Patent Description:
Heat exchangers, particularly charge air coolers, are provided in a vehicle at an air inlet circuit to cool the air flowing into an engine of the vehicle. Generally, the charge air cooler is connected downstream of a supercharger/turbocharger. The hot air received from the supercharger is cooled down at the charge air cooler, and the cooled air is provided to the engine. The charge air cooler may include two fluid circuits, one fluid circuit being the hot air flowing from the supercharger, and other fluid circuit being a coolant loop. Further, both fluid circuits are defined in a heat exchange configuration, so that the hot air exchanges heat with the coolant flowing therein. Further, the charge air cooler may include an inlet tank and an outlet tank to enable circulation of the hot air into a core of the charge air cooler. In some vehicles, the charge air cooler may be strategically positioned in order to optimally utilize the space in the vehicle. In such case, the supercharger and the charge air cooler may be in parallel with each other, so the inlet port may be angled to connect with the supercharger.

In such cases, the hot airflow entering into the inlet port may not uniformly distributed on the core of the charge air cooler. Further, the non-uniform distribution of the hot air on the core may lead to inefficient heat exchange between the coolant and the hot air that results in inefficient performance of the charge air cooler. In other cases, an air duct connecting the inlet port of the charge air cooler may be angled or U-shaped, due to arrangement of various components connected in the air inlet circuit. Further, the hot airflow entering into the housing may not be homogenous on the cross-section of the core, due to non-symmetrical inlet port or a curvature of flow path in the inlet tank. Such non-uniform distribution of airflow leads to inefficient heat exchange and thermal performance. Further, there is a possibility of thermal shock issue on the charge air cooler due to the non-uniform distribution of air at the inlet, which may damage the parts of the charge air cooler.

Accordingly, there remains a need for an inlet tank or port that enables uniform distribution of airflow on a core of a charge air cooler. Further, there remains another need for a charge air cooler having an angled inlet with features to enable uniform distribution of fluid on the core of the charge air cooler.

In view of the foregoing, the present invention relates to a heat exchanger according to claim <NUM>.

Further, the deflector includes a base portion and the flap is connected to the base portion.

The heat exchanger further includes at least one protruded portions, in particular two protruded portions, formed on adjacent sides of the flap and protruding from the base portion of the deflector.

Further, the protruded portion protrudes from the base portion of the deflector in a direction towards the core of the heat exchanger.

Further, the protruded portions are inclined towards the flap.

In one embodiment, the flap and at least one protruded portion are angled at different angles on a same plane.

In another embodiment, the flap and at least one protruded portion are inclined on parallel planes.

Further, an end portion of the flap is bent at an angle with respect to the body of the flap.

In one embodiment, the deflector is connected to an inner wall of the inlet tank.

It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

The present invention generally relates a charge air cooler provided with a deflector in an inlet tank of the charge air cooler to enable uniform distribution of air on a core of the charge air cooler. In conventional charge air cooler, the inlet air duct may be bent or in non-symmetrical shape, so the air entering into a housing of the charge air cooler may non-uniformly distributed in the inlet area of the core that leads to inefficient heat exchange between the air and a coolant and leads to thermal shock. To avoid such scenario, a deflector is provided in the inlet tank that uniformly distribute the air on a core provided in a housing of the charge air cooler. Further, the geometry and placement of the deflector is explained with respect to the following figures.

<FIG> illustrates a schematic view of a heat exchanger <NUM>, in accordance with an embodiment of the present invention. The heat exchanger <NUM> can be a charge air cooler or any other heat exchanger. In the present embodiment, the heat exchanger <NUM> is a charge air cooler. The charge air cooler <NUM> includes a core (not shown in <FIG>), a housing <NUM> accommodating the core, an inlet tank 104A and an outlet tank 104B. The inlet tank 104A is connected to a first header 12A and the outlet tank 104B is connected to a second header 12B. The first header and the second header 12A-B are fluidically connected to heat exchange elements (not shown in Fig) of the core. In other words, a cooling fluid may flow from the first header 12A to the second header 12B through the heat exchange elements. Further, the inlet tank 104A and the outlet tank 104B are fluidically connected to the heat exchange elements to enable a first fluid flow, preferably airflow over the heat exchange elements. Further, a second fluid flow, preferably a coolant, flows into the heat exchange elements. The first fluid flow and the second fluid flow are defined in the housing in such a way that the first fluid flow is adapted to exchange heat with the second fluid flow. The inlet tank 104A is connected to an inlet conduit <NUM>, which may be angled due to various requirements. As the inlet conduit <NUM> is angled, the first fluid flow, hereinafter referred to as air flow, entering into the housing <NUM> is non-uniform at the inlet area of the core. To avoid non-uniform distribution air on the core of the, a deflector <NUM> is provided within the inlet tank 104A. The deflector <NUM> is adapted to uniformly distribute the first fluid onto the core of the charge air cooler.

<FIG> and <FIG> illustrate different views of the inlet tank 104A of the charge air cooler <NUM> of <FIG> showing the deflector <NUM>. In one example, <FIG> illustrates a perspective view of the inlet tank nozzle 104A of <FIG> and <FIG> illustrates a front view of the inlet tank 104A of <FIG>. The charge air cooler <NUM> includes at least one deflector <NUM> provided within the inlet tank 104A to uniformly distribute the first fluid entering into the inlet tank 104A on the core of the charge air cooler <NUM>. In one embodiment, the at least one deflector <NUM> includes at least one flap <NUM> inclined at an angle towards the core of the charge air cooler <NUM>. In other words, the flap <NUM> is angled with respect to the conduit in which it is mounted and points towards the core. Although the inlet tank 104A of the proposed invention is explained with at least one deflector <NUM>, it is possible to configure more than one deflector <NUM> within the inlet tank 104A. Further, the at least one deflector <NUM>, hereinafter referred to as deflector <NUM>, includes a base portion <NUM> in which the at least one flap <NUM>, hereinafter referred to as flap, is connected thereto.

The base portion <NUM> may be rectangular and comprise protruding end portions 110A, which may be bent at angle with respect to the base portion <NUM>. In other words, both lateral ends of the base portion <NUM>, which is in vicinity to the inner wall of the inlet tank 104A and serve as mounting portions for the base portion <NUM>, are bent at angle with respect to it and the conduit walls to which it is mounted. The end portions 110A of the base portion <NUM> is connected to the inner wall <NUM> of the inlet tank 104A. The base portion <NUM> further includes protruded portions <NUM> formed on adjacent sides of the flap <NUM> and protruding from the base portion <NUM> of the deflector <NUM>. In particular, the protruded portions <NUM> are formed on the end portions 110A of the base portion <NUM>. In one example, the deflector <NUM> includes two protruded portions <NUM> formed on the both end portions 110A of the base portion <NUM>. In such example, the two protruded portion <NUM> are inclined with respect to the base portion <NUM> and towards each other. In another example, at least one protruded portion <NUM> is coupled to any one of the end portions 110A of the base portion <NUM> of the deflector <NUM>. In such example, the at least one protruded portion <NUM> is inclined towards the flap <NUM> of the deflector <NUM>. Further, the protruded portions <NUM> are protruded from the base portion <NUM> in a direction towards the core. In other words, the protruded portions <NUM> are protruded from the base portion <NUM> generally in the same direction as the flap <NUM> protruding therefrom, but in a differing orientation with respect to the conduit.

<FIG> illustrates a perspective view of the deflector of <FIG> depicting the flap <NUM> and the protruded portions <NUM>, and <FIG> illustrates a perspective view of inlet tank nozzle 104A depicting the inner wall <NUM>. The flap <NUM> and the protruded portions <NUM> are angled at different angles on a same plane. In one example, the flap <NUM> is bent more than of the protruded portions <NUM>, in such a way that the protruded portions <NUM> are in a plane above the flap <NUM>. In another example, the flap <NUM> and the protruded portions <NUM> are inclined on parallel planes. Further, the base portion <NUM> of the deflector <NUM> includes tongues <NUM> formed on the end portions 110A of the base portion <NUM> and adapted to be received in slots <NUM> formed on the inner wall <NUM> of the inlet tank 104A. As shown in <FIG>, the slots <NUM> are formed on the inner wall <NUM> of the inlet tank 104A, corresponding to the tongues <NUM> formed in the base portion <NUM> of the deflector <NUM>. In another embodiment, the deflector <NUM> is brazed to the inner wall <NUM> of the inlet tank 104A. In yet another embodiment, the inner wall <NUM> of the inlet tank 104A is provided with an "O" ring, on which the end portions 110A of the deflector <NUM> is connected thereto. Further, an end portion <NUM> of the flap <NUM> is bent at an angle with respect to the body of the flap <NUM>.

In order to attain homogenous fluid distribution on the core of the charge air cooer <NUM>, the deflector <NUM> may divert the first fluid across the heat exchange elements. As the deflector <NUM> is provided in the inlet tank 104A, the first fluid flowing into the inlet tank 104A is uniformly distributed on the core by directing the fluid at desired location of the heat exchange elements. At the core, the first fluid exchanges the heat with the second fluid entering into the heat exchange elements. As the first fluid, e.g., hot air, uniformly distributed on the inlet side of the core, the heat exchange between the first fluid and the second fluid can be optimum, thereby attaining optimal thermal efficiency of the charge air cooler <NUM>. Thereafter, the first fluid exits the housing <NUM> through the outlet tank 104B. Although the deflector <NUM> is defined in the charge air cooler <NUM> to enable uniform distribution of fluid on the core, the deflector <NUM> can be defined in any other heat exchanger to enable uniform distribution at an inlet area of the core of the heat exchanger.

Claim 1:
A heat exchanger (<NUM>) comprising: a core, a housing (<NUM>) connected with an inlet tank (104A), said core being accommodated in said housing; and at least one deflector (<NUM>) provided within the inlet tank (104A), wherein the deflector (<NUM>) comprises at least one flap (<NUM>) inclined towards the core of the heat exchanger (<NUM>), characterised in that the inner wall (<NUM>) of the inlet tank (104A) is provided with slots (<NUM>) and tongues (<NUM>) formed on the deflector (<NUM>) are received in the slots (<NUM>).