US20250207873A1

US20250207873A1 - Heat exchanger

Info

Publication number: US20250207873A1
Application number: US18/856,416
Authority: US
Inventors: Jin Gi Ban; Woo Jae Jeon; Ji Hun Han
Original assignee: Hanon Systems Corp
Current assignee: Hanon Systems Corp
Priority date: 2022-09-14
Filing date: 2023-04-10
Publication date: 2025-06-26
Also published as: DE112023001571T5; KR20240036850A; WO2024058330A1

Abstract

The present invention relates to a heat exchanger including a header including a tube joining part having a tube insertion hole into which a tube is inserted, in which the tube joining part is formed in a concave-convex shape to increase a contact area (joint area) between the heat exchange medium tube and the tube joining part, thereby reducing thermal stress to be applied to the tube and the tube joining part.

Description

TECHNICAL FIELD

The present invention relates to a heat exchanger in which a plurality of heat exchange parts are integrated.

BACKGROUND ART

In general, a heat exchanger refers to a device installed in a particular flow path and configured to perform heat exchange by allowing a heat exchange medium, which circulates in the flow path, to absorb heat of outside air or dissipate heat from the heat exchange medium.
The heat exchangers are variously manufactured depending on purpose of use and the use thereof, such as condensers and evaporators that use refrigerants as heat exchange media, radiators and heater cores that use coolants as heat exchange media, and oil coolers that use oil as heat exchange media to cool oil flowing in an engine, a transmission, or the like.
Further, recently, with the increasing global interest in the worldwide environment and energy in vehicle industries, research has been conducted to improve fuel economy, and research has been continuously conducted to reduce the weight and size and improve the functionality in order to meet the needs of various consumers.
However, in case that a plurality of heat exchangers for a vehicle is separately manufactured and installed, the number of manufacturing processes increases, which degrades productivity. Further, a significantly large number of materials are wasted, which increases costs and makes it difficult to ensure a space in which the heat exchangers are mounted. Therefore, various technologies for integrating a plurality of heat exchangers have been developed and used to solve the above-mentioned problems.
FIGS. 1 and 2 are perspective views illustrating a header tank and a header for an integrated heat exchanger in the related art.
As illustrated, the header tank of the integrated heat exchanger in the related art broadly includes a tank 10, a header 20, and a gasket 30. The header 20 and the tank 10 may be coupled and tightly attached to each other in a state in which the gasket 30 is interposed between the header 20 and the tank 10. Further, a baffle 11 is integrated with the tank 10, and a bridge 32 is connected to a central portion of a peripheral portion 31 of the gasket 30. The header 20 has a seating portion 21 on which the gasket 30 is seated. A dummy tube insertion hole 22 is formed in the central portion of the gasket 30, and a dummy tube for blocking heat is inserted into the dummy tube insertion hole 22. Tube insertion holes 23 are formed at two opposite sides of the central portion, and heat exchange medium tubes are inserted into the tube insertion holes 23.
However, in the header tank for the integrated heat exchanger in the related art, a distance between a coupling portion, where the header and the tank are coupled, to an end of the heat exchange medium tube is relatively short, which causes high stress applied to a portion where the heat exchange medium tube and the header are joined. For this reason, a joint portion between the heat exchange medium tube and the header may crack, which may cause a leak of a coolant that results in degrading the life expectancy of the heat exchanger.

DOCUMENT OF RELATED ART

Patent Document

- KR 10-2019-0033710 A (Apr. 1, 2019)

DISCLOSURE

Technical Problem

The present invention has been made in an effort to solve the above-mentioned problem, and an object of the present invention is to provide a heat exchanger capable of reducing thermal stress to be applied to a tube in the heat exchanger in which a plurality of heat exchange parts are integrated.

Technical Solution

In order to achieve the above-mentioned object, a heat exchanger of the present invention may include: a header including base portions, a plurality of tube contact portions having tube insertion holes formed through the base portions, the plurality of tube contact portions protruding toward a tank from peripheries of the tube insertion holes and arranged to be spaced apart from one another in a longitudinal direction, and concave portions provided in at least some of the plurality of tube contact portions, formed at two opposite ends based on a width direction, and formed concavely in a direction opposite to a direction in which the tube contact portions protrude; the tank coupled to the header and configured to define a space in which a heat exchange medium is stored and flows; and a plurality of heat exchange medium tubes inserted into the tube insertion hole of the header and coupled to the tube contact portions.
In addition, grooves may be formed between the adjacent tube contact portions, and recessed portions, which are concave in the same direction as the concave portions, may be positioned in at least some of the grooves.
In addition, the recessed portion may further protrude in a direction opposite to the tank than the remaining portion of the groove other than the recessed portion.
In addition, a width of the recessed portion and a width of the concave portion may be defined at the same level.
In addition, a recessed depth of the recessed portion and a recessed depth of the concave portion may be defined at the same level.
In addition, the recessed portion and the concave portion may be formed simultaneously.
In addition, straight portions, which have flat upper surfaces, may be formed at two opposite ends of the tube contact portion based on the width direction, and the concave portion may be disposed between the straight portions formed at the two opposite ends.
In addition, a protruding height of the straight portion may be larger than a protruding height of the concave portion.
In addition, the concave portion and the straight portions at the two opposite ends of the tube contact portion based on the width direction may be inclinedly connected.
In addition, no straight portion, which has a flat upper surface, may be provided at two opposite ends of the tube contact portion based on the width direction, and the two opposite ends of the tube contact portion based on the width direction and the concave portion may be inclinedly connected.
In addition, the base portions may be present outside the tube contact portions positioned at the two opposite ends based on the longitudinal direction without a groove and a concave portion.
In addition, the header may further include dummy tube contact portions having dummy tube insertion holes formed through the base portions, the dummy tube contact portions protruding toward the tank from peripheries of the dummy tube insertion holes, and the dummy tube contact portion and two opposite sides based on the longitudinal direction adjacent to the dummy tube contact portion may be formed to be inclined downward from a central portion both the width direction toward two opposite ends.
In addition, the two opposite ends of the dummy tube contact portion based on the width direction may have a smaller protruding height than the central portion.
In addition, the plurality of tube contact portions may each be disposed at the two opposite sides of each of the base portions based on the longitudinal direction, and the dummy tube contact portion may be disposed between the two opposite sides based on the longitudinal direction.
In addition, the header may have gasket seating grooves formed concavely downward along peripheries of the base portions, tank coupling portions may be formed along outer rims of the gasket seating grooves, the heat exchanger may further include a gasket having peripheral portions inserted into the gasket seating grooves of the header, the gasket including a pair of bridges configured to connect the peripheral portions in the width direction and disposed adjacent to the dummy tube contact portion of the header, a lower end of the tank may be inserted into the gasket seating groove of the header and coupled to the tank coupling portion of the header, a pair of baffles may be integrally formed in the tank, and the baffles may be tightly attached and coupled to the bridges.
In addition, the heat exchanger may further include: dummy tubes inserted into the dummy tube insertion holes of the header and coupled to the dummy tube contact portions; and heat radiating fins interposed between the plurality of heat exchange medium tubes.

Advantageous Effects

According to the heat exchanger of the present invention, the joint area between the header and the tube increases, which may reduce stress applied to the tube by heat, impact, and the like.
Therefore, it is possible to reduce a likelihood of the occurrence of a leak caused by a crack in the joint portion between the header and the tube and increase a lifespan of the heat exchanger.

DESCRIPTION OF DRAWINGS

FIGS. 1 and 2 are perspective views illustrating a header tank and a header for an integrated heat exchanger in the related art.

FIGS. 3 and 4 are perspective views illustrating a header of a heat exchanger according to a first embodiment of the present invention.

FIG. 5 is a top plan upper side view illustrating the header of the heat exchanger according to the first embodiment of the present invention.

FIGS. 6 to 9 are cross-sectional views illustrating cross-sections taken along lines AA′, BB′, and CC′ in FIG. 5 .

FIG. 10 is a perspective view illustrating a header of a heat exchanger according to a second embodiment of the present invention.

FIG. 11 is a top plan upper side view illustrating the header of the heat exchanger according to the second embodiment of the present invention.

FIGS. 12 and 13 are cross-sectional views illustrating cross-sections taken along lines DD′ and EE′ in FIG. 11 .

FIGS. 14 and 15 are an exploded perspective view and an assembled perspective view illustrating the heat exchanger according to the embodiment of the present invention.

BEST MODE

Hereinafter, a heat exchanger of the present invention configured as described above will be described in detail with reference to the accompanying drawings.
FIGS. 3 to 5 are perspective views and a top plan upper side view illustrating a header of a heat exchanger according to a first embodiment of the present invention, and FIGS. 6 to 9 are cross-sectional views illustrating cross-sections taken along lines AA′, BB′, and CC′ in FIG. 5 .
As illustrated, a header 110 of a heat exchanger according to an embodiment of the present invention may broadly include base portions 110-1, tube contact portions 113 having tube insertion holes 112, and concave portions 113-1 and further include gasket seating grooves 111 and tank coupling portions 111-1.
First, the header 110 may be integrally formed by plastically deforming one sheet of metal board by using a press. Further, an approximate shape of the header 110 may be a rectangular shape having a length relatively larger than a width.
The base portion 110-1 is a portion that serves as a criterion. The tube contact portion 113 may protrude toward a tank, i.e., an upper side based on the base portion 110-1, and a groove 115 may be concavely formed toward a lower side, i.e., in a direction opposite to a direction in which the tube contact portion 113 protrudes. That is, the base portion 110-1 may be a portion where the tube contact portion 113 and the groove 115 meet together. Further, as illustrated, the base portion 110-1 may be formed as a very fine portion. The base portion 110-1 may not be almost present or may be formed to have a relatively large area in accordance with a size of the header 110, an interval between the tube contact portions 113, or the like.
The gasket seating groove 111 is a portion into which a gasket to be described below is inserted or seated. The gasket seating groove 111 may be formed to concavely downward along an entire periphery of the base portion 110-1. Further, the gasket seating groove 111 may be formed further concavely downward than the groove 115.
The tank coupling portion 111-1 is a portion of the header 110 to which a tank 130 may be fixedly coupled. The tank coupling portion 111-1 may be formed along an outer rim of the gasket seating groove 111. For example, the tank coupling portion 111-1 may protrude upward from an upper end of the outer rim of the gasket seating groove 111. The plurality of tank coupling portions 111-1 may be arranged to be spaced apart from one another along the entire outer rim of the gasket seating groove 111.
A heat exchange medium tube, in which a heat exchange medium flows, is inserted into the tube contact portion 113 and joined to the tube contact portion 113 by brazing. The tube contact portion 113 is a portion that connects the header 110 and the heat exchange medium tube. The tube insertion hole 112 may be formed in the tube contact portion 113, and the heat exchange medium tube may be inserted into the tube insertion hole 112. Further, the tube contact portion 113 may be formed in a shape protruding upward from a periphery of the tube insertion hole 112. In addition, the tube contact portions 113 may be provided as a plurality of tube contact portions 113, and the plurality of tube contact portions 113 may be arranged to be spaced apart from one another in the longitudinal direction.
The concave portion 113-1 may be formed between two opposite ends of the tube contact portion 113 based on a width direction. The concave portion 113-1 may be formed concavely downward from an upper end of the tube contact portion 113.
Therefore, a contact area (joint area) between the tube contact portion of the header and the heat exchange medium tube increases, which may reduce stress applied to the tube by heat, impact, and the like. Therefore, it is possible to reduce a likelihood of the occurrence of a leak caused by a crack in the joint portion between the header and the tube and increase a lifespan of the heat exchanger.
In addition, the groove 115 is formed concavely downward based on the base portion 110-1 and provided between the adjacent tube contact portions 113. A recessed portion 115-1, which is concave downward while corresponding to the concave portion 113-1 formed in the tube contact portion 113, may be formed in the groove 115. Therefore, the concave portion 113-1 may be formed to have a relatively large depth, which may further increase the contact area between the tube contact portion 113 and the heat exchange medium tube. Further, the occurrence of a rapid curved surface may be reduced, which makes it advantageous to uniformly maintain a thickness of a material according to a shape during press-forming. In addition, horizontal portions 115-2, which have bottom surfaces parallel to the width direction, may be formed at two opposite ends of the groove 115 based on the width direction. The recessed portion 115-1 may be formed between the horizontal portions 115-2.
In addition, straight portions 113-2, which have flat upper surfaces, may be formed at two opposite ends of the tube contact portion 113 based on the width direction. The concave portion 113-1 may be formed between the straight portions 113-2. Further, the straight portion 113-2 and the concave portion 113-1 may be inclinedly connected. That is, the straight portion 113-2 and the concave portion 113-1 may be connected in a shape inclined downward from the straight portions 113-2 at the two opposite sides based on the width direction toward the concave portion 113-1 at the center. Therefore, it is possible to further increase the contact area between the tube contact portion 113 and the heat exchange medium tube.
In addition, the straight portions 113-2 at the two opposite ends of the tube contact portion 113 based on the width direction may be disposed adjacent to the gasket seating grooves 111. Therefore, the straight portion 113-2, which has a relatively large joint area with the heat exchange medium tube, may be positioned at an edge of the header 110 at which impact caused by heat or vibration is high, thereby reducing stress.
FIGS. 10 and 11 are a perspective view and a top plan upper side view illustrating a header of a heat exchanger according to a second embodiment of the present invention, and FIGS. 12 and 13 are cross-sectional views illustrating cross-sections taken along lines DD′ and EE′ in FIG. 11 .
As illustrated, the two opposite ends of the tube contact portion 113 based on the width direction may be formed to be spaced apart inward from the gasket seating groove 111 in the width direction. That is, the two opposite ends of the tube contact portion 113 based on the width direction do not have straight portions having flat upper surfaces. The two opposite ends of the tube contact portion 113 based on the width direction may be immediately inclined connected to the concave portion 113-1. Therefore, the tube contact portion 113 is disposed at a position spaced apart from the edge of the header 110 at which impact caused by heat or vibration is high, thereby reducing stress.
In addition, with reference to FIG. 9 , in both the first and second embodiments of the present invention, the base portions 110-1 may be present outside the tube contact portions 113 positioned at the two opposite ends of the header 110 based on the longitudinal direction without a groove and a concave portion. Therefore, it is possible to prevent the gasket from being crushed while being withdrawn at the time of inserting the gasket into the gasket seating groove 111 of the header 110 and coupling the tank 130.
Further, the header 110 for the heat exchanger of the present invention may further include dummy tube contact portions 117. A dummy tube insertion hole 116 may be formed in the dummy tube contact portion 117, and a dummy tube may be inserted into the dummy tube insertion hole. Further, the dummy tube contact portion 117 may be formed in a shape protruding upward from a periphery of the dummy tube insertion hole 116. In addition, the dummy tube contact portions 117 may be provided as a plurality of dummy tube contact portions 117, and the plurality of dummy tube contact portions 117 may be arranged to be spaced apart from one another in the longitudinal direction. In addition, the tube contact portions 113 may be disposed at the two opposite sides of the header 110 based on the longitudinal direction, and the dummy tube contact portion 117 may be disposed between the tube contact portions 113. In addition, portions between the dummy tube contact portions 117, i.e., portions between the dummy tube contact portion 117 and two opposite sides based on the longitudinal direction adjacent to the dummy tube contact portion 117 may be formed to be inclined downward from the central portion based on the width direction toward the two opposite ends based on the width direction. Further, the two opposite ends based on the width direction of the two opposite sides based on the longitudinal direction adjacent to the dummy tube contact portion 117 may be inclinedly connected to the bottom surface of the gasket seating groove 111.
Therefore, it is possible to reduce thermal stress applied to joint portions between the header 110 and the tubes by means of a complex structure of a region in which the tube contact portions 113 are formed and a region in which the dummy tube contact portions 117 are formed.
FIGS. 14 and 15 are an exploded perspective view and an assembled perspective view illustrating the heat exchanger according to the embodiment of the present invention.
As illustrated, the header tank 100, which constitutes the heat exchanger of the present invention, may include the header 110, a gasket 120, and the tank 130 having baffles 140.
The gasket 120 may include a peripheral portion 121 and a pair of bridges 122. An overall shape of the peripheral portion 121 may correspond to the gasket seating groove 111 of the header 110. A cross-section of the peripheral portion 121 may be formed in a circular shape. Further, the pair of bridges 122 may connect the peripheral portions 121 in the width direction. The pair of bridges 122 may be formed in shapes that may be disposed at two opposite sides with the dummy tube contact portion 117 interposed therebetween. In addition, the pair of bridges 122 may each be formed in a flat band shape.
The tank 130 is a part coupled to the header 110 and configured to define a space in which the heat exchange medium is stored and flows. The tank 130 may be formed in a shape as if a container is turned upside down, and a foot portion 131 may protrude from a rim portion, i.e., a lower end of the tank 130. The gasket seating groove 111 of the header 110 is inserted into the foot portion 131. The tank 130 may be fixedly coupled to the header 110 by pushing and bending the tank coupling portion 111-1 of the header 110 toward the foot portion 131 in the state in which the peripheral portion 121 of the gasket 120 is interposed between the foot portion 131 and the gasket seating groove 111. Further, the pair of baffles 140 may be integrated with the tank 130, and the baffle 140 may be formed at a position corresponding to the bridge 122. In addition, the bridge 122 may be pushed and tightly attached between the baffle 140 and the header 110 when the tank 130 is coupled after the gasket 120 is assembled to the header 110.
Therefore, the header tank 100 of the heat exchanger according to the embodiment of the present invention may allow the heat exchange media to flow to the two opposite sides of the pair of baffles 140 based on the longitudinal direction without being mixed together. Further, because no heat exchange medium is present in the space between the pair of baffles 140, the space between the pair of baffles 140 may serve to block heat between the two opposite sides.
In addition, a heat exchanger 1000 of the present invention may broadly include the pair of header tanks 100, the plurality of heat exchange medium tubes 200, dummy tubes 300, and a plurality of heat radiating fins 400.
The header tanks 100 may define flow paths in which the heat exchange medium flows. The header tanks 100 may be disposed in parallel and spaced apart from one another at predetermined distances. Further, the tank of the header tank 100 may have an inlet pipe through which the heat exchange medium is introduced, and an outlet pipe through which the heat exchange medium is discharged.
The heat exchange medium tube 200 defines a heat exchange medium flow path as two opposite ends of the heat exchange medium tube 200 are inserted into the tube insertion holes 112, which are formed in the header 110 of the header tank 100, and then fixed by brazing or the like. The heat exchange medium tube 200 is a portion where the heat exchange medium performs heat exchange while passing through the heat exchange medium tube 200.
The two opposite ends of the dummy tube 300 may be inserted into the dummy tube insertion holes 116, which are formed in the header 110 of the header tank 100, and then fixed by brazing or the like. Further, the dummy tube 300 may have a shape having two closed opposite ends, and no heat exchange medium may flow in the dummy tube 300.
The heat radiating fins 400 may be interposed between the heat exchange medium tubes 200 and coupled by brazing or the like. The heat radiating fins 400 may serve to increase heat dissipation areas, thereby improving the heat exchange efficiency. Further, the heat radiating fins 400 may be interposed between the dummy tubes 300. The heat radiating fins 400 may be interposed between the dummy tube 300 and the heat exchange medium tube 200.
Therefore, in the heat exchanger of the present invention, based on the baffle 140 and the dummy tube 300, a first heat exchange part 1000-1 may be provided at one side based on the longitudinal direction, and a second heat exchange part 1000-2 may be provided at the other side. Further, the first heat exchange part 1000-1 and the second heat exchange part 1000-2 may respectively have inlet pipes and outlet pipes, such that different heat exchange media may flow in the first heat exchange part 1000-1 and the second heat exchange part 1000-2, or heat exchange media with different temperatures may flow in the first heat exchange part 1000-1 and the second heat exchange part 1000-2.
The present invention is not limited to the above embodiments, and the scope of application is diverse. Of course, various modifications and implementations made by any person skilled in the art to which the present invention pertains without departing from the subject matter of the present invention claimed in the claims.

DESCRIPTION OF REFERENCE NUMERALS

- 1000: Heat exchanger, 1000-1: First heat exchange part, 1000-2: Second heat exchange part,
- 100: Header tank, 110: Header, 110-1: Base portion,
- 111: Gasket seating groove, 111-1: Tank coupling portion, 112: Tube insertion hole,
- 113: Tube contact portion, 113-1: Concave portion, 113-2: Straight portion,
- 115: Groove, 115-1: Recessed portion, 115-2: Horizontal portion,
- 116: Dummy tube insertion hole, 117: Dummy tube contact portion,
- 120: Gasket, 121: Peripheral portion, 122: Bridge,
- 130: Tank, 131: Foot portion, 140: Baffle,
- 200: Heat exchange medium tube, 300: Dummy tube, 400: Heat radiating fin.

Claims

1. A heat exchanger comprising:

a header comprising base portions, a plurality of tube contact portions having tube insertion holes formed through the base portions, the plurality of tube contact portions protruding toward a tank from peripheries of the tube insertion holes and arranged to be spaced apart from one another in a longitudinal direction, and concave portions provided in at least some of the plurality of tube contact portions, formed at two opposite ends based on a width direction, and formed concavely in a direction opposite to a direction in which the tube contact portions protrude;

the tank coupled to the header and configured to define a space in which a heat exchange medium is stored and flows; and

a plurality of heat exchange medium tubes inserted into the tube insertion hole of the header and coupled to the tube contact portions.

2. The heat exchanger of claim 1, wherein grooves are formed between the adjacent tube contact portions, and recessed portions, which are concave in the same direction as the concave portions, are positioned in at least some of the grooves.

3. The heat exchanger of claim 2, wherein the recessed portion further protrudes in a direction opposite to the tank than the remaining portion of the groove other than the recessed portion.

4. The heat exchanger of claim 2, wherein a width of the recessed portion and a width of the concave portion are defined at the same level.

5. The heat exchanger of claim 2, wherein a recessed depth of the recessed portion and a recessed depth of the concave portion are defined at the same level.

6. The heat exchanger of claim 2, wherein the recessed portion and the concave portion are formed simultaneously.

7. The heat exchanger of claim 1, wherein straight portions, which have flat upper surfaces, are formed at two opposite ends of the tube contact portion based on the width direction, and the concave portion is disposed between the straight portions formed at the two opposite ends.

8. The heat exchanger of claim 7, wherein a protruding height of the straight portion is larger than a protruding height of the concave portion.

9. The heat exchanger of claim 7, wherein the concave portion and the straight portions at the two opposite ends of the tube contact portion based on the width direction are inclinedly connected.

10. The heat exchanger of claim 1, wherein no straight portion, which has a flat upper surface, is provided at two opposite ends of the tube contact portion based on the width direction, and the two opposite ends of the tube contact portion based on the width direction and the concave portion are inclinedly connected.

11. The heat exchanger of claim 1, wherein the base portions are present outside the tube contact portions positioned at the two opposite ends based on the longitudinal direction without a groove and a concave portion.

12. The heat exchanger of claim 1, wherein the header further comprises dummy tube contact portions having dummy tube insertion holes formed through the base portions, the dummy tube contact portions protruding toward the tank from peripheries of the dummy tube insertion holes, and

wherein the dummy tube contact portion and two opposite sides based on the longitudinal direction adjacent to the dummy tube contact portion are formed to be inclined downward from a central portion both the width direction toward two opposite ends.

13. The heat exchanger of claim 12, wherein the two opposite ends of the dummy tube contact portion based on the width direction have a smaller protruding height than the central portion.

14. The heat exchanger of claim 12, wherein the plurality of tube contact portions are each disposed at the two opposite sides of each of the base portions based on the longitudinal direction, and the dummy tube contact portion is disposed between the two opposite sides based on the longitudinal direction.

15. The heat exchanger of claim 12, wherein the header has gasket seating grooves formed concavely downward along peripheries of the base portions,

wherein tank coupling portions are formed along outer rims of the gasket seating grooves,

wherein the heat exchanger further comprises a gasket having peripheral portions inserted into the gasket seating grooves of the header, the gasket comprising a pair of bridges configured to connect the peripheral portions in the width direction and disposed adjacent to the dummy tube contact portion of the header,

wherein a lower end of the tank is inserted into the gasket seating groove of the header and coupled to the tank coupling portion of the header, and

wherein a pair of baffles is integrally formed in the tank, and the baffles are tightly attached and coupled to the bridges.

16. The heat exchanger of claim 15, further comprising:

dummy tubes inserted into the dummy tube insertion holes of the header and coupled to the dummy tube contact portions; and

heat radiating fins interposed between the plurality of heat exchange medium tubes.