EP4474749A1

EP4474749A1 - A manifold for a heat exchanger

Info

Publication number: EP4474749A1
Application number: EP23178527.0A
Authority: EP
Inventors: Michal KARES; Martin MYSLIKOVJAN; Jakub JIRSA; Jan Forst; Radek Lohonka
Original assignee: Valeo Systemes Thermiques SAS
Current assignee: Valeo Systemes Thermiques SAS
Priority date: 2023-06-09
Filing date: 2023-06-09
Publication date: 2024-12-11
Also published as: WO2024251688A1

Abstract

The heat exchanger 100 includes a first manifold 10 for distribution of a heat exchange fluid, said first manifold 10 comprises a first header 12 extending along a longitudinal axis of the first manifold L1. The first header 10 comprising a first set of apertures 12a adapted to configure connection and fluid communication between the first header 12 and heat exchange core 15. Further, a first distribution plate 14 comprising a second set of apertures 14a corresponding to the first set of apertures 12a. In addition, a first intermediate plate 16 adapted to receive heat exchange fluid thereon from an inlet, characterized in that the first intermediate plate 16 comprises at least two channels 16a, 16b, wherein the channels 16a, 16b are asymmetrical with respect to each other; and at least a portion of at least one of the channels 16a, 16b follows a sinusoidal pattern.

Description

FIELD OF INVENTION

The present invention relates to a manifold for a heat exchanger. More particularly, the present invention relates to the manifold for the heat exchanger for a motor vehicle.

BACKGROUND OF THE INVENTION

The present invention relates to the field of heat exchanger and in particular to heat exchangers through which a refrigerant fluid under high pressure flows. In this regard, the invention relates more particularly to air conditioning gas coolers, inner gas coolers or evaporators through which a refrigerant fluid in the supercritical state, such as for example, carbon dioxide, also known as CO₂ or R744 flows. It should be noted that such heat exchanger may also be suitable for other types of refrigerant fluids like R290 and alike, including mixture thereof. Such heat exchangers find particular application in motor vehicles.
A heat exchanger includes a heat exchanger core with a plurality of flow passages, which is formed by arranging a plurality of heat exchanger tubes parallel with respect to each other to reduce the pressure loss of the refrigerant fluid, which flows through the said heat exchanger tubes. The heat exchanger also includes a first manifold and a second manifold in fluid communication with the heat exchanger tubes. The heat exchanger tubes are configured to allow the refrigerant fluid to transverse between the first and second manifolds. The heat exchange tubes are also configured to allow a thermal exchange between the refrigerant fluid, flowing inside said heat exchange tubes, and air flowing outside the heat exchanger, thus extracting or adding heat away from or into the air flowing extracting heat from the air flowing across the heat exchanger core.
The manifold includes a header plate extending along a longitudinal axis of the manifold, a distribution plate an intermediate plate and a cover plate intended to delimit the internal volume of the said manifold. An intermediate plate is disposed at the inlet portion of the heat exchanger tubes and is intended to uniformly distribute the refrigerant fluid among the heat exchanger tubes. In order to achieve a high heat transfer performance, it is important that the refrigerant fluid is uniformly distributed among the heat exchanger tubes.
Although, an intermediate plate is intended to distribute the refrigerant fluid to the heat exchanger tubes in case of the conventional heat exchangers. However, the presence of the intermediate plate may not ensure the homogenous distribution of the refrigerant fluid, which causes non-homogenous temperature spread across the heat exchanger active area and therefore directs the treated air non-uniformly into different zones of the passenger cabin. This may be an issue especially for multi-zone heating air conditioning and ventilation systems, wherein there is temperature difference between air streams egressing through the different air vents. The failure of the intermediate plate of the existing heat exchangers is non-uniform distribution of the refrigerant throughout the heat exchanger core that leaves a significantly large area at the center of the heat exchanger poorly supplied by the refrigerant fluid and thus leaving the area much colder than the other areas of the heat exchanger. In addition, this results in a non-conforming left/right temperature balance under specific air conditioning loop operation conditions, which is a problem in case of multi-zone car climate control systems. This phenomenon is mainly caused due to the bypass section of the heat exchanger located at the second manifold distribution plate in the form of communication channels that directs the refrigerant to flow preferably through the mentioned bypass section leaving low flow throughout the rest of the heat exchanger.
Accordingly, there is a need for an improved heat exchanger that can achieve homogeneous distribution of the refrigerant fluid across the heat exchanger. More particularly, there is a need for an improved distribution that can maintain homogeneity in distributing the refrigerant fluid across the heat exchanger core, which causes the homogeneous temperature spread.

SUMMARY OF THE INVENTION

The present invention discloses a heat exchanger for a motor vehicle includes a first manifold for distribution of a heat exchange fluid with respect to a heat exchanger, wherein said manifold elongates along a longitudinal axis. The first manifold comprises a first header elongating along the axis of elongation of the first manifold, wherein said first header comprising a first set of apertures adapted to configure connection and fluid communication between the header and a first set of parallel heat exchanger tubes and a second set of parallel heat exchanger tubes, wherein said second set of parallel heat exchanger tubes disposed parallel to the first set of parallel heat exchanger tubes. The first manifold further comprises a first cover adapted to be fixed to the first header. In addition, the first manifold includes at least one first distribution plate comprising a second set of apertures corresponding to the first set of apertures, and at least one first intermediate plate adapted to receive heat exchange fluid thereon from an inlet. The at least one first distribution plate and the at least one first intermediate plate being disposed between the first header and the first cover, characterized in that the first intermediate plate comprises at least two channels, wherein the channels are asymmetrical with respect to each other; and at least a portion of at least one of the channels follows a sinusoidal pattern.
Preferably, the first intermediate plate is disposed between the first distribution plate and the first cover.
In accordance with an embodiment of the present invention, at least a portion of at least one of the channels configured on the first intermediate plate follows a straight pattern.
In accordance with an embodiment of the present invention, the longitudinal length of one channel can be longer than the other channel wherein the longitudinal length being measured along the axis of extension of the first manifold.
In accordance with an embodiment of the present invention, the configuration of sinusoidal pattern of at least one channel can vary across the length of the channel.
Advantageously, the first set of apertures and the second set of apertures are aligned to each other.
In accordance with an embodiment of the present invention, the second set of apertures adapted to further distribute the heat exchange fluid percolated and distributed thereto from the first intermediate plate to the first set of apertures.
The heat exchanger further includes a second manifold disposed opposite to and spaced apart from the first manifold and in fluid communication with the first manifold by means of a first set of heat exchanger tubes and a second set of heat exchanger tubes disposed parallel to the first set of heat exchanger tubes. The second manifold comprises a second header comprising a first set of holes, a second cover adapted to be fixed to the header, a second distribution plate comprising a second set of holes corresponding to the first set of holes, and a second intermediate plate, wherein said second intermediate plate comprises at least two straight channels and the second distribution plate comprising multiple bypass communication channels.
Advantageously, at least one of the channels formed on the first intermediate plate terminates before the bypass communication channels configured on the second distribution plate proximal to distal end thereof.
Advantageously, the first set of holes and the second set of holes are aligned to each other.
Preferably, the second intermediate plate is disposed between the second distribution plate and the second cover.
In accordance with another embodiment of the present invention, the bypass communication channels can be configured at the center of the second distribution plate.
Advantageously, the bypass communication channels are separated by a second set of holes.
In accordance with another embodiment of the present invention, one or more bypass communication channels are configured in various locations across the length of the second distribution plate.
In accordance with another embodiment of the present invention, the bypass communication channels are configured in various patterns across the length of the second distribution plate.

BRIEF DESCRIPTION OF THE DRAWINGS

Other characteristics, details and advantages of the invention may 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 depicting a heat exchanger comprising a first manifold and a second manifold in accordance with an embodiment of the present invention.
FIG. 2 illustrates an exploded view depicting the heat exchanger of FIG. 1.
FIG. 3 shows a first intermediate plate and a second distribution plate of the heat exchanger according to an embodiment of the present invention.
FIG. 4 shows a second intermediate plate of the heat exchanger of FIG. 3.
FIG. 5 shows a first intermediate plate and a second distribution plate of the heat exchanger according to another embodiment of the present invention.
FIG. 6 shows a first intermediate plate and a second distribution plate of the heat exchanger according to yet another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

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.
FIG. 1 of the accompanying drawings illustrates an isometric view of a heat exchanger 100 in accordance with an embodiment of the present invention. The heat exchanger 100 includes a first manifold 10 for distribution and collection of a heat exchange fluid with respect to a heat exchanger core, wherein said first manifold is elongating along a longitudinal axis L1 and a second manifold 20 is disposed opposite to and spaced apart from the first manifold. The heat exchanger core 15 includes a plurality of heat exchanger tubes, wherein the first manifold 10 and the second manifold 20 are in fluid communication with each other by means of the heat exchanger core 15.
FIG. 2 illustrates an exploded view of the heat exchanger 100. The first manifold 10 comprises a first header 12 elongating along the axis L1 of elongation of the first manifold. The first header 12 comprising a first set of apertures 12a adapted to configure connection and fluid communication between the first manifold and a first set of parallel heat exchanger tubes 15a and a second set of parallel heat exchanger tubes 15b, wherein said second set of parallel heat exchanger tubes 15b disposed parallel to the first set of parallel heat exchanger tubes 15a. The first manifold 10 further comprising a first cover 18 adapted to be fixed to the first header 12, wherein the first header 12 may comprise a plurality of tabs which can be crimped to the first cover 18 in order to provide secure connection between the components before the brazing process. However, the present invention is not limited to any particular joining process for forming secure connection between the components and is not limited to brazing. In addition, the first manifold 10 incudes at least one first distribution plate 14 comprising a second set of apertures 14a corresponding to the first set of apertures 12a, and at least one first intermediate plate 16 adapted to receive heat exchange fluid thereon from an inlet 17. The at least one first distribution plate 14 and the at least one first intermediate plate 16 being disposed between the first header 12 and the first cover 18. Preferably, the first intermediate plate 16 is disposed between the first distribution plate 14 and the first cover 18. However, the present invention is not limited to any particular configuration and sequence of connections between the first header 12, the first distribution plate 14, the first intermediate plate 16 and the first cover 18.
In accordance with an embodiment of the present invention, the first set of apertures 12a and the second set of apertures 14a are aligned and compliment to each other. The second set of apertures 14a adapted to further distribute the heat exchange fluid percolated and distributed thereto from the first intermediate plate 16 to the first set of apertures 12a.
In accordance with another embodiment of the present invention, one of the second set of apertures 14a is large enough to cover two or more first set of apertures 12a arranged in series along the length of the first header 12.
In accordance with another embodiment of the present invention, the first distribution plate 14 includes three or more rows of second set of apertures. However, the present invention is not limited to any number of rows of second set of apertures 14a.
The second manifold as shown in FIG. 2 comprises a second header 22 comprising first set of holes 22a adapted to configure connection and fluid communication between the second header 22 and the first set of parallel heat exchanger tubes 15a and the second set of parallel heat exchanger tubes 15b disposed parallel to the first set of parallel heat exchanger tubes 15a. The second manifold 20 further comprises a second cover 28 adapted to be fixed to the second header 22, wherein the second header 22 may comprise a plurality of tabs which can be crimped to the second cover 28 in order to provide tight connection between the components before the brazing process. However, the present invention is not limited to any particular joining process for forming secure connection between the components and is not limited to brazing. In addition, the second manifold 20 comprises a second distribution plate 24 comprising a second set of holes 24a corresponding to the first set of holes 22a. The second distribution plate 24 further comprising multiple bypass communication channels 24b configured proximal to distal end of the second distribution plate 24. The bypass channels 24b configure fluid communication between the first set of tubes 15a and the second set of tubes 15b. Further, the second manifold 20 comprises at least one second intermediate plate 26, wherein said second intermediate plate 26 comprises at least two straight channels 26a, 26b. The at least one second distribution plate 24 and the at least one second intermediate plate 26 being disposed between the second header 22 and the second cover 28. Preferably, the second intermediate plate 26 is disposed between the second distribution plate 24 and the second cover 28. However, the present invention is not limited to any particular configuration and sequence of connections between the second header 22, the second distribution plate 24, the second intermediate plate 26 and the second cover 28.
In accordance with an embodiment of the present invention, the first set of holes 22a and the second set of holes 24a are aligned and compliment to each other.
FIG. 3 illustrates an exemplary embodiment of the first intermediate plate 16 and the second distribution plate 24 of the corresponding first manifold 10 and second manifold 20 of the present invention. In order to provide a homogeneous distribution of refrigerant fluid across the heat exchanger 100, the first intermediate plate 16 may comprise at least two channels 16a, 16b configured on the said first intermediate plate 16, wherein the channels may be asymmetrical to each other with respect to an axis "A" between the said channels 16a, 16b. More specifically, the longitudinal length of one channel 16b is longer than the other channel 16a, wherein the longitudinal length being measured along the axis of extension of the first manifold L1, and the channel 16a formed on the first intermediate plate terminates before the bypass communication channels 24b configured on the second distribution plate 24 proximal to distal end thereof. However, the present invention is not limited to any particular configuration for the channels 16a, 16b in the intermediate plate 16. The channel 16a, 16b may extend along the longitudinal length of the first intermediate plate 16, wherein longitudinal length of the first intermediate plate is parallel to the axis of elongation of the first manifold L1. In addition, at least a portion of at least one of the channels 16a, 16b follows a sinusoidal pattern, wherein the configuration of the sinusoidal pattern of channel 16a, 16b can vary across the longitudinal length of the channel. The term sinusoidal refers mainly to the zigzag shape or meandering shape with the geometrical properties of a sinusoid. In accordance with another embodiment, the asymmetry between the channels 16a and 16b with respect to the axis "A" may be virtue of different configurations of the channels 16a and 16b, particularly by virtue of different amplitude and frequency of the sinusoidal channels 16a and 16b. The sinusoidal configuration of the channel 16a and 16b slows the refrigerant flow there through to enhance refrigerant distribution to the corresponding the first set of tubes 15a, thereby ensuring uniform distribution of the refrigerant to the first set of tubes 15a of the heat exchanger core.
In accordance with an embodiment of the present invention, at least a portion of at least one of the channels 16a, 16b configured on the first intermediate plate 16 follows a straight pattern. The portion of the channel 16a, 16b with straight pattern can be configured between two portions of the channel 16a, 16b with sinusoidal pattern or the portion of the channel 16a, 16b with straight pattern can be configured at the extreme ends of the channels 16a, 16b. However, the present invention is not limited to any particular configuration or pattern for the channels 16a, 16b on the intermediate plate 16.
FIG. 4 illustrates another embodiment of the present invention in which the second intermediate plate 26 comprises at least two channels 26a, 26b, wherein the two channels 26a, 26b can be continuous or intermittent. Additionally one of the channel 26a, 26b may have to have an incorporated sinusoidal shape in any part of its length or a refrigerant flow constraints in a shape of cross sectional restriction or similar mechanical feature.
FIG. 5 shows another embodiment of the present invention in which the second distribution plate 24 comprises more number of bypass communication channels 24b, wherein the channel 16a formed in the first intermediate plate terminates before the said bypass communication channels 24b configured on the said second distribution plate 24. However, the present invention is not limited to any particular number of bypass communication channels 24b. The more number of the bypass communication channels 24b enhances the fluid communication between the corresponding the first set of tubes 15a and the second set of tubes 15b, thereby optimizing the fluid flow to the corresponding second set of the tubes 15b. Accordingly, with increase in the number of bypass communication channels 24b the refrigerant supply to the corresponding second set of tubes 15b is increased, thereby optimizing the refrigerant distribution of the heat exchanger core.
In accordance with another embodiment of the present invention shown in FIG. 6, in which one or more bypass communication channels 24b are configured in various locations across the length of the second distribution plate 24, wherein the bypass communication channels 24b are separated by one or more second set of holes 24a. In addition, the channels 16a, 16b configured in the first intermediate plate 16 extends across the length of the said first intermediate plate 16.
Advantageously, one or more bypass communication channels 24b are configured at the center of the second distribution plate 24. Advantageously, the bypass communication channels 24b are configured in various patterns across the length of the second distribution plate 24. However, the present invention is not limited to any particular configuration or pattern for the bypass communication channels 24b.

Claims

A first manifold 10 for distribution of a heat exchange fluid within a heat exchanger 100, said first manifold 10 comprises;
- a first header 12 extending along a longitudinal axis L1 of the first manifold 10, said first header 10 comprising a first set of apertures 12a adapted to configure connection and fluid communication between the first manifold 10 and a first set of parallel heat exchanger tubes 15a and a second set of parallel heat exchanger tubes 15b disposed parallel to the first set of heat exchange tubes 15a;

- a first cover 18 adapted to be fixed to the first header 12;

- at least one first distribution plate 14 comprising a second set of apertures 14a corresponding to the first set of apertures 12a;

- at least one first intermediate plate 16 adapted to receive heat exchange fluid thereon from an inlet 17; and

the at least one first distribution plate 14 and the at least one first intermediate plate 16 being disposed between the first header 12 and the first cover 18,

characterized in that the first intermediate plate 16 comprises at least two channels 16a, 16b, wherein the channels 16a, 16b are asymmetrical with respect to each other; and at least a portion of at least one of the channels 16a, 16b follows a sinusoidal pattern.
The first manifold 10 of claim 1, wherein the first intermediate plate 16 is disposed between the first distribution plate 14 and the first cover 18.
The first manifold 10 of claim 1, wherein at least a portion of at least one of the channels 16a, 16b configured on the first intermediate plate 16 follows a straight pattern.
The first manifold 10 according to any of the preceding claims, the longitudinal length of one channel 16b is longer than the other channel 16a, wherein the longitudinal length being measured along the axis L1 of extension of the first manifold 10.
The first manifold 10 according to any of the preceding claims, the sinusoidal configuration of channels 16a, 16b can vary across the length of the channel.
The first manifold 10 according to any of the preceding claims, wherein the first set of apertures 12a and the second set of apertures 14a are aligned to each other.
The manifold according to any of the preceding claims, wherein the second set of apertures 14a adapted to further distribute the heat exchange fluid percolated and distributed thereto from the first intermediate plate 16 to the first set of apertures 12a.
The heat exchanger comprising:
- a first manifold 10 as claimed in claim 1;

- a second manifold 20 disposed opposite to and spaced apart from the first manifold 10 and in fluid communication with the first manifold 10 by means of a first set of parallel heat exchanger tubes 15a and a second set of parallel heat exchanger tubes 15b disposed parallel to the first set of heat exchanger tubes 15a;

- the second manifold 20 comprises:
• a second header 22 comprising a first set of holes 22a;

• a second cover 28 adapted to be fixed to the second header 22;

• a second distribution plate 24 comprising a second set of holes 24a corresponding to the first set of holes 22a; and

• a second intermediate plate 26;

wherein, said second intermediate plate 26 comprises at least two straight channels 26a, 26b and the second distribution plate 24 comprising multiple bypass communication channels 24b configuring fluid communication between distal ends of the first and the second set of heat exchange tubes 15a and 15b.
The heat exchanger of claim 8, wherein at least one of the channels 16a, 16b formed on the first intermediate plate 16 terminates before the bypass communication channels 24b.
The heat exchanger of claim 8, wherein the first set of holes 22a and the second set of holes 24a are aligned to each other.
The heat exchanger of claim 8, wherein the second intermediate plate 26 is disposed between the second distribution plate 24 and the second cover 28.
The heat exchanger according to claim 8, the bypass communication channels 24b are configured at the center of the second distribution plate 24.
The heat exchanger according to claim 8, wherein the bypass communication channels 24b are separated by one or more second set of holes 24a.
The heat exchanger according to claim 8, wherein one or more bypass communication channels 24b configured in various locations across the length of the second distribution plate 24.
The heat exchanger according to claim 8, wherein the bypass communication channels 24b are configured in various patterns across the length of the second distribution plate 24.