Patent Publication Number: US-9429367-B2

Title: Automobile condenser having enhanced integration

Description:
RELATED APPLICATIONS 
     This application claims priority to and all the advantages of International Patent Application No. PCT/EP2010/064358, filed on Sep. 28, 2010, which claims priority to French Patent Application No. FR 09/04668, filed on Sep. 30, 2009. 
     The invention relates to the field of air conditioning circuits, in particular for motor vehicles. 
     It concerns more specifically a condenser, to be used in such a circuit, comprising punched plates stacked in a longitudinal direction and defining first blades intended for the circulation of a first fluid as well as second blades intended for the circulation of a second fluid, the said second blades being interleaved with the said first blades; two first collectors formed by the alignment in the longitudinal direction and the placing in fluid communication of inlet and outlet orifices belonging respectively to the blades intended for the first fluid, a first of the said first collectors, known as the inlet collector for the first fluid, comprising at least two connection lines, the other of the said first collectors, known as the outlet collector for the first fluid, comprising at least two other connection lines; a first inlet pipe stub intended for the first fluid discharging into one connection line, referred to as upstream, of the said connection lines of the inlet collector for the first fluid; a first outlet pipe stub intended for the first fluid discharging into a connection line, referred to as downstream, of the said connection lines of the outlet collector for the first fluid, the said connection lines of the inlet collector and the said connection lines of the outlet collector for the first fluid being arranged to permit the alternating circulation of the first fluid from the inlet collector towards the outlet collector, from the upstream connection line towards the downstream connection line. 
     A condenser of this type is already known, in particular from FR 2 846 733. 
     Condensers of this type must be mounted in the interior of the vehicle and connected to the circuits of the first and second fluids. The size and the connection possibilities of these condensers are especially critical for the integration of the condensers into the vehicle. In addition, ready accessibility to the connection between the condenser and the rest of the circuits is sought in order to facilitate assembly and subsequent maintenance operations. 
     Because currently known condensers have proven to be only partially satisfactory, the applicant has adopted the aim of improving the situation. 
     The proposed condenser is a condenser as defined by way of introduction comprising an outlet line placing the said downstream connection line in communication with the said outlet pipe stub in such a way that the first inlet pipe stub and the first outlet pipe stub are provided on the same first end surface of the said stack. 
     Thus, the inlets and outlets for the first fluid, including when this concerns the refrigerant fluid passing through the condenser, are on the same side of the exchanger. This facilitates integration in the motor vehicle and improves accessibility to the connections of the condenser in question. 
     In the configuration of the condenser according to the invention, the said upstream connection line is close to the said first end surface, whereas the said downstream connection line is remote from it. 
     The condenser additionally comprises, for example, two second collectors formed by the alignment in the longitudinal direction and the placing in fluid communication of inlet and outlet orifices belonging respectively to the blades intended for the second fluid. 
     According to one embodiment, the said first collectors are mutually juxtaposed in the lateral direction and/or the said second collectors are mutually juxtaposed in the lateral direction. 
     The first inlet pipe stub and/or the first outlet pipe stub are able to pass through the said first end surface. 
     The said condenser comprises, for example, blanking plates for the inlet and/or outlet orifices belonging to the blades intended for the first fluid, each being a blanking plate defining two connection lines in the first respective connector. At least one of the blanking plates is also adapted to be passed through by the outlet line. 
     For this purpose, the said blanking plate is provided, for example, with an orifice having a form corresponding to the cross section of the outlet line, at least in the vicinity of the said blanking plate, and with a sealing means arranged externally between the outlet line and the blanking plate. The sealing means comprise, in particular, a solder deposit. 
     According to one embodiment, the outlet line passes successively through the inlet and/or outlet orifices of each blade forming a connection line adjacent to the downstream connection line in the outlet collector for the first fluid. 
     The outlet line is also able to pass through the inlet and/or outlet orifices of each blade forming each connection line arranged longitudinally between the first end surface and the downstream connection line in the outlet collector for the first fluid. 
     According to one particular embodiment, a first part of the said stack defines the second blades interleaved with a part of the said first blades, whereas a second part of the stack defines third blades intended for the circulation of a third fluid, the said third blades being interleaved with the other part of the said first blades, the said downstream connection line belonging to the second part of the said stack. 
     According to this embodiment, the condenser additionally comprises, for example, two third collectors that are mutually juxtaposed in the lateral direction and are formed by the alignment in the longitudinal direction and the placing in fluid communication of inlet and outlet orifices belonging respectively to the blades intended for the second fluid, the said third collectors being defined in their entirety by at least two connection lines; a third inlet pipe stub and a third outlet pipe stub intended for the third fluid. 
     The third inlet pipe stub and the third outlet pipe stub pass through, in particular, a second end surface of the said stack, the said second surface being longitudinally opposite the said first end surface. 
     The third inlet pipe stub and the third outlet pipe stub can be in fluid communication respectively with the third collectors. 
     The said first and second parts of the said stack are, for example, separated from one another by an intermediate separation plate. The latter consists of, in particular, a first orifice adapted to be passed through by the outlet pipe stub. It can also be adapted to block the inlet and outlet orifices belonging to the blades intended for the second fluid that are remote from the said first end surface. 
     According to one particular embodiment, the separation plate is provided with supplementary orifices calibrated to place the second collectors and the third collectors respectively in fluid communication, the second and the third fluids then being the same and the condenser exhibiting a single inlet pipe stub and a single outlet pipe stub for the said same fluid. 
    
    
     
       Other characteristics and advantages of the invention will become apparent from an examination of the following detailed description and the accompanying drawings, in which: 
         FIG. 1  illustrates a first embodiment of a condenser according to the invention, viewed in isometric perspective, 
         FIG. 2  illustrates the condenser in  FIG. 1  viewed in exploded isometric perspective, certain of the plates having been omitted, 
         FIG. 3  illustrates the condenser in  FIG. 1  viewed in plan and from above, 
         FIG. 4  is a view of the condenser in  FIG. 1  viewed in cross section according to the line IV-IV in  FIG. 3 , 
         FIG. 5  illustrates the condenser in  FIG. 1  viewed in cross section according to the line V-V in  FIG. 3 , and 
         FIG. 6  illustrates a second embodiment of a condenser in a view similar to that in  FIG. 5 . 
     
    
    
     The drawings comprise, in the main, elements of a certain character. Nevertheless, they can be used not only to facilitate understanding of the description, but also to contribute to its definition, should this be necessary. 
       FIGS. 1 to 5  illustrate a condenser  10  intended to be part of an air conditioning circuit, not depicted here, in particular for a motor vehicle. 
     In such a circuit, a refrigerant fluid, or a first fluid, passes in a closed loop through a compressor, the aforementioned condenser, a pressure reducer and an evaporator, before returning to the compressor, and so on. 
     Here, the condenser  10  is intended to function with a refrigerant fluid that is capable of being present both in liquid form and in gaseous form, for example a fluorinated fluid such as that known as R134a. 
     The condenser  10  comprises a first heat exchange block  12  to ensure the cooling of the refrigerant fluid until its point of condensation by means of a first cooling fluid. 
     This cooling fluid may consist of water with the addition of an antifreeze agent, for example of the glycol type. 
     The condenser  10  also comprises a second heat exchange block  14  to ensure sub-cooling of the refrigerant fluid by means of a second cooling fluid. 
     The second cooling fluid may also be constituted by water with the addition of an antifreeze agent. In particular, the second cooling fluid and the first cooling fluid may together form one and the same fluid circulating in one and the same circuit. 
     The condenser  10  may also comprise a bottle, not depicted here, disposed between the first block  12  and the second block  14  and suitable to be passed through by the refrigerant fluid. 
     The refrigerant fluid in the gaseous phase, as it arrives from the compressor, is initially cooled until its point of condensation in the first block  12 . If necessary, this refrigerant fluid passes through the bottle, where it is filtered and dehydrated. The condensed refrigerant fluid then passes through the second block  14 , which ensures its sub-cooling. 
     The condenser  10  also comprises a first sole plate  16  and a second sole plate  18 , both of which sole plates are interleaved between the first block  12  and the second block  14 . The first sole plate  16  and the second sole plate  18  form interfaces for the circulation of refrigerant fluid between this first block  12  and this second block  14 . 
     In a variant embodiment, not depicted here, the condenser comprises a specific plate of similar form to the other plates of the first and the second block, but exhibiting only two orifices, the said specific plate separating the said blocks while at the same time permitting, through its said two orifices, communication of the refrigerant fluid between the two blocks. 
     The first block  12  comprises a series of punched plates  20  stacked in one longitudinal direction of the condenser  10 . In this case, the punched plates  20  exhibit the general form of a rectangular bowl. The punched plates  20  of the first block  12  define circulation blades for the refrigerant fluid, which alternate with circulation blades for the first cooling fluid. In other words, these punched plates  20  define first blades intended for the circulation of the refrigerant fluid and second blades intended for the circulation of the first cooling fluid, the said second blades being interleaved with the said first blades. 
     The second block  14  also comprises a series of punched plates  22  stacked in the longitudinal direction of the condenser  10 . In this case, the punched plates  22  exhibit a general appearance similar to that of the punched plates  20 . These punched plates  22  form circulation blades for the refrigerant fluid, which alternate with circulation blades for the second cooling fluid. In other words, these punched plates  22  define third blades intended for the circulation of the second refrigerant fluid, the said third blades being interleaved in a part of the said first blades. 
     In other words, the stack of punched plates  20  and  22  comprises a first part corresponding to the first heat exchange block  12 , which defines second blades interleaved in a first part of the said first blades, whereas the other part of this stack of plates defines third blades interleaved in the other part of the said first blades. 
     The punched plates  20  of the first block  12  are maintained between the first sole plate  16  and a first end plate  24 , longitudinally opposite the first sole plate  16 . The punched plates  22  of the second block  14  are contained between the second sole plate  18  and a second end plate  26 , longitudinally opposite the second sole plate  18 . 
     The first end plate  24  carries a coupling flange  28  for the inlet of the refrigerant fluid for condensation and a coupling flange  30  for the outlet of this condensed and sub-cooled refrigerant fluid. In  FIG. 4 , the circulation of this refrigerant fluid inside the condenser  10  is illustrated by arrows F 1 . 
     The first cooling fluid penetrates into the first block  12  via an inlet pipe stub  32  and exits from it via an outlet pipe stub  34 , both supported by the first end plate  24 . In  FIG. 5  The circulation of the first cooling fluid is represented by an arrow F 2 . 
     The second cooling fluid penetrates into the second block  14  via an inlet pipe stub  36  and exits from it via an outlet pipe stub  38 , both supported by the second end plate  26 . In  FIG. 5 , the circulation of the second cooling fluid is represented by an arrow F 3 . 
     The first and the second cooling fluid can be one and the same fluid taken at different points from the same circuit, or different fluids in the sense that they exhibit different compositions and/or belong to different circuits. 
     Each of the punched plates  20  of the first block  12  exhibits four circular orifices  39 , for example situated in the vicinity of each corner of the plate provided in substantially rectangular form. Each of the orifices of the same punched plate  20  belongs to an alignment, in the longitudinal direction, of the equivalent orifices of the group of punched plates  20  of the first block  12 . 
     In the same way, each of the punched plates  22  of the second block  14  is pierced by four circular orifices. Two of these orifices belong respectively to two alignments of equivalent orifices in the punched plates  22  of this block  14 , whereas the other two orifices belong to two respective alignments of the first heat exchange block  12 . 
     In a particular manner, each orifice of a punched plate  22  of the second block  14  is in alignment here, in the longitudinal direction with an alignment of equivalent orifices of punched plates  20  in the first block  12 . 
     The alignment of these latter orifices forms two first collectors  40  and  42 , mutually juxtaposed in the lateral direction, formed by the alignment, in the longitudinal direction, and the placing in fluid communication of inlet and outlet orifices belonging respectively to the blades intended for the refrigerant fluid. 
     These first two collectors  40  and  42  are formed by orifices belonging to punched plates  20  of the first block  12  and orifices arranged in the punched plates  22  of the second heat exchange block  14 . Two second collectors mutually juxtaposed in the lateral direction, formed by the alignment in the longitudinal direction and the placing in fluid communication of inlet and outlet orifices belonging respectively to the blades intended for the first cooling fluid, are also formed. These second collectors are formed by the alignment of orifices belonging to punched plates  20  of the first block  12  only. 
     Two third collectors, mutually juxtaposed in the lateral direction, formed by the alignment in the longitudinal direction and the placing in fluid communication of inlet and outlet orifices belonging respectively to the blades intended for the second cooling fluid, are also formed. These third collectors are formed by the alignment of orifices arranged in punched plates  22  of the second heat exchange block  14  only. 
     The first collectors  40  and  42  in their entirety are defined as a plurality of connection lines. 
     Thus, the first inlet collector  40 , attached to the inlet coupling flange  28 , is partitioned into four connection lines  52 ,  54 ,  56  and  58 , adjacent one to the other, whereas the first outlet collector  42 , attached to the outlet coupling flange  30 , is partitioned into three connection lines  60 ,  62  and  64 . 
     The coupling flange  28  for the inlet of refrigerant fluid discharges into the connection line  52  of the first inlet collector  40 . The connection line  52  thus forms an upstream connection line, close to the first end plate  24 . From there, the refrigerant fluid circulates within a part of the punched plates  20  in order to reach the connection line  60  of the first outlet collector  42 . From there, the refrigerant fluid passes laterally through the condenser  10  in order to reach the connection line  54  of the first inlet collector  40 , then the connection line  62  of the first outlet collector  42 , then the connection line  56  of the first inlet collector  40 , adjacent to the connection line  54  according to an alternating circulation of the first inlet collector towards the first outlet collector. 
     The connection line  58  of the first inlet collector  40  is formed by the alignment of the orifices of each of the punched plates  22  of the second heat exchange block  14 . 
     The first sole plate  16  and the second sole plate  18  are pierced respectively by a passageway, the two passageways coinciding one with the other to permit the passage of the refrigerant fluid from the connection line  56 , of the first block  12 , to the connection line  58  of the second block  14 . 
     From there, the refrigerant fluid reaches the connection line  64 , which thus forms a downstream line that is remote from the first end surface  24 . 
     The connection line  64  of the second block  14  is separated from the adjacent connection line  62  by the first sole plate  16  and the second sole plate  18 . These first and second  18  sole plates in this case are in mutual support over the largest part of their surface. 
     The rest of the connection lines  52 ,  54 ,  56 ,  60  and  62  are partitioned one in relation to the other by blocking the corresponding orifice of a punched plate  20  of the first block  12 , for example by means of a flat plug  66  that is visible in  FIG. 2 . 
     An outlet line  68  connects the outlet coupling flange  30  in fluid connection with an orifice  70  arranged in the second sole plate and discharging into the connection line  64  of the second block  14 . Here, the extremity of the inlet pipe stub  68 , close to the second block  14  is received in an adapted bore  72  provided in the first sole plate  16 . 
     The refrigerant fluid passes from the connection line  64  to the coupling flange  30  through the intermediary of the outlet line  68  in order to exit from the condenser  10 . 
     The outlet line  68  thus passes through a part of the first outlet collector  40 , specifically the connection lines  60  and  62 . 
     In other words, the outlet pipe stub  68  passes through the equivalent orifices of each of the punched plates  20  of the block  12 . 
     The flat plug  66  ensuring the separation of the connection line  60  from the connection line  66  is pierced by a conformed hole corresponding to the peripheral contour of the outlet line  68  at this level. 
     A soldering operation ensures sealing between the external wall of the outlet line  68  and the said flat plug  66 , by creating a deposit of solder there. 
     In general terms, the connecting line  68  passes through the first outlet collector  42 , being coaxial with it, the said connecting line  68  providing an annular passage for the circulation of the said first fluid in the one or more said connecting lines  60 ,  62  that are present above the downstream connecting line  64 . 
     The first cooling fluid penetrates into the first block  12  via the inlet pipe stub  32  and reaches the second inlet collector  44 . 
     From there, the cooling fluid passes through the condenser  10  through the intermediary of the blades that are intended for it and arrives at the second outlet collector  46  for exit via the pipe stub  34 . 
     One or more additional passes by this cooling liquid could be provided in a manner similar to that described above. 
     The second cooling fluid enters the second block  14  via the pipe stub  36  and thus discharges into the third inlet collector  48 . This cooling fluid reaches the outlet collector  50  through the intermediary of the blades that are intended for it and exits via the pipe stub  38 . 
     One or more additional passes could be provided in this case, too. 
       FIG. 6  illustrates a second condenser  20  as a variant of the condenser  10 . The condenser  20  differs from the condenser  10  in that the same cooling fluid is utilized in the first heat exchange block  12  and the second heat exchange block  14  as the first cooling fluid and the second cooling fluid respectively. 
     In this embodiment, the second end plate  50  is devoid of an inlet pipe stub  36  and an outlet pipe stub  38 . The first sole plate  16  and the second sole plate  18  are provided with calibrated orifices  78  and  80 , in correspondence with the third inlet collector  48  and the third outlet collector  50 , in order to provide a passage for the cooling fluid from the first heat exchange block  12  to the second heat exchange block  14 . 
     In another variant embodiment, an inlet pipe stub is provided for the second and third fluids on each of the blocks, whereas a single outlet pipe stub is provided for the said second and third fluids, the condenser permitting a mixture of the said second and third fluids in one of the said second or third outlet collector, pre-disposed for connection to the said single outlet pipe stub. In this variant, the one or more sole plates or separation plates between the two blocks are pierced with an orifice to permit the said second and third outlet collectors to be brought into communication, the said second and third inlet collectors being kept separate by the said one or more sole plates or separation plates. 
     All the connections of the condenser  20  to the rest of a fluid circuit are arranged on a same end surface of this condenser  20 , namely the first end plate  24 . 
     As a supplement or in addition, the second block  14  could be replaced by or completed with an internal heat exchanger, that is to say a heat exchanger in which the same fluid circulates in the two types of blades under different conditions of temperature and pressure. 
     The stack of punched plates  22  of the second block  14  can then be oriented in the opposite way in relation to the punched plates  20  of the first block  12 . 
     Here, the punched plates  20  of the first block  12  and those  22  of the second block  14  are configured in a similar manner and are stacked in such a way as to be oriented in an alternating fashion in relation to one another. This permits a condenser  10  to be produced at a lower cost and facilitates its assembly. For all that, the plates  20  of the first block  12  and those  22  of the second block  14  could differ from one another in their form, in the material utilized for their realization, or in other ways. 
     In a similar manner, the stacking pitch of the punched plates  20  of the first block  12  and that of the plates  22  of the second block  14  may differ from one another. 
     Although the first sole plate  16  and the second sole plate  18  are shown bearing against one another, they may also be remote from one another, in particular if it is necessary to interleave a circuit element between the first block  12  and the second block  14 . 
     The invention is not restricted to the embodiments described above, which are provided solely by way of example, but includes all the variants that could be envisaged by a person skilled in the art.