Patent Description:
A cooling module, in general, is provided in a vehicle to control thermal comfort of passengers and for thermal management of various elements in the vehicle, such as engine, electric motors etc. The cooling module may be disposed at the front end of the vehicle in such a way the ram air passes through the cooling module. The cooling module may include one or more heat exchangers arranged one after another with respect to the front end of the vehicle, so that the ram air can pass through the heat exchangers one by one. The heat exchangers are stacked together in such a way one heat exchanger is downstream with respect to another, so that the ram air may pass subsequently through the heat exchangers. In one example, the heat exchangers can be a plurality of radiators and a condenser. In another example, the cooling module may have at least one radiator, an oil cooler and a condenser. For instance, the condenser may be arranged upstream to the radiator(s)/oil cooler with respect to the ram airflow, so that the ram air passes through the condenser first, followed by the radiator(s)/oil cooler.

To avoid escaping of the ram air through a gap between the heat exchangers, sealing elements may be provided between the heat exchanger. Such sealing elements may also prevent entering of any foreign particles into the gap between the heat exchangers. For instance, the sealing elements may include plastic enclosures and other sealing components for sealing the gaps. The plastic enclosures may seal the gap between the condenser and one of the radiators, whereas the sealing components may seal rest of the gaps between the radiators. However, such technique is inefficient as it may require multiple elements to seal the gaps between the heat exchangers that detrimentally increases cost and time to install the sealing elements into the cooling module. Such plastic enclosures may need to be bolted to the side plates of the heat exchangers. As a result, cost and complexity of the cooling module is increased.

Therefore, there remains a need for a cooling module having heat exchangers provided with a sealing element adapted to seal gap between the heat exchanger. There remains another need for a simple design of a sealing element adapted to be coupled to the heat exchangers of a cooling module without any connecting means.

Document <CIT> discloses a cooling module according to the preamble of claim <NUM>.

In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements, which are similar but not identical.

In view of the foregoing, an embodiment provides a cooling module for a vehicle. The cooling module include a first heat exchanger having at least one side plate, at least two second heat exchangers and a sealing element. The second heat exchangers are arranged on opposite sides of the first heat exchanger, and each heat exchanger includes at least one second side plate. Further, the sealing element includes a central part and at least two flaps attached to the opposite sides of the central part. Further, the central part is attached to the first heat exchanger and each flap is adapted to engage with the second side plate of the respective second heat exchanger.

Further, each flap extends in a first direction substantially away from the first side plate of the first heat exchanger.

In one example, each flap includes at least one protruding part protruding towards the second side plate of the second heat exchangers in a direction substantially perpendicular to the first direction.

Further, the protruding part is adapted to engage with the second side plate of the respective second heat exchanger in a tensioned stage against respective second heat exchanger.

In one example, the flaps further includes an overmold element overmolded on the edges of the flaps to restrict egressing of fluid from the cooling module through a space formed between the first heat exchanger and the second heat exchangers.

Further, the central part includes a snap-fit assembly adapted to engage with the first side plate of the first heat exchanger.

Further, the snap-fit assembly includes at least one resilient member having at least one L-shaped leg adapted to engage with a foot portion of the first side plate of the first heat exchanger, when the sealing element is coupled to the first heat exchanger.

Generally, one end of the flaps is attached to the respective resilient member and other end of the flaps is adapted to engage with the second side plates of the respective second heat exchanger in a tensioned state against the respective second heat exchanger.

Further, the flaps are adapted to engage with at least one second foot portion of the second side plate of each of the second heat exchanger.

In one embodiment, the sealing element includes at least one auxiliary flap formed on any one of a front lateral side and a rear lateral side of the central part of the sealing element and the auxiliary flap is adapted to be rested on manifolds of the first heat exchanger.

Generally, the flaps and the central part of the sealing element is integrally formed thereon.

In one example, the sealing element further includes at least one rib formed on a top side of the central part of the sealing element and the rib is adapted to couple with external elements.

In one embodiment, the sealing element is formed along the length of the core of the first heat exchanger and the second heat exchangers.

In another embodiment, the sealing element extends beyond the length of the core of the first heat exchanger and the second heat exchangers.

In yet another embodiment, the length of the sealing element is shorter than the length of the core of the first heat exchanger and the second heat exchangers.

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

The present invention relates to a cooling module having heat exchangers with at least one sealing element to seal gaps between heat exchangers. Conventionally, the gap between heat exchangers are sealed by multiple elements such as plastic enclosures and sealing components. Such method require multiple components and such components need to be bolted to the heat exchangers. Here, the plastic enclosure may seal the gap between first and second heat exchangers, whereas other sealing components may seal the gap between the second and third exchangers. Ultimately, cost and time required to assemble the cooling module is increased. As the sealing components are bolted to the heat exchangers, it may inadvertently cause any damage to the heat exchanger core. To avoid such problems, a sealing element is developed that can be inserted onto the heat exchangers to seal gap between heat exchangers. The sealing element can be snap-fitted on the at least one heat exchanger, so as the seal the gaps between the heat exchangers. Further, design and position of the sealing element are described with respect to following figures.

<FIG> illustrates a schematic view of a cooling module <NUM> having heat exchangers <NUM>, in accordance with an embodiment of the present invention. The cooling module <NUM> may be disposed at a front end of a vehicle. Generally, the cooling module <NUM> is provided in the vehicle to manage thermal conditions of various elements in the vehicle such as engine, motors, battery and/or passenger's comfort. The cooling module <NUM> is disposed in the vehicle in such a way that the ram air may pass through the cooling module <NUM> so as to exchange heat with fluid flowing there-through. The cooling module <NUM> includes the heat exchangers <NUM>. Here, the heat exchangers <NUM> are air-cooled heat exchangers, i.e., the ram air is used to cool the fluid flowing through the heat exchangers <NUM>. The cooling module <NUM> may include one or more heat exchangers arranged one next to the other as shown in <FIG>. For instance, the cooling module <NUM> may include a first heat exchanger 102A and at least two-second heat exchangers 102B-C. The first heat exchanger <NUM> and the second heat exchangers 102B-C are arranged one by one. Particularly, the second heat exchangers 102B-C are arranged on opposite sides of the first heat exchanger 102A. In other words, the first heat exchanger 102A is sandwiched between the second heat exchangers 102B-C.

In one example, the first heat exchanger 102A is a radiator, one of the second heat exchangers 102B is a condenser, and another second heat exchanger 102C is an oil cooler. In another example, the first heat exchanger 102A and one of the second heat exchanger 102C are radiators, and another second heat exchanger 102B is a condenser. In both cases, the heat exchangers <NUM> include their respective heat exchange tubes through which respective heat exchange fluids flow there-through. Each heat exchanger <NUM> includes the heat exchange tubes extended between their respective headers. Here, the fluid flows into the respective heat exchange tubes and the ram air flows around the heat exchange tubes, thereby enabling heat exchange between the fluids and ram air. Further, the flow direction of the fluids is generally transverse to the flow direction of the ram air. Further, the heat exchangers <NUM> may be provided with tanks adapted to couple to the respective header of the heat exchangers <NUM>. The tanks <NUM> may enable circulation of the heat exchange fluid inside the heat exchange tubes of the heat exchangers 102A-C. The tanks <NUM> may be crimped to the headers of the respective heat exchanger <NUM>. In one example, the tank of the first heat exchanger 102A may be physically connected to the tank of the second heat exchanger 102B, to provide rigid connection between the heat exchangers <NUM> in the cooling module <NUM>. Here, the header and the tanks are collectively referred to as manifolds.

Further, the heat exchangers <NUM> include their respective side plates stacked on their respective heat exchange tubes. Generally, the side plates in the heat exchanger <NUM> are to provide support to the heat exchange tubes and it acts as a support to add fins around the outermost heat exchange tubes in the heat exchanger <NUM>. Particularly, the first heat exchanger 102A includes at least one first side-plate 106A; preferably, a pair of first side-plates 106A adapted to sandwich the heat exchange tubes in the first heat exchanger 102A. Further, the second heat exchangers 102B-C include at least one second side-plate 106B-C sandwich the respective heat exchange tubes in the second heat exchangers 102B-C. The first side-plates 106A are the outermost plate in the stack of heat exchange tubes in the first heat exchanger 102A and the second side-plates 104B-C are the outermost plate in the respective stack of heat exchange tubes in the second heat exchanger 102B-C. Further, the heat exchange tubes along with the side plates and the headers are referred to as core of the heat exchangers <NUM>.

The heat exchangers <NUM> may be placed in the cooling module <NUM> in such a way that the headers and the tanks <NUM> of each heat exchanger <NUM> are in contact with each other, so as to block passing of the ram air there-between. For example, the headers and tanks of the first heat exchanger 102A is in contact with the headers and tanks of the second heat exchanger 102B so that there is no possibility of escaping of the ram air between the headers of the heat exchangers <NUM>. However, while assembling the heat exchangers <NUM> in the cooling module <NUM>, a gap between the heat exchangers <NUM> is inadvertently formed near the side-plates 106A-C of the heat exchangers 102A-C. Such gaps can be sealed by a sealing element (not shown in <FIG>).

<FIG> and <FIG> illustrate schematic views of the heat exchangers 102A-C of <FIG> with the sealing element <NUM>. Here, <FIG> is a sectional view of the heat exchangers 102A-C when the sealing element <NUM> is mounted on the side-plates 106A-C of the heat exchangers 102A-C. Further, <FIG> shows a schematic view of the sealing element <NUM> of the <FIG>. In this example, the cooling module <NUM> includes at least one sealing element <NUM> adapted to seal the gaps between the heat exchangers 102A-C. In the preferred embodiment, the cooling module <NUM> includes a pair of sealing elements <NUM> adapted to seal the gaps formed between the heat exchanger 102A-C at the both sides the heat exchangers 102A-C at their of the side-plates 106A-C. Although <FIG> shows one sealing element <NUM> adapted to seal the gap between one-side of the heat exchangers 102A-C, it is possible to apply similar sealing element to other side of the heat exchangers 102A-C. For sake of clarity and brevity, the heat exchangers 102A-C are explained with the sealing element <NUM> at one side of the heat exchangers 102A-C as shown in <FIG>.

The sealing element <NUM> includes a central part <NUM> and at least two flaps <NUM> attached to the opposite sides of the central part <NUM>. In one example, the sealing element <NUM> may include more than two flaps <NUM>, preferably four flaps attached to the four sides of the central part <NUM>. This embodiment will be shown in the forthcoming figures. Here, the two flaps <NUM> are referred to as the main flaps. According to previous embodiment, the flaps <NUM> may be connected to the lateral sides of the central part <NUM> of the sealing element <NUM>. In one example, the flaps <NUM> may be formed along the length of the central part <NUM> of the sealing element <NUM>. Here, the each flap <NUM> extends in a first direction "D" substantially away from the first side-plate 106A of the first heat exchanger 102A. In other words, the flaps <NUM> extend away from the central part <NUM> of the sealing element <NUM> so that the flaps <NUM> may seal the gap between the first side-plate 106A of the first heat exchanger 102A and the second side-plates 106B-C of the second heat exchangers 102B-C, when the sealing element <NUM> is assembled on the heat exchangers 102A-C.

Further, the central part <NUM> is attached the first heat exchanger 102A. Preferably, the central part <NUM> of the sealing element <NUM> is adapted to be detachably attached to the first side-plates 106A of the first heat exchanger 102A. Meanwhile, the flaps <NUM> are adapted to engage with the second side-plates 106B-C of the second heat exchangers 102B-C. The flaps <NUM> can extend in a direction towards the second side-plates 106B-C of the second heat exchangers 102B-C. Particularly, one flap <NUM> of the sealing element <NUM> extends towards the second side-plate 106B of the second heat exchanger 102B, and another flap <NUM> extends towards the second side-plate 106C of the second heat exchanger 102C. Hence, the flaps <NUM> can block the gap between the side-plates 106A-C of the first and second heat exchanger 102A-C, thereby blocking the ram air from escaping through the gap between the first side-plates 106A and the second side-plates 106B-C.

In one example, the central part <NUM> and the flaps <NUM> of the sealing element <NUM> are integrally formed thereon. In other words, the central part <NUM> and the flaps <NUM> are integrally molded to form the sealing element <NUM>. In a preferred embodiment, the sealing element <NUM> is formed along the length of the core of the first and second heat exchangers 102A-C. Particularly, the central part <NUM> of the sealing element <NUM> is formed along the length of the core of the first heat exchanger 102A and the flaps <NUM> of the sealing element <NUM> are formed along the length of the core of the second heat exchangers 102B-C. In another example, the central part <NUM> is formed to a length lesser than the length of the core of the first heat exchanger 102A, whereas the flaps <NUM> of the sealing element <NUM> are formed along the length of the core of the second heat exchangers 102B-C.

In another embodiment, the sealing element <NUM> extends beyond the length of the core of the first and second heat exchangers 102A-C. In such case, the central part <NUM> of the sealing element <NUM> extends beyond the length of the core of the first heat exchanger 102A, and the flaps <NUM> of the sealing element <NUM> extend beyond the length of the core of the second heat exchangers 102B-C. In another example, the central part <NUM> of the sealing element <NUM> is formed along the length of the core of the first heat exchanger 102A, whereas the flaps <NUM> of the sealing element <NUM> extend beyond the length of the core of the second heat exchangers 102B-C.

In another embodiment, the length of the sealing element <NUM> is shorter than the length of the core of the first and second heat exchangers 102A-C. Particularly, the length of the central part <NUM> of the sealing element <NUM> is shorter than the length of the core of the first heat exchanger 102A, whereas the length of the flaps <NUM> of the sealing element <NUM> is equal to the length of the core of the second heat exchangers102B-C. In another example, the length of the central part <NUM> of the sealing element <NUM> is shorter than the length of the core of the first heat exchanger 102A, whereas the length of the flaps <NUM> of the sealing element <NUM> is shorter than the length of the core of the second heat exchangers102B-C.

Further, the flaps <NUM> may include an overmold element <NUM> overmolded on the flaps <NUM> to restrict egressing of fluid from the cooling module <NUM> through a space formed between the first heat exchanger 102A and the second heat exchangers 102B-C. In one example, the overmold element <NUM> is overmolded on the edges of the flaps <NUM> of the sealing element <NUM>. In another example, the overmold element <NUM> is overmolded throughout the area of the flaps <NUM> of the sealing element <NUM>.

In one embodiment, the central part <NUM> of the sealing element <NUM> includes a snap-fit assembly <NUM> adapted to engage with the first side-plate 106A of the first heat exchanger 102A. Further, the snap-fit assembly <NUM> is formed on the bottom side of the central part <NUM>. The first and second side-plates 106A-C may include foot portions 208A-C to receive the snap-fit assembly <NUM> of the sealing element <NUM>. The snap-fit assembly <NUM> further includes at least one resilient member <NUM>, preferably a pair of resilient members <NUM>, adapted to engage with the first foot portion 208A of the first side-plate 106A of the first heat exchanger 102A. Particularly, the resilient members <NUM> formed on a side of the central part <NUM> facing the first side-plate 106A of the first heat exchanger 102A. In one example, the resilient members <NUM> may include at least one L-shaped leg <NUM>, preferably a pair of L-shaped legs <NUM>, adapted to engage with the first foot portion 208A of the first side-plate 106A of the first heat exchanger 102A, when the central part <NUM> of the sealing element <NUM> is coupled to the first heat exchanger 102A. Meanwhile, edges of the both flaps <NUM> of the sealing element <NUM> are engaged to respective foot portion 208B-C of the second heat exchangers 102B-C as shown in <FIG>. As the sealing element <NUM> is provided with the snap-fit assembly <NUM>, the sealing element <NUM> can be mounted on the heat exchangers without any external connecting means.

In one example, one end of the flaps <NUM> is attached to the respective resilient member <NUM> and another end of the flaps <NUM> is engaged to the second side-plates 106B-C of the second heat exchangers 102B-C in a tensioned state against respective second heat exchanger 102B-C, when the sealing element <NUM> is coupled on the heat exchangers 102A-C. As the flaps <NUM> of the sealing element <NUM> are disposed on the heat exchangers 102A-C in a tensioned state against the respective second heat exchanger 102B-C, the flaps <NUM> of the sealing element <NUM> may effectively block egressing of the ram air between the heat exchangers 102A-C. Also, the flaps <NUM> can be rigid due to the flaps <NUM> positioned in a tensioned state. In one example, the flaps <NUM> bear against the side plates 106B, 106C in a tensioned state without direct fixing.

Further, the sealing element <NUM> includes at least one rib <NUM> formed on a top side of the central part <NUM> as shown in <FIG>. The rib <NUM> is adapted to couple with the external elements outside the cooling module <NUM> to provide stability to the sealing element <NUM>. Further, the rib <NUM> is formed on a longitudinal direction along the direction of extension of the heat exchange tubes in the heat exchangers 102A-C. In one example, as shown in <FIG>, the rib <NUM> is formed along the length of the central part <NUM> of the sealing element <NUM>. In another example, the length of the rib <NUM> is shorter than the length of the central part <NUM> of the sealing element <NUM>.

<FIG> illustrates a sectional view of the sealing element <NUM> of <FIG>, when the sealing element <NUM> is in a free state and mounted on the heat exchangers 102A-C. In one embodiment, each flap <NUM> of the sealing element <NUM> includes at least one protruding part <NUM> protruding towards the respective second side-plate 106B-C of the second heat exchangers 102B-C in a direction substantially perpendicular to the first direction "D" of the flaps <NUM>. In one example, the protruding parts <NUM> may be formed along the length of the flaps <NUM> of the sealing element <NUM>. As indicated with FREE STATE visualisation of the sealing element <NUM> before assembly in <FIG>, the protruding parts <NUM> provided in the flaps <NUM> of the sealing element <NUM> may be pointing towards the first side-plate 106A of the first heat exchanger 102A, i.e. be inclined with respect to the central part <NUM> to ensure tensioned arrangement after assembly. When the sealing element <NUM> is assembled to the heat exchangers 102A-C, the protruding parts <NUM> of the sealing element <NUM> engage with the second side-plates 106B-C of the second heat exchangers 102B-C as shown in <FIG>. In both states, the protruding parts <NUM> of the sealing element <NUM> are substantially perpendicular to the extension direction of the flaps <NUM> of the sealing element <NUM>. Here, the protruding parts <NUM> of the sealing element <NUM> are adapted to deflect towards the second heat exchangers 102B-C and engage with the second side-plate 106B-C of the respective second heat exchanger 102B-C in a tensioned stage against respective second heat exchanger 102B-C, when the sealing element <NUM> is assembled on the heat exchangers 102A-C. As a result, the flaps <NUM> of the sealing element <NUM> can be rigidly connected to the second heat exchangers 102B-C.

<FIG> illustrates a schematic view of the sealing element <NUM> for the heat exchangers 102A-C, in accordance with another embodiment of the present invention. According to the present embodiment, the sealing element <NUM> of the cooling module <NUM> further includes at least one auxiliary flap <NUM>, preferably a pair of auxiliary flaps <NUM>, formed the lateral sides of the central part <NUM> of the sealing element <NUM>. The auxiliary flaps <NUM> formed on the central part <NUM> at the sides that is adjacent to the main flaps <NUM>. The auxiliary flaps <NUM> of the sealing element <NUM> may be rested on the manifolds of the first heat exchanger 102A, when the sealing element <NUM> is mounted on the heat exchangers 102A-C. Particularly, the auxiliary flaps <NUM> of the sealing element <NUM> may restrict any leakage of ram air between the heat exchangers 102A-C at the manifolds. As the main flaps <NUM> and auxiliary flaps <NUM> of the sealing element <NUM> is disposed on the heat exchangers 102A-C in a tensioned state against the respective second heat exchanger 102B-C, the flaps <NUM> of the sealing element <NUM> may effectively block egressing of the ram air between the heat exchangers 102A-C and the flaps <NUM> can be rigid.

Claim 1:
A cooling module (<NUM>) comprising:
a first heat exchanger (102A) comprising at least one first side plate (106A);
at least two second heat exchangers (102B-C) arranged on opposite sides of the first heat exchanger (102A), each second heat exchanger (102B-C) comprising at least one second side plate (106B-C); and
at least one sealing element (<NUM>) having a central part (<NUM>) and at least two flaps (<NUM>) attached to the opposite sides of the central part (<NUM>), wherein the central part (<NUM>) is attached to the first heat exchanger (102A)
characterised in that each flap (<NUM>) is adapted to engage with the second side plate (106B-C) of the respective second heat exchanger (102B-C).