Abstract:
A bracket for stabilizing a heat exchanger has a base member extending between first and second ends. An aperture at the first end of the base member receives a fastener. The bracket is fixedly secured to a vehicle through the fastener. A flex zone extends between the first and second ends of the base member. The flex zone is movable between a first, relaxed position and a second, flexed position.

Description:
FIELD 
       [0001]    The present disclosure relates to heat exchangers, and more particularly, to a vibration stabilization system for heat exchangers. 
       BACKGROUND 
       [0002]    This section provides background information related to the present disclosure which is not necessarily prior art. Heat exchangers may be used to cool liquids that are continuously circulated through heat generating devices on a vehicle. For example, a vehicle air-conditioning system may compress a refrigerant, which is then cooled by passing through a multi-cooler. 
         [0003]    The rate at which heating and cooling occurs depends upon the temperature, flow rate, and quantity of heat of incoming liquid supplied into and through the material of the heat exchanger relative to the temperature and rate of change of the temperature of external airflow. While external airflow may be delivered to the heat exchanger through either natural flow and/or with the assistance of a fan, the material of the heat exchanger may still increase in temperature over time. Additionally, certain heat exchangers experience internal temperature differentials related to their specific operation. For example, during operation of a multi-cooler the temperature of an oil cooler reaches a much higher temperature than that of a condenser. This higher temperature translates to higher thermal expansion in the oil cooler. 
         [0004]    Thermal stress occurs as a result of expansion and contraction of the material of the heat exchanger during heating and cooling cycles with respect to constrained locations. For example, the multi-cooler experiences thermal stress in a header plate at locations between the oil cooler and the condenser. 
         [0005]    A post-braze saw cut in the header plate of the multi-cooler may alleviate thermal stresses by allowing unrestrained expansion between the two portions; however, such a post-braze saw cut reduces stiffness in the multi-cooler. Current designs incorporate multiple brackets or complex-shaped brackets. What is needed, then, is a structure for reintroducing stiffness to the multi-cooler to stabilize against vibration, while providing a cost savings and a less complex design compared to current designs. 
       SUMMARY 
       [0006]    This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
         [0007]    A bracket for stabilizing a heat exchanger has a base member extending between first and second ends. An aperture at the first end of the base member receives a fastener. The bracket is fixedly secured to a vehicle through the fastener. A flex zone extends between the first and second ends of the base member. The flex zone is movable between a first, relaxed position and a second, flexed position. 
         [0008]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0009]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0010]      FIG. 1  is a side view of a vehicle depicting the location of an engine and heat exchanger in accordance with the present disclosure; 
           [0011]      FIG. 2  is a front view of a multi-cooler depicting a location of a relief bracket in accordance with the present disclosure; 
           [0012]      FIG. 3A  is a plan view showing the relief bracket in accordance with an embodiment of the present disclosure; 
           [0013]      FIG. 3B  is a side view of the relief bracket of  FIG. 3A ; 
           [0014]      FIG. 4A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0015]      FIG. 4B  is a side view of the relief bracket of  FIG. 4A ; 
           [0016]      FIG. 5A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0017]      FIG. 5B  is a side view of the relief bracket of  FIG. 5A ; 
           [0018]      FIG. 6A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0019]      FIG. 6B  is a side view of the relief bracket of  FIG. 6A ; 
           [0020]      FIG. 7A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0021]      FIG. 7B  is a side view of the relief bracket of  FIG. 7A ; 
           [0022]      FIG. 8A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0023]      FIG. 8B  is a side view of the relief bracket of  FIG. 8A ; 
           [0024]      FIG. 9A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0025]      FIG. 9B  is a side view of the relief bracket of  FIG. 9A ; 
           [0026]      FIG. 10A  is a perspective view showing a stabilizer in accordance with an embodiment of the present disclosure; 
           [0027]      FIG. 10B  is a side view of the stabilizer of  FIG. 10A ; 
           [0028]      FIG. 11A  is a perspective view showing a stabilizer in accordance with an embodiment of the present disclosure; 
           [0029]      FIG. 11B  is a side view of the stabilizer of  FIG. 11A ; 
           [0030]      FIG. 12A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0031]      FIG. 12B  is a side view of the relief bracket of  FIG. 12A ; 
           [0032]      FIG. 13A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0033]      FIG. 13B  is a side view of the relief bracket of  FIG. 13A ; 
           [0034]      FIG. 14A  is a plan view showing the relief bracket in accordance with another embodiment of the present disclosure; 
           [0035]      FIG. 14B  is a front view of an attachment location of the relief bracket of  FIG. 14A ; 
           [0036]      FIG. 15A  is a plan view of a multi-cooler of the present disclosure before a saw-cut operation; 
           [0037]      FIG. 15B  is a side view of the multi-cooler of  FIG. 15A ; 
           [0038]      FIG. 16A  is a plan view of the multi-cooler of  FIG. 15A  during the saw-cut operation; 
           [0039]      FIG. 16B  is a side view of the multi-cooler of  FIG. 16A ; 
           [0040]      FIG. 17  is a plan view of the multi-cooler of  FIG. 15A  after the saw-cut operation; 
           [0041]      FIG. 18  is a plan view of the multi-cooler of  FIG. 15A  after installation of a relief bracket in accordance with the present disclosure; 
           [0042]      FIG. 19A  is a plan view of a multi-cooler of the present disclosure before another embodiment of a saw-cut operation; 
           [0043]      FIG. 19B  is a side view of the multi-cooler of  FIG. 19A ; 
           [0044]      FIG. 20A  is a plan view of the multi-cooler of  FIG. 15A  during the saw-cut operation; 
           [0045]      FIG. 20B  is a side view of the multi-cooler of  FIG. 20A ; and 
           [0046]      FIG. 21  is a plan view of the multi-cooler of  FIG. 15A  after the saw-cut operation. 
       
    
    
       [0047]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0048]    Example embodiments will now be described more fully with reference to  FIGS. 1-21  of the accompanying drawings. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies will not be described in detail. 
         [0049]    Referring now to  FIG. 1 , a motor vehicle  10  (e.g., automobile) may be equipped with an engine  12  and a multi-cooler  14 . Multi-cooler  14  may be fixedly secured to a frame member  16  of motor vehicle  10  within an engine compartment  18 . While the following description refers to the heat exchanger as multi-cooler  14 , it should be understood that the teachings of the present disclosure might also be applicable to other types of heat exchangers. For example, the present disclosure may be applicable to transmission cooler heat exchangers (i.e., for cooling transmission fluid of an automatic transmission) and heater core heat exchangers (i.e., for transferring heat to a passenger compartment of a vehicle). Additionally, the teachings of the present disclosure may be applicable whether such heat exchangers are made of metal, plastic, or any other material. 
         [0050]    With reference now to  FIG. 2 , multi-cooler  14  may include an inlet manifold  20  for receiving heated and/or compressed fluid, a main core  22  for cooling the compressed fluid, and an outlet manifold  24  for expelling the cooled fluid. Multi-cooler  14  may be secured to a location within engine compartment  18  through a plurality of fasteners  26  (e.g., bolts) extending through a plurality of mounting brackets  28 . 
         [0051]    In an isochoric cooling operation, heated and/or compressed fluid may be delivered to inlet manifold  20  of multi-cooler  14  for balanced distribution to main core  22 . Main core  22  may incorporate a plurality of channels  30  surrounded by a plurality of ribs or fins  32 . As the heated fluid flows through channels  30  of main core  22 , heat may be expelled through fins  32 . External airflow delivered to multi-cooler  14  through either natural flow (as depicted by arrows  34 ) and/or through a mechanical device, such as by a fan  36 , may also assist in removing heat from main core  22 . The cooled fluid may then be passed to outlet manifold  24  before being reintroduced to vehicle  10 . 
         [0052]    Main core  22  may be divided into an oil cooler portion  40  and a condenser portion  42  so as to receive and cool a first fluid, such as oil from a motor vehicle transmission, and a second fluid, such as a refrigerant from a vehicle air conditioner. As should be understood, inlet and outlet manifolds  20 ,  24  may include an internal separation plate (not shown) to prevent intermixing of fluids between oil cooler portion  40  and condenser portion  42 . Oil cooler and condenser portions  40 ,  42  of main core  22  may be rigidly joined over a distance between inlet and outlet manifolds  20 ,  24  through a joining operation so as to form an attachment region  44  (e.g., brazing or soldering). 
         [0053]    Both oil cooler  40  and condenser  42  may experience temperature fluctuations after repeated operation and as the temperature in engine compartment  18  rises. The rate at which heating and cooling occurs depends upon the temperature, flow rate, and quantity of heat of incoming liquid supplied to oil cooler  40  and condenser  42  relative to the temperature and rate of change of the external temperature. Increases in temperature may result in thermal expansion of certain components of oil cooler  40  and condenser  42 , while decreases in temperature may result in thermal constriction of these same components. Further, these temperature fluctuations may vary between oil cooler  40  and condenser  42  because of the alternate materials flowing therethrough. These temperature fluctuations may result in thermal stress at constrained locations of oil cooler  40  and condenser  42 , such as at manifolds  20 ,  24 . In order to alleviate these thermal stresses, inlet manifold  20  may be partitioned, such as at saw-cut region  46 . 
         [0054]    In order to retain the independent motion of oil cooler  40  and condenser  42  while still fixing multi-cooler  14  to engine compartment  18 , a thermal expansion relief bracket  48  may be fastened to saw-cut region  46 . Relief bracket  48  may provide for controlled movement between oil cooler  40  and condenser  42  while increasing durability and vibratory strength. 
         [0055]    Referring now to  FIGS. 3 through 9 , multiple embodiments of a flexible relief bracket  148  are shown having a substantially straight base  50  extending from a fixed end  52  to a relief end  54 . A first rib  56  may extend a predetermined distance L 1  from an upper surface  58  of base  50 , so as to provide a channel or concavity  60  along a lower surface  62  of base  50 . First rib  56  may extend from a first side  64  of base  50  to an opposing second side  66  of base  50  and may be bisected by a relief aperture  68  (see  FIGS. 3 ,  4 , and  5 ) or by a slot  69  (see  FIG. 9 ). Alternatively, first rib  56  may terminate at relief aperture  68  or slot  69  (see  FIGS. 6 ,  7 , and  8 ). 
         [0056]    Relief aperture  68  or slot  69  may be located centrally on base  50  and may extend parallel to first and second sides  64 ,  66  over a distance L 2 . Relief aperture  68  or slot  69  may begin a predetermined distance L 3  from fixed end  52  and may either terminate a predetermined distance L 4  from relief end  54  (e.g., aperture  68 ) or may extend through relief end  54  (e.g., slot  69 ). 
         [0057]    In certain embodiments, a second rib  70  substantially similar to first rib  56 , may also extend from first side  64  of base  50  and terminate at opposing second side  66  of base  50  (see  FIG. 4 ). Alternatively, second rib  70  may terminate at relief aperture  68  (see  FIGS. 3 and 5 ) or slot  69  (see  FIG. 8 ). It should be understood that ribs  56 ,  70  may extend in any manner over base  50  (e.g., laterally, diagonally, curved). 
         [0058]    Flexible relief bracket  148  may be fixedly secured to oil cooler portion  40  of multi-cooler  14  through a mounting fastener  72  ( FIG. 2 ) extending through a first hole  74  and to condenser portion  42  through a mounting fastener  76  ( FIG. 2 ) extending through a second hole  78 . Flexible relief bracket  148  may also be secured to a location within engine compartment  18  through fastener  26  as described with respect to mounting brackets  28 . In this way, as oil cooler  40  and condenser  42  expand and contract, flexible relief bracket  148  may stiffen the structure at saw-cut region  46  while still absorbing vibration and allowing for expansion and contraction. In particular, ribs  56 ,  70  may be configured so as to flex to absorb the strain between oil cooler  40  and condenser  42 . 
         [0059]    Additionally, aperture  68  allows flexible relief bracket  148  to absorb the tension and/or compression stresses generated perpendicular to the length of flexible relief bracket  148 . Thus, flexible relief bracket  148  of the present design behaves as both a bracket and a stabilizer reducing and/or eliminating thermal stresses and vibration in the fore/aft direction, cross car direction, and up/down direction. This reduction of the thermal stresses and vibration increases durability and rigidity of multi-cooler  14 . The design of flexible relief bracket  148  also allows for manufacture by stamping or extrusion, thereby minimizing manufacturing costs and potentially increasing the rate of production. 
         [0060]    Design benefits of the present embodiment may also be used with heat exchanger designs that omit mounting brackets. With reference to  FIGS. 10 through 11 , a stabilizer  248  may be designed to be substantially similar to flexible relief bracket  148  shown in  FIGS. 3 through 9  except omitting fixed end  52  and fastener  26 . Stabilizer  248  achieves the same benefits as flexible relief bracket  148 , but is not fixed to vehicle  10 . 
         [0061]    Other embodiments of the disclosure will be described with reference to  FIGS. 12 through 14 . Like or similar parts to those of the first embodiment are designated by like or similar reference numerals and will not be described in detail herein. 
         [0062]    Multiple embodiments of a sliding relief bracket  348  are shown having a substantially straight base  350  extending from a fixed end  352  to a relief end  354 . Sliding relief bracket  348  may be fixedly secured to oil cooler portion  40  of multi-cooler  14  through a pin or mounting fastener  72  ( FIG. 2 ) extending through a first hole  374  and to condenser portion  42  through a mounting fastener  76  ( FIG. 2 ) extending through a slotted aperture  380  (see  FIG. 12 ) or through an open slot  382  (see  FIG. 13 ). Sliding relief bracket  348  may also be secured to a location within engine compartment  18  through fastener  26  as described with respect to mounting brackets  28 . In this way, as oil cooler  40  and condenser  42  expand and contract, sliding relief bracket  348  may stiffen the structure at saw-cut region  46  while still absorbing vibration and allowing for expansion and contraction. In particular, mounting fastener  76  may slide within slotted aperture  380  or open slot  382  so as to absorb the strain between oil cooler  40  and condenser  42 . It should be understood that a rubber grommet  384  may be incorporated with slotted aperture  380  or open slot  382  so as to absorb additional thermal strain between oil cooler  40  and condenser  42 . 
         [0063]    Thus, sliding relief bracket  348  of the present design behaves as both a bracket and a stabilizer reducing and/or eliminating thermal stresses and vibration in the fore/aft direction, cross car direction, and up/down direction. This reduction of the thermal stresses and vibration increases durability and rigidity of multi-cooler  14 . The design of sliding relief bracket  348  also allows for manufacture by stamping or extrusion, thereby minimizing manufacturing costs. 
         [0064]    A method for manufacturing multi-cooler  14  of the present disclosure will now be described with reference to  FIGS. 15 through 18 . In a first operation as shown in  FIG. 15A , a bracket mounting block  486  is brazed onto a main core  422  of multi-cooler  14  at a saw-cut region  488  (See  FIG. 15 ). A saw  490  is then brought into contact with bracket mounting block  486  at a mid-portion  488  of bracket mounting block  486 , so as to separate both bracket mounting block  486  and an inlet manifold  420  (See  FIG. 16 ). Saw  490  is then removed, leaving a saw-cut region  446 , as shown in  FIG. 17 . Bracket  148 ,  348  of the present disclosure is then bolted to saw-cut region  446  with fasteners  72 ,  76  as described above (See  FIG. 18 ). 
         [0065]    Another method for manufacturing multi-cooler  14  of the present disclosure will now be described with reference to  FIGS. 19 through 21 . In a first operation as shown in  FIG. 19A , bracket  148 ,  348  of the present disclosure is secured to a main core  522  of multi-cooler  14  at a saw-cut region  588  (e.g., brazing or soldering). A saw  590  is then brought into contact with bracket  148 ,  348  at a mid-portion  588  of bracket  148 ,  348 , so as to separate an inlet manifold  520  (See  FIG. 20 ). Saw  590  is then removed, leaving a saw-cut region  546  and slot  69 ,  369 , as shown in  FIG. 21 . 
         [0066]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.