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(11) | EP 4 317 882 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | A HEAT EXCHANGER |
| (57) A heat exchanger (100) for a motor vehicle includes at least one first manifold (10a,
10b), a first set of tubes (20), at least one second manifold (40a, 40b) and a second
set of tubes (50). The at least one first manifold (10a, 10b) is for circulation of
a first fluid within the first set of tubes (20) to define at least a portion of a
first fluid circuit. The at least one second manifold (40a, 40b) is for circulation
of a second fluid within the second set of tubes (50) to define at least a portion
of a second fluid circuit. At least one second tube (50) includes a plurality of micro-channels
(52) formed by at least one of extrusion and folding is received inside the first
tube (20). The annular space between the first and second tubes (20) and (50) defines
fluid flow passage for the first fluid.
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FIELD OF THE INVENTON
[0001] The present invention relates to a heat exchanger. More specifically, the present invention relates to a heat exchanger for a motor vehicle.
BACKGROUND OF THE INVENTION
[0002] Generally, a vehicle may include several heat exchangers for example, a radiator and a condenser, a charge air cooler, etc. The condenser is a part of an air-conditioning loop, whereas the radiator is part of a drive cooling loop that can be at least one of engine cooling loop or battery/ motor cooling loop depending upon whether the vehicle is any one of internal combustion engine driven vehicle hybrid vehicle and electric vehicle. The radiator and condenser are both disposed at front of a vehicle to be impinged by ram air acting as cooling fluid, the operating heat exchange fluids flowing through the radiator and the condenser undergo heat exchange with the cooling air flowing there across, as the vehicle traverses. More specifically, coolant flowing through the radiator rejects heat picked up from an engine to the environment, particularly, air flowing across the radiator. The refrigerant flowing through the condenser rejects heat to the outside air, particularly, ram air for causing the phase change of the refrigerant from vapor to liquid state. The inlet temperature of the coolant entering the Low temperature radiator is maximum 70 degree Celsius and has coolant flow rate is maximum 1500l/h. The outlet temperature of the coolant egressing the radiator is in the range of 40-60 degree Celsius. The inlet temperature of refrigerant entering the condenser is maximum 140 degree Celsius and the outlet temperature of the refrigerant is 80 -110 degree Celsius.
[0003] Generally, the radiator 1 and the condenser 2 are disposed overlapping with respect to one other in the direction of the ram air, as illustrated in FIG. 1. Generally, the radiator 1 is disposed downstream of the condenser 2 in the direction of ram air. With such arrangement of the radiator 1 and the condenser 2, the air reaches the radiator 1 after picking heat rejected by the condenser 2 as such the air reaching the radiator 1 is at elevated temperature than the ambient air. Accordingly, the heat rejecting performance of the radiator 1 is substantially reduced. Inefficient performance of the radiator can have serious implications on the drive cooled by the radiator and in worst circumstances can cause seizure or mechanical failure of drive due to over-heating thereof. Similarly, in case the condenser is disposed downstream of the radiator in the direction of ram air, the air reaches the condenser after picking heat rejected by the radiator and the air reaching the condenser is at elevated temperature than the ambient air. Accordingly, the efficiency and performance of the condenser is substantially reduced.
[0004] In case the condenser is a water-cooled condenser, the coolant, i.e. water is received from the radiator after the coolant had extracted heat from the radiator. Accordingly, the temperature of the coolant received in the condenser is insufficient to cool the refrigerant. Accordingly, the efficiency and performance of the condenser is reduced. None of the prior art heat exchangers that function as multiple heat exchangers with at least one heat exchanger being condenser defines condensing and sub-cooling passes that are in fluid communication with each other via a receiver drier.
[0005] Further, the radiator and the condenser are required to be disposed sufficiently spaced apart to achieve sufficient and proper air-flow there across. Such an overlapping arrangement of the radiator and the condenser occupies more space thereby resulting in packaging issues.
[0006] Accordingly, there is a need for a heat exchanger called, for example, a hybrid heat exchanger that combines functions of two heat exchangers in one heat exchanger, thereby addressing the packaging issues, reduces overall weight and the vehicle on which such heat exchanger is mounted exhibits improved performance. Also, there is a need for a heat exchanger that combines function of two or more heat exchanger in one, wherein at least one of the heat exchanger is a condenser that includes a condensing and sub-cooling passes in fluid communication with each other via a receiver drier. Further, there is a need for a hybrid heat exchanger that obviates the disadvantages caused by overlapping configuration of the radiator and condenser. More specifically, there is a need for a hybrid heat exchanger that prevents the problems arising due to obstructed air flow to one of radiator and condenser by the other, packaging issues and the downstream radiator or condenser receiving air at elevated temperature due to air being pre-heated by the other radiator or condenser disposed upstream thereof.
[0007] An object of the present invention is to provide a heat exchanger that combines functions of two heat exchangers in one heat exchanger, thereby addressing packaging issues and reliability issues.
[0008] Yet another object of the present invention is to provide a heat exchanger that prevents problems of reduced efficiency and performance of one of the heat exchanger due to obstructed air-flow there through faced in conventional heat exchangers.
[0009] Still another object of the present invention is to provide a heat exchanger that functions as multiple heat exchangers with at least one heat exchanger being condenser defining condensing and sub-cooling passes that are in fluid communication with each other via a receiver drier.
[0010] 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
[0011] A heat exchanger for a motor vehicle is disclosed in accordance with an embodiment of the present invention. The heat exchanger includes at least one first manifold, a first set of tubes, at least one second manifold and a second set of tubes. The at least one first manifold is for circulation of a first fluid within the first set of tubes to define at least a portion of a first fluid circuit. Similarly, the at least one second manifold is for circulation of a second fluid within the second set of tubes to define at least a portion of a second fluid circuit. At least one second tube includes a plurality of micro-channels formed by at least one of extrusion and folding is received inside the first tube. The micro-channels define fluid flow passage for the second fluid. The annular space between the first tube and the second tube defines fluid flow passage for the first fluid.
[0013] Particularly, the second tube is comparatively longer than the corresponding first tube, passes through the first manifold and is in fluid communication with the second manifold disposed after the first manifold.
[0014] Generally, the first tube and the second tube includes at least one of dimples and protrusions respectively formed thereon.
[0015] Particularly, the first tube includes dimples formed on opposite sides thereof that protrudes inwardly into interior of the first tube for securely holding the corresponding second tube inside the first tube.
[0016] Specifically, the dimples formed on opposite sides of the first tube are of same size to coaxially hold the second tube within the first tube.
[0017] Alternatively, the dimples formed on opposite sides of the first tube are of different dimensions to eccentrically hold the second tube within the first tube.
[0019] Further, the first manifold and the second manifold is formed by assembling a first header, a second header and a cover.
[0020] Particularly, the first header includes first apertures to receive the first tubes that configure fluid communication between the spaced apart first manifolds.
[0021] Similarly, the second header includes second apertures to receive the second tubes that configure fluid communication between the spaced apart second manifolds.
[0022] Generally, the first header and the cover are assembled to each other with the corresponding second header received in either one of the first header and the cover to define the first manifold and the corresponding second manifold.
[0023] Particularly, the second header is received in an open end of the first header, the first header along with second header is received in a first opening of the corresponding cover to define the first manifold and the second manifold.
[0024] In accordance with an embodiment of the present invention, at least one of the first fluid and the second fluid is a coolant.
[0025] Particularly, the first fluid circuit is for coolant flow with a radiator being part of the first fluid circuit, whereas the second fluid circuit is for refrigerant flow with a condenser being part of the second fluid circuit.
[0026] Further, the heat exchanger includes a first inlet, a first outlet, a second inlet and a second outlet. The first inlet and the first outlet are either configured on the same first manifold or on different first manifolds. The second inlet and the second outlet configured on the same second manifold but reverse to the first inlet and first outlet configures U-flow of the second fluid through the second set of tubes and configures counter flow between first fluid flowing through the first tubes and second fluid flowing through the second tubes. Some tubes of the second tubes define a first pass that is a condensing pass while the remaining tubes of the second tubes define a return pass that is the sub-cooling pass.
[0027] Generally, the condensing pass is in fluid communication with the sub-cooling pass via a receiver drier disposed along and in fluid communication with the second manifold opposite to the second manifold on which the second inlet and second outlet are formed.
[0028] Particularly, the receiver drier includes a first hole and a second hole. The receiver drier receives condensed second fluid from the condensing pass defined by few of the second heat exchange tubes through the first hole to remove incompressible moisture and debris therefrom and delivers the condensed second fluid substantially free of debris and incompressible moisture to the sub-cooling pass defined by the remaining of the second heat exchange tubes through the second opening.
[0029] Generally, the heat exchanger of the present invention can be incorporated in any cooling loop configured in a vehicle, wherein the heat exchanger functioning as radiator supplies coolant to any of the vehicle heat exchangers to extract heat from any of the heat-generating components in the vehicle.
[0030] Particularly, the vehicle heat exchangers can be any one of radiator, water charged air cooler, chiller and the heat-generating means can be any one of engine, e-motor and battery in a vehicle that is either one of internal-combustion engine driven, electric motor driven or any hybrid vehicle.
BRIEF DESCRITPTION OF DRAWINGS
[0031] 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 a conventional arrangement of a first heat exchanger and a second heat exchanger arranged in overlapping manner with respect to each other;
FIG. 2 illustrates an isometric view of a heat exchanger in accordance with an embodiment of the present invention;
FIG. 3 illustrates an exploded view of the heat exchanger of FIG. 2;
FIG. 4 illustrates a side sectional view depicting internal details of a first manifold and a second manifold of the heat exchanger of FIG. 2;
FIG. 5 illustrates a tube in tube configuration, wherein a second tube that includes a plurality of micro-channels is received and held inside a first tube;
FIG. 6 illustrates an isometric sectional view of the second manifold of FIG. 4 without a cover for depicting internal details thereof;
FIG. 7 illustrates an isometric sectional view of the first manifold of FIG. 6 without a second header for depicting internal details thereof;
FIG. 8 illustrates an isometric view of a first tube of a first set of tubes with dimples formed thereon, also are depicted enlarged views of the end portions of the first tube;
FIG. 9 illustrates an isometric sectional view of the first tube of FIG. 8 depicting internal details thereof, also is depicted an enlarged view depicting the dimple protruding into interior of the first tube;
FIG. 10 illustrates an isometric view depicting tube in tube arrangement of the first tube of FIG. 8 and a second tube received and held within the first tube;
FIG. 11 - FIG. 16 illustrate different configurations of the heat exchanger with different positioning of the first inlet and first outlet for coolant, second inlet and second outlet for refrigerant and receiver drier inlet and outlet on at least one of first manifold and second manifold.
DETAILED DESCRIPTION OF EMBODIMENTS
[0032] 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.
[0033] Although, the present invention is explained in the forthcoming description and the accompanying drawings with an example of heat exchanger for a motor vehicle, particular a heat exchanger that that combines functions of two heat exchangers in one heat exchanger. More specifically, combines functions of a radiator and a condenser for a vehicle, thereby eliminating the need for multiple heat exchangers and problems associated with multiple heat exchangers arranged in overlapping configuration, for example packaging issues and performance and efficiency issues. However, the present invention is applicable for any heat exchanger for use in vehicular and non-vehicular environment where it is required to combine functions of two heat exchangers into one to address packaging issues, and other problems faced with overlapping arrangement of multiple heat exchangers.
[0034] FIG. 2 of the accompanying drawings illustrate an isometric view of a heat exchanger 100 in accordance with an embodiment of the present invention for a motor vehicle. FIG. 2 illustrates an exploded view of the heat exchanger 100. The heat exchanger 100 includes at least one first manifold 10a, 10b and at least one second manifold 40a, 40b.
[0035] At least one first manifold 10a, 10b is for circulation of a first fluid within a first set of tubes 20 to define at least a portion of a first fluid circuit 30. In accordance with an embodiment of the present invention, the first fluid circuit 30 is an engine cooling circuit for coolant flow with a radiator 32 being part of the first fluid circuit 30. In accordance with an embodiment, the heat exchanger 100 includes a pair of first manifolds 10a and 10b, particularly, a first distribution manifold 10a and a first collection manifold 10b to configure I -flow of the coolant. In such configuration, the first distribution manifold 10a distributes heated coolant from the first fluid circuit, particularly, the engine cooling circuit, to the first set of tubes 20. The first collection manifold 10b collects coolant from the first set of tubes 20 after the heated coolant had rejected heat to the refrigerant flowing through micro-channels 52 of corresponding second tubes 50 received in the first tubes 20. In accordance with another embodiment of the present invention as illustrated in FIG. 2, although, the heat exchanger 100 includes two first manifolds 10a and 10b, however, one of the two first manifolds 10a and 10b, for example, 10a is divided into a distribution section and a collecting section by an internal baffle. In such configuration, a first inlet 16a for ingress of the coolant and the a first outlet 16b for egress of the coolant are formed on the first manifold 10a, particularly, on the distribution section and the collection section of the first manifold 10a to configure U-flow of the coolant in the first set of tubes 20. Particularly, the distribution section distributes coolant to few first tubes 20 configuring a first coolant pass and the collecting section collects coolant from the remaining first tubes to configuring a coolant return pass. More specifically, the other of the two first manifolds 10a and 10b, the first manifold 10b in this case, configures fluid communication between the coolant first pass and the coolant return pass. The flow of the coolant through the first manifolds 10a and 10b and the first tubes 20 is depicted by line arrows A in the FIG. 3. Further, the heat exchanger 100 configured with a single first manifold 10a, 10b divided into separate sections by a baffle disposed inside the single first manifold 10a, 10b, wherein, the separate sections of the single first manifold 10a, 10b are connected by U-tubes is also within the scope of the present invention. In such configuration, the first section of the single first manifold 10a, 10b distributes the coolant to one end of the U-tubes and the second section of the single manifold 10a, 10b collects the coolant from the other end of the U-tubes. However, for sake of brevity of the present document, such configuration of single first manifold 10a,10b is not described in details.
[0036] At least one second manifold 40a, 40b is configured for circulation of a second fluid within the second set of tubes 50 to define at least a portion of a second fluid circuit 60. In accordance with an embodiment of the present invention, the second fluid circuit 60 is an air conditioning loop for refrigerant flow with a condenser 62 being part of the second fluid circuit 60. Similar to the first manifold 10a, 10b, the heat exchanger 100 may comprise a pair of second manifolds 40a and 40b, particularly, a second distribution manifold 40a and a second collection manifold 40b to configure I-flow of refrigerant. In one embodiment, the first distribution manifold 40a distributes refrigerant from the second fluid circuit, particularly, an air-conditioning loop, to the second set of tubes 50, particularly, the micro-channels 52 of the second tubes 50. The second collection manifold 40b collects refrigerant from the second set of tubes 50 after the refrigerant had rejected heat to the coolant flowing in annular space between first tubes 20 and the second tubes 50 received in the first tubes 20. The heat exchanger 100 may include the pair of second manifolds 40a and 40b, however, one of the second manifolds 40a and 40b, for example, 40a may be divided into a distribution section and a collecting section by an internal baffle. In such configuration a second inlet 46a for ingress of the refrigerant and a second outlet 46b for egress of the refrigerant are formed on the manifold 40a, particularly, on the distribution section and the collection section of the second manifold 40a to configure U-flow of the refrigerant in the second set of tubes 50. The position of the second inlet 46a and the second outlet 46b on the second manifold 40a is reversed with respect to the position of the first inlet 16a and the first outlet 16b on the first manifold 10a. The distribution section distributes refrigerant to few of the second tubes 50 configuring a first refrigerant pass and the collecting section collects refrigerant from the remaining second tubes to configuring a refrigerant return pass. More specifically, the other of the second manifolds 40a and 40b, particularly, the second manifold 40b in this case, configures fluid communication between the refrigerant first pass and the refrigerant return pass via a receiver drier 80. The flow of the refrigerant through the second manifolds 40a and 40b and the second tubes 50 is depicted by solid arrows B in the FIG. 3.
[0037] Referring to the FIG. 4, the first manifold 10a, 10b and the second manifold 40a, 40b are formed by assembling a first header 12a, 12b, a second header 22a, 22a and a cover 44a, 44b. The first header 12a, 12b, the second header 22a, 22b and the cover 44a, 44b are assembled and joined together by using any of the joining processes, such as for example, brazing. 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. The first header 12a, 12b includes first apertures 12c, 12d formed thereon to receive the first tubes 20 that configure fluid communication between the spaced apart first manifolds 10a and 10b. Extreme ends of the first tubes 20 are securely held within respective first apertures 12c and 12d formed on the respective first header 12a and 12b and are joined thereto by any of the joining process such as for example, brazing. The present invention is not limited to any particular joining process for configuring secure connection between the extreme ends of the first tubes 20 and the first header 12a and 12b and is not limited to brazing. Such configuration prevents any leakage from first manifold 10a, 10b through the corresponding first apertures 12c, 12d. The second header 22a, 22b includes second apertures 22c, 22d to receive the second tubes 50 that configures fluid communication between the spaced apart second manifolds 40a and 40b. The extreme ends of the second tubes 50 are securely held within respective second apertures 22c and 22d formed on the respective second header 22a and 22b and are joined thereto by any of the joining process such as for example, brazing. Again, the present invention is not limited to any particular joining process for configuring secure connection between the extreme ends of the second tubes 50 and the second header 22a and 22b and is not limited to brazing. Such configuration prevents any leakage between the first manifold 10a, 10b and the respective second manifold 40a, 40b through the respective second apertures 22c, 22d. The first header 12a, 12b and the cover 44a, 44b are assembled to each other with the corresponding second header 22a, 22b received in either one of the first header 12a, 12b and the cover 44a, 44b to define the first manifold 10a, 10b and the corresponding second manifold 40a, 40b.
[0038] The cover 44a, 44b is in the form of an enclosure with a stepped configuration that includes a first portion with first opening and second portion with a second opening. The first opening is wider than the second opening to form an intermediate neck portion at the interface between the first portion and the second portion of the cover 44a, 44b.
[0039] The first header 12a, 12b may be also in the form of an enclosure having a closed end and an open end. The second header 22a, 22b is received in the open end of the first header 12a, 12b. The first header 12a, 12b with the second header 22a, 22b received therein is received in the first opening of the corresponding cover 44a, 44b. The neck portion 48a, 48b formed on the cover 44a, 44b prevents further advance of the first header 12a, 12b along with the second header 22a, 22b within the cover 44a, 44b to define the first manifold 10a, 10b and the second manifold 40a, 40b. More specifically, the second header 22a, 22b separates the first manifold 10a, 10b with respect to the second manifold 40a, 40b. Alternatively, the second header 22a, 22b is received in the first opening of the corresponding cover 44a, 44b and thereafter, the first header 12a, 12b is received in the first opening of the corresponding cover 44a, 44b to define the first manifold 10a, 10b and the second manifold 40a, 40b. However, the present invention is not limited to any particular configuration and sequence of connections between the first header 12a, 12b, the second header 22a, 22b and the cover 44a, 44b to form the first manifold 10a, 10b and the second manifold 40a, 40b.
[0040] At least one second tube 50 includes plurality of micro-channels 52 formed by at least one of extrusion and folding. The micro-channels 52 can have square or triangular cross section. However, the present invention is not limited to any particular cross section of the micro-channels 52 or method of forming the micro-channels 52. At least one of the second tubes 50 may be received inside the first tube 20 formed by bending of plate joined along the end sides. Referring to the FIG. 4, the second tube 50 is comparatively longer than the corresponding first tube 20, so that it extends out of the first tube 20. The second tube 50 passes through the first manifold 10a, 10b, it extends out of the second header 22a, 22b and it is in fluid communication with the second manifold 40a, 40b disposed after the first manifold 10, 10b. In a preferred embodiment, one second tube 50 is received in one first tube 20 as illustrated in FIG. 5 - FIG. 7. Further, the second tube 50 is co-axially arranged within the corresponding first tube 20. Generally, first tube 20 and the second tube 50 include at least one of dimples 20a and protrusions 54, respectively formed thereon. In accordance with an embodiment as illustrated in FIG. 5, the first tube 20 includes the dimples 20a formed on opposite sides thereof. The dimples 20a protrudes inwardly into interior of the first tube 20 to interact with opposite sides of the corresponding second tube 50 to securely hold the corresponding second tube 50 inside the first tube 20. The dimples 20a formed on opposite sides of the first tube 20 are of same size to coaxially hold the second tube 50 within the first tube 20. Alternatively, the dimples 20a formed on opposite sides of the first tube 20 are of different dimensions to eccentrically hold the second tube 50 within the first tube 20. The dimples 20a formed on opposite sides of the tube 20 are off set from each other. In case the first tube 20 is formed by bending of plate joined along the end sides, the end sides are bent inwardly to form an inwardly extending protrusion 20b that in conjunction with the dimples 20a hold the second tube 50 inside the first tube 20. The second tube 50 may further include outwardly extending protrusions 54 protruding from opposite sides thereof to enable placement and holding of the second tube 50 inside the first tube 20. The outwardly extending protrusions 54 is formed during extrusion of the channels 52. In accordance with another embodiment, the dimples are partially formed on the first tube 20 and partially formed on the second tube 50 to interact with each other for securely holding the second tubes 50 within the corresponding first tubes 20. However, the present invention is not limited to any particular configuration, number, and placement of the dimples 20a or protrusions 54 formed on the first tube 20 and the second tube 50 respectively, as far as the dimples 20a or protrusions 54 facilitate secure holding of the second tube 50 inside the first tube 20.
[0041] In such "tube in tube" configuration, wherein the second tube 50 received in the first tube 20, the micro-channels 52 may define fluid flow passages for the second fluid, for example the refrigerant and the annular space between the first tube 20 and the second tube 50 may define fluid flow passage for the first fluid, for example, the coolant. Further, the channels 52 of the second tubes define the flow passages for the second fluid, for example, the refrigerant. In accordance with an embodiment of the present invention, at least one of the first fluid and the second fluid is a coolant. Instead of single second tube 50 being held in the first tube 20, multiple second tubes 50 are received and held in one first tube 20. In such case, the multiple second tubes 50 are connected and inserted within the first tube 20. The inwardly extending dimples 20a formed on the first tube interact with the opposite sides of the extreme second tubes 50 held in the first tube 20 and adjacent to the walls of the first tube 20 to hold the second tubes 50 within the first tube 20.
[0042] The flow of the coolant and the refrigerant through the first set of tubes 20 and the second set of tubes 50 can be either parallel flow or counter flow based on the positioning of the first inlet 16a and the first outlet 16b for the coolant, a second inlet 46a and a second out let 46b for the refrigerant and a receiver drier inlet 80a and a receiver drier outlet 80b on at least one of the first manifold 10a, 10b and second manifold 40a, 40b. FIG. 11 - FIG. 16 illustrate different configurations of the heat exchanger based on different combinations of the positioning of the first inlet 16a and the first outlet 16b for coolant, the second inlet 46a and the second outlet 46b for refrigerant and the receiver drier inlet 80a and the receiver drier outlet 80b on at least one of first manifold 10a, 10b and second manifold 40a, 40b. However, the heat exchanger of the present invention is not limited to any particular configurations depicted, can have any configuration, with different combinations of refrigerant and coolant flows based on position of the first inlet 16a, the first outlet 16b, the second inlet 46a, the second outlet 46b, and receiver drier inlet and first and second holes 80a and 80b on the receiver drier 80.
[0043] Generally, the first inlet 16a and the first outlet 16b are configured either on the same first manifold 10a, 10b or on different first manifolds 10a and 10b of the first manifolds 10a and 10b. In accordance with an embodiment as illustrated in FIG. 11, 12, 14-16, the first inlet 16a and the first outlet 16b are formed one of the first manifold 10a. In accordance with another embodiment of the present invention as illustrated in FIG. 13, the first inlet 16a and the first outlet 16b are formed on different first manifolds 10a and 10b disposed opposite to one another.
[0044] Further, the second inlet 46a and the second outlet 46b are configured on the same second manifold 40a, 40b to configure U-flow of the second fluid through the second set of tubes 50. Furthermore, such configuration of the first inlet 16a and the first outlet 16b formed revered to the second inlet and outlet 46a and 46b configures counter flow between first fluid flowing through the first tubes 20 and second fluid flowing through the second tubes 50. In accordance with an embodiment, some tubes 50a of the second tubes 50 define a first pass that is a condensing pass while the remaining tubes 50b of the second tubes 50 define a return pass that is the sub-cooling pass. Generally, the condensing pass includes more number of second tubes 50 than the second heat exchange tubes in the sub-cooling pass. The condensing pass is in fluid communication with the sub-cooling pass via the receiver drier 80. The receiver drier 80 is disposed along and in fluid communication with the second manifold 40b disposed opposite to the second manifold 40a of the second manifolds 40a and 40b on which the second inlet and outlet 46a and 46b are formed.
[0045] The receiver drier 80 includes a first hole 80a and a second hole 80b formed thereon. The receiver drier 80 receives condensed second fluid from the condensing pass defined by few of the second tubes through the first hole 80a to remove incompressible moisture and debris therefrom. The receiver drier 80 delivers the condensed second fluid substantially free of debris and incompressible moisture to the sub-cooling pass defined by the remaining of the second tubes through the second opening 80b.
[0046] The heat exchanger 100 can be incorporated in any cooling loop configured in a vehicle, wherein the heat exchanger functioning as radiator 32 supplies coolant to any of the vehicle heat exchangers to extract heat from any of the heat-generating component in the vehicle. Specifically, the vehicle heat exchangers can be any one of radiator, water charged air cooler, chiller and the heat-generating means can be any one of engine, e-motor and battery in a vehicle that is either one of internal-combustion engine driven, electric motor driven or any hybrid vehicle.
1. A heat exchanger (100) for a motor vehicle comprising:
• at least one first manifold (10a,10b) adapted for circulation of a first fluid within a first set of tubes (20) to define at least a portion of a first fluid circuit (30); and
• at least one second manifold (40a, 40b) adapted for circulation of a second fluid
within a second set of tubes (50) to define at least a portion of a second fluid circuit
(60),
characterized in that at least one second tube (50) comprising a plurality of micro-channels (52) formed
by at least one of extrusion and folding is received inside the first tube (20), the
micro-channels (52) define fluid flow passage for the second fluid and annular space
between the first tube (20) and the second tube (50) defines fluid flow passage for
the first fluid.
2. The heat exchanger (100) as claimed in the previous claim, wherein the second tube
(50) is co-axially arranged within the corresponding first tube (20).
3. The heat exchanger (100) as claimed in any of the preceding claims, wherein the second
tube (50) is longer than the corresponding first tube (20), passes through the first
manifold (10a, 10b) and is in fluid communication with the second manifold (40a, 40b)
disposed after the first manifold (10a, 10b).
4. The heat exchanger (100) as claimed in any of the preceding claims, wherein the first
tube (20) and the second tube (50) comprises at least one of dimples (20a) and protrusions
(54) respectively formed thereon.
5. The heat exchanger (100) as claimed in any of the preceding claims, wherein the first
tube (20) comprises dimples (20a) formed on opposite sides thereof that protrudes
inwardly into interior of the first tube (20) for securely holding the corresponding
second tube (50) inside the first tube.
6. The heat exchanger (100) as claimed in claim 5, wherein the dimples (20a) formed on
opposite sides of the first tube (20) are of same size to coaxially hold the second
tube (50) within the first tube (20).
7. The heat exchanger (100) as claimed in claim 5, wherein the dimples (20a) formed on
opposite sides of the first tube (20) are of different dimensions to eccentrically
hold the second tube (50) within the first tube (20) .
8. The heat exchanger (100) as claimed in any of the preceding claims, wherein the first
manifold (10a, 10b) and the second manifold (40a, 40b) are formed by assembling a
first header (12a, 12b), a second header (22a, 22b) and a cover (44a, 44b).
9. The heat exchanger (100) as claimed in claim 8, wherein the first header (12a, 12b)
comprises first apertures (12c, 12d) adapted to receive the first tubes (20) that
configure fluid communication between the spaced apart first manifolds (10a) and (10b).
10. The heat exchanger (100) as claimed in claim 8, wherein the second header (22a, 22b)
comprises second apertures (22c, 22d) adapted to receive the second tubes (50) that
configure fluid communication between the spaced apart second manifolds (40a) and
(40b).
11. The heat exchanger (100) as claimed in the claim 8, wherein at least one of the first
header (12a, 12b) and the cover (44a, 44b) are assembled to each other with the corresponding
second header (22a, 22b) received in either one of the first header (12a, 12b) and
the cover (44a, 44b) to define the first manifold (10a,10b) and the corresponding
second manifold (40a, 40b).
12. The heat exchanger (100) as claimed claim 8, wherein the second header (22a, 22b)
is received in the open end of the first header (12a, 12b) and the first header (12a,
12b) along with the second header is received in a first opening of the corresponding
cover (44a, 44b) to define the first manifold (10a, 10b) and the second manifold (40,
40b).
13. The heat exchanger (100) as claimed in any of the preceding claims comprising:
• a first inlet (16a) and a first outlet (16b) either configured on the same first manifold (10a, 10b) or on different first manifolds (10a) and (10b) of the first manifolds (10a) and (10b); and
• a second inlet (46a) and a second outlet (46b) configured on the same second manifold (40a, 40b) but reverse to the first inlet (16a) and first outlet (16b) and adapted to configure U-flow of the second fluid through the second set of tubes (50) also configures counter flow between first fluid flowing through the first tubes (20) and second fluid flowing through the second tubes (50).,some tubes (50a) of the second tubes (50) define a first pass that is a condensing pass while the remaining tubes (50b) of the second tubes (50) define a return pass that is the sub-cooling pass.
14. The heat exchanger (100) as claimed in the previous claim, wherein the condensing
pass is in fluid communication with the sub-cooling pass via a receiver drier (80)
disposed along and in fluid communication with one of the second manifold (40b) opposite
to the second manifold (40a) of the second manifolds (40a) and (40b) on which the
second inlet (46a) and second outlet (46b) are formed,
15. The heat exchanger (100) as claimed in the previous claim, wherein the receiver drier
(80) comprises a first hole (80a) and a second opening (80b), the receiver drier (80)
receives condensed second fluid from the condensing pass through the first hole (80a)
to remove incompressible moisture and debris therefrom and delivers the condensed
second fluid substantially free of debris and incompressible moisture to the sub-cooling
pass through the second opening (80b).