U.S. patent application number 10/810161 was filed with the patent office on 2005-09-29 for heat exchanger having an improved baffle.
This patent application is currently assigned to Valeo, Inc.. Invention is credited to Bonnet, Pascal, McKittrick, Jason.
Application Number | 20050211425 10/810161 |
Document ID | / |
Family ID | 34963877 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050211425 |
Kind Code |
A1 |
McKittrick, Jason ; et
al. |
September 29, 2005 |
Heat exchanger having an improved baffle
Abstract
There is disclosed a heat exchanger for transferring heat
between at least two fluids and a method for forming the heat
exchanger. The heat exchanger preferably includes one or more end
tanks, one or more inlets and outlets, one or more tubes, one or
more fins, one or more bypasses, one or more improved baffles
combinations thereof or the like. The improved baffles act as a
baffle system, with advantages over multiple-piece double baffle
system due to being assembled in one piece.
Inventors: |
McKittrick, Jason; (Holton,
IN) ; Bonnet, Pascal; (Fishers, IN) |
Correspondence
Address: |
Valeo, Inc.
Intellectual Property Department
4100 North Atlantic Boulevard
Auburn Hills
MI
48326
US
|
Assignee: |
Valeo, Inc.
|
Family ID: |
34963877 |
Appl. No.: |
10/810161 |
Filed: |
March 26, 2004 |
Current U.S.
Class: |
165/174 |
Current CPC
Class: |
F28F 9/0212 20130101;
F28F 2265/16 20130101; F28F 9/0243 20130101; F28F 9/0224
20130101 |
Class at
Publication: |
165/174 |
International
Class: |
F28D 007/00; F28F
009/22 |
Claims
What is claimed is:
1. A heat exchanger for an automotive vehicle having a heat
exchanger tank and a baffle system, comprising: a first end tank
divided into a first portion and a second portion by a baffle in
the first end tank; a plurality of a first tubes in fluid
communication with the first portion of the first end tank, the
plurality of first tubes configured to have a first fluid flow
therethrough; a plurality of second tubes in fluid communication
with the second portion of the first end tank; the end tank further
comprising a contact area having a deformation, perforation, slot
or other shaped mating hole for a tab; wherein: i) the baffle
system comprises at least one one-piece double baffle, the
one-piece double baffle including at least two baffle profiles and
at least one tab; and ii) the one-piece double baffle is disposed
within the end tank and is folded so that the one-piece double
baffle has baffle profiles that are roughly parallel to each
other.
2. A heat exchanger as in claim 1 wherein the one-piece double
baffle comprises a tab at one section of its folded area and the
end tank has a perforation, slot or shaped mating hole for
insertion of the tab of the one-piece double baffle.
3. A heat exchanger as in claim 2 wherein the tab extends through
the wall of end tank, thereby securing its position and forming a
seal.
4. A heat exchanger as in claim 3, wherein the seal formed is
essentially leak-tight.
5. A heat exchanger as in claim 1, wherein the at least one
one-piece double baffle comprises at least two baffle profiles,
each of the at least two baffle profiles having a common central
portion and forming a chamber portion.
6. A heat exchanger as in claim 1 wherein the at least one tab has
a relief means throughout its thickness.
7. A heat exchanger as in claim 2 wherein the end tank has a relief
means at a point contiguous with the tab.
8. A heat exchanger as in claim 1 wherein the one-piece double
baffle is formed from one continuous piece of material.
9. A heat exchanger tank according to claim 1 wherein the one-piece
double baffle for separating fluid sections has perimeter walls
that are approximately perpendicular to the tank wall surface.
10. A heat exchanger as in claim 9 wherein the perimeter walls of
the baffle profiles have a common center area.
11. A heat exchanger for an automotive vehicle having a heat
exchanger tank and a baffle system, comprising: a first end tank
divided into a first portion and a second portion by a baffle the
first end tank including; a plurality of a first tubes in fluid
communication with the first portion of the first end tank, the
plurality of first tubes configured to have a first fluid flow
therethrough; a plurality of second tubes in fluid communication
with the second portion of the first end tank, the plurality of
second tubes configured to have a second fluid different from the
first fluid, flow therethrough; and the end tank further comprising
at least one deformation, perforation, slot or other shaped mating
hole for a tab; wherein: i) the baffle system comprises at least
one one-piece double baffle, each one-piece double baffle including
at least two baffle profiles and at least one tab, and, ii) each
one-piece double baffle is disposed within the end tank and is
folded so that the one-piece double baffle has baffle profiles that
are roughly parallel to each other.
12. A heat exchanger as in claim 11 wherein the one-piece double
baffle comprises a tab at one section of its folded area and the
end tank has a perforation, slot or shaped mating hole for
insertion of the tab of the one-piece double baffle.
13. A heat exchanger as in claim 12 wherein the tab extends through
the wall of end tank, thereby securing its position and forming a
seal.
14. A heat exchanger as in claim 13, wherein the seal formed is
essentially leak-tight.
15. A heat exchanger as in claim 11, wherein the at least one
one-piece double baffle comprises at least two baffle profiles,
each of the at least two baffle profiles having a common central
portion or area and forming a chamber portion.
16. A heat exchanger as in claim 11 wherein the at least one tab
has relief means throughout its thickness.
17. A heat exchanger as in claim 12 wherein the end tank has a
relief means throughout its thickness at a point contiguous with
the tab.
18. A heat exchanger as in claim 11 wherein the one-piece double
baffle is formed from one continuous piece of material.
19. A heat exchanger tank according to claim 11 wherein the
one-piece double baffle for separating fluid sections has perimeter
walls that are approximately perpendicular to the tank wall
surface.
20. A heat exchanger as in claim 19 wherein the perimeter walls of
the baffle profiles have a common center portion or area.
21. A method for making a heat exchanger tank assembly comprising:
manufacturing a one-piece double baffle comprising a tab at an area
of insertion, fold or bend on the double baffle and with peripheral
walls of the double baffle formed so that they form a central
chamber; providing a heat exchanger end tank which comprises a
contact area comprising a deformation, perforation, slot or other
shaped mating hole for insertion of the tab of the double baffle;
aligning the tab of the baffle and the end tank contact area so
that the tab may be inserted into the contact area chamber;
inserting the one-piece double baffle in the end tank at the
contact of the end tank; and applying a sealing technique such that
the double baffle remains in place after the assembly process and
the completed heat exchanger assembly may be used in automotive
applications.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a heat exchanger
and more particularly a multi-fluid heat exchanger, employing an
improved baffle.
BACKGROUND OF THE INVENTION
[0002] In the automotive industry, in particular, it has become
increasingly necessary to combine multiple functions in a single
heat exchanger assembly. The need to reduce the number of overall
components and to optimize assembly efficiency has driven the need
for improved heat exchanger devices that combine increasingly
efficient designs and multiple functions in packaging heretofore
attainable using plural separate components or devices having
inefficient designs. More specifically, there has been a growing
need for an improved heat exchanger device, particularly for under
the hood automotive vehicle applications, which combines multiple
functions in a single assembly that is efficient to make and
operate and that occupies substantially the same or less space than
existing heat exchanger devices. Due to relatively recent
advancements in the field, including, in particular, the
development of combination heat exchanger assemblies or `combo
coolers`, there is also a need to develop systems of more than one
baffle to insure that multiple fluids be maintained basically
separated from one another.
[0003] As stated above, particularly where a multi-fluid heat
exchanger is to be employed, it is attractive to be able to
maintain each of the different fluids of the exchanger separated
from each other. The employment of baffles is one possible
approach. However, until the present invention, baffle designs have
often resulted in space problems, and the like, contributing to the
loss of function or efficiency of one or more of the heat exchanger
tubes. In particular, certain heat exchanger assemblies may have
space requirements that extend to at least one core tube end in the
tank. In such assemblies, space restrictions have led to `rolling`
of baffle perimeter walls or "flanges" that increase bonding
against the tank perimeter and take up additional space that
eventually restricts performance due to the fact that tube center
to center spaces can not be optimized. Furthermore, in multi-fluid
heat exchanger assemblies, the solution has often been to insert,
during assembly, at least two separate pieces, each providing a
baffle, to form a so called double baffle. Often a first and a
second baffle are assembled back to back.
[0004] Such a double baffle is in actuality, therefore, two
baffles, as the two separate baffles have a space between the
pieces to ensure that one fluid in the separate fluid systems
remains separated from the other. To provide most effective
functioning of such a system, it was found that a `weep hole` must
often be placed on the cover surface of the double piece double
baffle, between the pieces of the double baffles, in order to let
flux enter prior to brazing and to serve a potential leak detection
function. This has caused a problem, however, since the two baffles
need to be affixed in some manner to maintain their positions to
perform their function, and positional control needs to be
optimized to allow for reduced tube pitches, especially in higher
performance heat exchanger assemblies applications. Thus, it would
be especially desirable for an improved baffle design that can be
incorporated into a heat exchanger, and particularly a multi-fluid
heat exchanger, which makes efficient use of all heat exchanger
tubes and solves this positional control problem.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a heat exchanger for an
automotive vehicle. The heat exchanger includes a first end tank
divided into a first portion and a second portion by a baffle. The
heat exchanger also includes a plurality of a first tubes in fluid
communication with the first portion of the first end tank, the
plurality of first tubes configured to have a first fluid flow
there through. Preferably, a plurality of second tubes are in fluid
communication with the second portion of the first end tank, the
plurality of second tubes configured to have a second fluid,
different from the first fluid, flow there through. It is also
preferable for the heat exchanger to include a plurality of fins
disposed between the first tubes and the second tubes. Baffles may
be used in single fluid or multifluid heat exchangers. In
particular, in combo coolers, a common tank section often needs a
separator between the separate fluid systems. It has been found
that a baffle, or, in particular, a double (or multiple) baffle
system, can be used that provides the separation of fluids
necessary for adequate functioning of heat exchange for each fluid.
Preferably, in combination heat exchanger assembles or combo
coolers, a one-piece double baffle may be used to ensure that the
separate fluids of the multi-fluid systems remain essentially
separated from one another.
[0006] Therefore, the present invention relates to a heat exchanger
for an automotive vehicle having a heat exchanger tank and a baffle
system, comprising: a first end tank divided into a first portion
and a second portion by a baffle in the first end tank; a plurality
of a first tubes in fluid communication with the first portion of
the first end tank, the plurality of first tubes configured to have
a first fluid flow therethrough; and a plurality of second tubes in
fluid communication with the second portion of the first end tank.
In preferred embodiments of the present invention, the plurality of
second tubes in fluid communication with the second portion of the
first end tank are configured to have a second fluid different from
the first fluid, flow therethrough. The end tank further comprises
a contact area having a deformation, perforation, slot or other
shaped mating hole for a tab, wherein the baffle system comprises
at least one one-piece double baffle, the one-piece double baffle
including at least two baffle profiles and at least one tab; and
each one-piece double baffle is disposed within the end tank and is
folded so that the one-piece double baffle has baffle profiles that
are roughly parallel to each other. The one-piece double baffle
preferably comprises a tab at one section of its folded area. The
end tank preferably has a perforation, slot or shaped mating hole
for insertion of the tab of the one-piece double baffle. The tab
may extend to the interior edge of the end tab or, preferably, the
tab extends through the wall of the end tank, thereby securing its
position and forming a seal. In preferred embodiments, the seal
formed is essentially leak-tight.
[0007] The baffle system of the present invention includes a
one-piece baffle, and, particularly, a one-piece double baffle,
that can be easily assembled and provides a high level of
positional control in order to allow for reduction in heat
exchanger tube core tube pitch. It is understood that a one piece
baffle is essentially formed into one piece prior to assembly into
the heat exchanger tank. In preferred aspects of the present
invention, the one-piece double baffle is placed between adjoining
tubes to separate the fluids. The space available for baffle
placement is dependant on the tube spacing, or `tube pitch` as it
is also known. A reduction in tube pitch generally increases the
performance of the heat exchanger, but provides less space for a
double baffle. The present invention, by improving the positional
tolerance of the double baffle on the end tank, allows more
efficient allocation of the space to the function of the double
baffle. Therefore, it is one objective of the present invention to
have a one-piece double baffle that can be easily assembled and
provide positive positional control to allow further reductions in
the core's tube pitch.
[0008] In preferred embodiments of the present invention, a heat
exchanger has a one-piece double baffle formed prior to assembly
into the heat exchanger end tank. More preferably, the one-piece
double baffle is formed from one continuous piece of material.
[0009] Preferably, the baffle system comprises at least one
one-piece double baffle, and preferably, a one-piece double baffle
formed preferably out of one piece of material and having at least
two baffle profiles.
[0010] In a particular embodiment of the invention, a "hole" or
"weep hole" may be placed on the cover surface between double
baffles, to provide a communication towards the exterior. In an
even more preferred embodiment, the entry passage is placed on the
cover surface so as to enable entry of material, and particularly
fluid materials such as flux, to prepare any wetted surfaces for
brazing or the like. An additional preferred feature and advantage
of such an embodiment is that said entry passage may also provide a
means to facilitate leak detection. In preferred embodiments, the
double baffle has an outer perimeter edge separated by a short
distance to provide a relief channel at the sealing edge. Even more
preferred is a sealing edge which is not `rolled` or `flanged`,
thus reducing the overall width of the baffle between the tubes for
shorter tube spacing. In a particularly preferred embodiment, the
at least one profile of the double baffle is of a reduced thickness
being assembled back to back with a common center contact portion
area.
[0011] This at least one chamber is preferably formed in a bend,
more preferably a bend of a U-type shape when viewed perpendicular
to the end tank of each exchanger. In preferred embodiments, bends
can be added to the basic U shape to allow for a more stable
assembly. Additional bends can be added to fit into the space
between adjacent tubes of each exchanger. It is preferable that at
least one of the profiles of the one-piece double baffle matches or
complements the shape of the end tank cross-section; it is more
preferable that both profiles of the one-piece double baffle match
the shape of the end tank cross-section. It has been found that by
matching the shape of the end tank to the profile of the one-piece
double baffle that a sealing surface may be formed when brazed.
[0012] Also, in preferred embodiments of the present invention, a
heat exchanger tank has a one-piece double baffle for separating
fluid sections that has perimeter walls that are approximately
perpendicular to the tank wall surface. In more preferred
embodiments, the perimeter walls of the baffle profiles have a
common center portion or area and a chamber portion or area.
[0013] Also, in preferred embodiments of the present invention, a
heat exchanger tank has a one-piece double baffle for separating
fluid sections that has perimeter walls that are approximately
perpendicular to the tank wall surface. In more preferred
embodiments, the perimeter walls of the baffle profiles have a
common center portion or area and a chamber portion or area.
[0014] In preferred embodiments of the present invention, the
one-piece double baffle is folded in at least one section to form
at least one projection or `tab` that extends through a
deformation, perforation, slot or other shaped mating hole in the
end tank, thereby securing its position in space and forming a
seal. In more preferred embodiments, the at least one tab further
comprises a relief means, for example, the at least one tab may be
perforated in order to allow passage of fluid from the interior of
the baffle or the baffle `chamber`, to the outside of the end tank
in a sort of `relief` function. The one-piece double baffle, in
accordance with one aspect of the present invention, comprises at
least two baffle profiles, the at least two baffle profiles having
a common central portion and forming a chamber portion. The
one-piece double baffle may have one or more tabs. Preferably, at
least one tab of the at least one tabs has a relief means
throughout its thickness. Also preferably, the at least one tab may
have a relief means that is not throughout the thickness of the at
least one tab, but wherein the end tank has a relief means at a
point contiguous with the tab. In other preferred embodiments, two
or more projections or tabs extend through deformations,
perforations, slots or other shaped mating holes in the end tank.
In certain embodiments, as described above, the tab may be
perforated or even mechanically or otherwise removed after being
inserted into the contact area of the tank. This removal may take
place anywhere near, at, or above the interior edge of the tank,
where such removal does not compromise the functioning of the heat
exchanger assembly. In particular, after assembly of the tab and
tank, the tab may be removed, and a relief means or hole formed,
and, the profiles of the baffle remain in place, even with the
relief means between the profiles at the area of the tab, and even
if the profiles are separated by the relief means. Since the baffle
has been stabilized at assembly to a sufficient degree to maintain
its position as required to be utilized in heat exchanger
applications, it will be clear to the man of ordinary skill in the
art that further manipulations of the tab or other elements such as
the shape or linear or non-linear essence of the relief means, are
possible, and within the prevue of the present invention.
[0015] The present invention provides for a one-piece double baffle
wherein the advantages of a multi-piece double baffle can be
achieved by using only a one piece part. In addition to the
functional advantages, in preferred embodiments a tab is formed and
included as a part of the one-piece double baffle, the tab securing
the double baffle in place and preventing undesirable positional
changes or movement of the one-piece double baffle as it goes
through the steps of the overall heat exchanger assembly
process.
[0016] Preferably, the one-piece double baffle provides a shape
that can be held easily by tooling to allow the precise and
automatic assembly into the end tank assembly. This shape, in
addition to the need for only one part, allows for automatic
assembly of the part. In particularly preferred embodiments of the
present invention, a wider wall portion of a one-piece baffle
beyond the tube walls extends and provides extra support to provide
a stable base. This wider base allows the baffle to be constrained
from rotating and allows the baffle to rest against a positive stop
to ensure its full and correct assembly. The tab provides positive
location for the baffle to be placed along the end tank's
length.
[0017] Preferably, the one-piece double baffle is shaped to provide
for ease of automatic assembly of the part. By providing for a
portion of the one-piece double baffle to be of a particular width
outside the tube walls, support is provided to create a stable base
for the baffle in the finally assembled unit. In the preferred
embodiments, the baffle, and, particularly, the tab, comprises a
wall portion of significant width beyond the tube walls to provide
such a support.
[0018] Preferably, the one-piece double baffle is made out of one
piece of continuous material. Preferred materials for use in making
the one-piece double baffle include metals or metallic materials,
or alloys of such metals or metallic materials. More preferred are
metals or metallic materials or alloys of such materials that can
be employed in assembly processes using brazing processes. Most
preferred are metals such as aluminum or aluminum alloys. It is
also preferred that the one-piece double baffle be made from a flat
or planar section or piece of material. In more preferred
embodiments, a flat piece of metal is stamped or otherwise shaped,
to form a one-piece double baffle with profiles having a short tab,
located at a folded or bended region. In more preferred
embodiments, the profiles of the one-piece double baffle are
downwardly projecting in similar planes, in most preferred
embodiments each baffle profile is approximately parallel to one
another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1. Elevational schematic side view of a one-piece
double baffle in accordance with an aspect of the present
invention.
[0020] FIG. 2. Cross sectional view of a one-piece double baffle,
with wide wall portion beyond the tubes walls, in accordance with
an aspect of the present invention, assembled in a heat exchanger
assembly core.
[0021] FIG. 3. Isometric view of a one-piece double baffle, in
accordance with an aspect of the present invention, prior to
assembly with end tank.
[0022] FIG. 4. Elevational view from outside the end tank of a one
piece baffle in accordance with an aspect of the present invention,
after assembly with end tank.
[0023] FIG. 5. Elevational cross-sectional view of a one-piece
double baffle from inside the end tank, in accordance with an
aspect of the present invention, after assembly.
[0024] FIG. 6. An elevational cross-sectional view of a one-piece
double baffle with inwardly formed features on each baffle profile
in accordance with an aspect of the present invention.
[0025] FIG. 7. An elevational view of a one-piece double baffle
with tabs added to each portion of the double baffle and inserted
into slots on the opposing side of the end tank.
[0026] FIG. 8. An elevational view of a one-piece double baffle
with a connecting tab entirely within the end tank which is not
inserted into a complementary mating hole on the heat exchanger
tank, in accordance with an aspect of the present invention.
[0027] FIG. 9. An elevational view of a one-piece double baffle
with tabs added to each portion of the double baffle so that they
insert into slots on the opposing side of the end tank and where a
connecting tab is contained entirely within the end tank.
[0028] FIG. 10. An elevational view from outside the end tank of a
one piece baffle in accordance with an aspect of the present
invention, after assembly with end tank where the relief means is
located in the end tank.
[0029] FIG. 11. An elevational cross sectioned view of a one-piece
double baffle indicating positive stop or stabilizing capacity of
the double baffle, in accordance with an aspect of the present
invention.
[0030] FIG. 12. An elevational cross-sectional view of a one-piece
double baffle with differently formed features on each baffle
profile in accordance with an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] Generally, the present invention relates to a heat exchanger
having a baffle system and to a method of forming the heat
exchanger. The heat exchanger may be a single fluid or multi-fluid
(e.g., 2, 3 or 4 fluid) heat exchanger. The heat exchanger may also
be a single pass or multi-pass heat exchanger. Although the heat
exchanger according to the present invention may be used for a
variety of articles of manufacture (e.g., air conditioners,
refrigerators or the like), the heat exchanger has been found
particularly advantageous for use in automotive vehicles. For
example, the heat exchanger may be used for heat transfer of one or
more various fluids within a vehicle such as air or gasses, oil,
transmission oil, power steering oil, radiator fluid, refrigerant,
combinations thereof or the like. For example, in a highly
preferred embodiment of the present invention there is contemplated
a multi-fluid heat exchanger that includes an oil cooler or
condenser in combination with a cooler selected from the group
consisting of a power steering oil cooler, a transmission oil
cooler, a radiator fluid cooler and a combination thereof. In
general, a preferred heat exchanger contemplates at least two
spaced apart end tanks bridged together in at least partial fluid
communication by a plurality of generally parallel tubes, with fins
disposed between the tubes.
[0032] The present invention is further optimized by the employment
of an improved double baffle and heat exchanger tubes, and the
employment of a bypass or a combination thereof. Heat exchangers of
the present invention will typically include one or more tubes, one
or more end tanks, one or more inlets and outlets, one or more
one-piece double baffles, one or more fins or a combination
thereof. Depending upon the embodiment of the heat exchanger,
various different shapes and configurations are contemplated for
the components of the heat exchanger. For example, and without
limitation, the components may be integral with each other or they
may be separate. The shapes and sizes of the components may be
varied as needed or desired for various embodiments of the heat
exchanger. Additional variations will become apparent upon reading
of the following description.
[0033] According to one aspect of the invention, one or more of the
components of the heat exchanger such as the baffles, the end
tanks, the tubes, the inlets, the outlets, a bypass or combinations
thereof may be attached to each other using brazing techniques. In
preferred embodiments of the present invention, profiles of the
one-piece double baffle are formed whereby the end tank and baffle
profile shapes provide for a sealing surface through a brazing
process or technique. Although various brazing techniques may be
used, one preferred technique is referred to as controlled
atmosphere brazing. Controlled atmosphere brazing typically employs
a brazing alloy for attaching components wherein the components are
formed of materials with higher melting points than the brazing
alloy. The brazing alloy is preferably positioned between
components or surfaces of components to be joined and,
subsequently, the brazing alloy is heated and melted (e.g., in an
oven or furnace, and preferably under a controlled atmosphere).
Upon cooling, the brazing alloy preferably forms a metallurgical
bond with the components for attaching the components to each
other. According to one highly preferred embodiment, the brazing
alloy may be provided as a cladding on one of the components of the
heat exchanger. In such a situation, it is contemplated that the
components may be formed of a material such as a higher melting
point aluminum alloy while the cladding may be formed of a lower
melting point aluminum alloy.
[0034] Referring to FIGS. 1 and 2, a one-piece double baffle forms
a seal with the end tank in the area about the perimeter of 1 and
form a baffle chamber 3 separating the functional areas of end
tanks 4, 5 of a two or more pass assembly. The baffle of the
present invention may be uniform (same or basically the same width
of chamber throughout) or non-uniform in shape. In heat exchanger
assemblies with reduced tube pitches, the one-piece double baffle
is, preferably, non-uniform in shape.
[0035] Referring to FIG. 2, a portion of the one-piece double
baffle is formed with an overall chamber width 10 between opposing
profile sides 36 larger or, preferably, significantly larger at the
area of the end tank than at the interior. A one-piece double
baffle may be used in heater assembly cores 7 with reduced tube
pitches 8. Tab 2 is formed so that it will fit into a perforation
or hole 9 in the end tank 12 of the heat exchanger. In the
preferred embodiments of FIG. 2, the tab is formed so that it will
form a snug, leak-tight seal, and securely hold the one-piece
double baffle 6 in position via the tab 2. In FIGS. 1, 2, 4 and 5,
preferred embodiments show a perforation, slot or hole 13 from
which fluid within the baffle chamber may escape from between the
baffle sections 3 to the exterior of the end tank 15.
[0036] Referring to FIG. 6, a one-piece double baffle 6 with
inwardly formed feature(s) 16 on at least one side of the baffle
profile so that the center(s) 17 contact forming a thicker wall 18
thickness.
[0037] Referring to FIG. 7, at least one tab 19 added to each
portion of the double baffle 6 so that they insert into at least
one slot 20, 21 on the opposing side 22 of the end tank 12.
[0038] Referring to FIG. 8, a connecting tab 23 is provided and may
be within the tank.
[0039] Referring to FIG. 9, at least one tab 19 added to each
portion of the double baffle 6 so that the at least one tab can
insert into at least one slot 20, 21 on the opposing side 22 of the
end tank 12.
[0040] Referring to FIG. 10, the relief means is a slot or hole 24
from which fluid within the baffle chamber may escape from between
the baffle sections 3 to the exterior of the end tank 15 is located
in the end tank 12.
[0041] Referring to FIG. 11, the wider wall portion of the baffle
10 beyond the tube wall extends and provides extra support to
provide a stable base. This wider base allows the baffle to be
constrained from rotating and allows the baffle to rest against a
positive stop to ensure its full and correct assembly. The tab 2
provides positive location for the baffle to be placed along the
end tank's 12 length.
[0042] Referring to FIG. 12, baffle profiles 46, 47, are different
in form from one another, particularly in the common central area
48 of the baffle.
[0043] From the above, it will thus be appreciated that one
preferred method of the present invention contemplates providing a
heat exchanger assembled in a common assembly; passing a first
fluid through one portion of the heat exchanger for heat exchange,
and passing at least one fluid through at least one additional
portion of the heat exchanger for heat exchange of the fluid.
[0044] From the above, it will thus be appreciated that in a
particularly method of the present invention a multi-fluid heat
exchanger is assembled in a common assembly; passing a first fluid
through one portion of the heat exchanger for heat exchange, and
passing at least one additional fluid through at least one
additional portion of the heat exchanger for heat exchange of the
additional fluid.
[0045] Another advantage of the one-piece double baffle is that it
can detect leaks across a flow dividing partition in a single fluid
exchanger, in a condenser, for example.
[0046] Preferably, a heat exchanger in accordance with the present
invention includes at least one one-piece double baffle for
dividing a region within a component of a heat exchanger into two
or more portions. The one-piece double baffle of the present
invention may be provided in a variety of different shapes and
having a variety of configurations depending upon which component
of the heat exchanger the baffle is to be placed within and also
depending, for instance, upon the configuration of that
component.
[0047] According to one preferred embodiment, the portions
separated by the one-piece double baffle are part of an internal
opening within an end tank of the heat exchanger. According to a
highly preferred embodiment, a one-piece double baffle is employed
to separate the respective portions in a heat exchanger wherein
each of the subdivided portions is adapted to receive the same
fluid under different conditions, or different fluids. As to the
latter, for example, one portion may receive a first fluid (e.g., a
condenser fluid or the like) while the other portion receives a
second fluid (e.g., a transmission oil or power steering oil),
which is different from the first fluid. In this manner, the use of
one-piece double baffles allows different fluids of a multi fluid
heat exchanger to be maintained separate from each other as they
flow through the heat exchanger. In a most preferred embodiment,
the double baffle is a one-piece double baffle with a relief
means.
[0048] It may be possible to achieve the desired resulting
structure using any of a number of art-disclosed forming
techniques. Particularly preferred methods start off with one
continuous piece of material. For example, a coining, casting,
machining or other suitable operation may be employed. According to
one preferred embodiment, the one-piece double baffle is formed by
attaching (preferably, for example, with a weld, a braze, or a
solder material, or the like) two substantially identical metal
pieces, or, more preferably, taking a continuous piece of material,
such as a sheet metal and folding it together in mirror symmetrical
relation to each other.
[0049] Once formed, the double baffle 6 is installed within a heat
exchanger, such as within the interior of an end tank. It will be
appreciated that the peripheral surface 1 of the double baffle 6
preferably has a shape that complements the end tank, so that the
peripheral surface is substantially engaged with the inner wall
surface of the end tank about the peripheral surface, thereby
facilitating sealing as desired between end tank subdivided
portions. Optionally a seal or gasket is applied to the peripheral
surface for assuring seal integrity.
[0050] Preferably, the double baffle 6 is positioned within an
opening of the end tank to separate a first portion of the opening
from a second portion of the opening. The first outer surface
preferentially faces the first portion and the second outer surface
faces the second portion.
[0051] In one highly preferred embodiment, though not required, the
baffle or double baffle is adapted for providing leak detection or
for otherwise assuring seal integrity. To do so, it is preferred
that the end tank be provided with at least one relief means.
During assembly, the baffle is positioned so that the relief means
is substantially juxtaposed with the hole or channel of the baffle.
In this manner, it will be appreciated that if there is a faulty
seal between portions of the end tank, fluid from that portion will
enter the channel and exit through the `relief means`. The fact of
a leak is then detectable by the fluid escape. The location of the
faulty seal is also pinpointed by analyzing the escaped fluid to
determine from which portion of the end tank it originated.
[0052] It is contemplated that various specific techniques may be
used to secure the double baffle within the end tank. For example,
the one-piece double baffle 6 may be interference fit within the
tank and seals (not shown) may be used to prevent passage of fluid
past the double baffle 6. Alternatively, the double baffle 6 may be
adhesively bonded at its peripheral surface 1 to the end tank. In a
highly preferred embodiment, the outer peripheral surface of the
double baffle 6 substantially corresponds to an inner surface of
the end tank such that the outer peripheral surface and the inner
surface substantially continuously oppose and contact each
other.
[0053] Accordingly, the outer peripheral surface may be attached to
the inner surface by welding, brazing soldering or the like.
Advantageously, the double baffle 6 provides good resistance to
pressures, or pressure fluctuations provided by fluids within the
portions of the end tank, even in one-piece double baffles that
include two plates integrated for reinforcing each other. Also
advantageous, the double baffle 6 can provide fluid tight seals
separated by the chamber since the outer peripheral surface is
separated into portions by the chamber. Thus, each of the seals can
buffer the other from pressure fluctuations thereby providing
greater overall sealing between the portions of the end tank. The
double baffles 6 are thus fit between tube entrances and exits to
the end tank without interfering with flow of fluid through the
tubes. The flexibility in mounting also helps to assure that the
presence of dead tubes or other tube inefficiencies can be
avoided.
[0054] Other embodiments of baffles other than the ones described
above are also within the scope of the present invention, including
but not limited to the additional preferred embodiments that are
described in the following discussion. It should be understood that
principles of operation and assembly of the embodiments described
in the following are substantially identical to the one-piece
double baffle 6 and end tank of FIG. 1, and the description of
those general aspects applies also to the embodiments in the
following discussion. Therefore, to avoid repetition, the
description of the embodiments will focus more on unique structural
features of the embodiments.
[0055] The present invention also provides methods method for
making a heat exchanger tank assembly, one of the preferred methods
comprising: manufacturing a one-piece double baffle comprising a
tab at an area of insertion, fold or bend on the double baffle and
with peripheral walls of the double baffle formed so that they form
a central chamber; providing a heat exchanger end tank which
comprises an contact area comprising a deformation, perforation,
slot or other shaped mating hole for insertion of the tab of the
double baffle; aligning the tab of the baffle and the end tank
contact area so that the tab may be inserted into the contact area
chamber; inserting the one piece double baffle in the end tank at
the contact of the end tank; and applying a sealing technique such
that the double baffle remains in place after the assembly process
and the completed heat exchanger assembly may be used in automotive
applications.
[0056] Generally, it is contemplated, and, in fact, expected, that
various changes may be made to the preferred embodiments of the
baffles and one-piece double baffles to accommodate different
designs of heat exchangers while still remaining within the scope
of the present invention. As an example, and referring to FIG. 7,
there is illustrated another alternative one-piece double baffle 6
which has multiple tabs. Such a double baffle would preferable rest
within an end tank of a heat exchanger. The double baffle 6 of FIG.
9 preferentially includes an perforation or hole through a tab or
tabs 19 and, thereby extending through a wall 20, 21 of the end
tank 12.
[0057] As indicated previously, the baffles of the present
invention are useful in a number of different applications. In one
preferred use an end tank for a multi-fluid heat exchanger is
provided and is subdivided with at least one-piece double baffle in
accordance with the present teachings. In another embodiment, a
one-piece double baffle as described herein is employed to
subdivide an end tank of a single fluid heat exchanger. The present
baffles need not be used only to subdivide end tanks, but may be
used to subdivide any structure that provides a fluid passageway.
In still another preferred embodiment, the peripheral walls spacing
varies to a wider position beyond the tube slot area (for example
see FIG. 2) in order to allow for a more stable base.
[0058] As described above, after assembly of the tank and tab, the
tab many be removed, and a relief means formed near, at or above
the interior edge 10 of the end tank 12.
[0059] The preferred embodiment of the present invention has been
disclosed. A person of ordinary skill in the art would realize
however, that certain modifications would come within the teachings
of this invention. Therefore, the following claims should be
studied to determine the true scope and content of the
invention.
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