U.S. patent application number 13/746448 was filed with the patent office on 2014-07-24 for heat exchanger manifold improvements for transient start-up.
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 Nandlal Goenka.
Application Number | 20140202672 13/746448 |
Document ID | / |
Family ID | 51206811 |
Filed Date | 2014-07-24 |
United States Patent
Application |
20140202672 |
Kind Code |
A1 |
Goenka; Lakhi Nandlal |
July 24, 2014 |
HEAT EXCHANGER MANIFOLD IMPROVEMENTS FOR TRANSIENT START-UP
Abstract
A heat exchanger configured to condition a flow of fluid
therein. The heat exchanger includes a first manifold, a second
manifold, and a conditioning assembly having a plurality of tubular
elements extending between the first manifold and the second
manifold. The first manifold includes a first end having an inlet
formed therein and a second end formed opposite the first end,
wherein a generally tapered portion of the second end of the first
manifold and a fluid drain feature formed in the generally tapered
portion of the first manifold are configured to minimize an amount
of the first fluid remaining in at least one of the first manifold
and the tubular elements after operation of the heat exchanger.
Inventors: |
Goenka; Lakhi Nandlal; (Ann
Arbor, 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: |
51206811 |
Appl. No.: |
13/746448 |
Filed: |
January 22, 2013 |
Current U.S.
Class: |
165/173 |
Current CPC
Class: |
F28F 9/02 20130101; F28F
2009/029 20130101; F28D 1/05366 20130101; F28D 2021/0094
20130101 |
Class at
Publication: |
165/173 |
International
Class: |
F28F 9/00 20060101
F28F009/00 |
Claims
1. A heat exchanger, comprising: a conditioning assembly including
a plurality of tubular elements configured to receive a flow of a
fluid therein, each of the tubular elements having an inlet opening
and an outlet opening formed therein; and a manifold coupled to the
conditioning assembly, the manifold including a first end having an
inlet formed therein and a second end opposite the first end,
wherein the manifold is formed by at least one wall, and wherein a
generally tapered portion of the manifold and a fluid drain feature
located in the generally tapered portion of the manifold are
configured to minimize an amount of the fluid remaining in at least
one of the manifold and the tubular elements after operation of the
heat exchanger, and wherein at least one of a volume of the
generally tapered portion of the manifold and a distance between an
inner surface of a wall opposite the inlet openings of the tubular
elements and a plane generally defined by the inlet openings of the
tubular elements generally decreases along the generally tapered
portion of the manifold as a distance from the inlet increases.
2. The heat exchanger of claim 1, wherein the generally tapered
portion of the manifold at least one of directs and increases a
velocity of the flow of the fluid into the last ten (10) tubular
elements of the conditioning assembly.
3. The heat exchanger of claim 1, wherein the fluid drain feature
is integrally formed with the manifold.
4. The heat exchanger of claim 1, wherein the fluid drain feature
extends laterally outwardly from the generally tapered portion of
the manifold.
5. The heat exchanger of claim 1, wherein the fluid drain feature
includes a cavity formed by a portion of the wall of the manifold
opposite the inlet openings of the tubular elements.
6. The heat exchanger of claim 5, wherein the fluid drain feature
includes an aperture at least partially surrounded by the portion
of the wall of the manifold opposite the inlet openings of the
tubular elements.
7. The heat exchanger of claim 6, wherein a hydraulic diameter of
the cavity is substantially the same as a hydraulic diameter of the
aperture.
8. A heat exchanger, comprising: a conditioning assembly including
a plurality of tubular elements configured to receive a flow of a
fluid therein, each of the tubular elements having an inlet opening
and an outlet opening formed therein; and a manifold coupled to the
conditioning assembly, the manifold including a first end having an
inlet formed therein and a second end opposite the first end,
wherein the manifold is formed by at least one wall, and wherein a
generally tapered portion of the second end of the manifold is
configured to minimize an amount of the fluid remaining in at least
one of the manifold and the tubular elements after operation of the
heat exchanger, and wherein at least one of a volume of the
generally tapered portion of the second end of the manifold and a
distance between an inner surface of a wall opposite the inlet
openings of the tubular elements and a plane generally defined by
the inlet openings of the tubular elements generally decreases
along the generally tapered portion of the manifold as a distance
from the inlet in a general direction of the flow of the fluid
through the manifold increases, and wherein the manifold further
includes a fluid drain feature extending laterally outwardly from
the generally tapered portion of the second end of the
manifold.
9. The heat exchanger of claim 8, wherein the generally tapered
portion of the manifold at least one of directs and increases a
velocity of the flow of the fluid into the last ten (10) tubular
elements of the conditioning assembly.
10. The heat exchanger of claim 8, wherein the fluid drain feature
is integrally formed with the generally tapered portion of the
second end of the manifold.
11. The heat exchanger of claim 8, wherein the fluid drain feature
includes a cavity formed by a portion of a wall of the manifold
opposite the inlet openings of the tubular elements.
12. A heat exchanger, comprising: a conditioning assembly including
a plurality of tubular elements configured to receive a flow of a
fluid therein, each of the tubular elements having an inlet opening
and an outlet opening formed therein; and a manifold coupled to the
conditioning assembly, the manifold including a first end having an
inlet formed therein and a second end opposite the first end,
wherein the manifold is formed by at least one wall, and wherein at
least one of a generally tapered first portion of the first end of
the manifold and a generally tapered second portion of the second
end of the manifold is configured to minimize an amount of the
fluid remaining in at least one of the manifold and the tubular
elements after operation of the heat exchanger, and wherein at
least one of a rate of change in a volume of the generally tapered
first portion is less than a rate of change in a volume of the
generally tapered second portion and a rate of change in a distance
between an inner surface of a wall opposite the inlet openings of
the tubular elements which defines the generally tapered first
portion and a plane generally defined by the inlet openings of the
tubular elements is less than a rate of change in a distance
between an inner surface of a wall opposite the inlet openings of
the tubular elements which defines the generally tapered second
portion and the plane generally defined by the inlet openings of
the tubular elements.
13. The heat exchanger of claim 12, wherein the rate of change in
the volume of the generally tapered first portion of the manifold
is one of substantially constant and variable.
14. The heat exchanger of claim 12, wherein the rate of change in
the volume of the generally tapered second portion of the manifold
is one of substantially constant and variable.
15. The heat exchanger of claim 12, wherein the rate of change in
the distance between the inner surface of the wall opposite the
inlet openings of the tubular elements which defines the generally
tapered first portion and the plane generally defined by the inlet
openings of the tubular elements is one of substantially constant
and variable.
16. The heat exchanger of claim 12, wherein the rate of change in
the distance between the inner surface of the wall opposite the
inlet openings of the tubular elements which defines the generally
tapered second portion and the plane generally defined by the inlet
openings of the tubular elements is one of substantially constant
and variable.
17. The heat exchanger of claim 12, wherein the volume of the
generally tapered first portion of the manifold generally decreases
as a distance from the inlet in a general direction of the flow of
the fluid through the manifold increases.
18. The heat exchanger of claim 12, wherein the distance between
the inner surface of the wall opposite the inlet openings of the
tubular elements which defines the generally tapered first portion
of the manifold and the plane generally defined by the inlet
openings of the tubular elements generally decreases as a distance
from the inlet in a general direction of the flow of the fluid
through the manifold increases.
19. The heat exchanger of claim 12, wherein the volume of the
generally tapered second portion of the manifold generally
decreases as a distance from the inlet in a general direction of
the flow of the fluid through the manifold increases.
20. The heat exchanger of claim 12, wherein the distance between
the inner surface of the wall opposite the inlet openings of the
tubular elements which defines the generally tapered second portion
of the manifold and the plane generally defined by the inlet
openings of the tubular elements generally decreases as a distance
from the inlet in a general direction of the flow of the fluid
through the manifold increases.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a heat exchanger
and, more particularly, to a heat exchanger manifold with for
transient start.
BACKGROUND OF THE INVENTION
[0002] Conventional radiators are usually provided with a cooling
portion in which a radiator liquid is cooled, and two manifolds
which are connected to the cooling portion at opposite ends. The
first manifold receives the heated radiator liquid before it is led
into the cooling portion. The second manifold 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 manifolds.
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 manifolds are usually made of injection-molded plastic
material.
[0003] One drawback of such conventional radiators is poor heat
exchange efficiency, especially during cold start-up transients.
During a cold start-up in cold ambient conditions, the cooled
radiator liquid, which remained within the first manifold and the
tubular elements after operation of the radiator, typically has a
temperature of about -20.degree. C. Whereas, the heated radiator
liquid entering the radiator typically has a temperature of about
110.degree. C. The heated radiator liquid is introduced into a
first end of the first manifold through an inlet and a flow
momentum causes the heated radiator liquid to contact a back wall
of the first manifold. The back wall directs the radiator liquid
downward, causing the tubular elements adjacent the inlet to
receive the heated radiator liquid which leads to difficulty in
introduction of the heated radiator liquid into the tubular
elements adjacent a second end of the first manifold, especially
during the cold start up. As the heated radiator fluid flows
through the first manifold, the heated radiator liquid mixes with
the cooled radiator liquid in the second end of the first manifold.
The cooled radiator liquid cools the heated radiator liquid,
increasing a viscosity thereof, and thereby minimizing the flow of
the first fluid through the tubular elements adjacent the second
end of the first manifold. Because the heated radiator liquid is
unable to flow through the tubular elements adjacent the second end
of the first manifold, a temperature imbalance develops between the
tubular elements adjacent the first end of the first manifold and
the tubular elements adjacent the second end of the first manifold.
As a result of the temperature imbalance, severe thermal stresses
may occur which can potentially damage the first manifold, the
tubular elements adjacent the second end of the first manifold,
and/or a joint formed between the first manifold and the tubular
elements.
[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, each of the
tubular elements having an inlet opening and an outlet opening
formed therein; and a manifold coupled to the conditioning
assembly, the manifold including a first end having an inlet formed
therein and a second end opposite the first end, wherein the
manifold is formed by at least one wall, and wherein a generally
tapered portion of the manifold and a fluid drain feature located
in the generally tapered portion of the manifold are configured to
minimize an amount of the fluid remaining in at least one of the
manifold and the tubular elements after operation of the heat
exchanger, and wherein at least one of a volume of the generally
tapered portion of the manifold and a distance between an inner
surface of a wall opposite the inlet openings of the tubular
elements and a plane generally defined by the inlet openings of the
tubular elements generally decreases along the generally tapered
portion of the manifold as a distance from the inlet increases.
[0007] In another embodiment, a heat exchanger, comprises: a
conditioning assembly including a plurality of tubular elements
configured to receive a flow of a fluid therein, each of the
tubular elements having an inlet opening and an outlet opening
formed therein; and a manifold coupled to the conditioning
assembly, the manifold including a first end having an inlet formed
therein and a second end opposite the first end, wherein the
manifold is formed by at least one wall, and wherein a generally
tapered portion of the second end of the manifold is configured to
minimize an amount of the fluid remaining in at least one of the
manifold and the tubular elements after operation of the heat
exchanger, and wherein at least one of a volume of the generally
tapered portion of the second end of the manifold and a distance
between an inner surface of a wall opposite the inlet openings of
the tubular elements and a plane generally defined by the inlet
openings of the tubular elements generally decreases along the
generally tapered portion of the manifold as a distance from the
inlet in a general direction of the flow of the fluid through the
manifold increases, and wherein the manifold further includes a
fluid drain feature extending laterally outwardly from the
generally tapered portion of the second end of the manifold.
[0008] In a further embodiment, a heat exchanger, comprises: a
conditioning assembly including a plurality of tubular elements
configured to receive a flow of a fluid therein, each of the
tubular elements having an inlet opening and an outlet opening
formed therein; and a manifold coupled to the conditioning
assembly, the manifold including a first end having an inlet formed
therein and a second end opposite the first end, wherein the
manifold is formed by at least one wall, and wherein at least one
of a generally tapered first portion of the first end of the
manifold and a generally tapered second portion of the second end
of the manifold is configured to minimize an amount of the fluid
remaining in at least one of the manifold and the tubular elements
after operation of the heat exchanger, and wherein at least one of
a rate of change in a volume of the generally tapered first portion
is less than a rate of change in a volume of the generally tapered
second portion and a rate of change in a distance between an inner
surface of a wall opposite the inlet openings of the tubular
elements which defines the generally tapered first portion and a
plane generally defined by the inlet openings of the tubular
elements is less than a rate of change in a distance between an
inner surface of a wall opposite the inlet openings of the tubular
elements which defines the generally tapered second portion and the
plane generally defined by the inlet openings of the tubular
elements.
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 of the following detailed description of the
invention when considered in the light of the accompanying drawings
in which:
[0010] FIG. 1 is an elevational view of a heat exchanger according
to an embodiment of the present invention including a first
manifold, a second manifold, and conditioning assembly, wherein a
portion of the first manifold is cutaway; and
[0011] FIG. 2 is an elevational view of a heat exchanger according
to another embodiment of the present invention including a first
manifold, a second manifold, and conditioning assembly, wherein a
portion of the first manifold is cutaway.
DETAILED DESCRIPTION OF THE INVENTION
[0012] 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.
[0013] 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 be 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 if desired.
[0014] The heat exchanger 10 includes a first manifold 12, a second
manifold 14, and a conditioning assembly 16 extending between the
first manifold 12 and the second manifold 14. Each of the first
manifold 12 and the second manifold 14 can be formed from any
material and by any process as desired. In certain embodiments, the
first manifold 12 and the second manifold 14 are formed by
injection-molding a plastic material. In other embodiments, the
first manifold 12 may be formed from a material of sufficient
strength so that a wall thickness of the first manifold 12 can be
minimized, thereby enhancing heat transfer between the first fluid
in the first manifold 12 and the second fluid. For example, the
first manifold 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 manifold 12 and the second manifold 14 if
desired.
[0015] An inlet 18 of the first manifold 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 flows through the first
manifold 12 and into the conditioning assembly 16. The conditioning
assembly 16 shown includes a plurality of tubular elements 20
extending between the first manifold 12 and the second manifold 14.
An inlet opening 21 and an outlet opening (not shown) of each of
the tubular elements 20 is fluidly connected to the first manifold
12 and the second manifold 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.
[0016] The second fluid flows through the gaps 22 between the
tubular elements 20 to cool the heated first fluid flowing through
the 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 such as a
fan, 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 manifold
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 manifold 14 to the
fluid-conditioning system via an outlet 26.
[0017] As illustrated, the first manifold 12 has a generally
rectangular shape and includes a first end 46 and a second end 48.
It is understood, however, that the first manifold 12 can have any
shape and size as desired. In certain embodiments, the first
manifold 12 includes a pair of opposing end walls 50, 52, a pair of
opposing side walls 54, 56, and a back wall 58 opposite the inlet
openings 21 of the tubular elements 20. The walls 50, 52, 54, 56,
58 define an opening configured to receive a portion of the
conditioning assembly 16 and a chamber 59 configured to receive the
first fluid therein.
[0018] As illustrated, a generally tapered portion 60 of the first
manifold 12 is configured to distribute at least a portion of the
first fluid into the tubular elements 20 adjacent the second end 48
of the first manifold 12. The generally tapered portion 60 is also
configured to increase a velocity of the flow of the first fluid
into the tubular elements 20 adjacent the second end 48 of the
first manifold 12. As a non-limiting example, the generally tapered
portion 60 is configured to distribute and increase the velocity of
at least a portion of the first fluid flowing into the last ten
(10) tubular elements 20 in respect of a general direction of flow
of the first fluid through the first manifold 12. The configuration
of the generally tapered portion 60 of the first manifold 12
advantageously minimizes an amount of the first fluid remaining
within the first manifold 12 and the tubular elements 20 after
operation of the heat exchanger 10. Thus, the configuration of the
generally tapered portion 60 militates against an accumulation of
cooled first fluid within the first manifold 12 and the tubular
elements 20, and thereby ensures that the heated first fluid is
able to flow through the second end 48 of the first manifold 12 and
the tubular elements 20 adjacent thereof. As such, a difference in
temperature between the tubular elements 20 adjacent the first end
46 of the first manifold 12 and the tubular elements 20 adjacent
the second end 48 of the first manifold 12 is minimized. As a
result, a potential for severe thermal stresses which may cause
damage to the heat exchanger 10 is minimized.
[0019] In certain embodiments, a volume of the generally tapered
portion 60 of the first manifold 12 generally decreases in respect
of the general direction of flow of the first fluid through the
first manifold 12. Accordingly, the volume of the generally tapered
portion 60 adjacent the first end 46 is greater than the volume of
the generally tapered portion 60 adjacent the second end 48
thereof. It is understood that a rate of change of the volume of
the generally tapered portion 60 of the first manifold 12 can be
variable or substantially constant as shown.
[0020] In other embodiments, a distance between an inner surface 62
of the back wall 58 which at least partially forms the generally
tapered portion 60 of the first manifold 12 and a plane A generally
defined by the inlet openings 21 of the tubular elements 20
generally decreases along the generally tapered portion 60 as a
distance from the inlet 18 in the general direction of flow of the
first fluid in the first manifold 12 increases. Accordingly, the
distance between the inner surface 62 of the back wall 58 of the
generally tapered portion 60 adjacent the first end 46 thereof and
the plane A generally defined by the inlet openings 21 of the
tubular elements 20 is greater than the distance between the inner
surface 62 of the back wall 58 of the generally tapered portion 60
of the first manifold 12 adjacent the second end 48 thereof and the
plane A generally defined by the inlet openings 21 of the tubular
elements 20. It is understood that a rate of change in the distance
between the inner surface 62 of the back wall 58 and the plane A
generally defined by the inlet openings 21 of the tubular elements
20 can be variable or substantially constant as shown in FIG.
1.
[0021] A fluid drain feature 70 may be formed in the generally
tapered portion 60 of the first manifold 12. As illustrated, the
fluid drain feature 70 is integrally formed with the generally
tapered portion 60 of the first manifold 12. However, those skilled
in the art will appreciate that the fluid drain feature 70 can be
separately formed from the first manifold 12 if desired. It is also
understood that the fluid drain feature 70 can be formed elsewhere
in the heat exchanger 10 if desired. The fluid drain feature 70 can
be formed with the generally tapered portion 60 of the first
manifold 12 by any suitable forming process such as an
injection-molding forming process, for example. In certain
embodiments, the fluid drain feature 70 is a portion 71 of the back
wall 58 extending laterally outwardly from the generally tapered
portion 60 of the fluid manifold 12. The portion 71 of the back
wall 58 shown is contoured to define a cavity 72. An aperture 74 is
formed in the back wall 58 to permit the first fluid to flow,
either directly or through an external component (i.e. fitting) or
system, from the cavity 72 to a collection tank (not shown). In
certain embodiments, the portion 71 of the back wall 58 at least
partially surrounds the aperture 74. As illustrated, a hydraulic
diameter of the cavity 72 is substantially the same as a hydraulic
diameter of the aperture 74, thereby minimizing a volume of the
cavity 72. The fluid drain feature 70 is configured to minimize the
volume of the cavity 72 in order to minimize an amount of the first
fluid remaining in the cavity 72 after operation of the heat
exchanger 10. As discussed hereinabove, minimizing the amount of
first fluid remaining in the first manifold 12 advantageously
militates against an accumulation of cooled first fluid within the
first manifold 12 and the tubular elements 20, and thereby ensures
that the heated first fluid is able to flow through the second end
48 of the first manifold 12 and the tubular elements 20 adjacent
thereto. As a result, the potential for severe thermal stresses
which may cause damage to the first manifold 12, the tubular
elements 20 adjacent the second end 48 of the first manifold 12,
and/or a joint formed between the first manifold 12 and the tubular
elements 20 is further minimized.
[0022] During operation of the heat exchanger 10, a heated first
fluid from the fluid-conditioning system is received into the
chamber 59 of the first manifold 12 through the inlet 18. As the
first fluid flows from the first end 46 of the first manifold 12
through the chamber 59 and into the second end 48 of the first
manifold 12, the generally tapered portion 60 of the first manifold
12 directs and increases the velocity of the flow of the first
fluid into the tubular elements 20 adjacent thereto. The generally
tapered portion 60 of the first manifold 12 ensures that at least a
portion of the heated first fluid flows into the inlet openings 21
of the tubular elements 20 adjacent the second end 48 of the first
manifold 12. Once the first fluid flows into the tubular elements
20 of the conditioning assembly 16, the first fluid undergoes a
main conditioning by the second fluid flowing through the
conditioning assembly 16. The conditioned first fluid then flows
from the conditioning assembly 16 through the outlet openings
thereof into the second manifold 14. The conditioned first fluid is
then discharged from the heat exchanger 10 through the outlet 26
into the fluid-conditioning system.
[0023] FIG. 2 depicts a heat exchanger 100 according to another
embodiment of the present invention. The heat exchanger 100 shown
is a radiator to be used in a vehicle (not shown). The heat
exchanger 100 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 be used to cool an engine (not shown) which powers the
vehicle. Those skilled in the art will appreciate that the heat
exchanger 100 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 if desired.
[0024] The heat exchanger 100 includes a first manifold 112, a
second manifold 114, and a conditioning assembly 116 extending
between the first manifold 112 and the second manifold 114. Each of
the first manifold 112 and the second manifold 114 can be formed
from any material and by any process as desired. In certain
embodiments, the first manifold 112 and the second manifold 114 are
formed by injection-molding a plastic material. In other
embodiments, the first manifold 112 may be formed from a material
of sufficient strength so that a wall thickness of the first
manifold 112 can be minimized, thereby enhancing heat transfer
between the first fluid in the first manifold 112 and the second
fluid. For example, the first manifold 112 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 manifold 112 and the
second manifold 114 if desired.
[0025] An inlet 118 of the first manifold 112 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 flows through the first
manifold 112 and into the conditioning assembly 116. The
conditioning assembly 116 shown includes a plurality of tubular
elements 120 extending between the first manifold 112 and the
second manifold 114. An inlet opening 121 and an outlet opening
(not shown) of each of the tubular elements 120 is fluidly
connected to the first manifold 112 and the second manifold 114,
respectively. The tubular elements 120 are arranged in parallel and
spaced apart at substantially equal distances so that substantially
constant gaps 122 are formed between adjacent tubular elements
120.
[0026] The second fluid flows through the gaps 122 between the
tubular elements 120 to cool the heated first fluid flowing through
the tubular elements 120. The flow of the second fluid through the
conditioning assembly 116 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 116 of the heat exchanger 110
such as a fan, for example. In certain embodiments, the gaps 122
may be provided with at least one heat transfer element 124.
Various heat transfer elements 124 can be employed such as thin
folded metal elements or fins, for example. The heat transfer
elements 124 are arranged to abut the tubular elements 120, thereby
increasing a contact surface of the tubular elements 120 with the
second fluid to maximize a heat transfer from the first fluid to
the second fluid. Each of the tubular elements 120 and the heat
transfer elements 124 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 manifold 114 receives the cooled first fluid from the
respective tubular elements 120 of the conditioning assembly 116,
after which the cooled first fluid is discharged from the second
manifold 114 to the fluid-conditioning system via an outlet
126.
[0027] As illustrated, the first manifold 112 has a generally
rectangular shape and includes a first end 146 and a second end
148. It is understood, however, that the first manifold 112 can
have any shape and size as desired. In certain embodiments, the
first manifold 112 includes a pair of opposing end walls 150, 152,
a pair of opposing side walls 154, 156, and a back wall 158
opposite the inlet openings 121 of the tubular elements 120. The
walls 150, 152, 154, 156, 158 define an opening configured to
receive a portion of the conditioning assembly 116 and a chamber
157 configured to receive the first fluid therein.
[0028] As illustrated, the first manifold 112 includes a generally
tapered first portion 159 and a generally tapered second portion
160. The generally tapered first portion 159 of the first manifold
112 is configured to distribute at least a portion of the first
fluid into the tubular elements 120 adjacent the first end 146 of
the first manifold 112. The generally tapered second portion 160 of
the first manifold 112 is configured to distribute at least a
portion of the first fluid into the tubular elements 120 adjacent
the second end 148 of the first manifold 112. Each of the generally
tapered portions 159, 160 is also configured to increase a velocity
of the flow of the first fluid into the tubular elements 120 of the
first manifold 112. As a non-limiting example, the generally
tapered second portion 160 is configured to distribute and increase
the velocity of at least a portion of the first fluid flowing into
the last ten (10) tubular elements 120 in respect of a general
direction of flow of the first fluid through the first manifold
112. The configuration of the generally tapered second portion 160
of the first manifold 112 advantageously minimizes an amount of the
first fluid remaining within the first manifold 112 and the tubular
elements 120 after operation of the heat exchanger 100. Thus, the
configuration of the generally tapered second portion 160 militates
against an accumulation of cooled first fluid within the first
manifold 112 and the tubular elements 120, and thereby ensures that
the heated first fluid is able to flow through the second end 148
of the first manifold 112 and the tubular elements 120 adjacent
thereof. As such, a difference in temperature between the tubular
elements 120 adjacent the first end 146 of the first manifold 112
and the tubular elements 120 adjacent the second end 148 of the
first manifold 112 is minimized. As a result, a potential for
severe thermal stresses which may cause damage to the heat
exchanger 100 is minimized.
[0029] In certain embodiments, a volume of the generally tapered
first portion 159 of the first manifold 112 generally decreases in
respect of the general direction of flow of the first fluid through
the first manifold 112. It is understood that a rate of change of
the volume of the generally tapered first portion 159 of the first
manifold 112 can be variable or substantially constant as shown.
Similarly, a volume of the generally tapered second portion 160 of
the first manifold 112 generally decreases in respect of the
general direction of flow of the first fluid through the first
manifold 112. It is understood that a rate of change of the volume
of the generally tapered second portion 160 of the first manifold
112 can be variable or substantially constant as shown. As shown,
the rate of change of the volume of the generally tapered first
portion 159 is less than the rate of change of the volume of the
generally tapered second portion 160.
[0030] In other embodiments, a distance between an inner surface
162 of the back wall 158 which at least partially forms the
generally tapered first portion 159 of the first manifold 112 and a
plane B generally defined by the inlet openings 121 of the tubular
elements 120 generally decreases along the generally tapered first
portion 159 as a distance from the inlet 118 in the general
direction of flow of the first fluid in the first manifold 12
increases. It is understood that a rate of change in the distance
between the inner surface 162 of the back wall 158 and the plane B
generally defined by the inlet openings 121 of the tubular elements
120 can be variable or substantially constant as shown. Similarly,
a distance between the inner surface 162 of the back wall 158 which
at least partially forms the generally tapered second portion 160
of the first manifold 112 and the plane B generally defined by the
inlet openings 121 of the tubular elements 120 generally decreases
along the generally tapered second portion 160 as the distance from
the inlet 118 in the general direction of flow of the first fluid
in the first manifold 112 increases. It is understood that a rate
of change in the distance between the inner surface 162 of the back
wall 158 and the plane B generally defined by the inlet openings
121 of the tubular elements 120 can be variable or substantially
constant as shown. The rate of change in the distance between the
inner surface 162 of the back wall 158 of the generally tapered
first portion 159 and the plane B is less than the rate of change
in the distance between the inner surface 162 of the back wall 158
of the generally tapered second portion 160 and the plane B.
[0031] A fluid drain feature 170 may be formed in the generally
tapered second portion 160 of the first manifold 112. As
illustrated, the fluid drain feature 170 is integrally formed with
the generally tapered second portion 160 of the first manifold 112.
However, those skilled in the art will appreciate that the fluid
drain feature 170 can be separately formed from the first manifold
112 if desired. It is also understood that the fluid drain feature
170 can be formed elsewhere in the heat exchanger 100 if desired.
The fluid drain feature 170 can be formed with the generally
tapered second portion 160 of the first manifold 112 by any
suitable forming process such as an injection-molding forming
process, for example. In certain embodiments, the fluid drain
feature 170 is a portion 171 of the back wall 158 extending
laterally outwardly from the generally tapered second portion 160
of the fluid manifold 112. The portion 171 of the back wall 158
shown is contoured to define a cavity 172. An aperture 174 is
formed in the back wall 158 to permit the first fluid to flow,
either directly or through an external component (i.e. fitting) or
system, from the cavity 172 to a collection tank (not shown). In
certain embodiments, the portion 171 of the back wall 158 at least
partially surrounds the aperture 174. As illustrated, a hydraulic
diameter of the cavity 172 is substantially the same as a hydraulic
diameter of the aperture 174, thereby minimizing a volume of the
cavity 172. The fluid drain feature 170 is configured to minimize
the volume of the cavity 172 in order to minimize an amount of the
first fluid remaining in the cavity 172 after operation of the heat
exchanger 100. As discussed hereinabove, minimizing the amount of
first fluid remaining in the first manifold 112 advantageously
militates against an accumulation of cooled first fluid within the
first manifold 112 and the tubular elements 120, and thereby
ensures that the heated first fluid is able to flow through the
second end 148 of the first manifold 112 and the tubular elements
120 adjacent thereto. As a result, the potential for severe thermal
stresses which may cause damage to the first manifold 112, the
tubular elements 120 adjacent the second end 148 of the first
manifold 112, and/or a joint formed between the first manifold 112
and the tubular elements 120 is further minimized.
[0032] During operation of the heat exchanger 100, a heated first
fluid from the fluid-conditioning system is received into the
chamber 157 of the first manifold 112 through the inlet 118. As the
first fluid flows from the first end 146 of the first manifold 112
through the chamber 157 and into the second end 148 of the first
manifold 112, the generally tapered first portion 159 and the
generally tapered second portion 160 of the first manifold 112
direct and increase the velocity of the flow of the first fluid
into the tubular elements 120 adjacent thereto. More particularly,
the generally tapered second portion 160 of the first manifold 112
ensures that at least a portion of the heated first fluid flows
into the inlet openings 121 of the tubular elements 120 adjacent
the second end 148 of the first manifold 112. Once the first fluid
flows into the tubular elements 120 of the conditioning assembly
116, the first fluid undergoes a main conditioning by the second
fluid flowing through the conditioning assembly 116. The
conditioned first fluid then flows from the conditioning assembly
116 through the outlet openings thereof into the second manifold
114. The conditioned first fluid is then discharged from the heat
exchanger 100 through the outlet 126 into the fluid-conditioning
system.
[0033] 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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