Patent Abstract:
A seal member may include a base portion, a plurality of deflector portions, and an expansion portion. The base portion may include a plurality of tabs adapted to be mounted to a heat exchanger. The plurality of deflector portions may each extending from a corresponding one of the plurality of tabs and manipulate a flow of fluid proximate the heat exchanger. The expansion portion may be disposed between adjacent deflector portions and may be expandable in response to exposure to heat between a first position at which the adjacent deflector portions are a first distance apart from each other and a second position at which the adjacent deflector portions are a second distance apart from each other.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/319,766, filed on Mar. 31, 2010. The entire disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to a seal mounted to a heat exchanger. 
       BACKGROUND 
       [0003]    This section provides background information related to the present disclosure and is not necessarily prior art. 
         [0004]    Modern vehicles may include a variety of heat exchangers for transferring heat from various fluids that are used within the vehicle to accomplish a variety of tasks. Such tasks may include control a temperature within a cab of the vehicle, cooling an engine or motor, and/or cooling a flow of fluid prior to the fluid entering the engine for combustion to boost an efficiency and/or capacity of the engine, for example. Such heat exchangers may be exposed to a wide range of temperatures which causes the heat exchanger to thermally expand and contract. Accordingly, heat exchangers in vehicles can be provided with features to allow the heat exchanger to expand and contract without exposing the heat exchanger to potentially harmful levels of stress. 
       SUMMARY 
       [0005]    This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
         [0006]    In one form, the present disclosure provides a seal member that may include a base portion, a plurality of deflector portions, and an expansion portion. The base portion may include a plurality of tabs adapted to be mounted to a heat exchanger. Each of the plurality of deflector portions may extend from a corresponding one of the plurality of tabs and manipulate a flow of fluid proximate the heat exchanger. The expansion portion may be disposed between adjacent deflector portions and may be expandable in response to exposure to heat between a first position at which the adjacent deflector portions are a first distance apart from each other and a second position at which the adjacent deflector portions are a second distance apart from each other. 
         [0007]    In another form, the present disclosure provides an assembly that may include a heat exchanger and a member associated with the heat exchanger. The member may include a base portion mounted to an outer perimeter of the heat exchanger and a deflector portion extending from the base portion away from the heat exchanger. The deflector portion may restrict air from flowing through a space adjacent the heat exchanger and direct the air through the heat exchanger. 
         [0008]    In yet another form, the present disclosure provides a vehicle that may include a source of rotary motive power, a heat exchanger, a body component, and a seal member. The source of rotary motive power may propel the vehicle. The heat exchanger may be disposed between the source of rotary motive power and a front end of the vehicle. The body component may at least partially house the heat exchanger and may cooperate with the heat exchanger to define a gap therebetween. The seal member may include a plurality of tabs, a plurality of deflector portions, and an accordion portion. The tabs may be mounted to an outer perimeter of the heat exchanger. Each of the deflector portions may extend from a corresponding one of the tabs and away from the heat exchanger. The accordion portion may be disposed between adjacent deflector portions. The accordion portion may expand and contract in response to changes in temperature proximate the heat exchanger to allow relative movement between the adjacent deflector portions. The deflector portions may restrict air from flowing through the gap between the heat exchanger and the body component and force the air through the heat exchanger. 
         [0009]    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 
         [0010]    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. 
           [0011]      FIG. 1  is a front perspective view of a vehicle depicting a location of a thermal expansion resistant heat exchanger seal in accordance with the present disclosure; 
           [0012]      FIG. 2  is a diagram of an example arrangement of heat exchanger components in accordance with the present disclosure; 
           [0013]      FIG. 3  is a front view of an example arrangement of heat exchanger components in accordance with the present disclosure; 
           [0014]      FIG. 4  is a perspective view of a heat exchanger equipped with a thermal expansion resistant heat exchanger seal in accordance with the present disclosure; 
           [0015]      FIG. 5  is a front view of the thermal expansion resistant heat exchanger seal of  FIG. 4  in accordance with the present disclosure; 
           [0016]      FIG. 6  is a perspective view a thermal expansion resistant heat exchanger seal in accordance with the present disclosure; 
           [0017]      FIG. 7  is a front view of the thermal expansion resistant heat exchanger seal of  FIG. 6  in accordance with the present disclosure; 
           [0018]      FIG. 8  is a perspective view of a thermal expansion resistant heat exchanger seal in accordance with the present disclosure; 
           [0019]      FIG. 9  is a top view of a thermal expansion resistant heat exchanger seal in accordance with the present disclosure; 
           [0020]      FIG. 10  is a top view of a thermal expansion resistant heat exchanger seal in accordance with the present disclosure; and 
           [0021]      FIG. 11  is a perspective view of the thermal expansion resistant heat exchanger seal of  FIGS. 8 and 9  in accordance with the present disclosure installed on a heat exchanger. 
       
    
    
       [0022]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0023]    Example embodiments will now be described more fully with reference to  FIGS. 1-11  of the accompanying drawings.  FIG. 1  is a front perspective view of a vehicle  10  depicting a location of a thermal expansion resistant heat exchanger seal  12  mounted to a heat exchanger  14 .  FIG. 2  depicts an example arrangement of an internal combustion engine  16  and numerous heat exchangers, any of which may be equipped with a thermal expansion resistant heat exchanger seal, as will be explained later. More specifically, arranged serially in front of engine  16  may be an air conditioning condenser  18 , a charge air cooler  20 , and an engine radiator  22 , all of which are heat exchangers, and a fan  24 . As is known, charge air cooler  20  may work in cooperation with a turbo charger  26 . While  FIG. 2  depicts heat exchangers  18 ,  20  and  22  arranged serially, with respect to a direction of airflow  27 , heat exchangers  18 ,  20  and  22  may be arranged or “stacked” one on top of another. More specifically, as depicted in  FIG. 3 , arranged in front of engine radiator  22  may be charge air cooler  20  located above or stacked upon condenser  18 . 
         [0024]      FIG. 4  depicts one embodiment of the present disclosure in which a thermal expansion resistant heat exchanger seal  28  (“seal  28 ”) is mounted to a heat exchanger, such as charge air cooler  20 . When thermal expansion resistant heat exchanger seal  28  is mounted to charge air cooler  20 , charge air cooler  20  may be arranged as depicted in  FIG. 3 , for example. Thus, reverting back to  FIG. 1 , with such an arrangement, gap  30  defined between charge air cooler  20  and a body component  32  of vehicle  10  may be closed or blocked by thermal expansion resistant heat exchanger seal  28 . An advantage of thermal expansion resistant heat exchanger seal  28  located atop charge air cooler  20  or any heat exchanger at such a location, is that airflow that might otherwise pass through gap  30  is prevented from bypassing or flowing around charge air cooler  20  via gap  30  and instead is forced to flow through charge air cooler  20  and any additionally arranged heat exchangers, thus increasing airflow through charge air cooler  20  and increasing efficiency of turbo charger  26  and engine  16 , for example. Continuing with  FIG. 4  and introducing  FIG. 5 , thermal expansion resistant heat exchanger seal  28  may, as an example, be attached or connected to a top surface  34  of charge air cooler  20 . More specifically, seal  28  may be riveted, screwed, pinned in an interference fit, spot-welded, etc. to charge air cooler  20  at locations  36 ,  38 ,  40 ,  42  for example. Attachment at other locations of flaps  44 ,  46 ,  48 ,  50  of seal  28  is possible. 
         [0025]    Continuing with  FIGS. 4 and 5 , seal  28  may be equipped with tabs  44 ,  46 ,  48 ,  50  that are substantially the same and air deflector portions  52 ,  54 ,  56 ,  58  that are also substantially the same. Any number of corresponding tabs and air deflector portions may be provided as part of seal  28 , depending upon the size of heat exchanger to which seal  28  is attached. Because seal  28  may be a series of tabs and air deflector portions, operation of which is substantially the same, only air deflector portions  52 ,  54  and tabs  44 ,  46  will be discussed. Similarly, because seal  28  may also employ a series of accordion portions  60 ,  62 ,  64 , such as accordion portion  60  between a pair of air deflector portions  52 ,  54 , operation of accordion portion  60  will primarily be discussed. 
         [0026]    Accordion portion  60  may be a foldable portion about a crease  66 , which may also be referred to as a pivot point. However, accordion portions do not have to have a pointed crease nor have a single pivot point or foldable portion. Thus, accordion portion(s) may have the geometry as depicted in  FIGS. 4-7  and may also be shaped in a “W” or have multiple folds, a “wave” type of form, such as a sinusoidal wave form having multiple periods, and even multiple periods with a variety of different “frequencies.” Accordion portions may further take on the shape of an “S” having any number of curves. Sawtooth configurations are conceivable with any number of “teeth.” However, for ease of discussion, accordion portion(s) may be referred to as that depicted as accordion portion  60  in  FIG. 5 , with an edge for a crease portion. 
         [0027]    Crease  66  may equally divide (e.g. bifurcate) accordion portion  60 . That is, crease  66  may divide accordion portion  60  into two halves of equal surface area. More specifically, crease  66  may divide accordion portion  60  into accordion half  72  and accordion half  74 , such that a surface area of a surface  76  of accordion half  72  and a surface area of a surface  78  of accordion half  78  are equal. Crease  68  may be a dividing and pivot point between accordion half  72  and air deflector  52  and crease  70  may be a dividing and pivot point between accordion half  74  and air deflector  54 . Similarly, crease  68  and crease  70  may be located equidistantly from, and on opposite sides of, crease  66 . Crease  66 , crease  68  and crease  70  may be parallel. To provide strength to seal  28 , impressions  80 ,  82 ,  84 ,  86  may be stamped or formed into seal  28 , such as in air deflectors  52 ,  54  and their corresponding tabs  44 ,  46  as opposed to separate pieces that may be attached by welding or bolting. Corresponding impressions may be similarly located in air deflectors  56 ,  58  and their corresponding tabs  48 ,  50 . Seal  28  may be fabricated from steel, stainless steel, aluminum or other suitable metal or plastic. Each flap, such as flaps  44 ,  46  may have holes  88 ,  90  drilled, punched, etc. into them to facilitate attachment to heat exchanger  20 . Thus, holes  88 ,  90  may each be occupied by a different post, as depicted at locations  36 ,  38  in  FIG. 4 . Such posts may protrude through holes  88 ,  90 . 
         [0028]    With continued reference to  FIGS. 4 and 5 , in operation on a vehicle, as heat exchanger  20  becomes warmer, locations  36 ,  38  of heat exchanger  20 , may begin to move farther apart from each other due to heat expansion of the material from which heat exchanger is fabricated. Because accordion portion  60  is equipped with folds or creases  66 ,  68 ,  70 , accordion portion may expand to accommodate separation of holes  88 ,  90 , which may be filled with posts  36 ,  38 , which may be rigidly fixed into surface  34  of heat exchanger  20 . Thus, during warming, surfaces  76 ,  78  move farther apart from each other. Upon cooling from a warmed or elevated temperature condition, accordion portion  60  may begin to contract when locations  36 ,  38  move closer together as heat exchanger  20  cools. Thus, during cooling, surfaces  76 ,  78  move closer together to each other. In expanding and contracting, a bottom edge  92  of accordion portion  60  may maintain alignment as a straight line with a crease  94  or fold between tab  44  and air deflector  52  and with a crease  96  or fold between tab  46  and air deflector  54  from a first end  98  to a second end  100  of seal  28 . 
         [0029]      FIGS. 6 and 7  depict a thermal expansion resistant heat exchanger seal  102  (“seal  102 ”), which although not depicted, may be mounted to a heat exchanger, such as charge air cooler depicted in  FIG. 4 . Seal  102  may be the same as seal  28  with the exception of accordion portions  104 ,  106 ,  108  and air deflectors  110 ,  112 ,  114 ,  116 . As depicted, air deflectors  110 - 116  may be slanted or angled relative to ends  118 ,  120  of seal  102 . Accordion portions  104 ,  106 ,  108  may be tilted to provide strength or rigidity in more than one direction and over a larger surface area of air deflectors  110 ,  112 , which may be located next to each other. More specifically, and with reference to accordion portion  104  located between air deflectors  110 ,  112 , by slanting accordion portion  104 , strength may be provided to at least the area of air deflectors  110 ,  112  bounded by or between dashed line  122  and dashed line  124 . Thus, such bounded area may be larger than an area bounded by crease  126  and crease  128  if creases  126 ,  128  were made parallel to ends  118 ,  120  assuming distance  134  between flap  130  and flap  132  is maintained and crease  126  maintains its origination point  135  and crease  128  maintains its origination point  136 . 
         [0030]    Similar to seal  28 , seal  102  may have a crease  138  located parallel to and equidistant from each of crease  126  and crease  128 . Accordion portions  104 ,  106 ,  108  function in a similar manner to accordion portions  60 ,  62 ,  64  previously described. A heat exchanger to which seal  102  is mounted undergoes expansion and contraction due to thermal events such as heating and cooling. Similar to seal  28 , seal  102  may be equipped with stamped-in or pressed-in impressions  140 ,  142 ,  144 ,  146 ,  148 ,  150 ,  152 ,  154  to provide additional strength to seal  102  to better resist forces due to flowing air directed against air deflectors  110 ,  112 ,  114 ,  116  as vehicle  10  equipped with seal  102  moves along a road. Thus, seal  102  depicted in  FIGS. 6 and 7  may provided greater strength and resistance to airflow to better direct air through heat exchanger  20 . 
         [0031]      FIGS. 8 and 9  depict another embodiment of a thermal expansion resistant heat exchanger seal  160  (“seal  160 ”) in accordance with the present disclosure and  FIG. 11  depicts seal  160  installed upon a heat exchanger, such as charge air cooler  20 . More specifically, seal  160  may be an L-shaped bracket, or similarly shaped bracket, with a horizontal portion  162  and a vertical portion  164  that together may form a right angle; however, as depicted in  FIG. 8 , vertical portion  164  may not necessarily be “vertical” and may form nearly any angle with horizontal portion  162  to accommodate surrounding vehicle structure. Horizontal portion  162 , which may also be called a base portion, is so called because its position may be horizontal or parallel to the ground upon which a vehicle may reside when seal  160  is installed upon heat exchanger  14 , within vehicle  10 . However, horizontal portion may not necessarily be horizontal to the ground depending upon the structure to which horizontal portion  162  is mounted. Vertical portion  164  is so called because its position is vertical or perpendicular relative to the ground upon a vehicle resides when seal  160  is installed upon a heat exchanger  14 , for example, within vehicle  10 . Horizontal portion  162  may be equipped with a number of slots  166 ,  168 ,  170 ,  172  to permit movement relative to a respective pin  174 ,  176 ,  178 ,  180  installed within each slot. 
         [0032]      FIG. 10  depicts another embodiment of a thermal expansion resistant heat exchanger seal  161  (“seal  161 ”) in accordance with the present disclosure. More specifically, seal  161  may be an L-shaped bracket with a base portion  163  and an upright portion  165  that together may or may not form a right angle. That is, similar to the embodiment depicted in  FIG. 8 , upright portion  165  may not necessarily be vertical and may form nearly any angle with base portion  163  to accommodate surrounding vehicle structure and close an air gap. Base portion  163  may be horizontal or parallel to the ground upon which a vehicle resides when seal  161  is installed upon a heat exchanger  14 , for example, within vehicle  10 . However, base portion  161  may not necessarily be positioned horizontal to the ground depending upon the structure to which base portion  163  is mounted. Upright portion  165  may be positioned at a non-ninety degree angle or perpendicular relative to the ground upon which a vehicle resides when seal  161  is installed upon a heat exchanger  14 , for example, within a vehicle. Base portion  163  may be equipped with a number of slots  167 ,  169 ,  171 , to permit movement relative to respective pins  176 ,  178 ,  180  installed within each slot. However, seal  161  may be constructed with one round hole  173  to accommodate a round pin  174  in an interference type of fit, for example. With such an arrangement, expansion and contraction of the material of seal  161  will be relative to pin  174 , thus providing the advantage of a controlled expansion and contraction about pin  174 . 
         [0033]    Movement of pins fixed within a heat exchanger relative to a corresponding seal will now be explained.  FIG. 9  depicts pin  174  and pin  176  which may be fixedly mounted within a top surface  34  ( FIG. 4 ) of heat exchanger  20 . When heat exchanger  20  experiences an increase in temperature that causes the material of heat exchanger  20  to expand, pin  174  may move from location indicated by line  182  to a location indicated by line  184 , while at the same time, pin  176  may move from a location indicated by line  186  to a location indicated by line  188 . Similarly, when heat exchanger  20  experiences a decrease in temperature that causes the material of heat exchanger  20  to contract, pin  174  may move from location indicated by line  182  to a location indicated by line  190 , while at the same time, pin  176  may move from a location indicated by line  186  to a location indicated by line  192 . Thus, because of movement of pins  174 - 180  in accordance with the representative example noted above, horizontal portion  162  may be equipped with slots  166 - 172 . More specifically, slot  172  is sized to permit movement of pin  174  and slot  170  is sized to permit movement of pin  176  over a full range of temperatures to which heat exchanger  20  may be exposed. Pins  174 - 180  may be capped with a cotter pin or other suitable device to prevent seal  160  from dislodging. Thus, with installation of seal  160  upon heat exchanger  20 , airflow  194  may be prevented from flowing above heat exchanger  20 , such as between heat exchanger  20  and a body component  32 , thus increasing airflow through heat exchanger  20  and increasing efficiency of turbo charger  26  and engine  16 , for example. 
         [0034]    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. 
         [0035]    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 are not described in detail. 
         [0036]    The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
         [0037]    When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0038]    Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
         [0039]    Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Technology Classification (CPC): 5