Patent Publication Number: US-9903670-B2

Title: Insert for heat exchanger and heat exchanger having the same

Description:
TECHNICAL FIELD 
     The present disclosure relates to an insert for a heat exchanger. The present disclosure relates to the heat exchanger having the insert. 
     BACKGROUND 
     A vehicle is generally equipped with an air conditioner having a refrigerant cycle. The refrigerant cycle generally includes an evaporator for cooling air drawn into a cabin of the vehicle. It may be desirable to provide individually conditioned air to a front compartment and a rear compartment in the vehicle at different conditions such as different temperatures. 
     SUMMARY 
     According to an aspect of the disclosure, an insert is for a heat exchanger having a plurality of tubes. The insert comprises a base. The insert further comprises a plurality of blades extended from the base. At least one of the blades has a spring portion, which is resiliently deformable and configured to be resiliently inserted between two of the tubes. 
     According to another aspect of the disclosure, an insert is for a heat exchanger having a plurality of tubes. The insert comprises a base. The insert further comprises a plurality of blades extended from the base. At least one of the blades has a spring portion including two arms. The two arms are projected outward to form an aperture therebetween. The spring portion is resiliently deformable inward to squish the aperture when the spring portion is inserted between two of the tubes. 
     According to another aspect of the disclosure, a heat exchanger comprises a plurality of tubes arranged in parallel to form a core including a first section and a second section. The heat exchanger further comprises a first insert inserted between the first section and the second section from one direction to partition the first section from the second section. The first insert is integrally formed in a comb shape to include a first base and a plurality of first blades. The first blades are extended from the first base. At least one of the first blades has a first spring portion, which is resiliently deformable and resiliently inserted between two of the tubes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings: 
         FIG. 1  is a perspective view showing an evaporator and inserts; 
         FIG. 2  is a schematic view showing the evaporator in an HVAC case  400 ; 
         FIG. 3  is a sectional view showing the evaporator and inserts to be inserted in the evaporator; 
         FIG. 4  is a sectional view showing the evaporator and inserts inserted in the evaporator; 
         FIG. 5  is a top view showing a blade of one insert; 
         FIG. 6  is a sectional view showing one insert to be inserted in the evaporator; 
         FIG. 7  is a sectional view showing one insert being inserted in the evaporator; 
         FIG. 8  is a sectional view showing one insert inserted in the evaporator; 
         FIG. 9A  is a sectional view showing a spring portion of the blade according to a first embodiment,  FIG. 9B  is a sectional view showing a spring portion of a blade according to a first modification of the first embodiment,  FIG. 9C  is a sectional view showing a spring portion of a blade according to a second modification of the first embodiment; and 
         FIG. 10  is a sectional view showing one insert inserted in the evaporator according to a second embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     First Embodiment 
     As follows, a first embodiment of the present disclosure will be described with reference to drawings. In the description, a vertical direction is along an arrow represented by “VERTICAL” in drawing(s). A lateral direction is along an arrow represented by “LATERAL” in drawing(s). A depth direction is along an arrow represented by “DEPTH” in drawing(s). A thickness direction is along an arrow represented by “THICKNESS” in drawing(s). A length direction is along an arrow represented by “LENGTH” in drawing(s). A width direction is along an arrow represented by “WIDTH” in drawing(s). 
     As shown in  FIG. 1 , an evaporator  500  (heat exchanger) includes an upper tank  510 , a lower tank  550 , multiple tubes  600 , and multiple fins  700 . The upper tank  510 , the lower tank  550 , the tubes  600 , and the fins  700  are integrated with each other and brazed into one component. The evaporator  500  functions as a component of a refrigerant cycle to circulate a thermal medium, such as CO2, therethrough. The refrigerant cycle includes, for example, the evaporator  500 , a thermal expansion valve, a compressor, and a condenser (none shown), which are connected with each other via unillustrated pipes. The upper tank  510  includes an inlet  512  and an outlet  514 . The inlet  512  is connected with the thermal expansion valve via a pipe. The outlet  514  is connected with the compressor via a pipe. 
     The tubes  600  and the fins  700  are stacked alternately in the lateral direction to form a core. The alternately stacked tubes  600  and fins  700  are interposed between the upper tank  510  and the lower tank  550  at both ends. One ends of the tubes  600  on the upper side are inserted into the upper tank  510  and communicated with a fluid space formed in the upper tank  510 . The other ends of the tubes  600  are inserted into the lower tank  550  and communicated with a fluid space formed in the lower tank  550 . Thus, the upper tank  510 , the tubes  600 , and the lower tank  550  form a fluid passage to flow the thermal medium therethrough. 
     Each of the fins  700  is extended in the vertical direction and is interposed between adjacent tubes  600  in the lateral direction. The fin  700  and the adjacent tubes  600  form air passages to flow air therethrough. The fins  700  enhance a performance of heat exchange between the thermal medium, which flows through the tubes  600 , with air, which passes through the air passages. 
     The core includes a first section  520 , an intermediate section  530 , and a second section  540 . The intermediate section  530  is located between the first section  520  and the second section  540 . The intermediate section  530  is located around the chain line III-III in  FIG. 1 . Each fin  700  of the first section  520  extends downward from its upper end to the intermediate section  530 . Each fin  700  of the second section  540  extends from its lower end upward to the intermediate section  530 . Thus, each fin  700  of the first section  520  and the corresponding fin  700  of the second section  540  form a clearance  532  therebetween in the vertical direction. The fins  700  of the first section  520  stacked in the lateral direction and the fins  700  of the second section  540  stacked in the lateral direction form the clearances  532 , which are linearly arranged in the lateral direction. 
     The evaporator  500  is configured to be equipped with a fore insert (first insert)  10  and a rear insert (second insert)  60  to partition the evaporator  500  into the first section  520  and the second section  540 . In  FIG. 1 , the inserts  10  and  60  are to be inserted into the clearances  532  between the first section  520  and the second section  540  along the bold arrows. The fore insert  10  includes multiple blades (first blades)  20  extended from a base  12 . The blades  20  are configured to be inserted into the clearances  532 , respectively. The rear insert  60  also includes multiple blades (second blades)  70  extended from a base  62 . The blades  70  are configured to be inserted into the clearances  532 , respectively. The fore insert  10  may be identical to the rear insert  60 . 
       FIG. 2  shows a heater and ventilator air conditioner (HVAC) system. In  FIG. 2 , the evaporator  500  is equipped in a case  400  of the HVAC system. The case  400  has partitions  430  to partition an interior of the case  400  into an upper passage  420  and a lower passage  440 . The inserts  10  and  60  are inserted in the evaporator  500  and are connected with the partitions  430 , respectively. 
     The bold arrows show airflows in the upper passage  420  and the lower passage  440 , respectively. The inserts  10  and  60  enables the upper passage  420  on the upstream side of the first section  520  to communicate with the upper passage  420  on the downstream side of the first section  520  through the first section  520 . The inserts  10  and  60  further enables the lower passage  440  on the upstream side of the second section  540  to communicate with the lower passage  440  on the downstream side of the second section  540  through second section  540 . 
     A heater core and doors (none shown) are provided at the downstream of the first section  520  and the second section  540  of the evaporator  500  to heat air after passing through the evaporator  500  and to conduct the air into the front compartment  810  and the rear compartment  820  separately in the vehicle. In the present example, the upper passage  420  and the lower passage  440  are provided with a front fan  710  and a rear fan  720 , respectively, to cause airflows separately. 
     The front fan  710  and the rear fan  720  flow air through the upper passage  420  and the lower passage  440 , respectively, and through the first section  520  and the second section  540  of the evaporator  500 , respectively. Thus, the air flowing through the first section  520  and the air flowing through the second section  540  are conditioned, i.e., cooled separately. Thus, the conditioned air is conducted toward the front compartment  810  and the rear compartment  820  separately. In the present configuration, the inserts  10  and  60  function to restrict air from crosstalk (leakage) between the upper passage  420  and the lower passage  440 . As shown by dotted arrow in  FIG. 2 , the airflows may cause a small crosstalk by an allowable quantity. 
       FIG. 3  is a sectional view showing the intermediate section  530  of the evaporator  500  taken along the line III-III in  FIG. 1 .  FIG. 3  shows the intermediate section  530  before being equipped with the inserts  10  and  60  in the clearances  532 .  FIG. 4  is a sectional views showing the intermediate section  530  of the evaporator  500  being equipped with the inserts  10  and  60  in the clearances  532 . In  FIGS. 3, 4  and in  FIGS. 6 to 8 and 10  mentioned later, hatching for showing cross sections of the tubes  600  and reinforcement  680  are omitted. 
     As shown in  FIG. 3 , the fore insert  10  is to be inserted from one side in the depth direction, and the rear insert  60  is to be inserted from the other side in the depth direction. The depth direction is substantially in parallel with a direction of the airflow described with reference to  FIG. 2 . The evaporator  500  includes two rows of the tubes  600  arranged, with respect to the airflow, on the upstream side and on the downstream side, respectively. Each row includes tubes  600 , which are arranged in parallel along the lateral direction. The tubes  600  interpose the fins  700  alternately therebetween. Each fin  700  extends in the depth direction between the two rows to bridge the tubes  600  in the two rows. The evaporator  500  is equipped with reinforcements  680  at ends, respectively. 
     As shown in  FIG. 4 , the fore insert  10  is inserted into the evaporator  500  from the upstream side of airflow, and the rear insert  60  is inserted into the evaporator  500  from the downstream side of airflow. In the state of  FIG. 4 , each blade  20  is inserted into the corresponding clearance  532 . Thus, each blade  20  is interposed between adjacent two tubes  600  or interposed between the tube  600  and the reinforcement  680 , which are adjacent to each other. In the state of  FIG. 4 , the comb-shaped fore insert  10  and the comb-shaped rear insert  60  are opposed to each other in the depth direction. The blades  20  of the fore insert  10  and the blades  70  of the rear insert  60  are arranged alternately and located substantially at the same level in the vertical direction ( FIG. 1 ). In the present example, the blades  20  of the two inserts  10  and the blades  70  of the rear insert  60  do not overlap one another and positioned within a thin space in the vertical direction. 
     As follows, detailed configurations of the insert  10  will be described. The configurations of the rear insert  60  may be substantially the same as the configurations of the fore insert  10 . Therefore, following detailed description of the fore insert  10  may be applied to the rear insert  60 . 
     The insert  10  is substantially in a comb shape and integrally formed of a resin material such as ABS resin by, for example, injection molding or stamping. The insert  10  includes the blades  20  and the base  12 . The base  12  is substantially in a bar shape. The blades  20  are extended from the base  12  in the same direction perpendicularly to a longitudinal direction of the base  12 . The blades  20  are arranged in parallel along the width direction. 
     As shown in  FIG. 5 , each blade  20  and the base  12  are integrally formed to form a cantilever structure. The blade  20  includes a root end  22 , two arms  30 , and a tip end  28 , which are arranged in this order from the base  12 . The root end  22  extends from the base  12 . The arms  30  are extended from the base  12 . The tip end  28  is extended from the arms  30  to form a free end of the cantilever structure. The tip end  28  is chamfered at its free end. 
     The two arms  30  are arranged in parallel. The two arms  30  form an aperture  30   a  therebetween. The aperture  30   a  is a single hollow space including a first slit  32   a , a center hole  35   a , and a second slit  38   a  in this order. The dimension of the first slit  32   a , the center hole  35   a , and the second slit  38   a  are determined in consideration of a resilience of the two arms  30 , a mechanical strength of the two arms  30 , and an allowable communication (crosstalk) of air between the upper passage  420  and the lower passage  440  ( FIG. 2 ) through the aperture  30   a.    
     The arms  30  are symmetrical with respect to an axis  20   a  of the blade  20 . Each arm  30  includes a first linear portion  32 , a first bent portion  34 , a center portion  35 , a second bent portion  36 , and a second linear portion  38 , which are arranged in this order. The first bent portion  34 , the center portion  35 , and the second bent portion  36  form a C-shaped portion  25  projected outward from the axis  20   a  in the width direction relative to the first linear portion  32  and the second linear portion  38 . 
     The first linear portion  32  is extended linearly from the root end  22  along the axis  20   a . The first bent portion  34  is extended from the first linear portion  32  and inclined outward from the axis  20   a . The first bent portion  34  is inclined relative to the first linear portion  32  and the center portion  35  The center portion  35  is extended linearly along the axis  20   a  and is located outward relative to the first linear portion  32  and the second linear portion  38 . The center portion  35  is connected with the first linear portion  32  via the first bent portion  34 . The center portion  35  is further connected with the second linear portion  38  via the second bent portion  36 . The second bent portion  36  is extended from the center portion  35  and is inclined inward toward the axis  20   a . The second bent portion  36  is inclined relative to the center portion  35  and the second linear portion  38 . The second linear portion  38  extends linearly from the second bent portion  36  to the tip end  28 . The root end  22 , the first linear portion  32 , the center portion  35 , the second linear portion  38 , and the tip end  28  are extended substantially in parallel. 
     The two arms  30  form the first slit  32   a , the center hole  35   a , and the second slit  38   a  therebetween. Specifically, the first linear portions  32  form the first slit  32   a  therebetween. The first bent portions  34 , the center portions  35 , and the second bent portions  36  form the center hole  35   a  thereamong. The second linear portions  38  form the second slit  38   a  therebetween. The first slit  32   a , the center hole  35   a , and the second slit  38   a  are arranged in this order. 
     Each arm  30  is resiliently deformable (bendable) at its various connections. Specifically, each arm  30  is resiliently bendable at a connection between the root end  22  and the first linear portion, at a connection between the first linear portion and the first bent portion  34 , and at a connection between the first bent portion  34  and the center portion  35 . Each arm  30  is resiliently bendable further at a connection between the center portion  35  and the second bent portion  36 , at a connection between the second bent portion  36  and the second linear portion, and at a connection between the second linear portion and the tip end  28 . 
     The arms  30  and the connections among the arms  30 , the root end  22 , and the tip end  28  form a spring portion  24 . The spring portion  24  is configured to be resiliently squished (squishable) inward toward the axis  20   a  when being applied with an external force in the width direction. Specifically, the first linear portions  32  can be bent resiliently inward around the connections with the root end  22  to squish the first slit  32   a . The first bent portions  34  can be bent resiliently inward around the connections with the first linear portions and around the connections with the center portions  35 . The second bent portions  36  can be bent resiliently inward around the connections with the second linear portions  38  and around the connections with the center portions  35 . Thus, the first bent portions  34  and the second bent portions  36  squish the aperture  30   a  with the center portions  35 . The second linear portions  38  can be bent resiliently inward around the connections with the tip end  28  to squish the second slit  38   a . In this way, the spring portion  24  is resiliently deformable inward toward the axis  20   a.    
     As follows, a process to inert the blade  20  into the tubes  600  will be described. As shown in  FIG. 6 , the blade  20  is to be inserted among four tubes  600  including a first front tube  610 , a second front tube  620 , a first rear tube  630 , and a second rear tube  640 . The first front tube  610  and the second front tube  620  are located in parallel with each other in a fore row. The first rear tube  630  and the second rear tube  640  are located in parallel with each other in a rear row. The first rear tube  630  is located linearly behind the first front tube  610 . The second rear tube  640  is located linearly behind the second front tube  620 . The first front tube  610 , the second front tube  620 , the first rear tube  630 , and the second rear tube  640  form an in-between clearance  532 A, 
     In the state of  FIG. 6 , the spring portion  24  has a width W in the width direction. The first front tube  610  and the second front tube  620  form the clearance  532  having a width C in the width direction. The width W is grater than the width C before the spring portion  24  is inserted between the first front tube  610  and the second front tube  620 . In  FIG. 6 , the tip end  28  is inserted between the first front tube  610  and the second front tube  620  frictionally or loosely. As the blade  20  is further inserted, the spring portion  24  makes contact with the first front tube  610  and the second front tube  620 . 
       FIG. 7  shows a state in which the spring portion  24  is further inserted in the depth direction into the clearance  532  between the first front tube  610  and the second front tube  620 . In  FIG. 7 , the tip end  28  is positioned in the in-between clearance  532   a . In addition, the spring portion  24  is squished inward in the width direction and positioned between the first front tube  610  and the second front tube  620 . The arms  30  are interposed between the first front tube  610  and the second front tube  620  and are resiliently bent inward in the width direction. The aperture  30   a  is squished inward in the width direction to enable the spring portion  24  to be positioned between the first front tube  610  and the second front tube  620 . In the state of  FIG. 7 , the width W of the spring portion  24  is reduced to be substantially equal to the width C of the clearance  532 . 
       FIG. 8  shows a state in which the spring portion  24  is further inserted in the depth direction through the clearance  532  between the first front tube  610  and the second front tube  620  into the clearance  532  between the first rear tube  630  and the second rear tube  640 . In  FIG. 8 , the tip end  28  is inserted into the clearance  532  between the first rear tube  630  and the second rear tube  640 . In addition, the spring portion  24  is positioned in the in-between clearance  532   a . The root end  22  is positioned in the clearance  532  between the first front tube  610  and the second front tube  620 . In the state of  FIG. 8 , the spring portion  24  is bent back into its original form before being squished. Therefore, the width W of the spring portion  24  is restored to be grater than the width C of the clearance  532  after the spring portion  24  is inserted into the in-between clearance  532 A. Thus, the spring portion  24  maintains the position of the blade  20  in the depth direction and restricts the blade  20  from being pulled out of the evaporator  500 . The inert  10  may be resiliently detachable from the evaporator  500  when, for example, the evaporator  500  is under a maintenance work. 
     In the state of  FIG. 8 , the spring portion  24  may be supported frictionally or loosely among the first front tube  610 , the second front tube  620 , the first rear tube  630 , and the second rear tube  640 . For example, the spring portion  24  may be resiliently in contact with all the first front tube  610 , the second front tube  620 , the first rear tube  630 , and the second rear tube  640  in four directions. In this case, as shown by the four arrows, the spring portion  24  may be applied with resilient forces F from the contacts with the first front tube  610 , the second front tube  620 , the first rear tube  630 , and the second rear tube  640 . Alternatively, the spring portion  24  may be loosely supported by all or part of the first front tube  610 , the second front tube  620 , the first rear tube  630 , and the second rear tube  640 . 
     In addition, the tip end  28  may be supported frictionally or loosely between the first rear tube  630  and the second rear tube  640 . The root end  22  may be supported frictionally or loosely between the first front tube  610  and the second front tube  620 . 
     The base  12  may be in contact with the first front tube  610  and the second front tube  620  in the depth direction. The tip end  28  of the fore insert  10  may be in contact with the base  62  of the rear insert  60  ( FIG. 4 ), which is inserted from the opposed side in the depth direction. 
     The blades  20  may be placed on upper end surfaces the fins  700  of the second section  540  and supported by the fins  700  when positioned in the state of  FIG. 2 . 
     Modification of First Embodiment 
       FIG. 9A  is a sectional view taken along the line IXA-IXA in  FIG. 5  and showing a cross section of the center portions  35  and the center hole  35   a . In the first embodiment, the dimension of the aperture  30   a  is determined in consideration of, for example, the allowable communication (crosstalk) through the aperture  30   a.    
       FIG. 9B  shows the spring portion  24  equipped with a film  210  according to a first modification. The film  210  is formed in the center hole  35   a . In addition to the center hole  35   a , the film  210  is also formed integrally in the first slit  32   a  and the second slit  38   a  ( FIG. 5 ) to screen and/or block the first slit  32   a , the center hole  35   a , and the second slit  38   a  entirely. The film  210  is formed of an elastic material such as an ethylene propylene diene monomer rubber (EPDM rubber). The film  210  may be formed by insert molding or by dipping the spring portion  24  into a fluidic material of the film  210 . In the example of  FIG. 9B , the film  210  is formed to bridge the center portions  35  therebetween along the width direction. Specifically, the film  210  is formed between center positions of the center portions  35  in the thickness direction. The film  210  may be formed elastic enough to be squished and/or folded, when the spring portion  24  is squished and inserted between the tubes  600  ( FIG. 7 ). The configuration of  FIG. 9B  may effectively restrict the crosstalk through the aperture  30   a.    
       FIG. 9C  shows the spring portion  24  equipped with a film  220  according to a second modification. In addition to the center hole  35   a , the film  220  is formed integrally in the first slit  32   a  and the second slit  38   a  ( FIG. 5 ). The film  220  is formed of an elastic material such as an EPDM rubber. In the example of  FIG. 9C , the film  220  is formed between a lower edge of the center portion  35  on the left side in  FIG. 9C  and an upper edge of the center portion  35  on the right side in  FIG. 9C . That is, the film  220  is inclined relative to both the width direction and the thickness direction. The configuration of  FIG. 9C  may further facilitate the film  220  to be folded and/or squished when the spring portion  24  is squished and inserted between the tubes  600 . The configuration of  FIG. 9C  may also effectively restrict the crosstalk through the aperture  30   a.    
     Second Embodiment 
     As shown in  FIG. 10 , a second embodiment of the present disclosure employs a first tube  1610  and a second tube  1620 , which are arranged in a single row. Dissimilarly to the first embodiment, each of tubes  1610  and  1620  is not separated in the direction of airflow and is integrated along the airflow. In the state of  FIG. 10 , the fore insert  10  is inserted between the adjacent tubes  1610  and  1620 , and the spring portion  24  is squashed inward. Thus, the insert is resiliently and frictionally supported by the adjacent two tubes  1610  and  1620 . In the configuration of  FIG. 10 , the aperture  30   a  is maintained as being squished. Thus, the configuration of the second embodiment may reduce crosstalk between through the aperture  30   a.    
     Other Embodiment 
     The number of the blades  20  may be two or more to form the comb shape of the insert. The spring portion  24  may be formed in at least one of the blades. For example, the spring portion  24  may be formed in three blades including one blade located at the center of the insert and two blades located at both ends of the insert. 
     The fore insert  10  and the rear insert  60  may be integrated into a single piece having all the blades  20  enough to partition the first section  520  from the second section  540 . In this case, the insert may be inserted to the intermediate section  530  from only one direction. The insert may be formed of a metallic material, such as aluminum alloy, by casting or stamping. 
     The fins  700  may be continual between the first section  520  and the second section  540 . In this case, the blades  20  may be inserted into air passages formed between the fins  700  and the tubes  600 . In this case, the air passages, into which the blades  20  are inserted, may function as clearances  532 . 
     The configurations of the present disclosure are not limited to be employed in an evaporator  500  and may be employed in various heat exchangers such as a condenser and/or radiator. The configuration of the present disclosure may be employed in a heat exchanger for an exterior and interior two-layer air conditioning system. In this case, the heat exchanger may be partitioned for separating exterior air passage and an interior air passage. 
     For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical or. 
     It should be appreciated that while the processes of the embodiments of the present disclosure have been described herein as including a specific sequence of steps, further alternative embodiments including various other sequences of these steps and/or additional steps not disclosed herein are intended to be within the steps of the present disclosure. 
     While the present disclosure has been described with reference to preferred embodiments thereof, it is to be understood that the disclosure is not limited to the preferred embodiments and constructions. The present disclosure is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, which are preferred, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the present disclosure.