DE102014217314A1 - Intercooler for an internal combustion engine and arrangement of an intercooler on a cylinder head of an internal combustion engine - Google Patents

Abstract

The invention relates to a charge air cooler (10) for an internal combustion engine as well as an arrangement of a charge air cooler (10) on a cylinder head (30) of an internal combustion engine, which should enable a simple, safe and cost-effective installation. In particular, the known negative effect of undesired transverse forces to be counteracted. An inventive intercooler (10) for an internal combustion engine comprises a housing (12), wherein the housing (12) has a first contact surface (20) for surface conditioning and attachment of the intercooler (10) on a cylinder head (30) of the internal combustion engine, wherein Attachment of the housing (12) at least one along a connecting axis (26) extending opening (24) in the housing (12) is formed, which penetrates the first bearing surface (20) and wherein the connecting axis (26) in a deviating from 90 ° Angle to the first contact surface (20) extends. In this case, at least one support projection (28) is formed on the housing (12), which extends in the direction of a cylinder head (30) to be connected with respect to the first contact surface (20) and is designed such that a surface formed on the support projection (28) (32) when mounting the charge air cooler (10) on a cylinder head (30) serves as a second contact surface (34).

Description

The invention relates to a charge air cooler for an internal combustion engine according to the preamble of claim 1 and an arrangement of a charge air cooler on a cylinder head of an internal combustion engine. In particular, the invention relates to the attachment of a housing of a so-called intake manifold integrated intercooler. These are in particular those intercoolers understood in which in the intake manifold of an internal combustion engine - especially liquid-based - heat exchanger is integrated to extract air to be supplied to the combustion chamber of an internal combustion engine, immediately before flowing into the combustion chamber heat and thus the introduction of a allow larger air mass in the combustion chamber. For dissipating the heat, so-called cooling cassettes are sometimes used as separate components in such heat exchangers.

Out WO 2008/061692 A1 is a designed as a compact module, intake manifold integrated intercooler for an internal combustion engine known.

In addition, charge air cooler according to the preamble of claim 1 are known from practice, wherein the housing of the charge air cooler has a first contact surface for surface contact and attachment of the intercooler to a cylinder head of the internal combustion engine and at least one extending along a connecting axis opening in to secure the housing is formed of the housing, which penetrates the first contact surface and wherein the connecting axis extends at an angle deviating from the 90 ° to the first contact surface.

In the known from practice intercoolers according to the preamble of claim 1 caused by design due to the not perpendicular to the first contact surface connecting axis transverse forces that lead to an at least partially bending the first contact surface.

From practice it is known to use a so-called intermediate flange to avoid or reduce the above-mentioned bending of the first contact surface. It is a manufactured as a separate component adapter that allows a screw perpendicular to the first contact surface. This solution not only leads to a higher weight of the intercooler with cylinder head and adapter, but also increases the cost of installing a charge air cooler.

From practice, it is also known to use so-called terminal strips for mounting a charge air cooler. When using terminal strips of the intercooler is fixed on one side by means of a clamp and screwed otherwise. The terminal strips are designed in such a way that the clamping force in the area of the terminal strip is increased with increasing screwing force. A disadvantage of this solution is that the clamping force in the region of the terminal strip is highly dependent on compliance with small manufacturing tolerances.

The invention has for its object to provide a charge air cooler for an internal combustion engine according to the preamble of claim 1 and an arrangement of such a charge air cooler on a cylinder head of an internal combustion engine, which allow a simple, safe and cost-effective installation. In particular, the known negative effect of undesired transverse forces to be counteracted.

The object is achieved according to the invention with the features of the independent claims. Further practical embodiments are described in the subclaims.

An inventive intercooler for an internal combustion engine comprises a housing, wherein the housing has a first contact surface for surface conditioning and attachment of the intercooler to a cylinder head of the internal combustion engine, wherein for attachment of the housing at least one extending along a connecting axis opening in the housing is formed, which penetrates the first contact surface and wherein the connecting axis extends at a different angle from the 90 ° to the first contact surface. In this case, at least one support projection is formed on the housing, which extends relative to the first contact surface in the direction of a cylinder head to be connected and is designed such that a surface formed on the support projection surface when mounting the intercooler on a cylinder head serves as a second contact surface. In other words, a second contact surface is formed on a housing of a charge air cooler according to the invention in addition to a first contact surface, which allows for a simple and cost-effective mounting option of a charge air cooler to a cylinder head of an internal combustion engine secure attachment. For in a charge air cooler according to the invention caused by an oblique screw or other attachment transverse forces can be initiated directly from the housing of the charge air cooler in the cylinder head and thus supported. This is done by a suitable design and arrangement of the support projection.

In a practical embodiment of an intercooler according to the invention are the first Contact surface and the second contact surface arranged at an angle between 45 ° and 135 ° to each other or formed. Particularly preferred are ranges between 80 ° and 100 °, more preferably arrangements with an angle of 90 °. Such angles are conventional angles provided on a cylinder head between a side wall and a top wall. The use of a charge air cooler according to the invention with existing cylinder head designs is particularly preferred because the structural change of a cylinder head is associated with significantly higher costs than the change of a charge air cooler or its housing.

In a further practical embodiment of an intercooler according to the invention, the first contact surface and the second contact surface are at least partially adjacent to each other. This embodiment is advantageous in that a full-surface, extending over an edge support, as it results in this case, ensures a particularly high reliability.

In a further practical embodiment of a charge air cooler according to the invention, the at least one support projection is arranged directly adjacent to the at least one opening and / or between two openings. If a plurality of openings are provided in the housing, this applies to all openings whose connecting axis extends in an angle deviating by 90 ° to the first contact surface. In this case, lateral forces that occur due to the oblique connecting axis, transferred directly in the region of their formation by the support projection of the charge air cooler to the cylinder head and thus compensated. The formation of a bend in the region of the first contact surface is thus counteracted efficiently.

For the sake of completeness, it is pointed out that a supporting projection can also extend over the entire length of that housing wall of the housing of an intercooler, which adjoins the cylinder head. This is even associated with a particularly high stability and thus advantageous. For weight reasons, however, a partial formation of support projections directly in the region of the openings and / or centrally between openings is preferred.

The housing of a charge air cooler according to the invention is preferably made of a metallic material, in particular of aluminum. Aluminum has the advantage that it has a relatively low density and thus the component has a low mass. Furthermore, aluminum is very temperature resistant, especially when air or exhaust gases with a temperature of well over 200 ° C flow through the housing. The housing of a charge air cooler according to the invention can also be made of plastic. In conjunction with a plastic housing, the use of metallic inserts, in particular for receiving bolting forces in the range of screw connections between the intercooler and a cylinder head is suitable.

The invention also relates to the arrangement of a charge air cooler, in particular a charge air cooler as described above, on a cylinder head of an internal combustion engine, wherein the charge air cooler has a housing, on which a first contact surface for surface contact and attachment of the intercooler is formed on a side wall of the cylinder head, said for fastening the housing, at least one opening extending along a connecting axis is formed in the housing, which penetrates the first contact surface and wherein the connecting axis extends at an angle deviating from 90 ° to the first contact surface, and wherein at least one support projection is formed on the housing is, which extends relative to the first contact surface in the direction of the cylinder head in such a way that formed on the support projection surface when mounting the intercooler at the same time as a second contact surface for engagement with a top wall or bottom wall of the cylinder head is used. The advantages already described in connection with the intercooler are hereby referred to again. In particular, a deflection of the contact surface of the housing of the intercooler is counteracted with an inventive arrangement, since the support projection is supported on the cylinder head at the place of origin of the transverse force.

In particular, the invention relates to arrangements in which a plurality of openings are provided and the intercooler is bolted to the cylinder head via screws inserted into the openings.

If, in a practical embodiment of the arrangement according to the invention, the at least one opening in the housing of the intercooler in the cylinder head continues through an edge extending between a side wall and a top wall of the cylinder head or between a side wall and a bottom wall of the cylinder head, this results in the housing of the According to the invention intercooler a particularly large height for a heat sink, at the same time the geometry of a cylinder head according to the invention, which usually has a side wall and a top wall or bottom wall, does not need to be changed. In an inventive Intercoolers are formed in a further practical embodiment, a plurality of openings as above in the charge air cooler and in the cylinder head such that they are suitable for screwing the cylinder head with the intercooler. This makes it possible to connect the intercooler safely and space economically with the cylinder head. The openings are preferably arranged at a regular distance around the at least one outflow opening, more preferably arranged in the form of a rectangle. It should be noted that not all openings must have connecting axes which extend at an angle deviating from 90 ° to the first bearing surface. Usually arranged only in the region of the top of a cylinder head openings are arranged at a different angle from 90 ° to increase the space for inserted into the housing heat sink in this area.

In a further practical embodiment, the housing of the intercooler abuts directly on a side wall and / or on a top wall or bottom wall of the cylinder head. The intercooler thus forms a suction pipe of the internal combustion engine. Such intercoolers are also referred to as suction tube-based intercooler.

Further practical embodiments and advantages of the invention are described below in conjunction with the drawings. Show it:

1 3 shows a three-dimensional representation of an embodiment of a housing of an intercooler according to the invention,

2 a sectional view through the in 1 shown housing according to cross-sectional line II-II and

3 an enlarged sectional view through an embodiment of a screw connection of a housing according to the invention with a cylinder head in the region of one of the two outer upper openings.

An inventive intercooler 10 includes a housing 12 in which inflow openings 14 are designed for the introduction of charge air to be cooled. Further, in the housing discharge openings 16 designed to charge air cooled within the housing via a to the intercooler 10 immediately adjoining cylinder head 30 (please refer 2 ) to a combustion chamber (not shown) to supply. Air passing through the inlet openings 14 in the case 12 flows in the embodiment shown during the passage through a into a cooling opening 18 used cooling cassette (not shown) cooled and then through the outlet openings 16 fed to a combustion chamber of a cylinder of an internal combustion engine. The intercooler 10 thus forms the intake manifold of the internal combustion engine and is therefore also referred to as intake manifold integrated intercooler. The cooling cassette to be used in the embodiment shown comprises channels for fluid (here: water) and a multiplicity of lamellae for the flow of air from the inlet openings 14 to the outlet openings 16 to extract heat from the air passing through the cooling cassette. It is therefore a liquid-based intercooler 10 ,

About the inlet openings 14 Incoming air, in the illustrated embodiment, which is intended for a twin-turbo internal combustion engine, usually temperatures between -30 ° C and 250 ° C. Air flowing out through the outlet openings usually has temperatures between 30 ° C and 60 ° C.

How out 1 is recognizable, is in the area of the outlet openings 16 of the housing 12 a (here: just) trained, first contact surface 20 for surface contact of the housing on a cylinder head (in 2 shown schematically) formed. The contact surface surrounds the outflow openings 16 frame shape. The cylinder head has a housing 12 of the intercooler 10 facing sidewall 36 and one in the upper part of the side wall 36 subsequent top wall 38 on.

In the lower part of the case 12 as well as in the middle area of the housing 12 are openings 22 formed, extending through the first contact surface 20 extend and their extension axes perpendicular to the contact surface 20 run. They serve to screw the housing 12 with a cylinder head, as in the 2 shown arrangement shown.

The screwing takes place in the embodiment shown from the side of the intercooler 10 ,

In the upper part of the case 12 are five more openings 24 formed, extending along connecting axes 26 through the first contact surface 20 extend through, wherein the connection axes 26 at an angle of about 60 °. These openings 24 also serve to screw the housing 12 with the cylinder head 30 as described above.

For screwing with the help of screws 44 are in the cylinder head 30 openings 40 with corresponding threads 42 (Internal thread) formed (see. 3 ).

In the 1 - 3 It can also be seen that on the housing 12 just above the openings 24 supporting projections 28 are formed, which are opposite to the first contact surface 20 in the direction of the cylinder head to be connected 30 extend (ie, the projections protrude in the direction of the cylinder head 30 opposite the first contact surface 20 and) are formed such that surfaces formed on the support projection 32 when mounting the intercooler 10 on the cylinder head 30 as a second contact surface 34 serve. This is especially in 3 clearly visible.

In the in 2 reproduced cutting plane is the second contact surface 34 relatively small, as the support projection 28 not very far towards the cylinder head 30 protrudes. How out 1 is recognizable, extend the support projections 28 however, in a view according to the arrow P in FIG 1 - At least partially in the areas to the right and left of the upper openings 24 , In other words, the support projections are 28 in the embodiment shown above the support projections 28 formed so as to extend laterally across the width of the openings.

This results in each case a larger second contact surface on the right and left of the openings 34 extending to the first contact surface 20 extends and in the area next to the openings 24 also directly to the side surface 36 the cylinder head is adjacent, ie in these areas is the housing 12 L-shaped on the cylinder head 30 at. Due to the oblique screw connection resulting longitudinal forces can so on the side wall 36 and lateral forces over the top wall 38 of the cylinder head 38 be recorded immediately.

The in the 1 - 3 shown embodiment in which the bore in the cylinder head 30 in the between side wall 36 and top wall 38 formed edge leads, has the advantage that existing cylinder heads 30 can be used and do not need to be changed and yet a safe and easy installation taking advantage of the existing geometry of the cylinder head shown 30 and by maximizing the space available for the intercooler to dispose a refrigeration cassette.

In the illustrated embodiment of a charge air cooler according to the invention 10 and in the 2 and 3 illustrated arrangement of the intercooler 10 on a cylinder head 30 are both the case 12 as well as the cylinder head 30 made of aluminum. All openings 22 . 24 serve to guide screws which are used via a thread formed in the cylinder head (not shown) for fixing the intercooler on the cylinder head.

In 3 is the example of a support projection 28 yet to realize that these are in the area of their free ends 50 in the embodiment shown, a material thickening 46 include. It can also be seen that the material thickness m (perpendicular to the connection axis 26 considered) of the outside screw 48 continuously increases in the screwing.

The features of the invention disclosed in the present description, in the drawings and in the claims may be essential both individually and in any desired combinations for the realization of the invention in its various embodiments. The invention is not limited to the described embodiments. It can be varied within the scope of the claims and taking into account the knowledge of the person skilled in the art. In this regard, reference is made in particular to the fact that the above-mentioned geometric features are not mandatory and in particular to an increasing material thickness m or to material thickening 46 as well as further details can be dispensed with.

LIST OF REFERENCE NUMBERS

10

Intercooler

12

casing

14

inflow

16

outflow

18

cooling vent

20

first contact surface

22

openings

24

upper openings

26

connecting axes

28

supporting projections

30

cylinder head

32

area

34

second contact surface

36

left side wall

38

top wall

40

Opening (in the cylinder head)

42

inner thread

44

screw

46

material thickening

48

screw flange

50

free end

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

• WO 2008/061692 A1 [0002]

Claims (10)

Intercooler ( 10 ) with a housing ( 12 ) for an internal combustion engine, wherein the housing ( 12 ) a first contact surface ( 20 ) for surface conditioning and attachment of the intercooler ( 10 ) on a cylinder head ( 30 ) of the internal combustion engine, wherein for fastening the housing ( 12 ) at least one along a connecting axis ( 26 ) extending opening ( 24 ) in the housing ( 12 ) is formed, which the first contact surface ( 20 penetrates and wherein the connecting axis at an angle deviating from 90 ° to the first bearing surface ( 20 ), characterized in that on the housing ( 12 ) at least one support projection ( 28 ) is formed, which is opposite to the first contact surface ( 20 ) in the direction of a cylinder head to be connected ( 30 ) and is formed such that one on the support projection ( 28 ) trained area ( 32 ) when mounting the intercooler ( 10 ) on a cylinder head ( 30 ) as a second contact surface ( 34 ) serves. Intercooler ( 10 ) according to the preceding claim, characterized in that the first contact surface ( 20 ) and the second contact surface ( 34 ) are arranged or formed at an angle between 45 ° and 135 ° to each other. Intercooler ( 10 ) according to one or more of the preceding claims, characterized in that the first contact surface ( 20 ) and the second contact surface ( 34 ) are formed at least partially adjacent to each other. Intercooler ( 10 ) according to one or more of the preceding claims, characterized in that a plurality of openings ( 24 ) around at least one outflow opening ( 16 ) are arranged for cooled charge air. Intercooler ( 10 ) according to one or more of the preceding claims, characterized in that the at least one support projection ( 28 ) immediately adjacent to the at least one opening ( 24 ) in the region of the first contact surface ( 20 ) and / or between two openings ( 24 ) is arranged. Intercooler ( 10 ) according to one or more of the preceding claims, characterized in that the housing ( 12 ) is made of a metallic material and / or plastic. Arrangement of a charge air cooler ( 10 ) on a cylinder head ( 30 ) of an internal combustion engine, wherein the intercooler ( 10 ) a housing ( 12 ), on which a first contact surface ( 20 ) for surface conditioning and attachment of the intercooler ( 10 ) on a side wall ( 36 ) of the cylinder head ( 30 ) is formed, wherein for fastening the housing ( 12 ) at least one along a connecting axis ( 26 ) extending opening ( 24 ) in the housing ( 12 ) is formed, which the first contact surface ( 20 penetrates) and wherein the connection axis ( 26 ) at an angle deviating from 90 ° to the first contact surface ( 20 ), and wherein on the housing ( 12 ) further at least one support projection ( 28 ) is formed, which is opposite to the first contact surface ( 20 ) in the direction of the cylinder head ( 30 ) such that one on the support projection ( 28 ) trained area ( 32 ) when mounting the intercooler ( 10 ) simultaneously as a second contact surface ( 34 ) for installation with a top wall ( 38 ) or bottom wall of the cylinder head ( 30 ) serves. Arrangement according to the preceding claim, characterized in that a plurality of openings ( 24 ) are provided and the intercooler ( 10 ) into the openings ( 24 ) used screws with the cylinder head ( 30 ) is screwed. Arrangement according to one or more of claims 7 and 8, characterized in that the at least one opening ( 24 ) in the housing ( 12 ) in the cylinder head ( 30 ) by a between a side wall ( 36 ) and the top wall ( 38 ) of the cylinder head or between a side wall ( 36 ) and a bottom wall of the cylinder head ( 30 ) continues running edge. Arrangement according to one or more of claims 8 or 9, characterized in that the housing of the intercooler directly to a side wall ( 36 ) and / or on a top wall ( 38 ) or bottom wall of the cylinder head ( 30 ) is present.

Images