CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National Stage application of PCT/IB2017/000675, filed May 11, 2017 and published on Nov. 15, 2018 as WO2018/206991, all of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The invention relates to a heat exchanger apparatus, in particular to a heat exchanger apparatus for use in combustion engines. The present invention also relates to a vehicle comprising a heat exchanger apparatus, a method for manufacturing a heat exchanger apparatus, and a method of heating a heat exchange unit.

The invention can be applied in heavy-duty vehicles, such as trucks, buses and construction equipment. Although the invention will be described with respect to a motor vehicle and, as such, the invention is not restricted to any particular vehicle but may be particularly applicable to heavy-duty vehicles.

BACKGROUND

It can be difficult to start combustion engines of vehicles during winter months due to the low external temperatures. If an engine is started when the operating components of the engine are at a low temperature the engine produces an increased level of pollution during the first few miles. Fuel consumption is also high when the engine is operating at low temperatures. It has however been found that engines are easier to start, pollution is reduced or minimised, and fuel efficiency is improved if one or more of the operating members of the engine are warmed during the process of starting the engine.

There are a number of conventional devices for raising the temperature of components of a combustion engine. For example, engine heaters are used in regions with cold winters such as northern US, Canada, Russia and Scandinavia. Typically, an engine heater is immersed directly into either the engine coolant or the lubricant of a vehicle. There is however a risk of pressure loss within the system during the insertion of the engine heater into the engine fluids. Once inserted, the engine heater is connected to a normal AC power overnight or before driving via external power outlets. The heater element heats the fluid which is circulated by thermo-siphon through the engine. The use of an external power supply means that it is not possible to use the heater once the engine has been started. The heater can therefore not be used to speed up the rate at which the engine temperature increases once the engine has started. Furthermore, the dimensions, and therefore the exchange surfaces, of the engine heater are also limited by the need to be able to insert the heater directly into the engine fluids. As a result, the power than can be delivered from the engine heater to the fluid is also limited. There is also an associated risk of coolant boiling or oil cocking in regions adjacent to the engine heater.

Alternative devices for warming components of an engine include external heating devices, such as for example pumping systems, which may be fitted in parallel or series to a coolant system. Heating reservoirs, such as for example Thermo-like reservoirs, may be filled when the engine is still hot. The capacity of the reservoir is however limited and the effect produced by the heating reservoirs on the coolant or lubricant also has a limited duration.

SUMMARY

There are a number of disadvantages associated with conventional heating devices for raising the temperature of components of a combustion engine. As such it is an object of embodiments of the invention to provide a heat exchanger apparatus which is capable of providing improved heat transfer to components of a combustion engine without causing any associated pressure loss within the system. It is a further object of embodiments of the invention to provide a heat exchanger apparatus which is capable of providing improved heat transfer to components of a combustion engine prior to and after starting the engine. It is a further object of embodiments of the invention to provide a heat exchanger apparatus which is capable of affecting the temperature of both lubricant and coolant within a combustion engine.

At least some of these objects may be achieved by a heat exchanger apparatus for a combustion engine, in which the apparatus comprises:a heat exchange unit comprising at least one magnetic component; andat least one induction heater positioned adjacent to at least one magnetic component of the heat exchange unit,in which the induction heater is connectable to a power supply to provide inductive heating to the heat exchange unit.

The heat exchange unit may be of any suitable shape and dimension. The heat exchange unit may be a plate heat exchange unit. The term “plate heat exchange unit” is used herein to refer to a heat exchange unit comprising a plurality of plate members.

Preferably, at least one or each of the plurality of plate members are composed of magnetic material. In one embodiment, the heat exchange unit is brazed plate heat exchange unit.

Preferably, a plurality of channels extend through the heat exchange unit. Preferably, the plurality of channels extend substantially perpendicular to the plane of the plate members. At least one first channel is connectable to a first fluid medium, such as for example a coolant supply. At least one second channel is connectable to a second fluid medium, such as for example a lubricant supply, i.e. an oil supply. Preferably, the at least one first channel extends substantially parallel to and is spaced apart from the at least one second channel.

Plate members are superimposed and define between them first flow passages for first fluid medium and second flow passages for second fluid medium. First flow passages and second flow passages are arranged in an alternating manner between plate members. First flow passages are connected to the first channel and second flow passages are connected to the second channel. In use, heat is transferred from the second fluid medium flowing in the second flow passages to the first fluid medium flowing in the first flow passages through plate members. First flow passages and second flow passages may comprise turbulators to create turbulences in the flows in order to promote thermal exchanges.

In one embodiment, the induction heater is positioned adjacent to the heat exchange unit so as to substantially surround the heat exchange unit. The term “substantially surround” is used herein to refer to the induction heater surrounding substantially an entire outer perimeter surface of the heat exchange unit.

Preferably, the heat exchange unit is a coolant/oil heat exchanger and the coolant is a liquid coolant.

In one embodiment, the induction heater provides at least one opening extending into a cavity. The at least one opening and cavity are shaped and dimensioned to receive the heat exchange unit. In one embodiment, a first end of the induction heater provides a first opening, a second opposed end of the induction heater provides a second opening, and a channel (or cavity) is in communication with the first and second openings and extends therebetween. The channel or cavity defines the longitudinal axis of the induction heater.

Preferably, the induction heater is positioned adjacent to the heat exchange unit so as to substantially surround an entire outer perimeter surface of the heat exchange surface while the longitudinal axis of the induction heater extends substantially parallel to at least one of the plurality of channels provided within the heat exchange unit. Preferably, the induction heater is positioned such that the longitudinal axis of the induction heater extends substantially parallel to the at least one first channel connectable to a first fluid medium (for example a coolant supply) and/or the at least one second channel connectable to a second fluid medium (for example a lubricant supply).

In use, at least a portion of the heat exchange unit is received or positioned within the channel or cavity provided by the induction heater. In order to maximise the efficiency of the heat exchanger apparatus, substantially all of the heat exchange unit is received or positioned within the channel or cavity provided by the induction heater. The channel or cavity of the induction heater unit may be shaped and dimensioned to be in contact with the outer perimeter surface of the heat exchange unit. Alternatively, the channel or cavity of the induction heater unit may be shaped and dimensioned to be spaced apart from the outer perimeter surface of the heat exchange unit during use.

In one embodiment, the induction heater may be located between a pair of adjacent plate members of the heat exchange unit. Preferably, the induction heater is located between a pair of adjacent plate members located substantially centrally within the heat exchange unit. The induction heater may however be located between any pair of adjacent plate members located at any suitable location within the heat exchange unit.

In one embodiment, the induction heater and the heat exchange unit are provided as a single, integral unit. Alternatively, the induction heater may be mounted within or around the heat exchange unit prior to use. For example, the induction heater may be insertable, prior to use, between an adjacent pair of plate members of a heat exchange unit.

In one embodiment, the heat exchange unit may provide at least one opening extending into a cavity. The at least one opening and cavity are preferably provided between a pair of adjacent plate members. The pair of adjacent plate members preferably define a pair of opposed surfaces forming the cavity of the heat exchange unit. The at least one opening and cavity are preferably shaped and dimensioned to receive an induction heater. The induction heater may be slideable through the at least one opening to be received within the cavity of the heat exchange unit.

In one embodiment, the heat exchange unit comprises a plurality of plate members which are releasably mounted. Prior to set up, the plate members may be separated and the induction heater mounted therebetween.

The heat exchanger apparatus may further comprise at least one, preferably a plurality, of fixation members for retaining the induction heater in position relative to the heat exchange unit. The fixation members may be any suitable means, such as for example threaded screws. For example, one or more of the induction heater and the heat exchange unit, for example the plate members of the heat exchange unit, comprise at least one threaded bore shaped and dimensioned to cooperatively engage one or more threaded screws. Preferably, the induction heater and the heat exchange unit, for example the plate members, comprise at least one, preferably a plurality of, threaded bore(s) which are aligned in use to receive at least one, preferably a plurality of, threaded screw(s).

The heat exchange unit may comprise a flange located at and extending outwardly from and along the perimeter of a first end of the unit. The at least one threaded bore may be provided by the flange. The induction heater may comprise a flange located at and extending outwardly from and along the perimeter of a first end of the heater. The at least one threaded bore may be provided by the flange of the heater. The flange of the induction heater may be arranged to abut the flange of the heat exchange unit. In use, the flange of the induction heater may abut the flange of the heat exchange unit such that the threaded bore(s) of each flange are aligned to releasably engage the fixation member(s).

At least one magnetic component of the heat exchange unit, preferably each of the magnetic components, may be composed of steel. It is however to be understood that the magnetic components may be composed of any suitable magnetic material. Each magnetic component may be composed of the same magnetic material, or different magnetic material, to other components within the heat exchange unit.

The heat exchanger apparatus may further comprise a power supply in communication with the induction heater. The power supply may be selected from: an external AC power supply or a vehicle battery.

According to a second aspect one or more objects of the invention may be achieved by a vehicle comprising a combustion engine in communication with a heat exchanger apparatus as described herein. The vehicle battery is preferably connected to the heat exchanger apparatus.

According to a third aspect of the present invention one or more objects of the invention may be achieved by a method of manufacturing a heat exchanger apparatus, comprising:positioning an induction heater adjacent to at least one magnetic component of a heat exchange unit.

The induction heater may according to one embodiment of the invention be retro-fitted to a heat exchange unit of an engine. The heat exchange unit of the engine will therefore already have been optimised for heat exchanges for that engine. The present invention therefore provides a method of providing optimised heat transfer to the heat exchange unit of the engine.

According to a fourth aspect of the present invention, one or more objects of the invention may be achieved by a method of heating a heat exchange unit comprising at least one magnetic component, comprising:positioning an induction heater adjacent to at least one magnetic component of a heat exchange unit; andconnecting the induction heater to a power supply such that the induction heater generates inductive heating to the heat exchange unit.

According to a fifth aspect of the present invention, one or more objects of the invention may be achieved by a kit for providing a heat exchanger apparatus, comprising:a heat exchange unit comprising at least one magnetic component; andan induction heater positionable adjacent the at least one magnetic component of the heat exchange unit, in which the induction heater is connectable to a power supply to provide inductive heating to the heat exchange unit.

Further advantages and advantageous features of the invention are disclosed in the following description and in the dependent claims.

