Patent Publication Number: US-2010126704-A1

Title: Heat Exchanger with Direct Flow Path Modules

Description:
TECHNICAL FIELD 
     The present disclosure relates to heat exchangers, and more particularly to modular heat exchangers. 
     BACKGROUND 
     Machine and engine systems include a variety of heat exchangers to cool components, fluids, and air. Such heat exchangers include, for example, engine radiators and air-to-air aftercoolers (ATAAC) associated with a turbocharger. These heat exchangers include a core with a plurality of tubes to pass a cooling media through and fins to help dissipate heat. 
     The use of a modular heat exchanger may improve maintenance and manufacturability issues. An example of a modular radiator is described in U.S. Pat. No. 5,137,080 (the &#39;080 patent). Modular radiators include a plurality of heat exchanger modules. During maintenance, only damaged modules may have to be replaced, saving time and money. The modules shown in the &#39;080 patent include small mini-tanks or module tanks attached to each end of the core. The module tanks are used to direct flow and form a seal between the modules and an inlet or outlet tank. 
     The need for module tanks, however, may limit the applicability of modular heat exchangers. The module tanks restrict flow and cause a pressure drop of the cooling media as it passes in an indirect path; into the inlet tank, through the module tank, through the core, through another module tank, and into the outlet tank. The use of modular heat exchangers may accordingly be limited to applications with sufficient cooling media pressure. The module tanks may also add cost and consume valuable space in a machine where it is used. 
     The present disclosure is directed to overcoming one or more of the problems set forth above. 
     SUMMARY 
     In one aspect, the present disclosure provides a modular heat exchanger through which a cooling media passes. The heat exchanger includes an inlet tank, outlet tank, and a plurality of modules having tubes that terminate in an internal manifold space of the inlet and outlet tanks to allow for a direct flow of the cooling media between the tanks and modules. In another aspect, the inlet and outlet tanks include a first side with a plurality of module apertures for receiving the modules and a seal lip extending from the first side and around the periphery of the module apertures to form a seal between the seal lip and the module. 
     In yet another aspect, the modules include a core having a first and second end and a header coupled to at least one of the first and second end. In still another aspect, the header includes a base coupled to the core and a boss around a periphery of the base. The boss extends from the base to form a seal between a periphery of the boss and the tank. 
     Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of a heat exchanger including an inlet tank, outlet tank, and modules there between; 
         FIG. 2  is an enlarged cross-sectional front view from  FIG. 1  showing the module and the inlet tank; 
         FIG. 3  is a cross-sectional top view of the module and inlet tanks shown in  FIG. 2 ; and 
         FIG. 4  is a diagrammatic illustration of an exemplary engine system using heat exchangers. 
     
    
    
     DETAILED DESCRIPTION 
     A heat exchanger  10  includes a wide variety of devices that may involve passing a fluid or cooling media through it to dissipate heat. Such devices may include (but are not limited to) radiators where the cooling media is a liquid or an air-to-air aftercooler (ATAAC) where the cooling media is air. As seen in  FIG. 1 , the heat exchanger  10  may include an inlet tank  12 , an outlet tank  14 , and plurality of modules  16 . 
     The modules  16  are installed in fluid communication with the inlet tank  12  and outlet tank  14 . As shown, the inlet and outlet tanks  12  and  14  both include a first side  18 , second side  20  opposite first side  18 , first wall  22 , second wall  24  opposite first wall  22 , third wall  26 , and fourth wall  28  opposite third wall  26  to form a box structure. The modules  16  may be installed in the first side  18  of the inlet and outlet tanks  12  and  14  so that the modules  16  are in fluid communication with the inlet and outlet tanks  12  and  14 . In other embodiments, the inlet and outlet tanks  12  and  14  need not form a box structure and may be cylindrical, spherical, or another geometric shape. The modules  16  may also be installed in another side or part of the inlet and outlet tanks  12  and  14 . 
     The inlet tank  12  includes one or more inlets  30  and outlet tank  14  includes one or more outlets  32 . The cooling media enters the heat exchanger  10  through inlet  30  and into the inlet tank  12 . The cooling media then passes through the modules  16 , into the outlet tank  14 , and exits through the outlet  32 . 
       FIG. 2  shows the modules  16  coupled or installed to the inlet tank  12  to form a seal. The modules  16  are installed in outlet tank  14  in a similar manner as they are installed in the inlet tank  12 . It is also contemplated that the installation of the modules  16  may vary between the inlet tank  12  and the outlet tank  14 . For example, modular tanks may be used for the inlet tank  12  and not the outlet tank  14 , or visa versa. The modules  16  may be inserted, press fit, caulked, glued, welded or otherwise installed and sealed into the inlet tank and outlet tank  12  and  14 . 
     The inlet and outlet tank  12  and  14  both include an interior space or internal manifold space  34  inside the box structure formed by the walls. Inlet and outlet tank  12  and  14  also include module apertures  36  in the first side  18  to receive modules  16 . The module apertures  36  may also be in another side where the modules  16  could be installed. Around the outer perimeter or periphery of the module apertures  36  is a seal lip  38 . 
     The seal lip  38  extends substantially vertically or perpendicular to the first side  18  and into the manifold space  34 . The seal lip  38  may also extend away from the manifold space  34  or at any angled orientation from the first side  18 . The seal lip  38  may also include an outer surface  40  facing away from the module  16 , an inner surface  42  facing toward the module  16 , and a seal surface  44  contacting the module  16 . In other embodiments, the seal lip  38  may also be formed as part of first wall  22 , second wall  24 , third wall  26 , fourth wall  28 , or other surface or structure of the inlet or outlet tank  12  or  14 . 
     The modules  16  include a first end  46  installed in the inlet tank  12  and a second end  48  installed in the outlet tank  14 . The modules  16  also include a header  50  at each of the first end  46  and second end  48  and a core  52  extending between the headers  50 . The headers  50  may be coupled to the ends of the core  52  via welding, brazing, adhesive, seals, bolts, or other fastening means. 
     The core  52  includes fins  54  and tubes  56 . The tubes  56  are in fluid communication with the inlet and outlet tanks  12  and  14 . The tubes  56  extend through the fins  54  and headers  50  and may have tube ends  58  opening and terminating inside the manifold space  34  of the inlet and outlet tanks  12  and  14 . The fins  54  may include a plurality of appendages that function to facilitate heat dissipation of the cooling media as it travels through the tubes  56 . The appendages may be relatively thin and flat and may form a grid pattern. 
     As seen in  FIGS. 2 and 3 , the headers  50  may include a base  60  with tube apertures  62 . The tube apertures  62  receive tubes  56 . The base  60  may be defined by a perimeter encompassing the tubes  56 . Additional structure may be added beyond this perimeter of the base  60 . 
     The headers  50  may also include a boss  64 . The boss  64  may extend substantially vertically or perpendicular to the outer perimeter or periphery of the base  60  and into the manifold space  34 . In other embodiments, the boss  64  may extend away from the manifold space  34  or extend at an angle that may match the angle of the seal lip  38 . 
     The boss  64  includes an exposed surface  66  and a seal  68 . The exposed surface  66  is the portion of the boss  64  open to the manifold space  34 . The seal  68  provides the engagement between the module  16  and either the inlet or outlet tank  12  or  14 . The seal  68  includes a seal surface  70  facing the seal lip  38 . The seal surface  70  may include one or more seal slots  72  around the boss  64 . The seal slots  72  may be depressions cut, stamped, or otherwise formed in the boss  64 . 
     The seal  68  may also include one or more seal rings  74  extending around the seal surface  70 . In one embodiment, the seal ring  74  is disposed, at least partially, inside the seal slot  72 . The seal ring  74  makes contact with the seal lip  38  to form an engagement sufficient to prevent significant leakage of the cooling media passing through the heat exchanger  10 . The seal ring  74  may include a rubber o-ring, gasket, rubber or elastic member, caulk, sealant, or other seal-forming component. The seal ring  74  may be circular, square, oval, rectangular, or any other shape in cross-section to achieve a seal. Similarly, the seal slots  72  may be partially circular in cross-section or have another shape to accept the seal rings  74 . The seal  68  may include two seal slots  72  and seal rings  74 , as seen in  FIG. 2 . In alternative embodiments, the seal  68  may include more or fewer seal slots  72 . Other embodiments include the use of a seal ring  74  without the seal slots  72 . The seal  68  may also include any appropriate sealing mechanism. For example, a gasket may be pressed between corresponding overhanging flanges on the modules  16  and outlet and inlet tanks  12  and  14  and may include bolts to help form the seal  68 . 
     In operation, the cooling media enters the inlet tank  12  and into the manifold space  34 . From the manifold space  34 , the cooling media may enter directly or have a straight line path, direct line of sight, direct flow path, or direct path into each of the tubes  56  in the core  52  of the modules  16  without having to pass into another intermediary structure. Utilizing the direct path configuration, the tube ends  58  of the tubes  56  terminate inside the manifold space  34 . Similarly, the cooling media has a direct path from the tubes  56  into the manifold space  34  of the outlet tank  14 . The direct path configuration may limit pressure drop and restrictions on the flow of the cooling media as it passes through the heat exchanger  10 . 
     The materials used to construct the inlet tank  12 , outlet tank  14 , and modules  16  are varied. The materials may include aluminum, copper, brass, steel, plastic, PVC, or any other material capable of withstanding the temperature and corrosive environment the heat exchanger  10  could be exposed to. Material may also be selected for cost, strength, weight, temperature tolerance, heat conductivity properties, and other performance criteria. Individual components may also be constructed of materials different than the other components of the heat exchanger  10 . For example, the fins  54  may be constructed from copper, while the tubes  56  are steel, and the inlet and outlet tanks  12  and  14  are plastic. 
     In alternative embodiments, a passover tank (not shown) is added to allow the cooling media to pass through two modules  16  before leaving the heat exchanger  10 . The passover tank is coupled to one end of the modules  16  and the inlet tank  12  and outlet tank  14  are arranged side by side at the opposite end of the modules  16  as the passover tank. The inlet tank  12  is coupled to half the modules  16  and the outlet tank  14  is coupled to the other half of the modules  16 . 
     In yet other embodiments, the headers  50  may include baffles (not shown). The baffles include structures that extend around select tubes  56 . The baffles direct the cooling media through select tubes and not other tubes so that the cooling media passes through two or more modules before leaving the heat exchanger  10 . 
     INDUSTRIAL APPLICABILITY 
     Heat exchanger  10  may be used in an application such as that illustrated in  FIG. 4 . An exemplary engine system  76  is used to power a machine  78  or other device. The machine  78  may include on-highway trucks or vehicles, off-highway trucks or machines, earth moving equipment, generators, aerospace applications, marine applications, locomotive applications, pumps, stationary equipment, or other engine powered applications. 
     The engine system  76  includes one or more engines  80 . Engine  80  may be any type of engine (internal combustion, gas, diesel, gaseous fuel, natural gas, propane, etc.), may be of any size, with any number of cylinders, and in any configuration (“V,” in-line, radial, etc.). The engine system  76  further includes an intake  82  for delivering intake air to a compressor  84  of a turbocharger  85 . Heated charge air travels from the compressor  84  to an ATAAC  86  through a heated air intake line  88 . The ATAAC  86  cools the air prior to entering the engine air intake manifold  90 . The air is then used by engine  80 , discharged through the engine exhaust manifold  92 , and powers the turbine  94  of the turbocharger  85 . The engine system  76  may also include other features or systems not shown, such as fuel systems, air systems, aftertreatment systems, peripheries, drivetrain components, etc. and may not include the turbocharger  85  or other components. 
     The engine  80  is cooled by the cooling media traveling through a radiator input line  96  from the engine&#39;s  80  block, through an inlet in a radiator  98 , through the radiator  98 , out an outlet in the radiator  98 , through a radiator output line  100 , and back into the engine&#39;s  80  block. The cooling media may include glycol, water, air, or any other fluid. A fan  102  may also be used to facilitate heat dissipation. The ATAAC  86  may be mounted in front of or behind the radiator  98  for packaging and to also benefit from the fan  102 . The ATAAC  86  may also be mounted entirely separate from radiator  98 . 
     The disclosed heat exchanger  10  may be applied to the intake ATAAC  86  or the radiator  98 . The heat exchanger  10  may be used with liquid, air, gas, fuel, fluid, or any other cooling media. Heat exchanger  10  may also be used as a transmission fluid cooler. Heat exchanger  10  may additionally be applied to the cooling of air in an exhaust gas recirculation (EGR) system or clean gas induction (CGI) system. 
     Heat exchanger  10  is assembled by mounting one of the inlet tank  12  or outlet tank  14  to the engine system  76  or machine  78 . The inlet tank  12  or outlet tank  14  is mounted by securing it directly to a structural member, coupling it to a rigid cooling media feed line, or coupling it to the radiator  98  or another heat exchanger. The modules  16  are then inserted into the mounted inlet tank  12  or outlet tank  14  and the seal  68  is formed. Next, the remaining of the inlet tank  12  or outlet tank  14  is added to the other end of the modules  16 . 
     Alternatively, the heat exchanger  10  may also be assembled as a unit separate from the engine system  76  or the machine  78 . The modules  16  may be rigidly attached to the inlet tank  12  and outlet tank  14  using bolts, a tight seal, or other fastening means. Tie rods with bolts may also be used extending between the inlet tanks  12  and outlet tank  14  to hold the heat exchanger  10  together as a unit. The inlet tank  12  and outlet tank  14  may also be coupled to a separate frame to form an assembled unit. 
     A support structure (not shown) may also be added to support the modules  16  that may allow for thermal expansion. Support structure members may be added that extend from the machine  78  frame, engine system  76 , or inlet or outlet tanks  12  or  14 . A support structure may also be included in the seal lip  38 . Structures may also be added to prevent the modules  16  from moving in and out relative to the module apertures  36 . 
     Although the embodiments of this disclosure as described herein may be incorporated without departing from the scope of the following claims, it will be apparent to those skilled in the art that various modifications and variations can be made. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.