US20100025024A1 - Heat exchanger and method - Google Patents
Heat exchanger and method Download PDFInfo
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- US20100025024A1 US20100025024A1 US12/521,892 US52189208A US2010025024A1 US 20100025024 A1 US20100025024 A1 US 20100025024A1 US 52189208 A US52189208 A US 52189208A US 2010025024 A1 US2010025024 A1 US 2010025024A1
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- Prior art keywords
- insert
- heat exchanger
- tube
- structural
- peak
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
- F28D7/1684—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation the conduits having a non-circular cross-section
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
- F02M26/13—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories
- F02M26/22—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories with coolers in the recirculation passage
- F02M26/29—Constructional details of the coolers, e.g. pipes, plates, ribs, insulation or materials
- F02M26/32—Liquid-cooled heat exchangers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/025—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
- F28F9/02—Header boxes; End plates
- F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2240/00—Spacing means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2265/00—Safety or protection arrangements; Arrangements for preventing malfunction
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/12—Fastening; Joining by methods involving deformation of the elements
- F28F2275/122—Fastening; Joining by methods involving deformation of the elements by crimping, caulking or clinching
Definitions
- the present invention relates to heat exchangers and, more particularly, to an exhaust gas recirculation cooler, a method of assembling the same, and a method of operating the same.
- the present invention provides a heat exchanger defining a flow path for a first working fluid and a flow path for a second working fluid, a tube at least partially defining one of the first and second flow paths, and a corrugated insert secured to the tube and positioned along the flow path of the first working fluid.
- a structural deficit is provided at a location on the insert so that failures occur at that location.
- the present invention also provides a heat exchanger having a header and a tube secured to the header.
- a corrugated insert can be secured to a surface of the tube and can include a groove formed along at least a portion of a length of the insert and spaced apart from the surface of the tube to which the insert is secured.
- the corrugated insert can be secured between two opposing surfaces of the tube and the groove can be formed midway along a height of the insert.
- the present invention provides a heat exchanger having a tube and an insert supported by the tube.
- the insert can have a corrugated shape with a peak and an adjacent valley and a groove extending along a longitudinal dimension of the insert between the peak and the valley such that structural failures occur at a preferred location between the peak and the valley.
- the present invention also provides a method of assembling a heat exchanger including providing a heat exchanger tube and positioning an insert in the tube.
- the method can also include the steps of connecting the insert to a surface of the tube and forming a structural deficiency along at least a portion of a length of the insert at a maximum distance from a point of connection between the insert and the surface of the tube so that failures occur along the structural deficiency.
- FIG. 1 is a perspective view of a heat exchanger according to some embodiments of the present invention.
- FIG. 2 is a partially cut-away view of a portion of the heat exchanger shown in FIG. 1 .
- FIG. 3 is a perspective view of a portion of a tube of the heat exchanger shown in FIG. 1 .
- FIG. 4 is an exploded view of a portion of a tube and an insert of the heat exchanger shown in FIG. 1 .
- FIG. 5 is an end view of a portion of a tube and an insert of the heat exchanger shown in FIG. 1 .
- FIG. 6 is an exploded view of a tube and an insert of a heat exchanger according to another embodiment of the present invention.
- FIG. 7 is an end view of a portion of a tube and an insert of the heat exchanger shown in FIG. 6 .
- phraseology and terminology used herein with reference to device or element orientation are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation.
- terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.
- FIGS. 1-5 illustrate a heat exchanger 10 according to some embodiments of the present invention.
- the heat exchanger 10 can operate as an exhaust gas recirculation cooler (EGRC) and can be operated with the exhaust system of a vehicle.
- EGRC exhaust gas recirculation cooler
- the heat exchanger 10 can be used in other (e.g., non-vehicular) applications, such as, for example, in electronics cooling, industrial equipment, building heating and air-conditioning, and the like.
- the heat exchanger 10 of the present invention can take many forms, utilize a wide range of materials, and can be incorporated into various other systems.
- the heat exchanger 10 can transfer heat energy from a high temperature first working fluid (e.g., exhaust gas, water, engine coolant, CO 2 , an organic refrigerant, R12, R245fa, air, and the like) to a lower temperature second working fluid (e.g., exhaust gas, water, engine coolant, CO 2 , an organic refrigerant, R12, R245fa, air, and the like).
- a high temperature first working fluid e.g., exhaust gas, water, engine coolant, CO 2 , an organic refrigerant, R12, R245fa, air, and the like
- a lower temperature second working fluid e.g., exhaust gas, water, engine coolant, CO 2 , an organic refrigerant, R12, R245fa, air, and the like.
- the heat exchanger 10 can operate to transfer heat energy between three or more fluids.
- the heat exchanger 10 can operate as a recuperator and can transfer heat energy from a high temperature location of a heating circuit to a low temperature location of the same heating circuit.
- the heat exchanger 10 can transfer heat energy from a working fluid traveling through a first portion of the heat transfer circuit to the same working fluid traveling through a second portion of the heat transfer circuit.
- the heat exchanger 10 can include a first header 18 and a second header 20 positioned at respective first and second ends 22 , 24 of a stack of heat exchanger tubes 26 .
- the first header 18 includes a first collecting tank 30 and the second header 20 includes a second collecting tank 32 .
- the heat exchanger 10 can include a single header 18 located at one of the first and second ends 22 , 24 or at another location on the heat exchanger 10 .
- each of the tubes 26 can be secured to the first and second headers 18 , 20 such that a first working fluid flowing through the heat exchanger 10 is maintained separate from a second working fluid flowing through the heat exchanger 10 .
- the heat exchanger 10 defines a first flow path (represented by arrows 34 in FIG. 1 ) for the first working fluid and a second flow path (represented by arrows 36 in FIG. 1 ) for a second working fluid, and the first and second flow paths 34 , 36 are separated such that the first working fluid is prevented from entering the second flow path 36 and such that the second working fluid is prevented from entering the first flow path 34 .
- the tubes 26 are secured to the first and second headers 18 , 20 such that the first working fluid enters the heat exchanger 10 through a first inlet aperture 40 in the first header 18 , travels through the heat exchanger 10 along the first flow path 34 , and is prevented from entering the second flow path 36 .
- the tubes 26 can be secured to the first and second headers 18 , 20 such that the second working fluid enters the heat exchanger 10 through a second inlet aperture 42 in the second header 20 , travels through the heat exchanger 10 along the second flow path 36 , and is prevented from entering the first flow path 34 .
- the first flow path 34 extends through the first inlet aperture 40 in the first header 18 , through the tubes 26 , and out of the heat exchanger 10 through a first outlet aperture 44 in the second header 20
- the second flow path 36 extends through the second inlet aperture 42 , around and between the tubes 26 (e.g., along outer surfaces 45 of the tubes 26 ), and out of the heat exchanger 10 through a second outlet aperture 46 in the first header 18 .
- the tubes 26 can have other orientations and configurations and the first and second flow paths 34 , 36 can be maintained separate by dividers, inserts, partitions, and the like.
- the first flow path 34 can extend through some of the tubes 26 while the second flow path 36 can extend through other tubes 26 .
- dividers 38 can be positioned in the first and/or second headers 18 , 20 to separate or at least partially separate the first and second flow paths 34 , 36 .
- the dividers 38 can be contoured to closely engage the interior of the first and/or second headers 18 , 20 and to prevent the first and/or second working fluids from leaking between the interior walls of the first and/or second headers 18 , 20 and the outer perimeter of the dividers 38 .
- the dividers 38 can have apertures 39 sized to receive one or more of the tubes 26 .
- the first working fluid flowing along the first flow path 34 can enter the tubes 26 through apertures 39 formed in the dividers 38 .
- the dividers 38 prevent the second working fluid from entering the tubes 26 .
- the dividers 38 can also direct the second working fluid from the second inlet aperture 42 between adjacent tubes 26 and can prevent the second working fluid from flowing into the tubes 26 .
- the dividers 38 can also prevent the first working fluid from flowing between the tubes 26 .
- the heat exchanger 10 is configured as a cross-flow heat exchanger such that the first flow path 34 or a portion of the first flow path 34 is opposite to or counter to the second flow path 36 or a portion of the second flow path 36 .
- the heat exchanger 10 can have other configurations and arrangements, such as, for example, a parallel-flow or a counter-flow configuration.
- the heat exchanger 10 is configured as a single-pass heat exchanger with the first working fluid traveling along the first flow path 34 through at least one of a number of tubes 26 and with the second working fluid traveling along the second flow path 36 between adjacent tubes 26 .
- the heat exchanger 10 can be configured as a multi-pass heat exchanger with the first working fluid traveling in a first pass through one or more of the tubes 26 and then traveling in a second pass through one or more different tubes 26 in a direction opposite to the flow direction of the first working fluid in the first pass.
- the second working fluid can travel along the second flow path 36 between adjacent tubes 26 .
- the heat exchanger 10 can be configured as a multi-pass heat exchanger with the second working fluid traveling in a first pass between a first pair of adjacent tubes 26 and then traveling in a second pass between another pair of adjacent tubes 26 in a direction opposite to the flow direction of the second working fluid in the first pass.
- the first working fluid can travel along the first flow path 34 through at least one of the tubes 26 .
- the heat exchanger 10 includes seven tubes 26 , each of which has a substantially rectangular cross-sectional shape.
- the heat exchanger 10 can include one, two, three, four, five, six, eight, or more tubes 26 , each of which can have a triangular, circular, square or other polygonal, oval, or irregular cross-sectional shape.
- reinforcing plates 52 can be added to the stack of tubes 26 to at least partially enclose the tubes 26 .
- reinforcing plates 52 can be positioned adjacent to the top and bottom of the stack of tubes 26 .
- a housing can be provided around at least some of the tubes 26 . In embodiments having reinforcing plates 52 and/or a housing, the reinforcing plates 52 and/or the housing can protect the tubes 26 from the mechanical effects of temperature fluctuations.
- the second flow path 36 or a portion of the second flow path 36 can extend across the outer surface 45 of one or more of the tubes 26 .
- a housing can be provided around the tubes 26 to prevent the second fluid from leaking out of the heat exchanger 10 between adjacent tubes 26 .
- ribs 56 can be formed along the outer surfaces 45 of the tubes 26 to at least partially define channels 58 .
- the heat exchanger 10 can include connectors 54 for supporting the heat exchanger 10 and/or for securing the heat exchanger 10 to an external structure.
- connectors 54 can be provided on the collecting tanks 22 , 23 .
- the second inlet aperture 42 and/or the second outlet aperture 46 can be positioned along the connectors 54 .
- a sealing groove or sealing rim 55 can be formed around the second inlet aperture 42 and/or the second outlet aperture 46 so that the heat exchanger 10 can be directly fastened to an external structure and so that the second working fluid does not leak out of the heat exchanger 10 around the second inlet aperture 42 and/or the second outlet aperture 46 .
- the ribs 56 of each tube 26 can be secured to an adjacent tube 26 .
- the ribs 56 of one tube 26 can be soldered, brazed, or welded to an adjacent tube 26 .
- adjacent tubes 26 can be secured together with inter-engaging fasteners, other conventional fasteners, adhesive or cohesive bonding material, by an interference fit, etc.
- Additional elevations, recesses, or deformations 60 can also or alternatively be provided on the outer surfaces 45 of the tubes 26 to provide structural support to the heat exchanger 10 , prevent the deformation or crushing of one or more tubes 26 , maintain a desired spacing between adjacent tubes 26 , improve heat exchange between the first and second working fluids, and/or generate turbulence along one or both of the first and second flow paths 34 , 36 .
- the heat exchanger 10 can include inserts 66 to improve heat transfer between the first and second working fluids as the first and second working fluids travel along the first and second flow paths 34 , 36 , respectively.
- the inserts 66 can be positioned in the tubes 26 .
- inserts 66 can be positioned between adjacent tubes 26 .
- inserts 66 can be integrally formed with the tubes 26 and can extend outwardly from the outer surfaces 45 of the tubes 26 .
- an insert 66 is supported in each of the tubes 26 , and extends along the entire length or substantially the entire length of each of the tubes 26 between opposite ends 68 of the tubes 26 .
- an insert 26 can be supported in only one or less than all of the tubes 26 , and the insert(s) 66 can extend substantially the entire length of the tube(s) 26 between opposite ends 68 of the tube(s) 26 , or alternatively, the insert 66 can extend through the tube(s) 26 along substantially less than the entire length of the tube(s) 26 .
- two or more inserts 66 can be supported by or in each tube 26 .
- the inserts 66 can be secured to the tubes 26 .
- the inserts 66 are soldered, brazed, or welded to the tubes 26 .
- the inserts 26 can be connected to the tubes 26 in another manner, such as, for example, by an interference fit, adhesive or cohesive bonding material, fasteners, etc.
- the ends 68 of the tubes 26 can be press-fit into one or both of the first and second headers 18 , 20 .
- the ends 68 of the tubes 26 and the inserts 66 supported in the tubes 26 or between the tubes 26 can be at least partially deformed when the tubes 26 and/or the inserts 66 are press-fit into the first and/or second headers 18 , 20 .
- the tubes 26 and/or the inserts 66 are pinched and maintained in compression to secure the tubes 26 and/or the inserts 66 in a desired orientation and to prevent leaking.
- the inserts 66 are formed from folded sheets of metal.
- the inserts 66 can be cast or molded in a desired shape and can be formed from other materials (e.g., aluminum, iron, and other metals, composite material, and the like).
- the inserts 66 can be cut or machined to shape in any manner, can be extruded or pressed, can be manufactured in any combination of such operations, and the like.
- the inserts 66 can be corrugated and can have a series of alternating peaks 72 and valleys 74 .
- the peaks 72 and valleys 74 can engage respective upper and lower interior sides of a tube 26 , and flanks 76 can extend (e.g., in a generally vertical direction in the illustrated embodiment of FIGS. 2 , 4 , and 5 ) between adjacent peaks 72 and valleys 74 .
- the flanks 76 can extend in a generally linear direction between opposite interior sides (e.g., between upper and lower opposing sides in the illustrated embodiment of FIGS. 6 and 7 ) of the tubes 26 .
- the flanks 76 can extend in a non-linear direction between the opposite interior sides (e.g., between upper and lower sides in the illustrated embodiment of FIGS. 1-5 ) of the tubes 26 .
- the peaks 72 and valleys 74 extend along a longitudinal dimension of the insert 66 and the tube 26 .
- the insert 66 may be in contact with only one side of the tube 26 .
- the flanks 76 can have a generally wavy cross-sectional shape.
- the inserts 66 can have other shapes and configurations.
- the inserts 66 can have pointed, squared, or irregularly shaped peaks 72 and/or valleys 74 .
- the inserts 66 can have a saw-toothed or sinusoidal profile.
- the inserts 66 operate as springs to absorb or at least partially absorb vibrations and/or to absorb expansions and contractions of the inserts 66 caused by fluctuating inlet temperatures of the first and/or second working fluids.
- the elasticity of the wavy inserts 66 prevents and/or reduces cracking and breaking of the inserts 66 .
- the elasticity of the wavy inserts 66 prevents and/or reduces cracking and breaking of connections (e.g., solder points, braze points, weld points, etc.) between the peaks 72 and valleys 74 of the inserts 66 and the interior sides of the tubes 26 .
- the wavy cross-section of the insert 66 may extend only a portion of a length L of the insert 66 .
- the wavy cross-section may be provided at the ends of the insert 66 where the tube 26 is connected to a header 18 , 20 , or alternatively where the tube 26 and/or insert 66 experiences the most thermal and mechanical stress.
- At least one structural deficiency 78 can be formed along at least one of the flanks 76 of an insert 66 .
- the structural deficiency 78 can include a groove extending along the entire length L or substantially the entire length L of a flank 76 between opposite ends 80 of the insert 66 .
- the groove 78 can extend along less than the entire length L of the flank 76 (e.g., a groove 78 can be staggered along the length L of a flank 76 ).
- the structural deficiency 78 may extend only a portion of a length L of the insert 66 .
- a groove 78 may be provided at the ends of the insert 66 where the tube 26 is connected to a header 18 , 20 , or where the tube 26 and or insert 66 experiences the most thermal and mechanical stress.
- a groove 78 or other structural deficiency 78 can be formed in opposing sides of the insert 66 to further weaken the insert at a particular location on the flank 76 .
- Structural deficiencies 78 can take various forms and shapes, and can be provided on the inserts 66 in various manners including scoring, stamping, etching, and the like. In some embodiments, groove 78 has a cross-section that is V-shaped, U-shaped, rectangular, or irregular. Structural deficiencies 78 can be formed in the insert 66 prior to or after folding or cutting of the insert 66 .
- the grooves 78 are positioned at locations on the inserts 66 where cracks and/or failures are anticipated to cause the least damage to the structural integrity of the inserts 66 and/or where cracks or failures are anticipated to have a minimal affect on the heat transfer characteristics of the heat exchanger 10 .
- the grooves 78 can be located midway along the height H of the flanks 76 so that the grooves 78 are spaced a maximum distance from the peaks 72 , valleys 74 , and corresponding connection points of the inserts 66 .
- structural failures i.e., cracking, buckling, etc. of the insert 66
- connection points e.g., solder points, braze points, weld points, etc.
- any cracks or failures occur at or near a midpoint of the height H of the flanks 76 and at a maximum distance from the connection points (e.g., solder points, braze points, weld points, etc.) between the peaks 72 and valleys 74 of the inserts 66 and the interior sides of the tubes 26 .
- the height H of the flanks 76 is approximately equal to 1 ⁇ 2 of the original height H of the flanks 76 prior to cracking or failure of the flanks 76 .
- the peaks 72 and valleys 74 of the inserts 66 remain connected to the interior sides (e.g., the upper and lower interior sides in the illustrated embodiment of FIGS. 1-5 ) of the tubes 26 . In this manner, the inserts 66 remain connected to the tubes 26 and continue to provide a maximum structural support to the tubes 26 , even after cracking or failure of the flanks 76 .
- the stiffness of an insert 66 can be calculated using the equation 1/12*(insert thickness T)*(insert height H) 3 . Accordingly, in embodiments, such as the illustrated embodiment of FIGS.
- each of the flanks 76 can maintain a maximum possible stiffness, even after failure or cracking.
- FIGS. 6 and 7 illustrate an alternate embodiment of a heat exchanger 210 according to the present invention.
- the heat exchanger 210 shown in FIGS. 6 and 7 is similar in many ways to the illustrated embodiments of FIGS. 1-5 described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment of FIGS. 6 and 7 and the embodiments of FIGS. 1-5 , reference is hereby made to the description above accompanying the embodiments of FIGS. 1-5 for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment of FIGS. 6 and 7 .
- Features and elements in the embodiment of FIGS. 6 and 7 corresponding to features and elements in the embodiments of FIGS. 1-5 are numbered in the 200 series.
- the tubes 226 of the heat exchanger 210 support inserts 266 having a series of alternating peaks 272 and valleys 274 .
- the peaks 272 and valleys 274 can engage respective upper and lower interior sides of a tube 226 .
- Flanks 276 can extend in a generally vertical direction in the illustrated embodiment of FIGS. 6 and 7 between adjacent peaks 272 and valleys 274 .
- flanks 276 can extend in a generally linear direction between upper and lower interior sides of the tubes 226 and can be substantially perpendicular to the upper and lower interior sides of the tubes 226 .
- the inserts 266 can have other shapes and configurations.
- Grooves 278 can be formed along at least some of the flanks 276 of the inserts 266 .
- the grooves 278 can take various forms and shapes, and can be provided on the inserts 266 in various manners including scoring, stamping, bending, and the like. As shown in FIGS. 6 and 7 , the grooves 278 can be positioned at locations on the inserts 266 where cracks and/or failures are anticipated to cause the least damage to the structural integrity of the inserts 266 and/or where cracking or failures are anticipated to have a minimal affect on the heat transfer characteristics of the heat exchanger 210 .
- the grooves 278 can be located midway along the height H of the flanks 276 so that the grooves 278 are spaced a maximum distance from the peaks 272 and valleys 274 of the inserts 266 and so that the grooves 278 are spaced a maximum distance from the connection points (e.g., solder points, braze points, weld points, etc.) between the peaks 272 and valleys 274 of the inserts 266 and the interior sides of the tubes 226 .
- connection points e.g., solder points, braze points, weld points, etc.
Abstract
A heat exchanger including a first flow path for a first working fluid, a second flow path for a second working fluid, a tube at least partially defining one of the first and second flow paths, and a corrugated insert secured to the tube and positioned along the first flow path. A structural deficit is provided at a location on the insert such that structural failures occur at the location in preference to other locations on the insert.
Description
- This application claims priority to U.S. provisional application Ser. No. 60/881,919 filed Jan. 23, 2007.
- The present invention relates to heat exchangers and, more particularly, to an exhaust gas recirculation cooler, a method of assembling the same, and a method of operating the same.
- In some embodiments, the present invention provides a heat exchanger defining a flow path for a first working fluid and a flow path for a second working fluid, a tube at least partially defining one of the first and second flow paths, and a corrugated insert secured to the tube and positioned along the flow path of the first working fluid. In some embodiments, a structural deficit is provided at a location on the insert so that failures occur at that location.
- The present invention also provides a heat exchanger having a header and a tube secured to the header. A corrugated insert can be secured to a surface of the tube and can include a groove formed along at least a portion of a length of the insert and spaced apart from the surface of the tube to which the insert is secured. In some embodiments, the corrugated insert can be secured between two opposing surfaces of the tube and the groove can be formed midway along a height of the insert.
- In some embodiments, the present invention provides a heat exchanger having a tube and an insert supported by the tube. The insert can have a corrugated shape with a peak and an adjacent valley and a groove extending along a longitudinal dimension of the insert between the peak and the valley such that structural failures occur at a preferred location between the peak and the valley.
- The present invention also provides a method of assembling a heat exchanger including providing a heat exchanger tube and positioning an insert in the tube. The method can also include the steps of connecting the insert to a surface of the tube and forming a structural deficiency along at least a portion of a length of the insert at a maximum distance from a point of connection between the insert and the surface of the tube so that failures occur along the structural deficiency.
- Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
-
FIG. 1 is a perspective view of a heat exchanger according to some embodiments of the present invention. -
FIG. 2 is a partially cut-away view of a portion of the heat exchanger shown inFIG. 1 . -
FIG. 3 is a perspective view of a portion of a tube of the heat exchanger shown inFIG. 1 . -
FIG. 4 is an exploded view of a portion of a tube and an insert of the heat exchanger shown inFIG. 1 . -
FIG. 5 is an end view of a portion of a tube and an insert of the heat exchanger shown inFIG. 1 . -
FIG. 6 is an exploded view of a tube and an insert of a heat exchanger according to another embodiment of the present invention. -
FIG. 7 is an end view of a portion of a tube and an insert of the heat exchanger shown inFIG. 6 . - Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
- Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
- Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “central,” “upper,” “lower,” “front,” “rear,” and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.
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FIGS. 1-5 illustrate aheat exchanger 10 according to some embodiments of the present invention. In some embodiments, including the illustrated embodiment ofFIGS. 1-5 , theheat exchanger 10 can operate as an exhaust gas recirculation cooler (EGRC) and can be operated with the exhaust system of a vehicle. In other embodiments, theheat exchanger 10 can be used in other (e.g., non-vehicular) applications, such as, for example, in electronics cooling, industrial equipment, building heating and air-conditioning, and the like. In addition, it should be appreciated that theheat exchanger 10 of the present invention can take many forms, utilize a wide range of materials, and can be incorporated into various other systems. - During operation and as explained in greater detail below, the
heat exchanger 10 can transfer heat energy from a high temperature first working fluid (e.g., exhaust gas, water, engine coolant, CO2, an organic refrigerant, R12, R245fa, air, and the like) to a lower temperature second working fluid (e.g., exhaust gas, water, engine coolant, CO2, an organic refrigerant, R12, R245fa, air, and the like). In addition, while reference is made herein to transferring heat energy between two working fluids, in some embodiments of the present invention, theheat exchanger 10 can operate to transfer heat energy between three or more fluids. Alternatively or in addition, theheat exchanger 10 can operate as a recuperator and can transfer heat energy from a high temperature location of a heating circuit to a low temperature location of the same heating circuit. In some such embodiments, theheat exchanger 10 can transfer heat energy from a working fluid traveling through a first portion of the heat transfer circuit to the same working fluid traveling through a second portion of the heat transfer circuit. - As shown in
FIG. 1 , theheat exchanger 10 can include afirst header 18 and asecond header 20 positioned at respective first andsecond ends heat exchanger tubes 26. In the illustrated embodiment ofFIGS. 1-5 , thefirst header 18 includes afirst collecting tank 30 and thesecond header 20 includes asecond collecting tank 32. In other embodiments, theheat exchanger 10 can include asingle header 18 located at one of the first andsecond ends heat exchanger 10. - As shown in
FIGS. 1-5 , each of thetubes 26 can be secured to the first andsecond headers heat exchanger 10 is maintained separate from a second working fluid flowing through theheat exchanger 10. More specifically, theheat exchanger 10 defines a first flow path (represented byarrows 34 inFIG. 1 ) for the first working fluid and a second flow path (represented byarrows 36 inFIG. 1 ) for a second working fluid, and the first andsecond flow paths second flow path 36 and such that the second working fluid is prevented from entering thefirst flow path 34. - In some embodiments, such as the illustrated embodiment of
FIGS. 1-5 , thetubes 26 are secured to the first andsecond headers heat exchanger 10 through afirst inlet aperture 40 in thefirst header 18, travels through theheat exchanger 10 along thefirst flow path 34, and is prevented from entering thesecond flow path 36. In these embodiments, thetubes 26 can be secured to the first andsecond headers heat exchanger 10 through asecond inlet aperture 42 in thesecond header 20, travels through theheat exchanger 10 along thesecond flow path 36, and is prevented from entering thefirst flow path 34. - In some such embodiments, the
first flow path 34 extends through thefirst inlet aperture 40 in thefirst header 18, through thetubes 26, and out of theheat exchanger 10 through afirst outlet aperture 44 in thesecond header 20, and thesecond flow path 36 extends through thesecond inlet aperture 42, around and between the tubes 26 (e.g., alongouter surfaces 45 of the tubes 26), and out of theheat exchanger 10 through asecond outlet aperture 46 in thefirst header 18. - In other embodiments, the
tubes 26 can have other orientations and configurations and the first andsecond flow paths first flow path 34 can extend through some of thetubes 26 while thesecond flow path 36 can extend throughother tubes 26. - Alternatively or in addition,
dividers 38 can be positioned in the first and/orsecond headers second flow paths FIGS. 1-5 , thedividers 38 can be contoured to closely engage the interior of the first and/orsecond headers second headers dividers 38. - As shown in
FIG. 2 , thedividers 38 can haveapertures 39 sized to receive one or more of thetubes 26. In embodiments such as the illustrated embodiment ofFIGS. 1-5 havingdividers 38 supported in the first and/orsecond headers first flow path 34 can enter thetubes 26 throughapertures 39 formed in thedividers 38. In these embodiments, thedividers 38 prevent the second working fluid from entering thetubes 26. In these embodiments, thedividers 38 can also direct the second working fluid from thesecond inlet aperture 42 betweenadjacent tubes 26 and can prevent the second working fluid from flowing into thetubes 26. Thedividers 38 can also prevent the first working fluid from flowing between thetubes 26. - In the illustrated embodiment of
FIGS. 1-5 , theheat exchanger 10 is configured as a cross-flow heat exchanger such that thefirst flow path 34 or a portion of thefirst flow path 34 is opposite to or counter to thesecond flow path 36 or a portion of thesecond flow path 36. In other embodiments, theheat exchanger 10 can have other configurations and arrangements, such as, for example, a parallel-flow or a counter-flow configuration. - In the illustrated embodiment of
FIGS. 1-5 , theheat exchanger 10 is configured as a single-pass heat exchanger with the first working fluid traveling along thefirst flow path 34 through at least one of a number oftubes 26 and with the second working fluid traveling along thesecond flow path 36 betweenadjacent tubes 26. In other embodiments, theheat exchanger 10 can be configured as a multi-pass heat exchanger with the first working fluid traveling in a first pass through one or more of thetubes 26 and then traveling in a second pass through one or moredifferent tubes 26 in a direction opposite to the flow direction of the first working fluid in the first pass. In these embodiments, the second working fluid can travel along thesecond flow path 36 betweenadjacent tubes 26. - In yet other embodiments, the
heat exchanger 10 can be configured as a multi-pass heat exchanger with the second working fluid traveling in a first pass between a first pair ofadjacent tubes 26 and then traveling in a second pass between another pair ofadjacent tubes 26 in a direction opposite to the flow direction of the second working fluid in the first pass. In these embodiments, the first working fluid can travel along thefirst flow path 34 through at least one of thetubes 26. - In the illustrated embodiment of
FIGS. 1-5 , theheat exchanger 10 includes seventubes 26, each of which has a substantially rectangular cross-sectional shape. In other embodiments, theheat exchanger 10 can include one, two, three, four, five, six, eight, ormore tubes 26, each of which can have a triangular, circular, square or other polygonal, oval, or irregular cross-sectional shape. - As shown in
FIG. 2 , thetubes 26 are assembled together in a stackingdirection 50. In some embodiments, such as the illustrated embodiment ofFIGS. 1-5 , reinforcingplates 52 can be added to the stack oftubes 26 to at least partially enclose thetubes 26. In some such embodiments, reinforcingplates 52 can be positioned adjacent to the top and bottom of the stack oftubes 26. Alternatively or in addition, a housing can be provided around at least some of thetubes 26. In embodiments having reinforcingplates 52 and/or a housing, the reinforcingplates 52 and/or the housing can protect thetubes 26 from the mechanical effects of temperature fluctuations. - As mentioned above, in some embodiments, the
second flow path 36 or a portion of thesecond flow path 36 can extend across theouter surface 45 of one or more of thetubes 26. In some such embodiments, a housing can be provided around thetubes 26 to prevent the second fluid from leaking out of theheat exchanger 10 betweenadjacent tubes 26. Alternatively or in addition,ribs 56 can be formed along theouter surfaces 45 of thetubes 26 to at least partially definechannels 58. - As shown in
FIG. 1 , theheat exchanger 10 can includeconnectors 54 for supporting theheat exchanger 10 and/or for securing theheat exchanger 10 to an external structure. In some embodiments, such as the illustrated embodiment,connectors 54 can be provided on the collectingtanks 22, 23. As shown inFIG. 1 , thesecond inlet aperture 42 and/or thesecond outlet aperture 46 can be positioned along theconnectors 54. As also shown inFIG. 1 , a sealing groove or sealingrim 55 can be formed around thesecond inlet aperture 42 and/or thesecond outlet aperture 46 so that theheat exchanger 10 can be directly fastened to an external structure and so that the second working fluid does not leak out of theheat exchanger 10 around thesecond inlet aperture 42 and/or thesecond outlet aperture 46. - In embodiments, such as the illustrated embodiment of
FIGS. 1-5 , having outwardly extendingribs 56, theribs 56 of eachtube 26 can be secured to anadjacent tube 26. In some such embodiments, theribs 56 of onetube 26 can be soldered, brazed, or welded to anadjacent tube 26. In other embodiments,adjacent tubes 26 can be secured together with inter-engaging fasteners, other conventional fasteners, adhesive or cohesive bonding material, by an interference fit, etc. - Additional elevations, recesses, or
deformations 60 can also or alternatively be provided on theouter surfaces 45 of thetubes 26 to provide structural support to theheat exchanger 10, prevent the deformation or crushing of one ormore tubes 26, maintain a desired spacing betweenadjacent tubes 26, improve heat exchange between the first and second working fluids, and/or generate turbulence along one or both of the first andsecond flow paths - In some embodiments, the
heat exchanger 10 can includeinserts 66 to improve heat transfer between the first and second working fluids as the first and second working fluids travel along the first andsecond flow paths FIGS. 1-5 , theinserts 66 can be positioned in thetubes 26. Alternatively or in addition, inserts 66 can be positioned betweenadjacent tubes 26. In other embodiments, inserts 66 can be integrally formed with thetubes 26 and can extend outwardly from theouter surfaces 45 of thetubes 26. - In the illustrated embodiment of
FIGS. 1-5 , aninsert 66 is supported in each of thetubes 26, and extends along the entire length or substantially the entire length of each of thetubes 26 between opposite ends 68 of thetubes 26. In other embodiments, aninsert 26 can be supported in only one or less than all of thetubes 26, and the insert(s) 66 can extend substantially the entire length of the tube(s) 26 between opposite ends 68 of the tube(s) 26, or alternatively, theinsert 66 can extend through the tube(s) 26 along substantially less than the entire length of the tube(s) 26. In still other embodiments, two ormore inserts 66 can be supported by or in eachtube 26. - In some embodiments, the
inserts 66 can be secured to thetubes 26. In some such embodiments, theinserts 66 are soldered, brazed, or welded to thetubes 26. In other embodiments, theinserts 26 can be connected to thetubes 26 in another manner, such as, for example, by an interference fit, adhesive or cohesive bonding material, fasteners, etc. - In some embodiments, such as the illustrated embodiment of
FIGS. 1-5 , the ends 68 of thetubes 26 can be press-fit into one or both of the first andsecond headers tubes 26 and theinserts 66 supported in thetubes 26 or between thetubes 26 can be at least partially deformed when thetubes 26 and/or theinserts 66 are press-fit into the first and/orsecond headers tubes 26 and/or theinserts 66 are pinched and maintained in compression to secure thetubes 26 and/or theinserts 66 in a desired orientation and to prevent leaking. - In the illustrated embodiment of
FIGS. 1-5 , theinserts 66 are formed from folded sheets of metal. In other embodiments, theinserts 66 can be cast or molded in a desired shape and can be formed from other materials (e.g., aluminum, iron, and other metals, composite material, and the like). In still other embodiments, theinserts 66 can be cut or machined to shape in any manner, can be extruded or pressed, can be manufactured in any combination of such operations, and the like. - As shown in
FIGS. 2 , 4, and 5, theinserts 66 can be corrugated and can have a series of alternatingpeaks 72 andvalleys 74. As also shown inFIGS. 2 , 4, and 5, thepeaks 72 andvalleys 74 can engage respective upper and lower interior sides of atube 26, and flanks 76 can extend (e.g., in a generally vertical direction in the illustrated embodiment ofFIGS. 2 , 4, and 5) betweenadjacent peaks 72 andvalleys 74. - In some embodiments, such as the illustrated embodiment of
FIGS. 6 and 7 (described in detail below), theflanks 76 can extend in a generally linear direction between opposite interior sides (e.g., between upper and lower opposing sides in the illustrated embodiment ofFIGS. 6 and 7 ) of thetubes 26. In other embodiments, such as the illustrated embodiment ofFIGS. 1-5 , theflanks 76 can extend in a non-linear direction between the opposite interior sides (e.g., between upper and lower sides in the illustrated embodiment ofFIGS. 1-5 ) of thetubes 26. In the illustrated embodiments, thepeaks 72 andvalleys 74 extend along a longitudinal dimension of theinsert 66 and thetube 26. In other embodiments, theinsert 66 may be in contact with only one side of thetube 26. - As shown in
FIGS. 2 , 4, and 5, in some such embodiments, theflanks 76 can have a generally wavy cross-sectional shape. In other embodiments, theinserts 66 can have other shapes and configurations. For example, in some embodiments, theinserts 66 can have pointed, squared, or irregularly shapedpeaks 72 and/orvalleys 74. In other embodiments, theinserts 66 can have a saw-toothed or sinusoidal profile. - In embodiments, such as the illustrated embodiment of
FIGS. 1-5 , having a wavy cross-sectional shape, theinserts 66 operate as springs to absorb or at least partially absorb vibrations and/or to absorb expansions and contractions of theinserts 66 caused by fluctuating inlet temperatures of the first and/or second working fluids. In some such embodiments, the elasticity of the wavy inserts 66 prevents and/or reduces cracking and breaking of theinserts 66. Alternatively or in addition, the elasticity of the wavy inserts 66 prevents and/or reduces cracking and breaking of connections (e.g., solder points, braze points, weld points, etc.) between thepeaks 72 andvalleys 74 of theinserts 66 and the interior sides of thetubes 26. In some embodiments, the wavy cross-section of theinsert 66 may extend only a portion of a length L of theinsert 66. For example, the wavy cross-section may be provided at the ends of theinsert 66 where thetube 26 is connected to aheader tube 26 and/or insert 66 experiences the most thermal and mechanical stress. - As shown in
FIGS. 2 , 4, and 5, at least onestructural deficiency 78 can be formed along at least one of theflanks 76 of aninsert 66. In some embodiments, thestructural deficiency 78 can include a groove extending along the entire length L or substantially the entire length L of aflank 76 between opposite ends 80 of theinsert 66. In other embodiments, thegroove 78 can extend along less than the entire length L of the flank 76 (e.g., agroove 78 can be staggered along the length L of a flank 76). In some embodiments, thestructural deficiency 78 may extend only a portion of a length L of theinsert 66. For example, agroove 78 may be provided at the ends of theinsert 66 where thetube 26 is connected to aheader tube 26 and or insert 66 experiences the most thermal and mechanical stress. In some embodiments, agroove 78 or otherstructural deficiency 78, can be formed in opposing sides of theinsert 66 to further weaken the insert at a particular location on theflank 76. -
Structural deficiencies 78 can take various forms and shapes, and can be provided on theinserts 66 in various manners including scoring, stamping, etching, and the like. In some embodiments,groove 78 has a cross-section that is V-shaped, U-shaped, rectangular, or irregular.Structural deficiencies 78 can be formed in theinsert 66 prior to or after folding or cutting of theinsert 66. - In embodiments, such as the illustrated embodiment of
FIGS. 1-5 , havinggrooves 78, failures and/or cracking of theinserts 66 caused by expansion and contraction of theinserts 66 will occur along thegrooves 78 where theinserts 66 are weakest. In these embodiments, thegrooves 78 are positioned at locations on theinserts 66 where cracks and/or failures are anticipated to cause the least damage to the structural integrity of theinserts 66 and/or where cracks or failures are anticipated to have a minimal affect on the heat transfer characteristics of theheat exchanger 10. - As shown in
FIGS. 2 , 4, and 5, thegrooves 78 can be located midway along the height H of theflanks 76 so that thegrooves 78 are spaced a maximum distance from thepeaks 72,valleys 74, and corresponding connection points of theinserts 66. Thus, structural failures (i.e., cracking, buckling, etc. of the insert 66) will be spaced a maximum distance from the connection points (e.g., solder points, braze points, weld points, etc.) between thepeaks 72 andvalleys 74 of theinserts 66 and the interior sides of thetubes 26. This enables theinsert 66 to provide sufficient structural support to thetube 26 and simultaneously maximize the heat transfer between the first and second fluids despite a structural failure of theinsert 66 as is described in more detail below. - In embodiments, such as the illustrated embodiment of
FIGS. 1-5 , in whichgrooves 78 are located along theflanks 76 of theinserts 66, any cracks or failures occur at or near a midpoint of the height H of theflanks 76 and at a maximum distance from the connection points (e.g., solder points, braze points, weld points, etc.) between thepeaks 72 andvalleys 74 of theinserts 66 and the interior sides of thetubes 26. In these embodiments, even after cracking or failure of theflanks 76, the height H of theflanks 76 is approximately equal to ½ of the original height H of theflanks 76 prior to cracking or failure of the flanks 76. Alternatively or in addition, even after cracking or failure of theflanks 76, thepeaks 72 andvalleys 74 of theinserts 66 remain connected to the interior sides (e.g., the upper and lower interior sides in the illustrated embodiment ofFIGS. 1-5 ) of thetubes 26. In this manner, theinserts 66 remain connected to thetubes 26 and continue to provide a maximum structural support to thetubes 26, even after cracking or failure of the flanks 76. - More particularly, it has been found that for
corrugated inserts 66, such as, for example, theinserts 66 of the illustrated embodiment ofFIGS. 1-5 , the stiffness of aninsert 66 can be calculated using the equation 1/12*(insert thickness T)*(insert height H)3. Accordingly, in embodiments, such as the illustrated embodiment ofFIGS. 1-5 , in which cracking and failures occur at thegrooves 78, which are spaced a maximum distance from thepeaks 72 andvalleys 74 of theinserts 66 and which are spaced a maximum distance from the connection points (e.g., solder points, braze points, weld points, etc.) between thepeaks 72 andvalleys 74, the height H of each of theflanks 76, even after cracking or failure, is maximized. In this manner, each of theflanks 76 can maintain a maximum possible stiffness, even after failure or cracking. -
FIGS. 6 and 7 illustrate an alternate embodiment of a heat exchanger 210 according to the present invention. The heat exchanger 210 shown inFIGS. 6 and 7 is similar in many ways to the illustrated embodiments ofFIGS. 1-5 described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIGS. 6 and 7 and the embodiments ofFIGS. 1-5 , reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-5 for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIGS. 6 and 7 . Features and elements in the embodiment ofFIGS. 6 and 7 corresponding to features and elements in the embodiments ofFIGS. 1-5 are numbered in the 200 series. - In the illustrated embodiment of
FIGS. 6 and 7 , thetubes 226 of the heat exchanger 210 support inserts 266 having a series of alternatingpeaks 272 andvalleys 274. As also shown inFIGS. 6 and 7 , thepeaks 272 andvalleys 274 can engage respective upper and lower interior sides of atube 226.Flanks 276 can extend in a generally vertical direction in the illustrated embodiment ofFIGS. 6 and 7 betweenadjacent peaks 272 andvalleys 274. - As shown in
FIGS. 6 and 7 , theflanks 276 can extend in a generally linear direction between upper and lower interior sides of thetubes 226 and can be substantially perpendicular to the upper and lower interior sides of thetubes 226. In other embodiments, theinserts 266 can have other shapes and configurations. -
Grooves 278 can be formed along at least some of theflanks 276 of theinserts 266. Thegrooves 278 can take various forms and shapes, and can be provided on theinserts 266 in various manners including scoring, stamping, bending, and the like. As shown inFIGS. 6 and 7 , thegrooves 278 can be positioned at locations on theinserts 266 where cracks and/or failures are anticipated to cause the least damage to the structural integrity of theinserts 266 and/or where cracking or failures are anticipated to have a minimal affect on the heat transfer characteristics of the heat exchanger 210. - As shown in
FIGS. 6 and 7 , thegrooves 278 can be located midway along the height H of theflanks 276 so that thegrooves 278 are spaced a maximum distance from thepeaks 272 andvalleys 274 of theinserts 266 and so that thegrooves 278 are spaced a maximum distance from the connection points (e.g., solder points, braze points, weld points, etc.) between thepeaks 272 andvalleys 274 of theinserts 266 and the interior sides of thetubes 226. - The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention.
Claims (34)
1. A heat exchanger comprising:
a first flow path for a first working fluid;
a second flow path for a second working fluid;
a corrugated insert positioned along the first flow path;
a structural deficit provided at a location on the insert such that structural failures occur at the location in preference to other locations on the insert; and
a tube at least partially defining one of the first and second flow paths, the insert being secured to the tube.
2. The heat exchanger of claim 1 , wherein the structural deficit comprises a groove.
3. The heat exchanger of claim 1 , wherein the structural deficit comprises a staggered groove.
4. The heat exchanger of claim 1 , wherein the corrugated insert comprises a peak and an adjacent valley and wherein the structural deficit is positioned between the peak and the valley.
5. The heat exchanger of claim 4 , wherein the peak and valley extend along a longitudinal dimension of the insert and the structural deficit extends along a portion of the longitudinal dimension of the insert in a direction substantially parallel to a fold of the insert.
6. The heat exchanger of claim 4 , wherein the structural deficit is positioned substantially equidistantly between the peak and valley such that structural failures occur at a midpoint between the peak and valley.
7. The heat exchanger of claim 1 , wherein the insert comprises adjacent folds such that the insert extends between opposing surfaces of the tube and is secured to the surfaces of the tube at the folds.
8. The heat exchanger of claim 7 , wherein the structural deficit is located midway along a height of the insert between the opposing surfaces of the tube.
9. The heat exchanger of claim 7 , wherein the structural deficit is spaced away from the folds of the insert.
10. The heat exchanger of claim 7 , wherein the folds are secured to the surfaces of the tube by one of welded, soldered, and brazed connections.
11. A heat exchanger comprising:
a header;
a tube secured to the header; and
a corrugated insert secured to at least one surface of the tube, the insert having a groove formed along at least a portion of a length of the insert and spaced apart from the surface of the tube to which the insert is secured.
12. The heat exchanger of claim 11 , wherein the insert defines adjacent legs, and wherein the groove is located along one of the legs.
13. The heat exchanger of claim 12 , wherein at least a portion of one of the legs has a wavy cross-section.
14. The heat exchanger of claim 12 , wherein the insert is secured between opposing surfaces of the tube, and wherein the groove is positioned along the insert such that the insert remains secured to the opposing surfaces after a structural failure.
15. The heat exchanger of claim 14 , wherein the legs of the insert provide sufficient structural support for the opposing surfaces of the tube after a structural failure.
16. The heat exchanger of claim 12 , wherein the corrugated insert comprises a peak and an adjacent valley and wherein the groove is positioned between the peak and the valley.
17. The heat exchanger of claim 12 , wherein the corrugated insert comprises a peak and an adjacent valley, and wherein the groove is positioned substantially equidistantly between the peak and valley such that the structural failures occur at a midpoint between the peak and valley.
18. The heat exchanger of claim 12 , wherein the groove has a cross-section that is substantially V-shaped.
19. A heat exchanger having a tube and an insert supported by the tube, the insert comprising:
a corrugation defining a peak and an adjacent valley;
a groove extending along a longitudinal dimension of the insert between the peak and the adjacent valley and providing a preferred location for structural failures.
20. The heat exchanger of claim 19 , wherein the groove is positioned substantially equidistantly between the peak and the valley such that structural failures occur at a midpoint between the peak and the valley.
21. The heat exchanger of claim 19 , wherein the groove is located at a maximum distance between the peak and the valley.
22. The heat exchanger of claim 19 , wherein the insert is attached to opposing surfaces of the tube in at least one location along at least one of the peak and the valley.
23. The heat exchanger of claim 19 , wherein the groove extends substantially along the entire longitudinal dimension of the insert.
24. The heat exchanger of claim 19 , wherein the longitudinal dimension of the insert terminates in opposing ends of the insert, and wherein the groove extends from an end to a location along the longitudinal dimension of the insert.
25. The heat exchanger of claim 24 , and further comprising a header into which an end of the tube extends, wherein the insert extends substantially the entire length of the tube and the groove extends to a location where the tube connects to the header.
26. The heat exchanger of claim 24 , and further comprising a header into which an end of the tube extends, wherein the insert extends substantially the entire length of the tube and the groove extends beyond a location where the tube connects to the header.
27. A method of assembling a heat exchanger comprising the steps of:
providing a heat exchanger tube;
positioning an insert in the tube;
connecting the insert to a surface of the tube;
forming a structural deficiency along at least a portion of a length of the insert at a maximum distance from a point of connection between the insert and the surface of the tube so that failures occur along the structural deficiency.
28. The method of claim 27 , wherein forming the structural deficiency includes forming a groove, and wherein the structural deficiency is formed having a cross-section that is one of substantially U-shaped, V-shaped, or rectangular.
29. The method of claim 27 , wherein the structural deficiency is formed by one of scoring, stamping, and etching.
30. The method of claim 27 , wherein the insert is connected to the surface of the tube by one of brazing, soldering, or welding.
31. The method of claim 27 , and further comprising folding the insert to form alternating peaks and valleys.
32. The method of claim 31 , wherein the structural deficiency is formed prior to the folding of the insert.
33. The method of claim 31 , wherein the structural deficiency is formed after the folding of the insert.
34. The method of claim 31 , wherein the peaks and valleys of the insert are connected to opposing surfaces of the tube.
Priority Applications (1)
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US12/521,892 US20100025024A1 (en) | 2007-01-23 | 2008-01-23 | Heat exchanger and method |
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Cited By (26)
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US20050161206A1 (en) * | 2003-12-19 | 2005-07-28 | Peter Ambros | Heat exchanger with flat tubes |
US8261816B2 (en) | 2003-12-19 | 2012-09-11 | Modine Manufacturing Company | Heat exchanger with flat tubes |
US20090025916A1 (en) * | 2007-01-23 | 2009-01-29 | Meshenky Steven P | Heat exchanger having convoluted fin end and method of assembling the same |
US9395121B2 (en) | 2007-01-23 | 2016-07-19 | Modine Manufacturing Company | Heat exchanger having convoluted fin end and method of assembling the same |
US8424592B2 (en) | 2007-01-23 | 2013-04-23 | Modine Manufacturing Company | Heat exchanger having convoluted fin end and method of assembling the same |
US20090250201A1 (en) * | 2008-04-02 | 2009-10-08 | Grippe Frank M | Heat exchanger having a contoured insert and method of assembling the same |
US8516699B2 (en) | 2008-04-02 | 2013-08-27 | Modine Manufacturing Company | Method of manufacturing a heat exchanger having a contoured insert |
US8511074B2 (en) | 2008-08-02 | 2013-08-20 | Pierburg Gmbh | Heat transfer unit for an internal combustion engine |
US8844504B2 (en) * | 2010-03-18 | 2014-09-30 | Modine Manufacturing Company | Heat exchanger and method of manufacturing the same |
US20110226222A1 (en) * | 2010-03-18 | 2011-09-22 | Raduenz Dan R | Heat exchanger and method of manufacturing the same |
US20130098588A1 (en) * | 2010-06-23 | 2013-04-25 | Aldes Aeraulique | Air-air heat exchanger |
US20120151950A1 (en) * | 2010-12-15 | 2012-06-21 | Grundfos Holding A/S | Heat transfer system |
US9151541B2 (en) * | 2010-12-15 | 2015-10-06 | Grundfos Holding A/S | Heat transfer system |
US10514189B2 (en) * | 2012-02-17 | 2019-12-24 | Hussmann Corporation | Microchannel suction line heat exchanger |
US20130264031A1 (en) * | 2012-04-09 | 2013-10-10 | James F. Plourde | Heat exchanger with headering system and method for manufacturing same |
US20140090812A1 (en) * | 2012-09-28 | 2014-04-03 | Behr Gmbh & Co., Kg | Heat exchanger |
US20160146552A1 (en) * | 2013-06-28 | 2016-05-26 | Schneider Electric It Corporation | Indirect evaporator cooler heat exchanger manufacturing method |
US10072901B2 (en) * | 2013-06-28 | 2018-09-11 | Schneider Electric It Corporation | Indirect evaporator cooler heat exchanger manufacturing method |
US20180320975A1 (en) * | 2015-10-29 | 2018-11-08 | T.Rad Co., Ltd. | Structure of heat exchanger core without header plate |
US10634431B2 (en) * | 2015-10-29 | 2020-04-28 | T.Rad Co., Ltd. | Structure of heat exchanger core without header plate |
US20190162489A1 (en) * | 2017-10-30 | 2019-05-30 | Hanon Systems | Heat exchanger for an internal combustion engine |
US10801788B2 (en) * | 2018-09-05 | 2020-10-13 | Mingjia LI | Lead-supercritical carbon dioxide intermediate heat exchanger |
US11319905B2 (en) * | 2019-02-20 | 2022-05-03 | Hyundai Motor Company | EGR cooler and engine system having the same |
US20210333055A1 (en) * | 2020-04-28 | 2021-10-28 | Hamilton Sundstrand Corporation | Stress relieving additively manufactured heat exchanger fin design |
US20220316813A1 (en) * | 2021-04-06 | 2022-10-06 | General Electric Company | Heat exchangers including partial height fins having at least partially free terminal edges |
US11940232B2 (en) * | 2021-04-06 | 2024-03-26 | General Electric Company | Heat exchangers including partial height fins having at least partially free terminal edges |
Also Published As
Publication number | Publication date |
---|---|
BRPI0807410A2 (en) | 2014-05-27 |
DE112008000114T5 (en) | 2010-02-25 |
WO2008091918A1 (en) | 2008-07-31 |
CN101589286A (en) | 2009-11-25 |
CN101589286B (en) | 2011-09-28 |
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Legal Events
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Owner name: MODINE MANUFACTURING COMPANY,WISCONSIN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MESHENKY, STEVEN P.;RADUENZ, DAN R.;REEL/FRAME:022903/0177 Effective date: 20090617 |
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