HEAT EXCHANGER ASSEMBLY

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to Korean Patent Application No. 10-2024-0087371, filed on Jul. 3, 2024, the entire contents of which are incorporated herein for all purposes by this reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates to a heat exchanger assembly and a coupling structure between a first component, which includes a heat exchanger, and a second component configured to communicate with the first component.

Description of the Related Art

Recently, global warming and climatic change have been regarded as serious issues worldwide. In order to cope with these issues, environmentally-friendly vehicles, such as hybrid vehicles, electric vehicles, and hydrogen fuel cell electric vehicles, have been developed. The environmentally-friendly vehicles are equipped with components, such as batteries and motors, and require thermal management systems configured to appropriately cool/heat the components. The thermal management system may representatively use a heat exchanger assembly.

A heat exchanger used for a vehicle plays an important role in air conditioning in the vehicle or thermal management for components (an engine, a battery, a motor, an electrical component, and the like) disposed in the vehicle and requiring thermal management. However, because the heat exchanger is mounted in a limited space in the vehicle, the heat exchanger having heat exchange efficiency optimized in a predetermined layout is required, and an arrangement structure optimized between the heat exchanger and peripheral connection components is required.

However, it is difficult to optimize a connection structure without causing a leak of a heat exchange fluid during a process of connecting the heat exchanger and the peripheral components, and there is a problem in that a leak of the heat exchange fluid occurs, which degrades efficiency of the heat exchanger.

DOCUMENT OF RELATED ART

• • (Patent Document 1) Korean Patent Application Laid-Open No. 10-2021-0093040 (published on Jul. 27, 2021)

SUMMARY OF THE INVENTION

The present disclosure is proposed to solve these problems and aims to provide a heat exchanger capable of being efficiently disposed in a layout of a limited space in a vehicle.

The present disclosure also aims to provide a heat exchanger assembly with improved flow efficiency and heat exchange efficiency.

The present disclosure also aims to provide a heat exchanger assembly capable of achieving sealability between components and improving durability.

Technical problems of the present disclosure are not limited to the aforementioned technical problems, and other technical problems, which are not mentioned above, may be clearly understood by those skilled in the art from the following descriptions.

The present disclosure relates to a heat exchanger assembly including: a first component including a heat exchanger; a second component configured to communicate with the first component; and a connection body disposed between the first component and the second component and configured to connect the first component and the second component and allow a heat exchange fluid to flow, in which one surface of the connection body is coupled to an interface of the first component, and the other surface of the connection body is coupled to an interface of the second component.

The connection body may include a main plate configured to adjoin the interface of the first component, the main plate may have a flow hole vertically formed through the main plate, a first inlet/outlet port may be formed in the interface of the first component and connected directly to one end of the flow hole, and a second inlet/outlet port may be formed in the interface of the second component and connected directly to the other end of the flow hole.

The flow hole, the first inlet/outlet port, and the second inlet/outlet port may be disposed so that central axes thereof are consistent with one another.

The main plate may be brazed with the interface of the first component.

An embossed protruding portion may be formed on the interface of the first component and protrude toward the main plate, a debossed groove may be formed in the main plate and correspond in shape to the embossed protruding portion, and the embossed protruding portion may be inserted into the debossed groove.

The connection body may include an outer rib extending perpendicularly from a rim of the main plate and protruding toward the second component, and an end of the outer rib may adjoin the interface of the second component.

A stepped section may be formed in at least a part of the end of the outer rib and recessed toward the main plate, and the stepped section may be formed on a portion adjacent to the flow hole.

The connection body may include an inner rib formed to surround at least a part of the flow hole and protruding in parallel with the outer rib, and an end of the inner rib may adjoin the interface of the second component.

Sealing materials may be provided on at least a part of the end of the outer rib and at least a part of the end of the inner rib.

The connection body may include a tubular flange protruding from one end of the flow hole toward the interface of the second component.

A burring part may be formed on the interface of the second component and protrude from the second inlet/outlet port toward the connection body, and the burring part may be inserted into the tubular flange.

At least one O-ring may be inserted between the tubular flange and the burring part.

Grooves, into which the O-rings are inserted, may be respectively formed in an inner peripheral surface of the tubular flange and an outer peripheral surface of the burring part.

The heat exchange fluid may be introduced into the second component through the flow hole from the first component or introduced into the first component through the flow hole from the second component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view schematically illustrating a heat exchanger assembly 1000.

FIG. 2 is an overall perspective view of the heat exchanger assembly 1000.

FIG. 3 is an exploded perspective view of FIG. 2.

FIG. 4 is a partial cross-sectional view taken along line A-A′ in FIG. 2.

FIG. 5 is a rear perspective view and an enlarged view of a connection body 300 according to an example of the present disclosure.

FIG. 6 is a partially enlarged view of FIG. 4.

FIG. 7 is a view illustrating a position at which a sealing material is provided on the connection body.

FIG. 8 is a view illustrating a position at which the sealing material is provided on a second component.

FIG. 9 is a partially enlarged view of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

The heat exchanger assembly 1000 of the present disclosure may be applied to a vehicle such as a hybrid electric vehicle, a fuel vehicle, or a pure electric vehicle. The heat exchanger assembly 1000 may be applied to other heat exchange fields such as household or industrial applications and used for some devices necessary for cooling and heating.

Hereinafter, the present disclosure will be described in detail with reference to the accompanying drawings. However, this is provided for illustrative purposes only, and the present disclosure is not limited to the exemplarily described specific embodiment.

Hereinafter, the heat exchanger assembly 1000 according to the example of the present disclosure will be described with reference to FIGS. 1 to 3. FIG. 1 is a view schematically illustrating the heat exchanger assembly 1000, FIG. 2 is an overall perspective view of the heat exchanger assembly 1000, and FIG. 3 is an exploded perspective view of FIG. 2.

The heat exchanger assembly 1000 according to the example of the present disclosure may include a first component 100 including a heat exchanger, a second component 200 configured to communicate with the first component 100, and the connection body 300 configured to connect the first component 100 and the second component 200 and configured to allow a heat exchange fluid to flow.

As illustrated in FIG. 1, the first component 100, the connection body 300, and the second component 200 may be configured to be sequentially stacked. In this case, all the first component 100, the connection body 300, and the second component 200 may have approximately rectangular parallelepiped shapes. Because the configurations having approximately rectangular parallelepiped shapes are sequentially stacked, the heat exchanger assembly 1000 according to the example of the present disclosure may also have an approximately rectangular parallelepiped shape. Therefore, the heat exchanger assembly may be efficiently disposed in a layout of a limited space in the vehicle.

Hereinafter, the first component 100 will be described in detail. The first component 100 may include the heat exchanger and further include members (a pipe, a flange, a socket, a valve, and the like) disposed in the heat exchanger and configured to introduce or discharge the heat exchange fluids. An interface 102 of the first component 100 may be coupled to one surface of the connection body 300.

Meanwhile, a first inlet/outlet port 101 may be formed in the interface 102 of the first component 100 and introduce or discharge the heat exchange fluid into or from the first component 100. The heat exchange fluid may be discharged from the first component 100 through the first inlet/outlet port 101 and then introduced into the second component 200. Alternatively, the heat exchange fluid discharged from the second component 200 may be introduced into the first component 100 through the first inlet/outlet port 101. A flow hole 301, through which the heat exchange fluid flows, may be formed in the connection body 300. The first inlet/outlet port 101 may be connected directly to one end of the flow hole 301 and allow the heat exchange fluid to flow.

For example, the heat exchanger may be a plate-shaped heat exchanger. In the case of the plate-type heat exchanger, plates may be stacked in a direction identical to a direction (z-axis direction) in which the first component 100, the connection body 300, and the second component 200 are stacked. In this case, when the plate disposed at a lowermost side of the heat exchanger is referred to as a lowermost end plate, an interface of the lowermost end plate may be coupled to one surface of the connection body 300.

In this case, two different types of heat exchange fluids may exchange heat with each other while alternately flowing between the plates. For example, the two types of heat exchange fluids may be coolants different in states (temperatures, pressure, and the like) from each other. Alternatively, one type of heat exchange fluid may be a coolant, and the other type of heat exchange fluid may be a refrigerant.

Hereinafter, the second component 200 will be described in detail. The second component 200 may communicate with the first component 100. The second component 200 may be configured such that the heat exchange fluid flows in the second component 200. For example, the second component 200 may include a heat exchanger, a reservoir tank having a chamber, a pump, a valve, and the like. The heat exchange fluid flowing in the second component 200 may be one fluid selected from the two types of fluids flowing in the heat exchanger of the first component 100.

As described above, one surface of the connection body 300 may be coupled to one side interface 102 of the first component 100. The other surface of the connection body 300, which is formed to be opposite to one surface of the connection body 300, may be coupled to one side interface 202 of the second component 200. That is, the first component 100 may be disposed at one side and the second component 200 may be disposed at the other side with the connection body 300 interposed therebetween.

A second inlet/outlet port 201 may be formed in the interface 202 of the second component 200 and introduce or discharge the heat exchange fluid into or from the second component 200. The heat exchange fluid may be discharged from the second component 200 through the second inlet/outlet port 201 and then introduced into the first component 100. Alternatively, the heat exchange fluid discharged from the first component 100 may be introduced into the second component 200 through the second inlet/outlet port 201. The second inlet/outlet port 201 may be connected directly to the other end of the flow hole 301 and allow the heat exchange fluid to flow.

That is, the heat exchange fluid may be introduced into the second component 200 through the flow hole 301 from the first component 100. Alternatively, on the contrary, the heat exchange fluid may be introduced into the first component 100 through the flow hole 301 from the second component 200.

A burring part 250 may be formed on the interface 202 of the second component 200 and extend along a periphery of the second inlet/outlet port 201. The burring part 250 may improve assemblability and connectivity between the second inlet/outlet port 201 and the flow hole 301.

Hereinafter, the connection body 300 will be described in detail. The connection body 300 may be disposed between the first component 100 and the second component 200 and serve to connect the two components.

The connection body 300 may include a main plate 310 configured to adjoin the interface 102 of the first component 100. The main plate 310 may be formed as a rectangular plate having a predetermined thickness, and the flow hole 301 may be formed through the main plate 310 vertically (z-axis direction) and disposed at one side of the main plate 310.

As described above, one end of the flow hole 301 may be connected directly to the first inlet/outlet port formed in the interface 102 of the first component, and the other end of the flow hole 301 may be connected directly to the second inlet/outlet port formed in the interface 202 of the second component. Therefore, the heat exchange fluid may flow between the first component and the second component through the flow hole 301.

In addition, the flow hole 301, the first inlet/outlet port 101, and the second inlet/outlet port 201 may be disposed so that central axes thereof are consistent with one another. That is, the heat exchange fluid discharged through one of the first and second inlet/outlet ports may flow straight through the flow hole and the other inlet/outlet port. This may reduce flow path resistance, thereby improving the efficiency of the heat exchanger assembly 1000.

Meanwhile, in order to assemble the connection body 300 and the first component 100 at an exact position, embossed protruding portions 111 protruding toward the main plate 310 may be formed on the interface 102 of the first component, and debossed grooves 311 having shapes corresponding to shapes of the embossed protruding portions 111 may be formed in the main plate 310. For example, the embossed protruding portion 111 and the debossed groove 311 may each have a dog-bone shape having two large ends and a small central portion.

At least one embossed protruding portion and at least one debossed groove may be formed. The embossed protruding portions 111 are respectively inserted into the corresponding debossed grooves 311, such that the first component 100 may be assembled to the connection body at the exact position. FIG. 3 exemplarily illustrates that two embossed protruding portions 111 and two debossed grooves 311 are formed.

According to the example of the present disclosure, with the insertion structure between the embossed protruding portion and the debossed groove, the connection body 300 and the first component 100 may be easily aligned, and the structure in which the embossed protruding portion and the debossed groove are locked to each other may be implemented, which may improve assembling strength of the connection body 300 and the first component 100.

Meanwhile, the heat exchange fluid may move through the flow hole 301 formed in the main plate 310 instead of moving from the first component to the second component (or from the second component to the first component) through a separate pipe or hose. Therefore, because an additional space in which a separate pipe or hose is disposed is not required, it is possible to provide the heat exchanger assembly with a minimized package.

In addition, the connection body 300 is disposed between the first component 100 and the second component 200. This configuration is provided such that the connection body 300 allows the heat exchange fluid to flow through the flow hole 301 and prevents physical contact between the first component and the second component at a portion other than the communication portion. That is, because the connection body is provided, it is possible to prevent heat between the first component 100 and the second component 200 from being unnecessarily transferred.

Hereinafter, a coupling structure of the heat exchanger assembly 1000 will be described with reference to FIGS. 4 to 6. FIG. 4 is a partial cross-sectional view taken along line A-A′ in FIG. 2, FIG. 5 is a rear perspective view and an enlarged view of a connection body 300 according to an example of the present disclosure, and FIG. 6 is a partially enlarged view of FIG. 4.

With reference to FIG. 4, as described above, one surface of the connection body 300 may be coupled to the interface 102 of the first component, and the other surface of the connection body 300 may be coupled to the interface 202 of the second component.

Specifically, the connection body 300 may include the main plate 310. In this case, one surface of the main plate 310 may be brazed with the interface 102 of the first component, such that the first component 100 and the connection body 300 may be coupled.

The brazing is a technology that joins base materials by melting only a filler material without melting the base materials. The brazing is characterized by high joining strength, a low likelihood of the occurrence of a leak and leakage, and excellent bondability between different types of materials. That is, the interface of the first component and the main plate of the connection body may be coupled to each other by brazing, such that the sealability of the outer peripheral portion may be maintained, and a leak of the heat exchange fluid may be prevented.

Further, the first component 100 including the heat exchanger may be made of aluminum, copper, nickel, and an alloy thereof as a main material in consideration of thermal conductivity, corrosion resistance, and the like. Even different types of materials are coupled by brazing with excellent bondability, such that the material selection for the connection body 300 and the main plate 310 is not restricted, which may improve a degree of design freedom.

With reference to FIG. 5, the connection body 300 may include an outer rib 320 extending perpendicularly from a rim of the main plate 310 and protruding toward the second component 200. In this case, an end of the outer rib 320 may adjoin the interface 202 of the second component 200. The outer rib 320 may be integrated with the main plate 310.

Because the end of the outer rib 320 adjoins the interface 202 of the second component, the main plate 310 may be stably supported, and the external shape of the connection body 300 may be maintained even though an external force is applied to the heat exchanger assembly in the vertical direction (z-axis direction).

A stepped section 325 may be formed on at least a part of the end of the outer rib 320 and recessed toward the main plate 310, and the stepped section 325 may be formed on a portion adjacent to the flow hole 301. As illustrated in the enlarged view in FIG. 5, the stepped section 325 having a level difference corresponding to a thickness t may be formed on the portion of the end of the outer rib 320 adjacent to the flow hole 301.

In addition, the connection body 300 may further include an inner rib 330 protruding in parallel with the outer rib 320. Like the outer rib 320, the end of the inner rib 330 may adjoin the interface 202 of the second component. The inner rib 330 may be integrated with the main plate 310 and the outer rib 320. The inner rib 330 serves to block the flow hole 301 from an inner space of a connection body to be described below. Hereinafter, the inner rib 330 will be described with reference to FIG. 6.

As illustrated in FIG. 6, a predetermined space (Inner space) may be defined by the main plate 310, the outer rib 320, the inner rib 330, and the interface 202 of the second component. Hereinafter, the space is referred to as an inner space of the connection body.

Flat components may be embedded in the inner space of the connection body. For example, the component may be a plate-shaped controller, a plate-shaped electric heater, or the like. Therefore, in order to prevent erroneous operations of the components, it is necessary to prevent moisture and foreign substances from being introduced into the inner space of the connection body.

In order to block the inner space of the connection body and the flow hole 301 through which the heat exchange fluid flows, the inner rib 330 may be formed on a portion adjacent to the flow hole 301, and an end of the inner rib 330 may be formed to adjoin the interface 202 of the second component. In case that the interface 202 of the second component is flat, the inner rib 330 may also protrude by a length equal to a length by which the outer rib 320 protrudes, such that both the end of the outer rib 320 and the end of the inner rib 330 may adjoin the interface 202 of the second component 200.

That is, with reference to FIG. 6, the partition wall structure, such as the inner rib 330, may physically block the inner space of the connection body and the space in which the flow hole 301 is formed. Therefore, even though the heat exchange fluid leaks from the flow hole 301, it is possible to prevent the leaking heat exchange fluid from being introduced into the inner space of the connection body. In this case, the heat exchange fluid, which is prevented from being introduced into the inner space of the connection body, may be discharged (drain) to the outside of the heat exchanger assembly 1000 through the stepped section 325.

According to the present disclosure, it is possible to provide the heat exchanger assembly in which the inner rib 330 is provided at one side of the flow hole 301 to prevent the leaking heat exchange fluid from being introduced into the inner space of the connection body and discharge the leaking heat exchange fluid to the outside of the heat exchanger assembly through the stepped section 325, thereby improving the durability.

Hereinafter, a sealing material 10 will be described with reference to FIGS. 7 and 8. FIGS. 7 and 8 illustrate the positions at which the sealing material 10 is provided on the connection body and the second component by the dotted lines. The sealing material 10 may be provided along the end of the outer rib 320 and the end of the inner rib 330 in order to efficiently seal the inner space of the connection body and implement the sealability between the second component 200 and the connection body 300.

For example, the sealing material 10 may be a ring-shaped rubber gasket. Alternatively, the sealing material may have a film shape and be attached to the end of the outer rib 320 and the end of the inner rib 330 or attached to the interface 202 of the second component. Alternatively, the sealing material may be applied along a sealing line.

According to the present disclosure, the portion between the connection body and the second component is sealed by the sealing material, such that the sealability of the inner space of the connection body may be achieved, and the components may be safely embedded in the inner space.

Meanwhile, in case that the first component 100 and the main plate 310 are coupled by brazing, high-temperature heat produced by brazing may be transferred to the peripheral portion. In order to prevent a deterioration in performance of the components caused by a transfer of high-temperature heat to the components embedded in the inner space of the connection body, the components may be embedded in the inner space of the connection body after the first component 100 and the main plate 310 are coupled by brazing.

Hereinafter, a coupling structure of a periphery of the flow hole 301 will be described with reference to FIG. 9. FIG. 9 is a partially enlarged view of FIG. 4.

The connection body 300 may include a tubular flange 350 protruding toward the interface 202 of the second component from one end of the flow hole 301. The tubular flange 350 may be provided on a surface of the main plate 310 facing the second component 200. The tubular flange 350 may be integrated with the main plate 310 or assembled to the main plate 310 by welding, screwing, or the like. The flow hole 301 and the second inlet/outlet port 201 may be coupled at the exact position by the tubular flange 350.

Meanwhile, the burring part 250 may be formed on the interface 202 of the second component and protrude from the second inlet/outlet port 201 toward the connection body, and the burring part 250 may be inserted into the tubular flange 350. Therefore, the flow hole 301 and the second inlet/outlet port 201 may be directly connected.

An O-ring 20 may be inserted between the tubular flange and the burring part to improve the sealability between the tubular flange and the burring part. The O-ring may have a ring shape containing a rubber material. The O-ring may be transformed by elasticity of the rubber and block the space into which the O-ring is inserted, thereby improving the sealability between the tubular members.

According to the example of the present disclosure, at least one O-ring 20 may be inserted between the tubular flange and the burring part, thereby improving the sealability between the tubular flange and the burring part. FIG. 9 exemplarily illustrates that two O-rings 20 are inserted.

In order to insert the O-rings 20 into exact positions, grooves 355 and 255, into which the O-rings 20 are inserted, may be respectively formed in an inner peripheral surface of the tubular flange 350 and an outer peripheral surface of the burring part 250. That is, the O-rings 20 may be transformed by an elastic force and seal spaces of the grooves, thereby improving the sealability between the tubular flange and the burring part.

As described above, according to the example of the present disclosure, it is possible to provide the heat exchanger capable of being efficiently disposed in the layout of the limited space in the vehicle. In addition, it is possible to provide the heat exchanger assembly with the improved flow efficiency and heat exchange efficiency. In addition, it is possible to provide the heat exchanger assembly capable of achieving the sealability between the components and improving the durability.

According to the embodiment of the present disclosure, the heat exchanger assembly may be efficiently disposed in the limited space in the vehicle.

In addition, it is possible to improve the flow efficiency and heat exchange efficiency of the heat exchanger assembly.

In addition, it is possible to achieve the sealability of the heat exchanger assembly and improve the durability.

The effects of the present disclosure are not limited to the above-mentioned effects, and other effects, which are not mentioned above, may be clearly understood by those skilled in the art from the present specification and the accompanying drawings.

While the embodiments of the present disclosure have been described with reference to the accompanying drawings, those skilled in the art will understand that the present disclosure may be carried out in any other specific form without changing the technical spirit or an essential feature thereof. Therefore, it should be understood that the above-described embodiments are illustrative in all aspects and do not limit the present disclosure.

DESCRIPTION OF REFERENCE NUMERALS

• • 100: First component
  • 101: First inlet/outlet port
  • 102: Interface of first component
  • 111: Embossed protruding portion
  • 200: Second component
  • 201: Second inlet/outlet port
  • 202: Interface of second component
  • 250: Burring part
  • 255: Groove
  • 300: Connection body
  • 301: Flow hole
  • 310: Main plate
  • 311: Debossed groove
  • 320: Outer rib
  • 325: Stepped section
  • 330: Inner rib
  • 350: Tubular flange
  • 355: Groove
  • 10: Sealing material
  • 20: O-ring