Patent Description:
Generally, the heat exchangers are provided in a vehicle to change temperature of the fluid flowing there through. The heat exchangers can be evaporators, radiators and condensers. To mount the heat exchangers in the vehicle, a module provided with a frame is connected to the heat exchangers. The module is commonly known as a heat exchanger module. The heat exchanger module may include one or more heat exchangers coupled to the frame of the module. The frame is to provide support to the heat exchangers and may provide a mounting means for mounting the heat exchangers in the vehicle. The frame may include a receiving means for receiving the heat exchangers. Further, the frame made of four parts adapted to be connected each other upon receiving the heat exchanger. Further, a gap may inadvertently formed between the frame and a manifold of the heat exchanger. Such gap may enable flow of ambient air through the gap without passing through a core of the heat exchanger. Hence, the heat exchange between the fluid flowing in the heat exchanger and the air flowing around the core of the heat exchanger is reduced. As a result, the thermal performance of the heat exchangers is be affected. To avoid such problem, a sealing element such as foam is applied to four sides of the heat exchanger before connecting the heat exchanger with the frame. Generally, the foam is glued to the sides of the heat exchanger. However, such technique has detrimental effect on the environment, due to usage of glue in the module. Further, it causes reliability issues as the foam may dislocate from its position while handling the heat exchanger or while assembling the heat exchanger into the frame. Such technique may require more components to connect to the heat exchanger that inadvertently increases production time and complexity.

Accordingly, there remains a need for a heat exchanger module having a means for blocking airflow between a frame and a manifold of a heat exchanger of the module. Further, there remains another need for a frame adapted to seal a gap between the frame and a heat exchanger so as to redirect air to the heat exchanger. Further, it would be desirable that the sealing means are fixed to the heat exchanger in an effortless manner, so that the time required for sealing the outer surfaces of the heat exchanger is as low as possible.

In view of the foregoing, an embodiment of the invention herein provides a module for a motor vehicle, particularly, a heat exchanger module for a motor vehicle. The module includes the features of claim <NUM>.

In one embodiment, the first portion is adapted to be fixed to the first and second sides of the manifolds and the third side of the heat exchange elements. Further, the closing portion is adapted to be fixed to the fourth side of the heat exchange elements.

Further, the pair of sliders of the first portion is in contact with the first and second sides of the manifolds and the base part of the first portion is in contact with the third side of the heat exchanger.

In another embodiment, the first portion is adapted to be fixed to the first side of the manifold and third and fourth sides of the heat exchange elements, whereas the closing portion is adapted to be fixed in parallel to the second side of the manifold.

Further, the base part of the first portion is in contact with the first side of the manifold, and the pair of sliders of the first portion is in contact with the third and fourth sides of the heat exchange elements.

In this example, the heat exchanger is configured as an operation of a condenser, the first fluid being air and the second fluid being a liquid refrigerant.

Further, at least one straight rib is aligned between the bottle and the second side of the manifold.

In one example, the sealing frame includes at least one clip formed on at least one of the closing portion and the first portion and the clip is facing the heat exchange elements to abut on at least one heat exchange element.

Further, the closing portion includes at least one coupling part formed at an end of the closing portion and the coupling part is adapted to couple with the first portion.

In one example, the heat exchanger further mounting brackets formed on the terminal plates of the heat exchange elements.

Further, the closing portion includes apertures to allow passing of the mounting brackets there through when the closing portion is coupled to the heat exchanger.

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 if needs be. The invention should however not be limited to the embodiments disclosed in the description.

The present invention envisages a module for a motor vehicle. The present invention is directed to address a problem of sealing between a frame and a manifold of a heat exchanger received in the frame. In addition, the conventional frame has multiple components connected together to form the frame, thereby increasing production/assembly time of the frame. Conventionally, the module, also referred to as a heat exchanger module, is provided with the frame to receive the heat exchanger and to mount the heat exchanger in the vehicle. Further, a gap may be inadvertently formed between the frame and the heat exchanger. The gap allows airflow between the frame and the heat exchanger, which results in reduced airflow across the heat exchanger. As a result, the thermal performance of the heat exchanger is reduced. To mitigate the problems, a frame designed so as to be in contact to manifolds of the heat exchanger. Geometry and design of the frame are described with respect to the forthcoming figures.

<FIG> illustrates a schematic view of a module <NUM> for a motor vehicle, in accordance with an embodiment of the present invention. The module <NUM> may also be referred to as a heat exchanger module. The module <NUM> includes at least one heat exchanger <NUM> and a sealing frame <NUM>. <FIG> illustrates a perspective view of the heat exchanger <NUM> of <FIG> without the sealing frame <NUM>. The heat exchanger <NUM> is configured for a heat exchange between a first fluid and a second fluid. In one example, the heat exchanger <NUM> maybe a condenser. In such case, the first fluid is air and the second fluid is a liquid refrigerant.

The heat exchanger <NUM> includes a pair of manifolds 104A-B forming a first side 108A and a second side108B, and a plurality of heat exchange elements <NUM>. In this example, the heat exchange elements <NUM> being heat exchange tubes stacked between the manifolds 104A-B to enable the first fluid flow in between the heat exchange elements <NUM>. Here, the first fluid flows in between the heat exchange elements <NUM> and the second fluid flows through the heat exchange elements <NUM>, thereby enabling the heat exchange between the first fluid and the second fluid. Further, the heat exchange elements <NUM> form a third side 108C and a fourth side 108D on terminal ends of the stack of heat exchange elements <NUM>.

In case the heat exchanger <NUM> is a condenser, the heat exchanger <NUM> may include a bottle <NUM> fluidically connected to the heat exchange elements <NUM> to enable the second fluid flow in the bottle <NUM>. Here, the bottle <NUM> is receiver drier adapted to remove moisture content from the second fluid and act as a reservoir for the second fluid. To provide structural support to the bottle <NUM>, the bottle <NUM> may attached to the second side 108B of the manifold 104B without disturbing fluidal connection with the heat exchange elements <NUM>. Further, there is a possibility to form a gap between the bottle <NUM> and respective side 108B of the manifold 104B. Such gap may reduce the first fluid flowing across the heat exchange elements <NUM>, as some portion of the first fluid may flow through the gap and flow in the vicinity of the manifolds 104A-B. Such phenomenon causes detrimental effect on the performance of the heat exchanger <NUM>.

To avoid such problems, the heat exchanger <NUM> is provided with a sealing frame <NUM>. In this example, the module <NUM> includes the sealing frame <NUM> adapted to be fixed all the four sides 108A-D of the heat exchanger <NUM>. The sealing frame <NUM> is provided with the heat exchanger <NUM> to isolate the sides 108A-D from the first fluid. In other words, the sealing frame <NUM> prevents the first fluid from at least in the vicinity of the sides 108A-D of the heat exchanger <NUM>. Here, the sealing frame <NUM> is adapted to be in contact with all the four sides 108A-D of the heat exchanger <NUM>, thereby avoiding creation of gap between the sides 108A-D of the heat exchanger <NUM> and the sealing frame <NUM>. Particularly, the sealing frame <NUM> is in contact with the first and second sides 108AB of the manifolds 104A-B and the third and fourth sides 108C-D formed on the terminal tubes/end plates of the heat exchanger <NUM>.

Further, the heat exchanger includes mounting brackets <NUM> formed on the terminal tubes of the heat exchanger <NUM> to mount the module <NUM> in the vehicle. In another example, the module <NUM> may include the mounting brackets <NUM> formed on the sealing frame <NUM>. The mounting brackets <NUM> may be coupled to the complementary features provided in the vehicle, so that the module <NUM> can be assembled in the vehicle.

<FIG> and <FIG> illustrate schematic views of the sealing frame <NUM> of <FIG>. As explained above, the sealing frame <NUM> is extending away from the manifolds 104A-B in such a way that the sealing frame <NUM> may prevent the first fluid flowing around the vicinity of the manifolds 104A-B. Generally, the manifolds 104A-B do not contribute to heat exchange between two fluids, hence it is necessary to restrict the first fluid flowing around the vicinity of the manifolds 104A-B to increase performance of the heat exchanger <NUM>. In one example, the sealing frame <NUM> can be attached to the first and second sides 108A-B of the manifolds 104A-B and the third and fourth sides 108C-D of the heat exchange elements <NUM>. In another example, the sealing frame <NUM> may be provided with an open end to receive the heat exchanger <NUM> and a means to seal the open end of the sealing frame <NUM>. In both examples, the sealing frame <NUM> is in contact with the four sides 108A-D of the heat exchanger <NUM>.

The sealing frame <NUM> includes a first portion <NUM> and a closing portion <NUM>. Here, the first portion is in form of an essentially U-shaped portion <NUM> adapted to fixed to the heat exchanger <NUM> and the closing portion <NUM> adapted to couple to an open end of the U-shaped portion <NUM>. In a preferred example, the first portion <NUM> is of single piece integrally formed together. Here, the first portion <NUM> includes a base part <NUM> and a pair of sliders <NUM> integrally formed with the base part <NUM> so as to form the U-shaped first portion <NUM>. Particularly, the base part <NUM> is formed with the pair of sliders <NUM> at a first side of the sliders <NUM> as shown in <FIG>. As explained above, the base part <NUM> integrally formed with the sliders <NUM> is to form the U-shaped first portion <NUM> with an open end. The closing portion <NUM> may be coupled to the open end of the U-shaped first portion <NUM> upon positioning the heat exchanger <NUM> in the U-shaped first portion <NUM>, thereby forming the sealing frame <NUM> around the heat exchanger <NUM>.

In first embodiment, the sliders <NUM> of the first portion <NUM> may be in contact with the first and second sides 108A-B of the manifolds 104A-B and the base part <NUM> of the first portion <NUM> may be in contact with the third side 108C of the heat exchange elements <NUM>, as shown in <FIG>. In this embodiment, the first portion <NUM> may be in contact with the first and second sides 108A-B of the manifolds 104A-B and the third side 108C of the heat exchanger <NUM>, wherein the heat exchanger <NUM> is received in the first portion <NUM> of the sealing frame <NUM>. Thereafter, the closing portion <NUM> may be coupled to the open end of the U-shaped first portion <NUM> in such a way that the closing portion <NUM> is in contact with fourth side 108D of the heat exchange elements <NUM>.

In second embodiment, the first portion <NUM> is adapted to be fixed to the third and fourth sides 108C-D of the heat exchanger <NUM> and the first side 108A of the manifold 104A. Further, the closing portion <NUM> is adapted to be fixed in parallel manner to the second side of the manifold 104B after receiving the heat exchanger <NUM> in the first portion <NUM>. Particularly, the sliders <NUM> of the first portion <NUM> is adapted to be in contact with the third and fourth sides 108C-D of the heat exchange elements <NUM>, and base part <NUM> is in contact with the first side 108A of the manifold 104A. This embodiment is not shown in Figures.

According to the invention, the sealing frame <NUM> further includes ribs to accommodate the bottle <NUM> of the heat exchanger <NUM>. Particularly, any one of the slider amongst the pair of sliders <NUM> includes at least two straight ribs 302A-B and a plurality connecting ribs <NUM>. The straight ribs 302A-B are extending along the stacking direction of the heat exchange elements <NUM> and are in contact with the second side 108B of the manifold 104B. In other words, the straight ribs 302A-B are parallely extending with respect to the manifolds 104A-B of the heat exchanger <NUM>. Further, the connecting ribs <NUM> are connected between the two ribs 302A-B to accommodate the bottle <NUM> of the heat exchanger <NUM>. Here, the connecting ribs <NUM> are curved ribs complementary to the outer circumference of the bottle <NUM> so that the connecting ribs <NUM> can be in contact with the outer surface of the bottle <NUM>. Further, at least one straight rib 302A is aligned between the bottle <NUM> and the second side 108B of the manifold 104B.

As explained above, a gap may be inadvertently formed between the bottle <NUM> and the manifold 104B, when the bottle <NUM> is installed in the heat exchanger <NUM>. As the straight rib 302A is positioned in between the bottle <NUM> and the manifold 104B, the straight rib 302A may close the gap between the bottle <NUM> and the manifold 104B, thereby redirecting the first fluid flow to the heat exchange elements <NUM> and avoiding the first fluid flow around the manifolds 104A-B of the heat exchanger <NUM>.

The sealing frame <NUM> further includes at least one clip <NUM> formed on any of the closing portion <NUM> and the first portion <NUM>. In another example, the sealing frame <NUM> may include multiple clips <NUM>. In such case, the clips <NUM> can be formed on both the first portion <NUM> and the closing portion <NUM>. The clips <NUM> formed on the first portion <NUM> and the closing portion <NUM> are facing towards the heat exchange elements <NUM> received in the sealing frame <NUM>. The clips <NUM> are adapted to abut at least one heat exchange element <NUM> amongst the stack of heat exchange elements <NUM> to arrest the movements of the heat exchange elements <NUM>. In another example, the clips <NUM> may receive the terminal tube when the heat exchanger <NUM> is received in the sealing frame <NUM>.

Referring to <FIG>, the closing portion <NUM> is provided with at least one coupling part <NUM> formed at an end of the closing portion <NUM>. The coupling <NUM> is adapted to be coupled to the sliders <NUM> of the first portion <NUM> at a second side, when the closing portion <NUM> is coupled to the open end of the first portion <NUM>, thereby enabling connection between the first portion <NUM> and the closing portion <NUM>. The closing portion <NUM> further includes apertures <NUM> to allow passing of the mounting brackets <NUM> there-through when the closing portion <NUM> is coupled to the heat exchanger <NUM>.

Here, the sealing frame <NUM> is collectively made of two parts, one being the U-shaped first portion <NUM> and another being the closing portion <NUM>. As the first portion <NUM> made of single element/piece, it enables ease assembly of the heat exchanger <NUM> in the sealing frame <NUM>, thereby reducing production time and cost of the manufacturing of the module <NUM>. Meantime, the straight ribs 302A-B of the sealing frame <NUM> reduces the first fluid flow in the vicinity of the manifolds 104A-B, thereby increasing the first fluid flow across the heat exchange elements <NUM>. As a result, thermal performance of the heat exchanger <NUM> can be increased.

Claim 1:
A module (<NUM>) for a motor vehicle comprising:
at least one heat exchanger (<NUM>) for a heat exchange between the first fluid and a second fluid, comprising a pair of manifolds (104A-B) forming a first side (108A) and a second side (104B), and a plurality of heat exchange elements (<NUM>) stacked between the manifolds (104A-B) to enable first fluid flow in-between the heat exchange elements (<NUM>), wherein the heat exchange elements (<NUM>) form a third side (108C) and a fourth side (108D) on the terminal ends of the stack of heat exchange elements (<NUM>),
wherein the module (<NUM>) comprises:
a sealing frame (<NUM>) configured to isolate the sides (108A-108D) from the first fluid, wherein the sealing frame (<NUM>) further comprises:
a first portion (<NUM>) adapted to be fixed to any of three sides of the heat exchanger (<NUM>) and
a closing portion (<NUM>) adapted to be fixed to the side of the heat exchanger (<NUM>) unoccupied by the first portion (<NUM>), wherein the first portion (<NUM>) being a U-shaped portion comprises a base part (<NUM>) and a pair of sliders (<NUM>), wherein the base part (<NUM>) is formed at a first side of the pair of sliders (<NUM>), characterized in that at least one slider amongst the pair of sliders (<NUM>) comprises at least two straight ribs (302A-B) extending along the stacking direction of the heat exchange elements (<NUM>) and a plurality of connecting ribs (<NUM>) connected between the two straight ribs (302A-B) to accommodate a bottle (<NUM>) of the heat exchanger (<NUM>).