FRAMELESS COOLING MODULE

Abstract

A heat exchanger adapted to be coupled with a platform is disclosed. The heat exchanger comprises two or more core units having an upper surface and a lower surface, the lower surface of each core unit being fixed to the platform. The heat exchanger further includes a plate disposed along the upper surface of the core units, the plate having a plurality of bend enhancement regions and a plurality of holes, each bend enhancement region being placed at a predetermined distance from the nearest adjacent holes, and a plurality of spacers interposed between the plate and the upper surface to couple the plate to the upper surface, the plurality of spacers adapted to provide offset between the plate from the core units. During operation of the heat exchanger, each bend enhancement region is configured to facilitate flexibility of the plate to accommodate any uneven expansion of the core units.

Description

TECHNICAL FIELD

The present disclosure relates to heat exchangers and more specifically, to an assembly of heat exchangers.

BACKGROUND

Heat exchangers are utilized across various machines for exchanging heat. The heat exchangers include multiple tubes having an outlet port, and an inlet port. The heat exchangers include fins on the outer surface of the tubes. As fluid flows through the tubes, the heat is dissipated away into ambient air with the help of fins.

Due to prolonged heat dissipation, cores of the heat exchangers exhibit thermal expansion/contraction in all directions. Currently, the heat exchangers are mounted within a rigid framed structure. The framed structure utilizes various types of isolators that are able to compress to account for the thermal expansion/contraction of the cores. However, the framed structure is expensive due to cost of frames and the isolators. Moreover, frameless designs are also known for mounting the cores of the heat exchangers. The frameless designs are cheaper, but uneven rates of expansion of the cores reduces overall thermal life. Further, there are also challenges in controlling uneven expansion of the cores. Therefore, there is a need for packaging or assembly of such frameless heat exchangers to accommodate the uneven expansion of the cores.

U.S. Pat. No. 6,523,603 (hereinafter referred to as '603) discloses a double heat exchanger. The double heat exchanger includes a multi-core radiator which consists of a condenser and a radiator for heat dissipation. Further, a connecting member is provided with a slit and a wavy shaped flexible member, As the condenser and the radiator begin to heat, expansion and contraction of the flexible member allows the thermal expansion within the frame, However, '603 reference fails to provide a cheaper and easily fabricable solution for controlling uneven expansion of the core units. Therefore, there is a need for a cost effective plate to accommodate uneven expansion of the core units of the heat exchangers.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a heat exchanger adapted to be coupled with a platform is disclosed. The heat exchanger comprises two or more core units having an upper surface and a lower surface, the lower surface of each core unit being fixed to the platform. The heat exchanger further includes a plate disposed along the upper surface of the core units, the plate having a plurality of bend enhancement regions and a plurality of holes, each bend enhancement region being placed at a predetermined distance from the nearest adjacent holes, and a plurality of spacers interposed between the plate and the upper surface to couple the plate to the upper surface, the plurality of spacers adapted to provide offset between the plate from the core units. During operation of the heat exchanger, each bend enhancement region is configured to facilitate flexibility of the plate to accommodate any uneven expansion of the two or more core units.

Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a heat exchanger having east two core units and a plate mounted on an upper surface of the at least two core units, in accordance with the concepts of the present disclosure;

FIG. 2 is a perspective view of the plate of FIG. 1, in accordance with the concepts of the present disclosure;

FIG. 3 is a top view of the plate of FIG. 1, in accordance with the concepts of the present disclosure;

FIG. 4 is a front view of the heat exchanger of FIG. 1 with the plate mounted on the upper surface of the core units in a first configuration, in accordance with the concepts of the present disclosure; and

FIG. 5 is a front view of the heat exchanger of FIG. 1 with the plate mounted on the upper surface of the core units in a second configuration, in accordance with the concepts of the present disclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, a heat exchanger 10 is shown without specific reference to one or more outlet ports and one or more inlet ports for coolant, and a plurality of fins coupled to outer surface of a plurality of tubes. The heat exchanger 10 can include one or more cores 28, 30 and/or 32 forming a core assembly 20, and a plate 12 disposed along an upper surface 22 of the core assembly 20 and a platform 26 disposed along a lower surface 24 of the core assembly 20. In some embodiments, the plate 12 may be disposed along the lower surface 24 and the platform 26 may be disposed along the upper surface 22. The plate 12 may be disposed offset at a distance from the upper surface 22 to define a spacing therebetween. To facilitate maintaining the spacing or offset distance, a plurality of spacers 16 (also can be called bosses) can be interposed between a second surface 38 of the plate 12 and the upper surface 22. A plurality of fasteners 14 can be used to couple the plate 12 to the core assembly 20. As shown in FIG. 1, the fasteners 14 can be integrated with the locations of the spacers 16, so that the fastener 14 is extended through a hole formed into the plate 12, is extended through a corresponding spacer 16, and terminated into the core assembly 20. The plate 12 may also include a plurality of bend enhancement regions 18, as will be discussed.

The terms “core” and “core unit” have similar meaning and interpretations and may be interchangeably used with the description without departing from the meaning and scope of the disclosure. The core assembly 20 may include one or more cores, such, for example, shown: a first core 28 (also called a first core unit), a second core 30 (also called a second core unit) and a third core 32 (also called a third core unit). In an embodiment, the core assembly 20 may include oil cooling core, turbo compressed air core, engine coolant core, among others and other components, such as inlets, outlets, fins (not shown in FIG. 1). It will be apparent to one skilled in the art that the heat exchanger 10 may have any other configuration or have more number of cores without departing from the meaning and scope of the disclosure.

The lower surface 24 of the core assembly 20 can be coupled to the platform 26. In one example, the platform 26 is fixedly secured to the lower surface 24 of the core assembly 20 or lower surface 24 of each of the cores 28, 30 or 32. The platform 26 is utilized for mounting onto a machine, a vehicle frame or any other implement which requires the heat exchanger 10. The spacers 16 are provided for preventing interference between the plate 12 and the core assembly 20. During thermal expansion, the spacers 16 are adapted to provide offset between the core assembly 20 and the plate 12. It will be apparent to one skilled in the art that the spacers 16 may be of different shapes, configuration and material, but not limited to steel, stainless steel, iron, copper, among others. The spacers 16 may be separate components or may be a part of the core assembly 20 without departing from the meaning and scope of the disclosure. The spacers 16 are inboard on the first core 28, the second core 30, and the third core 32 to reduce the overall stiffness of the plate 12. As a result, thermal stress is reduced as the first core 28, the second core 30, the third core 32 expand or contract. For the purpose of simplicity various other components of the heat exchanger 10 are not labeled in FIG. 1.

Referring to FIG. 2, the plate 12 can have a plurality of holes 34 formed therein. The plate 12 includes a first surface 36, the second surface 38, a first edge 40, a second edge 42, a third edge 44 and a fourth edge 46. The plate 12 may have a predetermined width W defined as the distance between the first and second edges 40, 42, a predetermined thickness T defined as the distance between the first and the second surfaces 36, 38, and a predetermined length L defined as the distance between the third and fourth edges 44, 46. It will be apparent to one skilled in the art that the predetermined width W, the predetermined thickness T, and the predetermined length L are defined as per the design requirements and may also he varied without departing from the meaning and scope of the disclosure.

Referring to FIG. 2, the bend enhancement regions 18 are positioned at a predetermined distance ‘D’ from holes 34 that are the nearest adjacent thereto, generally each along a line X-X′. It will be apparent to one skilled in the art that the predetermined distance D is defined as per the design requirements (shown in FIG. 1) and may also be varied without departing from the meaning and scope of the disclosure. The plate 12 is constructed from materials that include, but is not limit to, steel, stainless steel, copper, among others. The bend enhancement regions 18 is defined as a region within the plate 12 at which a portion of material is removed or added to facilitate relative movement or flexing along the line X-X′ along with the region is formed at a predetermined location. This predetermined location for flexing of the plate 12 is generally located to overlap the outer boundary of the core unit, i.e. the first core 28, the second core 30 and/or the third core 32. In some examples, the predetermined location can he positioned along the lateral space or boundary between adjacent core units so as not to overlap the outer boundary of the core unit, i.e. the first core 28, the second core 30 and/or the third core 32. The bend enhancement region 18 facilitates in modifying the surface area of the plate 12 and adding flexibility around the line X-X′, that typically extends between the first and second edges 40, 42 or along the third and fourth edges 44, 46. In an embodiment, the bend enhancement region 18 has a predetermined shape in form of a series of scallops or ovalic shapes removed from the plate, in other examples, this region can be perforated or material removed having rounded, rectangular or other shapes. It will he apparent to one skilled in the art that the bend enhancement regions 18 may have any other suitable shape, depth variation, and patterns around the plate 12 that allows flexibility to the plate 12 without departing from the meaning and scope of the disclosure. The holes 34 are adapted to receive the fasteners 14 (as shown in FIG. 1) for attaching the plate 12 to the core assembly 20 (as shown in FIG. 1). It will be apparent to one skilled in the art that the fasteners 14 may be other kind of fasteners, such as bolts, screws, among others without departing from the meaning and scope of the disclosure. Also the fasteners 14 may be constructed of materials includes, but not limited to, steel, stainless steel, iron, copper, among others.

Referring to FIG. 3, the plate 12 is mounted on the first core 28, the second core 30, and the third core 32 via the fasteners 14. The plate 12 is mounted on the upper surface 22 (as shown in FIG. 1) of the first core 28, the second core 30 and the third core 32.

Referring to FIG. 4, the plate 12 is mounted on the first core 28, the second core 30 and the third core 32 a first configuration. In the first configuration, the first core 28, and the third core 32 are in a cold state, while the second core 30 is in a hot state. During operations, prolonged thermal exposure causes the second core 30 to expand. During expansion of the second core 30, the plate 12 bends or flexes around the line X-X′ of the bend enhancement regions 18. The bend enhancement regions 18 (not shown in FIG. 4) are at the predetermined distance D from the spacers 16 or the fasteners 14.

Referring to FIG. 5, the plate 12 is mounted on the first core 28, the second core 30 and the third core 32 in a second configuration. In the second configuration, the first core 28, and the third core 32 are in a hot state, while the second core 30 is in a cold state. During operations, prolonged thermal exposure causes the first core 28 and the third core 32 to expand. During expansion of the first core 28 and the third core 32, the plate 12 bends around the line X-X′ of the bend enhancement regions 18. The bend enhancement regions 18 (not shown in FIG. 5) are at the predetermined distance D from the number of spacers 16 or the fasteners 14.

INDUSTRIAL APPLICABILITY

Currently, there are challenges for controlling uneven thermal expansion of the core assembly 20 of the heat exchanger 10 having various cores for oil cooling, turbo compressed air cooling, engine coolant core, among others and other components for an engine. During operation of the heat exchanger 10, the plate 12 having the bend enhancement regions 18 that offer flexibility to the plate 12 to accommodate any uneven expansion of the first core 28, the second core 30 and the third core 32. The plate 12 is made from a sheet metal that is manufactured easily and mounted within any frameless configuration without requiring a complete dismantling of the core assembly 20. As a result, the maintenance cost and machine down time is reduced. The plate 12 is light weight, and easily fabricable.

Referring to FIGS. 4 and 5, in an exemplary embodiment, if the first core 28 and the third core 32 are expanded more with respect to the second core 30, then the plate 12 flexes as per the expansion rates of the first core 28 and the third core 32, The flexibility is obtained by bending the plates at the line X-X′. During expansion or contraction, the bend enhancement regions 18 are subjected to a tensile load along the first edge 40, which causes a deformation in the shape of the bend enhancement regions 18 while providing the bend along the line X-X′ in the plate 12.

While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.

Claims

1. A heat exchanger adapted to be coupled with a platform, the heat exchanger comprising:

two or more core units having an upper surface and a lower surface, the lower surface of each core unit being fixed to the platform;

a plate disposed along the upper surface of the core units, the plate having a plurality of bend enhancement regions and a plurality of holes, each bend enhancement region being placed at a predetermined distance from the nearest adjacent holes; and

a plurality of spacers interposed between the plate and the upper surface to couple the plate to the upper surface, the plurality of spacers adapted to provide offset between the plate from the core units;

wherein, during operation of the heat exchanger, each bend enhancement region is configured to facilitate flexibility of the plate to accommodate any uneven expansion of the two or more core units.