DE102017213182A1 - Fresh air distributor for a fresh air system - Google Patents

Abstract

The invention relates to a fresh air distributor (1) for a fresh air system of an internal combustion engine. The fresh air distributor (1) comprises a distributor housing (3) delimiting a distributor interior (4) into which a charge air cooler (2) is introduced by means of a mounting opening (5) provided in the distributor housing (3). The charge air cooler (2) along the stacking direction (S) by a first end plate and one of the first end plate in the stacking direction (S) opposite second end plates (7b) is limited, between which a plurality of tubular bodies (6) is arranged. Essential to the invention is a sealing element (12) which is arranged in the distributor interior (4) and there seals the intercooler (2) against the distributor housing (3). In this case, the sealing element (12) extends in the distributor housing (3) along an extension direction (E) and has in profile perpendicular to the extension direction (E) a base body (16) resting against the charge air cooler (2). From the main body (16) are spaced from each other from two sealing body (17a, 17b) from which abut with their from the base body (16) facing away from the end (18) on the distributor housing (3).

Description

The present invention relates to a fresh air manifold for a fresh air system of an internal combustion engine and a fresh air system with such a fresh air manifold. Finally, the invention relates to an internal combustion engine with such a fresh air system.

In a supercharged internal combustion engine, the fresh air is brought by means of a corresponding charging device to an elevated pressure level during operation. The required compression or compression of the fresh air also leads to a warming of the fresh air. In order to increase the mass flow of fresh air to the combustion chambers of the internal combustion engine, the charged fresh air, which is also referred to as charge air, cooled. For this purpose, the fresh air system on a charge air cooler. The charge air to be cooled is distributed to the individual fresh air paths of the charge air cooler by means of a so-called fresh air distributor. The intercooler is used in a distributor housing of the fresh air manifold, in such a way that a guided through the distributor housing fresh air supply also passes through the intercooler. To avoid a leakage flow, which bypasses the charge air cooler on the air side between the outside of the charge air cooler facing the housing and the inside of the distributor housing facing the charge air cooler, a bypass seal may be provided which extends transversely to the fresh air paths of the charge air cooler and thus runs transversely to the flow direction of the fresh air ,

Suitably, the distributor housing of the fresh air system is made of a plastic. In contrast, the intercooler is usually made of metal. This results in different thermal expansion coefficients. Strongly varying temperatures can thus lead to relative movements between the charge air cooler and the distributor housing during operation. Furthermore, the distributor housing has a certain elasticity, so that the distributor housing depending on the prevailing air pressure, ie depending on the current boost pressure, elastically deform, so more or less expand or inflate. It is noteworthy that modern charging devices, such as e.g. an exhaust gas turbocharger with variable turbine geometry, depending on demand can produce different boost pressures. Accordingly, the respective charge pressure for relative movements between the intercooler and the distributor housing lead. Such relative movements between the intercooler and the distributor housing, which are oriented substantially transversely to the fresh air path, can reduce the efficiency of the bypass seal. In addition, there is always the risk of damage to the bypass seal.

A fresh air system with such a bypass seal is from the WO 2014/122148 A1 known.

The present invention is concerned with the problem of providing an improved embodiment for a fresh air distributor of the type mentioned above, which is characterized in particular by the fact that the respective bypass seal has increased efficiency and / or increased durability.

This problem is solved according to the invention by the subject matter of the independent claim. Advantageous embodiments are the subject of the dependent claims.

The basic idea of the invention is therefore to provide a sealing element for sealing the charge air cooler against the distributor housing of the fresh air distributor between the intercooler and the distributor housing, which is designed such that it bears against both the intercooler and the distributor housing. Such a sealing element follows the operating principle of a bypass seal, which prevents unwanted passing of fresh air introduced into the charge air cooler into the fresh air paths provided in the intercooler. For this purpose, the sealing element in profile has a base body which bears against the charge air cooler. From this body are two spaced-apart sealing body to the outside, which abut with their remote from the base end respectively on the distributor housing. On the one hand, a very high sealing effect is achieved by means of such a geometry, but on the other hand a sealing element designed in this way can also be very easily mounted on the intercooler so that the intercooler can be used together with the preassembled sealing element as a unit in the distributor housing. The sealing element can be performed circumferentially around the two opposite end plates of the intercooler and to the coolant distributor - known to those skilled in the art as a coolant box. In this case results for the entire sealing element around the intercooler including the coolant distributor encircling U-shaped or C-shaped geometric shape.

As a result, the fresh air distributor with the present invention, essential to the invention sealing element structurally very simple and thus inexpensive to manufacture. At the same time, the sealing element is easy to mount on the intercooler or in the distributor housing and yet ensures a high sealing effect, so that a unwanted bypass flow can be avoided past the air thread of the intercooler. Due to its simple construction, the sealing element essential to the invention also has a very long service life.

An inventive fresh air distributor for a fresh air system of an internal combustion engine comprises a distributor housing, which limits a distributor interior. An intercooler is introduced or inserted into the distributor interior through a mounting opening provided in the distributor housing. The intercooler comprises a plurality of stacked along a stacking direction and can be flowed through by a coolant tube body. Along the stacking direction of the charge air cooler is limited by a first end plate and one of the first end plate in the stacking direction opposite second end plate. Between the two end plates, the plurality of tubular bodies is arranged. Essential to the invention is a sealing element, which is arranged in the distributor interior and there seals the intercooler against the distributor housing. The sealing element is also referred to below as a "bypass seal". According to the invention, the sealing element extends along an extension direction and has in profile perpendicular to the direction of extension a voltage applied to the intercooler body, spaced from each other two sealing bodies protrude, which rest in turn with their remote from the base end to the distributor housing.

According to a preferred embodiment, the sealing element with the base body and the two sealing bodies in profile has a U-shaped geometry. Thus, on the one hand, the main body can be arranged flat on the respective end plate of the intercooler. On the other hand, the two sealing bodies can be stably supported on the distributor housing. In this way, by means of the sealing element, it is possible in particular to compensate for the aforementioned thermal expansion effects as well as the expansion effects dependent on the boost pressure. As a result, the efficiency of the sealing element is improved, at the same time the life of the sealing element is extended.

According to another preferred embodiment, the entire sealing element as a whole has a U-shaped geometric shape with a base portion and with a first and second leg portion. In this embodiment, the first leg portion of the sealing member is disposed in a space between the intercooler and the distributor housing and is supported at one end on the first end plate and the other end on the distributor housing. Also, the second leg portion of the sealing member is disposed in the space between the intercooler and the distributor housing and is supported at one end on the second end plate and the other end on the distributor housing. In this way, a particularly good sealing effect is ensured even with pronounced thermal or charge pressure-dependent expansion effects.

Particularly preferably, the sealing element divides the intermediate space between the intercooler and the distributor housing into two fluidly separated subspaces. This ensures that no fresh air or charge air can flow past the fresh air paths provided in the intercooler, without entering into thermal interaction with the coolant flowing through the pipe bodies.

In a particularly preferred embodiment of at least one of the two end plates of the charge air cooler to the outside, at least one fastener from the distributor housing. By means of said fastening element, the sealing element is fixed on the outside of the relevant end plate. This allows a simple pre-assembly of the sealing element on the intercooler before it is used together with the sealing element as a unit through the mounting opening into the distributor housing limited distributor space.

Suitably, the at least one fastening element is designed as an integrally formed on the first and second end plate and protruding from this fastening tab. Such a fastening tab may be realized by one or more slots punched in the respective end plate. This measure allows an inexpensive design of the fastener directly to the end plates of the intercooler. Since typically several such fastening tabs are provided, this measure leads to not inconsiderable cost advantages in the production of the entire fresh air manifold.

In an advantageous development, the respective fastening tab for fixing the sealing element to the relevant end plate penetrates an opening provided in the sealing element. In this development, the fastening tab is located at a side facing away from the end plate, angled end portion on the sealing element. This measure facilitates the assembly of the sealing element on the two end plates.

According to a further preferred embodiment, the intercooler comprises a cover, preferably a cover plate, which closes the mounting opening provided in the distributor housing. In said cover, a coolant inlet may be provided, over which the Coolant is introduced into the tubular body of the intercooler. Likewise, in the cover, a coolant outlet be integrated, via which the coolant is discharged after passing through the tubular body of the charge air cooler again from this. In this embodiment, the charge air cooler further includes a coolant receiver that faces the cover along a tube body extending direction of the tube bodies that extends orthogonal to the stacking direction. In the coolant collector, the coolant is collected after flowing through the individual tubular body of the charge air cooler before it is redistributed in the reverse flow direction to the individual tubular body. The coolant collector thus allows a flow through the tubular body of the charge air cooler in countercurrent principle. In this embodiment, the plurality of pipe bodies are arranged along the pipe body extending direction between the cover and the coolant collector. The base portion of the sealing member is arranged in this embodiment in the space between the charge air cooler and the distributor housing and is supported on both the coolant collector and the distributor housing. Thus, a high sealing effect of the sealing element between the coolant collector and the distributor housing is ensured.

In an advantageous development, the base portion of the sealing element is supported on a coolant collector housing of the coolant collector.

In an advantageous development, a receiving groove is formed in the coolant collector, preferably in the coolant collector housing of the coolant collector, in which the base body of the sealing element is partially received. This variant enables a simple and stable mounting of the sealing element on the coolant collector or on the coolant collector housing.

In another advantageous development, the coolant collector housing consists of a plastic and is connected by means of at least one, preferably more, clip or snap or snap connection (s) releasably connected to the sealing element. This ensures additional fixation of the sealing element on the coolant collector or on the coolant collector housing.

In an advantageous development, at least one reinforcing rib is formed integrally on the sealing element, preferably on the two leg sections of the sealing element. In this development, the sealing element in profile connects the two sealing bodies for the purpose of mechanical stiffening in addition to the main body with each other. By means of such a reinforcing rib, therefore, the mechanical strength of the sealing element is increased and in particular prevents a folding apart or a collapse of the sealing element. In principle, any number of such reinforcing ribs can be provided. Also, the reinforcing rib (s) may be arranged uniformly or non-uniformly along the both leg portions of the sealing member.

In a particularly advantageous development, a plurality of reinforcing ribs are arranged at a distance from each other along the direction of extent of the sealing element. This measure additionally increases the mechanical strength.

Expediently, the openings, which are penetrated by fastening straps, interchange with the stiffening ribs on the sealing element along the direction of extent. In this way, a uniform stiffening of the sealing element is ensured at the same time mechanically stable attachment to the intercooler over the entire sealing element away.

According to a preferred embodiment, the sealing element is designed elastically deformable. Preferably, the sealing element consists of an elastomer. An elastically formed sealing element has particularly good sealing properties even with pronounced thermal or pressure-related relative movements between the charge air cooler and the distributor housing.

Particularly preferably, the sealing element is integrally formed. This allows a particularly inexpensive production of the sealing element and a simple pre-assembly of the charge air cooler before insertion into the distributor housing.

The invention further relates to a fresh air system with a fresh air distributor presented above. The advantages of the fresh air distributor explained above are therefore also transferred to the fresh air system according to the invention.

The invention further relates to an internal combustion engine with such a fresh air system. The above-explained advantages of the fresh air system are therefore also transferred to the internal combustion engine according to the invention.

Other important features and advantages of the invention will become apparent from the dependent claims, from the drawings and from the associated figure description with reference to the drawings.

It is understood that the features mentioned above and those yet to be explained below can be used not only in the particular combination given, but also in other combinations or in isolation, without departing from the scope of the present invention.

Preferred embodiments of the invention are illustrated in the drawings and will be described in more detail in the following description, wherein like reference numerals refer to the same or similar or functionally identical components.

• 1 ein Beispiel eines erfindungsgemäßen Frischluftverteilers beim Montieren des Ladeluftkühlers im Verteilergehäuse,
• 2 den Frischluftverteiler der 1 in einer Schnittansicht nach Abschluss des Montagevorgangs,
• 3 das erfindungswesentliche Dichtungselement des Frischluftverteilers in separater, perspektivischer Darstellung,
• 4 das Dichtungselement der 3 in einem im Ladeluftkühler montierten Zustand in einer Draufsicht,
• 5 das Dichtungselement der 3 in dem im Ladeluftkühler montierten Zustand in einem Längsschnitt,
• 6 den Ladeluftkühler des Frischluftverteilers mit montiertem Dichtungselement in separater Darstellung in einem Längsschnitt,
• 7 den Ladeluftkühler des Frischluftverteilers mit montiertem Dichtungselement in separater Darstellung in einem Querschnitt.

Show, in each case schematically,

• 1 an example of a fresh air distributor according to the invention when mounting the intercooler in the distributor housing,
• 2 the fresh air distributor of 1 in a sectional view after completion of the assembly process,
• 3 the sealing element according to the invention of the fresh air distributor in a separate, perspective view,
• 4 the sealing element of 3 in a state mounted in the intercooler in a plan view,
• 5 the sealing element of 3 in the state mounted in the intercooler in a longitudinal section,
• 6 the intercooler of the fresh air manifold with mounted sealing element in a separate representation in a longitudinal section,
• 7 the intercooler of the fresh air manifold with mounted sealing element in a separate representation in a cross section.

1 shows an example of a fresh air manifold according to the invention 1 when mounting the intercooler 2 , The 2 shows the fresh air manifold 1 in a sectional view after completion of the assembly process. The fresh air manifold 1 includes a distributor housing 3 which has a distributor interior 4 limited. In the distributor housing 3 is a mounting hole 5 present, through which the intercooler 2 in the distributor interior 4 along one direction X can be introduced. The intercooler 2 is formed as a fin-tube heat exchanger and includes a plurality of along a stacking direction S stacked on each other and from a coolant K permeable tubular bodies 6 , The tubular body 6 extend along a tubular body extension direction R perpendicular to the stacking direction S runs. Between two in the stacking direction S adjacent tubular bodies 6 is each a fresh air path 8th arranged to flow through with fresh air. Furthermore, the intercooler 2 along the stacking direction S through a first end plate 7a and one of the first end plates 7a in the stacking direction S opposite, second end plates 7b limited. The majority of the tubular body 6 as well as the fresh air paths 8th So are between the two end plates 7a . 7b arranged.

According to 1 can the intercooler 2 a cover 19 have, in turn, a cover plate 20 includes. In the distributor housing 3 mounted intercooler 2 closes the cover 19 or cover plate 20 in the distributor housing 3 provided mounting opening 5 , At the cover 19 is a coolant inlet 21 for introducing the coolant K in the intercooler 2 and a coolant outlet 22 for discharging the coolant K after flowing through the intercooler 2 intended. The intercooler 2 further includes a coolant collector 23 , which along the tubular body extension direction R the cover 19 or the cover plate 20 opposite. The tubular body 6 are along the pipe body extension direction R between the cover 19 or cover plate 20 and the coolant collector 23 arranged.

The sectional view of 2 one removes that to seal the intercooler 2 against the distributor housing 3 in one between the intercooler 2 and the distributor housing 3 existing gap 10 a sealing element 12 is arranged. The sealing element 12 divides the gap 10 between the intercooler 2 and the distributor housing 3 in two fluidly separated subspaces 11a . 11b , By means of the sealing element 12 , which follows the operating principle of a bypass seal, prevents the over one in the distributor housing 3 provided fresh air supply 9 in the distributor interior 4 introduced fresh air outside the fresh air paths 8th of the intercooler 2 can flow past, without thermally with the through the tubular body 6 guided coolant K to interact.

The sealing element essential to the invention 12 is in 3 shown in a separate, perspective view. Corresponding 3 owns the sealing element 12 a U-shaped geometry with a base section 13 and two leg sections 14a . 14b , The two leg sections 14a . 14b form with the base section 13 each at an angle of 90 ° (see. 3 ). The sealing element 12 is formed elastically deformable and for this purpose preferably consists of an elastomer. According to 3 is the U-shaped sealing element 12 as extending along an extension direction E profile part 15 formed, which in profile perpendicular to the direction of extension E one on the intercooler 2 adjacent body 16 has. From the main body 16 stand spaced from each other two sealing bodies 17a . 17b off with her from body 16 opposite end 18 abut the distributor housing. According to 3 also owns this as a profile part 15 formed sealing element 12 with the main body 16 and the two sealing bodies 17a . 17b in profile a U-shaped geometry. The first leg section 14a of the sealing element 12 supports both the first end plate 7a as well as on the distributor housing 3 from (cf. 1 ). The second leg section 14b of the sealing element 12 supports both the second end plate 7b as well as on the distributor housing 3 from. The also in the space 10 arranged base section 13 of the sealing element 12 rests on both the coolant collector 23 or its coolant collector housing 31 as well as on the distributor housing 3 from.

The 4 shows the sealing element 12 in one in the intercooler 2 assembled state in a plan view, the 5 in a longitudinal section. The 3 to 5 one takes that on the sealing element 12 integral multiple reinforcing ribs 24 can be formed. The reinforcing ribs 24 are in this case designed such that they are in the profile of the sealing element 12 perpendicular to the extension direction E (see in particular 2 and 4 ) the two sealing bodies 17a . 17b for the purpose of stiffening in addition to the basic body 16 connect with each other.

As the 3 to 5 can be seen along the direction of extension of the sealing element 12 several reinforcing ribs 24 be spaced apart. From the two end plates 7a . 7b of the intercooler 2 stand outwards, to the distributor housing 3 towards several fasteners 25 from, by means of which the sealing element 12 on the outside 26a . 26b the relevant end plate 7a respectively. 7b is fixed. Also the fasteners 25 are arranged along the extension direction E at a distance from each other. The fasteners 25 are integral with the first and second end plates, respectively, according to the figures 7a . 7b molded and protruding from this attachment straps 27 educated. For fixing the sealing element 12 at the relevant end plate 7a respectively. 7b passes through a respective fastening strap 27 a complementary, in the main body 16 of the sealing element 12 intended breakthrough 28 , In addition, the fastening tab lies 27 and with one of the end plate 7a respectively. 7b facing away, folded over by 90 ° end portion 29 at the base body 16 of the sealing element 12 at.

As 5 can recognize, can be at the base body 16 of the sealing element 12 the ones from the fastening straps 27 interspersed breakthroughs 28 and the stiffening ribs 24 alternate along the direction of extension E. In the base section 13 of the sealing element 12 on the other hand, they are not necessarily fastening straps 27 intended. To fix the base section 13 of the sealing element 12 is therefore on the coolant collector housing 31 of the coolant collector 23 a receiving groove 30 formed, in which the basic body 16 of the sealing element 12 partially recorded. The main body 16 of the sealing element 12 can be solved by means of several clip, snap or snap connections with the coolant collector housing 31 , which preferably consists of a plastic, to be connected.

To clarify the scenario explained above is in the 6 the intercooler 2 with mounted sealing element 12 in a separate representation in a longitudinal section along the tubular body extension direction R shown.

Furthermore, in the 7 the intercooler 2 with mounted sealing element 12 shown in a separate representation in a cross section perpendicular to the tube body extension direction R.

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 2014/122148 A1 [0004]

Claims (18)

Fresh air distributor (1) for a fresh air system of an internal combustion engine, with a distributor housing (3) delimiting a distributor interior (4), in which a charge air cooler (2) is inserted through a mounting opening (5) provided in the distributor housing (3), - wherein the intercooler (2) comprises a plurality of along a stacking direction (S) stacked and by a coolant (K) can be flowed through tubular body (6), - wherein the charge air cooler (2) along the stacking direction (S) by a first end plate (7b) and one of the first end plate (7a) in the stacking direction (S) opposite the second end plate (7b) is limited, between which the plurality of tubular bodies (6 ) is arranged - With a sealing element (12) which is arranged in the distributor interior (4) and there seals the intercooler (2) against the distributor housing (3), - wherein the sealing element (12) extends in the distributor housing (3) along an extension direction (E) and in profile perpendicular to this extension direction (E) has a charge air cooler (2) adjacent base body (16), from which spaced from each other two sealing bodies ( 17a, 17b) projecting, which are integrally formed on the base body (16) and abut with their from the base body (16) facing away from the end (18) in each case on the distributor housing (3). Fresh air distributor after Claim 1 , characterized in that the sealing element (12) with the base body (16) and the two sealing bodies (17a, 17b) in profile has a substantially U-shaped geometry. Fresh air distributor after Claim 1 or 2 , characterized in that - the sealing element (12) as a whole has a U-shaped geometric shape with a base portion (13) and first and second leg portions (14a, 14b), each preferably at right angles to the base portion (13 ), wherein the first leg portion (14a) of the sealing element (12) is arranged in a gap (10) between the charge air cooler (2) and the distributor housing (3) and on both the first end plate (7a) and the distributor housing (3), wherein the second leg portion (14b) of the sealing member (12) is disposed in the space (10) between the charge air cooler (2) and the manifold housing (3) and on both the second end plate (7b) and supported on the distributor housing (3). Fresh air distributor after one of Claims 1 to 3 , characterized in that the sealing element (12) the intermediate space (10) between the intercooler (2) and the distributor housing (3) divided into two fluidly separate subspaces (11a, 11b). Fresh air distributor according to one of the preceding claims, characterized in that at least one fastening element (25) projects from at least one of the two end plates (7a, 7b) of the charge air cooler (2) towards the outside, towards the distributor housing (3), by means of which the sealing element (12 ) is fixed externally to the respective end plate (7a, 7b). Fresh air distributor according to one of the preceding claims, characterized in that the at least one fastening element (25) as integrally formed on the first and second end plate (7a, 7b) and formed by this protruding fastening tab (27) is formed. Fresh air distributor after Claim 6 , characterized in that the fastening tab (27) for fixing the sealing element (12) to the respective end plate (7a, 7b) penetrates an opening (28) provided in the sealing element (12) and faces away from the end plate (7a, 7b) , Angled end portion (29) on the sealing element (12). Fresh air distributor according to one of the preceding claims, characterized in that - the charge air cooler (2) comprises a cover (19), preferably a cover plate (20), which closes the mounting opening (5) provided in the distributor housing (3), - the intercooler ( 2) comprises a coolant collector (23) which faces the cover (19) along a pipe body extending direction (R) orthogonal to the stacking direction (S), so that the pipe bodies (6) along the pipe body extending direction (R ) are arranged between the cover (19) and the coolant collector (23), - the base portion (13) of the sealing element (12) is arranged in the intermediate space (10) between the charge air cooler (2) and the distributor housing (3) and both on the coolant collector (23) and on the distributor housing (3) is supported. Fresh air distributor after Claim 8 , characterized in that the base portion (13) of the sealing element (12) is supported both on the coolant collector (23), preferably on the coolant collector housing (31) of the coolant collector (23), and on the distributor housing (3). Fresh air distributor after Claim 8 or 9 , characterized in that in the coolant collector (23), preferably in a coolant collector housing (31) of the coolant collector (23), a receiving groove (30) is formed, in which the base body (16) of the sealing element (12) is partially received. Fresh air distributor after Claim 9 or 10 , characterized in that the coolant collector housing (31) consists of a plastic and by means of at least one, preferably more, clip or snap or snap connection (s) is releasably connected to the sealing element (12). Fresh air distributor according to one of the preceding claims, characterized in that integrally formed on the sealing element (12) at least one reinforcing rib (24) which in the profile of the sealing element (12), the two sealing bodies (17a, 17b) in addition to the base body (16) interconnected , Fresh air distributor after Claim 12 , characterized in that along the extension direction (E) of the sealing element (12) a plurality of reinforcing ribs (24) are arranged spaced from each other. Fresh air distributor after Claim 12 or 13 , characterized in that on the sealing element (12) of the fastening tabs (27) interspersed openings (28) and the stiffening ribs (24) along the extension direction (E) alternate. Fresh air distributor according to one of the preceding claims, characterized in that the sealing element (12) is designed to be elastically deformable and preferably consists of an elastomer. Fresh air distributor according to one of the preceding claims, characterized in that the sealing element (12) is integrally formed. Fresh air system, - With at least one fresh air path and with a fluidically communicating with the at least one fresh air path fresh air manifold (1) according to one of the preceding claims. Internal combustion engine with a charging device, in particular an exhaust gas turbocharger, and with a fresh air system after Claim 17 ,

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