SE543365C2 - Heat Exchanger, Powertrain, and Vehicle - Google Patents

Abstract

A heat exchanger (1) for a vehicle (3) is disclosed. The heat exchanger (1) comprises a tank unit (5), a set of tubes (7’) fluidly connected to the tank unit (5), and a reinforcement assembly (9). The reinforcement assembly (9) comprises a support element (11) attached to a tube (7) of the set of tubes (7’), and a beam (13) attached to the support element (11) and to the tank unit (5). The present disclosure further relates to a powertrain (30) comprising a heat exchanger (1), and a vehicle (3) comprising a heat exchanger (1).

Description

Heat Exchanger, Powertrain, and Vehicle.

TECHNICAL FIELDThe present disclosure relates to a heat exchanger comprising a reinforcement assembly.The present disclosure further relates to a powertrain comprising a heat exchanger, as well as a vehicle comprising a heat exchanger.

BACKGROUND Heat exchangers are used in vehicles to transfer heat from a medium to ambient air.Examples of heat exchangers are power source radiators, retarder radiators, charge aircoolers, and the like. A heat exchanger usually comprises tank units and a set of tubes fluidlyconnected to the tank units. Such a tank unit usually comprises a header and a tank, whereinthe tubes are attached to the tank unit via the header. Usually, the tubes are attached to thetank unit using welding or crimping. During operation, a medium, such as coolant, oil, orcompressed air, is ducted through the tubes. A power source radiator is usually arranged totransfer heat of a coolant to ambient air. A retarder radiator is usually arranged to transferheat of coolant or oil to ambient air. A charge air cooler is arranged to transfer heat of compressed air to ambient air.

Heat exchangers of vehicles are subjected to high degree of stress and vibrations duringoperation of the vehicle. Moreover, during operation, a heat exchanger is subjected topulsating heat and varying pressures. At a result thereof, at some occasions, a heatexchanger can become damaged, for example by formation of cracks. Such damages canhave serious consequences for a vehicle, often leads to a standstill of the vehicle, and isusually difficult and expensive to remedy. ln general, operational reliability of vehicles is a problem vehicle manufacturers face.

Moreover, in general, on today's consumer market, it is an advantage if products, such asvehicle components, have conditions and/or characteristics suitable for being manufactured and assembled in a cost-efficient manner.

SUMMARYlt is an object of the present invention to overcome, or at least alleviate, at least some of the above-mentioned problems and drawbacks.

According to a first aspect of the invention, the object is achieved by a heat exchanger for a vehicle, wherein the heat exchanger comprises a tank unit, a set of tubes fluidly connected to 2 the tank unit, and a reinforcement assembly. The reinforcement assembly comprises asupport element attached to a tube of the set of tubes and a beam attached to the support element and to the tank unit.

Since the reinforcement assembly comprises a support element attached to a tube of the setof tubes and a beam attached to the support element and to the tank unit, the tube issupported relative the tank unit by the reinforcement assembly. Thereby, the tube isprevented from moving and vibrating during operation of the vehicle. As a result, the risk ofcracks in the connection between the tube and the tank unit is reduced. Accordingly, a heatexchanger is provided with improved operational reliability. Field studies have shown that theconnections between tubes and tank units are susceptible to damage, such as cracks. Thus,since the reinforcement assembly provides support of the tube relative the tank unit, such damages can be avoided.

Moreover, a heat exchanger is provided with a reinforcement assembly having conditionsand characteristics suitable for being manufactured and assembled in a cost-efficientmanner. Furthermore, a reinforcement assembly is provided which can be mounted onto aheat exchanger in a manufacturing step following a manufacturing step of the heatexchanger in which the tubes are connected to the tank assembly. Thereby, a reinforcementassembly is provided which can be mounted onto already existing heat exchangers ofvehicles, for example onto heat exchangers of vehicles operating in extra demanding environments, to thereby reduce the risk of formation of cracks.

Accordingly, a heat exchanger is provided overcoming, or at least alleviating, at least someof the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.Qptier-æaliyvtïhe tank unit comprises a tank and a header, wherein the beam is attached tothe tank. Thereby, a rigid support is provided between the tube and the tank. As a result, the risk of cracks in the connection between the tube and the header is reduced.

»GFpåšenat-liy,--éhe-fia-ak-tara-it--semp:fåses--a-tara-k--and--a--heaëer,-WHerein-the-beam--is--attaehed-êe--the Optionally, the support element is attached to the tube in a plane substantially parallel to an intended air flow direction through the heat exchanger. Thereby, a more rigid support is 3 provided between the tube and the tank unit. This because the tube is supported in directionsin which it is more likely to move and vibrate during operation of the vehicle. Accordingly, areinforcement assembly is provided further reducing the risk of cracks in the connection between the tube and the tank unit.

Optionally, the heat exchanger comprises a multiplicity of fins arranged between tubes of theset of tubes, and wherein the support element comprises at least one aperture at the locationof a fin. Thereby, a reinforcement assembly is provided capable of supporting the tube relative the tank unit along a length of the tube in the extension direction thereof.

Optionally, the support element comprises a first portion attached to a first side of the tubeand a second portion attached to a second side of the tube. Thereby, an even more rigidsupport is provided between the tube and the tank unit. This because the tube is furtherprevented from moving and vibrating during operation of the vehicle. Accordingly, areinforcement assembly is provided further reducing the risk of cracks in the connection between the tube and the tank unit.

Optionally, the second side is substantially opposite to the first side. Thereby, an even morerigid support is provided between the tube and the tank unit. This because the tube issupported in directions in which it is more likely to move and vibrate during operation of thevehicle. Accordingly, a reinforcement assembly is provided further reducing the risk of cracks in the connection between the tube and the tank unit.

Optionally, the reinforcement assembly comprises a ledge attached to the tank unit, andwherein the beam is attached to the tank unit via the ledge. Thereby, a heat exchanger isprovided with a reinforcement assembly having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.

Optionally, the tubes of the set of tubes are arranged side by side such that the tubestogether form a quadrilateral tube package, wherein the support element is attached to atube at a first corner the quadrilateral tube package. Field studies have shown that theconnections between tubes and tank units at corners of a heat exchanger are moresusceptible to damage, such as cracks, than other connections between tubes and tank unitsof the heat exchanger. Thus, since the support element is attached to a tube at a first cornerthe quadrilateral tube package, a heat exchanger is provided with improved operational reliability. 4 Optionally, the heat exchanger comprises a second reinforcement assembly, and whereinthe second reinforcement assembly comprises a second support element attached to a tubeat a second corner of the quadrilateral tube package. Thereby, a heat exchanger is provided with further improved operational reliability.

Optionally, the heat exchanger comprises a third reinforcement assembly comprising a thirdsupport element attached to a tube at a third corner of the quadrilateral tube package, andwherein the heat exchanger comprises a fourth reinforcement assembly comprising a fourthsupport element attached to a tube at a fourth corner of the quadrilateral tube package.

Thereby, a heat exchanger is provided with further improved operational reliability.

According to a second aspect of the invention, the object is achieved by a powertrain for avehicle, wherein the powertrain comprises a heat exchanger according to someembodiments of the present disclosure. Since the powertrain comprises a heat exchangeraccording to some embodiments, a power train is provided with improved operationalreliability. This because the heat exchanger of the power train is less likely to become damaged during operation of the powertrain.

Accordingly, a powertrain is provided overcoming, or at least alleviating, at least some of theabove-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.

According to a third aspect of the invention, the object is achieved by a vehicle comprising aheat exchanger according to some embodiments of the present disclosure. Since the vehiclecomprises a heat exchanger according to some embodiments, a vehicle is provided with improved operational reliability. This because the heat exchanger of the vehicle is less likely to become damaged during operation of the vehicle.Accordingly, a vehicle is provided overcoming, or at least alleviating, at least some of theabove-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.

Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS Various aspects of the invention, including its particular features and advantages, will bereadily understood from the example embodiments discussed in the following detailed description and the accompanying drawings, in which: Fig. 1 illustrates a heat exchanger, according to some embodiments, Fig. 2 illustrates an enlarged view of a portion of a heat exchanger, according to someembodiments, Fig. 3 illustrates a cross section through a tube and a support element of the heat exchangerillustrated in Fig. 2, Fig. 4 illustrates a powertrain for a vehicle, and Fig. 5 illustrates a vehicle, according to some embodiments.

DETAILED DESCRIPTIONAspects of the present invention will now be described more fully. Like numbers refer to likeelements throughout. Well-known functions or constructions will not necessarily be described in detail for brevity and/or clarity.

Fig. 1 illustrates a heat exchanger 1 according to some embodiments. According to theillustrated embodiments, the heat exchanger 1 is a power source radiator for a vehicle.According to further embodiments, the heat exchanger 1, as referred to herein, may beanother type of vehicle heat exchanger, such as a retarder radiator, a charge air cooler, orthe like. The heat exchanger 1 comprises two tank units 5, 5' each comprising a header 17,17' and a tank 15, 15'. The heat exchanger 1 further comprises a set of tubes 7' fluidlyconnected to the tank units 5, 5'. The tubes 7 of the set of tubes 7' are connected to the tankunits 5, 5' via the respective header 17, 17', for example by welding or crimping. The heatexchanger 1 comprises a multiplicity of fins 19 arranged between tubes 7 of the set of tubes7'. During operation of the heat exchanger 1, a medium to be cooled flows from one of thetanks 5 to the other tank 5' via the tubes 7.

According to the illustrated embodiments, the heat exchanger 1 comprises four reinforcement assemblies 9, 9', 9", 9 . As is further explained herein, the heat exchanger 1 may comprise another number of reinforcement assemblies 9, 9', 9", 9 than four. A first reinforcement assembly 9 of the four reinforcement assemblies 9, 9', 9", 9"' is in thefollowing described in detail. However, the second, third, and fourth reinforcementassemblies 9', 9", 9"' may comprise the same features, functions, and advantages as thefirst reinforcement assembly 9. For the reason of brevity and clarity, the first reinforcement assembly 9 is in the following referred to as “the reinforcement assembly 9".

The reinforcement assembly 9 comprises a support element 11 attached to a tube 7 of theset of tubes 7'. The support element 11 may for example be attached to the tube 7 usingwelding, soldering, crimping, gluing, or by using one or more fastening elements such asscrew, bolts, or the like. Moreover, the reinforcement assembly 9 comprises a beam 13attached to the support element 11 and to the tank unit 5. ln this manner, the reinforcementassembly 9 supports the tube 7 relative the tank unit 5 and prevents the tube 7 from movingand vibrating during operation of the heat exchanger 1. As a result, the risk of cracks, or other damages, of the connection between the tube 7 and the header 17 is reduced.

According to the illustrated embodiments, the beam 13 is attached to the tank 15 of the tankunit 5. As is further explained herein, according to further embodiments, the beam 13 may beattached to the header 17 of the tank unit 5. According to the illustrated embodiments, thereinforcement assembly 9 comprises a ledge 23 attached to the tank unit 5, and wherein the beam 13 is attached to the tank unit 5 via the ledge 23.

As can be seen in Fig. 1, the tubes 7 of the set of tubes 7' are arranged side by side suchthat the tubes together form a quadrilateral tube package 25. The wording “quadrilateral tubepackage” is herein intended to encompass a rectangular-, square-, parallelogram-, ortrapezoid-shaped tube package 25. Thus, throughout this disclosure, the wording“quadrilateral tube package” may be replaced by the wording “rectangular-, square-, parallelogram-, or trapezoid-shaped tube package 25".

According to the illustrated embodiments, the support element 11 of the reinforcementassembly 9, i.e. of the first reinforcement assembly 9, is attached to a tube 7 at a first corner25.1 the quadrilateral tube package 25. Moreover, the second reinforcement assembly 9'comprises a second support element 11' attached to a tube 7 at a second corner 25.2 of thequadrilateral tube package 25. Furthermore, the third reinforcement assembly 9" comprisesa third support element 11" attached to a tube 7 at a third corner 25.3 of the quadrilateral tube package 25, and the fourth reinforcement assembly 9 comprises a fourth support element 11 attached to a tube 7 at a fourth corner 25.4 of the quadrilateral tube package25. Thus, according to the illustrated embodiments, tubes 7 are supported at each corner25.1, 25.2, 25.3, 25.4 of the quadrilateral tube package 25. Field studies have shown that theconnections between tubes 7 and tank units 5, 5' at corners 25.1, 25.2, 25.3, 25.4 of a heatexchanger 1 are more susceptible to damage, such as cracks, than other connectionsbetween tubes and tank units 5, 5' of the heat exchanger 1. Thus, by supporting tubes 7 at corners 25.1, 25.2, 25.3, 25.4 of the heat exchanger 1, using the herein disclosed 7 reinforcement assembly 9, the operational reliability of the heat exchanger 1 is significantly improved.

According to the illustrated embodiments, the support elements 11, 11', 11", 11"' areattached to the outermost tubes 7 of the set of tubes 7'. That is, according to the illustratedembodiments, the first, second, third, and fourth reinforcement assemblies 9, 9', 9", 9"' areeach arranged to support an outermost tube 7 of the set of tubes 7'. The outermost tubes 7of the set of tubes 7' are the most susceptible to damage, such as cracks, in their connectionto a header 17, 17'. Thus, by supporting these tubes 7, the operational reliability of the heat exchanger 1 is further improved.

According to further embodiments, the heat exchanger 1 may comprise less or more reinforcement assemblies 9, 9', 9", 9 than depicted in Fig. 1. As an example, the heatexchanger 1 may comprise reinforcement assemblies 9, 9', 9", 9"' supporting the first andsecond outermost tubes 7 of the set of tubes 7' at each corner 25.1, 25.2, 25.3, 25.4 thequadrilateral tube package 25. According to such embodiments, the heat exchanger 1 comprises eight reinforcement assemblies 9, 9', 9", 9 . As a further example, the heatexchanger 1 may comprise reinforcement assemblies 9, 9', 9", 9"' supporting the first,second, and third outermost tubes 7 of the set of tubes 7' at each corner 25.1, 25.2, 25.3,25.4 the quadrilateral tube package 25. According to such embodiments, the heat exchanger 1 comprises twelve reinforcement assemblies 9, 9', 9", 9 .

The tubes 7 of the set of tubes 7' are arranged in a row in the quadrilateral tube package 25extending from the first and fourth corners 25.1, 25.4 to the second and third corners 25.2,25.3 of the quadrilateral tube package 25. The wording “outermost tubes 7 of the set of tubes 7"' is herein intended to encompass the first and last tube 7 of such a row of tubes.

Fig. 2 illustrates an enlarged view of a portion of a heat exchanger 1 according to someembodiments. The heat exchanger 1 comprises a reinforcement assembly 9 in a partiallyassembled state. The reinforcement assembly 9 comprises a support element 11 attached toa tube 7 of the heat exchanger. Moreover, the reinforcement assembly 9 comprises a ledge23 attached to a tank 15 and to a header 17 of a tank unit 5 of the heat exchanger 1.According to further embodiments, the ledge 23 may be attached solely to the tank 15 orsolely to the header 17. The ledge 23 may for example be attached to the tank unit 5 usingwelding, soldering, gluing, or by using one or more fastening elements such as screw, bolts, or the like. 8 As can be seen in Fig. 2, the heat exchanger 1 comprises a multiplicity of fins 19 arrangedbetween tubes 7 of the heat exchanger. According to the illustrated embodiments, thesupport element 11 protrudes into the tube package of the heat exchanger 1. Moreover, thesupport element 11 has a length, measured in a direction of elongation of the tube 7, beinggreater than the distance between two adjacent fins 19 at the tube 7. Furthermore, accordingto these embodiments, the support element 11 of the reinforcement assembly 9 comprises apertures 21 at the location of fins 19.

The reinforcement assembly 9 comprises a beam 13. ln Fig. 2, the beam 13 is illustrated inan unassembled state. The beam 13 is configured to be attached to the support element 11and to the ledge 23, for example using welding, soldering, gluing, or by using one or more fastening elements such as screw, bolts, or the like. ln an assembling process of the reinforcement assembly 9, the support element 11 can beattached to the tube 7 and the ledge can be attached to the tank unit 5. Then, the beam 13can be attached to the support element 11 and to the ledge 23. Thus, the reinforcementassembly 9 disclosed herein can be mounted onto completely produced heat exchangers 1,which gives more freedom in the production process of the heat exchanger 1. As anexample, the tank unit 5 can be manufactured using welding or crimping. Moreover, thereinforcement assembly 9 disclosed herein can be mounted onto heat exchangers 1 of already existing vehicles to thereby improve the operational reliability of the heat exchanger.

According to the embodiments illustrated in Fig. 1 and in Fig. 2, the reinforcement assembly9 comprises a ledge 23. However, according to some embodiments, the beam 13 of the reinforcement assembly 9 may be directly attached to the tank unit 5, i.e. directly attached tothe tank 15, and/or to the header 17, of the tank unit 5, for example using welding, crimping, or by using one or more fastening elements such as screw, bolts, or the like.

Fig. 3 illustrates a cross section through the tube 7 and the support element 11 of the heatexchanger 1 illustrated in Fig. 2. As can be seen in Fig. 3, according to these embodiments,the support element 11 comprises a first portion 11.1 attached to a first side 7.1 of the tube 7and a second portion 11.2 attached to a second side 7.2 of the tube 7, wherein the secondside 7.2 is substantially opposite to the first side 7.1. Thereby, a rigid support of the tube 7 is provided in several directions.

Moreover, according to the illustrated embodiments, the support element 11 is attached to the tube 7 in a plane p substantially parallel to an intended airflow direction d through the 9 heat exchanger 1. ln this manner, the tube 7 is supported in directions in which the tube ismost likely to move and vibrate during operation of the heat exchanger. The feature that theplane p is substantially parallel to the intended airflow direction d is herein intended toencompass that the angle between the plane p and the air flow direction d is less than 20 degrees.

Fig. 4 illustrates a powertrain 30 for a vehicle. According to the illustrated embodiments,powertrain 30 is configured to provide motive power to a vehicle, via wheels 32 of thevehicle. The power train comprises a power source 34, which may comprise an internalcombustion engine, for example a compression ignition engine, such as a diesel engine, oran Otto engine with a spark-ignition device, wherein the Otto engine may be configured torun on gas, petrol, alcohol, similar volatile fuels, or combinations thereof. As an alternative, or in addition, the power source 34 may comprise one or more electrical machines.

The powertrain 30 comprises a heat exchanger 1. The heat exchanger 1 may be a heatexchanger 1 according to the embodiments illustrated in Fig. 1, or a heat exchanger 1according to the embodiments illustrated in Fig. 2. According to the illustrated embodiments,the heat exchanger is arranged to cool the power source 34 of the powertrain 30. Accordingto further embodiments, the heat exchanger 1 may be arranged to cool a retarder of the power train 30 or a fuel cell of the powertrain 30.

Fig. 5 illustrates a vehicle 3 according to some embodiments. The vehicle 3 comprises apowertrain 30 provided with a heat exchanger 1 according to the embodiments illustrated inFig. 4.

According to the illustrated embodiments, the vehicle 3 is a truck. However, according tofurther embodiments, the vehicle 3, as referred to herein, may be another type of manned orunmanned vehicle for land or water based propulsion such as a lorry, a bus, a construction vehicle, a tractor, a car, a ship, a boat, or the like. lt is to be understood that the foregoing is illustrative of various example embodiments andthat the invention is defined only by the appended claims. A person skilled in the art willrealize that the example embodiments may be modified, and that different features of theexample embodiments may be combined to create embodiments other than those describedherein, without departing from the scope of the present invention, as defined by the appended claims.

As used herein, the term "comprising" or "comprises" is open-ended, and includes one ormore stated features, elements, steps, components or functions but does not preclude the presence or addition of one or more other features, elements, steps, components, functionsor groups thereof.

Claims (1)

1. CLAI l\/IS 1. A heat exchanger (1) for a vehicle (3), wherein the heat exchanger (1) comprises: - a tank unit (5), wherein the tank unit (5) comprises a tank (15) and a header (17),- a set of tubes (7') fluidly connected to the tank unit (5), and - a reinforcement assembly (9), whare-š-n--characterizæd in that the reinforcement assembly (9) comprises: - a support element (11) attached to a tube (7) of the set of tubes (7'), and - a beam (13) attached to the support element (11) and to the tank (15). The heat exchanger (1) according to claim 1, the supportelement (11) is attached to the tube (7) in a plane (p) substantially parallel to an intended air flow direction (d) through the heat exchanger (1 ). The heat exchanger (1) according to any one of the preceding claims, characteršzed inthaixfvheafein the heat exchanger (1) comprises a multiplicity of fins (19) arrangedbetween tubes (7) of the set of tubes (7'), and wherein the support element (11) comprises at least one aperture (21) at the location of a fin (19). The heat exchanger (1) according to any one of the preceding claims, charactæršzæü intëgíyvlïer-ein the support element (11) comprises a first portion (11.1) attached to a first side (7.1) of the tube (7) and a second portion (11.2) attached to a second side (7.2) of the tube (7). The heat exchanger (1) according to claim 4, cšfæaracterized in tšfzatwl-äerein the second side (7.2) is substantially opposite to the first side (7.1) The heat exchanger (1) according to any one of the preceding claims, charactæršzæü inthaiwhereiaw the reinforcement assembly (9) comprises a ledge (23) attached to the tankunit (5), and wherein the beam (13) is attached to the tank unit (5) via the ledge (23). The heat exchanger (1) according to any one of the preceding claims, characteršzed in thaiwheafein the tubes (7) of the set of tubes (7') are arranged side by side such that the 2 tubes (7) together form a quadrilateral tube package (25), wherein the support element (11) is attached to a tube (7) at a first corner (25.1) the quadrilateral tube package (25). _ The heat exchanger (1) according to claim 7, the heat exchanger (1) comprises a second reinforcement assembly (9'), and wherein the secondreinforcement assembly (9') comprises a second support element (11') attached to a tube (7) at a second corner (25.2) of the quadrilateral tube package (25). _ The heat exchanger (1) according to claim 8, the heat exchanger (1) comprises a third reinforcement assembly (9”) comprising a third supportelement (11”) attached to a tube (7) at a third corner (25.3) of the quadrilateral tubepackage (25), and wherein the heat exchanger (1) comprises a fourth reinforcement assembly (9 ) comprising a fourth support element (11 ) attached to a tube (7) at a fourth corner (25.4) of the quadrilateral tube package (25). 10. A powertrain (30) for a vehicle (3), charactæršzed in thatwhereša the powertrain (30) comprises a heat exchanger (1) according to any one of the preceding claims. 11. A vehicle (3) charactærizefi in thai the 'vehicle šíå) eempr-š-eing--comgufises a heat exchanger (1) according to any one of the claims 1 - 9 or a powertrain (30) according toclaim 10.