EP4198441A1

EP4198441A1 - A heat exchanger

Info

Publication number: EP4198441A1
Application number: EP21214334.1A
Authority: EP
Inventors: Martin MYSLIKOVJAN; Jiri Volf; Jan Forst; Jakub JIRSA; Lukas BERANEK; Radek VYVADIL; Jakub ZAPOTOCKY
Original assignee: Valeo Vymeniky Tepla sro
Current assignee: Valeo Vymeniky Tepla sro
Priority date: 2021-12-14
Filing date: 2021-12-14
Publication date: 2023-06-21

Abstract

A heat exchanger (100) includes a manifold (10), a core (20), at least one header (30) and a connector block (50). The connector block (50) includes an inlet and an outlet port (50a) and (50b). The connector block (50) is directly mounted on the manifold (10) and includes a first fluid passage (52a) and a second flow passage (52b) formed therein. The first flow passage (52a) and the second fluid passage (52b) configures angular fluid flow trajectory and fluid communication between the inlet port (50a) and an inlet manifold (10a) and an outlet manifold (10b) and the outlet port (50b) respectively. The inlet and the outlet ports (50a) and (50b) being extending orthogonally to the longitudinal axis of the manifold (10) and the tubular elements (22a) and (22b) renders the heat exchanger (100) further compact along longitudinal side of the manifold (10).

Description

FIELD OF THE INVENTION

The present invention relates to a heat exchanger. In particular, the present invention relates to a heat exchanger for a motor vehicle.

BACKGROUND OF THE INVENTION

The present invention relates to the field of heat exchangers suitable for the heat exchange between a first fluid (e.g. refrigerant), and at least one second fluid (e.g. air). For example, the heat exchanger of such kind may include an air conditioning gas coolers, inner gas coolers or evaporators capable of using, for example, a carbon dioxide, also known as CO2 or R744 as the refrigerant. Such heat exchangers find particular application in motor vehicles. Such heat exchanger includes an inlet manifold and an outlet manifold disposed on opposite sides of a heat exchanger core, wherein, tubular elements configure fluid communication between the inlet manifold and the outlet manifold. Separate connection conduits are connected to the inlet manifold and the outlet manifold to respectively supply heat exchange fluid to and collect heat exchange fluid therefrom. However, such configuration of the heat exchanger faces packaging, connection, routing issues.
To address the above issues, prior art suggests a heat exchanger 1, particularly, a condenser, for a vehicle that includes an inlet manifold 2a and an outlet manifold 2b disposed on same side of the heat exchanger 1, tubular elements 4 and a connector block 6 as illustrated in FIG. 1. The inlet manifold 2a is supplied heat exchange fluid from an inlet port 6a of the connector block 6 via by an inlet conduit 7a. The outlet manifold 2b delivers the first heat exchange fluid to an outlet port 6b of the connector 6 via an outlet conduit 7b after the first heat exchange fluid had undergone heat exchange with air surrounding the tubular elements 4, while passing through the tubular elements 4. In such configuration, the tubular elements 4 are divided into a first set of tubular elements 4a and a second set of tubular elements 4b that are interconnected and in fluid communication with each other via an intermediate manifold 2c. Also, the connector block 6 with the inlet port 6a and the outlet port 6b is disposed proximal to the inlet and outlet manifolds 2a and 2b. Accordingly, shorter lengths of inlet and outlet conduits 7a and 7b can be used for configuring connection and fluid communication between the inlet port 6a and the inlet manifold 2a and between the outlet manifold 2b and the outlet port 6b respectively. The inlet manifold 2a distributes the heat exchange fluid received thereby to a first set of tubular elements 4a. The heat exchange fluid undergoes heat exchange with a second heat exchange fluid, particularly, air around the first set of tubular elements 4a as the first heat exchange fluid flows through the first set of tubular elements 4a. The second set of tubular elements 4b receive the heat exchange fluid from the first set of tubular elements 4a via the intermediate manifold 2c and the second heat exchange fluid undergoes further heat exchange as it passes through the second set of tubular elements 4b. The outlet manifold 2b collects the first heat exchange fluid from the second tubular elements 4a after the first heat exchange fluid had rejected heat to the air flowing across the tubular elements 4a and 4b as it passes through the the tubular elements 4a and 4b. The outlet manifold 2b delivers the first heat exchange fluid collected thereby to the outlet conduit 7b for egress of the first heat exchange fluid from the heat exchanger 1 via the outlet port 6b. The tubular elements 4a are separated by fins 4c disposed there-between and the tubular elements 4b are also separated by fins 4c disposed there-between. The fins 4c retard flow of the second heat exchange fluid, particularly, the air outside the tubular elements 4a and 4b to improve the heat exchange between the heat exchange fluid flowing inside and air flowing outside the tubular elements 4a and 4b.
The connector block 6 with the inlet port 6a and the outlet port 6b for ingress and egress of fluid with respect to the heat exchanger 1 is generally mounted on a vehicle frame proximal to the inlet and outlet manifolds 2a and 2b. However, use of inlet and outlet conduits 7a and 7b involves routing of the connecting inlet and outlet conduits 7a and 7b in limited space, particularly, in areas proximal to the lateral side of the heat exchanger 1. The inlet and outlet conduits 7a and 7b and connections thereof cause packaging issues and pressure losses due to length of the inlet and outlet conduits 7a and 7b and bends in the inlet and outlet conduits 7a and 7b. In order to prevent connection conduits 7a and 7b and connection of the connection conduits 7a and 7b with the connector block 6 and the inlet and outlet manifold 2a and 2b, the connector block 6 itself is configured with the fluid flow passages. The fluid flow passages configured in the connector block 6 configures fluid communication between the inlet port 6a and inlet manifold 2a and between the outlet manifold 2b and the outlet port 6b, thereby eliminating the inlet and outlet conduits 7a and 7b. However, in such conventional arrangement, the inlet and outlet ports 6a and 6b extend parallel to manifold 2 and perpendicular to the longitudinal sides of the tubular elements 4a and 4b and protrude outside the heat exchanger 1 along the longitudinal direction of the manifold 2 and cause packaging issues in the longitudinal direction of the manifold 2.
Accordingly, there is a need of a heat exchanger with a connector that renders compactness to the heat exchanger and addresses the packaging issues, particularly, along lateral sides of the heat exchanger and longitudinal direction of the inlet and outlet manifolds. Further, there is a need of a heat exchanger with a connector block that prevents inlet and outlet conduits, thereby preventing problems such as energy losses and pressure drop between the inlet / outlet ports and corresponding inlet / outlet manifolds due to lengthy inlet and outlet connection conduits and bends in the inlet and outlet connection conduits. Further, there is a need for a heat exchanger with a connector that improves efficiency and reliability of the heat exchanger. There is a need of a heat exchanger with a connector block that reduces the number of parts, thereby reducing maintenance and enhancing reliability of the heat exchanger.
An object of the present invention is to obviate the problems associated with conventional heat exchanger that uses inlet and outlet conduits or conventional heat exchangers that use connector block with fluid flow passages integrally formed therewith but with inlet and outlet ports extending along longitudinal direction of the inlet and outlet manifolds.
Another object that renders the renders compactness to the heat exchanger and addresses the packaging issues, particularly, along lateral sides of the heat exchanger and longitudinal direction of the inlet and outlet manifolds.
Yet another object of the present invention is to provide a heat exchanger with a connector that improves efficiency and reliability of the heat exchanger.
Still another object of the present invention is to provide a heat exchanger that reduces the number of parts, thereby reducing maintenance and enhancing reliability of the heat exchanger.
In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

SUMMARY OF THE INVENTION

A heat exchanger is disclosed in accordance with an embodiment of the present invention. The heat exchanger includes a manifold, a heat exchanger core, at least one header, an intermediate manifold and a connector block. The manifold includes an inlet manifold and an outlet manifold. The heat exchanger core includes a first set of tubular elements defining a first pass and a second set of tubular elements defining a second pass. The at least one header is formed with tabs that configures crimping connection with at least one of the inlet manifold and the outlet manifold. The at least one header includes a first set of openings and a second set of openings. The first set of openings receive the first set of tubular elements therein to configure fluid communication between the inlet manifold and the first set of tubular elements. The second set of opening receive the second set of tubular elements therein to configure fluid communication between the second set of tubular elements and the outlet manifold. The intermediate manifold configures fluid communication between corresponding tubular elements of the first set of tubular elements and the second set of tubular elements to define U-flow trajectory between the first pass defined by the first set of tubular elements and the corresponding second pass defined by the second set of tubular elements. The connector block includes an inlet port for ingress of fluid inside the heat exchanger and an outlet port for egress of fluid outside the heat exchanger. The connector block is directly mounted on the manifold and includes a first fluid passage and a second flow passage integrally formed therein. The first flow passage configures angular fluid flow trajectory and fluid communication between the inlet port and the inlet manifold. The second fluid flow passage formed in the connector block configures angular flow trajectory and fluid communication between the outlet manifold and the outlet port. Such configuration of the connector block with first and second fluid flow passages permits inlet port and the outlet port being extending orthogonally to the longitudinal axis of the manifold and the longitudinal axis of the tubular elements.
Particularly, at least one of the first and second fluid flow passages is of variable cross section and cross section thereof changes from circular cross section at a first end thereof to rectangular cross section at a second end thereof.
More specifically, at least one of the first and second fluid flow passages includes a first section and a second section orthogonal to each other.
Generally, the header includes an extension portion extending therefrom and formed with at least one, first aperture and at least one, second aperture. The at least one, first aperture is aligned with corresponding second end of the first fluid passage on one side thereof and the inlet manifold on the other side thereof for configuring fluid communication between the first fluid flow passage and the inlet manifold. At least one, second aperture is aligned with the corresponding second end of the second fluid passage on one side thereof and with the outlet manifold on the other side thereof for configuring fluid communication between the second fluid flow passage and the outlet manifold as the connector is mounted on the manifold.
Particularly, the extension portion is extending beyond the heat exchanger core on the connector block side of the heat exchanger core.
Particularly, the connector block is crimped over the manifold and the extension portion is sandwiched between the manifold and the connector block.
More specifically, the connector block is configured with crimping tabs for crimping the connector block over the manifold.
Generally the crimping tabs are provided along longitudinal sides of the connector block.
In accordance with an embodiment of the present invention, the crimping tabs are provided along a lateral side of the connector block distal from the heat exchanger core in the assembled configuration of the connector block with respect to the manifold.
Particularly, the connector block includes grooves formed on portions thereof between the first and the second fluid flow passages to insulate the first and the second fluid flow passages with respect to each other.
In accordance with an embodiment of the present invention, the heat exchanger includes a single header with the first set of openings and the second set of openings and the tabs along opposite longitudinal sides of, the tabs configures crimping connection between the header and the manifold.
Alternatively, the heat exchanger includes two separate headers and two separate inlet and outlet manifolds. The first header includes a first set of openings along length thereof and a first set of tabs along opposite longitudinal sides thereof to configure crimping connection between the first header and the corresponding inlet manifold. Similarly, the second header includes a second set of openings along length thereof and a second set of tabs along opposite longitudinal sides thereof to configure crimping connection between the second header and the corresponding outlet manifold.
Generally, the heat exchanger includes two separate headers that includes separate extension portions extending beyond the heat exchanger core along longitudinal axis of the manifolds on the connector side thereof. Each extension portion is formed with corresponding first and second apertures. The first aperture is aligned with the first manifold and second end of the first fluid flow passage to configure fluid communication between the first manifold and the first fluid flow passage. The second aperture is aligned with the second manifold and second end of the second fluid flow passage to configure fluid communication between the second manifold and the second fluid flow passage.
The connector includes a first set of tabs and a second set of tabs. The first set of tabs are crimped to the inlet manifold with the first extension portion sandwiched between the inlet manifold and the connector block. The second set of tabs are crimped to the second manifold with the second extension portion sandwiched between the outlet manifold and the connector block.

BRIEF DESCRIPTION OF DRAWINGS

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:

FIG. 1 illustrates an isometric view of a conventional heat exchanger with a connector block separately mounted with respect to the manifold and connected to and fluid communication with the manifold by means of inlet an outlet conduits;
FIG. 2 illustrates an isometric view of heat exchanger with a connector block in accordance with an embodiment of the present invention;
FIG. 3 illustrates another isometric view of the heat exchanger of FIG. 2;
FIG. 4 illustrates an exploded view of the heat exchanger of FIG. 2 depicting the relative position and sequence in which the various elements of the heat exchanger are arranged for assembly of the heat exchanger;
FIG. 5 illustrates an isometric view of the connector block of the heat exchanger of FIG. 2;
FIG. 6 illustrates a side view of the connector block of FIG. 5;
FIG. 7 illustrates a top view of the connector block of FIG. 5;
FIG. 8 illustrates a sectional view of the connector block along sectional line A-A' of FIG. 6;
FIG. 9 illustrates an isometric view of the connector block in accordance with another embodiment of the present invention, wherein the heat exchanger includes separate headers corresponding to the separate manifolds;
FIG. 10 illustrates another isometric view of the connector block without the manifolds to depict the separate headers in details; and
FIG. 11 illustrates an isometric view of the connector block in accordance with another embodiment of the present invention, wherein a single manifold is crimped to a single header to define separate inlet and outlet manifolds.

DETAILED DESCRIPTION OF EMBODIMENTS

The present invention envisages a heat exchanger, wherein an inlet manifold and an outlet manifold are disposed on same side of the heat exchanger to render compact configuration to the heat exchanger. The heat exchanger utilizes a connector block disposed proximal to the manifold and configured with fluid flow passages integrally formed therein instead of using inlet and outlet conduits for configuring connection and fluid communication between inlet and outlet ports and inlet and outlet manifolds respectively. Such configuration of the heat exchanger avoids inlet and outlet conduits and packaging, connection and routing issues faced due to the inlet and outlet conduits. The inlet port is formed on the connector for ingress of fluid inside the heat exchanger and the outlet port is for egress of fluid outside the heat exchanger. The connector block is directly mounted on the manifold by crimping and brazing. The first flow passage formed in the connector block configures angular fluid flow trajectory and fluid communication between the inlet port and the inlet manifold. The second fluid flow passage formed in the connector block configures orthogonal flow trajectory and fluid communication between the outlet manifold and the outlet port. The inlet port and the outlet port being extending orthogonally to the longitudinal axis of the manifold and the longitudinal axis of the tubular elements renders further compactness to the heat exchanger, particularly, along longitudinal side of the manifolds, thereby addressing packaging issues. Although, the present invention is explained in the forthcoming description and accompanying drawings with example of condenser for use in vehicle air conditioning, however, the heat exchanger of the present invention is also applicable in any other vehicular or non-vehicular applications, where the inlet and the outlet manifold are on same side of the heat exchanger and the heat exchanger is required to be compact, particularly, along longitudinal side of the manifold to address packaging issues.
FIG. 2 illustrates a heat exchanger 100 in accordance with an embodiment of the present invention. FIG. 3 illustrates another isometric view of the heat exchanger 100. FIG. 4 illustrates an exploded view of the heat exchanger 100. Particularly, FIG. 4 depicts the relative position and sequence in which the various elements of the heat exchanger 100 are arranged for assembly with respect to each other for assembling the heat exchanger. The heat exchanger 100 includes a manifold 10, a heat exchanger core 20, at least one header 30, an intermediate manifold 10c and a connector block 50.
The manifold 10 includes an inlet manifold 10a and an outlet manifold 10b. The inlet manifold 10a and the outlet manifold 10b are disposed adjacent to each other and the same side of the heat exchanger 100. Such configuration of the heat exchanger 100 with the inlet manifold 10a and the outlet manifold 10b disposed adjacent to each other and on same side of the heat exchanger 100 provides certain advantages. For example, such configuration renders the heat exchanger 100 compact and addresses the packaging issues, connection issues and prevents clutter. Further, such configuration reduces the number of connection parts and hence reduces maintenance and improves reliability. However, such configuration requires the heat exchange fluid entering the heat exchanger to follow a U-turn trajectory within the heat exchanger 100 that is achieved by providing first and second sets tubular elements 22a and 22b and the intermediate manifold 10c configuring fluid communication between different sets of tubular elements 22a and 22b. More specifically, the intermediate manifold 10c interconnects and configures fluid communication between a first set of tubular elements 22a defining a first pass and a second set of tubular elements 22b defining a second pass or return pass.
The heat exchanger core 20 includes the first set of tubular elements 22a and the second set of tubular elements 22b. The tubular elements of the first set of tubular elements 22a are in fluid communication with corresponding tubular elements of the second set of tubular elements 22b via the intermediate manifold 10c. The adjacent tubular elements of the first set of tubular elements 22a are separated by fins 24. Similarly, the adjacent tubular elements of the second set of tubular elements 22b is also separated by fins 24. The fins 24 retard the flow of the second heat exchange fluid, particularly, the air outside the tubular elements 22a and 22b to improve the heat exchange between the heat exchange fluid flowing inside the tubular elements 22a and 22b and air flowing outside the tubular elements 22a and 22b.
The at least one header 30 is formed with tabs 32 that configures crimping connection with at least one of the inlet manifold 10a and the outlet manifold 10b. The at least one header 30 includes a first set of openings 34a and a second set of openings 34b. The first set of openings 34a receive the first set of tubular elements 22a therein to configure fluid communication between the first set of tubular elements 22a and the inlet manifold 10a. The second set of opening 34b receive the second set of tubular elements 22b therein to configure fluid communication between the second set of tubular elements 22b and the outlet manifold 10b.
The intermediate manifold 10c configures fluid communication between corresponding tubular elements of the first set of tubular elements 22a and the second set of tubular elements 22b to define U-flow trajectory between the first set of tubular elements 22a and the corresponding second set of tubular elements 22b.
Referring to FIG. 5 - FIG. 7 of the accompanying drawings, the connector block 50 includes an inlet port 50a for ingress of fluid inside the heat exchanger 100 and an outlet port 50b for egress of fluid outside the heat exchanger 100. The connector block 50 is directly mounted on the manifold 10. The connector block 50 is crimped over the manifold 10 with an extension portion 36 of the header 30 sandwiched between the connector block 50 and the manifold 10 in the assembled configuration of the connector block 50 with respect to the manifold 10. The connector block 50 is configured with crimping tabs 54 for crimping the connector block 50 over the manifold 10. Generally, the crimping tabs 54 are provided along longitudinal sides of the connector block 50. In accordance with another embodiment of the present invention, the crimping tabs 54 are provided along a lateral side of the connector block 50 distal from the heat exchanger core 20 in the assembled configuration of the connector block 50 with respect to the manifold 10. However, the present invention is not limited to any particular configuration of the connection between the connector block 50 and the manifold 10, the number or placement of the crimping tabs as far as the connection permits aligned connection between the extension portion 36 and the connector block 50 on one side and with the manifold 10 on the other side of the extension portion 36 for configuring fluid communication between fluid flow passages 52a and 52b integrally formed in the connector block 50 and the inlet and outlet manifolds 10a and 10b respectively through the extension portion. FIG. 8 illustrates a sectional view of the connector 50 block along sectional line A-A'. The connector block 50 is mounted on the manifold 10 and is connected to and fluid communication with the inlet and the outlet manifolds 10a and 10b by means of first and second fluid flow passages 52a and 52b integrally formed within the connector block 50. Referring to the FIG. 8, the connector block 50 includes the first fluid passage 52a and the second flow passage 52b formed therein. The first flow passage 52a formed in the connector block 50 configures angular fluid flow trajectory and fluid communication between the inlet port 50a and the inlet manifold 10a. The second fluid flow passage 52a formed in the connector block 50 configures angular flow trajectory and fluid communication between the outlet manifold 10b and the outlet port 50b. At least one of the first and second fluid flow passages 52a, 52b is of variable cross section and cross section thereof changes from circular cross section at a first end 51a, 51b thereof to rectangular cross section at a second end thereof 53a, 53b. Particularly, the cross section of the first flow passage 52a changes from circular cross section at the first end 51a thereof to rectangular cross section at the second end thereof 53a. Similarly, the cross section of the first flow passage 52b changes from circular cross section at the first end 51b thereof to rectangular cross section at a second end thereof 53b.
Further, at least one of the first and second fluid flow passages 52a, 52b includes a first section and a second section orthogonal to each other. Particularly, the first fluid passage 52a includes a first horizontal section and a second vertical section. Similarly, the second fluid flow passage 52b includes a first section and a second section that are orthogonal to each other. Particularly, the second fluid passage 52b includes a first horizontal section and a second vertical section. Such configuration of the first fluid flow passage 52a enables orthogonal fluid flow trajectory and fluid communication between the inlet port 50a and the inlet manifold 10a. Further, such configuration of the second fluid flow passages 52b enables orthogonal flow trajectory and fluid communication between the outlet manifold 10b and the outlet port 50b. The orthogonal fluid flow trajectory of the first fluid passage 52a between the inlet port 50a and the inlet manifold 10a enables fluid communication between the inlet port 50a and the inlet manifold 10a for delivering heat exchange fluid to the inlet manifold 10a. Similarly, the orthogonal fluid flow trajectory of the second fluid passage 52b between the outlet manifold 10b and the outlet port 50b and enables fluid communication between the outlet manifold 10b and the outlet port 50b .
The connector block 50 further includes features for achieving thermal insulation between the fluid flowing through the first and the second flow passages 52a and 52b. Particularly, the connector block 50 includes grooves 56a and 56b formed on portions thereof between the first and the second fluid flow passages 52a and 52b to insulate the fluid flowing through the first and the second fluid flow passages 52a and 52b. In accordance with an embodiment of the present invention, the groove 56a thermally isolates the horizontal sections of the first and second fluid flow passages 52a and 52b. Further, the groove 56b thermally isolates the vertical sections of the first and second fluid flow passages 52a and 52b. In accordance with an embodiment of the present invention, a single groove with horizontal and vertical groove portions thermally insulates the first fluid passages 52a and 52b. Particularly, the horizontal portion of the groove thermally isolates the horizontal sections of the first and second fluid flow passages 52a and 52b whereas the vertical portion of the groove thermally isolates the vertical sections of the first and second fluid flow passages 52a and 52b. In accordance with an embodiment of the present invention, the grooves are filled with insulating material to further enhance the thermal insulation between the fluid flowing through the first and the second flow passages 52a and 52b. However, the present invention is not limited to any particular configuration of the grooves 56a and 56b as far as the grooves are capable of thermally insulating the fluid flowing through the first fluid flow passages 56a and the second fluid flow passages 56b.
The inlet port 50a and the outlet port 50b being extending orthogonally to the longitudinal axis of the manifold 10 and the longitudinal axis of the tubular elements 22a and 22b, provides advantages. Such configuration of the inlet port 50a and the outlet port 50b renders the heat exchanger 100 compact, particularly, along the longitudinal direction of the manifold 10 as compared to when the inlet port and outlet port are extending parallel to the manifold and along longitudinal direction of the manifold as in the conventional connector. Accordingly, such configuration of the inlet and outlet ports 50a and 50b address packing issues along the lateral side of the heat exchanger on the connector side, particularly, along the longitudinal sides of the manifold 10.
The header 30 of the present invention is also configured with features for configuring fluid communication between the fluid flow passages 52a and 52b and the inlet and outlet manifolds 10a and 10b respectively. Particularly, the header 30 is configured with features for smooth flow from the first flow passages 52a and 52b to the inlet and outlet manifolds 10a and 10b respectively. Generally, the header 30 includes the extension portion 36 extending therefrom that extends beyond the heat exchanger core 20 on the connector block side of the heat exchanger core 20 and is sandwiched between the manifold 10 and the connector block 50. The extension portion 36 is formed with at least one, first aperture 36a and at least one, second aperture 36b. The at least one, first aperture 36a is aligned with corresponding second end 53a of the first fluid passage 52a on one side thereof and the inlet manifold 10a on the other side thereof for configuring fluid communication between the first fluid flow passage 52a and the inlet manifold 10a. The at least one, second aperture 36b is aligned with the corresponding second end 53b of the second fluid passage 52b on one side thereof and with the outlet manifold 10b on the other side thereof for configuring fluid communication between the second fluid flow passage 52b and the outlet manifold 10b as the connector 50 is mounted on the manifold 10.Generally, the at least one first aperture 36a and the at least one second aperture 36b are complimentary to the cross section of the first and second fluid flow passages 52a and 52b at the second end 53a and 53b thereof. Particularly, the first and the second apertures 36a and 36b are also of rectangular section and of same size as that of the cross section of the first and second fluid flow passages 52a and 52b at the second end 53a and 53b thereof.
In accordance with an embodiment of the present invention as illustrated in FIG. 2 - FIG. 4, the heat exchanger 100 includes a single header 30 with the first set of openings 34a and the second set of openings 34b and the tabs 32 along opposite longitudinal sides of, wherein the tabs 32 configures crimping connection between the header 30 and the manifold 10. The first set of openings 34a receive the first set of tubular elements 22a and the second set of openings 34b receive the second set of tubular elements 22b. Each tubular element of the first set of tubular elements 22a is connected to and fluid communication with corresponding tubular element of the second set of tubular elements 22b via the intermediate manifold 10c. The connector block 50 as described in detail above, is mounted on the manifold 10 by crimping.
Alternatively as illustrated in FIG. 9 and 10, the heat exchanger 100 includes two separate headers 30a and 30b corresponding to the two separate inlet and outlet manifolds 10a and 10b respectively. The first header 30a includes a first set of openings 34a along length thereof and a first set of tabs 32a along opposite longitudinal sides thereof and on opposite sides of the first set of openings 34a. The first and the second headers 30a and 30b includes separate first and second extension portions 37a and 37b, each extension portion 37a and 37b formed with corresponding apertures 38a and 38b. The first set of tabs 32a configure crimping connection between the first header 30a and the corresponding inlet manifold 10a so that the aperture 38a formed on the first extension portion 37a is aligned with the first manifold 10a and second end 53a of the first fluid flow passage 52a to configure fluid communication between the first manifold 10a and the first fluid flow passage 52a. Similarly, the second header 30b includes a second set of openings 34b along length thereof and a second set of tabs 32b along opposite longitudinal sides thereof and on opposite sides of the first set of openings 34a. The second set of tabs 32b configures crimping connection between the second header and the corresponding outlet manifold. Such configuration of the heat exchanger 100 with separate headers 30a and 30b in conjunction with the different manifolds 10a and 10b defining separate distribution and collection channels respectively, improved insulation between the fluid flowing through the inlet and outlet manifolds 10a and 10b is achieved.
The connector 50 includes a first set of tabs 54a and a second set of tabs 54b. The first set of tabs 54a are crimped to the inlet manifold 10a with the first extension portion 37a sandwiched between the inlet manifold 10a and the connector block 50. The second set of tabs 54b are crimped to the second manifold 10b with the second extension portion 37b sandwiched between the outlet manifold 10b and the connector block 50.
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.

Claims

A heat exchanger (100) comprising:
• a manifold (10) comprising an inlet manifold (10a) and an outlet manifold (10b);

• a heat exchanger core (20) comprising:
∘ a first set of tubular elements (22a) defining a first pass;

∘ a second set of tubular elements (22b) defining a second pass;

• at least one header (30) formed with tabs (32) adapted to configure crimping connection with at least one of the inlet manifold (10a) and the outlet manifold (10b) and formed with,
∘ a first set of openings (34a) adapted to receive the first set of tubular elements (22a) therein to configure fluid communication between the first set of tubular elements (22a) and the inlet manifold (10a); and

∘ a second set of opening (34b) adapted to receive the second set of tubular elements (22b) therein to configure fluid communication between the second set of tubular elements (22b) and the outlet manifold (10b);

• an intermediate manifold (10c) configuring fluid communication between corresponding tubular elements of the first set of tubular elements (22a) and the second set of tubular elements (22b) to define U-flow trajectory between the first set of tubular elements (22a) and the corresponding second set of tubular elements (22b),

• a connector block (50) comprising an inlet port (50a) for ingress of fluid inside the heat exchanger (100) and an outlet port (50b) for egress of fluid outside the heat exchanger (100),
characterized in that the connector block (50) is mounted directly on the manifold (10) and comprises a first fluid passage (52a) and a second flow passage (52b) formed therein, the first flow passage (52a) configures angular fluid flow trajectory and fluid communication between the inlet port (50a) and the inlet manifold (10a) and the second fluid flow passage (52b) formed in the connector block (50) configures angular flow trajectory and fluid communication between the outlet manifold (10b) and the outlet port (50b), the inlet port (50a) and the outlet port (50b) being extending orthogonally to the longitudinal axis of the manifold (10) and the longitudinal axis of the tubular elements (22a) and (22b).
The heat exchanger (100) as claimed in the previous claim, wherein at least one of the first and second fluid flow passages (52a) and (52b) is of variable cross section and cross section thereof changes from circular cross section at a first end (51a, 51b) thereof to rectangular cross section at a second end (53a, 53b) thereof.
The heat exchanger (100) as claimed in any of the preceding claims, wherein at least one of the first and second fluid flow passages (52a) and (52b) comprises a first section and a second section orthogonal to each other.
The heat exchanger (100) as claimed in claim 2, wherein the header (30) comprises an extension portion (36) extending therefrom and formed with at least one first aperture (36a) and at least one second aperture (36b), the at least one first aperture (36a) is aligned with the corresponding second end (53a) of the first fluid passage (52a) on one side thereof and the inlet manifold (10a) on the other side thereof for configuring fluid communication between the first fluid flow passage (52a) and the inlet manifold (10a) and at least one second aperture (36b) is aligned with the corresponding second end (53b) of the second fluid passage (52b) on one side thereof and with the outlet manifold (10b) on the other side thereof for configuring fluid communication between the second fluid flow passage (52b) and the outlet manifold (10b) as the connector (50) is mounted on the manifold (10).
The heat exchanger (100) as claimed in previous claim, wherein the extension portion (36) is extending in longitudinal direction of the manifold (10) and beyond the heat exchanger core (20) on the connector block side of the heat exchanger core (20).
The heat exchanger (100) as claimed in claim 5, wherein the connector block (50) is crimped over the manifold (10) and the extension portion (36) is sandwiched between the manifold (10) and the connector block (50).
The heat exchanger (100) as claimed in any of the preceding claims, wherein the connector block (50) is configured with crimping tabs (54) for crimping the connector block (50) over the manifold (10).
The heat exchanger (100) as claimed in any of the preceding claims, wherein the connector block (50) is configured with crimping tabs (54) provided along longitudinal sides of the connector block (50).
The heat exchanger (100) as claimed in any of the preceding claims, wherein the crimping tabs (54) are provided along a lateral side of the connector block (50) distal from the heat exchanger core (20) in the assembled configuration of the connector block (50) with respect to the manifold (10).
The heat exchanger (100) as claimed in any of the preceding claims, wherein the connector block (50) comprises grooves (56a) and (56b) formed on portions thereof between the first and the second fluid flow passages (52a) and (52b) to insulate the first and the second fluid flow passages (52a) and (52b) with respect to each other.
The heat exchanger (100) as claimed in any of the preceding claims comprises a single header (30) comprises the first set of openings (34a) and the second set of openings (34b) and the tabs (32) along opposite longitudinal sides thereof, the tabs (32) configures crimping connection between the header (30) and the manifold (10).
The heat exchanger (100) as claimed in any of the preceding claims comprises two separate headers (30a) and (30b) and two separate inlet and outlet manifolds (10a) and (10b), the first header (30a) comprises a first set of openings (34a) along length thereof and a first set of tabs (32a) along opposite longitudinal sides thereof to configure crimping connection between the first header (30) and the corresponding inlet manifold (10), similarly, the second header (30b) comprises a second set of openings (34b) along length thereof and a second set of tabs (32b) along opposite longitudinal sides thereof to configure crimping connection between the second header (30b) and the corresponding outlet manifold (10b).
The heat exchanger as claimed in the previous claim, wherein the separate headers (30a) and (30b) comprises separate extension portions (37a) and (37b) extending beyond the heat exchanger core (20) along longitudinal axis of the manifolds (10a) and (10b) on the connector side thereof, each extension portion (37a) and (37b) formed with corresponding first and second apertures (38a) and (38b), the first aperture (38a) is aligned with the first manifold (10a) and second end (53a) of the first fluid flow passage (52a) to configure fluid communication between the first manifold (10a) and the first fluid flow passage (52a) and the second aperture (38b) is aligned with the second manifold (10b) and second end (53b) of the second fluid flow passage (52b) to configure fluid communication between the second manifold (10b) and the second fluid flow passage (52b).
The heat exchanger as claimed in the previous claim, wherein the connector (50) comprises a first set of tabs (54a) and a second set of tabs (54b), the first set of tabs (54a) are crimped to the inlet manifold (10a) with the first extension portion (37a) sandwiched between the inlet manifold (10a) and the connector block (50) and the second set of tabs (54b) are crimped to the second manifold (10b) with the second extension portion (37b) sandwiched between the outlet manifold (10b) and the connector block (50).