CN101223411A

CN101223411A - Automotive heat exchanger

Info

Publication number: CN101223411A
Application number: CN 200680025904
Authority: CN
Inventors: 安东尼厄斯·玛丽亚·维特; 汉斯·胡伯图斯·亨利克斯·霍恩曼
Original assignee: DSM IP Assets BV
Current assignee: DSM IP Assets BV
Priority date: 2005-07-15
Filing date: 2006-07-04
Publication date: 2008-07-16
Anticipated expiration: 2026-07-04
Also published as: CN100573022C; EP1744117A1

Abstract

The invention relates to an automotive heat exchanger comprising a) a heat exchange core (2) comprising a header part (10) comprising a plurality of heat transfer tubes (4), b) a plastic manifold body (18) forming an aperture for receiving end portions of heat transfer tubes (4), and C) a plastic insert plate (16) having a plurality of openings (24), wherein i) end portions of the heat transfer tubes (4) are received by and extend through the openings (24) of the plastic insert plate (16) and extreme parts of the end portions of the heat transfer tubes (4) have been bended outwardly, ii) the plastic insert plate (16) is fastened to the side walls of the manifold body (18) , and iii) the manifold body (18) is joined to the heat exchange core (2) only through fastening of the plastic insert plate (16) to the manifold body (18).

Description

Automotive heat exchanger

The present invention relates to a kind of automotive heat exchanger.Heat exchanger is transferred to heat energy one other fluid (or gas) and both is mixed from a kind of fluid (or gas).Vehicle radiator is common example.Heat from hot engine water is drawn out of by radiator tube, and air is blown into by heat radiator fin.The heat energy that engine produced is transferred to air via cooling water, so that water remains on suitable temperature, thereby prevents engine overheat.Engine radiator mainly is liquid-air heat exchanger.The heat exchanger of other type is common by everyday devices, for example boiler, stove, refrigerator and air-conditioning system, and be usually used in various industry, chemistry and the electronics processing procedure, to shift energy and required heating and cooling be provided.Automotive heat exchanger is meant the heat exchanger that is designed for motor vehicles (being also referred to as motor vehicle) here.

The present invention relates to a kind of automotive heat exchanger, relate more specifically to a kind of automotive heat exchanger that comprises a beam tube and header pipe component (header part), wherein in described header pipe component, the end of described pipe imports in the hole of plate.This pipe is also referred to as heat-exchange tube or heat transfer tubes, and cooling tube or cooling duct.As other heat exchange elements, automotive heat exchanger generally includes fin or the corrugated plating that generally is made of metal.Pipe and cooling element are stacked usually and form bigger external member, and with the plate welding with hole or soldering together, to form single or unit-type heat exchanger is examined core.Heat exchange core is also referred to as cooler body, and is made by lightweight heat-conducting metal (for example aluminium) usually.Automotive heat exchanger also comprises the manifold bodies with the opening surface that is limited by this header pipe component.The manifold bodies of automotive heat exchanger is also referred to as end cap.Manifold bodies and header pipe component constitute manifold jointly, are also referred to as manifold shell.The end of the heat-exchange tube that the air that confession is to be cooled or other medium (being generally water or water/ethylene glycol mixture) pass through is accepted and is extended in the manifold shell by the hole in the manifold bodies.Automotive heat exchanger generally includes 2 manifolds: an inlet manifold is also referred to as lead-in groove; An outlet manifold is also referred to as letdown tank.Inlet manifold is meant a kind of being used for the conduit like device of medium transport to be cooled to pipe.The outlet manifold is meant and is used for cooling medium is delivered to the outside conduit like device of pipe.

This manifold can be learnt from U.S. Pat 5351751.This patent has been described the heat exchanger that is used for motor vehicle, for example is used for the charge air cooler of turbocharger.The known heat exchanger of US 5351751 comprises manifold bodies (being called manifold in US 5351751) and the heat exchange core that is the separating tank form.Heat exchange core comprises header pipe component and heat-exchange tube.Heat-exchange tube is connected with this header pipe component in its end.This header pipe component and manifold bodies define manifold together, are called manifold shell.In the heat exchanger of US 5351751, manifold bodies has and comprises inside fringe region and to the sidewall of outer edge region, itself and this header pipe component engagement.Header pipe component in the heat exchange core comprises the collar, and this collar forms passage, and the accepting by manifold bodies from this collar to outer edge region.Manifold bodies among the US 5351751 can be made by metal (preferred aluminium), and can for example engage with header pipe component by welding.According to US 5351751, also can use the manifold bodies that forms by plastics.

The another kind of method that manifold bodies is engaged with header pipe component is to utilize crimping operation.This method need comprise the heat exchanger of header pipe component and manifold bodies, and wherein this header pipe component comprises the have compression bonding apparatus collar of (for example crimp jaws), and this manifold bodies comprises the surrounding edge of being accepted by crimp jaws.This method can be applicable to metal manifold bodies, is generally used for the manifold bodies that plastics are made.

As described in US 5351751, the manifold shell in the automotive heat exchanger is subjected to the high temperature and high pressure of to be heated or cooling medium and expands, and this causes the mechanical breakdown of heat exchanger easily.Especially, the fluctuation pressure that is produced in the automotive heat exchanger can cause problem.Issuable defective for example be breaking of header pipe component and explosion, crimp jaws open and header pipe component in heat transfer tubes and the welding seam breaking between the substrate.The traditional solution of describing among the US 5351751 comprises: strengthen manifold bodies or channel parts by increasing wall thickness, increase inside and/or outside timber or being increased in the draw-in bar that extends between the cabinet wall, thereby resist above-mentioned expansion.Improve the collector material specification and use thicker crimp jaws also to can be used as enhancements.Yet, mentioned a series of problems that these enhancements exist among the US 5351751 simultaneously.Increase extra reinforcing material weight is increased, and improved the cost of manifold.Make required processing, design, mould etc. more complicated simultaneously.The use of internal tie bars has also strengthened the difficulty of making.Power that the thickness of increase crimp jaws need be bigger and bigger machine also need motor vehicle to have bigger space to come receiving heat-exchanger to engage manifold bodies and header pipe component.Yet in existing vehicle, the space of distributing to this device is more and more limited, and needs to reduce the space requirement of heat exchanger, keeps suitable thermal efficiency simultaneously.

The purpose of this invention is to provide a kind of automotive heat exchanger that does not have or alleviate the problem of conventional heat exchanger, a kind of automotive heat exchanger more specifically is provided, its mechanical breakdown to the header pipe component of heat exchanger is more insensitive, and can be, and can save the space with limited extra cost and weight manufacturing.

Above-mentioned purpose realizes that by automotive heat exchanger of the present invention wherein said automotive heat exchanger comprises the plastic slab with a plurality of openings, and the quantity of the heat transfer tubes that described number of openings and heat exchange core are contained is identical, and wherein:

I) this opening is accepted and extended through in the end of heat transfer tubes by the opening of plastic slab, and the outermost end portion of the end of heat transfer tubes outwards turns down, thereby form pressure tight joint between plastic slab and header pipe component;

Ii) plastic slab is fastened to the sidewall of manifold bodies, so that plastic slab contacts fully with sidewall; With

Iii), make manifold bodies be engaged to heat exchange core only by plastic slab is fastened to manifold bodies.

Find surprisingly, the intensity of automotive heat exchanger of the present invention is enough to stand internal pressure, reduced the pressure loss risk relevant simultaneously with the mechanical breakdown of crimp jaws and/or substrate, in automotive heat exchanger of the present invention, this opening is accepted and extended through in the end of heat transfer tubes by the opening of plastic slab, and the outermost end portion of the end of heat transfer tubes outwards turns down, thereby by pressure tight joint with heat exchange core and plastic slab mechanical engagement, and, make manifold bodies be engaged to heat exchange core only by plastic slab is fastened to manifold bodies.Another advantage is that heat exchange core does not have the compression bonding apparatus that manifold bodies is joined to heat exchange core, thereby causes the space significantly to be saved.In addition, method of the present invention can't cause serious extra cost and weight, even may reduce cost and/or weight.Because reduced susceptibility to mechanical breakdown, the size increment that other parts of manifold or header pipe component are used to strengthen can be less, under particular condition, the size of these other parts even may reduce, or even omit these parts fully.In addition, plastic slab itself can be in light weight and be easy to make.

Use with plastic slab of a plurality of openings (quantity of the heat transfer tubes in its quantity and the automotive heat exchanger equates) is known, and for example is described among the US 6296051B1.Pipe in the automotive heat exchanger of US6296051B1 also has the end of widening.But it should be noted that in the automotive heat exchanger of US 6296051B1 the end of heat transfer tubes is inserted and accepted by the opening of plastic slab, but does not extend through this opening.More particularly, mention among the US 6296051B1 that the thickness of plastic slab is greater than the height of end.And, enlarged width end portions and opening flush fit, but be not to be used for heat exchange core and plastic slab mechanical engagement, because plate is by the periphery holding position of manifold box.In addition, the manifold bodies in the automotive heat exchanger of US 6296051B1 engages with header pipe component by crimping operation.For this purpose, header pipe component is provided with the manifold plate that comprises crimping tongue piece (being similar to tooth or notch).Plastic slab among the US 6296051B1 is used as the cross spacing device at manifold bodies edge, so that this edge keeps in crimping operation is horizontal.Otherwise, inwardly motion under the high pressure effect that manifold bodies can apply in crimping operation.US 6296051B1 had not both described and had not advised method of the present invention yet, and did not instruct yet or hint effect of the present invention.

Contact fully at this and be meant that plastic slab contacts with the manifold bodies sidewall along closed line.In other words, there is not opening between plastic slab and the manifold bodies.

This contact fully can realize by for example following plastic slab, and the outer perimeter of the plane cross section of this plastic slab is similar to or equals the interior girth of the plane cross section of manifold side mural margin location or near manifold bodies.If the described outer perimeter of plastic slab equals girth in manifold described, then can be for example by plastic slab being inserted or being crimped to manifold or realizing on the manifold contacting fully by plastic slab is welded on.If the described outer perimeter of plastic slab is similar to the described interior girth of manifold, then can be for example by the plastic slab crimping being fastened to manifold bodies and using binding agent to realize contacting fully.

The realization of effect of the present invention need be provided with pressure tight joint between plastic slab and header pipe component, described effect is meant that automotive heat exchanger of the present invention can will stand internal pressure, reduces the pressure loss risk relevant with other parts mechanical breakdown of heat exchanger simultaneously.This pressure tight joint can be realized by variety of way, for example adopts the plastic slab that contacts with the tube end sealing.Also can realize by using sealant or seal between plastic slab and the substrate.Preferably, plastic slab contact with sealing between the tube end with plastic slab and substrate between sealant or seal engage.

Binding agent is suitable as sealant.And rubber washer is suitable as seal.

In automotive heat exchanger of the present invention, can be by being suitable for any method that plate body is fixed to hollow plastic body is fastened to plastic slab the sidewall of manifold bodies.Suitable method is for example: mechanical bond, as crimping and snapping, for example use the detent mechanism that is fastened or adopts undercutting, or other sealing mechanism; And chemical bond, as the adhesive bond of use binding agent or use bonding wire (for example by Vibration Welding or laser weld), or any combination of said method.

Preferably, use mechanical bond and chemically combined combination.Its advantage is that manifold is firmer and can stand bigger pressure and change.

Mechanical bond and/or chemical bond combine with seal or sealant alternatively, so that better combination seal to be provided.

Plastic slab in the automotive heat exchanger of the present invention preferably have periphery location to the outstanding circumferential flange of manifold bodies diapire direction.The advantage of described chimb is that manifold is being reinforced near manifold bodies fringe region place, and uses the heat exchanger of this manifold to become more insensitive to mechanical breakdown.Term " periphery location " is meant that described chimb is positioned at or near the edge of plastic slab at this.

The sidewall that is secured to manifold bodies that contacts with peripheral edge area that the plastic slab of described chimb can be by described chimb for example and sidewall.In this embodiment, chimb has formed the extension of manifold bodies sidewall.In fact, the height of chimb can approximate the height of sidewall or even higher.Plastic slab with this high chimb can be illustrated as having the shape of groove on directly perceived.Under particular condition, the height of chimb can make the sidewall height significantly reduce, and keeps enough volumes for manifold shell simultaneously.In its extreme form, manifold has the casing form, and wherein the plastic slab with chimb forms the base portion with the end and wall, and the manifold bodies with sidewall (it highly reduces to minimum) then forms case lid.The advantage of this embodiment (particularly when the chimb height is big) is that heat exchanger is further reduced the susceptibility of mechanical breakdown.

In another embodiment, chimb is accepted and adjacency with it by the inside fringe region of manifold bodies sidewall, perhaps the sidewall of manifold bodies accept by chimb and chimb and sidewall to the outer edge region adjacency.Preferably, the sidewall of manifold bodies is accepted by chimb, and chimb and sidewall to the outer edge region adjacency.Its advantage is that heat exchanger can stand higher pressure.

Preferably use the combination of these embodiments.This can realize by the plastic slab with described chimb, wherein said chimb has peripheral edge area, this zone has inside or outside excision portion, is used to accept the fringe region of manifold bodies sidewall and respectively in abutting connection with the outside or inside fringe region of sidewall.Be selected from or combination with it as another kind, the sidewall of manifold bodies has peripheral edge area, and this zone has the inside or outside excision portion that is used to accept the chimb fringe region.

In addition, use binding agent and/or scolder that plastic slab and manifold bodies are meshed better alternatively.Equally alternatively, described chimb can be provided with ripple or other finishing, so that plastic slab and manifold bodies mesh better.

Opening in the plastic slab preferably have with by the close-fitting size of its heat transfer tubes of accepting.For this reason, opening should have the long minimum interior girth of cross-sectional circumference that equals or be similar to the heat transfer tubes end.Advantage with plastic slab of this close-fitting opening is that heat transfer tubes is fixed on its position, and has reduced the mechanical breakdown that heat transfer tubes gets loose and caused from its position.Another advantage is that plastic slab can be engaged to header pipe component so that heat exchanger has firmer structure.

And preferably, described a plurality of openings have to small part convergent shape, make this opening broaden gradually when the diapire direction of manifold bodies is observed.Advantage with convergent shaped aperture is, to the inflow of to be heated or cooling or to flow out the disturbance of medium less, thereby reduces the pressure drop in the manifold.

The convergent shape can be the Any shape that opening is broadened when the diapire direction is observed.Suitable convergent shape for example is the linear ramp shape with fixed elevation, or the curved shape with variable-pitch, or its combination.Have convergent shaped aperture at least and preferably have 5-80 °, more preferably 20-70 ° or 30-60 °, 45 ° the inboard of fixing or variable-pitch most preferably from about.

Should also be noted that the outermost end portion that has shorter end (as used in the conventional heat exchanger, for example 1-2mm) by outside turnover, can obtain to increase the effect of pressure.Yet for the better sealing that obtains plastic slab and collector substrate and fastening, it is preferred using long end (for example 3-10, preferred 4-5mm).

The end of the outside turnover of heat transfer tubes allows that the effect of higher internal pressure can further be strengthened by following embodiment: its split shed has inner surface, the end of heat transfer tubes has outer surface, and plastic slab is by being coated on the sealant sealing between described inner surface and the outer surface.The advantage of this embodiment is to be suitable for higher internal pressure.

In automotive heat exchanger of the present invention, plastic slab and manifold bodies can be made by various materials.Plastic slab and manifold bodies can be manufactured from the same material, though these parts also can be made by different materials.

Plastic slab can be made by thermoset polymer compositions or thermoplastic polymer composition, is preferably made by thermoplastic polymer composition.The material of making manifold bodies can be the plastic material with the identical or different polymer composition of plastic slab, or another kind of material, particularly metal (for example aluminium).Manifold bodies is also preferably made by thermoplastic polymer composition.

The thermoplastic polymer composition of making plastic slab and/or manifold bodies comprises at least a thermoplastic polymer.The suitable thermoplastic polymer that can be used for thermoplastic polymer composition for example is polyester and polyamide.The example of suitable polyamide is an aliphatic polyamide, as polyamide-6, polyamide-6,6 and polyamide-4,6, and partially aromatic polyamide, as polyamide-6, T, polyamide-9, T, copolyamide are as polyamide-6,6/6, T and polyamide 6,6/6, I, and the mixture of these polyamide and other copolyamide.

More preferably, polyamide is that fusion temperature (Tm) is at least 230 ℃ hypocrystalline (aliphatic series or half an aromatics) polyamide, or glass transition temperature (Tg) is at least 230 ℃ an amorphous state partially aromatic polyamide.Preferably, described Tm or Tg are at least 240 ℃, more preferably at least 260 ℃, or even 280 ℃, and can be up to 330 ℃ or higher.

Except that described at least a thermoplastic polymer, this thermoplastic polymer composition also can comprise one or more additives.Spendable additive can be any additives of manifold in the thermoplastic polymer composition that be applicable to known in the art.Suitable additive for example comprises, inorganic filler, reinforcing agent (for example glass fibre), nucleator, stabilizing agent, processing aid, pigment etc.In principle, the optimised quantity of additive or its combination can be determined by the system research experiment by those skilled in the art.Preferably, the amount of additive should make added additive the moulding character of polymer not caused negative effect.

Plastic slab and manifold are also preferably made at least 240 ℃ thermoplastic polymer composition by heat distortion temperature (HDT).HDT is preferably at least 250 ℃, and more preferably at least 270 ℃, or even 290 ℃.

But thermoplastic polymer composition also is preferably the composition of laser weld.The manifold bodies sidewall combines with fastening step by fastening the suiting of laser weld with plastic slab, and wherein the chimb of plastic slab or its periphery location inserts manifold bodies, or on the contrary, the chimb that the periphery of the fringe region of manifold bodies insertion plastic slab is located.In this regard, plastic slab preferably is different from the thermoplastic polymer composition that forms the manifold bodies material therefor by the absorption behavior to laser and makes, and preferably, accept the parts that are inserted into parts by lower to used laser absorption in the laser welding process or even transparent thermoplastic polymer composition make, and this is inserted into parts and is made by the thermoplastic polymer composition that absorbs used laser in the laser welding process.Be that by inserting the automotive heat exchanger construction of gained has better mechanical strength and variation has better resistivity to pressure with the fastening advantage that combines of laser weld with plastic slab and manifold bodies.

But the thermoplastic polymer composition of making plastic slab and/or manifold bodies is suitably the composition of injection mo(u)lding, and plastic slab and/or manifold bodies are suitable to equally the injection molding process manufacturing.

Automotive heat exchanger of the present invention can be any heat exchanger that is designed for motor vehicle and comprises medium to be cooled.Aptly, heat exchanger is oil cooler, aerial cooler (for example, the charge air cooler of turbogenerator) or radiator.In automotive heat exchanger of the present invention, the manifold with plastic slab can be inlet manifold and outlet manifold, or both.Preferably, this manifold is the parts of charge air cooler, and this manifold is air inlet manifold and/or air outlet slit manifold.

The invention still further relates to a kind of manufacture method of automotive heat exchanger, described automotive heat exchanger comprises aforesaid heat exchange core, plastic slab and plastic manifold body.Method of the present invention comprises: at first

(i) opening of described plastic slab is inserted in the end of the heat transfer tubes of described heat exchange core, and make it extend through described opening;

(ii) the outermost end portion with the end of described heat transfer tubes outwards turns down, thereby forms pressure tight joint between plastic slab and header pipe component; Then

(iii) near the fringe region place of the sidewall of described manifold bodies or its, described plastic slab is fastened to described sidewall.

The method has the above-mentioned advantage of automotive heat exchanger of the present invention.

The outside turnover of step in (ii) can for example realize by sour jujube shape thing.

Alternatively, with the step (i) of this method and the plastic slab (ii) and the fastening of header pipe component combine with the seal between the contained substrate of plastic slab and heat exchange core or the use of sealant.Aptly, seal is packing ring, for example rubber washer.

Plastic slab and manifold bodies sidewall fastening of step in (iii) can be undertaken by any method that is applicable to this purpose, and be for example as indicated above by crimping, snapping, bonding or welding, or any combination of these methods.

Heat exchanger by method manufacturing of the present invention is preferably automotive heat exchanger of the present invention or its preferred implementation.

Below each figure illustrate the present invention.

Fig. 1 is the schematic three dimensional views of heat exchange core;

Fig. 2 is the schematic three dimensional views of the assembly of automotive heat exchanger of the present invention;

Fig. 3 is the schematic three dimensional views of the assembly of automotive heat exchanger of the present invention;

Fig. 4 is the side view of the manifold bodies used in the automotive heat exchanger of the present invention;

Fig. 5 is the cutaway view of the manifold bodies used in the automotive heat exchanger of the present invention;

Fig. 6 is the schematic three dimensional views of step of assemble method of the assembly of automotive heat exchanger of the present invention;

Fig. 7 is the side view that has the manifold bodies of the fringe region that comprises excision portion and accept the plastic slab of this manifold bodies;

Fig. 8 is the manifold bodies among Fig. 7 and the cutaway view of plastic slab;

Fig. 9 is manifold bodies among Fig. 7 and the plastic slab cutaway view after according to the present invention and heat transfer tubes assembling.

Fig. 1 shows the schematic three dimensional views of heat exchange core (2). Heat exchange core comprises the external member of a plurality of heat-exchange tubes (4) and cooling fins (6), described heat-exchange tube (4) and cooling fins (6) replace stacking and are fixed together by plate (8), and described plate is called as substrate or end plate or a plate. Heat exchange core (2) comprises two header pipe components (10), the end (12) that it comprises substrate (8) and stretches out this substrate (8).

Fig. 2 shows the schematic three dimensional views of the assembly that can be assembled into automotive heat exchanger of the present invention. This assembly comprises heat exchange core (2), seal (14), plastic slab (16) and manifold bodies (18). Manifold bodies (18) comprises sidewall (20) and diapire (22).

Fig. 3 shows the schematic three dimensional views that the assembly of Fig. 2 is observed from different perspectives. This assembly comprises heat exchange core (2) (part only is shown), seal (14), plastic slab (16) and manifold (18). Plastic slab (16) comprises a plurality of openings (24), and open amount equals the quantity of the contained heat transfer tubes of heat exchange core (2) (4). Plastic slab (16) also comprises along the circumferential flange (26) of the outstanding periphery location of the diapire (22) of manifold bodies (18).

Fig. 4 shows the side view of the manifold bodies (18) of using in the automotive heat exchanger of the present invention. Manifold bodies (18) comprises sidewall (20) and diapire (22). Sidewall (20) comprises fringe region (28), and this fringe region is relative with diapire and comprise peripheral edge area (30). Peripheral edge area (30) is formed for accepting the slit (not shown) of end of the heat transfer tubes of heat exchange core (not shown).

Fig. 5 shows the cutaway view of manifold bodies on the Y-Y ' of plane that uses in the automotive heat exchanger of the present invention of Fig. 4. Manifold bodies (18) comprises sidewall (20) and diapire (22). Sidewall (20) comprises fringe region (28), and this fringe region is relative with diapire and comprise peripheral edge area (30), inside fringe region (32) and to outer edge region (34).

Fig. 6 shows the schematic three dimensional views of the step (Fig. 6 a-6f) of the assembly assemble method of automotive heat exchanger of the present invention.

Fig. 6 a shows the part of the heat exchange core (2) that comprises a header pipe component (10), and it comprises a plate (8) and the end (12) of the heat-exchange tube (4) that stretches out from this plate (8).

The end (12) that Fig. 6 b shows the same section of heat exchange core (2) and is arranged on heat-exchange tube (4) on every side and with the seal (14) of plate (8) adjacency.

Fig. 6 c shows the have seal same section of heat exchange core (2) of (14), the end (12) that described seal (14) is arranged on heat-exchange tube (4) on every side and with plate (8) adjacency. Fig. 6 c also shows the plastic slab (16) of the circumferential flange (26) that comprises that a plurality of openings (24) and the periphery that is fastened to heat exchange core (2) are located.

Fig. 6 d shows the same section of the heat exchange core (2) with seal (14) (invisible) of Fig. 6 c and the plastic slab (16) of arranging near heat exchange core (2), and described layout is so that this opening is accepted and extended through in the end (12) of heat-exchange tube (4) by the opening of plastic slab (16). Fig. 6 d also shows a plurality of sour jujube shape things (36), and by this sour jujube shape thing, the outermost end portion of the end (12) of heat transfer tubes (4) can outwards turn down.

Fig. 6 e shows the part of heat exchange core (2) of (14) (invisible) that have seal and the plastic slab (16) of arranging near heat exchange core (2), and the outermost end portion (38) of end (12) of heat transfer tubes (4) that wherein extends through the opening of plastic slab (16) is outwards turned down. Fig. 6 e also shows the manifold bodies (18) that is fastened to plastic slab (16).

Fig. 6 f shows the heat exchange core (2) of (14) (invisible) that have seal, by the fastening plastic slab (16) of outermost end portion (38) (invisible) and the heat exchange core (2) of outwards turnover and the manifold bodies (18) that is fastened to plastic slab (16).

Fig. 7 shows the side view of manifold bodies (18) and plastic slab (16), this manifold bodies is comprising cut portion (40) to outer edge region (34) one sides, this plastic slab comprises the circumferential flange (26) of periphery location, and this circumferential flange has in the inboard be used to the cut portion of accepting manifold bodies (42) (invisible).

Fig. 8 shows manifold bodies and the cutaway view of plastic slab on the Y-Y ' of plane of Fig. 7. Manifold bodies (18) is comprising cut portion (40) to outer edge region (34) one sides. Plastic slab (16) comprises be used to the circumferential flange (26) of the opening (24) of accepting heat-exchange tube (4) (not shown) and periphery location having cut portion (42) in circumferential flange (26) inboard of periphery location.

Fig. 9 shows manifold bodies and the plastic slab of Fig. 7 and assembles rear cutaway view on the Y-Y ' of plane according to the present invention and heat transfer tubes. Manifold bodies (18) is comprising cut portion (40) to outer edge region (34) one sides. Plastic slab (16) comprises the circumferential flange (26) of opening (24) and periphery location, has cut portion (42) in circumferential flange (26) inboard of periphery location. Fringe region with manifold bodies (18) of cut portion (40) is accepted and is adjacent by the circumferential flange (26) of the periphery location with cut portion (42) of plastic slab (16). Assembly also comprises heat-exchange tube (4), and heat-exchange tube (4) is accepted by opening (24) and its end extends through this opening, and the outermost end portion of end outwards turns down.

Further set forth the present invention by following examples.

The preparation of material

Test the heat exchanger that used heat exchange core is a business type, its canonical form comprises sealing the margin and the wide crimp jaws of 6.5mm that 3.6mm is wide.Further do not changing under the condition of heat exchange core structure, take out two central modules from heat exchange core, this heat exchange core comprises three heat transfer tubes, two cooling fins intermediate layers and two small-sized substrate elements (each one at heat transfer tubes two ends).The size of the excision portion of substrate is about 45 * 45mm.Stretch out from substrate element the end of heat transfer tubes, and its length is about 2-2.5mm.

Beginning to prepare four plastic slabs by plastic plate, respectively is that 80 * 80mm and 2mm are thick.The plastics of making plate are Stanyl TW200F6, and it is polyamide-4,6 molding compounds of Dutch DSM.For each plate, make three groove shape openings with heat transfer tubes size.This opening perimeter is with 45 ° gradient convergent.

In addition, use four aluminium sheets (respectively being that 80 * 80mm and 2mm are thick).Wherein two aluminium sheets have the valve that is used to connect pressure unit in the middle of being arranged on.Here, aluminium sheet is used as the model of manifold bodies.

Preparation of model

Experiment 1

Two plates that will have tapered openings slide on the end of the heat transfer tubes of one of two heat exchange core part, and arrange near substrate element (respectively there is a plate these parts both sides), thereby form first assembly.First assembly placed 200 ℃ baking oven 30 minutes.Then, the heat-exchange tube that extremely makes by outside turnover pipe forms flange.By some sealants of small-sized screw bolt and nut and perimeter, aluminium sheet (strip valve a, plate is not with valve) is fixed near the outside of plastic slab.Resulting part is called assembly A hereinafter.

Experiment 2

To the whole process of second heat exchange core part repeated experiments 1, difference is: with plastic slab near substrate arranged before, coated with adhesive between substrate and plastic slab.Used binding agent is Loctite 5366, and it is the silica-based binding agent of U.S. Henkel Group.This process resulting part is called assembly B hereinafter.

Pressure test

Assembly A and B are carried out two kinds of different pressure tests, at first carry out the nitrogen pressure test, carry out the water pressure test then.In these tests, the valve on the aluminium sheet links to each other with water pump with the nitrogen pump respectively.In each test, the pressure that raises gradually, and detect the damage of its leakage and other form.

For assembly A, nitrogen pressure can rise to 2.8bar and any problem not occur.When 2.8bar, some occur and leak, but the structure of assembly itself is kept perfectly.

For assembly B, nitrogen pressure can rise to 3bar and any problem not occur.For safety, test is proceeded with hydraulic pressure.Hydraulic pressure can rise to 6bar and not go wrong.When 6bar, some occur and leak, but the structure of assembly itself is kept perfectly.

These model experiments are the result show, the manifold that comprises the mould shapes of manifold bodies promptly can reach high workload pressure, it can keep the integrality of structure simultaneously, described manifold bodies is fixed to plastic slab, and itself is fixed to heat exchange core part plastic slab, and wherein said plastic slab just fixes by the end of outside turnover heat transfer tubes, but not uses crimp jaws or other to be used for manifold bodies is fixed to the device of heat exchange core.Experiment also shows, uses sealant can further significantly improve operating pressure.

Claims

1. automotive heat exchanger comprises:

A) comprise the heat exchange core of header pipe component with a plurality of heat transfer tubes;

B) comprise the plastic manifold body of sidewall and diapire, described sidewall has and described diapire opposed edges zone, described fringe region comprises inside fringe region, to outer edge region and peripheral edge area, and be formed for accepting the space of the end of described heat transfer tubes; And

C) have the plastic slab of a plurality of openings, described number of openings equals the quantity of the described heat transfer tubes that described heat exchange core comprises;

Wherein

I) described opening is accepted and extended through in the end of described heat transfer tubes by the opening of described plastic slab, and the outermost end portion of the end of described heat transfer tubes outwards turns down, thereby forms pressure tight joint between described heat exchange core and described plastic slab;

Ii) described plastic slab is secured to the sidewall of described manifold bodies, so that described plastic slab contacts fully with described sidewall; And

Iii) described manifold bodies only is engaged to described heat exchange core by described plastic slab and described manifold bodies fastening.

2. automotive heat exchanger as claimed in claim 1, wherein said plastic slab are at the fringe region place of described manifold bodies or be secured to the sidewall of described manifold bodies near it.

3. as the automotive heat exchanger of claim 1 or 2, wherein said plastic slab is secured to described sidewall by mechanical bond, chemical bond or its combination.

4. as any one automotive heat exchanger among the claim 1-3, wherein said plastic slab has along the circumferential flange of the outstanding periphery location of described diapire direction.

5. as any one automotive heat exchanger among the claim 1-4, wherein said opening has to the small part tapered shape, so that described opening broadens when described orientation substrate is observed gradually.

6. as any one automotive heat exchanger among the claim 1-5, wherein said manifold bodies is made by plastic material.

7. as any one automotive heat exchanger among the claim 1-6, wherein said heat exchanger comprises inlet manifold and outlet manifold, described manifold comprises plastic slab and manifold bodies, described manifold bodies only the secure engagement by described plastic slab and described manifold bodies to described heat exchange core.

8. method of making heat exchanger, described heat exchanger comprises:

B) comprise the manifold bodies of sidewall and diapire, described sidewall has and described diapire opposed edges zone, and described fringe region comprises inside fringe region, to outer edge region and peripheral edge area and be formed for accepting the space of the end of described heat transfer tubes; And

Described method comprises the following step of following order:

(i) extend through the opening of described plate by the end that makes described heat transfer tubes, described plastic slab is fastened to described header pipe component; Then

The outermost end portion of the end of described heat transfer tubes is outwards turned down; Then

9. method as claimed in claim 8, wherein said plastic slab is secured to described manifold bodies by crimping, snapping, bonding or welding or its combination.

10. as the method for claim 8 or 9, wherein said heat exchanger is as any one heat exchanger among the claim 1-7.