Two-fold combo-cooler

Abstract

A two-fold combo cooler comprising non gas cooler and gas cooler portions, is provided, particularly for use in an assembly. An assembly having a gas combo-cooler has been found especially useful in automotive applications.

Description

This patent application claims priority of Provisional Application No. 60/777,598 filed on Feb. 28, 2006

FIELD OF THE INVENTION

Heat exchangers, having tubes, manifolds, and fins, and particularly useful in automotive applications, are described.

BACKGROUND OF THE INVENTION

A combo-cooler is a cooler with one or more heat exchangers (multi-exchangers) sharing the same frontal area. For example, a combo-cooler can comprise a condenser and an oil-cooler portion, the oil cooler and condenser portion connected with a common pair of manifolds, and tubes connected with fins. The combo-cooler can be considered as an entire module or assembly, the main portions of the module, including tubes, fins and manifolds, can be assemble at the same time, providing saving in assembling cost (for example, heater core assembly, brazing), as well as material cost (for example, only one pair of manifold, only one pair of brackets).

Various types of heat exchangers are found for automotive applications.

A condenser often uses a special type of refrigerant for the cooling. More specifically, a refrigerant such as R-134a, is a widely accepted industrial standard. Compared to its predecessor (R-12) or FREON, it significantly reduced side effect to the environment. Because of this improvement, R-134a has gradually replaced R-12 to become the standard for air-conditioning refrigerant for auto industry.

Recently, other refrigerants, and, in particular, refrigerants such as gases, are emerging as potential replacements for refrigerants such as R-134a. Among these gases are, for example, CO₂ and HFC32. CO₂ is a highly potential replacement refrigerants for those such as R-134a, since compared to R-134a, its contribution to the global warming is only 1/1300 that of R-134a (on the per unit basis). Therefore, in some parts of world, there will probably be specific need for gas-coolers, such as those using refrigerants such as CO₂, in the near future. Combo coolers with gas-coolers, (gas combo-coolers) therefore, appear new in many applications.

SUMMARY OF THE INVENTION

Heat exchangers of the present invention will typically include one or more tubes, one or more end tanks, one or more inlets and outlets, one or more baffles, one or more fins or a combination thereof. Depending upon the embodiment of the heat exchanger, various different shapes and configurations are contemplated for the components of the heat exchanger. For example, and without limitation, the components may be integral with each other or they may be separate. The shapes and sizes of the components may be varied as needed or desired for various embodiments of the heat exchanger. Additional variations will become apparent upon reading of the following description.

Heat exchanger assemblies (in automotive applications often referred to a engine cooling assemblies or modular assemblies) comprising a heat exchanger with at least two manifolds and a plurality of tubes connecting the at least two manifolds, have applicability in automotive applications. In particular, heat exchanger assemblies often have a plurality of tubes linking the manifolds in such a way that fluid communication is established between at least one of the tubes and the at least two manifolds, and at least one fin, and, preferably, a plurality of fins, is present between the at least one tube in fluid communication with the at least two manifolds and at least one other tube.

It has been found that it is also possible to have heat exchanger assemblies comprising a heat exchanger module having tubes, manifolds and fins, as described above, with other elements that allow functioning of the heat exchanger assembly under conditions heretofore not found in the automotive environment. For example, use of gas-coolers, such as C0₂ coolers, operate at what can be considered high temperature and/or high pressure conditions (high temperature/pressure heat exchanger). These conditions are normally not experienced in a traditional automotive environment.

Various aspects of the present invention provide for a heat exchanger assembly for automobile vehicles having a ‘two-rows front to back of tube’ combo-cooler, where tubes of one combo cooler and tubes of another combo cooler are all in two rows or ‘two fold’, generally parallel, and separated by fins. In various aspects, tubes of each cooler portion are connected to and in fluid communication with manifolds at both tube ends, and same manifolds connect with tubes of each combo-cooler. At least at one end of tube, the manifold is two-fold, the manifold having two pieces or being ‘dual’ and generally described as having a front manifold and back manifold portion. Each of the manifolds of each separate combo cooler is connected by single row tubes. Each left manifold and right manifold, has, for example, in various aspects of the present invention, a connection between the dual back and front manifold portions, i.e. the front and back portions are in fluid communication.

Aspects of the present invention comprise an air-conditioning loop using CO₂ as a refrigerant, but due to CO₂'s nature, several components need to be quite different from those in A/C loop using, for example, R-134a. In systems wherein heat exchanger modules are used, for example, for engine cooling, an assembly also comprising a gas cooler having a gas-cooler portion and a non gas heat exchanger (non gas-cooler portion), an aspect of the present invention involves a a gas combo-cooler, for example. A gas-cooler portion of an aspect of the present invention, particularly wherein a gas combo-cooler is provided having a gas combo-cooler, has a function that a condenser might play in a non gas combo-cooler. The gas-cooler portion rejects heat gathered from inside the vehicle into external air. A strict replacement of condenser for gas cooler portion, however, is generally not possible. For example, gases such as CO₂ have specific features. One feature is the extreme high operating pressure inside a gas-cooler of about 100 bars, compared to 16-20 bars inside a condenser.

In various aspects, for example, when a combo cooler condenser portion is replaced by a gas-cooler portion to form a gas combo-cooler, condensation does not exist as in a condenser, inside the CO₂ gas-cooler, and the CO₂ temperature inside the gas-cooler is no longer a constant. The temperature difference between the CO₂ gas and air reduces at faster pace than that for a condenser. In a use such as a gas combo-cooler, as in one aspect of the present invention, both gas-cooler portion and other cooler portion (non gas-cooler, such as oil cooler, for example), need to be more optimized since the general design found in combo-coolers has generally used the same front area, and a radiator where present, and therefore, each cooler portion of the combo will have a very limited front area, which results in further requirements in thermal efficiency. The present invention overcomes such deficiencies.

Gas-coolers have characteristics and, in the case of two row or ‘two-fold’ gas-coolers, designs that are different from a normally one row (‘one fold’) condenser or one row (‘one fold’) radiator or a combination of two one fold heat exchangers connected with a common pair of manifolds (a non-gas combo-cooler). By gas combo-cooler, it is meant a design wherein a gas cooler, of two fold design, also comprises heat exchanger portions that form part of a non-gas combo cooler, the non gas combo-cooler portions being each of a one fold or two fold design.

The present invention, in various aspects, allows for high temperature and/or pressure heat exchanger, such as a gas-cooler, to be integrated into a combo-cooler, using, for example, a two-row (‘two-fold’) tube and core gas-cooler, to create an assembly comprising two-combo coolers. By providing for a higher thermal efficiency design, both gas-cooler and oil cooler, for example, can be found in a heat exchanger assembly comprising a combo-cooler in a gas combo-cooler. In various aspects of the present invention, a range of hydraulic diameter 0.2 mm-2 mm is provided; thereby enhancing and/or optimizing the tube/fin surface relationship in a heat exchanger having a two-fold combo-cooler.

A heat exchanger assembly, in accordance with an aspect of the present invention, can be made up of heat exchangers, which in the assembly are termed as heat exchanger portions, as they are part of the combo cooler module. A non gas-cooler portion and a gas-cooler portion are required as part of each combo-cooler module. As examples, a non gas-cooler portion can include, for example, oil coolers such as transmission oil and power steering oil coolers, radiators, charge air coolers, condensers, fuel coolers, and other such heat exchangers.

In one embodiment of the present invention, each portion of manifold (front/rear) has at least one chamber or ‘space’ formed by baffles which separate the manifold into portions depending on the type of fluid that is designed to flow therethrough. Each space and has at least one leak-detection hole towards external side.

Aspects of the present invention provide for a two-fold gas-cooler as part of a heat exchanger assembly that also includes a non gas-cooler heat exchanger, such as an oil cooler or combo-cooler, that is also of two-fold tube design.

The present invention, in various aspects, provides for a high temperature and/or pressure heat exchanger that can operate with the manifolds, tubes and fins of heat exchanger portions such as those found in combo-coolers that are non gas combo-coolers. A manifold provides for an overall grouping of the heat exchanger components, and, as such, are placed at the end of the core of the heat exchanger, where fluid that circulates in the tubes can access the manifold. The manifold can be a single manifold (for example, a manifold that encompasses or contains tubes from gas-cooler portions from both the front and the back of a gas combo-cooler), or a two piece or dual manifold, wherein each portion of a gas-cooler, both front and back, is respectively part of a separate piece or manifold that encompasses or contains only the tubes that are at the front or back of the gas-cooler portion of the gas combo-cooler respectively. In various aspects of the present invention, high temperature and/or pressure heat exchangers which avoid inter-cooler internal leaks or leakage often present in heat exchangers under high temperature/pressure by having a detection and/or pressure release means (‘detection means’) such as a detection holes, on the manifolds is provided.

In various embodiments of the present invention, at least one tube of at least one cooler has sub-passageways, and the product of hydraulic diameter of the tubes of at least one tube of each of the coolers of the gas combo cooler falls within the following range: 0.15 mm2<Dg Do<8.0 mm2.

In various aspects of the present invention, a gas combo-cooler assembly is described comprising two combo-cooler modules for high pressure applications. At least one portion of the module comprises a heat exchanger that operates under high temperature and/or high pressure conditions (‘high pressure heat exchanger’). In aspects of the present invention, a heat exchanger assembly for automotive vehicles comprising a gas combo-cooler having two combo cooler modules is described, each combo cooler module having: a gas cooler portion; a non gas cooler portion; a first manifold; a second manifold opposite the first manifold; a plurality of first tubes in fluid communication with the first and second manifolds, the plurality of first tubes adapted to have a first fluid flow therethrough; a plurality of second tubes in fluid communication with the first and second manifolds, the plurality of second tubes adapted to have a second fluid, different from the first fluid, flow therethrough; a plurality of fins disposed between the first and second tubes, with the first and second tubes and fins being generally co-planar relative to each other.

In various aspects of the present invention, at least one manifold of each combo cooler module has a fluid connection means between each other. In various aspects, a fluid connection means between front and back manifold or manifold parts in a gas combo cooler heat exchanger, wherein a fluid connection means is between the at least one manifold of the first combo cooler module and the at least one manifold of the second combo cooler module.

The fluid connection means can be channel, orifice, or tube, or any other connection device whereby fluid can flow from one manifold to another manifold, or in the cases of multi piece manifolds, from one piece or part to another piece or part of the multi piece manifold. For convenience, each combo cooler portion or module shall be described as having manifolds, for example, having one first part wherein one first fluid flows and a one second part wherein one second fluid flows. By front and back manifolds, it means one manifold associated with one combo cooler module, and another manifold with a second combo cooler module.

In various aspects of the present invention, heat exchanger is provided, wherein the first and the second manifold are separated into parts, one part of the manifold in communication with the plurality of first tubes and another part of the manifold in communication with the plurality of second tubes.

Each combo-cooler module comprises a high pressure heat exchanger having at least two manifolds on opposite sides of a set of essentially parallel tubes, the at least first manifold on one side of the set of essentially parallel tubes and the at least second manifold on the other side of the set of essentially parallel tubes. In aspects of the present invention, at least one first (front) manifold and at least one second (front) manifold is in combination, respectively, with a third manifold (back) manifold and a fourth (back) manifold the first and third manifold forming, for example, a two piece manifold and the second and fourth manifold forming, for example, a two piece manifold.

In aspects of the present invention, the first and third manifold can, alternatively, be in actuality, a one piece manifold that encompasses the tubes of both back and front sections of the gas combo-cooler, the core sections of the two non gas combo-coolers preserving their individual fluids without mixing of either of each combo cooler core portion. In other aspects, a communication means may be provided between the one piece or between two pieces of a two piece manifold in the area of the non gas combo-cooler portion such that a fluid communication between the non gas front and back combo cooler portions can occur.

In various aspects of the present invention, a gas combo-cooler is located in front of radiator of engine. In other words, the combo-cooler is in the up-stream of air-flow, and the radiator is in the down-stream of the air flow. In other aspects, the heat exchanger assembly with gas combo-cooler, has a non gas cooler that comprises an oil cooler, and, in particular, a two pass oil cooler portion, where the first pass of oil is in a row of tubes in back of or the down-stream of air-flow direction, and during the 2^nd pass the same tubes are up-stream of air-flow direction.

In aspects of the present invention, the gas combo-cooler has portions wherein the bottom, middle or top portion, or combinations thereof, have two fold or dual tubes associated with one type of cooler portion (for example, a CO₂ gas-cooler), while the front row tubes and rear-row tubes of another cooler portion, has one fold or one row tubes for each different coolers (for example, transmission oil cooler for front cooler, and rear cooler for power-steering oil cooler).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a non-gas combo-cooler module having oil cooler portion located at the top of combo-cooler, and a condenser portion at the bottom of combo-cooler module.

FIG. 2 shows a non-gas combo-cooler module having an oil cooler portion at the top of the combo-cooler, and a condenser portion at the bottom, with all tubes in a single row.

FIG. 3 shows a perspective view of a prior art gas-cooler having a layout with two tube rows, one tube row for a first pass and a second tube row portion for a second pass in the gas-cooler.

FIG. 4 shows a gas combo-cooler assembly having with a two-fold two piece manifold, the first manifold in fluid communication with the third manifold, in accordance with an aspect of the present invention.

FIGS. 5, 6 and 7 show schematic diagrams of the basic layout of a gas combo-cooler module comprising high internal pressure cooler portion, like CO₂ gas-cooler.

FIG. 5a shows a front-view of a gas combo-cooler including gas-cooler, with gas-cooler tubes and tubes of other coolers basically in parallel, with pairs of manifolds linking the tubes, in accordance with an aspect of the present invention.

FIG. 5b shows a perspective view of two row/fold combo-cooler.

FIG. 6 show a top view of a gas combo-cooler including a gas-cooler, having a two rows of tubes (‘two-fold tubes’) and a two-fold manifold, in accordance with an aspect of the present invention. The two-fold manifold is physically interconnected, so that fluid communication may occur between the manifolds. The two-row tubes of various embodiments lay in the direction of air flow.

FIG. 7 shows a gas combo-cooler module including gas-cooler, having two detection holes in a front manifold, on the same level as two detection holes in a rear manifold of the two piece manifolds, in accordance with an aspect of the present invention.

FIG. 8 is a top down schematic view of a one pass oil cooler portion (gas combo cooler portion not visible) of a combo-cooler module, with an oil inlet on one side of manifolds and an oil outlet on the other side of manifolds, in accordance with an aspect of the present invention.

FIGS. 9a and 9b show a top down schematic view of a heat exchanger assembly having gas combo-cooler, the two combo-cooler modules having an oil inlet and oil outlet on the same side of the manifold (s), in accordance with an aspect of the present invention.

FIG. 10 illustrates an assembly having an engine cooling module, the assembly having two-folds/two piece configurations having two tube rowed, two-fold gas-cooler in front of a radiator, so that the radiator is downstream the direction of airflow in normal operation of the vehicle, in accordance with an aspect of the present invention.

FIG. 11 shows a schematic side view of a gas combo-cooler where the front or first manifold and rear or second manifold have detection holes at different levels, in accordance with an aspect of the present invention.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE PRESENT INVENTION

FIG. 1 shows a common combo-cooler layout: an oil cooler (10) is located at the top of combo-cooler (13), and a condenser (11) is located at the bottom of the combo cooler (16). All tubes (22) are in a single row between manifolds (21), as shown in FIG. 2.

FIG. 3 shows a gas-cooler layout with two tube-rows (36, 37). Air flows through the first tube row (B), and then second tube row (A).

Refrigerant flows through two-fold tubes that communicate with one another. Corresponding manifold also has a design wherein a pair of manifolds (dual front and rear (back) manifold) replace a single manifold, and the front manifold communicates with the rear manifold.

FIG. 4 shows a manifold design for a gas combo-cooler (43) with two-fold (dual) manifolds (41, 42) in fluid communication (44) with one another.

In various aspects of the present invention, a heat exchanger assembly may be a brazed assembly or made of modules or components.

Integration of the higher internal pressure cooler (for example, a gas-cooler of CO₂) into a combo-cooler (not shown) is envisioned, in other aspects of the present invention.

FIGS. 5, 6 and 7 show schematically a layout of combo-cooler, including a high internal pressure cooler, for example a CO₂ gas-cooler, where CO₂ is the fluid which flows in the tube. By fluid, it is meant a gas or liquid that has flow characteristics that allow the substance to flow in either gaseous or liquid flow, through ‘conducts or ‘tubes’ of a heat exchanger assembly.

FIG. 5 shows a front-view of the gas combo-cooler including gas-coolers. Gas-cooler (500(a)) and another heat exchanger such as a non gas cooler portion (500(b)), share the same pairs of dual manifolds, and divide the frontal area of the gas-combo-cooler (510) into two or more, especially two or three, two tubes for combo-cooler of two coolers, three tubes in the case of tri-cooler, tubes (501) of gas-cooler (500(a)) are connected the pairs of manifold (503(a), 503(b)) by both tube ends (501(a), 501(b)), and tubes of other heat exchangers (506) are also connected to the same pairs of manifolds (503(a), 503(b)) by both tube ends (506(a), 506(b)), fins (502(b)) are in between tubes, at least one fin (509) is between one gas-cooler tube (501) and tube of other cooler (506). One part (P1) of manifold is in connection with the plurality of first tubes; one part (P2) of manifold is in communication with the plurality of second tubes.

In general, tubes of gas-cooler, tubes of other heat exchangers ‘coolers’ and fins are essentially in parallel, and the pairs of manifolds are essentially perpendicular to the tubes.

FIG. 5b show a side-view of a heat exchanger assembly with non-gas portion (521) combo-cooler and CO₂ gas-cooler portion (520). Each of four manifolds (front-left, front-right, rear-left, rear-right, has at least one non-communicating chamber or space (522), separated by a baffle (524) of gas-cooler (520), and a baffle (523) of another non-gas heat exchanger or cooler. By non-communicating chamber or space it is meant a chamber that has no communication with tubes (gas-cooler tubes or other cooler tubes) with one another. A non-communicating space can also occur where one or more tubes are connected into a space, however this (these) tube(s), are not in fluid communication with other tubes. In other words, this tube is normally called, in the art, a ‘dead tube’.

The non-communicating chamber (522) has an orifice or hole (525, 526) that extends from the internal surface to the external surface of the non-communicating chamber (522). This hole towards external side serves as a detection means (526) so that any possible leak from one of combo-coolers portions leads to refrigerant not going into another cooler directly, but passing external to the manifold where its presence can be detected.

In order to avoid any leak, the two chambers (525) (528) inside the two front manifolds (500(a)) (500(b)), for example, are at the same level. The two detection holes (525) (526) in the two front manifolds (500(a), 500(b)) are located between the same boundary gas-cooler tube and the same boundary other cooler tube.

The detection holes (525, 526) or holes are located in the space (522, 528) between the baffles (523, 524). Communicating means (X, Y) between front (520(a)) and back (520(b)) dual manifold are illustrated.

FIG. 6 shows a top view of a heat exchanger assembly (600) having combo-cooler module portions that are non-gas heat exchangers (not shown) and including a gas-cooler portion. Two rows of tubes (602(a), 602(b)) form two-fold tubes. The manifold 607(b), 603(b) and 607(a) 603(a) are a two-fold or dual manifolds. The two-fold/dual manifolds is physically connected at area (608(a), and at area (608(b)) where fluid communication occurs between the manifold. The two-fold tubes (602(a), 602(b)) lay in the direction of air flow A, and tubes are connected to a first manifold (603(a), 603(b)) and a second manifold (607(a), 607(b)) in an essentially parallel configuration.

FIG. 7 pertains to a similar heat exchanger assembly having combo-cooler module portions that are non-gas heat exchangers and including a gas-cooler portion. Two rows of tubes form two-fold tubes. A manifold is two-fold as well. The two-fold/dual manifold is physically connected at areas and at one area fluid communication occurs between the dual manifold. The two-fold tubes lay in the direction of air flow, and are connected to a first manifold and a second manifold in an essentially parallel configuration. Because of the extreme high internal pressure of the CO₂ gas-cooler (700), a leak detection means (701) is provided to show potential leaks prior to final shipping to customers.

FIG. 7b illustrates two sets of tubes having a single manifold (730) with varying separation to prevent fluid flow contact where not desired.

As can be appreciated numerous detection holes, in numerous areas of manifold, are possible when chambers or ‘spaces’ between fluid or baffle exist.

In FIG. 7, the at least one detection hole (701(a)) in at least one front manifold (750(a)) is on the same level as at least one detection hole (701(b)) in the rear manifold (750(b)).

FIG. 8 illustrates an oil cooler portion of a gas combo cooler of an external air conditioning loop and oil cooling loop, the heat exchanger assembly comprising a gas combo-cooler having gas-cooler portion with manifold(s) (807(b), 803(b) and 807(a) and 803(a)) inlet/outlet means (I, O) such as blocks, pipes or tubes, or the like. The inlet /outlet means (I, O) can be on the same manifold or on the opposite manifolds. FIG. 8 shows one example of 1-pass oil cooler and a non gas combo-cooler portion of the heat exchanger assembly. Oil inlet (I) is at one side of the manifolds (RT) (right manifolds), and oil outlet (O) is at the other side of manifolds (left manifolds) (LT).

FIGS. 9a and 9b illustrate the heat exchanger assembly having use in an external air conditioning loop and oil cooling loop, having a heat exchanger assembly comprising a non-gas combo-cooler portion and gas-cooler portion with manifold(s) and inlet/outlet means such as blocks, pipes or tubes, or the like another aspect wherein oil inlet (I) and outlet (O) are on the same side of the manifold or manifolds (907(a), 903(a) and 907(b), 903(b)) (right side (RT), for example). In an embodiment with a two pass oil cooler, FIG. 9a illustrates a configuration where oil can flow first through the rear row tubes (902(a)), and then comeback through the front-row tubes (902(b)). FIG. 9b shows a configuration where flow goes in the opposite direction, first through the front-row tubes, than through the rear row tubes.

Thermal efficiency of a gas combo-cooler is achieved by providing a gas combo-cooler with the following attributes: the product of hydraulic diameter of gas-cooler (Dg) and hydraulic diameter of the non-gas-cooler (Do) between about the following range:
0.15 mm²<Dg Do<8.0 mm².

In various aspects, the two-fold (two row) gas combo-cooler (sometimes referred to as a combined combo-cooler) has a distribution of thermal resistance such as the following. For combined combo of gas-cooler and oil cooler, the gas-cooler, external air side thermal resistance represents between about 70%-80% of total thermal resistance, with inside tube thermal resistance between about 20%-30%. For combined combo-cooler having a transmission oil cooler and gas-cooler only, however, external air side thermal resistance is between about 35% to 45%, and inside tube thermal resistance is between about 55%-65.

In various aspects of the present invention, more surfaces are provide at the external air side of the gas-cooler or gas cooler portion, the wetted areas (wet surface area) of the tubes of the oil cooler portion, on a per tube basis, being larger than the wet surface area of the gas cooler portion. The following expression summarizes this relationship (on the per tube basis):
Surface_OilnsideTube/Surface_externalAir>Surface_GasInsideTube/Surface_externalAir

In various aspects, fins are used within the non gas combo-cooler portion of the gas combo cooler, in accordance with an aspect of the present invention, are the same, or, different from one another. The fins used with the gas cooler portion of the gas-combo-cooler are also the same, or different from those used with the non gas-cooler portion.

Where the same type of fins is used for both cooler portions, the above expression can be simplified as:
Surface_OilInsideTube>Surface_GasInsideTube

Another aspect of the present invention provides for a gas combo-cooler in front of a radiator. FIG. 10 illustrates a heat exchanger assembly in an engine cooling module with two-folds configurations having two-row gas-cooler (Z) in front of a radiator (100). In the air flow direction (A), the combo-cooler (Z) is upstream, and radiator (1000) is down-stream of the air flow. Radiator manifold (1001) and core (102) are shown. Dual manifold (1101, 1103) is illustrated as well as tube (1101) of one gas combo cooler portion.

Tubes are preferably arranged so that they have at least one fin (not shown) and, preferably, fins that contact at least two of the tubes. Two tubes can have fins that are in one row or in two rows (two-fold fins). Therefore, fins can be internal to each non gas combo- cooler core of the each non-gas cooler portion or between cores of each non gas cooler portion of the gas combo cooler.

FIG. 11 shows a schematic side view of a gas combo-cooler (1110) where the front manifold (1114) and rear manifold (1113) have their detection holes (1112, 1111) at different levels. Baffles (1118) are illustrated which form manifold spaces or chambers internally (1200).

The number of passes for the gas-cooler portion of the gas combo-cooler is usually small. For example, the number of passes for an oil cooler portion is preferably less than 4, more preferably 1-3 passes and more preferably, either 1 or 2 passes.

According to one aspect of the invention, the heat exchanger will comprise a plurality of components that are assembled together by suitable joining techniques. In one preferred embodiment, one or more of the components of the heat exchanger such as the baffles, the end tanks, the tubes, fins, the inlets, the outlets, a bypass or combinations thereof may be attached to each other using brazing techniques. Although various brazing techniques may be used, one preferred technique is referred to as controlled atmosphere brazing. Controlled atmosphere brazing typically employs a brazing alloy for attaching components wherein the components are formed of materials with higher melting points than the brazing alloy. The brazing alloy is preferably positioned between components or surfaces of components to be joined and, subsequently, the brazing alloy is heated and melted (e.g., in an oven or furnace, and preferably under a controlled atmosphere). Upon cooling, the brazing alloy preferably forms a metallurgical bond with the components for attaching the components to each other. According to one highly preferred embodiment, the brazing alloy may be provided as a cladding on one of the components of the heat exchanger. In such a situation, it is contemplated that the components may be formed of a material such as a higher melting point aluminum alloy while the cladding may be formed of a lower melting point aluminum alloy.

Envisioned are also gas combo-coolers that are tri-coolers or quad-coolers. For example, in the two-fold row tube gas combo-cooler construction, a gas-cooler can be located at the bottom of the heat exchanger assembly (both front row and rear row tubes), a transmission oil cooler (TOC) at the top front-row of tubes, and a PSOC (power steering oil cooler) at the top rear (back) row of tubes.

Fins may be used for heat exchange portion of the gas combo-cooler or non-gas combo-cooler. Though different heat exchange cooler portions may use different tubes, but use the same kind of fins. They may also use different types of fins. By different types of fins, it is meant fins that vary in physical characteristics, such as height, pitch, thickness, materials, for example.

Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.

The preferred embodiment of the present invention has been disclosed. A person of ordinary skills in the art would realize, however, that certain modifications will come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

Claims

1. A heat exchanger assembly for automotive vehicles comprising a gas combo-cooler having a first and a second combo cooler module, each combo cooler module having:

a gas cooler portion;

a non gas cooler portion;

a first manifold;

a second manifold opposite the first manifold;

a plurality of first tubes in fluid communication with the first and second manifolds, the plurality of first tubes adapted to have a first fluid flow therethrough;

a plurality of second tubes in fluid communication with the first and second manifolds, the plurality of second tubes adapted to have a second fluid, different from the first fluid, flow therethrough;

a plurality of fins disposed between the first and second tubes, with the first and second tubes and fins being generally co-planar relative to each other.

2. The heat exchanger, as in claim 1, wherein a fluid connection means is between the at least one manifold of the first combo cooler module and the at least one manifold of the second combo cooler module.

3. The heat exchanger, as in claim 2, wherein the first and the second manifold are separated into parts, one part of the manifold in communication with the plurality of first tubes and another part of the manifold in communication with the plurality of second tubes.

4. The heat exchanger, as in claim 3, wherein the fluid connection means is between the part of the manifold in fluid communication with the plurality of first tubes.

5. The heat exchanger, as in claim 3, wherein the fluid connection means is between the parts of the manifold in fluid communication with the plurality of second tubes.

6. The heat exchanger assembly, as in claim 5, wherein the part of the manifold in fluid communication with the plurality of second tubes is the non gas cooler portion, and the non gas cooler portion is a two fold cooler.

7. The heat exchanger assembly as in claim 5, wherein the part of the manifold in fluid communication with the plurality of second tubes is the non gas cooler portion, and the non gas cooler portion is a one fold cooler.

8. The heat exchanger assembly, as in claim 4, wherein the part of the manifold in communication with the plurality of first tubes is the gas-cooler portion, and the part of the manifold in communication with the plurality of second tubes is the non gas cooler portion.

9. The heat exchanger assembly as in claim 8, wherein the gas fluid portion of the gas combo-cooler has fewer than 4 passes.

10. The heat exchanger assembly, as in claim 9, wherein the tubes have an external air side relative to the direction of air flow and the external air side thermal resistance of the gas cooler portion is between about 35 and 80% of the total thermal resistance.

11. The heat exchanger assembly, as in claim 9, wherein the inside tube thermal resistance is between about 20 and 65% of the total thermal resistance.

12. The heat exchanger assembly, as in claim 10, wherein the internal surface of the tubes is the wetted side of the tubes, and wherein the size of the wet surface area of the tubes of the gas cooler portion is smaller than the size of the wet surface area of the non gas cooler portion on a per tube basis.

13. The heat exchanger assembly, as in claim 12, wherein the Surface_oilnsideTube/Surface_externalAir>Surface_GasInsideTube/Surface_externalAir.

14. The heat exchanger assembly, as in claim 6, wherein the non gas cooler portion has at least two types of tubes.

15. The heat exchanger assembly, as in claim 6, wherein the hydraulic diameter of the tubes of the gas cooler is Dg and the hydraulic diameter of the non-gas cooler is Do, and the product of hydraulic (Dg) and (Do) is given by the following equation: 0.15 mm2<Dg Do<8.0 mm2.

16. The heat exchanger assembly, as in claim 14, wherein the non gas cooler portion is part of a non gas combo cooler.

17. The heat exchanger assembly, as in claim 14, wherein the non gas cooler portion is part of a non gas combo cooler.

18. The heat exchanger assembly, as in claim 18, further comprising at least one non-communication chamber in at least one manifold and at least one detection means.

19. The heat exchanger assembly, as in claim 18, wherein at each non-communication chamber has at least one detection means.

20. The heat exchanger assembly, as in claim 18, wherein at least one detection means is located on at least one manifold of the first and the second combo cooler manifold, and wherein the detection means are at approximately the same level.

21. The heat exchanger assembly, as in claim 18, wherein at least one detection means is located on at least one manifold of the first and the second combo cooler manifold, and wherein the detection means are at different levels.