HEAT EXCHANGER MANIFOLD WITH A FLUID FLOW DISTRIBUTION FEATURE

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. The first manifold is formed by at least one wall having at least one fluid flow distribution feature integrally formed therein. The at least one fluid flow distribution feature includes a channel extending substantially parallel to a general direction of flow of the fluid through the first manifold.

Description

FIELD OF THE INVENTION

The present invention relates generally to a heat exchanger and, more particularly, to a heat exchanger manifold with a fluid flow distribution feature formed therein.

BACKGROUND OF THE INVENTION

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 hot 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.

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 radiator liquid within the tubular elements typically has a temperature of about −20° C. Whereas, the hot radiator liquid entering the radiator typically has a temperature of about 110° C. The hot radiator liquid is introduced into an end of the first manifold through an inlet and a flow momentum causes the hot 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 hot radiator liquid which leads to difficultly in introduction of the hot radiator liquid into the tubular elements adjacent an opposite end of the first manifold, especially during the cold start up. Such non-uniform distribution of the hot radiator liquid can cause the tubular elements adjacent the opposite end of the first manifold to become obstructed by an accumulation of the radiator liquid therein resulting from a lack of use. As a result, severe thermal stresses which can potentially damage the tubular elements adjacent the opposite end of the first manifold may occur.

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

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.

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 having at least one fluid flow distribution feature integrally formed therein, the at least one fluid flow distribution feature including a channel extending substantially parallel to a general direction of flow of the fluid through the manifold.

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 a cross-sectional flow area of the manifold gradually decreases from the first end to the second end thereof, and wherein the manifold is formed by at least one wall having at least one fluid flow distribution feature integrally formed therein, the at least one fluid flow distribution feature including a first end adjacent the first end of the manifold, a second end adjacent the second end of the manifold, and a channel extending substantially parallel to a general direction of flow of the fluid through the manifold from the first end of the fluid flow distribution feature to the second end thereof.

The invention also relates to a method of forming a heat exchanger.

The method comprises the step of: injection molding a manifold having a first end provided with an inlet, a second end opposite the first end, an opening configured to receive a conditioning assembly of the heat exchanger therein, and at least one fluid flow distribution feature formed therein, wherein the at least one fluid flow distribution feature extends from adjacent the first end of the manifold to adjacent the second end thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

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

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

FIG. 2 is a top plan view of the first manifold illustrated in FIG. 1 according to an embodiment of the present invention;

FIG. 3 is a cross-sectional view of the first manifold illustrated in FIGS. 1-2 taken along line 3-3 of FIG. 1;

FIG. 4 is a top plan view of the first manifold according to another embodiment of the present invention;

FIG. 5 is a cross-sectional view of the first manifold illustrated in FIG. 4 taken along line 5-5 of FIG. 4;

FIG. 6 is a top plan view of the first manifold according to another embodiment of the present invention; and

FIG. 7 is a cross-sectional view of the first manifold illustrated in FIG. 6 taken along line 7-7 of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

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.

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.

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. In the illustrated embodiment, the first manifold 12 has a gradually decreasing cross-sectional flow area in respect of a general direction of flow of the first fluid therethrough, and the second manifold 14 has a gradually increasing cross-sectional flow area in respect of the general direction of flow of the first fluid therethrough. In other embodiments, at least one of the first manifold 12 and the second manifold 14 has a substantially uniform cross-sectional flow area in respect of the general direction of flow of the first fluid therethrough. It is understood, however, that the first manifold 12 and the second manifold 14 can have any shape and configuration as desired.

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.

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 (not shown) and an outlet opening (not shown) of each of the tubular elements 20 is fluidly connected to an interior of 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.

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.

FIGS. 1-3 show the first manifold 12 according to an embodiment of the invention. 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 is formed by an upper wall 50, a first pair of opposing side walls 52, 54, and a second pair of opposing side walls 56, 58 which define a chamber 59 (shown in FIG. 3) configured to receive the first fluid therein and an opening configured to receive the conditioning assembly 16 therein.

In certain embodiments, a cross-sectional flow area of the chamber 59 of the first manifold 12 gradually decreases from the first end 46 of the first manifold 12 to the second end 48 thereof. Accordingly, the cross-sectional flow area of the chamber 59 adjacent the first end 46 of the first manifold 12 is greater than a cross-sectional flow area of the chamber 59 adjacent the second end 48 thereof. It is understood that a rate of change of the cross-sectional flow area of the chamber 59 from the first end 46 to the second end 48 can be variable or substantially constant as shown in FIG. 1. In other embodiments, the cross-sectional flow area of the chamber 59 is substantially uniform from the first end 46 of the first manifold 12 to the second end 48 thereof. Accordingly, the cross-sectional flow area of the chamber 59 adjacent the first end 46 of the first manifold 12 is substantially the same as the cross-sectional flow area of the chamber 59 adjacent the second end 48 thereof.

In other embodiments, a distance between an inner surface of the upper wall 50 of the first manifold 12 and a plane generally defined by the inlet openings of the tubular elements 20 gradually decreases as a distance from the inlet 18 in a general direction of flow of the first fluid in the first manifold 12 increases. Accordingly, the distance between the inner surface of the upper wall 50 of the first manifold 12 adjacent the first end 46 thereof and the plane generally defined by the inlet openings of the tubular elements 20 is greater than the distance between the inner surface of the upper wall 50 of the first manifold 12 adjacent the second end 48 thereof and the plane generally defined by the inlet openings of the tubular elements 20. It is understood that a rate of change in the distance between the inner surface of the upper wall 50 and the plane generally defined by the inlet openings of the tubular elements 20 can be variable or substantially constant as shown in FIG. 1. In other embodiments, the distance between the inner surface of the upper wall 50 of the first manifold 12 and the plane generally defined by the inlet openings of the tubular elements 20 is substantially uniform as the 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 of the upper wall 50 of the first manifold 12 adjacent the first end 46 thereof and the plane generally defined by the inlet openings of the tubular elements 20 is substantially the same as the distance between the inner surface of the upper wall 50 of the first manifold 12 adjacent the second end 48 thereof and the plane generally defined by the inlet openings of the tubular elements 20.

A fluid flow distribution feature 60 having a first end 62 and a second end 64 is formed in the first manifold 12. The fluid flow distribution feature 60 is configured to enhance a flow of the first fluid therethrough and distribute at least a portion of the first fluid to the tubular elements 20 adjacent the second end 64 of the fluid flow distribution feature 60. As illustrated, the fluid flow distribution feature 60 can be formed in the upper wall 50 of the first manifold 12. The fluid flow distribution feature 60 extends substantially parallel to the general direction of flow of the first fluid through the first manifold 12. The fluid flow distribution feature 60 may also extend substantially parallel to a longitudinal axis of the first manifold 12 from the first end 46 of the first manifold 12 to the second end 48 thereof. In certain embodiments, the fluid flow distribution feature 60 is formed to extend along an entire length of the first manifold 12 from adjacent the side wall 52 to adjacent the opposite side wall 54. In other embodiments, the fluid flow distribution feature 60 is formed to extend along a portion of the length of the first manifold 12. As shown in FIGS. 1-2, the first end 62 of the fluid flow distribution feature 60 is formed adjacent the inlet 18 of the first manifold 12 and the second end 64 of the fluid flow distribution feature 60 is formed adjacent the side wall 54. As a non-limiting example, the fluid flow distribution feature 60 extends in a range of about 20% to about 100% of the length of the first manifold 12.

As shown in FIG. 3, the fluid flow distribution feature 60 has a generally U-shaped cross-section. It is understood, however, that the fluid flow distribution feature 60 can have any cross-sectional shape as desired such as semi-circular, triangular, rectangular, or an irregular shape, for example, to enhance a flow of the first fluid therethrough. In certain embodiments, the fluid flow distribution feature 60 includes an upper wall 66, a pair of opposing side walls 68, 70, and an end wall 72 which define a channel 73 configured to receive a portion of the first fluid therein. The channel 73 shown has a cross-sectional flow area in a range of about 10% to about 20% of the cross-sectional flow area of the first manifold 12. Those skilled in the art will appreciate that the channel 73 can have any cross-sectional flow area as desired.

In certain embodiments shown in FIGS. 1-3, the cross-sectional flow area of the channel 73 is substantially uniform from the first end 62 of the fluid flow distribution feature 60 to the second end 64 thereof. Accordingly, the cross-sectional flow area of the channel 73 adjacent the first end 62 of the fluid flow distribution feature 60 is substantially the same as a cross-sectional flow area of the channel 73 adjacent the second end 64 thereof. In other embodiments, the cross-sectional flow area of the channel 73 gradually decreases from the first end 62 of the fluid flow distribution feature 60 to the second end 64 thereof. Accordingly, the cross-sectional flow area of the channel 73 adjacent the first end 62 of the fluid flow distribution feature 60 is greater than the cross-sectional flow area of the channel 73 adjacent the second end 64 thereof. It is understood that a rate of change of the cross-sectional flow area of the channel 73 from the first end 62 to the second end 64 can be variable or substantially constant. As a non-limiting example, the rate of change of the cross-sectional flow area of the channel 73 from the first end 62 of the fluid flow distribution feature 60 to the second end 64 thereof can be substantially the same as the rate of change of the cross-sectional flow area of the chamber 59 from the first end 46 of the first manifold 12 to the second end 48 thereof. As another non-limiting example, the rate of change of the cross-sectional flow area of the channel 73 from the first end 62 of the fluid flow distribution feature 62 to the second end 64 thereof can vary as to the rate of change of the cross-sectional flow area of the chamber 59 from the first end 46 of the first manifold 12 to the second end 48 thereof.

In other embodiments, a distance between an inner surface of the upper wall 66 of the fluid flow distribution feature 60 and the plane generally defined by the inlet openings of the tubular elements 20 gradually decreases 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 of the upper wall 66 of the fluid flow distribution feature 60 adjacent the first end 62 thereof and the plane generally defined by the inlet openings of the tubular elements 20 is greater than the distance between the inner surface of the upper wall 66 of the fluid flow distribution feature 60 adjacent the second end 64 thereof and the plane generally defined by the inlet openings of the tubular elements 20. It is understood that a rate of change in the distance between the inner surface of the upper wall 66 and the plane generally defined by the inlet openings of the tubular elements 20 can be variable or substantially constant as shown in FIG. 1. As a non-limiting example, the rate of change of the distance between the inner surface of the upper wall 66 of the fluid flow distribution feature 60 and the plane generally defined by the inlet openings of the tubular elements 20 is substantially the same as the rate of change of the distance between the inner surface of the upper wall 50 of the first manifold 12 and the plane generally defined by the inlet openings of the tubular elements 20. It is understood, however, that the rate of change of the distance between an inner surface of the upper wall 66 of the fluid flow distribution feature 60 and the plane generally defined by the inlet openings of the tubular elements 20 can vary as to the rate of change of the distance between the inner surface of the upper wall 50 of the first manifold 12 and the plane generally defined by the inlet openings of the tubular elements 20. In other embodiments, the distance between the inner surface of the upper wall 66 of the fluid flow distribution feature 60 and the plane generally defined by the inlet openings of the tubular elements 20 is substantially uniform as the 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 of the upper wall 66 of the fluid flow distribution feature 60 adjacent the first end 62 thereof and the plane generally defined by the inlet openings of the tubular elements 20 is substantially the same as the distance between the inner surface of the upper wall 66 of the fluid flow distribution feature 60 adjacent the second end 62 thereof and the plane generally defined by the inlet openings of the tubular elements 20.

The fluid flow distribution feature 60 is configured to permit the first fluid to be substantially uniformly distributed into the tubular elements 20 of the conditioning assembly 16, which minimizes the potential for the tubular elements 20 adjacent the second end 48 of the first manifold 12 to become obstructed. The fluid flow distribution feature 60 shown is integrally formed with the upper wall 50 of the first manifold 12 to minimize a complexity of manufacture. However, those skilled in the art will appreciate that the fluid flow distribution feature 60 can be separately formed from the upper wall 50 of the first manifold 12 if desired. In certain embodiments, the fluid flow distribution feature 60 is formed in the first manifold 12 during an injection-molding forming process of the first manifold 12.

FIGS. 4-5 show a first manifold 12′ according to another embodiment of the invention. Reference numerals for similar structure in respect of the description of FIGS. 1-3 are repeated in FIGS. 4-5 with a prime (′) symbol. The first manifold 12′ is substantially similar to the first manifold 12 shown in FIGS. 1-3 except that the first manifold 12′ includes a fluid flow distribution feature 160 instead of the fluid flow distribution feature 60.

The fluid flow distribution feature 160 having a first end 162 and a second end 164 is formed in the first manifold 12′. The fluid flow distribution feature 160 is configured to enhance a flow of the first fluid therethrough and distribute at least a portion of the first fluid to the tubular elements 20′ adjacent the second end 164 of the fluid flow distribution feature 160. As illustrated, the fluid flow distribution feature 160 can be formed in the side wall 56′ of the first manifold 12′ opposite the inlet 18′. The fluid flow distribution feature 160 extends substantially parallel to the general direction of flow of the first fluid through the first manifold 12′. The fluid flow distribution feature 160 may also extend substantially parallel to a longitudinal axis of the first manifold 12′ from the first end 46′ of the first manifold 12′ to the second end 48′ thereof. In certain embodiments, the fluid flow distribution feature 160 is formed to extend along an entire length of the first manifold 12′ from adjacent the side wall 52′ to adjacent the opposite side wall 54′. As shown in FIG. 4, the first end 162 of the fluid flow distribution feature 160 is formed adjacent the side wall 52′ of the first manifold 12′ and the second end 164 of the fluid flow distribution feature 160 is formed adjacent the opposite side wall 54′. In other embodiments, the fluid flow distribution feature 160 is formed to extend along a portion of the length of the first manifold 12′. As a non-limiting example, the fluid flow distribution feature 160 extends in a range of about 20% to about 100% of the length of the first manifold 12′.

As illustrated in FIG. 5, the fluid flow distribution feature 160 has a generally U-shaped cross-section. It is understood, however, that the fluid flow distribution feature 160 can have any cross-sectional shape as desired such as semi-circular, triangular, rectangular, or an irregular shape, for example, to enhance a flow of the first fluid therethrough. In certain embodiments, the fluid flow distribution feature 160 includes a side wall 166, an upper wall 168, and an opposing lower wall 170 which define a channel 173 configured to receive a portion of the first fluid therein. The channel 173 shown has a cross-sectional flow area in a range of about 10% to about 20% of the cross-sectional flow area of the first manifold 12′. Those skilled in the art will appreciate that the channel 173 can have any cross-sectional flow area as desired.

In certain embodiments shown in FIGS. 4-5, the cross-sectional flow area of the channel 173 gradually decreases from the first end 162 of the fluid flow distribution feature 160 to the second end 164 thereof. Accordingly, the cross-sectional flow area of the channel 173 adjacent the first end 162 of the fluid flow distribution feature 160 is greater than the cross-sectional flow area of the channel 173 adjacent the second end 164 thereof. It is understood that a rate of change of the cross-sectional flow area of the channel 173 from the first end 162 to the second end 164 can be variable or substantially constant as shown in FIG. 4. As a non-limiting example, the rate of change of the cross-sectional flow area of the channel 173 from the first end 162 of the fluid flow distribution feature 160 to the second end 164 thereof can be substantially the same as the rate of change of the cross-sectional flow area of the chamber 59′ from the first end 46′ of the first manifold 12′ to the second end 48′ thereof. As another non-limiting example, the rate of change of the cross-sectional flow area of the channel 173 from the first end 162 of the fluid flow distribution feature 162 to the second end 164 thereof can vary as to the rate of change of the cross-sectional flow area of the chamber 59′ from the first end 46′ of the first manifold 12′ to the second end 48′ thereof. In other embodiments, the cross-sectional flow area of the channel 173 is substantially uniform from the first end 162 of the fluid flow distribution feature 160 to the second end 164 thereof. Accordingly, the cross-sectional flow area of the channel 173 adjacent the first end 162 of the fluid flow distribution feature 160 is substantially the same as the cross-sectional flow area of the channel 173 adjacent the second end 164 thereof.

In other embodiments, a distance between an inner surface of the side wall 166 and the plane generally defined by the side wall 56′ of the first manifold 12′ gradually decreases as a distance from the inlet 18′ in the general direction of flow of the first fluid in the first manifold' increases. Accordingly, the distance between the inner surface of the side wall 166 of the fluid flow distribution feature 160 adjacent the first end 162 thereof and the plane generally defined by the side wall 56′ of the first manifold 12′ is greater than the distance between the inner surface of the side wall 166 of the fluid flow distribution feature 160 adjacent the second end 164 thereof and the plane generally defined by the side wall 56′ of the first manifold 12′. It is understood that a rate of change in the distance between the inner surface of the side wall 166 and the plane generally defined by the side wall 56′ of the first manifold 12′ can be variable or substantially constant as shown in FIG. 4. As a non-limiting example, the rate of change of the distance between the inner surface of the side wall 166 and the plane generally defined by the side wall 56′ of the first manifold 12′ is substantially the same as the rate of change of the distance between the inner surface of the upper wall 50′ of the first manifold 12′ and the plane generally defined by the inlet openings of the tubular elements 20′. It is understood, however, that the rate of change of the distance between the inner surface of the side wall 166 and the plane generally defined by the side wall 56′ of the first manifold 12′ can vary as to the rate of change of the distance between the inner surface of the upper wall 50′ of the first manifold 12′ and the plane generally defined by the inlet openings of the tubular elements 20′. In other embodiments, the distance between an inner surface of the side wall 166 and the plane generally defined by the side wall 56′ of the first manifold 12′ is substantially uniform as the distance from the inlet 18′ in the general direction of flow of the first fluid in the first manifold' increases. Accordingly, the distance between the inner surface of the side wall 166 of the fluid flow distribution feature 160 adjacent the first end 162 thereof and the plane generally defined by the side wall 56′ of the first manifold 12′ is substantially the same as the distance between the inner surface of the side wall 166 of the fluid flow distribution feature 160 adjacent the second end 164 thereof and the plane generally defined by the side wall 56′ of the first manifold 12′.As such, the first fluid is substantially uniformly distributed into the tubular elements 20′ of the conditioning assembly 16′, which minimizes the potential for the tubular elements 20′ adjacent the second end 48′ of the first manifold 12′ to become obstructed, especially during cold start up transients.

The fluid flow distribution feature 160 is configured to permit the first fluid to be substantially uniformly distributed into the tubular elements 20′ of the conditioning assembly 16′, which minimizes the potential for the tubular elements 20′ adjacent the second end 48′ of the first manifold 12′ to become obstructed. The fluid flow distribution feature 160 shown is integrally formed with the side wall 56′ of the first manifold 12′ opposite the inlet 18′ to minimize a complexity of manufacture. However, those skilled in the art will appreciate that the fluid flow distribution feature 160 can be separately formed from the side wall 56′ of the first manifold 12′ if desired. In certain embodiments, the fluid flow distribution feature 160 is formed in the first manifold 12′ during an injection-molding forming process of the first manifold 12′.

FIGS. 6-7 show a first manifold 12″ according to another embodiment of the invention. Reference numerals for similar structure in respect of the description of FIGS. 1-5 are repeated in FIGS. 6-7 with a double prime (″) symbol. The first manifold 12″ is substantially similar to the first manifolds 12, 12′ shown in FIGS. 1-5 except that the first manifold 12″ includes both the fluid flow distribution feature 60″ and the fluid flow distribution feature 160″.

Those skilled in the art will appreciate that the first manifolds 12, 12′, 12″ may include fewer or additional fluid flow distribution features 60, 160 then shown.

Operation of the heat exchanger 10 including the first manifold 12 shown in FIGS. 1-3 is substantially similar to an operation of the heat exchanger including the first manifolds 12′, 12″ shown in FIGS. 4-7. Therefore, for simplicity, only the operation of the heat exchanger including the first manifold 12 is described hereinafter.

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 into the chamber 59, a portion of the first fluid flows into the channel 73 of the fluid flow distribution feature 60 of the first manifold 12. The fluid flow distribution feature 60 manipulates a direction of flow of the first fluid. The portion of the first fluid flows from the first end 46 of the first manifold 12 along the channel 73 of the fluid flow distribution feature 60 toward the second end 48 of the first manifold 12, ensuring substantially uniform distribution of the first fluid into the inlet openings of the tubular elements 20 of the conditioning assembly 16. In particular, the channel 73 of the fluid flow distribution feature 60 ensure that at least a portion of the first fluid flows into 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.

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.

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 having at least one fluid flow distribution feature integrally formed therein, the at least one fluid flow distribution feature including a channel extending substantially parallel to a general direction of flow of the fluid through the manifold.

2. The heat exchanger of claims 1, wherein the fluid flow distribution feature is formed in at least one of a wall of the manifold opposite the inlet and a wall of the manifold opposite the inlet openings of the tubular elements.

3. The heat exchanger of claim 1, wherein a cross-sectional flow area of the manifold is substantially uniform from the first end of the manifold to the second end thereof.

4. The heat exchanger of claim 1, wherein a cross-sectional flow area of the manifold gradually decreases from the first end of the manifold to the second end thereof.

5. The heat exchanger of claim 1, wherein a distance from an inner surface of the at least one wall of the manifold and a plane generally defined by the inlet openings of the tubular elements gradually decreases as a distance from the inlet in the general direction of the flow of the fluid through the manifold increases.

6. The heat exchanger of claim 1, wherein a distance from an inner surface of the at least one wall of the manifold and a plane generally defined by the inlet openings of the tubular elements is substantially uniform as a distance from the inlet in the general direction of the flow of the fluid through the manifold increases.

7. The heat exchanger of claim 1, wherein the channel of the at least one fluid flow distribution feature has a cross-sectional flow area in a range of about 10% to about 20% of a cross-sectional flow area of the manifold.

8. The heat exchanger of claim 1, wherein the channel extends in a range of about 20% to about 100% of a length of the manifold.

9. The heat exchanger of claim 1, wherein the fluid flow distribution feature has a first end adjacent the first end of the manifold and a second end adjacent the second end of the manifold.

10. The heat exchanger of claim 9, wherein a cross-sectional flow area of the channel is substantially uniform from the first end of the fluid flow distribution feature to the second end thereof.

11. The heat exchanger of claim 9, wherein a cross-sectional flow area of the channel gradually decreases from the first end of the fluid flow distribution feature to the second end thereof.

12. The heat exchanger of claim 1, wherein the channel is formed by at least one wall of the fluid flow distribution feature.

13. The heat exchanger of claim 12, wherein a distance from an inner surface of the at least one wall of the fluid flow distribution feature and a plane generally defined by the inlet openings of the tubular elements gradually decreases as a distance from the inlet in the general direction of the flow of the fluid through the manifold increases.

14. The heat exchanger of claim 12, wherein a distance from an inner surface of the at least one wall of the fluid flow distribution feature and a plane generally defined by the inlet openings of the tubular elements is substantially uniform as a distance from the inlet in the general direction of the flow of the fluid through the manifold increases.

15. 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 a cross-sectional flow area of the manifold gradually decreases from the first end to the second end thereof, and wherein the manifold is formed by at least one wall having at least one fluid flow distribution feature integrally formed therein, the at least one fluid flow distribution feature including a first end adjacent the first end of the manifold, a second end adjacent the second end of the manifold, and a channel extending substantially parallel to a general direction of flow of the fluid through the manifold from the first end of the fluid flow distribution feature to the second end thereof.

16. The heat exchanger of claims 15, wherein the fluid flow distribution feature is formed in at least one of a wall of the manifold opposite the inlet and a wall of the manifold opposite the inlet openings of the tubular elements.

17. The heat exchanger of claim 15, wherein the channel of the at least one fluid flow distribution feature has a cross-sectional flow area in a range of about 10% to about 20% of a cross-sectional flow area of the manifold.

18. The heat exchanger of claim 15, wherein the channel extends in a range of about 20% to about 100% of a length of the manifold.

19. A method of forming a heat exchanger, comprising the step of:

injection molding a manifold having a first end provided with an inlet, a second end opposite the first end, an opening configured to receive a conditioning assembly of the heat exchanger therein, and at least one fluid flow distribution feature formed therein, wherein the at least one fluid flow distribution feature extends from adjacent the first end of the manifold to adjacent the second end thereof.

20. The method of claims 19, wherein the fluid flow distribution feature is formed in at least one of a wall of the manifold opposite the inlet and a wall of the manifold opposite the opening.