Abstract:
A plate for a heat exchanger is disclosed, wherein surfaces of the plate have integrated turbulation features formed thereon.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a plate for a heat exchanger tank and more particularly to a plate for a heat exchanger tank having integrated fluid turbulation features. 
       BACKGROUND OF THE INVENTION 
       [0002]    Heat exchanger tanks are designed to transport a heat transfer fluid, such as in a motor vehicle for example. Typically, opposed plates carry the fluid such as oil, for example, in passageways formed therebetween. It is known to provide corrugated fins between pairs of plates, wherein the fins act as a turbulator to increase the heat transfer coefficient of the heat exchanger. 
         [0003]    One known method of making such a construction is to physically insert a corrugated fin between the plates after the plates have been manufactured. This has proved to be a difficult process since the corrugated fins are extremely thin and subject to deformation and damage during the insertion process. Further, inserting the fins can be a time consuming and costly process. 
         [0004]    It is also known to provide beaded plates for heat exchangers, wherein the beads define a plurality of passageways between adjacent plates for the passage of a fluid therethrough. An example of the beaded plates is disclosed in commonly owned U.S. Pat. No. 6,364,006, hereby incorporated herein by reference in its entirety. The beaded plates increase the surface area of conductive material available for heat transfer and cause turbulence of the fluid carried between the plates. Prior art plates include a plurality of beads formed thereon. The beads of the plates contact each other and are bonded together to force the flow of fluid therearound. The beads are aligned in rows, wherein a first row has an “A” pattern and the adjacent row has a “B” pattern. The rows are repeated in an A-B pattern, in which the beads in the A rows are aligned longitudinally or downstream from each other and the beads in the B rows are aligned longitudinally or downstream from each other. 
         [0005]    Although the above heat exchangers have worked well, it is desirable to eliminate the use of a turbulator between plates of a heat exchanger. It is also desirable to provide beaded plates for a heat exchanger wherein a turbulation of fluid flowing on both sides of the plate is caused to enhance heat transfer between the fluids. 
         [0006]    It is therefore considered desirable to produce a beaded plate for a heat exchanger tank, wherein the walls of the plate include integrated fluid turbulation features formed thereon for maximizing a turbulation of fluids flowing through the tank on both sides of the plate. 
       SUMMARY OF THE INVENTION 
       [0007]    Harmonious with the present invention, a beaded plate for a heat exchanger tank, wherein the walls of the plate include integrated fluid turbulation features formed thereon for maximizing a turbulation of fluids flowing through the tank on both sides of the plate, has surprisingly been discovered. 
         [0008]    In one embodiment, a plate for a heat exchanger comprises: an elongate first main body having a first surface, a second surface, and a lip extending laterally outwardly from a peripheral edge of the main body; a plurality of spaced apart first beads formed on the second surface of the plate, wherein a depth of the lip is larger than a depth of the first beads; and a plurality of spaced apart second beads formed on the first surface of the plate. 
         [0009]    In another embodiment, a stack for a heat exchanger comprises: a first plate having a first surface and a second surface, the second surface including a laterally outwardly extending lip and a plurality of spaced apart first beads formed thereon, the first surface including a plurality of spaced apart second beads formed thereon, wherein a depth of the lip is larger than a depth of the first beads; and a second plate having a first surface and a second surface, the second surface including a laterally outwardly extending lip and a plurality of spaced apart first beads formed thereon, the first surface including a plurality of spaced apart second beads formed thereon, wherein a depth of the lip is larger than a depth of the first beads, wherein the lip of the first plate is connected to the lip of the second plate. 
         [0010]    In another embodiment, a stack for a heat exchanger comprises: a plurality of plates having first surfaces and second surfaces, the second surfaces including a laterally outwardly extending lip and a plurality of spaced apart first beads formed thereon, the first surfaces including a plurality of spaced apart second beads formed thereon, wherein a depth of the lip is larger than a depth of the first beads, wherein the lips of pairs of plates are connected and the second beads of the pairs of plates are connected, and wherein a first plurality of flow passages is formed between the first surfaces of adjacent plates, and a second plurality of flow passages is formed between the second surfaces of adjacent plates. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings in which: 
           [0012]      FIG. 1  is a top plan view of a beaded plate for a heat exchanger in accordance with an embodiment of the invention; 
           [0013]      FIG. 2  is a sectional view of the beaded plate for a heat exchanger illustrated in  FIG. 1  taken along line  2 - 2 ; 
           [0014]      FIG. 3  is a side elevational view of a stack of beaded plates illustrated in  FIG. 1 ; 
           [0015]      FIG. 4  is a top plan view of a beaded plate for a heat exchanger in accordance with another embodiment of the invention; and 
           [0016]      FIG. 5  is a sectional view of the beaded plate for a heat exchanger illustrated in  FIG. 4  taken along line  4 - 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0017]    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. 
         [0018]      FIGS. 1 and 2  show a beaded plate  10  for a heat exchanger (not shown) in accordance with an embodiment of the invention. The plate  10  is formed from a metal material such as aluminum or an aluminum alloy, for example. The plate  10  extends longitudinally from a first end  12  to a second end  14 , and includes a first surface  11  and an opposed second surface  13 . A main body portion  16  of the plate is disposed between the first end  12  and the second end  14 , and has a substantially rectangular shape in plan. 
         [0019]    The first end  12  of the plate  10  includes a raised lip  18  surrounding an aperture  20 . The raised lip  18  forms a circular shaped channel (not shown) in the second side  13  of the plate  10 . A plurality of raised portions  21  is formed in the first end  12 . The raised portions  21  form channels (not shown) in the second side  13  of the plate  10 . The channels extend from the channel opposite the raised lip  18  to the main body portion  16 . It is understood that more or fewer channels can be formed in the first end  12  as desired. 
         [0020]    The second end  14  of the plate  10  includes a raised lip  22  surrounding an aperture  24 . The raised lip  22  forms a circular shaped channel (not shown) in the second side  13  of the plate  10 . A plurality of raised portions  25  is formed in the second end  14 . The raised portions  25  form channels (not shown) in the second side  13  of the plate  10 . The channels extend from the main body portion  16  to the channel opposite the raised lip  22 . It is understood that additional or fewer channels can be formed in the second end  14  as desired. 
         [0021]    As more clearly shown in  FIG. 2 , the second surface  13  of the plate  10  includes a laterally outwardly extending lip  26  having a depth d 0  that extends outwardly from a peripheral edge of the plate  10 . The plate  10  also includes a plurality of spaced apart first beads  32  extending laterally outwardly from the second surface  13 . The first beads  32  are generally dome shaped and have a predetermined radius such as 1.5 millimeters, for example. It is understood that a larger or smaller radius can be used. The first beads  32  have a depth d 1 . In the embodiment shown, the depth d 0  of the lip  26  is substantially similar to the depth d 1  of the first beads  32 , although other depths can be used as desired. 
         [0022]    The plate  10  also includes a plurality of spaced apart second beads  36  extending laterally outwardly from the first surface  11  of the plate  10 . The second beads  36  are generally trapezoid shaped and have a predetermined width such as five millimeters, for example. It is understood that a larger or smaller width can be used. The second beads  36  have a depth d 2 . In the embodiment shown, the depth d 2  of the second beads  36  is larger than the depth d 1  of the first beads  32 , although other depths can be used. A distal end  40  of the second beads  36  is generally flat. It is understood that the second beads  36  can be dome shaped or have other shapes as desired. 
         [0023]    The plate  10  includes a plurality of spaced apart third beads  42  that are substantially ovoid or football shaped, and extend laterally outwardly from the first surface  11 . The third beads  42  have a depth (not depicted) extending from the first surface  11  and terminating in a substantially flat distal end  45 . It is understood that the distal end  45  of the third beads  42  can be curved as desired. In the embodiment shown, the depth of the third beads  42  is larger than the depth d 2  of the second beads  36 . 
         [0024]    In the embodiment shown, the first beads  32 , the second beads  36 , and the third beads  42  are formed in a pattern of a plurality of rows. It is understood that the beads  32 ,  36 ,  42  can be formed in other configurations as desired. Each row contains a plurality of a predetermined number of the first beads  32 , the second beads  36 , and the third beads  42 , wherein the number of the second beads  36  and the third beads  42  in certain rows is zero (0). The rows of the beads  32 ,  36 ,  42  are spaced longitudinally on the main body portion  16  of the plate  10  a predetermined distance. 
         [0025]    When assembled, a pair of plates are brazed together to form a heat exchange plate  50 , as shown in  FIG. 3 . One of the plates  10  is oriented as shown in  FIGS. 1 and 2 , and the other of the plates is inverted from the orientation of  FIGS. 1 and 2  to permit corresponding lips  26  to abut one another. The lips  26  of the pair of the plates  10  are brazed together. Thus, the first surfaces  11  of the pairs of plates  10  are exposed. The first surfaces  11  of the pair of brazed plates  10  are then brazed together at the raised lips  18 ,  22 , the second beads  36 , and the third beads  42  to form a stack  44 . A gap  45  is formed between the first surfaces  11  of adjacent heat exchanger plates  50 . 
         [0026]    The first apertures  20  of the heath exchanger plates  50  in the stack  44  are aligned and cooperate to form a first conduit (not shown). The second apertures  24  of the plates  10  in the stack  44  are aligned and cooperate to form a second conduit (not shown). A first plurality of flow passages (not shown) is formed in the heat exchange plates  50  between the second surfaces  13  of brazed adjacent plates  10 . A second plurality of flow passages is formed within the gaps  45  formed by the first surfaces  11  of adjacent plates  10 . The second plurality of flow passages formed by the gaps  45  between adjacent heat exchanger plates  50  is in fluid communication with a pair of flow headers (not shown). 
         [0027]    A first mounting plate  54  is disposed on and brazed to the plate  10  at a first end of the stack  44 . A second mounting plate  56  is disposed on and brazed to the plate  10  at a second end of the stack  44 . The first mounting plate  54  includes a first aperture (not shown) that is aligned with the first conduit and a second aperture (not shown) that is aligned with the second conduit. The stack  44  includes a fluid inlet conduit  66  in fluid communication with the first conduit and a fluid outlet conduit  68  in communication with the second conduit. 
         [0028]    In use a first fluid (not shown) such as radiator fluid or oil, for example, flows through the fluid inlet conduit  66  into the first conduit. The first fluid flows through the channels  21  and into the first plurality of flow passages formed in the heat exchanger plates  50  between the second surfaces  13  of brazed adjacent plates  10 . As the first fluid travels through the first plurality of flow passages, the first fluid flows around the first beads  32 , which cause the first fluid to be turbulated. Thereafter, the first fluid flows through the channels  25  into the second fluid conduit and out of the stack  44  through the fluid outlet conduit  68 . 
         [0029]    A second fluid (not shown) such as a coolant, for example, is caused to flow through the gaps  45 . As the second fluid flows through the gaps  45 , the second fluid flows across the first surfaces  11  including the first beads  32 , which cause the second fluid to be turbulated. Additionally, heat is transferred from the first fluid to the second fluid. It is understood that heat can also be transferred from the second fluid to the first fluid. 
         [0030]    The turbulation caused by the first beads  32  to the first fluid and the second fluid minimizes a need for a separate turbulating fin to be disposed between the plates  10 . Accordingly, a cost of materials and a weight are minimized. 
         [0031]    It should be appreciated that the plates  10  could be used for heat exchangers in other applications besides motor vehicles. 
         [0032]      FIGS. 4 and 5  show a beaded plate  110  for a heat exchanger (not shown) in accordance with an embodiment of the invention. The plate  110  is formed from a metal material such as aluminum or an aluminum alloy, for example. The plate  110  extends longitudinally from a first end  112  to a second end  114 , and includes a first surface  111  and an opposed second surface  113 . A main body portion  116  of the plate is disposed between the first end  112  and the second end  114 , and has a substantially rectangular shape in plan. 
         [0033]    The first end  112  of the plate  110  includes a raised lip  118  surrounding an aperture  120 . The raised lip  118  forms a circular shaped channel (not shown) in the second side  113  of the plate  110 . A plurality of raised portions  121  is formed in the first end  112 . The raised portions plate form channels (not shown) in the second side  113  of the plate  110 . The channels extend from the channel opposite the raised lip  118  to the main body portion  116 . It is understood that more or fewer channels can be formed in the first end  112  as desired. 
         [0034]    The second end  114  of the plate  110  includes a raised lip  122  surrounding an aperture  124 . The raised lip  122  forms a circular shaped channel (not shown) in the second side  113  of the plate  110 . A plurality of raised portions  125  is formed in the second end  114 . The raised portions  125  form channels (not shown) in the second side  113  of the plate  110 . The channels extend from the main body portion  116  to the channel opposite the raised lip  122 . It is understood that additional or fewer channels can be formed in the second end  114  as desired. 
         [0035]    As more clearly shown in  FIG. 5 , the second surface  113  of the plate  110  includes a laterally outwardly extending lip  126  having a depth d 10  that extends outwardly from a peripheral edge of the plate  110 . The plate  110  also includes a plurality of spaced apart first beads  132  extending laterally outwardly from the second surface  113 . In a preferred embodiment, the first beads  132  are general wave shaped. The first beads  132  have a depth d 11 . In the embodiment shown, the depth d 10  of the lip  126  is substantially similar to the depth d 11  of the first beads  132 , although other depths can be used as desired. 
         [0036]    The plate  110  also includes a plurality of spaced apart second beads  136  extending laterally outwardly from the first surface  111  of the plate  110 . The second beads  136  are generally trapezoid shaped and have a predetermined width such as five millimeters, for example. It is understood that a larger or smaller width can be used. The second beads  136  have a depth d 12 . In the embodiment shown, the depth d 12  of the second beads  136  is larger than the depth d 11  of the first beads  132 , although other depths can be used. A distal end  140  of the second beads  136  is generally flat. It is understood that the second beads  136  can be dome shaped or have other shapes as desired. 
         [0037]    The plate  110  includes a plurality of spaced apart third beads  142  that are substantially ovoid or football shaped, and extend laterally outwardly from the first surface  111 . The third beads  142  have a depth (not depicted) extending from the first surface  111  and terminating in a substantially flat distal end  145 . It is understood that the distal end  145  of the third beads  142  can be curved as desired. In the embodiment shown, the depth of the third beads  142  is larger than the depth d 12  of the second beads  136 . 
         [0038]    In the embodiment shown, the first beads  132 , the second beads  136 , and the third beads  142  are formed in a pattern of a plurality of rows. It is understood that the beads  132 ,  136 ,  142  can be formed in other configurations as desired. Each row contains a plurality of a predetermined number of the first beads  132 , the second beads  136 , and the third beads  142 , wherein the number of the second beads  136  and the third beads  142  in certain rows is zero (0). The rows of the beads  132 ,  136 ,  142  are spaced longitudinally on the main body portion  116  of the plate  110  a predetermined distance. 
         [0039]    When assembled, a pair of plates  110  are brazed together to form a heat exchange plate (not shown) as discussed above. One of the plates  110  is oriented as shown in  FIGS. 4 and 5 , and the other of the plates is inverted from the orientation of  FIGS. 4 and 5  to permit corresponding lips  126  to abut one another. The lips  126  of the pair of the plates  110  are brazed together. Thus, the first surfaces  111  of the pairs of plates  110  are exposed. The first surfaces  111  of the pair of brazed plates  110  are then brazed together at the raised lips  118 ,  122 , the second beads  136 , and the third beads  142  to form a stack (not shown). A gap (not shown) is formed between the first surfaces  111  of adjacent heat exchanger plates. 
         [0040]    The first apertures  120  of the heath exchanger plates in the stack are aligned and cooperate to form a first conduit (not shown). The second apertures  124  of the plates  110  in the stack are aligned and cooperate to form a second conduit (not shown). A first plurality of flow passages (not shown) is formed in the heat exchange plates between the second surfaces  113  of brazed adjacent plates  110 . A second plurality of flow passages (not shown) is formed within the gaps formed by the first surfaces  111  of adjacent plates  110 . The second plurality of flow passages formed by the gaps between adjacent heat exchanger plates is in fluid communication with a pair of flow headers (not shown). 
         [0041]    Use of the plates  110  is substantially similar to use of the plates  10  as discussed above for  FIGS. 1-3 . The turbulation caused by the first beads  132  to the first fluid and the second fluid minimizes a need for a separate turbulating fin to be disposed between the plates  110 . Accordingly, a cost of materials and a weight are minimized. 
         [0042]    It should be appreciated that the plates  110  could be used for heat exchangers in other applications besides motor vehicles. 
         [0043]    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.