DE102012205844A1 - heat exchangers - Google Patents

Abstract

A heat exchanger for a vehicle is provided. The heat exchanger has a housing, a section of the housing defining a boundary of a coolant channel passing through the heat exchanger, the housing having first and second, opposite sides which have a layered structure, the first side being arranged on a vehicle periphery and has a greater number of layers than the second side. The heat exchanger also has coolant inlet and outlet openings that are fluidly coupled to coolant passages.

Description

Heat exchangers, such as radiators, are used in vehicles to release heat from an engine coolant circulating in an engine. Heat exchangers may use recirculated air generated by vehicle motion to transfer heat from the heat exchanger to the environment. In order to increase the circulated air flow and thus the heat transfer rate, heat exchangers may be located near the outer skin of the vehicle, such as in the grill of the vehicle. However, the heat exchanger may be damaged by the impact of foreign matter from the road or by a collision.

Therefore, attempts have been made to shield heat exchangers and thus reduce the likelihood of impact damage. For example, a shielded heat exchanger for a vehicle in US 2010/0089546 disclosed. The heat exchanger has a shielding channel, which is arranged in the vicinity of the periphery of the heat exchanger. The shielding channel acts as a crash barrier, which ensures increased shock resistance.

However, the inventors have several disadvantages of in US 2010/0089546 revealed heat exchanger detected. The shielding channel may not provide sufficient reinforcement to protect the heat exchanger from impact by external elements such as foreign objects from the road. In addition, the production of the complicated structure of the coolant channel may be expensive, as well as their repair.

Therefore, according to one approach, a heat exchanger for a vehicle is provided. The heat exchanger includes a housing, wherein a portion of the housing defines a boundary of a coolant channel passing through the heat exchanger, the housing having first and second opposing sides, each side having a layered construction, the first side proximate to one Peripheral of the vehicle is arranged and has a larger number of layers than the second side. The heat exchanger further includes coolant inlet and coolant outlet ports fluidly coupled to coolant passages in the vehicle.

In this way, the structural strength of an exposed portion of the heat exchanger can be enhanced by the multiple layers of the first side of the heat exchanger. As a result, the likelihood of damage to the heat exchanger caused by the impact of foreign objects from the road, collisions and other external elements can be reduced.

Further, in some embodiments, the layers of the first and / or second sides may be folded, and the housing may be formed of a continuous piece of material, thereby reducing the manufacturing cost of the heat exchanger, as compared to other manufacturing methods such as extrusion. It will also be appreciated that the number of layers in the first side of the housing may be adjusted during manufacture to provide a desired amount of reinforcement for different vehicle designs. For example, the number of layers in a vehicle requiring additional reinforcement may be increased. In this way, the heat exchanger can be used in a wide range of vehicles, thereby increasing the applicability and thus the market attractiveness of the heat exchanger.

This summary is provided to introduce, in a simplified manner, a selection of concepts, which are described in more detail below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that eliminate any or all of the disadvantages mentioned in any part of this disclosure.

The figures show:

1 shows a schematic representation of a vehicle having a heat exchanger and a motor.

2 shows an illustration of an example vehicle that the in 1 contains shown heat exchanger.

3 shows a sectional view of a first embodiment of the in 1 and 2 illustrated heat exchanger.

4 shows a perspective view of the in 3 shown first embodiment of the heat exchanger.

5 - 8th show sectional views of further embodiments of the in 1 and 2 illustrated heat exchanger.

9 shows a method for the operation of a cooling system in a vehicle.

In this specification, a heat exchanger having an increased structural strength is disclosed. The heat exchanger may have a housing, wherein a portion of the housing defines a boundary of a coolant channel passing through the heat exchanger, the housing having first and second opposing sides, each side having a layered construction, wherein the first side is disposed on a vehicle periphery and a larger number of layers has as the second side. In this way, the structural strength of the heat exchanger can be increased by increasing the thickness of the housing in a desired area (eg, the front of the heat exchanger). As a result, the likelihood of damage to the heat exchanger by external shocks can be reduced, thereby increasing the durability and life of the heat exchanger. Further, in some embodiments, the layers of the first and / or second sides may be folded, and the housing may be formed of a continuous piece of material, thereby reducing the manufacturing cost of the heat exchanger, as compared to other manufacturing methods such as extrusion.

1 shows a schematic representation of a vehicle 10 that's an engine 12 or another suitable engine and heat exchanger 14 having. The engine may be a suitable engine such as an internal combustion engine. Alternatively, the vehicle may include a hybrid electric powertrain having an internal combustion engine and an electric motor. Examples of hybrid powertrains include a parallel hybrid engine in which both the internal combustion engine and the electric motor can transfer mechanical power to the wheels via a transmission, and a serial hybrid engine in which the internal combustion engine is used as a generator to drive the electric motor , In another example, the vehicle may include a purely electric powertrain, the heat exchanger providing cooling for the electric motor, batteries, or combinations thereof.

The vehicle 10 also has an intake system 16 and an exhaust system 18 on. If, however, in the vehicle 10 an electric motor is used, the intake system and the exhaust system may not be included in the vehicle. The intake system 16 may be configured to supply air to the engine for combustion. Likewise, the exhaust system 18 be designed to dissipate exhaust gases from the engine. The arrow 15 denotes the flow of intake air into the engine 12 flows. The arrow 17 denotes the flow of exhaust gas into the exhaust system 18 flows. The motor 12 can a combustion chamber 19 having an inlet valve (not shown) and an outlet valve (not shown). The engine may be configured to burn fuel to generate motive power for the vehicle. Furthermore, the engine can be a cylinder head 20 and a cylinder block 22 having the at least one combustion chamber 19 form.

As illustrated, at least two coolant lines (eg, an inlet coolant line 24 and an outlet coolant line 26 ) with the heat exchanger 14 be fluidically coupled. The inlet and outlet coolant line ( 24 and 26 ) can with a coolant inlet port 28 or a coolant outlet opening 30 in the heat exchanger 14 be coupled. The coolant inlet port may be configured to allow coolant to flow into the heat exchanger, and the coolant outlet port may be configured to exhaust coolant from the heat exchanger. In this way, coolant can pass through the heat exchanger 14 be circulated through.

The heat exchanger 14 can with one or more coolant passages 25 be fluidically coupled to the engine 12 , the intake system 16 and / or the exhaust system 18 traverse. As shown, the heat exchanger is with the engine via the inlet coolant line 24 and the outlet coolant line 26 fluidly coupled. In particular, in some examples, the coolant passages 25 that the engine 12 traverse, in the cylinder block 22 and / or the cylinder head 20 be included. Thus, the coolant passages 25 traverse the cylinder head and / or the cylinder block. The coolant passage in the cylinder block 22 may be referred to as a cylinder block coolant jacket. Likewise, the coolant passages in the cylinder head 20 be referred to as a cylinder head coolant jacket. In this way, excess heat generated during engine operation may be concentrated on the working fluid in the coolant passages 25 transferred and then via the heat exchanger 14 be dissipated. Additionally or alternatively, the coolant inlet and outlet conduits may be fluidly coupled to coolant passages in the intake system and / or the exhaust system. The coolant passages may be included in an intercooler, an exhaust gas recirculation (EGR) cooler, and so on.

2 shows an exemplary vehicle 10 in which the heat exchanger 14 can be positioned. The heat exchanger 14 is in 2 shown schematically. As shown, the heat exchanger 14 near the periphery of the vehicle 10 be positioned. In particular, the heat exchanger can be positioned in the front of the vehicle.

3 - 8th show various embodiments of in 1 and 2 illustrated heat exchanger 14 , The views in 3 - 8th are sectional views. Therefore, it is clear that the cross-sectional planes which the cuts in 3 - 8th define perpendicular to the general coolant flow in the heat exchanger. In other words, coolant may be used during operation of the heat exchanger 14 into and out of the page, and vice versa. The various embodiments of the heat exchanger 14 , in the 3 - 8th have various advantages over prior designs of heat exchangers, such as heat exchangers constructed with a single layer of housing. Benefits include increased durability and low manufacturing costs.

It will be up now 3 Reference is made, which is a sectional view of a first embodiment of the heat exchanger 14 shows. As shown, the heat exchanger 14 a first housing 300 wherein a portion of the first housing is a boundary of a coolant channel 301 defines the heat exchanger 14 crosses. It is clear that the in 3 illustrated cross-section substantially perpendicular to the flow of the coolant through the coolant channel 301 is. As shown, the coolant channel 301 not circular. However, in other embodiments, the coolant channel may be circular. The first case 300 has a first and a second, opposite side, 302 respectively. 304 , on. The first case 300 may be made of a suitable material such as steel, aluminum, etc. Furthermore, the material may be deformable, so that the bending and folding during manufacture is facilitated.

The first page 302 has a layered structure. For example, the first page 302 multiple layers 306 of the first housing 300 exhibit. In the illustrated embodiment, the first housing 300 formed from a single continuous piece of material. To the first case 300 The following manufacturing method can be used. A first end 309 of the first housing 300 is folded to two layers 311 to build. The second end 313 of the first housing 300 is then folded and with the first two layers 311 connected, where there is a third layer 315 forms. That way, the first page 302 of the first housing 300 be formed of three layers. It is clear that the layers ( 311 and 315 ) of the first page 302 by a suitable method such as welding, gluing, etc. In particular, one side is located in the illustrated embodiments 303 the third layer 315 in surface contact with one side 305 one of the two layers 311 and is connected (eg, welded, glued, etc.) with this. In this way, the coolant channel 301 be sealed to reduce the likelihood of coolant leaks. Besides, the two layers are 311 and positioning the third layer in surface contact and adjacent each other. However, other manufacturing methods may be used in other embodiments. For example, the first end 309 and the second end 313 of the first housing 300 butt-jointed and connected (eg welded, glued, etc.) to the coolant channel 301 to build.

Also, the first page points 302 a larger number of layers than the second side 304 on. Thus owns the second side 304 also a layered structure. It is clear that a layered structure can also be a single-layer structure. In particular, as in 3 represented, the first page 302 three layers on, and the second side 304 has a single layer. In such an embodiment, the thickness T1 of the first side may be equal to three times the thickness T2 of the second side. However, other configurations are possible as described herein with reference to FIG 5 - 6 will be explained in more detail. The first page 302 of the first housing 300 may be exposed outside when in the vehicle 10 which makes it unprotected against the impact of foreign objects, collisions, etc. By increasing the number of layers of the first page 302 the durability of the first page is increased. In this way, the likelihood of impact damage from the road or a collision can be substantially reduced. As a result, the life of the heat exchanger can be reduced 14 increase.

The first case 300 also has a third and a fourth page, 308 respectively. 310 , on. The third and the fourth page ( 308 and 310 ) may also have fewer layers than the first side 302 , It will be understood that the first side may be the only side exposed outside and the second side, third side and fourth side may be protected over the vehicle structure. Therefore, in some examples, the second, third and fourth pages may not require as much structural reinforcement as the first page. In other embodiments, however, the second, third, and / or fourth sides may be exposed externally and / or may have additional layers for added durability.

3 further shows a second housing 312 that has a second coolant channel 314 forms. It is clear that the second case 312 an identical geometric construction as the first housing 300 can have. In some embodiments However, the housing can be designed differently. For example, the first page 302 of the first housing 300 have three layers, and the first page 316 of the second housing 312 can have two layers. In addition, the heat exchanger has 14 in other embodiments may not be a second housing 312 on.

In particular, the second housing 312 a first and a second, opposite side, 316 respectively. 318 , on. The second housing 312 may be made of a suitable material such as steel, aluminum, etc. Furthermore, the material may be deformable, so that the bending and folding during manufacture is facilitated. However, in other embodiments, the material may be a non-deformable material, such as a plastic. It is clear that the first case 300 and the second housing 312 in some embodiments may be made of similar materials.

Similar to the first case 300 shows the first page 316 of the second housing 312 a layered structure on. That is, the first page 316 can have multiple layers 318 of the second housing 312 exhibit. The layers can be formed by a suitable method such as wrinkles. Also, the first page points 316 a larger number of layers than the second side 318 on. In particular, as in 3 represented, the first page 316 three layers on, and the second side 318 has a single layer. In such an embodiment, the thickness T3 of the first side 316 equal to three times the thickness T4 of the second side 318 be. However, other configurations are possible as described herein with reference to FIG 5 - 6 will be explained in more detail.

The second housing 312 also has a third and a fourth page, 320 respectively. 322 , on. The third and the fourth page ( 320 and 322 ) may also have fewer layers than the first side 316 , It is clear that the first page may be the only page that is exposed outside, and the second page 318 , third page 320 and fourth page 322 can be protected over the vehicle structure. Therefore, the second, third and fourth pages ( 318 . 320 and 322 ) may not have as much structural reinforcement as the first page in some examples. In other embodiments, however, the second, third, and / or fourth sides may be exposed externally and / or may have additional layers for added durability.

In the illustrated embodiment, the second housing 312 formed from a single continuous piece of material. To make the layers, the second housing 312 folded or bent using a manufacturing process similar to that described above with respect to the first housing 300 is similar to described method. In other embodiments, however, the first housing 300 and the second housing 312 be prepared by different methods.

As shown, at least one rib can 324 between the first housing 300 and the second housing 312 extend. It will be appreciated that in other embodiments, multiple ribs may be used. The number of ribs may be selected based on the characteristics of the material of the housing and the rib, as well as the cooling requirement of the vehicle and so on.

More ribs 326 and 328 can with the first case 300 or the second housing 312 be connected. In particular, the rib is 328 with the third page 308 of the first housing 300 connected, and the rib 328 is on the fourth page 322 of the second housing 312 connected. During operation of the vehicle, air may flow through the fins. As a result, heat from the heat exchanger 14 be derived into the environment.

In some embodiments, the general direction of the flow of coolant through the first coolant channel 301 opposite to the general direction of the flow of coolant through the second coolant channel 314 be. However, in other embodiments, the general direction of flow through the first and second coolant channels may be ( 301 and 314 ) be the same.

4 shows a perspective view of the first embodiment of the heat exchanger 14 , As shown, several ribs extend 400 between the first and the second housing ( 300 respectively. 312 ). It is clear that in 3 illustrated rib 324 to the several ribs 400 belongs. Furthermore, several ribs can 402 from the first housing 300 extend out. The rib 326 , in the 3 is one of the several ribs 402 , Likewise, several ribs can 404 from the second housing 312 extend out. The rib 328 , in the 3 is one of the several ribs 404 ,

It can be a support structure 406 be provided to the first housing 300 on the second housing 312 to fix, whereby the relative position of the first housing is fixed relative to the second housing. However, in other embodiments, the support structure is 406 possibly not in the heat exchanger 14 contain. The cutting plane 408 defines the in 3 illustrated cross section of the heat exchanger 14 ,

5 - 8th show other embodiments of the first housing 300 in the heat exchanger 14 who in 3 and 4 is shown. It is clear that in 3 and 4 illustrated second housing 312 a similar configuration as the embodiments of the first housing 300 , in the 5 - 8th are shown. In addition, the embodiments of the first housing 300 , in the 5 - 8th are shown containing elements that correspond to the in 3 and 4 illustrated first embodiments of the first housing 300 correspond; similar parts are therefore marked accordingly.

In particular, show 5 and 6 a second and third embodiment of the first housing 300 in the heat exchanger 14 , As shown, the number of layers in the first page 302 to be changed.

In particular, the first page 302 contain two layers, as in 5 shown, or it may contain four layers, as in 6 shown. As in 6 As shown, the fold may be on opposite sides of the first housing 300 be arranged. However, other folding arrangements are possible. It is clear that if the first case 300 has a substantially equal width, the thicknesses of the pages multiples according to the number of in the first page 302 contained layers can be. For example, the thickness T1 of the first page 302 at the in 5 illustrated embodiment of the heat exchanger equal to twice the thickness T2 of the second side 304 be. Likewise, the thickness T1 of the first page 302 at the in 6 illustrated embodiment of the heat exchanger equal to four times the thickness T2 of the second side 304 be.

7 shows another embodiment of the heat exchanger 14 , As shown, the second page 304 be curved. It will be understood that the radius R1 of the curve may be equal to half the height H1 in some examples. If the second page 304 of the heat exchanger 14 is curved, the number of folds in the first housing 300 reduced. As a result, the manufacturing process is simplified, and therefore, the cost of the manufacturing process is lowered.

8th shows embodiments of a heat exchanger with a second coolant channel. In particular shows 8th an embodiment of the heat exchanger 14 in which a single continuous piece of material is folded around the first coolant channel 301 and a second coolant channel 800 to build. As shown, contains a wall 802 between the first and second coolant channels ( 301 and 800 ) two layers 804 ,

9 shows a method 900 for producing a heat exchanger such as the heat exchanger described above 14 , In 902 The method includes folding a continuous piece of material to form a housing defining a coolant channel, the housing having first and second opposing sides, the first side having a greater number of layers than the second side. Next, the method in 904 welding the multiple layers to seal the coolant channel. In some embodiments, the method 900 before the step 904 folding the piece of material to form a second coolant channel which is adjacent the second side. This step can be used to produce a heat exchanger, which is the in 7 similar embodiment is shown. In some embodiments, the method may further include steps 906 . 908 and or 910 include. It is clear that the steps 906 - 910 can be implemented to produce a heat exchanger which is the in 3 and 4 illustrated embodiment of a heat exchanger 14 is similar. However, in other embodiments, the method may be after step 904 end up. In 906 For example, the method may include folding a second continuous piece of material to form a second housing, wherein a portion of the second housing defines a boundary of a second coolant channel passing through the heat exchanger, the second housing having first and second opposing sides the first side has a larger number of layers than the second side. Next, the method in 908 welding two or more layers of the second housing to seal the second coolant channel. In 910 The method further includes attaching one or more ribs to the first housing and the second housing.

The procedure 900 offers several advantages over other manufacturing processes such as extrusion. First, it is inexpensive to produce a heat exchanger by this method. Furthermore, the manufacturing process can be easily modified to accommodate a variety of structural designs. In this way, the applicability of the heat exchanger can be extended to a number of different vehicles with different cooling requirements.

It will be understood that the configurations and / or procedures described herein are exemplary in nature and that these specific embodiments or examples are not to be considered in a limiting sense as numerous modifications are possible. The subject matter of the present disclosure includes all novel and not obvious lying combinations and sub-combinations of the various features, functions, steps and / or properties disclosed herein and any equivalents thereof.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 2010/0089546 [0002, 0003]

Claims (10)

A heat exchanger for a vehicle, comprising: a housing, wherein a portion of the housing defines a boundary of a coolant passage traversing the heat exchanger, the housing having first and second opposing sides having a layered construction, the first side being disposed at a vehicle periphery and a larger number of Has layers as the second side; and Coolant inlet and coolant outlet ports fluidly coupled to coolant passages. Heat exchanger according to claim 1, wherein the layers of the first and / or second side are folded. Heat exchanger according to claim 2, wherein the housing is formed of a continuous piece of material. The heat exchanger of claim 1, wherein the second side comprises a single layer of material. The heat exchanger of claim 1, wherein the coolant passages traverse a portion of an engine. Heat exchanger according to claim 5, wherein the coolant passages traverse a cylinder head and / or a cylinder block, wherein the cylinder head and the cylinder block form at least one combustion chamber. The heat exchanger of claim 1, further comprising a second housing, wherein a portion of the second housing defines a boundary of a second coolant channel passing through the heat exchanger, the second housing having first and second opposing sides, each side having a layered construction, wherein the first side is disposed on the vehicle periphery and has a larger number of layers than the second side. The heat exchanger of claim 7, further comprising at least one rib extending between the first housing and the second housing. The heat exchanger of claim 1, wherein a portion of the housing defines a boundary of a second coolant channel traversing the heat exchanger, the second coolant channel being disposed adjacent the second side. The heat exchanger of claim 1, wherein the coolant inlet and coolant outlet ports are fluidly coupled to coolant passages that traverse a cylinder head and / or a cylinder block in an engine.

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