U.S. patent application number 12/464200 was filed with the patent office on 2009-11-12 for heat exchanger support and method of assembling a heat exchanger.
Invention is credited to Catherine R. Braun, Brian P. Gilner, David W. Mast, Steven P. Meshenky, Charles M. Rastall, Thomas J. Reiss, III.
Application Number | 20090277606 12/464200 |
Document ID | / |
Family ID | 41265920 |
Filed Date | 2009-11-12 |
United States Patent
Application |
20090277606 |
Kind Code |
A1 |
Reiss, III; Thomas J. ; et
al. |
November 12, 2009 |
HEAT EXCHANGER SUPPORT AND METHOD OF ASSEMBLING A HEAT
EXCHANGER
Abstract
A heat exchanger that includes a heat exchanger core including a
plurality of stacked tubes defining a fluid flow path, a housing
substantially surrounding the heat exchanger core, and an
elastomeric member positioned between the heat exchanger housing
and the heat exchanger core and deformable to allow movement of one
of the heat exchanger core and the housing relative to an other of
the heat exchanger core and the housing in at least two
substantially perpendicular directions.
Inventors: |
Reiss, III; Thomas J.; (West
Allis, WI) ; Meshenky; Steven P.; (Racine, WI)
; Braun; Catherine R.; (Milwaukee, WI) ; Mast;
David W.; (Burlington, WI) ; Rastall; Charles M.;
(Cudahy, WI) ; Gilner; Brian P.; (Racine,
WI) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH LLP
100 E WISCONSIN AVENUE, Suite 3300
MILWAUKEE
WI
53202
US
|
Family ID: |
41265920 |
Appl. No.: |
12/464200 |
Filed: |
May 12, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61052299 |
May 12, 2008 |
|
|
|
Current U.S.
Class: |
165/69 ; 165/162;
29/890.03 |
Current CPC
Class: |
F28F 2265/26 20130101;
F28D 21/0003 20130101; Y10T 29/4935 20150115; F28D 7/1692 20130101;
F28F 9/013 20130101; F28F 2009/226 20130101 |
Class at
Publication: |
165/69 ;
29/890.03; 165/162 |
International
Class: |
F28F 9/013 20060101
F28F009/013; F28F 9/00 20060101 F28F009/00; B21D 53/02 20060101
B21D053/02 |
Claims
1. A heat exchanger comprising: a heat exchanger core including a
plurality of stacked tubes defining a fluid flow path; a housing
substantially surrounding the heat exchanger core; and an
elastomeric member positioned between the heat exchanger housing
and the heat exchanger core and deformable to allow movement of one
of the heat exchanger core and the housing relative to an other of
the heat exchanger core and the housing in at least two
substantially perpendicular directions.
2. The heat exchanger of claim 1 wherein the core includes a return
tank connecting sections of adjacent tubes to define a
substantially U-shaped portion of the flow path.
3. The heat exchanger of claim 2 wherein the elastomeric member is
positioned on the return tank.
4. The heat exchanger of claim 2 wherein the return tank is located
at a distal end of the core.
5. The heat exchanger of claim 2 wherein one of the housing and the
return tank includes an outwardly extending protrusion and an other
of the housing and the return tank defines a recess configured to
receive the protrusion.
6. The heat exchanger of claim 5 wherein the elastomeric member is
positioned in the recess and is engageable with the protrusion.
7. The heat exchanger of claim 1 wherein the elastomeric member
extends outwardly from the housing.
8. The heat exchanger of claim 1 wherein the heat exchanger is an
exhaust gas recirculation cooler.
9. The heat exchanger of claim 1 wherein the one of the heat
exchanger core and the housing is moveable in a third direction
substantially perpendicular to each of the at least two
directions.
10. The heat exchanger of claim 1 wherein the movement of the one
of the heat exchanger core and the housing in one of the two
directions is along an arc.
11. A cantilevered heat exchanger comprising: a housing; a heat
exchanger core including a plurality of stacked tubes and extending
through the housing, a first end of the core being secured to
prevent relative movement between the housing and the core; and an
elastomeric member positioned between the housing and the core
adjacent a second end of the core.
12. The cantilevered heat exchanger of claim 11 wherein the second
end of the heat exchanger core is moveable in a first direction
substantially parallel to a length of at least one tube of the
plurality of stacked tubes relative to the housing and in a second
direction substantially perpendicular to the first direction to
accommodate at least one of thermal expansion of the core and
vibrations.
13. The cantilevered heat exchanger of claim 11 wherein the
elastomeric member extends outwardly from one of the heat exchanger
housing and the heat exchanger core and engages a correspondingly
shaped recess in an other of the heat exchanger housing and the
heat exchanger core to accommodate relative movement while
supporting the second end of the core in the housing.
14. The cantilevered heat exchanger of claim 11 wherein the
elastomeric material at least partially surrounds a protrusion
extending outwardly from the one of the heat exchanger housing and
the heat exchanger core and engageable in a correspondingly shaped
recess in the other of the heat exchanger housing and the heat
exchanger core to accommodate relative movement while supporting
the second end of the core in the housing.
15. The cantilevered heat exchanger of claim 11 wherein the core
includes a return tank connecting sections of adjacent tubes to
define a substantially U-shaped portion of the flow path.
16. The cantilevered heat exchanger of claim 15 wherein the
elastomeric member is positioned on the return tank.
17. The cantilevered heat exchanger of claim 11 wherein the heat
exchanger is an exhaust gas recirculation cooler.
18. The cantilevered heat exchanger of claim 12 wherein the one of
the heat exchanger core and the housing is moveable in a third
direction substantially perpendicular to each of the at least two
directions.
19. A heat exchanger comprising: a heat exchanger core including a
plurality of stacked tubes defining a fluid flow path; a housing
substantially surrounding the heat exchanger core; and a protrusion
extending outwardly from one of the heat exchanger housing and the
heat exchanger core configured to engage a correspondingly shaped
recess in the other of the heat exchanger housing and the heat
exchanger core to accommodate relative movement in at least two
substantially perpendicular directions while supporting an end of
the core in the housing.
20. The heat exchanger of claim 19 wherein the core includes a
return tank connecting sections of adjacent tubes to define a
substantially U-shaped portion of the flow path.
21. The heat exchanger of claim 20 wherein the return tank is
located at the end of the core.
22. The heat exchanger of claim 19 wherein the heat exchanger is an
exhaust gas recirculation cooler.
23. The heat exchanger of claim 19 wherein the one of the heat
exchanger core and the housing is moveable in a third direction
substantially perpendicular to each of the at least two
directions.
24. The heat exchanger of claim 19, further comprising an
elastomeric member positioned between the protrusion and the
recess.
25. The heat exchanger of claim 19 wherein the protrusion is at
least partially formed of an elastomeric material.
26. The heat exchanger of claim 19 wherein the movement of the one
of the heat exchanger core and the housing in one of the two
directions is along an arc.
27. A method of assembling a heat exchanger, the method including
the acts of: positioning a heat exchanger core in a housing;
positioning an elastomeric member between a distal end of the core
and an interior of the housing; and accommodating movement of the
distal end of the core relative to the housing by selectively
deforming the elastomeric member between the core and the
housing.
28. The method of claim 27 wherein the elastomeric member
substantially surrounds a protrusion extending outwardly from one
of the heat exchanger housing and the heat exchanger core.
29. The method of claim 27 wherein the elastomeric member is
deformable to allow movement of one of the heat exchanger core and
the housing relative to an other of the heat exchanger core and the
housing in at least two substantially perpendicular directions.
30. The method of claim 29 wherein the one of the heat exchanger
core and the housing is moveable in a third direction substantially
perpendicular to each of the at least two directions.
31. The method of claim 27 wherein the elastomeric member is
deformable to allow movement of one of the heat exchanger core and
the housing relative to an other of the heat exchanger core in a
first direction and in a second direction along an arc.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present patent application claims priority to U.S.
Provisional Patent Application Ser. No. 61/052,299, titled "HEAT
EXCHANGER SUPPORT AND METHOD OF ASSEMBLING A HEAT EXCHANGER," filed
on May 12, 2008, the entire contents of which is hereby
incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to heat exchangers, and more
particularly, to a cantilevered heat exchanger.
SUMMARY
[0003] In some embodiments, the invention provides a heat
exchanger. The heat exchanger includes a heat exchanger core
including a plurality of stacked tubes defining a fluid flow path,
a housing substantially surrounding the heat exchanger core, and an
elastomeric member positioned between the heat exchanger housing
and the heat exchanger core and deformable to allow movement of one
of the heat exchanger core and the housing relative to an other of
the heat exchanger core and the housing in at least two
substantially perpendicular directions.
[0004] In other embodiments, the invention provides a cantilevered
heat exchanger. The cantilevered heat exchanger includes a housing,
a heat exchanger core including a plurality of stacked tubes and
extending through the housing, a first end of the core being
secured to prevent relative movement between the housing and the
core, and an elastomeric member positioned between the housing and
the core adjacent a second end of the core.
[0005] In yet other embodiments, the invention provides a heat
exchanger. The heat exchanger includes a heat exchanger core
including a plurality of stacked tubes defining a fluid flow path,
a housing substantially surrounding the heat exchanger core, and a
protrusion extending outwardly from one of the heat exchanger
housing and the heat exchanger core configured to engage a
correspondingly shaped recess in the other of the heat exchanger
housing and the heat exchanger core to accommodate relative
movement in at least two substantially perpendicular directions
while supporting an end of the core in the housing.
[0006] In other embodiments, the invention provides a method of
assembling a heat exchanger. The method includes the acts of
positioning a heat exchanger core in a housing, positioning an
elastomeric member between a distal end of the core and an interior
of the housing, and accommodating movement of the distal end of the
core relative to the housing by selectively deforming the
elastomeric member between the core and the housing.
[0007] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a core of a heat exchanger
embodying the present invention.
[0009] FIG. 2 is an exploded perspective view of the core of the
heat exchanger of FIG. 1, a portion of an inlet/outlet manifold,
and a housing for the heat exchanger.
[0010] FIG. 3 is a sectional view of the core of the heat exchanger
of FIG. 1 inside the housing.
DETAILED DESCRIPTION
[0011] 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.
[0012] FIGS. 1-3 illustrate a heat exchanger 10 according to some
embodiments of the present invention. In some embodiments,
including the illustrated embodiments of FIGS. 1-3, the heat
exchanger 10 can operate as an exhaust gas recirculation cooler
(EGRC) and can be operated with the exhaust system of a vehicle
having an internal combustion engine, not shown. In other
embodiments, the heat exchanger 10 can be used in other (e.g.,
non-vehicular) applications, such as, for example, in electronics
cooling, industrial equipment, building heating and
air-conditioning, and the like. In some applications, for example,
the heat exchanger 10 can function as a cooler, a condenser, a
radiator, a recuperator, or an evaporator. In addition, it should
be appreciated that the heat exchanger 10 of the present invention
can take many forms, utilize a wide range of materials, and can be
incorporated into various other systems.
[0013] During operation and as explained in greater detail below,
the heat exchanger 10 can transfer heat from a high temperature
first working fluid (e.g., exhaust gas, water, engine coolant,
CO.sub.2, an organic refrigerant, R12, R245fa, air, and the like)
to a lower temperature second working fluid (e.g., water, engine
coolant, CO.sub.2, an organic refrigerant, R12, R245fa, air, and
the like). In addition, while reference is made herein to
transferring heat between two working fluids, in some embodiments
of the present invention, the heat exchanger 10 can operate to
transfer heat between three or more fluids. Alternatively or in
addition, the heat exchanger 10 can operate as a recuperator and
can transfer heat from a high temperature location of a heating
circuit to a low temperature location of the same heating circuit.
In some such embodiments, the heat exchanger 10 can transfer heat
from a working fluid traveling through a first portion of the heat
transfer circuit to the same working fluid traveling through a
second portion of the heat transfer circuit.
[0014] The heat exchanger 10 shown in FIGS. 1-3 includes a heat
exchanger core 14 including a number of adjacent and substantially
parallel tubes 18, a header 22, a return tank 26, a coolant divider
30, and baffles 34 positioned along the tubes 18. The heat
exchanger core 14 can include a first or proximal end 16 and a
second or distal end 17. In embodiments in which the heat exchanger
core 14 includes a return tank 26, such as the illustrated
embodiment of FIGS. 1-3, the return tank 26 can at least partially
define the distal end 17 of the heat exchanger core 14. The heat
exchanger core 14 or at least a portion of the heat exchanger core
14 can be supported in a housing 38.
[0015] As shown in FIGS. 1-3, the heat exchanger 10 defines a first
flow path (represented by arrows 20 in FIG. 3) for the first
working fluid and a second flow path (represented by arrows 24 in
FIG. 1) for a second working fluid, and the first and second flow
paths 20, 24 are separated such that the first working fluid is
prevented from entering the second flow path 24 and such that the
second working fluid is prevented from entering the first flow path
20. More specifically, as shown in FIG. 3, each of the tubes 18 can
be secured to the header 22 such that a first working fluid
traveling through the heat exchanger 10 enters a first set of tubes
(e.g., the three lower tubes 18 in FIG. 3), travels along a first
pass through the heat exchanger core 14, passes through the return
tank 26, enters a second set of tubes (e.g., the four upper tubes
18 of FIG. 3), travels along a second pass through the heat
exchanger core 14, and is maintained separate from a second working
fluid traveling through the heat exchanger 10.
[0016] The second working fluid enters the interior space defined
between the inner wall of the housing 38 and the heat exchanger
core 14 and travels along the second flow path 24 before exiting
the heat exchanger 10 through an outlet (not shown). In the
illustrated embodiment of FIGS. 1-3, the second flow path 24
extends across the exterior surfaces of the tubes 18 and
serpentines around the coolant divider 30 and baffles 34 such that
heat can be transferred between the first fluid traveling along the
first flow path 20 through the heat exchanger core 14 and the
second fluid traveling along the second flow path 24 through the
heat exchanger housing 38.
[0017] In some embodiments, the tubes 18 can be formed from
aluminum, steel, iron, or other metal, whereas the header 22 can be
plastic. Although this material combination provides unique
performance results, other materials and material combinations are
possible. For example, in other embodiments, both the core 14 and
the header 22 are formed from plastic. In other embodiments, both
the core 14 and the header 22 are formed from metal. Alternatively,
in still other embodiments, the core 14 is plastic, while the
header 22 is formed from one or more metals. In the illustrated
embodiment, the return tank 26 is metal. Alternatively, in still
other embodiments, the return tank 26 or a portion of the return
tank 26 can be plastic.
[0018] As shown in FIGS. 1-3, the core 14 can be supported in a
housing 38 in a cantilevered manner such that the distal end 17 of
the core 14 is moveable relative to the housing 38. The housing 38
can be formed from cast aluminum or steel, formed sheet metal,
plastic, or similar housing material. Alternatively, the housing 38
or a portion of the housing 38 can be formed from a material having
a greater elasticity, such as, for example, plastic. The housing 38
is shown in FIGS. 2 and 3 as having a smooth outer surface and
configured to couple to an exterior portion of the inlet/outlet
manifold 12. However, in other embodiments, the housing 38 may have
bumps, ridges, or other protrusions creating a non-smooth outer
surface.
[0019] As shown in FIG. 2, the header 22 can be secured to an
inlet/outlet manifold 12, and a seal can be formed between the
header 22, an exterior portion of the inlet/outlet manifold 12, and
the housing 38. In this manner, the proximal end 16 of the core 14
is prevented from moving relative to the housing 38 and/or relative
to the header 22.
[0020] The coolant divider 30 extends axially along the length of
the core 14 between the proximal and distal ends 16, 17 of the core
14 and is configured, among other things, to separate the heat
exchange tubes 18 so as to define first and second passes through
the core 14. For example, in the illustrated embodiment of FIG. 3,
the divider 30 defines a first pass through the core 14 along the
three lower tubes 18 and a second pass through the core 14 along
the four upper tubes 18. As shown in FIGS. 1 and 2, comb-shaped
baffles 34 are positioned on opposite sides of the core 14 along
the length of the core 14 to define a serpentine flow path between
the exterior of the core 14 and the interior of the housing 38. The
baffles 34 can also or alternatively support the tubes 18 in the
housing 14 and maintain a desired relative spacing between the
tubes 18.
[0021] In some embodiments, the coolant divider 30 and/or the
baffles 34 can extend outwardly from the core 14 and contact the
interior of the housing 38. In some such embodiments, the coolant
divider 30 and/or the baffles 34 can support the distal end 17 of
the core 14 within the housing 38, while accommodating thermal
expansion of the core 14 relative to the housing 38 and/or
absorbing vibrations. In some such embodiments, the coolant divider
30 and/or the baffles 34 can also accommodate axial movement of the
core 14 (i.e., in a direction substantially parallel to the axis A
shown in FIG. 1). Alternatively or in addition, the coolant divider
30 and/or the baffles 34 can also accommodate movement of the core
14 relative to the housing 38 in a direction substantially
perpendicular to the axis A. In still other embodiments, the
coolant divider 30 and/or the baffles 34 can also accommodate
pivoting movement of the core 14 relative to the housing 38 when
one side (e.g., the upper side) of the core 14 experiences
different thermal expansion than the opposite side (e.g., the lower
side) of the core 14, causing the core 14 to bend or twist relative
to the housing 14. The movement of the core relative to the housing
can be along any direction, a plane, and/or an arc. In embodiments
in which the housing moves relative to the core, movement can be
along any direction, a plane, and/or an arc.
[0022] In some embodiments in which the coolant divider 30 and/or
the baffles 34 support the core 14 within the housing 38, the outer
ends of the coolant divider 30 and/or the baffles 34 can extend
outwardly and engage the inner wall of the housing 38. In some such
embodiments, the exterior edges of the coolant divider 30 and/or
the baffles 34 can be at least partially covered with an
elastomeric material (e.g., rubber, plastic, etc.) to accommodate
the movement of the core 14 relative to the housing 38 and/or to
absorb vibrations.
[0023] In other embodiments, the exterior edges of the coolant
divider 30 and/or the baffles 34 can be curved over and can ride
along the interior surface of the housing 38. In this manner, the
exterior edges of the coolant divider 30 and/or the baffles 34 can
be compressed or expand to accommodate movement of the core 14
relative to the housing 38. In this manner, the elasticity provided
by the curved exterior edges can function as a spring. Also, the
exterior edges of the coolant divider 30 and/or the baffles 34 can
move across the inner wall of the housing 38 in a wiping manner to
prevent fluid from traveling between the inner wall of the housing
38 and the outer edges of the coolant divider 30 and/or the baffles
34, even when thermal expansion causes the core 14 to move more
closely to or further from portions of the inner wall of the
housing 38.
[0024] In other embodiments, an elastomeric material may be secured
to the exterior edges of the coolant divider 30 and/or the baffles
34 and the exterior edges of the coolant divider 30 and/or the
baffles 34 can be seated or at least partially seated in grooves
formed along the inner wall of the housing 38 to accommodate
longitudinal expansion of the heat exchanger core 14.
[0025] As shown in FIGS. 1 and 3, the return tank 26 can include an
outwardly extending protrusion 42. The protrusion 42 can be any
shape or size that protrudes, or otherwise extends outwardly from
the exterior of the return tank 26. In the illustrated embodiment
of FIGS. 1-3, the protrusion 42 is formed into the return tank 26.
In other embodiments, the protrusion 42 may be welded, soldered, or
brazed onto the return tank 26.
[0026] In the illustrated embodiment of FIGS. 1 and 3, the
protrusion 42 extends outwardly from one end of the return tank 26.
In other embodiments, the protrusion 42 can be positioned in other
locations along the exterior of the return tank 26, such as, for
example, on an upper surface, a lower surface, the right side, or
left side of the return tank 26. In still other embodiments, two or
more protrusions 42 can extend outwardly from the same or different
sides or surfaces of the return tank 26. In some such embodiments,
one protrusion 42 can be located on a first surface (e.g., the left
side) of the return tank 26 and another protrusion 42 can be
located on an opposite surface (e.g., the right side) of the return
tank 26.
[0027] In the illustrated embodiment of FIGS. 1-3, the protrusion
42 is configured to be received or at least partially received in a
recess 50 formed in the inner wall of the housing 38. In other
embodiments, the protrusion 42 can be received or at least
partially received in a recess formed in an element (e.g., a liner,
a fastener extending into the housing 38, etc.) secured to the
inner wall of the housing 38.
[0028] As shown in FIG. 3, an elastomeric member 46 is supported in
the recess 50 and is configured to matingly receive the protrusion
42 so as to support the protrusion 42 and the distal end 17 of the
heat exchanger core 14. In the illustrated embodiment, the
elastomeric member 46 is a grommet formed from plastic, rubber, or
a similar resilient and deformable material. However, in other
embodiments, the elastomeric member 46 can be formed from a metal
or other rigid material and can be shaped to act as a spring.
[0029] The elastomeric member 46 is deformable to allow movement of
the heat exchanger core 14 relative to the housing 38 and to
accommodate vibrations and/or thermal expansion in at least two
substantially perpendicular directions, and in some embodiments, in
three substantially perpendicular directions. Also, in some
embodiments, the durometer of the elastomeric member 46 is
sufficiently high so that the engagement between the elastomeric
member 46 and the protrusion 42 supports the distal end 17 of the
heat exchanger core 14 while also allowing for limited movement of
the heat exchanger core 14 with respect to the housing 38.
[0030] In other embodiments, the return tank 26 may have two,
three, or more protrusions 42 configured to sit in a recess or a
plurality of recesses 50 formed on the inner wall of the housing 38
or on an element supported on the inner wall of the housing 38. In
some such embodiments, elastomeric members 46 having different
durometers can be supported in each of the recesses 50. In other
embodiments, each of the recesses 50 can support an elastomeric
member 46 and all of the elastomeric members 46 can have the same
durometer.
[0031] In still other embodiments, a reverse design may be employed
wherein the protrusion 42 extends inwardly from the inner wall of
the housing 38 and is further configured to be received in an
opening in an elastomeric member 46 supported in a recess 50 formed
in the return tank 26. In other embodiments, protrusions 42 may
extend from both the return tank 26 and the housing 38 and a
washer, sleeve, bushing, or similar elastomeric member 46 may
provide interference between the protrusions 42. In some such
embodiments, both protrusions 42 can be formed from or covered with
an elastomeric material. In other embodiments, the insert
positioned between the protrusions 42 can also or alternatively be
formed from or covered with an elastomeric material to accommodate
relative movement between the protrusions 42 and/or to absorb
vibrations.
[0032] In yet other embodiments, the return tank 26 and the housing
38 may be substantially planar and a washer, gasket, or similar
elastomeric member 46 may provide an interference between the
return tank 26 and the housing 38. In some such embodiments, the
elastomeric member 46 can be positioned around or at least
partially around the exterior surface of the return tank 26.
Alternatively or in addition, the elastomeric member 46 can be at
least partially received in a recess 50 formed around the external
surface of the return tank 26 and/or the internal wall of the
housing 38 to maintain the elastomeric member 46 in a desired
position while also absorbing vibrations and/or allowing relative
movement between the return tank 26 and the housing 38.
[0033] In still other embodiments, the return tank 26 can be formed
with a stamped bead pattern configured, among other things, to help
direct fluid (e.g., exhaust) flow along the first flow path 20
through the return tank 26 and seat a washer, gasket, or similar
elastomeric member 46 on an exterior surface of the return tank 26
between the exterior surface of the return tank 26 and the inner
wall of the housing 38. Alternatively, in other embodiments, an
interference fit can be maintained between the heat exchanger core
14 and the housing 38 in addition to or without any elastomeric
member 46 between the heat exchanger core 14 and the housing
38.
[0034] In alternate embodiments, a fastener, such as, for example,
a screw, nail, rivet, pin, post, clip, clamp, inter-engaging
element, and any combination of such fasteners, can be inserted
through the housing 38 to press or otherwise interface with the
return tank 26 and provide support to the heat exchanger core 14.
In some embodiments, the fastener may include an elastomeric
exterior or be at least partially covered with an elastomeric
material.
[0035] In still other embodiments, a fastener or a hollow
protrusion can extend outwardly from the return tank 26 toward the
inner wall of the housing 38, or alternatively, a fastener or a
hollow protrusion 42 can extend inwardly from the inner wall of the
housing 38 toward the return tank 26. In some such embodiments, an
opening provided in the fastener or the hollow protrusion 42 can
provide an alternate exit or bypass for fluid exiting the heat
exchanger core 14. In some such embodiments, the opening provided
in the fastener or the hollow protrusion 42, which can extend from
either the return tank 26 or the housing 38, can be substantially
aligned with an opening on either the return tank 26 or the housing
38 and a hollow elastomeric member 46 can be positioned between the
opening and the fastener or hollow protrusion 42 so as to provide
an alternate exit or bypass for fluid exiting the heat exchanger
core 14. In some such embodiments, a valve can be provided to
control flow through such an alternate exit or bypass. Such an
alternate exit or bypass can also or alternatively function as a
condensation trap, while the fastener or hollow protrusion 42 can
be formed of or at least partially covered with an elastomeric
material, as described above, to accommodate relative movement
between the heat exchanger core 14 and the housing 38.
[0036] While reference is made herein to protrusions 42 located
along the return tank 26 to be received in recesses 50 formed along
the inner wall of the housing 38 and to recesses 50 formed along
the return tank 26 to receive protrusions 42 extending inwardly
from the housing 38, in some embodiments of the present invention,
protrusions 42 can also or alternatively extend outwardly from
other locations along the heat exchanger core 14, such as, for
example, from the tubes 18, to be received in recesses 50 located
along the inner wall of the housing 38. Alternatively or in
addition, protrusions 42 can extend inwardly from the inner wall of
the housing 38 to be received in recesses 50 formed along other
portions of the heat exchanger core 14, such as, for example, the
tubes 18. Similarly, fasteners such as, for example, screws, nails,
rivets, pins, posts, clips, clamps, inter-engaging elements, and
any combination of such fasteners, can be inserted through the
housing 38 to press or otherwise interface with the other portions
of the heat exchanger core 14, such as, for example, the tubes 18.
Also or alternatively, grommets, bushings, washers, or other
elastomeric members 46 can be positioned between other portions of
the heat exchanger core 14 and the inner wall of the housing 38 to
accommodate relative movement and/or to absorb or at least
partially absorb vibrations.
[0037] In some such embodiments, the heat exchanger core 14 can be
formed without a return tank 26. In these embodiments, each of the
tubes 18 of the heat exchanger core 14 can be formed to have a
substantially U-shape such that the fluid traveling through the
first flow path 20 travels through the heat exchanger core 14 along
at least two passes. In some such embodiments, a header 22 can be
secured to the distal end 17 of the heat exchanger core 14 and the
header 22 can engage one or more elastomeric members 46 positioned
along the inner wall of the housing 38 to support or at least
partially support the distal end 17 of the heat exchanger core 14
while also accommodating relative movement between the heat
exchanger core 14 and the housing 38 and/or absorbing
vibrations.
[0038] 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 in the elements and their
configuration and arrangement are possible without departing from
the spirit and scope of the present invention. Variations and
modifications exist within the scope and spirit of one or more
independent aspects of the invention as described. Various features
and advantages of the invention are set forth in the following
claims.
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