HEAT EXCHANGER ASSEMBLY FOR A MOTOR VEHICLE

Abstract

A heat exchanger assembly for a motor vehicle includes a heat exchanger having at least one inlet tank, at least one outlet tank, and a plurality of exchanger tubes of an exchanger core. The exchanger tubes connect the inlet tank and the outlet tank and extend along a transverse axis that extends perpendicular to a longitudinal axis of the motor vehicle. Each exchanger tube defines a fluid passage path for fluid. A first pair of adjacent exchanger tubes form a first air passage path therebetween for ambient air and a second pair of adjacent exchanger tubes form a second air passage path therebetween for ambient air. The first air passage path has an air flow resistance that is different from an air flow resistance of the second air passage path.

Claims

1. A heat exchanger assembly for a motor vehicle, the heat exchanger assembly comprising: a heat exchanger including at least one inlet tank, at least one outlet tank, and a plurality of exchanger tubes of an exchanger core connecting the at least one inlet tank and the at least one outlet tank and extending along a transverse axis that extends perpendicular to a longitudinal axis, each exchanger tube of the plurality of exchanger tubes defines a fluid passage path for fluid, wherein a first pair of adjacent exchanger tubes form a first air passage path therebetween for ambient air and a second pair of adjacent exchanger tubes form a second air passage path therebetween for ambient air, the first air passage path and the second air passage path being continuous along the longitudinal axis, wherein the first air passage path has an air flow resistance that is greater than an air flow resistance of the second air passage path.

2. The heat exchanger assembly according to claim 1, wherein first air-turbulence elements are located between the first pair of adjacent exchanger tubes and second air-turbulence elements are located between the second pair of adjacent exchanger tubes, and wherein an arrangement of the first air-turbulence elements between the first pair of adjacent exchanger tubes is different than an arrangement of the second air-turbulence elements between the second pair of adjacent exchanger tubes.

3. The heat exchanger assembly according to claim 2, wherein the arrangement of the first air-turbulence elements comprises spacing between adjacent first air-turbulence elements and the arrangement of the second air-turbulence elements comprises spacing between adjacent second air-turbulence elements, and wherein the spacing between the adjacent second air-turbulence elements is greater than the spacing between the adjacent first air-turbulence elements.

4. The heat exchanger assembly according to claim 1, wherein the first pair of adjacent exchanger tubes extends along the longitudinal axis a greater distance than the second pair of adjacent exchanger tubes.

5. The heat exchanger assembly according to claim 1, wherein the first air passage path is aligned with a fan along the longitudinal axis.

6. The heat exchanger assembly according to claim 1, wherein the first air passage path is arranged behind an air inlet opening of the motor vehicle along the longitudinal axis.

7. The heat exchanger assembly according to claim 1, wherein at least one exchanger tube of the plurality of exchanger tubes has a cross-section which changes along its length.

8. The heat exchanger assembly according to claim 1, wherein at least one exchanger tube of the plurality of exchanger tubes has first fluid-turbulence elements and second fluid-turbulence elements disposed therein, and wherein an arrangement of the first fluid-turbulence elements is different than an arrangement of the second fluid-turbulence elements.

9. The heat exchanger assembly according to claim 8, wherein the arrangement of the first fluid-turbulence elements comprises spacing between adjacent first fluid-turbulence elements and the arrangement of the second fluid-turbulence elements comprises spacing between adjacent second fluid-turbulence elements, and wherein the spacing between the adjacent second fluid-turbulence elements is greater than the spacing between the adjacent first fluid-turbulence elements.

10. The heat exchanger assembly according to claim 8, wherein a thickness of the first fluid-turbulence elements is greater than a thickness of the second fluid-turbulence elements.

11. The heat exchanger assembly according to claim 1, wherein the first air passage path is located near a lower end of the heat exchanger and the second air passage path is located near an upper end of the heat exchanger.

12. The heat exchanger assembly according to claim 1, wherein the first air passage path is located adjacent the second air passage path.

13. A heat exchanger assembly for a motor vehicle, the heat exchanger assembly comprising: an inlet tank; an outlet tank; a plurality of exchanger tubes of an exchanger core fluidly connecting the inlet tank and the outlet tank and extending along a transverse axis, each exchanger tube of the plurality of exchanger tubes defines a fluid passage path for fluid, a first pair of adjacent exchanger tubes form a first air passage path therebetween for ambient air and a second pair of adjacent exchanger tubes form a second air passage path therebetween for the ambient air; first air-turbulence elements extending vertically and located between the first pair of adjacent exchanger tubes in the first air passage path; and second air-turbulence elements extending vertically and located between the second pair of adjacent exchanger tubes in the second air passage path, wherein spacing between the second air-turbulence elements is greater than spacing between the first air-turbulence elements such that the first air-turbulence elements deflect a portion of the ambient air flowing therethrough toward the second air passage path.

14. The heat exchanger assembly according to claim 13, wherein the first air passage path is aligned with a fan along a longitudinal axis that is perpendicular to the transverse axis.

15. The heat exchanger assembly according to claim 13, wherein the first air passage path is arranged behind an air inlet opening of the motor vehicle along a longitudinal axis of the motor vehicle, the longitudinal axis being perpendicular to the transverse axis.

16. The heat exchanger assembly according to claim 13, wherein at least one exchanger tube of the plurality of exchanger tubes has a cross-section which changes along its length.

17. The heat exchanger assembly according to claim 13, wherein the first pair of adjacent exchanger tubes extends along a longitudinal axis a greater distance than the second pair of adjacent exchanger tubes, the longitudinal axis being perpendicular to the transverse axis.

18. The heat exchanger assembly according to claim 13, wherein at least one exchanger tube of the plurality of exchanger tubes has first fluid-turbulence elements and second fluid-turbulence elements disposed therein, and wherein an arrangement of the first fluid-turbulence elements is different than an arrangement of the second fluid-turbulence elements.

19. The heat exchanger assembly according to claim 18, wherein the arrangement of the first fluid-turbulence elements comprises spacing between adjacent first fluid-turbulence elements and the arrangement of the second fluid-turbulence elements comprises spacing between adjacent second fluid-turbulence elements, and wherein the spacing between the adjacent second fluid-turbulence elements is greater than the spacing between the adjacent first fluid-turbulence elements.

20. A heat exchanger assembly for a motor vehicle, the heat exchanger assembly comprising: an inlet tank; an outlet tank; a plurality of exchanger tubes of an exchanger core fluidly connecting the inlet tank and the outlet tank and extending along a transverse axis that extends perpendicular to a longitudinal axis of the motor vehicle, each exchanger tube of the plurality of exchanger tubes defines a fluid passage path for fluid, a first pair of adjacent exchanger tubes form a first air passage path therebetween for ambient air and a second pair of adjacent exchanger tubes form a second air passage path therebetween for the ambient air; first air-turbulence elements extending vertically and located between the first pair of adjacent exchanger tubes in the first air passage path; and second air-turbulence elements extending vertically and located between the second pair of adjacent exchanger tubes in the second air passage path, wherein spacing between the second air-turbulence elements is greater than spacing between the first air-turbulence elements such that the first air-turbulence elements deflect a portion of the ambient air flowing therethrough toward the second air passage path, wherein the first pair of adjacent exchanger tubes extends along the longitudinal axis a greater distance than the second pair of adjacent exchanger tubes, and wherein at least one exchanger tube of the plurality of exchanger tubes has first fluid-turbulence elements and second fluid-turbulence elements disposed therein, and wherein spacing between the first fluid-turbulence elements is different than spacing between the second fluid-turbulence elements.

Description

DRAWINGS

[0036] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0037] FIG. 1A is a schematic cross-sectional view of a first form of a heat exchanger assembly according to the principles of the present disclosure;

[0038] FIG. 1B is a schematic front view of the heat exchanger assembly of FIG. 1A;

[0039] FIG. 2 is a schematic cross-sectional view of a second form of a heat exchanger assembly according to the principles of the present disclosure;

[0040] FIG. 3A is a schematic cross-sectional view of a third form of a heat exchanger assembly according to the principles of the present disclosure;

[0041] FIG. 3B is a schematic front view of the heat exchanger assembly of FIG. 3A;

[0042] FIG. 4 is a schematic front view of a fourth form of a heat exchanger assembly according to the principles of the present disclosure;

[0043] FIGS. 5-10 are plan views of different forms of part of a heat exchanger assembly according to the principles of the present disclosure;

[0044] FIG. 11 is a perspective view of exchanger tubes of a fifth form of a heat exchanger assembly according to the principles of the present disclosure; and

[0045] FIG. 12 is a cross-sectional view of exchanger tubes of a sixth form of a heat exchanger assembly according to the principles of the present disclosure.

[0046] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

[0047] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0048] In the different figures, identical parts are always provided with the same reference signs, for which reason these parts are generally also described only once.

[0049] FIGS. 1A and 1B show a motor vehicle 20, in this case a car, with a first form of a heat exchanger assembly 1 according to the disclosure which has a heat exchanger 2. The heat exchanger 2 is arranged mainly behind a front panel 21 of the motor vehicle 20 along a longitudinal axis X, wherein, however, the front panel 21 has an air inlet opening 22 (FIG. 1A). The heat exchanger 2 has an inlet tank 3 (FIG. 1B) and an outlet tank 4 (FIG. 1B) for a fluid (not illustrated here), for example a coolant of the motor vehicle 20. The inlet tank 3 and outlet tank 4 extend along a vertical axis Z and are connected to each other by exchanger tubes 6 of an exchanger core 5. Each of the exchanger tubes 6 has a hollow configuration and has a fluid passage path 8 for guiding the fluid. All of the exchanger tubes 6 have a similar cross-section which in this case is rectangular and extends along the longitudinal axis X. Alternatively, it could, however, also be configured as square, circular, elliptical, or otherwise. In the example illustrated, the exchanger tubes 6 extend parallel to a transverse axis Y and each have the same spacings with respect to the vertical axis Z. An air passage path 10, through which ambient air can pass in order to exchange heat with the fluid, is defined in each case between adjacent exchanger tubes 6. In order, on the one hand, to enlarge the surface of the exchanger core 5 and, on the other hand, to influence the flow behaviour of the air, air-turbulence elements 11 which here extend parallel to the vertical axis Z are in each case arranged between adjacent exchanger tubes 6. The heat exchanger 2 is manufactured from an aluminium alloy by an additive manufacturing method, for example by a powder bed method such as SLM or by liquid metal printing. The additive manufacturing method allows efficient manufacture even of complex three-dimensional structures.

[0050] The spacings between the air-turbulence elements 11 are not constant inside the exchanger core 5. Rather, it is possible to broadly distinguish two areas or sections 5.1 with a lower air resistance and an area or section 5.2 with a higher air resistance. In the areas 5.1 with a lower air resistance, the air-turbulence elements 11 have larger spacings than in the area 5.2 with a larger air resistance. Because the latter is arranged behind the air inlet opening 22 along the longitudinal axis X, air flows primarily onto this area 5.2. Because this area 5.2 has a higher air resistance, a portion of the air is displaced or deflected into other areas 5.1 such that the flow through the latter is better as a whole and the entire exchanger core 5 can participate effectively in the heat exchange.

[0051] FIG. 2 shows a second form of a heat exchanger assembly 1 according to the disclosure inside a motor vehicle 20 which largely corresponds to the first form and to this extent is not explained again. In contrast to the first form, the exchanger tubes 6 in this case have different cross-sections. That is, the exchanger tubes 6 in the section 5.2 with a higher air resistance are formed so that they are longer along the longitudinal axis X than in the sections 5.1 with a lower air resistance. Accordingly, the air passage paths 10, formed between exchanger tubes 6, in the section 5.2 with a higher air resistance are also longer, which increases the air friction and moreover causes more pronounced turbulence. In this example, the air-turbulence elements 11 are also lengthened along the longitudinal axis X so that they coincide to a certain extent with the exchanger tubes 6. The spacings of the air-turbulence elements 11 can in this example be the same in all areas 5.1, 5.2 of the exchanger core 5 but they can also be different in certain areas as in the first form.

[0052] FIGS. 3A and 3B show a third form of a heat exchanger assembly 1 according to the disclosure in which a fan 15 is arranged behind the heat exchanger 2 along the longitudinal axis X. The air inlet opening 22 is here large enough such that there can be a sufficient flow onto the entire exchanger core 5. The central area 5.2 has a higher air resistance (i.e., achieved by reducing the spacings between the air-turbulence elements 11), thereby inhibiting the central area 5.2 of the exchanger core 5 from experiencing a greater air flow than areas 5.1 due to the suction effect of the fan 15. Alternatively or additionally, there would also be the possibility here of lengthening the air passage paths 10 in certain areas.

[0053] FIG. 4 shows a fourth form of a heat exchanger assembly 1 according to the disclosure or a heat exchanger 2 representing different possible options provided according to the disclosure for varying the air passage paths 10. As already stated, the spacings between the air-turbulence elements 11 can be varied. Furthermore, the orientation of the air-turbulence elements 11 relative to the exchanger tubes 6 can be modified such that they can be oriented either perpendicularly to the direction in which they run (and hence parallel to the vertical axis Z) or alternatively obliquely to the direction in which they run (and hence obliquely to the vertical axis Z). Moreover, air-turbulence elements 11 between the adjacent exchanger tubes 6 can taper or widen out and/or they can cross over each other. It is also possible that individual air-turbulence elements 11 are not formed continuously from one exchanger tube 6 to the next and instead extend only partially in the direction of the adjacent exchanger tube 6. In addition, it is also possible to vary the spacings between adjacent exchanger tubes 6, wherein a larger spacing results in a smaller air resistance than a small spacing.

[0054] FIGS. 5-10 each show by way of example a single exchanger tube 6 with different forms of air-turbulence elements 11. In the form according to FIG. 5, the air-turbulence elements 11 are configured as fins and oriented parallel to the longitudinal axis X. FIGS. 6 and 7 each show column-like air-turbulence elements 11 with a circular cross-section, wherein only one row of air-turbulence elements 11 is provided in FIG. 6 while in FIG. 7 two rows are arranged offset to each other both with respect to the longitudinal axis X and with respect to the transverse axis Y. The form according to FIG. 7 also results in smaller spacings between the air-turbulence elements 11 and normally corresponds to a higher air resistance than the form according to FIG. 6.

[0055] FIGS. 8 and 9 show column-like air-turbulence elements 11 with an elliptical cross-section, wherein the semi-major axis of the ellipse is oriented parallel to the longitudinal axis X in FIG. 8 while it is inclined by approximately 45° with respect to the longitudinal axis X and the transverse axis Y in FIG. 9. FIG. 10 shows column-like air-turbulence elements 11 with a rectangular cross-section. While the number of air-turbulence elements 11 corresponds to that in FIG. 5, because of the greater width along the transverse axis Y, the spacings between the air-turbulence elements 11 are smaller such that a larger air resistance results.

[0056] FIG. 11 shows part of an exchanger core 5 of a fifth form of a heat exchanger assembly 1 according to the present disclosure, wherein for the sake of clarity the air-turbulence elements 11 have been omitted here. Shown here by way of example are three exchanger tubes 6 which each have a wall 7 with a rectangular cross-section in which a fluid passage path 8 is again formed. The latter is, however, modified by the cross-section not being continuously constant. In the case of the exchanger tube 6 which is uppermost with respect to FIG. 11, the extent along the vertical axis Z is reduced in certain sections such that lateral areas 5.3 with a smaller fluid resistance and a central area 5.4 with a larger fluid resistance result. In the case of the exchanger tube 6 which is lowermost with respect to FIG. 11, however, although the extent along the vertical axis Z is constant, here too a central area 5.4 with an increased fluid resistance is provided because the extent of the exchanger tube 6 along the longitudinal axis X reduces there. It should be noted that the reduction in the extent along the vertical axis Z also results in a local enlargement of the air passage path 10. Likewise, the reduction in the extent along the longitudinal axis X can result in a shortening of the air passage path 10 and hence in a reduction in the air friction.

[0057] FIG. 12 shows part of an exchanger core of a sixth form of a heat exchanger assembly 1 according to the present disclosure, wherein again three exchanger tubes 6 are illustrated in a cross-sectional view. A plurality of fluid-turbulence elements 9, which have been manufactured as a single piece with the wall 7 during the additive manufacturing, are in each case connected to the wall 7 of the respective exchanger tube 6. The uppermost and the central exchanger tube 6 here in each case have two fluid-turbulence elements 9 arranged offset along the longitudinal axis X, while the lowermost exchanger tube 6 has a total of six fluid-turbulence elements 9. In the case of the two upper exchanger tubes 6, the fluid-turbulence elements 9 each pass from one section of the wall 7 to the opposite section. In the case of the uppermost exchanger tube 6, however, the cross-sectional surface of the fluid-turbulence elements 9 is enlarged (i.e., has a greater thickness) compared with the central exchanger tube 6 such that the uppermost exchanger tube 6 corresponds to a section 5.4 with a larger fluid resistance, while the central exchanger tube 6 corresponds to a section 5.3 with a smaller fluid resistance. In the case of the lowermost exchanger tube 6, the spacings of the fluid-turbulence elements 9 are less than in the case of the upper two exchanger tubes 6, as a result of which here too overall a section 5.4 with a larger fluid resistance results and the fluid resistance is modified here by some fluid-turbulence elements 9 not extending continuously from one section of the wall 7 to the opposite section and instead are formed as it were in the manner of stumps such that a free area remains in the center of the fluid passage path 8.

[0058] With regard to the cross-section of the fluid-turbulence elements 9, a wide range of different options are provided. For example, they can, as illustrated in FIGS. 5-10 for the air-turbulence elements 11, be formed in the manner of fins or columns with a rectangular, circular, or elliptical cross-section.

[0059] Although a variation in the air resistance or a variation in the fluid resistance are in each case illustrated as alternatives in the exemplary form shown here, it should be clear that these possible variations can also be combined in a heat exchanger 2.

[0060] Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

[0061] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

[0062] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.