DE102015115147A1 - Heat exchanger and method for producing such a heat exchanger - Google Patents

Abstract

A heat exchanger with a housing (14) provided for the flow through a first fluid, a heat exchange packet (12) accommodated within the housing (14), which has one or more fluid lines (10) provided for flow through a second fluid and for flow around by means of the first fluid ), and with an inlet connection (18) and an outlet connection (20) for the heat exchange packet (12), characterized in that the inlet connection (18) and / or the outlet connection (20) has a connection channel integrated into the heat exchange package (12) (22) which is fluid-conductively connected to a connection opening (24) formed by the housing (14) by means of a connection element (28) deformable as a result of non-uniform thermal expansion of the housing (14) and heat exchange packet (12).

Description

The invention relates to a heat exchanger, which may be provided in particular for use as a charge air cooler of an internal combustion engine. The invention further relates to a method for producing such a heat exchanger.

An integrated in a intake manifold module intercooler is from the EP 2 765 286 A1 known. In this intercooler, the heat exchange package, which consists of several alternating layers of on the one hand flat tubes and on the other hand the flat tubes interconnecting corrugated fins, connected at a variety of locations directly to the housing of the intake manifold, which also serves as a housing of the intercooler.

An intake manifold module with integrated intercooler is also out of the WO 2010/146063 A1 known. In this intake manifold, it is provided that the heat exchange package is mounted on spring elements within the housing of the intake manifold, whereby it should be protected against vibration and also thermal expansion of the housing and the cooler package to be compensated. Relative movements between the housing and the heat exchange package are thereby to be made possible in the region of the connecting tubes of the heat exchange package which are guided through correspondingly large through openings in the housing by sufficiently elastic sealing elements.

Such a seal of connection pipes of a cooler package in through holes of a housing in a charge air cooler has proven to be difficult to implement. This is due to the considerable relative movements due to thermally induced non-uniform strains of heat exchange package and housing. The annular gap between the edges of the through holes and the outer sides of the connecting pipes must therefore be dimensioned correspondingly large. A durable seal is therefore possible due to the not insignificant pressure differences between the inner volume of the housing and the environment only with considerable design effort and possibly by means of elastomeric sealing elements. However, such elastomeric sealing elements are disadvantageous in terms of manufacturability of such a charge air cooler. This applies at least when it is intended to connect the components of the heat exchange package and the housing in a combined process step by soldering in a brazing furnace. The temperature to which such a charge air cooler is exposed would regularly lead to the destruction of elastomeric sealing elements. A subsequent insertion of elastomeric sealing elements after soldering the remaining components of a charge air cooler, however, is associated with a considerable additional assembly costs.

Based on this prior art, the present invention seeks to provide a particular intended for use as a charge air cooler heat exchanger, which has a long service life and at the same time is advantageous to produce.

This object is achieved by means of a heat exchanger according to the patent claim 1. A method for producing such a heat exchanger is the subject of claim 10. Advantageous embodiments of the heat exchanger according to the invention and preferred embodiments of the method according to the invention are objects of the other claims and / or will become apparent from the following description of the invention.

A heat exchanger is provided with a housing provided for throughflow by means of a first fluid, a heat exchange packet accommodated within the housing, which has one or more fluid lines provided for the flow through a second fluid and for flowing around by means of the first fluid, and with an inlet connection and an outlet connection for the heat exchange package. In such a heat exchanger, the invention provides that the inlet connection and / or the outlet connection (in each case) comprises a connection channel integrated in the heat exchange packet, which is formed by means of a connection element which is deformable by means of nonuniform thermally induced expansions of the housing and heat exchange packet, preferably formed of an elastic material formed by the housing connection opening is fluidly connected.

The connection element can thus have a multiple functionality. On the one hand this serves the structural connection between the housing and the heat exchange package and thus also a position assurance of the heat exchange package within the housing. Furthermore, this can seal both the inner volume of the housing relative to the environment and the inner volume of the associated connection channel and the fluid line (s) fluidly connected to this connection channel with respect to the interior of the housing. In this way, both a leakage of first fluid into the environment as well as a mixing of first and second fluid in the internal volume of the housing can be avoided. Furthermore, the connection element has a local due to non-uniform thermally induced strains of housing and heat exchange package Relative movements compensatory or enabling functionality. For this purpose, it is provided that the deformability and in particular the elasticity of the connection element by an appropriate choice of material and / or by a corresponding geometric shape (in particular dimensions) is so large that caused by the deformation resistance forces of the connection element preferably not to mechanical stresses on in particular the connection points lead between the connection element and the housing and / or the heat exchange package, which can lead to a lower life. The difference in the thermally induced elongations of housing and heat exchange package can be comparatively large, because it is preferably provided that the housing is relatively stable and particularly thick-walled, because this is to ensure the structural integrity of the entire heat exchanger and also for the connection to Other components, such as supply and discharge lines for the first fluid and the second fluid and for securing the heat exchanger can be provided on a structure provided therefor. For the heat exchange package, on the other hand, it is possible to provide the most thin-walled possible configuration of the components forming this because the heat transfer between the first and the second fluid can thereby be positively influenced.

Furthermore, the connection element can also have a fluid-conducting function for the second fluid, for which purpose it preferably represents a section of the inlet connection and / or the outlet connection provided for guiding the second fluid.

The connection element may be an integral part of the housing and / or the connection channel and thus of the heat exchange package. Preferably, however, it is provided that the connection element is designed as a separate component, which is firmly connected to the production of a fluid-conducting connection between the associated connection channel and the associated connection opening of the housing preferably sealingly connected to both this connection channel and a connection opening forming this connection opening of the housing ,

In a preferred embodiment of the heat exchanger according to the invention can be provided that the connection channel, the connection element and the connection opening forming portion of the housing are made of (in particular a solderable) metal. This allows an advantageous manufacturability of the heat exchanger according to the invention. In particular, this advantageously makes it possible to solder the connection element to the connection channel and / or to a section of the housing forming the connection opening. It can be provided in particular that at least the connection points between the connection element and the associated connection channel and / or the associated connection opening forming portion of the housing and preferably all joints of the heat exchanger in a single process step by the melting and re-solidification of at these connection points be formed existing Lot.

• – Verbindungsstellen zwischen mehreren Teilen des mehrteiligen Gehäuses und/oder
• – Nahtstellen der beispielsweise als Flachrohre ausgebildeten Fluidleitung(en) und/oder
• – Verbindungsstellen zwischen benachbarten Fluidleitungen und/oder
• – Verbindungsstellen zwischen dem oder den Fluidleitungen und optional vorhandenen, insbesondere zwischen jeweils zwei Fluidleitungen angeordneten Wärmeleitelementen, die vorzugsweise in Form von Wellrippenplatten ausgebildet sein können, und/oder
• – Verbindungsstellen zwischen einem oder mehreren optional vorhandenen weiteren Verbindungselementen und dem Gehäuse und/oder dem Wärmetauschpaket

sein.An inventive method for producing a heat exchanger according to the invention therefore provides that at least the housing, the at least one or more connection channels integrating heat exchange package and the connection element (preferably simultaneously) are exposed to a defined temperature in a soldering oven, for example, by a solder, at least in the Area of an intended connection point between the housing and the connection element and / or between the connection channel and the connection element is arranged, is melted, so that after cooling of the heat exchanger at least one solder joint is formed. Preferably, it is provided that even more and in particular all connection points of the heat exchanger are formed. This can be especially

• - Junctions between several parts of the multi-part housing and / or
• - Seams of the example formed as flat tubes fluid line (s) and / or
• - Connecting points between adjacent fluid lines and / or
• Connecting points between the fluid line (s) and optionally existing heat-conducting elements, in particular between each two fluid lines, which may preferably be in the form of corrugated fin plates, and / or
• - Connecting points between one or more optional further connecting elements and the housing and / or the heat exchange package

be.

Alternative connection methods for connecting the connection element to the housing and / or with the heat exchange package, for example welding, gluing or any form-fitting connection methods (for example screwing, riveting, etc.) may also be used.

That or the optionally existing further connecting elements, at any point can be arranged between the housing and the heat exchange package may preferably also according to the or (each) a connection channel of the heat exchange packet with a connection opening of the housing fluidly connecting connecting elements be designed such that they are deformable due to non-uniform thermally induced strains of housing and heat exchange package.

In a preferred embodiment of the heat exchanger according to the invention can be provided that the heat exchange packet is connected exclusively via the one or more connection elements and optionally via one or more further connection elements with the housing. In this way it can be ensured that the heat exchange packet can be as free as possible within the housing due to thermal reasons. This in turn has a positive effect on the achievable service life for the heat exchanger.

An advantageous deformability for the connection element, which in particular also acts in a plurality of directions, can be achieved if the connection element comprises (or is designed as) a ring element which is formed from a sheet-shaped semifinished product (in particular a metal sheet) which is arc-shaped in a (preferably uninterrupted) annularly circumscribing section in such a way that the two end sections of the semifinished product are oriented outwards (ie having a radial directional component with respect to the longitudinal axis) with respect to a longitudinal axis of the ring element. In this case, the end sections can preferably serve the connection with the associated connection channel of the heat exchange packet and / or the section of the housing forming the associated connection opening. Such a connection element can ensure a deformability in all radial directions (corresponding to a relative displacement of the two end sections relative to one another) and about all radial directions (corresponding to a relative rotation of the two end sections relative to one another) with respect to the longitudinal axis and a torsibility about the longitudinal axis.

A particularly advantageous deformability for the connection element formed in this way can still be achieved if the section of the ring component lying between the end sections and at least partially arcuate covers an angle range of at least 90 °, preferably of at least 180 °.

In particular, for an advantageous connectivity of the connection element with the heat exchange package and / or the housing may further be provided that the two end portions are aligned substantially parallel. Particularly in the case of this embodiment of the connection element, a particularly advantageous deformability can then be realized if the section of the ring component lying between the end sections, at least partially arcuate, covers an angle range of more than 180 ° and in particular of approximately 270 °.

Further preferably, it can be provided that one or both end portions (preferably interruption-free) are formed annularly circumferential. This is advantageous in particular when these end sections are used as fastening sections for the connection points between the connection element and the associated connection channel and / or the section of the housing forming the associated connection opening, because in this way the largest possible connection points are available, as a result both good structural strength as well as a good sealing effect of the joints can be realized.

The heat exchanger according to the invention is particularly suitable for use as a charge air cooler of a supercharged internal combustion engine. However, further advantageous uses are also possible. In an internal combustion engine, basically all of the heat exchangers integrated in these can be designed according to the invention.

Accordingly, the invention further relates to an internal combustion engine with a heat exchanger according to the invention, which may be provided in particular as a charge air cooler.

The invention also relates to a motor vehicle, in particular a wheel-based motor vehicle (preferably a car or truck), with a corresponding internal combustion engine. In this case, the internal combustion engine can be provided in particular for (direct or indirect) provision of the drive power for the motor vehicle.

The indefinite articles ("a", "an", "an" and "an"), in particular in the patent claims and in the description generally describing the claims, are to be understood as such and not as numerical words. Corresponding to this concretized components are thus to be understood that they are present at least once and may be present more than once.

The present invention will be explained in more detail with reference to an embodiment shown in the drawings. In the drawings shows:

1 a heat exchanger according to the invention;

2 a longitudinal section through the heat exchanger according to the 1 ;

3 : in the 2 Enlarged view marked III;

4 : the heat exchange package of the heat exchanger according to the 1 to 3 in isolated form

5 : in isolation, a connection element of the heat exchanger according to the 1 to 4 ; and

6 a radial section through the connecting element according to the 5 ,

The drawings show a simplified representation of a heat exchanger according to the invention. This heat exchanger can be used to cool a gas flowing through the heat exchanger in the longitudinal direction (mixture) (first fluid) by means of a transition of heat energy from the gas to one in fluid lines of a heat exchange package 12 flowing (second) fluid, in particular a liquid serve. For example, the heat exchanger can be used as a charge air cooler of an internal combustion engine (not shown).

The heat exchanger includes next to the heat exchange package 12 a housing 14 , at its two end faces, each with a passage opening 16 is formed, which allow entry and exit of the gas flowing through the heat exchanger. The multi-part housing 14 is formed of sheet metal, for example. The metal sheet used for this purpose has a comparatively large wall thickness, which ensures sufficient structural strength of the heat exchanger. This structural strength is required, for example, to attach the heat exchanger to a mounting structure, for example in the engine compartment of a motor vehicle, by fastening elements (not shown) acting on the housing. In addition, this can provide adequate pressure resistance for the housing 14 be realized, for example, in the intended use as a charge air cooler of importance, since the charge air flowing through this can have a significant excess pressure.

The heat exchange package 12 comprises a plurality of the fluid lines formed as flat tubes 10 which are arranged one above the other at a distance from one another. In the spaces between each adjacent fluid lines 10 Optionally, heat-conducting elements (not shown), which may be designed in particular in the form of corrugated ribbed plates, can be arranged.

To a flow through the fluid lines 10 by means of the second fluid is an inlet port 18 and an outlet port 20 for the heat exchange package 12 intended. Both the inlet connection 18 as well as the outlet port 20 each includes a through all fluid lines 10 of the heat exchange package 12 extending connection channel 22 , one from a connection opening 24 of the housing 14 outwardly extending connecting piece 26 and an annular connection element 28 , each one of the connection openings 24 inside the housing 14 with the proximal end of the associated connection channel 22 of the heat exchange package 12 fluid conducting connects. The connection channels 22 are each of annular peripheral wall sections 30 the fluid lines 10 limited, wherein in each case the end-contacting wall sections 30 adjacent fluid lines 10 one of these adjacent fluid lines 10 train connecting pipe segment. At the respect to the connection element 28 distal ends are the connection channels 22 closed trained.

The pumped in a cycle and the inlet port 18 the heat exchange package 12 supplied second fluid flows through the associated connection channel 22 into the fluid lines 10 , flows through these and is via the outlet port 20 discharged again. It takes heat energy from the internal volume of the housing 14 in the longitudinal direction of the heat exchanger flowing through and thus the fluid lines 10 flowing around first fluid. In order to allow the best possible heat transfer from the first fluid to the second fluid, the wall thicknesses of the formed of sheet metal fluid lines 10 comparatively (in comparison to those of the housing 14 ) designed thin.

Different elongations due to temperature fluctuations of the first fluid and (in particular) the second fluid or due to temperature differences of these fluids (and thus also the component temperatures) during operation of the heat exchanger lead to reaction forces at the attachment points of the heat exchanger package 12 on the housing 14 and thus to considerable material stresses. A rigid connection of the heat exchange package 12 to the inside of the case 14 For example, by soldering, to local stiffness increases and in conjunction with the different thermally induced elongations would lead to significant mechanical stress peaks. These could, especially as part of an alternating stress as a result frequently changing temperatures of the first and / or the second fluid, lead to a relatively rapid component failure and thus to a malfunction of the heat exchanger.

To these thermally induced very different elongations of the housing 14 on the one hand and the heat exchange package 12 on the other hand compensate or without allowing too large voltage spikes, is the heat exchange package 12 exclusively via soft and thus with comparatively small forces deformable connecting elements with the housing 14 connected. These are the one part of the inlet connection 18 and the outlet port 20 forming connecting elements 28 as well as two connection frames 32 that the heat exchange package 12 each fully surrounded at the longitudinal axial ends and thereby with the corresponding adjacent portion of the housing 14 connect. All of these fasteners are also, ie as the housing 14 and the components of the heat exchange package 12 also, formed of sheet metal. In particular, all the components of the heat exchanger described here can be made of aluminum (sheet metal).

This slight deformability of the connecting elements (connecting elements 28 and connection frame 32 ) results on the one hand from the wall thicknesses of the metal sheets used for this, which again below the wall thickness of the for the formation of the fluid lines 10 and optionally for between the fluid lines 10 arranged Wärmeleitelemente used metal sheets is located. On the other hand, this slight deformability also results from a specific shape for the connecting elements, in particular for the inlet connection 18 and the outlet port 20 integrated connection elements 28 ,

These connection elements 28 are each formed as a ring member, which in an annular peripheral portion 34 such arcuate runs that the two end portions 36 with respect to a longitudinal axis 38 the ring element pointing outwards, ie a radial direction component with respect to the longitudinal axis 38 are aligned. The two end sections 36 In this case, they are oriented substantially parallel to one another, as a result of which, as far as possible, they are as full-surface as possible on both the annular connection opening 24 surrounding section of the housing 14 as well as on the front sides of the adjacent circumferential wall section 30 the corresponding fluid line 10 issue. This largest possible contact between the connection elements 28 and the housing 14 and the heat exchange package 12 may be conducive to the structural strength and the sealing effect of the joints formed there. The arcuate section 34 each connection element 28 covers an angular range of about 270 ° (relative to one perpendicular to each of the radial cuts within the arcuate portion 34 arranged and therefore about the longitudinal axis 38 revolving axis 40 ). Here is the transition from the arcuate section 34 in the for a contact with the housing 14 provided end portion 36 formed continuously or paragraph-free, while the transition from the arcuate portion 34 in the for a contact to the heat exchange package 12 provided end portion 36 characterized by a bend of about 90 °. By this configuration of the connection elements 28 these have an advantageous deformability in all radial directions (corresponding to a relative displacement of the two end portions 36 or the corresponding sections of the housing 14 and the heat exchange package 12 to each other) and to all radial directions (corresponding to a relative rotation of the two end portions 36 or the corresponding sections of the housing 14 and the heat exchange package 12 to each other) with respect to the longitudinal axis 38 on. Furthermore, this form ensures high torsibility about the longitudinal axis 38 of the respective connection element 28 ,

The cross section of the training for the connection frame 32 used metal profile also forms two substantially parallel end portions 42 made a contact and the connection of the connection frame 32 with the housing 14 and the heat exchange package 12 serve. The end sections 42 are by means of an arcuate and in particular substantially semicircular portion extending 44 connected with each other. In the arcuate in cross-section or semicircular section 44 the connecting frames are longitudinally spaced from each other through holes 46 provided by the increased deformability for the connection frame 32 is realized.

Due to the inventive design of the heat exchanger this ensures a low-voltage compensation of different thermal elongations of the housing 14 on the one hand and the heat exchange package 12 on the other hand, whereby a reaching a high life for the heat exchanger is positively influenced. At the same time, the design of the easily deformable connecting elements (connection elements 28 and connection frame 32 ) On the one hand and provided for this contact points of the housing 14 and the heat exchange package 12 on the other hand from materials which can be soldered together an advantageous manufacturability, because the connection of the Heat exchange package 12 to the inside of the case 14 by means of the connection elements 28 and also by means of the connection frames 32 can be done in a single process step by loosely assembling all the components of the heat exchanger described here or provisionally (for example, by adhesive bonds) connected together in a brazing furnace (not shown), previously on at least some of the contact points provided for a solder, in particular a Brazing, can be applied, which melts by the prevailing in the brazing furnace high temperatures and forms after removal of the heat exchanger from the brazing furnace by cooling and curing serving as joints solder joints. The solder joints between the connection elements 28 and the associated sections of the housing 14 and the heat exchange package 12 At the same time, they act to a sufficient extent sealingly, so that it is possible to dispense with the integration of separate sealing elements. A subsequent insertion of particular elastomeric sealing elements, which can not be integrated in advance in the heat exchanger because of these too high temperatures in the brazing furnace, can be avoided in an advantageous manner.

When heating the heat exchanger in the soldering oven are preferably not only the joints between the connecting elements and on the one hand the housing 14 and on the other hand, the heat exchange package 12 formed, but preferably all provided in the heat exchanger joints. This can in particular be seen from the drawings seams 48 between each two a fluid line 10 forming half shells, between each two a respective two adjacent fluid lines 10 connecting pipe segment forming wall sections 30 the fluid lines 10 and between sub-housings of the multi-part housing 14 be.

LIST OF REFERENCE NUMBERS

10

 fluid line

12

 Heat exchange package

14

 casing

16

 Passage opening of the housing

18

 inlet port

20

 outlet

22

 connecting channel

24

 Connection opening of the housing

26

 spigot

28

 connecting element

30

 ring-shaped circumferential wall sections of the fluid lines

32

 connecting frame

34

 Section of the connection element

36

 End portion of the connecting element

38

 Longitudinal axis of the connecting element

40

 about the longitudinal axis encircling axis

42

 End portion of the connection frame

44

 Section of the connection frame

46

 Through opening of the connection frame

48

 join

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

• EP 2765286 A1 [0002]
• WO 2010/146063 A1 [0003]

Claims (10)

Heat exchanger with a housing provided for the flow through a first fluid ( 14 ), one inside the housing ( 14 ) received heat exchange package ( 12 ), one or more for the flow through a second fluid and the flow around the first fluid provided by the fluid lines ( 10 ) and with an inlet port ( 18 ) and an outlet port ( 20 ) for the heat exchange package ( 12 ), characterized in that the inlet port ( 18 ) and / or the outlet port ( 20 ) into the heat exchange package ( 12 ) integrated connection channel ( 22 by means of a non-uniform thermal expansion of housing ( 14 ) and heat exchange package ( 12 ) deformable connection element ( 28 ) with one of the housing ( 14 ) formed connection opening ( 24 ) is fluid-conductively connected. Heat exchanger according to claim 1, characterized in that the connection channel ( 22 ), the connecting element ( 28 ) and the connection opening ( 24 ) forming portion of the housing ( 14 ) are formed of metal. Heat exchanger according to claim 1 or 2, characterized in that the connecting element ( 28 ) with the connection channel ( 22 ) and / or a connection opening ( 24 ) forming portion of the housing ( 14 ) is soldered. Heat exchanger according to one of the preceding claims, characterized in that the connection element ( 28 ) provided for guiding the second fluid portion of the inlet port ( 18 ) or the outlet port ( 20 ). Heat exchanger according to one of the preceding claims, characterized in that the connection element ( 28 ) comprises a ring element which is formed from a flat component, which in an annular peripheral portion ( 30 ) is curved in such a way that the two end sections ( 36 ) with respect to a longitudinal axis ( 38 ) of the ring member are oriented outwardly facing. Heat exchanger according to claim 5, characterized in that one or both end sections ( 36 ) are formed annularly circumferentially. Heat exchanger according to one of claims 5 or 6, characterized in that the two end sections ( 36 ) are aligned substantially parallel. Heat exchanger according to claims 5 to 7, characterized in that between the end sections ( 36 ) lying at least partially arcuate section ( 30 ) of the flat component covering an angular range of at least 90 °, preferably of at least 180 ° and more preferably of about 270 °. Heat exchanger according to one of the preceding claims, characterized in that the heat exchange packet ( 12 ) exclusively by means of the connection element or elements ( 28 ) and by means of one or more optionally existing, due to non-uniform thermally induced strains of housing ( 14 ) and heat exchange package ( 12 ) deformable further connecting elements with the housing ( 14 ) connected is. Method for producing a heat exchanger according to one of the preceding claims, characterized in that at least the housing ( 14 ), which has at least one or more connection channels ( 22 ) integrating heat exchange package ( 12 ) and one or more connection elements ( 28 ) are exposed to a defined temperature, by which a solder, at least in the region of an intended connection point between the housing ( 14 ) and the connection element ( 28 ) and / or between the connection channel ( 22 ) and the connection element ( 28 ), is melted, so that at least one solder joint is formed by cooling the heat exchanger.

Images