Low profile, split flow charge air cooler with uniform flow exit manifold

Patent metadata

Field	Value
Publication number	US-9328968-B2
Application number	US-201213661422-A
Country	US
Kind code	B2
Filing date	Oct 26, 2012
Priority date	Oct 28, 2011
Publication date	May 3, 2016
Grant date	May 3, 2016

Abstract

A low profile, split flow charge air cooler with uniform flow exit manifold comprises a first heat exchanger core having a plurality of gas flow passages and a plurality of coolant flow passages arranged in alternating order. First and second gas outlet manifolds are in communication with the gas flow passages, and a gas inlet manifold is in communication with both the first and second gas outlet manifolds. The gas inlet manifold is located between the first and second gas outlet manifolds, such that the gas flows in two different directions from the inlet manifold toward the outlet manifolds. A gas outlet chamber receives the gas flows from the gas outlet manifolds and provides a space in which the gas flows are combined before being discharged from the heat exchanger.

First claim

What is claimed is:

1. A heat exchanger for cooling a gas with a coolant, the heat exchanger comprising:
a heat exchanger core having a central longitudinal axis, with a length defined along said central longitudinal axis, the heat exchanger core having a top and a bottom, and comprising a plurality of core plates joined together in a stack and defining a plurality of first gas flow passages and a plurality of first coolant flow passages, wherein the first gas flow passages and the first coolant flow passages are arranged in alternating order throughout the heat exchanger core, and wherein the core plates, the coolant flow passages and the gas flow passages extend along the length of the heat exchanger core, parallel to the central longitudinal axis;
a top plate located at the top of the heat exchanger core and extending along the length of the heat exchanger core, parallel to the central longitudinal axis;
a bottom plate located at the bottom of the heat exchanger core and extending along the length of the heat exchanger core, parallel to the central longitudinal axis;
a first gas outlet manifold and a second gas outlet manifold, at least one of which is in flow communication with the gas flow passages of the heat exchanger core, each of the outlet manifolds having a bottom which is open through an opening in the bottom plate and a top which is closed by the top plate;
a gas inlet manifold in flow communication with both the first and second gas outlet manifolds and being located upstream of the first and second gas outlet manifolds, the gas inlet manifold having a top which is open through one or more openings in the top plate, and the gas inlet manifold having a bottom which is closed by the bottom plate; and
a gas outlet chamber in flow communication with both the first and second gas outlet manifolds and being located downstream of the first and second gas outlet manifolds;
a gas outlet for discharging the gas from the heat exchanger;
wherein the gas inlet manifold is located between the first gas outlet manifold and the second gas outlet manifold, such that a first gas flow direction between the gas inlet manifold and the first gas outlet manifold differs from a second gas flow direction between the gas inlet manifold and the second gas outlet manifold; and
wherein the gas outlet chamber receives the gas flows from the first and second gas outlet manifolds and provides a space in which the gas flows from the first and second gas outlet manifolds are combined before being discharged from the heat exchanger;
wherein the gas inlet manifold extends along said central longitudinal axis and extends along substantially the entire length of the heat exchanger core;
wherein each of the first gas outlet manifold and the second gas outlet manifold is spaced away from said central longitudinal axis toward a generally axially-extending side of the heat exchanger core; and
wherein the first and second gas outlet manifolds each extend along one of the generally axially-extending sides of the heat exchanger core, and each of the first and second gas outlet manifolds extend along a greater part of the length of the heat exchanger core.

2. The heat exchanger according to claim 1 , wherein the first gas flow direction is at an angle of about 180 degrees relative to the second gas flow direction.

3. The heat exchanger according to claim 1 , wherein the gas inlet manifold is in flow communication with all of the gas flow passages of the heat exchanger core.

4. The heat exchanger according to claim 1 , wherein the inlet manifold and the first and second gas outlet manifolds are contained within the heat exchanger core, such that the heat exchanger core is self-enclosed.

5. The heat exchanger according to claim 1 , wherein each of the gas flow passages in the heat exchanger core is in flow communication with the gas inlet manifold and with both the first and second gas outlet manifolds.

6. The heat exchanger according to claim 1 , wherein each of the first and second gas outlet manifolds is in flow communication with each of the gas flow passages in the heat exchanger core.

7. The heat exchanger according to claim 1 , wherein the gas enters the gas inlet manifold through the top of the heat exchanger core, and the gas exits the first and second gas outlet manifolds through the bottom of the heat exchanger core; wherein the top and the bottom of the heat exchanger core are parallel to the gas flow passages; and wherein the gas outlet chamber is located along the bottom of the heat exchanger core.

8. The heat exchanger according to claim 7 , wherein a plate with a plurality of perforations is provided across the gas outlet.

9. The heat exchanger according to claim 8 , wherein the perforations are larger at a center of the gas outlet than at an outer edge of the gas outlet.

10. The heat exchanger according to claim 1 , wherein the heat exchanger further comprises a base plate for connection to a component which receives the gas from the heat exchanger, wherein the base plate has a top surface to which the heat exchanger core is mounted, and a central opening defining an outlet for the gas which is cooled in the heat exchanger, and wherein each of the gas outlet manifolds is in flow communication with the central opening of the base plate through one said opening of the bottom plate.

11. A heat exchanger for cooling a gas with a coolant, the heat exchanger comprising:
a heat exchanger core comprising a plurality of first gas flow passages and a plurality of first coolant flow passages, wherein the first gas flow passages and the first coolant flow passages are arranged in alternating order throughout the heat exchanger core;
a first gas outlet manifold and a second gas outlet manifold, at least one of which is in flow communication with the gas flow passages of the heat exchanger core;
a gas inlet manifold in flow communication with both the first and second gas outlet manifolds and being located upstream of the first and second gas outlet manifolds; and
a gas outlet chamber in flow communication with both the first and second gas outlet manifolds and being located downstream of the first and second gas outlet manifolds;
a gas outlet for discharging the gas from the heat exchanger;
wherein the gas inlet manifold is located between the first gas outlet manifold and the second gas outlet manifold, such that a first gas flow direction between the gas inlet manifold and the first gas outlet manifold differs from a second gas flow direction between the gas inlet manifold and the second gas outlet manifold; and
wherein the gas outlet chamber receives the gas flows from the first and second gas outlet manifolds and provides a space in which the gas flows from the first and second gas outlet manifolds are combined before being discharged from the heat exchanger;
wherein one or more of the gas flow passages or one or more of the coolant flow passages are provided with a turbulence-enhancing insert in the form of a fin or a turbulizer comprising a plurality of corrugations;
wherein, within said one or more gas flow passages, the corrugations of each insert extend along the gas flow direction between the gas inlet manifold and each of the gas outlet manifolds;
wherein the corrugations of said insert are interrupted in the vicinity of said gas inlet manifold so that the gas inlet manifold is left uncovered by said insert;
wherein gaps are provided between opposite ends of said gas inlet manifold and a peripheral edge of said gas flow passage, and wherein said insert includes at least one continuous corrugation extending continuously through each of said gaps, and said at least one continuous corrugation extends betwe

Assignees

• Dana Canada Corp

Inventors

• Vanderwees Doug

Classifications

• B60H1/143

  the heat being derived from cooling an electric component, e.g. electric motors, electric circuits, fuel cells or batteries · CPC title

• F28F9/0265

  by using guiding means or impingement means inside the header box · CPC title

• F28F2250/06

  Derivation channels, e.g. bypass · CPC title

• F28F9/0268

  in the form of multiple deflectors for channeling the heat exchange medium · CPC title

• F28F13/12

  by creating turbulence, e.g. by stirring, by increasing the force of circulation (F28F13/08 takes precedence) · CPC title