US20080041556A1 - Stacked/bar plate charge air cooler including inlet and outlet tanks - Google Patents
Stacked/bar plate charge air cooler including inlet and outlet tanks Download PDFInfo
- Publication number
- US20080041556A1 US20080041556A1 US11/838,809 US83880907A US2008041556A1 US 20080041556 A1 US20080041556 A1 US 20080041556A1 US 83880907 A US83880907 A US 83880907A US 2008041556 A1 US2008041556 A1 US 2008041556A1
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- US
- United States
- Prior art keywords
- charge air
- plate pairs
- coolant
- heat exchange
- air cooler
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
- F28D9/0043—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B29/00—Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
- F02B29/04—Cooling of air intake supply
- F02B29/045—Constructional details of the heat exchangers, e.g. pipes, plates, ribs, insulation, materials, or manufacturing and assembly
- F02B29/0462—Liquid cooled heat exchangers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
- F28D9/0043—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another
- F28D9/0056—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another with U-flow or serpentine-flow inside conduits; with centrally arranged openings on the plates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/04—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element
- F28F3/042—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element in the form of local deformations of the element
- F28F3/044—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being integral with the element in the form of local deformations of the element the deformations being pontual, e.g. dimples
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
- F28D2021/0082—Charged air coolers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2250/00—Arrangements for modifying the flow of the heat exchange media, e.g. flow guiding means; Particular flow patterns
- F28F2250/10—Particular pattern of flow of the heat exchange media
- F28F2250/102—Particular pattern of flow of the heat exchange media with change of flow direction
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
Definitions
- the present invention relates to a heat exchanger and a method of manufacturing a heat exchanger, and more particularly to a charge air cooler and a method of manufacturing a charge air cooler.
- One current area in need of improvement is for charge air coolers that can provide acceptable performance in connection with low coolant flow rates that are typical in low temperature coolant circuits such as are expected to become increasingly common for some engine applications (e.g., diesel engine applications) that will be required to meet increasingly demanding emission compliance strategies.
- the present invention provides a heat exchanger that is of particular use as a charge air cooler in engine systems having low coolant flow rates that are typical in low temperature coolant circuits.
- the heat exchanger utilizes a combination of bar-plate design and stacked plate design together with inlet and outlet tanks to eliminate air bypass around the core to the cooler while providing a highly manufacturable cooler.
- the design also allows for different core stack heights for different applications by changing the quantity of the components for the core without requiring any significant change to the component parts of the core.
- the design further can provide particular advantages wherein the core components, and potentially other components, of the heat exchanger are made from aluminum.
- the invention provides a charge air cooler for transferring heat between a coolant and charge air.
- the cooler can include a heat exchange core including a stack of embossed plate pairs. Each plate pair can define a circuitous or serpentine coolant flow path through the heat exchange core.
- the heat exchange core can also include a number of elongated spacers interleaved with the plate pairs to define charge air flow paths between adjacent plate pairs through the heat exchange core.
- the charge air cooler can also include a charge air inlet tank connected to a first side of the heat exchange core to direct the charge air into the charge air flow paths and a charge air outlet tank connected to a second side of the heat exchange core to collect the charge air from the charge air flow paths.
- the present invention provides a charge air cooler including a charge air inlet tank, a charge air outlet tank spaced from the inlet tank, and a heat exchange core positioned between the inlet and outlet tanks and including a stack of plate pairs.
- Each of the plate pairs can define a multi-pass path for the coolant.
- First and second elongated spacers can be positioned between adjacent plate pairs and can extend between the inlet tank and the outlet tank on opposite sides of the heat exchange core to define flow paths for the charge air through the heat exchange core.
- the present invention also provides a method of assembling a charge air cooler, the method comprising the acts of embossing a plurality of plates, stacking the plurality of plates in plate pairs such that embossments of each plate pair at least partially define a flow path for a coolant, interleaving a plurality of elongated spacers between the plate pairs, securing a charge air inlet tank to the stacked plate pairs to receive the charge air and to distribute the charge air to flow paths defined between adjacent plate pairs, and securing a charge air outlet tank to the assembled plate pairs to receive the charge air from the flow paths.
- FIG. 1 is a perspective view of a heat exchanger according to some embodiments of the present invention.
- FIG. 2 is a partially exploded, perspective view of the heat exchanger shown in FIG. 1 .
- FIG. 3 is a perspective view of a plate utilized in the heat exchanger shown in FIG. 1 .
- FIG. 4 is a view of an alternate embodiment of the heat exchanger of the present invention.
- phraseology and terminology used herein with reference to device or element orientation are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation.
- terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.
- the heat exchanger 10 is a charge air cooler configured to receive a charge air flow 12 from a charge air compressor 14 and to supply a cooled charge air flow 16 for combustion in an engine 18 after having transferred heat from the charge air flow 12 to a coolant flow 20 provided by a coolant system 22 associated with the engine 18 .
- charge air compressors 14 e.g., so-called “turbochargers”
- combustion engines 18 e.g., so-called “turbochargers”
- coolant systems 22 that are commonly employed in vehicles and other application, all of which are acceptable for use with the heat exchanger 10 of the present invention. Accordingly, further description of the components 14 , 18 , and 22 will not be provided herein.
- the heat exchanger 10 can include a core 30 , a charge air inlet tank 32 connected to one side of the core 30 to direct the charge air flow 12 into the core 30 , and a charge air outlet tank 33 connected to the opposite side of the core 30 to receive the cooled charge air flow 16 therefrom and direct the charge air flow to the engine 18 .
- the charge air inlet and outlet tanks 32 , 33 can be located on the same side of the core 30 .
- the charge air inlet and outlet tanks 32 , 33 can be integrally formed and can include one or more internal partitions for defining inlet and outlet portions of the integral tank.
- the charge air inlet and outlet tanks 32 , 33 can be located on adjacent sides of the core 30 (e.g., on top and left sides, bottom and left sides, front and left sides, etc.).
- the core 30 can include one or more coolant inlet ports 34 and one or more coolant outlet ports 36 to direct coolant flow into and out of the core 30 .
- the core 30 includes a single inlet port 34 and a single outlet port 36 located on a common side of the core 30 so as to provide a counterflow relationship between the coolant flow 20 and the charge air flow 12 through the core 30 .
- the core 30 can include two or more of each of the inlet and outlet ports 34 , 36 and/or the inlet and outlet ports 34 , 36 can be located on a common side of the core 30 , or alternatively, the inlet and outlet ports 34 , 36 can be located on different sides of the core 30 .
- the inlet and outlets 34 , 36 can be oriented so as to provide a crossflow or a parallel flow relationship between the coolant flow 20 and the charge air flow 12 through the core 30 .
- the core 30 includes a number of stacked plate pairs 40 ( 14 in the illustrated embodiment) with air side fins 42 and elongated spacer bars 44 , 45 interleaved between adjacent plate pairs 40 to define the air flow paths 46 through the core 30 .
- one air side fin 42 is supported between each adjacent plate pair 40 , and between a pair of spacer bars 44 , 45 , which seal opposite ends of the heat exchanger core 30 .
- two or more air side fins 42 can be supported between adjacent plate pairs 40
- the core 30 can include one or more pairs of adjacent plate pairs 40 not having an air side fin 42 and/or a spacer bar 44 located therebetween
- a single spacer bar 44 can be located between one or more adjacent plate pairs 40
- a pair of spacer bars 44 , 45 can seal adjacent sides of the heat exchanger core 30
- three or four spacer bars 44 can be located between adjacent plate pairs 40 .
- the core 30 can include one or more fins 42 having other configurations, such as, for example, lanced and offset, louvered, and the like.
- the spacer bars 44 , 45 can each have a substantially square cross-sectional shape.
- the spacer bars 44 , 45 can have a different cross sectional shape, such as, for example, round, triangular, wedge, rectangular, trapezoidal, or any other polygonal shape, oval, irregular, and the like.
- the core 30 can include a single plate folded or rolled over onto itself so that opposite ends of the of the plate contact one another and so that the single plate substantially encloses a coolant flow path 49 and maintains coolant in the coolant flow path 49 separate from the air flow paths 46 .
- the core 30 can include a number of adjacent folded or rolled plates, each of which can define a separate coolant flow path 49 , and spacer bars 44 and/or air side fins 42 can be supported in the core 30 between adjacent folded or rolled plates.
- each of the plate pairs 40 is formed from a pair of stamped or embossed plates 47 , 48 that are joined at their periphery so as to enclose and define a coolant flow path 49 (best seen in FIG. 3 ) for the coolant therebetween.
- Each of the plates 47 , 48 includes a pair of openings 50 , 52 that are aligned with the corresponding openings 50 , 52 of the other plates in order to define respective coolant manifolds 54 , 56 for distributing and collecting the coolant to and from the flow paths 49 .
- each of the openings 50 , 52 is surrounded by a corresponding raised boss 58 , 60 , respectively, that faces outwardly from each plate pair 40 to mate with an adjacent aligned boss 58 , 60 in order to seal the corresponding manifolds 54 , 56 .
- inserts can be positioned between each of the openings 50 , 52 to at least partially enclose one or both of the coolant manifolds 54 , 56 .
- the spacer bars 44 , 45 can be shaped to surround the openings 50 , 52 so as to form a seal between adjacent plate pairs 40 and to at least partially define one or both of the coolant manifolds 54 , 56 .
- a pair of coolant manifolds 54 , 56 are located on a common side of the heat exchanger core 30 .
- the core 30 can include a single manifold having an internal partition, or alternatively, the core 30 can include two or more manifolds 54 , 56 located on different sides of the heat exchanger core 30 .
- each spacer bar 44 , 45 can be shaped so as to conform to the corresponding end periphery of the adjacent stacked plate pairs 40 .
- the spacer bars 44 located on one side of the core 30 i.e., the right side in FIG. 2
- the spacer bars 44 located on one side of the core 30 include contoured portions 64 , 66 that wrap around the correspondingly contoured bosses 58 , 60 of the adjacent plate pairs 40 so as to seal the air side of the core 30 of the corresponding end of the core 30 .
- the spacer bars 45 located on the opposite side of the core 30 i.e., the left side in FIG.
- the spacer bars 44 , 45 of the illustrated embodiment of FIG. 2 are differently shaped to seal differently shaped sides of the core 30
- the spacer bars 44 , 45 can be similarly shaped to engage similarly shaped sides of the core 30
- common spacer bars can be located on opposed sides of the core 30 , eliminating the need for differently shaped spacer bars 44 , 45 and simplifying assembly of the core 30 .
- the core 30 can also include a top plate 67 and a bottom plate 68 that sandwich the plate pairs 40 and interleaved fins 42 and spacer bars 44 , 45 therebetween.
- the top plate 67 has a pair of openings for receiving the ports 34 , 36
- the bottom plate 68 does not have any openings so as to enclose the manifolds 54 , 56 .
- one of the ports 34 , 36 e.g., the inlet port 34
- the other port 34 , 36 e.g., the outlet port 36
- both ports 34 , 36 can extend through the bottom plate 68 .
- the top plate 67 engages an upper-most plate pair 40 and the bottom plate 68 engages a lower-most plate pair 40 .
- a fin 42 can be supported between the top plate 67 and the upper-most plate pair 40 and/or a fin 42 can be supported between the lower-most plate pair 40 .
- the top plate 67 can be eliminated and the upper-most plate pair 40 can define a top of the core 30 and/or the bottom plate 68 can be eliminated and the lower-most plate pair 40 can define the bottom of the core 30 .
- each of the plates 47 , 48 includes a peripheral embossment 70 and a plurality of longitudinal embossments 72 , 74 , 76 , 78 , and 80 , that extend interior from the peripheral embossment 70 to cooperate with the other plate 47 , 48 of the plate pair 40 to define the coolant flow paths 49 with multiple passes A, B, C, D, E, and F to create a cross flow with the charge air flow paths 46 through the core 30 .
- curved embossments 82 are provided between adjacent ends of the passes A-E to help direct the coolant flow from one pass to the next with an even distribution of the coolant flow. As shown in FIG.
- the longitudinal embossments 72 , 74 , 76 , 78 , and 80 and the curved embossments 82 define a circuitous coolant flow path 49 through each of the plate pairs 40 .
- one or both of the plates 47 , 48 can have embossments having other configurations and relative orientations to provide a circuitous coolant flow path 49 .
- one or both of the plates 47 , 48 can have other longitudinal protrusions and/or curved protrusions, one or more of which can be welded, soldered, or brazed to one or both of the plates 47 , 48 to at least partially define the coolant flow path 49 .
- one or both of the plates 47 , 48 can include a number of raised dimple-shaped embossments 84 , 86 to strengthen the connection between the plates 47 , 48 and/or act as turbulators for the coolant flow. While one preferred form is shown for the plates 47 , 48 , it should be appreciated that there are many possible forms for the plates 47 , 48 and that the particular form selected will depend upon a number of parameters for each specific application. For example, in some applications, fewer, or more, of the multiple passes A-F may be desired. Similarly, in some applications, the embossments 82 , 84 , and 86 may desirably be eliminated, or modified.
- the charge air inlet and charge air outlet tanks 32 , 33 each have a peripheral rim 90 , 92 , respectively, that correspond to and mates with the air side peripheries 94 , 96 , respectively, of the core 30 defined by edges of the top and bottom plates 67 , 68 , the spacer bars 44 , 46 , and the corresponding ends of the plate pairs 40 that surround the inlet and exit sides of the air flow paths 46 through the core 30 .
- the corresponding peripheries 90 , 94 and 92 , 96 can bonded in a suitable fashion, such as by welding, soldering, or brazing, so as to seal the peripheries 90 , 94 and 92 , 96 together to prevent or restrict leakage of the charge air flow from the heat exchanger 10 and around the flow paths 46 .
- a seal or gasket can be positioned between the core 30 and the charge air inlet tank 32 and/or between the core 30 and the charge air outlet tank 34 .
- charge air inlet and charge air outlet tanks 32 , 33 can be of any suitable construction, in the illustrated embodiment, the charge air inlet and charge air outlet tanks 32 , 33 are shown as castings or moldings formed from a suitable material, with the charge air inlet tank 32 having a suitable air inlet port 100 formed thereon and the outlet tank 32 having a suitable outlet air port 102 formed thereon.
- the use of the spacer bars 44 , 46 helps to provide a peripheral surface so that the tanks 30 , 32 can be mated and bonded in a suitable fashion with the core 30 .
- the heat exchanger 10 While any suitable material may be used for the heat exchanger 10 , in some preferred embodiments it is desirable to form the tanks 32 , 33 and the components for the core from aluminum and to bond all of the components of the heat exchanger 10 together using a suitable braze, welding, or soldering operation.
- FIG. 4 shows a core 30 formed from seven of the plate pairs 40 and a corresponding number of the interleaved fins 42 and spacer bars 44 , 45 .
- the charge air inlet tank 32 and charge air outlet tank 32 be sized so that their peripheries 90 , 92 conform to the peripheries 94 , 96 of the core 30 .
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
Abstract
The present invention provides a charge air cooler for transferring heat between a coolant and charge air including a charge air inlet tank, a charge air outlet tank spaced from the inlet tank, and a heat exchange core positioned between the inlet and outlet tanks and including a stack of plate pairs. Each of the plate pairs can define a multi-pass path for the coolant. Elongated spacers can be positioned between adjacent plate pairs and extend between the inlet tank and the outlet tank on opposite sides of the heat exchange core to define flow paths for the charge air through the heat exchange core.
Description
- The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/838,740, filed Aug. 18, 2006, the entire contents of which is hereby incorporated by reference.
- The present invention relates to a heat exchanger and a method of manufacturing a heat exchanger, and more particularly to a charge air cooler and a method of manufacturing a charge air cooler.
- There is always a need for improvements in heat exchangers. One current area in need of improvement is for charge air coolers that can provide acceptable performance in connection with low coolant flow rates that are typical in low temperature coolant circuits such as are expected to become increasingly common for some engine applications (e.g., diesel engine applications) that will be required to meet increasingly demanding emission compliance strategies.
- In some embodiments, the present invention provides a heat exchanger that is of particular use as a charge air cooler in engine systems having low coolant flow rates that are typical in low temperature coolant circuits. The heat exchanger utilizes a combination of bar-plate design and stacked plate design together with inlet and outlet tanks to eliminate air bypass around the core to the cooler while providing a highly manufacturable cooler. The design also allows for different core stack heights for different applications by changing the quantity of the components for the core without requiring any significant change to the component parts of the core. The design further can provide particular advantages wherein the core components, and potentially other components, of the heat exchanger are made from aluminum.
- In some embodiments, the invention provides a charge air cooler for transferring heat between a coolant and charge air. The cooler can include a heat exchange core including a stack of embossed plate pairs. Each plate pair can define a circuitous or serpentine coolant flow path through the heat exchange core. The heat exchange core can also include a number of elongated spacers interleaved with the plate pairs to define charge air flow paths between adjacent plate pairs through the heat exchange core. The charge air cooler can also include a charge air inlet tank connected to a first side of the heat exchange core to direct the charge air into the charge air flow paths and a charge air outlet tank connected to a second side of the heat exchange core to collect the charge air from the charge air flow paths.
- In other embodiments, the present invention provides a charge air cooler including a charge air inlet tank, a charge air outlet tank spaced from the inlet tank, and a heat exchange core positioned between the inlet and outlet tanks and including a stack of plate pairs. Each of the plate pairs can define a multi-pass path for the coolant. First and second elongated spacers can be positioned between adjacent plate pairs and can extend between the inlet tank and the outlet tank on opposite sides of the heat exchange core to define flow paths for the charge air through the heat exchange core.
- The present invention also provides a method of assembling a charge air cooler, the method comprising the acts of embossing a plurality of plates, stacking the plurality of plates in plate pairs such that embossments of each plate pair at least partially define a flow path for a coolant, interleaving a plurality of elongated spacers between the plate pairs, securing a charge air inlet tank to the stacked plate pairs to receive the charge air and to distribute the charge air to flow paths defined between adjacent plate pairs, and securing a charge air outlet tank to the assembled plate pairs to receive the charge air from the flow paths.
- Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
-
FIG. 1 is a perspective view of a heat exchanger according to some embodiments of the present invention. -
FIG. 2 is a partially exploded, perspective view of the heat exchanger shown inFIG. 1 . -
FIG. 3 is a perspective view of a plate utilized in the heat exchanger shown inFIG. 1 . -
FIG. 4 is a view of an alternate embodiment of the heat exchanger of the present invention. - Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
- Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
- Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “central,” “upper,” “lower,” “front,” “rear,” and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.
- In the illustrated embodiment of
FIGS. 1 and 2 , theheat exchanger 10 is a charge air cooler configured to receive acharge air flow 12 from acharge air compressor 14 and to supply a cooledcharge air flow 16 for combustion in anengine 18 after having transferred heat from thecharge air flow 12 to acoolant flow 20 provided by acoolant system 22 associated with theengine 18. There are many conventional and known types of charge air compressors 14 (e.g., so-called “turbochargers”),combustion engines 18, andcoolant systems 22 that are commonly employed in vehicles and other application, all of which are acceptable for use with theheat exchanger 10 of the present invention. Accordingly, further description of thecomponents - As shown in
FIGS. 1 and 2 , theheat exchanger 10 can include acore 30, a chargeair inlet tank 32 connected to one side of thecore 30 to direct thecharge air flow 12 into thecore 30, and a chargeair outlet tank 33 connected to the opposite side of thecore 30 to receive the cooledcharge air flow 16 therefrom and direct the charge air flow to theengine 18. In other embodiments, the charge air inlet andoutlet tanks core 30. In some such embodiments, the charge air inlet andoutlet tanks outlet tanks - The
core 30 can include one or morecoolant inlet ports 34 and one or morecoolant outlet ports 36 to direct coolant flow into and out of thecore 30. In the illustrated embodiment ofFIGS. 1 and 2 , thecore 30 includes asingle inlet port 34 and asingle outlet port 36 located on a common side of thecore 30 so as to provide a counterflow relationship between thecoolant flow 20 and thecharge air flow 12 through thecore 30. In other embodiments, thecore 30 can include two or more of each of the inlet andoutlet ports outlet ports core 30, or alternatively, the inlet andoutlet ports core 30. In some such embodiments, the inlet andoutlets coolant flow 20 and thecharge air flow 12 through thecore 30. - In the illustrated embodiment of
FIGS. 1 and 2 , thecore 30 includes a number of stacked plate pairs 40 (14 in the illustrated embodiment) withair side fins 42 andelongated spacer bars adjacent plate pairs 40 to define theair flow paths 46 through thecore 30. In the illustrated embodiment, oneair side fin 42 is supported between eachadjacent plate pair 40, and between a pair ofspacer bars heat exchanger core 30. In other embodiments, two or moreair side fins 42 can be supported betweenadjacent plate pairs 40, thecore 30 can include one or more pairs ofadjacent plate pairs 40 not having anair side fin 42 and/or aspacer bar 44 located therebetween, asingle spacer bar 44 can be located between one or moreadjacent plate pairs 40, a pair ofspacer bars heat exchanger core 30, and/or three or fourspacer bars 44 can be located betweenadjacent plate pairs 40. While a serpentine orcorrugated type fin 42 is shown (only the ends are actually illustrated for simplicity) for theair side fin 42, in some embodiments thecore 30 can include one ormore fins 42 having other configurations, such as, for example, lanced and offset, louvered, and the like. - As shown in
FIG. 2 , thespacer bars spacer bars - In still other embodiments, the
core 30 can include a single plate folded or rolled over onto itself so that opposite ends of the of the plate contact one another and so that the single plate substantially encloses acoolant flow path 49 and maintains coolant in thecoolant flow path 49 separate from theair flow paths 46. In some such embodiments, thecore 30 can include a number of adjacent folded or rolled plates, each of which can define a separatecoolant flow path 49, andspacer bars 44 and/orair side fins 42 can be supported in thecore 30 between adjacent folded or rolled plates. - In the illustrated embodiment of
FIGS. 1-3 , each of theplate pairs 40 is formed from a pair of stamped or embossedplates FIG. 3 ) for the coolant therebetween. Each of theplates openings corresponding openings respective coolant manifolds flow paths 49. In this regard, each of theopenings boss plate pair 40 to mate with an adjacent alignedboss corresponding manifolds openings coolant manifolds spacer bars openings adjacent plate pairs 40 and to at least partially define one or both of thecoolant manifolds - In the illustrated embodiment of
FIGS. 1-3 , a pair ofcoolant manifolds heat exchanger core 30. In other embodiments, thecore 30 can include a single manifold having an internal partition, or alternatively, thecore 30 can include two ormore manifolds heat exchanger core 30. - As shown in
FIG. 2 , eachspacer bar plate pairs 40. In the illustrated embodiment ofFIG. 2 , thespacer bars 44 located on one side of the core 30 (i.e., the right side inFIG. 2 ) includecontoured portions contoured bosses adjacent plate pairs 40 so as to seal the air side of thecore 30 of the corresponding end of thecore 30. As shown inFIG. 2 , thespacer bars 45 located on the opposite side of the core 30 (i.e., the left side inFIG. 2 ) can have a shape correspond to the ends of theadjacent plate pairs 40 so as to seal the air side of thecore 30 at the corresponding end of thecore 30. While the spacer bars 44, 45 of the illustrated embodiment ofFIG. 2 are differently shaped to seal differently shaped sides of the core 30, in other embodiments, the spacer bars 44, 45 can be similarly shaped to engage similarly shaped sides of thecore 30. In some such embodiments, common spacer bars can be located on opposed sides of the core 30, eliminating the need for differently shaped spacer bars 44, 45 and simplifying assembly of thecore 30. - The core 30 can also include a
top plate 67 and abottom plate 68 that sandwich the plate pairs 40 and interleavedfins 42 and spacer bars 44, 45 therebetween. In the illustrated embodiment, thetop plate 67 has a pair of openings for receiving theports bottom plate 68 does not have any openings so as to enclose themanifolds ports 34, 36 (e.g., the inlet port 34) can extend through an opening in thetop plate 67 and theother port 34, 36 (e.g., the outlet port 36) can extend through an opening in thebottom plate 68, or alternatively, bothports bottom plate 68. - In the illustrated embodiment of
FIG. 2 , thetop plate 67 engages anupper-most plate pair 40 and thebottom plate 68 engages alower-most plate pair 40. In other embodiments, afin 42 can be supported between thetop plate 67 and theupper-most plate pair 40 and/or afin 42 can be supported between thelower-most plate pair 40. In still other embodiments, thetop plate 67 can be eliminated and theupper-most plate pair 40 can define a top of thecore 30 and/or thebottom plate 68 can be eliminated and thelower-most plate pair 40 can define the bottom of thecore 30. - In the illustrated embodiment of
FIG. 3 , each of theplates peripheral embossment 70 and a plurality oflongitudinal embossments peripheral embossment 70 to cooperate with theother plate plate pair 40 to define thecoolant flow paths 49 with multiple passes A, B, C, D, E, and F to create a cross flow with the chargeair flow paths 46 through thecore 30. Additionally, curved embossments 82 are provided between adjacent ends of the passes A-E to help direct the coolant flow from one pass to the next with an even distribution of the coolant flow. As shown inFIG. 3 , thelongitudinal embossments curved embossments 82 define a circuitouscoolant flow path 49 through each of the plate pairs 40. In other embodiments, one or both of theplates coolant flow path 49. In still other embodiments, one or both of theplates plates coolant flow path 49. - In some embodiments one or both of the
plates embossments plates plates plates embossments - As shown in
FIGS. 1 and 2 , the charge air inlet and chargeair outlet tanks peripheral rim air side peripheries bottom plates air flow paths 46 through thecore 30. Thecorresponding peripheries peripheries heat exchanger 10 and around theflow paths 46. In some embodiments, a seal or gasket can be positioned between the core 30 and the chargeair inlet tank 32 and/or between the core 30 and the chargeair outlet tank 34. - While the charge air inlet and charge
air outlet tanks air outlet tanks air inlet tank 32 having a suitableair inlet port 100 formed thereon and theoutlet tank 32 having a suitableoutlet air port 102 formed thereon. In this regard, it is important to note that the use of the spacer bars 44, 46 helps to provide a peripheral surface so that thetanks core 30. - While any suitable material may be used for the
heat exchanger 10, in some preferred embodiments it is desirable to form thetanks heat exchanger 10 together using a suitable braze, welding, or soldering operation. - One advantage of the illustrated construction for the
core 30 is that it can allow for different sizes of theheat exchanger 10 by simply adding or subtracting the number of plate pairs 40 and interleavedfins 42 and spacer bars 44, 45 without requiring a change in component configuration for the components of thecore 30. This is illustrated inFIG. 4 which shows a core 30 formed from seven of the plate pairs 40 and a corresponding number of the interleavedfins 42 and spacer bars 44, 45. In this regard, it should be noted, that it is preferred that the chargeair inlet tank 32 and chargeair outlet tank 32 be sized so that theirperipheries peripheries core 30. - The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes are possible.
Claims (23)
1. A charge air cooler for transferring heat between a coolant and charge air, the cooler comprising:
a heat exchange core including a stack of embossed plate pairs, each plate pair defining a circuitous coolant flow path through the heat exchange core, and a plurality of elongated spacers interleaved with the plate pairs to at least partially define charge air flow paths between adjacent plate pairs through the heat exchange core;
a charge air inlet tank connected to a first side of the heat exchange core to direct the charge air into the charge air flow paths; and
a charge air outlet tank connected to a second side of the heat exchange core to collect the charge air from the charge air flow paths.
2. The charge air cooler of claim 1 , wherein each of the embossed plate pairs define a plurality of passes along the coolant flow paths between the charge air inlet tank and the charge air outlet tank.
3. The charge air cooler of claim 2 , wherein a plurality of dimples are formed in a plate of one of the plate pairs along at least one of the plurality of passes.
4. The charge air cooler of claim 2 , wherein arcuately-shaped protrusions are positioned along the plate pairs to distribute the coolant between the plurality of passes.
5. The charge air cooler of claim 1 , further comprising arcuately-shaped protrusions formed along at least one of the plates of each plate pair to direct the coolant through the circuitous coolant flow paths.
6. The charge air cooler of claim 1 , wherein the plurality of elongated spacers extend between the charge air inlet tank and the charge air outlet tank on opposite sides of the heat exchange core.
7. The charge air cooler of claim 1 , further comprising a corrugated fin positioned between two of the plurality of spacer bars.
8. The charge air cooler of claim 1 , wherein the elongated spacers seal the heat exchanger core.
9. A charge air cooler for transferring heat between a coolant and charge air, the cooler comprising:
a charge air inlet tank;
a charge air outlet tank spaced from the inlet tank; and
a heat exchange core positioned between the inlet and outlet tanks and including a stack of plate pairs, each of the plate pairs defining a multi-pass path for the coolant, first and second elongated spacers positioned between adjacent plate pairs and extending between the inlet tank and the outlet tank on opposite sides of the heat exchange core to define flow paths for the charge air through the heat exchange core.
10. The charge air cooler of claim 9 , wherein each plate pair defines a circuitous coolant flow path through the heat exchange core.
11. The charge air cooler of claim 9 , further comprising a plurality of substantially parallel embossments formed along at least one of the plates of each of the plate pairs defining the multi-pass path for the coolant.
12. The charge air cooler of claim 9 , further comprising arcuately-shaped protrusions formed along at least one of the plates of each of the plate pairs to define a circuitous portion of the coolant path.
13. The charge air cooler of claim 9 , further comprising dimples formed along at least one of the passes of the coolant path.
14. The charge air cooler of claim 9 , further comprising a corrugated fin positioned between the first and second elongated spacers and between adjacent plate pairs.
15. The charge air cooler of claim 9 , wherein the elongated spacers form a seal between the adjacent plate pairs.
16. A method of assembling a charge air cooler, the method comprising the acts of:
embossing a plurality of plates;
stacking the plurality of plates in plate pairs such that embossments of each plate pair at least partially define a flow path for a coolant;
interleaving a plurality of elongated spacers between the plate pairs;
securing a charge air inlet tank to the stacked plate pairs to receive the charge air and to distribute the charge air to flow paths defined between adjacent plate pairs; and
securing a charge air outlet tank to the assembled plate pairs to receive the charge air from the flow paths.
17. The method of claim 16 , further comprising forming a plurality of passes along the coolant flow path between the plate pairs and between the embossments.
18. The method of claim 17 , wherein embossing the plurality of plates includes forming arcuately-shaped embossments along the plurality of plates to at least partially define the plurality of passes.
19. The method of claim 16 , further comprising dimpling the plurality of plates between the embossments to form turbulators positioned along the coolant flow path.
20. The method of claim 16 , wherein embossing the plurality of plates includes forming arcuately-shaped embossments formed along at least one of the embossed plate pairs to define a serpentine flow path.
21. The method of claim 16 , wherein interleaving the plurality of elongated spacers between the plate pairs includes positioning the plurality of elongated spacers between the charge air inlet tank and the charge air outlet tank on opposite sides of heat exchange core.
22. The method of claim 16 , further comprising positioning a corrugated fin between two of the plurality of elongated spacers and along the charge air flow path.
23. The method of claim 16 , wherein interleaving the plurality of elongated spacers between the plate pairs includes sealing opposite sides of the stacked plate pairs.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/838,809 US20080041556A1 (en) | 2006-08-18 | 2007-08-14 | Stacked/bar plate charge air cooler including inlet and outlet tanks |
US12/560,696 US8985198B2 (en) | 2006-08-18 | 2009-09-16 | Stacked/bar plate charge air cooler including inlet and outlet tanks |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US83874006P | 2006-08-18 | 2006-08-18 | |
US11/838,809 US20080041556A1 (en) | 2006-08-18 | 2007-08-14 | Stacked/bar plate charge air cooler including inlet and outlet tanks |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/560,696 Continuation-In-Part US8985198B2 (en) | 2006-08-18 | 2009-09-16 | Stacked/bar plate charge air cooler including inlet and outlet tanks |
Publications (1)
Publication Number | Publication Date |
---|---|
US20080041556A1 true US20080041556A1 (en) | 2008-02-21 |
Family
ID=39016236
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/838,809 Abandoned US20080041556A1 (en) | 2006-08-18 | 2007-08-14 | Stacked/bar plate charge air cooler including inlet and outlet tanks |
Country Status (3)
Country | Link |
---|---|
US (1) | US20080041556A1 (en) |
DE (1) | DE102007038894A1 (en) |
FR (1) | FR2905003A1 (en) |
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US20170089253A1 (en) * | 2015-09-28 | 2017-03-30 | Halla Visteon Climate Control Corp. | Water-cooled charge air cooler with integrated multi-stage cooling |
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US20220049903A1 (en) * | 2018-12-13 | 2022-02-17 | Zhejiang Dunan Artificial Environment Co., Ltd. | Heat Exchanger and Air Conditioner with Heat Exchanger |
US11959705B2 (en) * | 2018-12-13 | 2024-04-16 | Zhejiang Dunan Artificial Environment Co., Ltd. | Heat exchanger and air conditioner with heat exchanger |
US20200248967A1 (en) * | 2019-02-04 | 2020-08-06 | Mahle International Gmbh | Stacked plate for a stacked-plate heat exchanger and associated stacked-plate heat exchanger |
Also Published As
Publication number | Publication date |
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FR2905003A1 (en) | 2008-02-22 |
DE102007038894A1 (en) | 2008-04-10 |
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