HEAT EXCHANGER TANK WITH REINFORCEMENT ELEMENT

Abstract

A heat exchanger tank 20a is disclosed in accordance with an embodiment of the present invention. The heat exchanger tank 20a include external ribs 22a that provide reinforcement to structure of the tank 20a, wherein at least one reinforcement element 30a engages with an external tank portion and is tensioned by press fitting the at least one reinforcement element 30a on the external tank portion such that limbs 31a of the reinforcement element 30a are separated by the external tank portion between the external ribs 22a. The reinforcement element 30a is further maintained in the tensioned configuration by using at least one retention means.

Claims

1. A heat exchanger tank comprising: external ribs adapted to provide reinforcement to a structure of said tank, wherein at least one reinforcement element is configured to be engaged with an external tank portion and tensioned by press fitting said at least one reinforcement element on said external tank portion such that limbs of said reinforcement element are separated by said external tank portion between said external ribs, said at least one reinforcement element being maintained in said tensioned configuration by using at least one retention means.

2. The heat exchanger tank as claimed in claim 1, wherein said retention means comprises at least one first latching elements configured on said limbs of said reinforcement element that are adapted to engage with corresponding at least one second latching elements configured on said external tank portion.

3. The heat exchanger tank as claimed in claim 2, wherein said first latching elements and said second latching elements are adapted to configure releasable engagement there-between.

4. The heat exchanger tank as claimed in claim 3, wherein said first latching elements are apertures formed on said limbs of said reinforcement element that are adapted to configure snap fit engagement with corresponding second latching elements in form of tongue elements formed on said external tank portion.

5. The heat exchanger tank as claimed in claim 3, wherein said first latching elements are tongue elements formed on limbs of said reinforcement element that are adapted to configure snap fit engagement with corresponding second latching elements in form of apertures formed on said external tank portion.

6. The heat exchanger tank as claimed in claim 2, wherein said at least one first latching element is configured near end portion of each limb of said reinforcement element.

7. The heat exchanger tank as claimed in claim 1, wherein in a disengaged configuration of said reinforcement element with respect to said tank and free-state thereof, spacing between said limbs of said reinforcement element is smaller than width of said tank.

8. The heat exchanger tank as claimed in claim 1, wherein said reinforcement element is of a material exhibiting spring properties and is selected from a group comprising of metals, plastics and composites.

9. The heat exchanger tank as claimed in claim 2, wherein at least two external ribs configured on said tank define a channel extending along outer periphery of said external tank portion, wherein said channel is configured to guide the reinforcement element on said external tank portion at least until said first latching elements configured on said reinforcement element engages with said second latching elements provided on either one of the external tank portion and the ribs defining the channel.

10. A heat exchanger comprising: a pair of spaced apart headers connected by a plurality of heat exchange elements; and a pair of tanks, wherein each tank is crimped to a corresponding header and is adapted to receive heat exchanging fluid, wherein at least one tank of the pair of tanks comprises: external ribs adapted to provide reinforcement to a structure of said at least one tank, wherein at least one reinforcement element is configured to be engaged with an external tank portion and tensioned by press fitting said at least one reinforcement element on said external tank portion such that limbs of said reinforcement element are separated by said external tank portion between said external ribs, said at least one reinforcement element being maintained in said tensioned configuration by using at least one retention means.

11. The heat exchanger as claimed in claim 10, wherein each header of the pair of headers is configured to receive the corresponding tank of said pair of tanks within a peripheral groove thereof, wherein the end portion of each limb of said reinforcement element is adapted to cover at least a part of said peripheral groove of said header.

12. The heat exchanger as claimed in claim 10, wherein end portion of each limb of each reinforcement element is adapted to cover at least a part of said header, at least a part of a corresponding crimped profile of said header formed by crimping between said header and said corresponding tank.

13. The heat exchanger as claimed in claim 10, wherein said retention means further comprises attaching elements configured at end portion of each limb of said reinforcement element that are adapted to be crimped over at least a part of said header, at least a part of said corresponding crimped profile of said header formed by crimping between said header and said corresponding tank.

14. The heat exchanger as claimed in claim 10, wherein said retention means further comprises at least one latching element in form of end portions of said limbs that are adapted to engage with corresponding at least one latching elements in form of at least a portion of crimped profile configured on said corresponding header.

Description

[0028] Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

[0029] FIG. 1a illustrates a schematic representation of a heat exchanger with a heat exchanger tank in accordance with an embodiment of the present invention crimped to a corresponding header for configuring a header-tank assembly, also is illustrated an enlarged view of the heat exchanger tank with reinforcement elements engaging with external tank portions for providing reinforcement to the tank:

[0030] FIG. 1b illustrates a cross sectional view of the header-tank assembly along section line C-C depicted in FIG. 1a;

[0031] FIG. 1c illustrates an enlarged cross sectional view depicting a foot portion of the heat exchanger tank received within a peripheral groove of the header of the header-tank assembly of FIG. 1b;

[0032] FIG. 1d illustrates a cross sectional view of the header-tank assembly along section line E-E depicted in FIG. 1b;

[0033] FIG. 2a illustrates a schematic representation depicting a front view of the reinforcement element of FIG. 1a;

[0034] FIG. 2b illustrates a schematic representation depicting a right hand side view of the reinforcement element of FIG. 2a;

[0035] FIG. 2c illustrates a cross sectional view of the reinforcement element along section line B-B depicted in FIG. 2a;

[0036] FIG. 2d illustrates a cross sectional view of the reinforcement element along section line A-A depicted in FIG. 2b;

[0037] FIG. 3a illustrates a schematic representation of the tank configured with reinforcement element in accordance with another embodiment of the present invention, wherein extreme end portion of each limb of the reinforcement element is covering at least a portion of a corresponding crimped profile formed by crimping between the header and the corresponding tank;

[0038] FIG. 3b illustrates a schematic representation depicting the tank configured with the reinforcement element of FIG. 3a, wherein extreme end portion of each limb of the reinforcement element is substantially covering the corresponding crimped profile formed by crimping between the header and the corresponding tank;

[0039] FIG. 4a illustrates an isometric view depicting a reinforcement element in accordance with another embodiment of the present invention, wherein an attaching element configured at end portion of each limb of the reinforcement element is crimped over at least a part of a corresponding crimped profile formed by crimping between a header and a corresponding tank:

[0040] FIG. 4b illustrates an isometric view of the reinforcement element of FIG. 4a, wherein the attaching elements in form of u-clips are depicted in un-crimped configuration; and

[0041] FIG. 4c illustrates an isometric view of the reinforcement element of FIG. 4a, wherein the attaching elements in form of u-clips are depicted in crimped configuration, however, for better understanding and visualization of attaching elements in the crimped configuration, the attaching elements are only depicted without depicting the tank and the header.

[0042] It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

[0043] A heat exchanger tank configured with reinforcement elements for strengthening and reinforcing the tank structure is disclosed in accordance with an embodiment of the present disclosure. Although, as per the disclosures made in the present specification, the heat exchanger tank is used in vehicle heat exchangers such as radiators, condensers, evaporators and charger air coolers. However, the tank of the present invention is also applicable for use in other systems and is not limited for use in vehicle heat exchangers only. Particularly, such tanks are also applicable in any other systems or applications in which the tank is required to hold liquid and withstand cyclic pressures.

[0044] Referring to FIG. 1a, a heat exchanger 102 is illustrated. The heat exchanger 102 generally includes a pair of identical header-tank assemblies 100a and 100b (or at least very similar header-tank assemblies), wherein each header-tank assembly of the pair is configured at extreme end portion of a heat exchanger core. Particularly, a first header 10a and a second header 10b of the first and the second header-tank assemblies 100a and 100b are integrally formed on respective first and second extreme end portions of the heat exchanger core. The heat exchanger core is configured of a plurality of heat exchange elements 2 (partially illustrated on FIG. 1a) and a plurality of fin elements 4 (also partially illustrated on FIG. 1s) formed on the heat exchanger elements 2. The heat exchange elements 2 may be either one of plates and tubes. Alternatively, the heat exchange elements 2 can have any other configuration that forms connection between the first header 10a and the second header 10b and configures adjacent yet separated spaces between the first and the second headers 10a and 10b for facilitating heat exchange between heat exchanging fluids flowing through the respective separated spaces and the heat exchanger elements. The heat exchanger further includes a pair of tanks 20a and 20b securely connected to the corresponding headers 10a and 10b by crimping for configuring the respective first and the second header-tank assemblies 100a and 100b. The tanks 20a and 20b receive heat exchanging fluid, often pressurized heat exchanging fluid at regular time intervals and holds the heat exchanging fluid therein.

[0045] Again referring to FIG. 1a, as the first and the second header-tank assemblies 100a and 100b are commonly identical (or quite similar), every embodiment disclosed henceforth for the header-tank assembly 100a and the elements configuring the header-tank assembly 100a may also be applicable for the header-tank assembly 100b and elements configuring the header-tank assembly 100b, for sake of brevity of present document, enlarged view depicting the details of only the first header-tank assembly 100a is illustrated in the Figures and described in the description. The first header-tank assembly 100a is configured at the first end portion of the heat exchanger core. Particularly, the first header 10a of the first header-tank assembly 100a is integrally formed on the end portion of the heat exchanger core and is crimped to the corresponding tank 20a. Generally, the header 10a includes a peripheral groove 11a that is configured to receive a foot portion of the corresponding tank 20a as illustrated in FIG. 1b and FIG. 1c. In accordance with an embodiment, a gasket (not illustrated in drawings) is disposed between the foot portion of the tank 20a and the inside walls of the header 10a defining the peripheral groove 11a, as the header 10a is crimped with the corresponding tank 20a for configuring sealing engagement there between. The gasket prevents leakage of the heat exchange fluid through the crimped portion configured by crimping between the header 10a and the tank 20a. In accordance with an embodiment, the gasket is of either one of synthetic polymeric material and natural polymeric material, such as for example rubber.

[0046] In accordance with an embodiment, the tank 20a includes a plurality of external ribs 22a configured on an outside surface of the tank 20a to provide reinforcement to structure of the tank 20a. In accordance with an embodiment, at least one reinforcement element 30a is engaged with an external tank portion and tensioned by press fitting the at least one reinforcement element 30a on the external tank portion such that limbs 31a of the reinforcement element 30a are separated by the external tank portion between the external ribs 22a. The reinforcement elements 30a are maintained in the tensioned configuration by using at least one retention means.

[0047] In accordance with a preferred embodiment, at least two external ribs 22a configured on the tank 20a define at least one channel 24a extending along an outer periphery of the external tank portion. Particularly, the adjacent external ribs 22a along with the external tank portion between the adjacent external ribs 22a configure the corresponding channel 24a. Referring to the FIG. 1d, the internal profile of each of the reinforcement element 30a is complementary to an external profile of the tank portion between the adjacent external ribs 22a. The reinforcement element 30a is tensioned, as the reinforcement element 30a is press fitted in the corresponding channel 24a. The reinforcement element 30a in the tensioned configuration received in the corresponding channel 24a facilitate in providing reinforcement to the tank 20a by pressing the side walls of the tank 20a inward. Also, as the reinforcement element 30a is detactably received in the corresponding channel 24a, the reinforcement element 30a can be shifted from one channel to another channel along the length of the tank 20a. Such configuration provides flexibility to reinforce any section of the tank 20a as per requirement. Each of the channel 24a is configured to guide the reinforcement element 30a on the external tank portion at least until at one first latching element 32a configured on the reinforcement element 30a engages with at least one second latching element 26a configured on external tank portion within the channel 24a in order to maintain the reinforcement element 30a in tensioned configuration. In accordance with an embodiment of the present invention, the external ribs 22a are parallel to each other and the number and spacing between the ribs 22a configured on the tank 20a is based on number and placement of the channels 24a to be configured on the tank 20a and width of reinforcement elements 30a to be received in the corresponding channel 24a. In accordance with an embodiment, the ribs 22a are integral with the tank 20a and are simultaneously formed along with the tank 20a by molding process. However, the present invention is not limited to any particular configuration of the external ribs 22a and any particular method for configuring the external ribs 22a on the tank 20a, as far as the external ribs 22a provide reinforcement to structure of the tank 20a and also configure the channels 24a extending along outer periphery of the tank 20a for receiving the reinforcement element 30a in tensioned configuration over the external tank portion. The reinforcement element 30a externally snap-on fits and clips on to the tank 20a as illustrated in FIG. 1b to provide reinforcement to the tank structure.

[0048] FIG. 2a illustrates a schematic representation depicting a front view of the reinforcement element 30a. The reinforcement element 30a is generally having an U-shaped profile, includes a pair of limbs 31a and at least one first latching element 32a configured on each limb 31a. FIG. 2b illustrates a schematic representation depicting a right hand side view of the reinforcement element 30a with the first latching element 32a formed on the right hand side limb 31a. FIG. 2c illustrates a cross sectional view of the reinforcement element 30a along section line B-B depicted in FIG. 2a. FIG. 2d illustrates a cross sectional view of the reinforcement element 30a along section line A-A depicted in FIG. 2b. The reinforcement element 30a is so configured that when the reinforcement element 30a is in free-state and disengaged from the tank 20a, the spacing between the limbs 31a of each of the reinforcement element 30a is lesser/smaller than width of the tank portion between the external ribs 22a defining the corresponding channel 24a. Also, the reinforcement element 30a is of material exhibiting spring properties and is selected from group comprising of metals, plastics and composites. Due to such configuration, the reinforcement element 30a is subjected to elastic deformation as the reinforcement element is press fitted on the tank to cause tensioning in the reinforcement element 30a. As such, the reinforcement element 30a is in the tensioned configuration when the reinforcement element 30a is received in the corresponding channel 24a. However, the present invention is not limited to any particular material and configuration of the reinforcement element 30a, as far as the reinforcement element 30a is elastically deformable to attain tensioned configuration as the reinforcement element 30a is received over the tank portion between the ribs 22a defining the corresponding channel 24a.

[0049] As the at least one reinforcement element 30a is tensioned by press fitting the at least one reinforcement element 30a on the tank portion between the ribs 22a defining the corresponding channel 24a, the limbs 31a of the reinforcement element 30a are pulled away from each other and separated by the tank portion. Further, in the tensioned configuration of the reinforcement element 30a, the limbs 31a thereof receive the tank portion that is wider than space between the limbs 31a of the reinforcement element 30a in free-state thereof, thereby causing the limbs 31a to deform elastically to receive the tank portion and inwardly press the tank portion received there-between. Particularly, in the tensioned configuration of the reinforcement element 30a, the limbs 31a of the reinforcement element 30a press the side walls of the tank portion between the adjacent external ribs 22a inwardly to prevent bulging out of the side walls of the tank 20a.

[0050] Similarly, other reinforcement elements 30a are also tensioned by press fitting the reinforcement elements 30a on the corresponding channels 24a configured at regular space intervals on the tank 20a, thereby reinforcing the tank 20a throughout the length of the tank 20a and preventing outward bulging of the sidewalls of the tank 20a, even when cyclic pressures are acting on internal walls of the tank 20a. The reinforcement of the tank 20a in this manner prevents outward bulging of the side walls of the tank 20a and failures resulting from outward bulging of side walls of the tank 20a, such as for example, lateral un-crimping between the tank 20a and the corresponding header 10a and formation of groove cracks on the header 10a.

[0051] The reinforcement element 30a, 130a, 230a is maintained in the tensioned configuration by using at least one retention means. The retention means may include at least one first latching element 32a configured on each of the limbs 31a of the reinforcement element 30a and at least one second latching element 26a complimentary to the first latching element 32a. The at least one second latching element 26a is configured on the corresponding tank portion disposed on each side of the tank 20a and defined by the ribs 22a, particularly, corresponding channel portion receiving the limbs 31a of the reinforcement element 30a. The retention means may further include, attaching means 234a in the form of u-clips configured at extreme ends of the limbs 231a of the reinforcement element 230a, in accordance with an embodiment of the present invention. However, the present invention is not limited to any particular number, placement and configuration of the first latching elements 32a, 132a, 232a, the second latching elements 26a and the attaching means 234a as far as these are capable of configuring engagement between the reinforcement element 30a, 130a, 230a in tensioned configuration and the corresponding tank portion, particularly, the channel 24a for maintaining the reinforcement element 30a, 130a, 230a in tensioned configuration as the reinforcement element is received in the corresponding channel 24a.

[0052] FIG. 3a illustrates an isometric view depicting the tank 20a configured with a reinforcement element 130a, in accordance with another embodiment of the present invention is illustrated, wherein first and second latching elements 132a and 26a are depicted in engaged configuration with each other and an extreme end portion 133a of each limb 131a of the reinforcement element 130a is covering at least a portion of a corresponding crimped profile 12a formed by crimping between the header 10a and the corresponding tank 20a. FIG. 3b illustrates a schematic representation depicting the tank 20a configured with the reinforcement element 130a, wherein the extreme end portion 133a of each limb 131a of the reinforcement element 130a is substantially covering the corresponding crimped profile 12a formed by crimping between the header 10a and the corresponding tank 20a.

[0053] Again referring to FIG. 3a and FIG. 3b, the reinforcement element 130a is tensioned when the reinforcement element 130a is received over the corresponding tank portion, particularly, the channel 24a defined by the ribs 22a by press fitting the reinforcement element 30a on the corresponding channel 24a. The reinforcement element 30a is maintained in the tensioned configuration in the corresponding tank portion, particularly, the channel 24a by the retention means in form of the first and second latching elements. Particularly, the first and the second latching elements are complimentary to each other, such that the at least one first latching element 132a, in form of aperture configured on the limbs 131a of the reinforcement element 130a engage with the corresponding second latching element 26a, in form of a tongue element configured on corresponding tank portions, particularly, channel portions disposed on each side of the tank 20a to facilitate maintaining the reinforcement element 30a in the tensioned configuration. In accordance with another embodiment, the first latching elements 132a, in form of tongue elements formed on the limbs 131a of the reinforcement element 130a configure snap fit engagement with corresponding second latching elements in form of apertures formed on corresponding channel portions disposed on each side of the tank 20a to facilitate in maintaining the reinforcement element 130a in the tensioned configuration. In accordance with an embodiment, the at least one first latching element 132a is configured near end portion of each limb 131a of the reinforcement element 130a. In accordance with an embodiment, the at least one second latching element 26a is configured on the corresponding tank portion, particularly, the channel 24a. In accordance with another embodiment, the at least one second latching element 26a is configured on the ribs 22a defining the channel 24a and is configured so as to engage with corresponding first latching element 132a configured near end portion of each limb 131a to facilitate maintaining the reinforcement element 130a in the tensioned configuration. Further, the end portion 133a of the limbs 131a latch/engage with the crimped profile 12a of the header 10a. With such configuration two point latching is achieved, wherein first latching is achieved between first latching element 132a and second latching element 26a, whereas the second latching is achieved between end portion 133a of limbs 131a and the crimped profile 12a of the header 10a. The end portion 133a of limbs 131a engaging with at least a portion of the crimped profile 12a redundantly maintains the reinforcement element 130a in tensioned configuration over the corresponding tank portion, particularly, the channel 24a. Such configuration prevents unintentional or accidental disengagement between the first latching elements 132a and the second latching element 26a and maintains the connection between the reinforcement element 130a and the corresponding tank portion, particularly, the channel 24a, thereby, facilitating in maintaining the reinforcement element 130a in the tensioned configuration over the corresponding tank portion, particularly, the channel 24a. However, the present invention is not limited to any particular configuration and placement of the latching elements as far as the latching elements engage with each other to facilitate in maintaining the reinforcement element 130a in the tensioned configuration. In accordance with an embodiment, the heat exchanger further includes a resilient material disposed between the at least one limb 131a of the reinforcement element 130a and corresponding tank portion, particularly, channel portion between the adjacent external ribs 22a defining the corresponding channel 24a. Such configuration further facilitates in maintaining the reinforcement element 130a in the tensioned configuration and prompts the limbs 131a of the reinforcement element 130a to further press the side walls of the tank 20a inwardly.

[0054] In accordance with another embodiment illustrated in FIG. 4a, apart from engagement between at least one first latching element 232a and at least one second latching element 26a, an attaching element 234a in the form of u-clips configured at an extreme end of each limb 231a of the reinforcement element 230a get crimped over at least a portion of the crimped profile 12a formed by crimping between the header 10a and the corresponding tank 20a to facilitate maintaining the reinforcement element 230a in the tensioned configuration. FIG. 4a illustrates an isometric view of the reinforcement element 230a depicting the attaching element 234a crimped over at least a part of a corresponding crimped profile 12a formed by crimping between the header 10a and the corresponding tank 20a. FIG. 4b and FIG. 4c illustrate the attaching element 234a in the form of u-clips in un-crimped and crimped configurations respectively, specifically, for the sake of clearly depicting the different configurations of the u-clips, the FIG. 4b and FIG. 4c depict only the u-clips without depicting the tank 20a and the header 10a.

[0055] More specifically, the crimping of the u-clips over at least a portion of the crimped profile 12a redundantly maintains the reinforcement element 230a in tensioned configuration over the corresponding tank portion, particularly, the channel 24a. Such configuration prevents unintentional or accidental disengagement between the first latching elements 232a and the second latching element 26a and maintains the connection between the reinforcement element 230a and the corresponding tank portion, particularly, the channel 24a, thereby, facilitating in maintaining the reinforcement element 230a in the tensioned configuration over the corresponding tank portion, particularly, the channel 24a. The engagement between the first latching elements 232a and the second latching elements 26a, further facilitates in locating and maintaining the reinforcement element 230a in desired position within the corresponding tank portion, particularly, the channel 24a as the u-clips configured at ends of the limbs 231a of the reinforcement element 230a are crimped being over at least a portion of the crimped profile 12a.

[0056] A similar header-tank assembly 100b, referred to as the second header tank assembly 100b is configured at opposite end portion of the heat exchanger core, wherein the second header 10b is crimped on the corresponding tank 20b. Also, similar reinforcement elements 30b in the tensioned configuration are detactably received in corresponding channels 24b configured on the tank 20b for providing reinforcement to the tank 20b. The details regarding the manner in which the reinforcement elements 30b are tensioned by press fitting the reinforcement elements 30b in the channels 24b and maintaining the reinforcement elements 30b in tensioned configuration by retention means is similar to the manner in which the reinforcement elements 30a are tensioned and maintained in the tensioned configuration by the retention means and as such are not elaborately disclosed in the present document for the sake of brevity of the present document.

[0057] Several modifications and improvement might be applied by the person skilled in the art to the heat exchanger tank as defined above, as long as it comprises external ribs that provide reinforcement to structure of the tank, wherein at least one reinforcement element engages with an external tank portion and is tensioned by press fitting the at least one reinforcement element on the external tank portion such that limbs of the reinforcement element are separated by the external tank portion between the external ribs. The reinforcement element is further maintained in the tensioned configuration by using at least one retention means.

[0058] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein.

[0059] In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means.