Heat Exchanger Tank With Flow Elements

Goenka; Lakhi ;   et al.

Patent Application Summary

U.S. patent application number 13/714983 was filed with the patent office on 2014-06-19 for heat exchanger tank with flow elements. This patent application is currently assigned to VISTEON GLOBAL TECHNOLOGIES, INC.. The applicant listed for this patent is VISTEON GLOBAL TECHNOLOGIES, INC.. Invention is credited to Lakhi Goenka, Mark Hatzung, Chris Shaw.

Application Number20140166249 13/714983
Document ID /
Family ID50929584
Filed Date2014-06-19

United States Patent Application 20140166249
Kind Code A1
Goenka; Lakhi ;   et al. June 19, 2014

HEAT EXCHANGER TANK WITH FLOW ELEMENTS

Abstract

A heat exchanger configured to condition a flow of fluid therein. The heat exchanger includes a first tank, a second tank, and a conditioning assembly having a plurality of tubular elements extending between the first tank and the second tank. The first tank includes a hollow interior, an inlet, and a flow element formed in the hollow interior, wherein a plane generally defined by the flow element is substantially orthogonal to a plane generally defined by inlet openings of the tubular elements, and wherein the flow element includes a first end which curves away from the inlet in respect to a general direction of flow of the fluid entering the tank to manipulate the direction of flow of the fluid.


Inventors: Goenka; Lakhi; (Ann Arbor, MI) ; Shaw; Chris; (Windsor, CA) ; Hatzung; Mark; (Wayne, MI)
Applicant:
Name City State Country Type

VISTEON GLOBAL TECHNOLOGIES, INC.

Van Buren Twp.

MI

US
Assignee: VISTEON GLOBAL TECHNOLOGIES, INC.
Van Buren Twp.
MI

Family ID: 50929584
Appl. No.: 13/714983
Filed: December 14, 2012

Current U.S. Class: 165/148
Current CPC Class: F28D 1/05366 20130101; F28F 2009/029 20130101; F28D 2021/0094 20130101; F28F 9/0268 20130101
Class at Publication: 165/148
International Class: F28D 1/06 20060101 F28D001/06

Claims



1. A heat exchanger, comprising: a conditioning assembly including a plurality of tubular elements configured to receive a flow of a fluid therein; and a tank coupled to the conditioning assembly, the tank including a hollow interior and at least one flow element formed in the hollow interior, wherein at least one plane generally defined by the at least one flow element is substantially orthogonal to a plane generally defined by inlet openings of the tubular elements.

2. The heat exchanger of claim 1, wherein an end of the at least one flow element one of extends into an inlet of the tank, abuts an inner surface which defines an opening of the inlet of the tank, and is spaced apart from the inlet of the tank.

3. The heat exchanger of claim 1, wherein the tank includes a plurality of the flow elements extending from an inlet of the tank into the hollow interior towards at least one of a first end and a second end of the tank.

4. The heat exchanger of claim 3, wherein the flow elements are uniformly spaced apart.

5. The heat exchanger of claim 3, wherein a ratio of a distance between the flow elements to a chord length of at least one of the flow elements is less than about 0.2.

6. The heat exchanger of claim 3, wherein a chord length of one of the flow elements is substantially equal to a chord length of another one of the flow elements.

7. The heat exchanger of claim 3, wherein a chord length of one of the flow elements adjacent a wall of the tank is greater than a chord length of another one of the flow elements adjacent an opposing wall of the tank.

8. A heat exchanger, comprising: a conditioning assembly configured to condition a fluid flowing therethrough; and a tank coupled to the conditioning assembly, the tank including a hollow interior, an inlet, and at least one flow element formed therein, wherein the at least one flow element includes a first end and a second end, and wherein the first end curves away from the inlet in respect of a general direction of flow of the fluid entering the tank to manipulate the direction of flow of the fluid.

9. The heat exchanger of claim 8, wherein the first end of the at least one flow element one of extends into the inlet of the tank, abuts an inner surface which defines an opening of the inlet of the tank, and is spaced apart from the inlet of the tank.

10. The heat exchanger of claim 8, wherein the tank includes a plurality of the flow elements extending from the inlet of the tank into the hollow interior towards at least one of a first end and a second end of the tank.

11. The heat exchanger of claim 10, wherein the flow elements are uniformly spaced apart.

12. The heat exchanger of claim 10, wherein a ratio of a distance between the flow elements to a chord length of at least one of the flow elements is less than about 0.2.

13. The heat exchanger of claim 10, wherein a chord length of one of the flow elements is substantially equal to a chord length of another one of the flow elements.

14. The heat exchanger of claim 10, wherein a chord length of one of the flow elements adjacent a wall of the tank is greater than a chord length of another one of the flow elements adjacent an opposing wall of the tank.

15. A heat exchanger, comprising: a conditioning assembly configured to condition a fluid flowing therethrough; and a tank coupled to the conditioning assembly, the tank including an inlet, a first end, a second end, and a plurality of flow elements formed therein, wherein one of the flow elements extends from the inlet towards the first end of the tank and another one of the flow elements extends from the inlet towards the second end of the tank.

16. The heat exchanger of claim 15, wherein an end of at least one of the flow elements one of extends into the inlet of the tank, abuts an inner surface which defines an opening of the inlet of the tank, and is spaced apart from the inlet of the tank.

17. The heat exchanger of claim 15, wherein the flow elements are uniformly spaced apart.

18. The heat exchanger of claim 15, wherein a ratio of a distance between the flow elements to a chord length of at least one of the flow elements is less than about 0.2.

19. The heat exchanger of claim 15, wherein a chord length of one of the flow elements is substantially equal to a chord length of another one of the flow elements.

20. The heat exchanger of claim 15, wherein a chord length of one of the flow elements adjacent a wall of the tank is greater than a chord length of another one of the flow elements adjacent an opposing wall of the tank.
Description



FIELD OF THE INVENTION

[0001] The present invention relates generally to a heat exchanger and, more particularly, to a radiator tank with turning vanes.

BACKGROUND OF THE INVENTION

[0002] Conventional radiators are usually provided with a cooling portion in which a radiator liquid is cooled, and two collection tanks which are connected to the cooling portion at opposite ends. The first collection tank receives the hot radiator liquid before it is led into the cooling portion. The second collection tank receives the radiator liquid after it has passed through the cooling portion. The cooling portion usually includes a plurality of tubular elements arranged in parallel which lead the radiator liquid between the tanks. Surrounding air flows in spaces between the tubular elements so that the radiator liquid is subjected to cooling within the tubular elements. Heat transfer elements of various kinds, e.g. in the form of thin folded fins, are usually arranged in the spaces between the tubular elements to provide an increased contact surface with the air which flows in the spaces between the tubular elements. The tubular elements and the heat transfer elements may be made of metals such as aluminum, copper, brass and magnesium or other materials which have desirable heat-conducting characteristics. Conventional collection tanks are usually made of injection-molded plastic material.

[0003] One drawback of such conventional radiators is poor heat exchange efficiency. Typically, the hot radiator liquid is introduced into an end of the first collection tank through an inlet and a flow momentum causes the hot radiator liquid to contact a back wall of the first collection tank. The back wall directs the radiator liquid downward causing the tubular elements adjacent the inlet to receive the hot radiator liquid which leads to difficultly in introduction of the hot radiator liquid into the tubular elements adjacent an opposite end of the first collection tank, especially during a cold start up. Such non-uniform distribution of the hot radiator liquid can cause the tubular elements adjacent the opposite end of the first collection tank to become obstructed by an accumulation of the radiator liquid therein resulting from a lack of use. As a result, severe thermal stresses which can potentially damage the tubular elements adjacent the opposite end of the first collection tank may occur.

[0004] It would be desirable to produce a radiator which is configured to substantially uniformly distribute a radiator liquid, wherein a structural complexity and a package size thereof are minimized.

SUMMARY OF THE INVENTION

[0005] In concordance and agreement with the present disclosure, a radiator which is configured to substantially uniformly distribute a radiator liquid, wherein a structural complexity and a package size thereof are minimized, has surprisingly been discovered.

[0006] In one embodiment, a heat exchanger, comprises: a conditioning assembly including a plurality of tubular elements configured to receive a flow of a fluid therein; and a tank coupled to the conditioning assembly, the tank including a hollow interior and at least one flow element formed in the hollow interior, wherein at least one plane generally defined by the at least one flow element is substantially orthogonal to a plane generally defined by inlet openings of the tubular elements.

[0007] In another embodiment, a heat exchanger, comprises: a conditioning assembly configured to condition a fluid flowing therethrough; and a tank coupled to the conditioning assembly, the tank including a hollow interior, an inlet, and at least one flow element formed therein, wherein the at least one flow element includes a first end and a second end, and wherein the first end curves away from the inlet in respect of a general direction of flow of the fluid entering the tank to manipulate the direction of flow of the fluid.

[0008] In a further embodiment, a heat exchanger, comprises: a conditioning assembly configured to condition a fluid flowing therethrough; and a tank coupled to the conditioning assembly, the tank including an inlet, a first end, a second end, and a plurality of flow elements formed therein, wherein one of the flow elements extends from the inlet towards the first end of the tank and another one of the flow elements extends from the inlet towards the second end of the tank.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from a reading the following detailed description of the invention when considered in the light of the accompanying drawings in which:

[0010] FIG. 1 is a front elevational view of a heat exchanger of the present invention including a first tank, a second tank, and conditioning assembly;

[0011] FIG. 2 is a bottom plan view of the first tank illustrated in FIG. 1 according to an embodiment of the present invention;

[0012] FIG. 3 is a bottom plan view of the first tank illustrated in FIG. 1 according to another embodiment of the present invention;

[0013] FIG. 4 is a bottom plan view of the first tank illustrated in FIG. 1 according to another embodiment of the present invention; and

[0014] FIG. 5 is a bottom plan view of the first tank illustrated in FIG. 1 according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0015] The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

[0016] FIG. 1 depicts a heat exchanger 10 according to the present invention. The heat exchanger 10 shown is a radiator to be used in a vehicle (not shown). The heat exchanger 10 conditions a first fluid (i.e. a radiator liquid), which circulates in a fluid-conditioning system (not shown), using a second fluid (i.e. surrounding air). The fluid-conditioning system may used to cool an engine (not shown) which powers the vehicle. Those skilled in the art will appreciate that the heat exchanger 10 can be used in various other fluid-conditioning systems, e.g. heating systems, cooling systems, and combination heating/cooling systems, related and unrelated to vehicle applications.

[0017] The heat exchanger 10 includes a first tank 12, a second tank 14, and a conditioning assembly 16 which extends between the first tank 12 and the second tank 14. As illustrated, the first tank 12 has a gradually decreasing cross-sectional flow area in respect of a direction of flow of the first fluid therethrough, and the second tank 14 has a gradually increasing cross-sectional flow area in respect of the direction of flow of the first fluid therethrough. It is understood, however, that the first tank 12 and the second tank 14 can have any shape and configuration as desired. Each of the first tank 12 and the second tank 14 can be formed from any material and by any process as desired. In certain embodiments, the first tank 12 and the second tank 14 are formed by injection-molding a plastic material. In other embodiments, the first tank 12 may be formed from a material of sufficient strength so that a wall thickness of the first tank 12 can be minimized, thereby enhancing heat transfer between the first fluid in the first tank 12 and the second fluid. For example, the first tank 12 can be formed from aluminum, which is a material with desirable heat-conducting characteristics and sufficient strength characteristics. Various other materials can be used to form the first tank 12 and the second tank 14 if desired.

[0018] An inlet 18 of the first tank 12 is in fluid communication with the fluid-conditioning system and receives the first fluid which has been heated by an external component (i.e. the engine) thereof. The heated first fluid is received in the first tank 12, from which it flows into the conditioning assembly 16. The conditioning assembly 16 shown includes a plurality of tubular elements 20 extending between the first tank 12 and the second tank 14. An inlet opening (not shown) and an outlet opening (not shown) of each of the tubular elements 20 is fluidly connected to the first tank 12 and the second tank 14, respectively. The tubular elements 20 are arranged in parallel and spaced apart at substantially equal distances so that substantially constant gaps 22 are formed between adjacent tubular elements 20.

[0019] The second fluid flows through the gaps 22 between the tubular elements 20 to cool the heated first fluid flowing through tubular elements 20. The flow of the second fluid through the conditioning assembly 16 may be caused by a movement of the vehicle and/or by a device which causes the second fluid to flow through the conditioning assembly 16 of the heat exchanger 10, for example. In certain embodiments, the gaps 22 may be provided with at least one heat transfer element 24. Various heat transfer elements 24 can be employed such as thin folded metal elements or fins, for example. The heat transfer elements 24 are arranged to abut the tubular elements 20, thereby increasing a contact surface of the tubular elements 20 with the second fluid to maximize a heat transfer from the first fluid to the second fluid. Each of the tubular elements 20 and the heat transfer elements 24 can be formed from any suitable material such as a metal (e. g. aluminum, copper, brass, magnesium, etc.) or other materials which have desired heat-conducting characteristics. The second tank 14 receives the cooled first fluid from the respective tubular elements 20 of the conditioning assembly 16, after which the cooled first fluid is discharged from the second tank 14 to the fluid-conditioning system via an outlet 26.

[0020] In certain embodiments, at least one of the first tank 12 and the second tank 14 has a plurality of spaced apart protruding material portions 28. The protruding material portions 28 are formed on an outer surface of the tanks 12, 14 and spaced apart at substantially constant distances from one another. The protruding material portions 28 may have any suitable shape and size as desired. The protruding material portions 28 provide increased contact surface with a portion of the second fluid which flows around the tanks 12, 14. As a result, the heated first fluid undergoes a moderate first step of cooling within the first tank 12 before it flows into the conditioning assembly 16.

[0021] FIGS. 1-2 show the first tank 12 according to an embodiment of the invention. The first tank 12 includes a first end 46 and a second end 48. A pair of spaced apart flow elements 30 is arranged within the first tank 12. Additional or fewer flow elements 30 than shown can be employed in the first tank 12 if desired. Although the flow elements 30 shown are substantially uniformly spaced apart from each other, it is understood that the flow elements 30 can be non-uniformly spaced apart if desired. The flow elements 30 extend substantially parallel to a longitudinal axis of the first tank 12 from the inlet 18 into a hollow interior of the first tank 12 towards the second end 48 of the first tank 12. As illustrated, each plane generally defined by each one of the flow elements 30 is substantially orthogonal to a plane generally defined by the inlet openings of the tubular elements 20 of the conditioning assembly 16. It is understood, however, that each plane generally defined by each one of the flow elements 30 can be substantially parallel to the plane generally defined by the inlet openings of the tubular elements 20 of the conditioning assembly 16 if desired. The flow elements 30 direct portions of the first fluid from the inlet 18 along flow paths 36a, 36b, 36c. The flow paths 36a, 36b, 36c are defined by the flow elements 30 and an inner surface 38 of the first tank 12. In certain embodiments, the flow elements 30 extend across an opening of the inlet 18 (shown in FIG. 1). In other embodiments, the flow elements 30 are spaced from the inlet openings of the tubular elements 20 to allow the portions of the first fluid to mix within the hollow interior of the first tank 12 before flowing into the tubular elements 20.

[0022] Each of the flow elements 30 has a first end 40 and a second end 42. As illustrated in FIG. 2, the first end 40 of the flow elements 30 is spaced from an opening of the inlet 18 which leads into the hollow interior of the first tank 12. Spacing the first end 40 of the flow elements 30 from the opening of the inlet 18 allows the incoming first fluid to enter the hollow interior of the first tank 12 before being directed into the flow paths 36a, 36b, 36c by the flow elements 30, as well as allows the opening of the inlet 18 to have a radius (not shown) formed thereon which enhances a distribution of flow of the first fluid into the hollow interior of the first tank 12. It is understood that the first end 40 of the flow elements 30 may be formed to abut an inner surface which defines the opening of the inlet 18 or extend through the opening into a passageway of the inlet 18 (as shown in FIGS. 3-5) if desired.

[0023] The first end 40 of the flow elements 30 is gradually curved away from the inlet 18 to manipulate a direction of flow of the first fluid entering the hollow interior of the first tank 12, while minimizing interference with the flow of the first fluid through the first tank 12. As illustrated, the flow elements 30 are configured so that the first fluid contacts a concave surface of the first end 50 in respect to the general direction of flow of the first fluid entering the hollow interior of the first tank 12 to manipulate the direction of flow of the first fluid. Each of the first end 40 and the second end 42 may also include a radius to further minimize interference with the flow of the first fluid through the first tank 12.

[0024] In certain embodiments, the shape, size, and positioning of the flow elements 30 are such that a ratio (hereinafter "gap-chord ratio") of a distance D1 between the flow elements 30 to a chord length extending between point A and point B of each of the respective flow elements 30 is less than about 0.2. A gap-chord ratio of less than about 0.2 has been found to facilitate sufficient manipulation of the direction of flow of the first fluid entering the hollow interior of the first tank 12, ensuring that at least a portion of the first fluid travels from the first end 46 of the first tank 12 along the flow paths 36a, 36b, 36c to the second end 48 of the first tank 12. As such, the first fluid is substantially uniformly distributed into the tubular elements 20 of the conditioning assembly 16, which minimizes the potential for the tubular elements 20 adjacent the second end 48 of the first tank 12 to become obstructed, especially during start up transients. As illustrated, the flow elements 30 have substantially equal chord lengths.

[0025] The flow elements 30 shown are integrally formed with a wall 50 of the first tank 12. However, those skilled in the art will appreciate that the flow elements 30 can be separately formed from the wall 50 of the first tank 12 if desired. In certain embodiments, the flow elements 30 are formed in the first tank 12 during an injection-molding forming process of the first tank 12. Accordingly, a thickness of each of the flow elements 30 may be tapered (i.e. about 0.5 degrees) from an outer edge 52 thereof to the wall 50 of the first tank 12 to allow for retraction of a molding tool during manufacture of the first tank 12. It is understood, however, that the thickness of each of the flow elements 30 can be substantially constant from the outer edge 52 to the wall 50 if desired. It is further understood that the thickness of each of the flow elements 30 may be any suitable thickness to militate against damage and/or breakage of the flow elements 30. Each of the flow elements 30 may also be formed from a material with desirable heat-conducting characteristics to further enhance heat transfer between the first fluid and the second fluid. Those skilled in the art will appreciate that the flow elements 30 can be formed from any material and by any suitable process as desired.

[0026] FIG. 3 shows a first tank 12' according to another embodiment of the invention. Reference numerals for similar structure in respect of the description of FIGS. 1-2 are repeated in FIG. 3 with a prime (') symbol. The first tank 12' is substantially similar to the first tank 12 shown in FIGS. 1-2 except that the chord lengths of the flow elements 30' are different. As illustrated, the chord length extending between point A and point B of the flow element 30' adjacent a wall 54 of the first tank 12' is greater than the chord length extending between point A and point B of the flow element 30' adjacent an opposing wall 55 of the first tank 12'. As such, the first fluid is caused to travel along the flow path 36c' further into the hollow interior of the first tank 12', ensuring that at least a portion of the first fluid reaches the tubular elements 20 at a second end 48' of the first tank 12'. Accordingly, the first fluid is substantially uniformly distributed into the tubular elements 20 of the conditioning assembly 16, which minimizes the potential for the tubular elements 20 adjacent the second end 48' of the first tank 12' to become obstructed, especially during start up transients.

[0027] FIG. 4 shows a first tank 12'' according to another embodiment of the invention. Reference numerals for similar structure in respect of the description of FIGS. 1-3 are repeated in FIG. 4 with a double prime ('') symbol. The first tank 12'' is substantially similar to the first tanks 12, 12' shown in FIGS. 1-2 and 3, respectively, except that the first tank 12'' includes three flow elements 30'' formed therein. The flow elements 30'' facilitate sufficient manipulation of the direction of flow of the first fluid entering the hollow interior of the first tank 12'', ensuring that at least a portion of the first fluid travels from a first end 46'' of the first tank 12'' along flow paths 56a, 56b, 56c, 56d to a second end 48'' of the first tank 12''. It is understood that the flow elements 30'' can have any shape, size, and positioning so as to ensure that the first fluid is substantially uniformly distributed into the tubular elements 20 of the conditioning assembly 16, and thereby minimize the potential for the tubular elements 20 adjacent the second end 48'' of the first tank 12'' to become obstructed, especially during start up transients.

[0028] FIG. 5 shows a first tank 12''' according to yet another embodiment of the invention. Reference numerals for similar structure in respect of the description of FIGS. 1-4 are repeated in FIG. 5 with a triple prime (''') symbol. The first tank 12''' is substantially similar to the first tanks 12, 12', 12'' shown in FIGS. 1-2, 3, and 4, respectively, except that an inlet 18''' is formed intermediate a first end 46''' and a second end 48''' of the first tank 12''' and the flow elements 62, 64, 66 have an alternate configuration.

[0029] The spaced apart flow elements 62, 64, 66 are arranged within the first tank 12'''. Additional or fewer flow elements than shown can be employed in the first tank 12''' if desired. As illustrated, the flow element 62 extends substantially parallel to a longitudinal axis of the first tank 12''' from the inlet 18''' into the hollow interior of the first tank 12''' towards a first end 46''' thereof. On the other hand, the flow elements 64, 66 extend substantially parallel to the longitudinal axis of the first tank 12''' from the inlet 18''' into the hollow interior of the first tank 12''' towards a second end 48''' thereof. As illustrated, each plane generally defined by each one of the flow elements 62, 64, 66 is substantially orthogonal to a plane generally defined by the inlet openings of the tubular elements 20 of the conditioning assembly 16. It is understood, however, that each plane generally defined by each one of the flow elements 62, 64, 66 can be substantially parallel to the plane generally defined by the inlet openings of the tubular elements 20 of the conditioning assembly 16 if desired. The flow element 62 directs portions of the first fluid from the inlet 18''' along flow paths 68a, 68b and the flow elements 64, 66 direct portions of the first fluid from the inlet 18''' along flow paths 68c, 68d, 68e. The flow paths 68a, 68b, 68c, 68d, 68e are defined by the flow elements 62, 64, 66 and an inner surface 38''' of the first tank 12'''. In certain embodiments, the flow elements 62, 64, 66 extend across an opening of the inlet 18'''. In other embodiments, the flow elements 62, 64, 66 are spaced from the inlet openings of the tubular elements 20 to allow the portions of the first fluid to mix within the hollow interior of the first tank 12''' before flowing into the tubular elements 20.

[0030] Each of the flow elements 62, 64, 66 has a first end 70 and a second end 72. As shown, the first end 70 of the flow elements 62, 64, 66 may be formed to abut an inner surface which defines an opening of the inlet 18''' that leads into the hollow interior of the first tank 12''' or extend through the opening into a passageway of the inlet 18'''. However, it is also contemplated that the first end 70 of the flow elements 30 may be spaced from the opening of the inlet 18''' which leads into the hollow interior of the first tank 12'''. Spacing the first end 70 of the flow elements 62, 64, 66 from the opening of the inlet 18''' allows the incoming first fluid to enter the hollow interior of the first tank 12''' before being directed into the flow paths 68a, 68b, 68c, 68d, 68e by the flow elements 62, 64, 66, as well as allows the inner surface which defines the opening of the inlet 18''' to have a radius (not shown) formed thereon which enhances a distribution of flow of the first fluid into the hollow interior of the first tank 12'''.

[0031] The first end 70 of the flow elements 62, 64, 66 is gradually curved away from the inlet 18''' to manipulate a direction of flow of the first fluid entering the hollow interior of the first tank 12''', while minimizing interference with the flow of the first fluid through the first tank 12'''. As illustrated, the flow elements 62, 64, 66 are configured so that the first fluid contacts a concave surface of the first end 70 in respect to the general direction of flow of the first fluid entering the hollow interior of the first tank 12''' to manipulate the direction of flow of the first fluid. Each of the first end 70 and the second end 72 may also include a radius to further minimize interference with the flow of the first fluid through the first tank 12'''.

[0032] In certain embodiments, the shape, size, and positioning of the flow elements 62, 64, 66 are such that at least one of a gap-chord ratio of a distance D4 between the flow elements 62, 64 to a chord length extending between point A and point B of the flow element 62; a gap-chord ratio of the distance D4 between the flow elements 62, 64 to a chord length extending between point A and point B of the flow element 64; a gap-chord ratio of a distance D7 between the flow elements 64, 66 to the chord length extending between point A and point B of the flow element 64; and a gap-chord ratio of the distance D7 between the flow elements 64, 66 to a chord length extending between point A and point B of the flow element 66, is less than about 0.2. A gap-chord ratio of less than about 0.2 has been found to facilitate sufficient manipulation of the direction of flow of the first fluid entering the hollow interior of the first tank 12''', ensuring that the flow of the first fluid travels from the inlet 18''' to the first end 46''' of the first tank 12''' along the flow paths 68a, 68b, and from the inlet 18''' to the second end 48''' of the first tank 12''' along the flow paths 68c, 68d, 68e. As such, the first fluid is substantially uniformly distributed into the tubular elements 20 of the conditioning assembly 16, which minimizes the potential for the tubular elements 20 adjacent either the first end 46''' or the second end 48''' of the first tank 12''' to become obstructed, especially during start up transients. As illustrated, the flow elements 62, 64 have substantially equal chord lengths and the flow element 66 has a greater chord length than the flow elements 62, 64. It is understood, however, that the chord lengths of the flow elements 62, 64, 66 can be any suitable length to sufficiently manipulate the direction of flow of the first fluid entering the first tank 12''' and substantially uniformly distribute the first fluid into the tubular elements 20 of the conditioning assembly 16.

[0033] The flow elements 62, 64, 66 shown are integrally formed with a wall 50''' of the first tank 12'''. However, those skilled in the art will appreciate that the flow elements 62, 64, 66 can be separately formed from the wall 50''' of the first tank 12''' if desired. In certain embodiments, the flow elements 62, 64, 66 are formed in the first tank 12''' during an injection-molding forming process of the first tank 12'''. Accordingly, a thickness of each of the flow elements 62, 64, 66 may be tapered (i.e. about 0.5 degrees) from an outer edge 76 thereof to the wall 50''' of the first tank 12''' to allow for retraction of a molding tool during manufacture of the first tank 12'''. It is understood, however, that the thickness of each of the flow elements 62, 64, 66 can be substantially constant from the outer edge 76 to the wall 50''' if desired. It is further understood that the thickness of each of the flow elements 62, 64, 66 may be any suitable thickness to militate against damage and/or breakage of the flow elements 62, 64, 66. Each of the flow elements 62, 64, 66 may also be formed from a material with desirable heat-conducting characteristics to further enhance heat transfer between the first fluid and the second fluid. Those skilled in the art will appreciate that the flow elements 62, 64, 66 can be formed from any material and by any suitable process as desired.

[0034] Operation of the heat exchanger 10 including the first tank 12 shown in FIGS. 1-2 is substantially similar to an operation of the heat exchanger including the first tanks 12', 12'', 12''' shown in FIGS. 3-5. Therefore, for simplicity, only the operation of the heat exchanger including the first tank 12 is described hereinafter.

[0035] During operation of the heat exchanger 10, a heated first fluid from the fluid-conditioning system is received into the hollow interior of the first tank 12 through the inlet 18. As the first fluid flows into the hollow interior of the first tank 12, the flow elements 30 manipulate a direction of flow of the first fluid. The incoming first fluid is directed through the flow paths 36a, 36b, 36c. Portions of the first fluid travels from the first end 46 of the first tank 12 along the flow paths 36a, 36b, 36c toward the second end 48 of the first tank 12, ensuring substantially uniform distribution of the first fluid into the inlet openings of the tubular elements 20 of the conditioning assembly 16. Within the conditioning assembly 16, the first fluid undergoes a main conditioning by the second fluid flowing through the conditioning assembly. The conditioned first fluid then flows from the conditioning assembly through the outlet openings thereof into the second tank. The conditioned first fluid is then discharged from the heat exchanger 10 through the outlet 26 into the fluid-conditioning system.

[0036] From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.

* * * * *


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