simple in construction and does not require many modifications at connection interface between the components being joined. Although, the connection system of the present disclosure is explained for use in connecting the flanges and the corresponding tanks of the EGR cooler used in a vehicle and that are subjected engine vibrations. However, the connection system of the present invention is applicable for configuring connection between components of any other system that is subject to vibrations, which require better surface contact between components for configuring a secure connection there between and the connection system can be used in vehicular and non-vehicular applications. Particularly, the connection system of the present invention is not limited to use in connecting the components of systems used in vehicles only.
FIG. 1 illustrates an isometric view of a heat exchanger such as for example an Exhaust Gas Re-circulation cooler, hereinafter referred to as an "EGR cooler" 100. The "EGR cooler" 100with heat exchange tubes configuring I-shaped fluid circulation path, generally includes a pair of spaced apart collector plates or headers 104a and 104b connected to two distant and opposite end portions of a housing 102 receiving a heat exchanger core 103. The heat exchanger core 103 is configured of a plurality of heat exchange elements, particularly, the heat exchange tubes 103a and a plurality of fin elements (not illustrated in FIGS.) lodged between the adjacent heat exchange tubes. The heat exchange tubes 103a of the EGR cooler 100 may configure U-shaped fluid circulation path or I- shaped fluid circulation path. In case heat exchange tubes 103a configure the U shaped circulation path, only one tank 120a is required whereas in case heat exchange tubes 103a configure the I-shaped circulation path, two tanks 120a and 120b are required, particularly, one tank disposed at each end of the heat exchanger core 103.
In case the heat exchange tubes 103a configure the I-shaped circulation path for the heat exchange fluid flowing there through, the EGR cooler 100 requires two tanks each tank of a pair of tanks 120a, 120b is joined to the corresponding header 104a and 104b disposed at end of the heat exchanger core 103 for configuring a sealed connection between the headers 104a, 104b and the corresponding tanks 120a, 120b and configuring the header tank assembly. The housing 102 receives first heat exchange fluid, particularly coolant around the heat exchange tubes 103a. The tanks 120a, 120b are capable of receiving second heat exchange fluid, often pressurized heat exchanging fluid such as exhaust gases. The tanks 120a and 120b in conjunction with the corresponding headers 104a and 104b distribute second heat exchange fluid to and collect second heat exchange fluid heat exchange tubes 103a of the heat exchanger core 103 respectively. With such configuration, heat exchange occurs between the second heat exchange fluid, particularly, exhaust gases flowing through the heat exchange tubes 103a and the first heat exchange fluid, particularly, coolant received inside the housing 102 and around the heat exchange tubes 103a. The tanks 120a and 120b are further connected to respective flanges 110a and 110b that configure connection and fluid communication between the tanks 120a and 120b and the inlet and outlet pipes respectively. The inlet pipe supplies exhaust gases from the engine to the EGR cooler 100. As the inlet pipe connects exhaust gas manifold of the engine to the tank 120a via the flange 110a, the connection between the flange 110a and the tank 120a is subjected to engine vibrations and hence prone to failures. The present invention provides a connection system and a method for connecting the flanges with the corresponding tanks of the EGR cooler that reduce stresses on the flanges, the tanks of the EGR cooler 100 and connection between the flanges and the tanks of the EGR cooler 100 and prevent formation of stress peaks arising due to the tanks, the flanges and the connection between the tanks and the flanges being subjected to vibration such as engine vibrations, thereby configuring secure connection between tanks and the flanges of the EGR cooler 100.
FIG. 2a illustrates a schematic representation of a connection system 101a in accordance with an embodiment of the present invention for configuring connection between the flange 110a and the corresponding tank 120a of the EGR cooler 100 depicted in FIG. 1 . As the present invention is explained with example of EGR cooler with heat exchange tubes 103a configuring I-shaped circulation path for the heat exchange fluid flowing there through and as such having two tanks 120a and 120b, a similar connection is formed between the flange 110b and the corresponding tank 120b. As the connection or the joint between the flange 110b and the corresponding tank 120b is identical to the connection between the flange 110a and the corresponding tank 120a, every embodiment disclosed henceforth for the connection system configuring the connection between the flange 110a and the corresponding tank 120a may also be applicable for the connection system configuring the connection between the flange 110b and the corresponding tank 120b, for sake of brevity of present document, drawings depicting the details of only the connection system configuring the connection between the flange 110a and the corresponding tank 120a is illustrated in the Figures and described in the forthcoming description.
The connection system 101a includes a first neck portion 114a configured along a first opening 112a formed on the flange 110a and a second neck portion 124a configured along a second opening 122a formed on the tank 120a, wherein the first neck portion 114a and the second neck portion 124a engage with each other to form a connection between the flange 110a and the corresponding tank 120a after the first neck portion 114a and the second neck portion 124a are joined at the connection interface between the first neck portion 114a and the second neck portion 124a by any of the joining processes such as for example brazing. With the first and the second neck portions 114a and 124a, the engagement at the connection interface becomes simpler and convenient and the manufacturing of the Exhaust Gas Re-circulation cooler is simplified. Such a connection system 101a configures secure connection, by improving surface contact and reducing the stresses acting on the flange 110a and the corresponding tank 120a due to vibration, such as engine vibration reaching the flange 110a and subsequently the corresponding tank 120a connected to the flange 110a of the EGR cooler 100. More specifically, the first neck portion 114a is received inside the second opening 122a to configure a connection interface. Alternatively, the second neck portion 124a is received in the first opening 112a to configure the connection interface. The flange 110a and the corresponding tank 120a are brazed together at the connection interface to configure secure connection there between. Specifically, due to neck configurations, better surface contact at the connection interface enhances quality of joint, particularly, brazing joint, thereby resulting in a secure connection between the flange 110a and the corresponding tank 120a after brazing at the connection interface between the first neck portion 114a of the flange 110a and the second neck portion 124a of the tank 120a.
FIG. 2a illustrates the connection system 101a, wherein the first neck portion 114a along with a groove 116a configured along the first opening 112a formed on the flange 110a configures a secure connection between the flange 110a and the corresponding tank 120a of the EGR cooler 100 after brazing between the first neck portion 114a and the second neck portion 124a. FIG. 2b illustrates a schematic representation of the flange 110a configured with the first neck portion 114a along with the groove 116a having a radius configured at bottom of the first neck portion 114a. Such a configuration of the connection system 101a reduces the stress levels at the connection interface, enhances surface contact to improve brazing connection at the connection interface, prevents formation of stress peaks and configures a secure connection between the flange 110a and the corresponding tank 120a at the connection interface. The present invention is not limited to configuration of the groove 116a as far as the groove 116a along with the first neck portion 114a and the second neck portion 124a reduces the stress levels at the connection interface, enhances surface contact at the connection interface to improve brazing connection to configure a secure connection between the flange 110a and the corresponding tank 120a. Generally, at least one of the first neck portion 114a and the second neck portion 124a are having same thickness as that of the tank 120a. In one embodiment of the present invention, the at least one of the first neck portion 114a and the second neck portion 124a is having a thickness of 1mm. The groove 116a at the bottom of the first neck portion 114a also reduces the stress levels at the connection interface and forms secure connection between the flange 110a and the corresponding tank 120a at the connection interface after brazing between the first neck portion 114a and the second neck portion 124a. The connection so configured by the connection system 101a is secure even when subjected to vibration, such as for example engine vibration. As such the connection system 101a is preferred in cases where the connected elements are subjected to vibrations as is in the case of connection between flange and tank of the EGR cooler that is subjected to engine vibration. In one embodiment of the present invention, the radius of the groove is 1mm. Such a configuration of the connection system 101a reduces the stress by 43 percent as compared to when there are no grooves 116a and the first and the second neck portions 114a and 124a respectively.
FIG. 3a illustrates a schematic representation of a connection system 101b in accordance with yet another embodiment of the present invention. The connection system 101b includes yet another groove 118a formed along the first opening 112a formed on the flange 110a and inherently forming the first neck portion 114a along the first opening 112a. The connection system 101b further includes the second neck portion 124a configured along the second opening 122a formed on the tank 120a. The first neck portion 114a and the second neck portion 124a engage with each other and get joined to each other by a joining process such as brazing to form a connection between the flange 110a and the corresponding tank 120a, while reducing the stresses acting on the flange 110a and the corresponding tank 120a even when subjected to vibration, particularly engine vibration. More specifically, the first neck portion 114a is received inside the second opening 122a and the second neck portion 124a is received in the groove 118a to configure a connection interface, and the flange 110a and the corresponding tank 120a are brazed together at the connection interface to configure a secure connection there between. Generally, the second neck portion 124a extends in the axial direction till extreme end of the groove 118a, however, the present invention is not limited to extend of insertion of the second neck portion 124a in the groove 118a. The groove 118a is wider than the second neck portion 124a so that there is sufficient gap around the second neck portion 124a received in the groove 118a for configuring the connection interface and achieving improved brazing connection. In one embodiment of the present invention, the width of the groove is 2 mm when the second neck portion 124a is having a thickness of 1 mm. The flange 110a and the corresponding tank 120a are brazed together at the connection interface to configure secure connection there-between. FIG. 3a illustrates the connection system 101b, wherein the groove 118a inherently forms the first neck portion 114a around the first opening 112a and receives the second neck portion 124a to form a secure connection between the flange 110a and the corresponding tank 120a of the EGR cooler 100 after brazing between the walls defining the groove 118a and the second neck portion 124a. FIG. 3b illustrates a schematic representation of the flange 110a with the groove 118a disposed around the first opening 112a to inherently configure the first neck portion 114a around the first opening 112a. Such a configuration of the connection system 101b reduces the stress levels at the connection interface, prevents formation of stress peaks and configures secure connection between the flange 110a and the corresponding tank 120a at the connection interface even when subjected to vibration, such as for example engine vibration during operation of the engine. The present invention is not limited to configuration of the groove 118a as far as the groove 118a along with the first neck portion 114a and the second neck portion 124a reduces the stress levels at the connection interface, enhances surface contact at the connection interface to improve brazing connection and configure a secure connection between the flange 110a and the corresponding tank 120a. Generally, the second neck portion 124a is having same thickness as that of the tank 120a. In one embodiment of the present invention, the second neck portion 124a is having a thickness of 1mm. The groove 118a disposed along the first neck portion 114a also reduces the stress levels at the connection interface and configuring secure connection between the flange 110a and the corresponding tank 120a at the connection interface. Such a configuration of the connection system 101b reduces the stress by 50 percent as compared to when there are no groove 118a and the first and the second neck portions 114a and 124a respectively.
At least a portion of at least one of the first neck portion 114a and the second neck portion 124a is reinforced with an additional material. FIG. 4a - FIG. 4b illustrate schematic representations of a connection system 101c in accordance with yet another embodiment of the present invention, wherein entire periphery of the first neck portion 114a is reinforced with the additional material to provide sufficient support to the second neck portion 124a to configure a connection interface. More specifically a rib structure protrudes along entire periphery of the first neck portion 114a to configure the connection interface. The flange 110a and the corresponding tank 120a are brazed together at the connection interface to configure secure connection there between. Such a configuration of the connection system 101c reduces the stress levels at the connection interface, prevents formation of stress peaks and configures secure connection between the flange 110a and the corresponding tank 120a at the connection interface even when subjected to vibration during service. Such a configuration of the connection system 101c reduces the stress by 50 percent as compared to when there is no reinforcement provided along the entire periphery of the first neck portion 114a.
FIG. 5a - FIG. 5c illustrates a schematic representation of a connection system 101d in accordance with another embodiment of the present invention, wherein at least a portion of the periphery of the first neck portion 114a is reinforced with the additional material to provide support to at least a portion of the second neck portion 124a to configure a connection interface. More specifically a rib structure protrudes along at least a portion of the periphery of the first neck portion 114a to configure the connection interface. The flange 110a and the corresponding tank 120a are brazed together at the connection interface to configure secure connection there between. More specifically, a portion 114aa of the first neck portion 114a is reinforced with additional material, whereas another portion 114ab of the first neck portion 114a is without any reinforcement. Such a configuration of the connection system 101d reduces the stress levels at the connection interface, prevents formation of stress peaks and configures secure connection between the flange 110a and the corresponding tank 120a at the connection interface even when subjected to vibration during service. Such a configuration of the connection system 101d reduces the stress by 60 percent as compared to when there is no reinforcement provided along at least a portion of the periphery of the first neck portion 114a.
A method for configuring connection between a flange 110a and a tank 120a of an EGR cooler 100 is disclosed in accordance with an embodiment of the present invention and is depicted with the help of a flow diagram, wherein steps of the method are depicted by blocks in the flow diagram. The order in which the individual blocks depicting the steps involved in the method appear in the flow chart is not intended to be construed as a limitation, and any number of steps described as method blocks can be combined in any order or can be performed in parallel to employ the method 200, or an alternative method. Additionally, individual blocks may be deleted from the flow chart depicting the method without departing from the scope and ambit of the present invention. The method may include steps mentioned in the below description to form connection between the flanges 110a, 110b and the respective tanks 120a, 120b to form the EGR cooler 100. The method 200 is to be understood with reference to the following description along with the Fig. 6 .
Fig. 6 illustrates a flow diagram depicting the steps involved in configuring connection between the flange 110a and the tank 120a of the Exhaust Gas Re-circulation cooler 100 in accordance with an embodiment of the present invention depicted in the form of blocks. The method 200 includes the steps of:

step 202 of aligning a first opening 112a formed on the flange 110a with a second opening 122a formed on the corresponding tank 120a;
step 204 of engaging a first neck portion 114a configured along the first opening 112a formed on the flange 110a with the second neck portion 124a configured along the second opening 122a formed on the corresponding tank 120a; and
finally, step 206 of joining the first neck portion 114a to the second neck portion 124a at interface there between for configuring connection between the flange 110a and the corresponding tank 120a.

An EGR cooler 100 is disclosed in accordance with an embodiment of the present invention. The EGR cooler 100 includes a housing 102, a heat exchanger core 103, a pair of collector plates or headers 104a, 104b, a pair of tanks 120a, 120b and a pair of flanges 110a, 110b. The heat exchanger core 103 includes a plurality of heat exchange tubes along with fins disposed between the heat exchange tubes. The pair of collector plates 104a, 104b is disposed at end portions of the heat exchange tubes 103a and is configured with slots that receive respective end portions of the heat exchange tubes 103a. The pair of collector plates 104a, 104b is disposed at the ends of the housing 102. The pair of tanks 120a, 120b is connected to the respective collector plates 104a, 104b. The pair of flanges 110a, 110b is connected to the respective tanks 120a, 120b for configuring connection between the tanks 120a, 120b and respective inlet and outlet pipes. A first neck portion 114a, 114b configured along a first opening 112a, 112b formed on the flange 110a, 110a and a second neck portion 124a, 124b configured along a second opening 122a, 122b formed on the tank 120a, 120b engage with each other and are joined to each other at the interface between the first neck portion 114a, 114b and the second neck portion 124a, 124b by a joining process such as brazing to form connection between the flange 110a, 110b and the corresponding tank 120a, 120b.
Several modifications and improvement might be applied by the person skilled in the art to the connection system as defined above and such modifications and improvements will still be considered within the scope and ambit of the present invention, as long as the connection system comprises a first neck portion configured along a first opening formed on the flange and a second neck portion configured along a second opening formed on the tank, wherein at least one of the first neck portion and the second neck portion engage with each other to form connection between the flange and the corresponding tank at the interface between the first neck portion and the second neck portion.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein.
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 connection system (101a, 101b, 101c, 101d) for forming connection between a flange (110a) and a tank (120a) of a heat exchanger (100), the connection system comprising a first neck portion (114a) configured along a first opening (112a) formed on the flange (110a) and a second neck portion (124a) configured along a second opening (122a) formed on the tank (120a), wherein the first neck portion (114a) and the second neck portion (124a) are adapted to engage with each other to form a connection between the flange (110a) and the corresponding tank (120a) at the interface between the first neck portion (114a) and the second neck portion (124a).
The connection system (101a, 101b, 101c, 101d) as claimed in any of the previous claims, further comprising a groove (116a) configured along a periphery of the first opening (112a) and disposed at bottom of the first neck portion (114a).
The connection system (101a, 101b, 101c, 101d) as claimed in any of the preceding claims, further comprising a groove (118a) configured along a periphery of the first opening (112a) to inherently form the first neck portion (114a) around the first opening (112a).
The connection system (101a, 101b, 101c, 101d) as claimed in claim 3, wherein the second neck portion (124a) extends till extreme end of the groove (118a).
The connection system (101a, 101b, 101c, 101d) as claimed in any of the preceding claims, wherein at least a portion of at least one of the first neck portion (114a) and the second neck portion (124a) is reinforced with an additional material.
A method for configuring connection between a flange (110a) and a tank (120a) of an Exhaust Gas Re-circulation cooler (100) comprising the steps of:
• aligning a first opening (112a) formed on the flange (110a) with a second opening (122a) formed on the tank (120a);

• engaging a first neck portion (114a) configured along the first opening (112a) formed on the flange (110a) with the second neck portion (124a) configured along the second opening (122a) formed on the tank (120a); and

• joining the first neck portion (114a) to the second neck portion (124a) at an interface there between for configuring connection between the flange (110a) and the tank (120a).
An EGR cooler (100) comprising:
• a housing (102) adapted to receive first heat exchange fluid;

• at least one tank (120a, 120b) adapted to receive second heat exchange fluid;

• a heat exchanger core (103) disposed inside the housing (102) and comprising a plurality of heat exchange tubes (103a) adapted to receive second heat exchange fluid; and

• at least one flange (110a, 110b) adapted to be connected to the at least one tank (120a, 120b) for configuring connection between the at least one tank (120a, 120b) and at least one of inlet and outlet pipes,
characterized in that the at least one flange (110a, 110b) is connected to the at least one tank (120a, 120b) by a joining process, wherein a first neck portion (114a, 114b) configured along a first opening (112a, 112b) formed on the at least one flange (110a, 110b) and a second neck portion (124a, 124b) configured along a second opening (122a, 122b) formed on the at least one tank (120a, 120b) are adapted to engage with each other to form connection between the at least one flange (110a, 110b) and the at least one tank (120a, 120b) at the interface between the first neck portion (114a, 114b) and the second neck portion (124a, 124b).