Heat Exchanger with Direct Flow Path Modules

Abstract

A heat exchanger including an inlet tank with an internal manifold space and a plurality of modules including a core having a plurality of tubes. The modules are in fluid communication with the inlet tank and the tubes terminate inside the manifold space so that a cooling media can flow in a direct path from the manifold space into the tubes.

1 . A heat exchanger comprising:
 an inlet tank including an internal manifold space;   a plurality of modules in fluid communication with the inlet tank, the modules including a core having a plurality of tubes, wherein a first end of the tubes terminate in the inlet tank manifold space.   
   
   
       2 . The heat exchanger of  claim 1  wherein a cooling media entering the manifold space can enter the tubes by a direct path. 
   
   
       3 . The heat exchanger of  claim 1  further including an outlet tank having an internal manifold space, wherein a second end of the tubes terminate in the outlet tank manifold space. 
   
   
       4 . The heat exchanger of  claim 1  further comprising the inlet tank including:
 a first side having a plurality of module apertures for receiving the modules; and   a seal lip around the periphery of the module apertures extending at an angle from the first side of the inlet tank, wherein the seal lip is configured to form a seal between the seal lip and the module.   
   
   
       5 . The heat exchanger of  claim 4  wherein the seal lip extends into the manifold space and at an angle substantially perpendicular to the first side of the inlet tank. 
   
   
       6 . The heat exchanger of  claim 1  further including:
 a header coupled to at least one of a first and second end of the core, wherein the header includes:
 a base coupled to the core; and 
 a boss around a periphery of the base extending at an angle from the base to form a seal between the periphery of the boss and the inlet tank. 
   
   
   
       7 . The heat exchanger of  claim 6  wherein the boss includes a seal slot and a seal ring disposed at least partially inside the seal slot to form the seal. 
   
   
       8 . A heat exchanger comprising:
 an inlet tank including a first side;   a plurality of modules in fluid communication with the inlet tank;   a plurality of module apertures in the first side of the inlet tank for receiving the modules;   a seal lip around the periphery of at least one of the module apertures and extending at an angle to the first side; and   a seal formed between the seal lip and the module.   
   
   
       9 . The heat exchanger of  claim 8  wherein the module includes a first end received in the inlet tank and a second end opposite the first end, the second end received in an outlet tank. 
   
   
       10 . The heat exchanger of  claim 9  wherein the module includes a core having a first and second end, and a header coupled to at least one of the first and second end. 
   
   
       11 . The heat exchanger of  claim 10  wherein the header includes a base coupled to the core and a boss around a periphery of the base and extending at an angle from the base, the boss configured to form the seal between the periphery of the boss and the inlet tank. 
   
   
       12 . The heat exchanger of  claim 11  wherein the boss includes a seal slot and a seal ring disposed at least partially inside the seal slot to form the seal. 
   
   
       13 . The heat exchanger of  claim 10  wherein the core includes a plurality of radiator fins and a plurality of tubes extending between the first and second ends. 
   
   
       14 . The heat exchanger of  claim 8  wherein the inlet tank includes:
 a second side opposite the first side;   a first wall;   a second wall opposite the first wall;   a third wall; and   a fourth wall opposite the third wall wherein, the third wall and fourth wall interconnect the first side, second side, first wall, and second wall to form a box structure with an internal manifold space.   
   
   
       15 . The heat exchanger of  claim 11  wherein the seal lip extends at an angle substantially perpendicular from the first side of the inlet tank and into a internal manifold space the inlet tank and the boss extends at an angle substantially perpendicular to the base and into the manifold space. 
   
   
       16 . A module for a heat exchanger comprising:
 a core having a first end;   a second end opposite the first end; and   a header coupled to at least one of the first and second end, the header including:
 a base coupled to the core; 
 and a boss around a periphery of the base extending at an angle to the base, wherein the boss is configured to form a seal between the periphery of the boss and a tank. 
   
   
   
       17 . The module of  claim 16  wherein the boss extends substantially perpendicular to the base and includes a seal slot in an outer seal surface and a seal ring to form the seal. 
   
   
       18 . The module of  claim 16  wherein the header is inserted into one of a plurality of module apertures in the tank. 
   
   
       19 . The module of  claim 18  wherein the seal is formed between the periphery of the boss and a seal lip extending to the periphery of the module apertures in the tank. 
   
   
       20 . The module of  claim 16  wherein the core includes a plurality of radiator fins and a plurality of tubes extending between the first end and second end.