HEAT EXCHANGER

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to European Patent Application No. 24181472.2 filed Jun. 11, 2024, the entire contents of which are hereby incorporated by reference herein.

BACKGROUND

The present disclosure relates to heat exchangers and a method of manufacturing heat exchangers.

SUMMARY

In one example of an embodiment, a heat exchanger includes a working fluid inlet configured to receive a working fluid, a working fluid outlet in fluid communication with the working fluid inlet, a coolant inlet configured to receive a coolant, a coolant outlet in fluid communication with the coolant inlet, a first plate, a second plate stacked on the first plate to define a working fluid channel between the first plate and the second plate, a third plate stacked on the second plate to define a coolant channel between the second plate and the third plate, a fourth plate stacked on the third plate, and a reinforcement plate positioned in the coolant channel. The working fluid channel provides fluid communication of the working fluid between the working fluid inlet and the working fluid outlet. The coolant channel provides fluid communication of the coolant between the coolant inlet and the coolant outlet. The coolant is configured to reduce a temperature of the working fluid as the coolant flows through the coolant channel. The working fluid channel is further defined between the third plate and the fourth plate. The reinforcement plate includes a first surface and a second surface opposite the first surface. The first surface is brazed to the second plate. The second surface is brazed to the third plate.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a heat exchanger positioned within a housing and an engine block.

FIG. 2 is a cross-sectional view of the housing, the heat exchanger, and the engine block of FIG. 1.

FIG. 3 is a cross-sectional view of the heat exchanger of FIG. 1.

FIG. 4 is a perspective view of a base plate, a first plate, a second plate, and a pair of reinforcement plates of the heat exchanger of FIG. 1.

FIG. 5 is an enlarged view of a portion of FIG. 4.

FIG. 6 is a perspective view of the base plate, the first plate, the second plate, and the pair of reinforcement plates of FIG. 4 along with a copper foil.

FIG. 7 is an enlarged view of a portion of the copper foil of FIG. 6.

FIG. 8 is an enlarged view of a portion of FIG. 6.

FIG. 9 is a perspective view of the base plate, the first plate, and the second plate of FIG. 4 along with a third plate and a fourth plate.

FIG. 10 is a side view of the base plate, the first plate, the second plate, the third plate, and the fourth plate of FIG. 9.

FIG. 11 is a perspective view the heat exchanger including a spacer plate between the base plate and the first plate.

FIG. 12 is a top view of the spacer plate and the base plate of the heat exchanger of FIG. 11.

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.

DETAILED DESCRIPTION

FIG. 1 illustrates a heat exchanger 10. In one embodiment, the heat exchanger 10 is a vehicle oil cooler and more particularly a stacked plate vehicle oil cooler. The heat exchanger 10 is coupled to a housing 14 (also referred to as a shell 14). The housing 14 supports the heat exchanger 10 and facilitates a flow of fluids through the heat exchanger 10. The housing 14 is coupled to an engine block 16. The engine block 16 houses an engine, which is lubricated by a first fluid (also referred to as a working fluid). In the illustrated embodiment, the first fluid is motor oil. In other embodiments, the first fluid can be, for example, exhaust gas. During operation of the engine, the engine heats (i.e., rises in temperature), which causes the oil to also heat. The heat exchanger 10 cools (i.e., decrease the temperature of) the oil, which is described in further detail below.

With reference now to FIG. 2, the heat exchanger 10 is illustrated in greater detail. The heat exchanger 10 is positioned within a cavity 18 defined by the housing 14 and the engine block 16. The cavity 18 is filled with a second fluid. The second fluid is a coolant. The coolant can be, for example, ethylene glycol, propylene glycol, etc. The coolant is configured to cool the oil. The heat exchanger 10 includes a base plate 22 and heat exchanger plates 26 stacked on the base plate 22. In one embodiment, the base and heat exchanger plates 22, 26 are formed from stainless steel. In other embodiments, the base and heat exchanger plates 22, 26 can be composed of another suitable material (e.g., cast iron, aluminum, etc.). In the illustrated embodiment, the base plate 22 is coupled to the housing 14 by fasteners 30 (shown in FIG. 1). The fasteners 30 can be bolts, screws, or any other suitable fastener. Each fastener 30 extends through an associated base aperture 34 in the base plate 22 (shown in FIG. 4). The base plate 22 can alternatively be coupled to the housing 14 (or alternatively to the engine block 16) by any suitable method (e.g., welding, brazing, etc.).

As illustrated in FIG. 3, the base plate 22 includes a first inlet 38 (also referred to as a working fluid inlet 38 or an oil inlet 38) and a first outlet 40 (also referred to as a working fluid outlet 40 or an oil outlet 40) in fluid communication with and downstream from the oil inlet 38. The oil inlet 38 defines an entrance into an inlet manifold 42. The inlet manifold 42 is a generally cylindrical recess that extends through the base plate 22 and the heat exchanger plates 26. The oil outlet 40 defines an exit from an outlet manifold 44. The outlet manifold 44 is a generally cylindrical recess that extends through the base plate 22 and the heat exchanger plates 26. The oil flows into the heat exchanger 10 through the inlet manifold 42 and out of the heat exchanger 10 through the outlet manifold 44.

With continued reference to FIG. 3, the heat exchanger plates 26 include a first plate 46 and a second plate 48. The first plate 46 is coupled to the base plate 22 and the second plate 48 is stacked on the first plate 46. The first and second plates 46, 48 each include a first aperture 50 and a second aperture 52. Each first aperture 50 is aligned with the oil inlet 38 of the base plate 22. The first apertures 50 further define the inlet manifold 42. Each second aperture 52 is aligned with the oil outlet 40 of the base plate 22. The second apertures 52 further define the outlet manifold 44.

The first plate 46 and the second plate 48 are coupled together and define a first fluid channel 54 (also referred to as a working fluid channel 54 or an oil channel 54) therebetween. The oil channel 54 is further defined by the inlet manifold 42 and the outlet manifold 44. The oil flows through the oil channel 54. More specifically, the oil is configured to flow from the inlet manifold 42, between the first and second plates 46, 48, and out the outlet manifold 44. The oil is configured to be cooled as the oil flows through the oil channel 54. Relatively warm oil passes into the heat exchanger 10 through the inlet manifold 42, flows through the oil channel 54, and relatively cool oil exits the heat exchanger 10 via the outlet manifold 44. In some embodiments, turbulators or fins are located in the oil channel 54. The turbulators provide turbulence to the flow of the oil within the oil channel 54 to increase heat transfer between the oil and coolant.

In some examples of embodiments, the heat exchanger 10 may not include a first plate 46. In these embodiments, the second plate 48 can be coupled directly to the base plate 22. The oil channel 54 is then defined between the base plate 22 and the second plate 48. In these embodiments, the base plate 22 can alternatively be referred to as a first plate.

With continued reference to FIG. 3, the heat exchanger plates 26 includes a third plate 58. The third plate 58 is stacked on the second plate 48. More specifically, the second plate 48 includes first dimples 62, and the third plate 58 includes second dimples 66. Each first dimple 62 extends from the second plate 48 in a direction toward the third plate 58. Each second dimple 66 extends from the third plate 58 in a direction toward the second plate 48. Each first dimple 62 engages one respective second dimple 66. More specifically, the first and second dimples 62, 66 are coupled together.

The second and third plates 48, 58 define a second fluid channel 70 (also referred to as a coolant channel 70) therebetween. As such, the first and second dimples 62, 66 extend into the coolant channel 70. The coolant channel 70 is further defined by the cavity 18. The coolant flows through the coolant channel 70. More specifically, the coolant flows into the cavity 18, between the second and third plates 48, 58, and then out of the cavity 18. The coolant cools (i.e., decreases a temperature of) the oil within the oil channel 54 when the coolant flows between the second and third plates 48, 58.

The heat exchanger plates 26 further includes a fourth plate 74. The fourth plate 74 is stacked on the third plate 58. The third and fourth plates 58, 74 are coupled together and further define the oil channel 54 therebetween. As such, the oil is configured to flow from the oil inlet 38, between third and fourth plates 58, 74, and out the oil outlet 40.

The heat exchanger plates 26 further includes a fifth plate 78. The fifth plate 78 is stacked on the fourth plate 74. More specifically, the fourth plate 74 includes third dimples 82, and the fifth plate 78 includes fourth dimples 86. Each third dimple 82 engages and is coupled to one respective fourth dimple 86. The third and fourth dimples 82, 86 have the same features as the first and second dimples 62, 66, respectively. As such, any feature or function described with reference to the first and second dimples 62, 66 can apply to the third and fourth dimples 82, 86 and any other dimple on the heat exchanger 10.

The heat exchanger plates 26 further includes a sixth plate 90. The sixth plate 90 is stacked on the fifth plate 78. The fifth and sixth plates 78, 90 are coupled together and further define the oil channel 54 therebetween. As such, the oil flows from the oil inlet 38, between fifth and sixth plates 78, 90, and out the oil outlet 40.

Similar to the first and second plates 46, 48, the third, fourth, fifth, and sixth plates 58, 74, 78, 90 include the first and second apertures 50, 52 that further define the inlet and outlet manifolds 42, 44, respectively.

The first and second plates 46, 48 can be referred to as a first plate pair, the third and fourth plates 58, 74 can be referred to as a second plate pair, and the fifth and sixth plates 78, 90 can be referred to as a third plate pair. In the illustrated embodiment, the first, second, and third plate pairs are identical except for the first plate 46 not including any dimples. In the illustrated embodiment, the heat exchanger 10 includes twelve plate pairs. In other embodiments, the heat exchanger 10 can include any suitable number of plate pairs. The oil flows within the plate pairs (i.e., through the oil channel 54), and the coolant flows between the plate pairs (i.e., through the coolant channel 70).

With reference now to FIGS. 4 and 5, the heat exchanger 10 includes a reinforcement plate 94. During operation, the heat exchanger 10 can receive high stresses due to vibration caused by the motor. Accordingly, the reinforcement plate 94 increases the strength of the heat exchanger 10 to prevent failure in high stress areas. As best illustrated in FIG. 5, the reinforcement plate 94 defines a first surface 96 (shown in FIG. 10), a second surface 98 opposite the first surface 96, and an outer surface 102 (also referred to as an outer edge 102) extending between the first surface 96 and the second surface 98. The illustrated first surface 96 is coupled to the second plate 48, and the illustrated second surface 98 is coupled to the third plate 58 (shown in FIG. 10).

The reinforcement plate 94 includes a plate aperture 106. The plate aperture 106 extends through the first surface 96 and the second surface 98 and is spaced from the outer surface 102. The plate aperture 106 is sized to receive one first dimple 62 and one second dimple 66 (shown in FIG. 3). As such, the plate aperture 106 can have the same size (e.g., diameter) or a greater size than the respective first and second dimples 62, 66. The reinforcement plate 94 is secured in place by the plate aperture 106. The first and second dimples 62, 66 extending through the plate aperture 106 prevent the reinforcement plate 94 from moving throughout the oil channel 54. In the illustrated embodiment, the reinforcement plate 94 includes one plate aperture 106. In other embodiments, the reinforcement plate 94 can include more than one plate aperture 106 (e.g., two, three, etc.). In these embodiments, each plate aperture 106 receives a pair of dimples.

With continued reference to FIG. 5, the reinforcement plate 94 includes a notch 110 in the outer surface 102. The notch 110 extends through the first surface, the second surface, and the outer surface 102. The illustrated notch 110 is shaped to receive a portion of one first dimple 62 and a portion of one second dimple 66 (shown in FIG. 3). As such, the notch 110 can have the same curvature or a greater curvature than the respective first and second dimples 62, 66. The reinforcement plate 94 is secured in place by the notch 110. The first and second dimples 62, 66 being received in the notch 110 prevent the reinforcement plate 94 from moving throughout the oil channel 54. In the illustrated embodiment, the reinforcement plate 94 includes three notches 110. Each notch 110 can have an identical profile or a different profile. Each notch 110 can extend around the respective first and second dimples 62, 66 by the same amount or a different amount. In other embodiments, the reinforcement plate 94 can have any suitable number of notches 110 (e.g., one, two, four, etc.).

The second plate 48 defines a first outer edge 114. The first outer edge 114 extends in a direction generally perpendicular to an upper surface of the second plate 48. The reinforcement plate 94 is spaced apart from the first outer edge 114 by a distance 116. Axial stresses absorbed by the reinforcement plate 94 are desirably not transferred to the first outer edge 114. The distance 116 can be 1 millimeter, 1.5 millimeters, or any other suitable distance to inhibit or minimize stresses being transferred to the first outer edge 114. The reinforcement plate 94 is spaced apart from a second outer edge (not shown) of the third plate 58 by the distance 116 for similar reasons as described with reference to the first outer edge 114.

With returned reference to FIG. 4, the reinforcement plate 94 defines a reinforcement plate area 118. The reinforcement plate area 118 can be defined as the area between the outer surface 102. Each heat exchanger plate 26 defines a heat exchanger area 120. The heat exchanger area 120 can be defined as the area between the outer edge (e.g., the first outer edge 114). The reinforcement plate area 118 is less than the heat exchanger area 120. More specifically, the reinforcement plate area 118 can be 25%, 10%, 5%, or less than the heat exchanger area 120. The ratio of the reinforcement plate area 118 to the heat exchanger area 120 can be any ratio suitable to best improve the structural integrity of the heat exchanger 10.

With returned reference to FIG. 3, the heat exchanger 10 includes reinforcement plates 94. Each reinforcement plate 94 is positioned in the coolant channel 70. The coolant contacts each reinforcement plate 94 as the coolant flows through the coolant channel 70. In the illustrated embodiment, the heat exchanger 10 includes two reinforcement plates 94 between the second and third plates 48, 58 and two reinforcement plates 94 between the fourth and fifth plates 74, 78. Between the second and third plates 48, 58, one reinforcement plate 94 is positioned adjacent the inlet manifold 42 and one reinforcement plate 94 is positioned adjacent the outlet manifold 44. Between the fourth and fifth plates 74, 78, one reinforcement plate 94 is positioned adjacent the inlet manifold 42 and one reinforcement plate 94 is positioned adjacent the outlet manifold 44. The reinforcement plates 94 adjacent the inlet manifold 42 are aligned, and the reinforcement plates 94 adjacent the outlet manifold 44 are aligned. In other embodiments, reinforcement plates 94 between different pairs of heat exchanger plates 26 can be offset or misaligned. In other embodiments, the heat exchanger 10 can include any suitable number of reinforcement plates 94 between any suitable heat exchanger plates 26. As one non-limiting example, the heat exchanger 10 can include four reinforcement plates 94 between the second and third plates 48, 58 and two reinforcement plates 94 between eighth and ninth plates (not shown). The reinforcement plates 94 can be positioned in any high stress area or areas of the heat exchanger 10 to prevent failure caused by vibrations from the motor.

With reference to FIG. 6, during the manufacturing process, a copper foil frame 122 is placed between each pair of heat exchanger plates 26. A copper foil frame 122 is placed between the second and third plates 48, 58, the fourth and fifth plates 74, 78, etc. The copper foil frame 122 melts when the heat exchanger 10 is placed in a braze furnace, which provides a filler metal for brazing and securing the heat exchanger plates 26 together. Each copper foil frame 122 can extend along the entire respective reinforcement plate 94. The copper foil frame 122 includes a body 124 with an inlet manifold aperture 126 and an outlet manifold aperture 130 extending through the body 124. The inlet and outlet manifold apertures 126, 130 are aligned with the inlet and outlet manifolds 42, 44, respectively. The copper foil frame 122 can optionally include void apertures 134 extending through the body 124. The void apertures 134 decrease the amount of material in the copper foil frame 122.

With reference now to FIGS. 7 and 8, the copper foil frame 122 includes a recessed portion 138. The recessed portion 138 is recessed relative to the body 124. The recessed portion 138 is defined by a leading edge 142 (also referred to as a slit 142) through the copper foil frame 122. The leading edge 142 is defined between a pair of connectors 146. The connectors 146 are positioned on a periphery of the copper foil frame 122 and connect the recessed portion 138 to the body 124. The recessed portion 138 includes a foil aperture 150.

With reference to FIG. 8, the foil aperture 150 receives a first dimple 62. In the illustrated embodiment, the recessed portion 138 includes four foil apertures 150. Each foil aperture 150 receives one first dimple 62. The recessed portion 138 engages the upper surface of the second plate 48 because the first dimples 62 extend through the foil apertures 150. The body 124 engages the tops of the respective first dimples 62. The recessed portion 138 is recessed relative to the body 124 by a height of the first dimples 62.

When placing the reinforcement plate 94 on the second plate 48, the leading edge 142 of the recessed portion 138 acts as a guide for the reinforcement plate 94. The leading edge 142 presents a clear position for the reinforcement plate 94 to be positioned. Because the body 124 rests upon the first dimples 62, and the recessed portion 138 rests upon the top surface of the second plate 48, the reinforcement plate 94 is only able to engage the first dimples 62 that extend though the foil apertures 150. This improves the accuracy of the position of the reinforcement plate 94 on the second plate 48.

The illustrated copper foil frame 122 includes one recessed portion 138. In other embodiments, the copper foil frame 122 can include any suitable number of recessed portions 138. For example, the copper foil frame 122 can include a number of recessed portions 138 that is equal to the number of reinforcement plates 94 adjacent that copper foil frame 122. Once the reinforcement plate 94 is positioned in the recessed portion 138, additional heat exchanger plates 26 can be stacked upon the reinforcement plate 94 and the second plate 48.

With reference to FIGS. 9 and 10, the third plate 58 is stacked on the second plate 48, and the fourth plate 74 is stacked on the third plate 58. As best illustrated in FIG. 10, the reinforcement plate 94 engages the two adjacent heat exchanger plates 26. In the illustrated embodiment, the reinforcement plate 94 engages the second plate 48 and the third plate 58. The copper foil frame 122 is positioned between the reinforcement plate 94 and the second plate 48 and/or the third plate 58 yet the reinforcement plate 94 is still considered to engage the second or third plate 48, 58. Following the brazing operation, the reinforcement plate 94 will be coupled to the second plate 48 and the third plate 58 due to the copper foil frame 122 melting and then hardening.

With reference to FIG. 11, the heat exchanger 10 can include a spacer plate 154. During operation, the heat exchanger 10 can receive high stresses due to vibration caused by the motor. Accordingly, the spacer plate 154 increases the strength of the heat exchanger 10 to prevent failure in high stress areas. The spacer plate 154 is positioned between the base plate 22 and the first plate 46. The spacer plate 154 is coupled to the base plate 22 and the first plate 46. The spacer plate 154 includes a first spacer aperture 156, which further defines the inlet manifold 42.

With continued reference to FIG. 11, the base plate 22 includes a first projection 158 to retain the reinforcement plate 154. The first projection 158 is an annular projection 158 that further defines the inlet manifold 42. The first projection 158 extends from the base plate 22 in a direction toward the first plate 46. The first projection 158 is received by the first spacer aperture 156. When placing the spacer plate 154 on the base plate 22, the first projection 158 can act as a guide for the spacer plate 154.

With reference to FIG. 12, the spacer plate 154 includes a second spacer aperture 160, which further defines the outlet manifold 44. The base plate 22 includes a second projection 162 to retain the reinforcement plate 154. The second projection 162 is an annular projection 162 that further defines the outlet manifold 44. The second projection 162 extends from the base plate 22 in a direction toward the first plate 46. The second projection 162 is received by the second spacer aperture 160. When placing the spacer plate 154 on the base plate 22, the second projection 162 can act as a guide for the spacer plate 154.

With continued reference to FIG. 12, the spacer plate 154 extends along a majority of the base plate 22. In other embodiments, the spacer plate 154 can have any suitable shape to improve the strength of the heat exchanger 10. In some embodiments, the heat exchanger 10 can include the spacer plate 154 in combination with one or more reinforcement plates 94. In other embodiments, the heat exchanger 10 can include either the spacer plate 154 or one or more reinforcement plates 94.

During operation, relatively warm oil flows from the motor and into the inlet manifold 42 through the oil inlet 38. The warm oil then flows through the plate pairs (e.g., the first and second plates 46, 48, the third and fourth plates 58, 74, the fifth and sixth plates 78, 90, etc.) in a direction towards the outlet manifold 44. The coolant flows between the plate pairs throughout the coolant channel 70. The coolant absorbs heat from the oil. The coolant reduces a temperature of the oil, which causes the temperature of the oil to decrease and the temperature of the coolant to increase. Once the oil flows into the outlet manifold 44, the oil is relatively cool. The oil then flows out of the outlet manifold 44 through the oil outlet 40 and returns into the engine. In some examples of embodiments, the coolant can be removed from the cavity 18 to be cooled. The coolant is cooler than the oil, such that the oil can dissipate heat to be absorbed by the coolant.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. Various features and advantages of the invention are set forth in the following claims.