EP0857922B1 - Noyau d'un échangeur de chaleur avec réchauffeur électrique - Google Patents

Noyau d'un échangeur de chaleur avec réchauffeur électrique Download PDF

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Publication number
EP0857922B1
EP0857922B1 EP98102091A EP98102091A EP0857922B1 EP 0857922 B1 EP0857922 B1 EP 0857922B1 EP 98102091 A EP98102091 A EP 98102091A EP 98102091 A EP98102091 A EP 98102091A EP 0857922 B1 EP0857922 B1 EP 0857922B1
Authority
EP
European Patent Office
Prior art keywords
core unit
electric heater
flat tubes
disposed
temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP98102091A
Other languages
German (de)
English (en)
Other versions
EP0857922A3 (fr
EP0857922A2 (fr
Inventor
Mikio Fukuoka
Mitsugu Nakamura
Isao Kuroyanagi
Toshio Ohara
Sadayuki Kamiya
Shinji Naruse
Yoshifumi Aki
Michiyasu Yamamoto
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Denso Corp
Original Assignee
Denso Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP02415497A external-priority patent/JP3812031B2/ja
Priority claimed from JP9241797A external-priority patent/JP3812045B2/ja
Priority claimed from JP21504297A external-priority patent/JP3794117B2/ja
Application filed by Denso Corp filed Critical Denso Corp
Publication of EP0857922A2 publication Critical patent/EP0857922A2/fr
Publication of EP0857922A3 publication Critical patent/EP0857922A3/fr
Application granted granted Critical
Publication of EP0857922B1 publication Critical patent/EP0857922B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
    • F24H1/0072—Special adaptations
    • F24H1/009—Special adaptations for vehicle systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0435—Structures comprising heat spreading elements in the form of fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0441—Interfaces between the electrodes of a resistive heating element and the power supply means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/04—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element
    • F24H3/0405—Air heaters with forced circulation the air being in direct contact with the heating medium, e.g. electric heating element using electric energy supply, e.g. the heating medium being a resistive element; Heating by direct contact, i.e. with resistive elements, electrodes and fins being bonded together without additional element in-between
    • F24H3/0429—For vehicles
    • F24H3/0452—Frame constructions
    • F24H3/047—Multiple-piece frames assembled on their four or more edges
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/06—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators
    • F24H3/08—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes
    • F24H3/081—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes using electric energy supply
    • F24H3/082—The tubes being an electrical isolator containing the heater
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H3/00—Air heaters
    • F24H3/02—Air heaters with forced circulation
    • F24H3/06—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators
    • F24H3/08—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes
    • F24H3/081—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes using electric energy supply
    • F24H3/085—The tubes containing an electrically heated intermediate fluid, e.g. water
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00—Details
    • F24H9/18—Arrangement or mounting of grates or heating means
    • F24H9/1854—Arrangement or mounting of grates or heating means for air heaters
    • F24H9/1863—Arrangement or mounting of electric heating means
    • F24H9/1872—PTC
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/12—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element
    • F28F1/126—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being only outside the tubular element consisting of zig-zag shaped fins
    • F28F1/128—Fins with openings, e.g. louvered fins

Definitions

  • the present invention is related to a core unit of a heat exchanger, according to the preamble of claim 1, and a method of manufacturing a core unit of a heat exchanger.
  • DE 44 33 814 A1 discloses a heat exchanger having a core comprising a plurality of parallel flat tubes, a plurality of corrugated fins each of which is disposed between adjacent two of the flat tubes, and a plurality of PTC - elements being arranged on both sides of the flat tubes for heating a fluid flowing in the flat tubes.
  • a heat exchanger of a heater in which hot water or engine coolant is used to heat air is provided with an integrated electric heater.
  • the electric heater When the coolant temperature is low, for example when the engine is just started, the electric heater is turned on to generate heat, thereby heating air.
  • This structure reduces pressure loss in the heating air blow system of the heater as compared with a structure having a separate PTC heater. Because the PTC heater has a positive temperature characteristic sharply changing the resistance thereof at a set temperature, it is not necessary to provide a temperature control circuit so that the driving circuit thereof can be made simple.
  • the electric heater is composed of a PTC element and electrodes and is soldered to a heat exchanger core. Therefore, the PTC element is exposed to high-temperature air for soldering (e.g. 600 °C for soldering aluminum members) and, accordingly, the electric characteristic of the heater element may be damaged substantially.
  • high-temperature air for soldering e.g. 600 °C for soldering aluminum members
  • a heat exchanger of a heater is disposed at a downstream side of a heat exchanger for cooling air to control reheating by the heat exchanger of the heater, thereby controlling temperature of the air blown into the passenger compartment of the vehicle. Therefore, condensed water formed on the heat exchanger for cooling air or snow coming from the air inlet may adhere the front surface of the heat exchanger of the heater. Because the electric heater is exposed to the outside from the heat exchanger core, the water or snow may cause short circuiting or electric leakage.
  • the set temperature of the PTC heater is 80 °C. There is no explanation about how to decide the set temperature. Our experiments have revealed that the heat generated by the PTC heater may not be utilized for the heating air to be heated if the set temperature of the PTC heater is not suitable.
  • a plurality of flat tubes for conducting water or engine coolant are parallelly disposed, and each of a plurality of corrugated fins is disposed between two of the flat tubes. If a PTC heater is installed in place of one of the flat tubes, the heat of the PTC heater is conducted via the corrugated fins and the adjacent flat tubes to the water. If the PTC heater is powered when the water temperature is low, temperature of portions of the corrugated fins adjacent to the PTC heater becomes higher than the temperature of portions of the corrugated fins adjacent to the flat tubes. If the set temperature of the PTC is too high, the heat generated by the PTC heater is transmitted to the water. That is, the PTC heater can not heat the heating air to be used for the heater effectively. On the other hand, if the set temperature is too low, the PTC heater can not generate power sufficient to heat the heating air.
  • the present invention has been made, in view of the above problems, to provide a core unit of a heat exchanger in which an electric heater can be installed without damage.
  • the support plates can be soldered to the corrugated fins before the electric heater is inserted between the two support plates. Therefore, the electric characteristic of the electric heater is not damaged during the soldering step of the core unit.
  • the corrugated fins have complicated shape, the electric heater can be inserted easily without damage on the corrugated fins. Further, because the electric heater is inserted between and insulated from the two support plates, electric current can be supplied to the electric heater without passing metal portions (tubes, etc.) of the core unit, so that electric corrosion of the metal portions of the core unit can be prevented.
  • the summits of corrugation of the corrugated fins can be soldered to the support plates with sure, and heat generated by the electric heater can be conducted from the support plates to the corrugated fins effectively.
  • a core unit of a heat exchanger core having an air inlet side and an air outlet side includes a plurality of parallelly disposed flat tubes which conduct heat carrier, a plurality of corrugated fins, a U-shaped support member having a pair of plates parallelly extending along the flat tubes, an opening end portion and a U-shaped closing end portion, and an electric heater disposed between the support plates and insulated from the support member.
  • the support member is disposed between the summits of corrugation of adjacent two of the corrugated fins, the U-shaped closing end portion is disposed at the air inlet side, and each of the plates is bonded to one of the corrugated fins at the summits of corrugation.
  • the opening end portion preferably projects from an end of the electric heater.
  • the opening end portion may spread in a skirt-shape.
  • the support member may have the same thickness as the core unit in the air flow direction, and the electric heater may have smaller thickness in the direction of core thickness than the support member.
  • the U-shaped closing portion of the support member is disposed at the air inlet side of the heat exchanger core, the closing portion prevents water from entering the inside of the support member even if water adheres to an upstream portion of the core unit. Therefore, condensed water can not adhere to the electric heater, and the short circuiting or electric leak of the electric heater due to water is prevented. Because the opening portion of the support member projects from an end of the electric heater, water can be prevented from adhering to the electric heater even if water moves along the surface of the support member to the opening portion.
  • a core unit of a heat exchanger core includes a plurality of parallelly disposed flat tubes which conduct heat carrier, a plurality of corrugated fins having summits of corrugation disposed between two of the flat tubes, and an electric heater disposed between two of the summits of corrugation instead of one of the flat tubes.
  • the electric heater has a positive temperature characteristic sharply changing resistance thereof at a set temperature and heats portions of the fins adjacent to the flat tubes at a temperature equal to temperature of water in the flat tubes if the water temperature is equal to or higher than 60 °C and temperature of air to be heated is equal to or lower than 0 °C.
  • the diesel engine operates at a high efficiency, and the water temperature thereof can not rise sufficiently even after engine has warmed up.
  • the water temperature may not rise up to 60 °C. If the water temperature in the flat tubes does not rise above 60 °C, the heat generated by the PTC heater is not transmitted to the water, so that the PTC heater can heat the heating air efficiently.
  • a core unit of a heat exchanger core may include a plurality of parallelly disposed flat tubes which conduct heat carrier, a plurality of corrugated fins each of which is disposed between two of the flat tubes, a PTC heater disposed at a portion of the core unit instead of the flat tubes.
  • the corrugated fins have summits of corrugation disposed between two of the flat tubes which has a height between 3.9 mm and 5 mm, and the set temperature of the PTC heater is between 85 °C and 110 °C.
  • the electric heater is preferably a three-layered sandwich structure composed of an electric heater element and two flat electrodes on opposite sides of the electric heater element and is inserted between the corrugated fins and the two electrodes, and the two electrodes are press-fitted to the summits of the corrugation.
  • the PTC heater may have a heater element whose positive temperature characteristic sharply changing resistance thereof at temperature between 120 °C and 170 °C.
  • the height and the set temperature of the PTC heater are set as the above, the heat of the PTC heater is not transmitted to the water under the conditions: the heating air temperature ⁇ 0 °C; the water temperature in the flat tubes ⁇ 60 °C.
  • the height of the fins between 3.9 mm and 5 mm reduces the difference in the temperature between the fins and the heating air, so that the corrugated-fin-type heat exchanger core unit can provide both sufficient heat radiation performance and effective heating of the heating air by the PTC heater.
  • the heat exchanger for a heater has a hot-water inlet tank 1, a hot-water outlet tank 2 and a heat exchanger core unit 3 disposed between the tanks 1 and 2.
  • the hot-water inlet tank 1 has an inlet pipe 4 through which hot water or engine coolant flows from a vehicle engine (not shown).
  • the hot-water outlet tank 2 has an outlet pipe 5 through which the hot water is discharged and returned to the engine.
  • the heat exchanger is symmetrical, and therefore the hot-water inlet tank 1 and the hot-water outlet tank 2 can be exchanged.
  • the inlet tanks 1 is composed of a tank body 1a
  • the outlet tank 2 is composed of a tank body 2a.
  • Sheet metals 1b and 2b close the open end of the tank bodies 1a and 2a respectively.
  • the vertical direction of the heat exchanger in Figs. 1 and 2 is the longitudinal direction of the tanks 1 and 2.
  • Each of the sheet metals 1b and 2b has a plurality of elliptic tube receiving holes (not shown).
  • the elliptic tube receiving holes are formed in the vertical direction in Figs. 1 and 2 in a single line or a plurality of lines.
  • the heat exchanger core unit 3 has a plurality of the flat tubes 6 stacked in the vertical direction.
  • One of a plurality of corrugated fins 7 is disposed between each pair of the flat tubes 6 and soldered thereto.
  • Each of the corrugated fins 7 has a plurality of louvers extending at an angle from the direction A of heating air to increase the heat exchange rate.
  • each of the flat tubes 6 are inserted into corresponding tube receiving holes of the sheet metals 1b and 2b of the inlet and outlet tanks 1 and 2 and soldered thereto.
  • Side plate 8a and 8b are disposed on the outermost corrugated fins 7 and are soldered to the same outermost corrugated fins 7 and to the sheet metals 1b and 2b.
  • a pair of support plates 10 and 11 is disposed between the summits of the corrugation of adjacent two of the corrugated fins 7 in place of one of the flat tube 6 at each one of four portion of the core unit 3 and extend in parallel with each other at a distance L.
  • the distance L is the same as thickness of the electric heater 9.
  • Each of four electric heaters 9 is inserted between the support plates 10 and 11 to be held therein.
  • Elements and components 1-8b of the core unit 3 as well as the support plates 10 and 11 are made of aluminum or aluminum alloy.
  • Each of the support plates 10 and 11 is made of a thin sheet having thickness between 0.1 and 0.5 mm and width (in the direction of the hot air) having nearly the same size as the corrugated fins 7.
  • the length (in the horizontal direction in Fig. 1) of the support plates 10 and 11 is nearly the same as the distance between the sheet metals 1b and 2b.
  • the electric heater 9 has a three-layered sandwich structure composed of a flat heating element 9a and long flat electrodes 9b and 9c disposed on the opposite surfaces of the heating element 9a as shown in Fig. 3.
  • An insulating cover 9d made of insulating material covers the circumferences of the electrodes 9b and 9c.
  • the heating element 9a is a PTC heater element made from resistance material (such as barium titanate), which has a positive temperature characteristic increasing the resistance sharply at a set temperature T0 (e.g. around 90 °C).
  • the thickness of the heating element 9a is between 1.0 - 2.0 mm.
  • the electrodes 9b and 9c is made of aluminum, copper or stainless or the like and has the thickness between 0.1 - 0.5 mm.
  • the length of the electrodes 9b and 9c (horizontal size in Fig. 1) is nearly equal to the length of the support plates 10 and 11.
  • the heating element 9a and the electrodes 9b and 9c are pressed to each other to provide good electric conduction.
  • the insulating cover 9d is press-fitted into the space. between the support plates 10 and 11 to insulate the support plates 10 and 11 from the plates 9b and 9c and to conduct heat generated by the heating element 9a to the support plates 10 and 11.
  • the thickness t1 of the insulating cover 9d disposed between the support member and one of the plates 9b and 9c is formed between 25 ⁇ -100 ⁇ .
  • the thickness t2 of the insulating cover 9d at the opposite sides of the heating elements is about 1-2 mm to protect the heating elements 9a.
  • the insulating cover 9d is preferably made of high temperature resistive resin (e.g. polyimide).
  • Terminals 9e and 9f are formed integrally with the plus electrode 9b and the minus electrode 9c respectively to be connected to an outside circuit.
  • the terminals 9e and 9f project from the rear side (down stream side of air flow A in Fig. 1) of the core unit 3.
  • the terminal 9e is formed at the right side of the plus electrode 9b, and the terminal 9f is formed at the left side of the minus terminal 9c. Both terminals 9e and 9f may project toward the rear side (air flow direction A ).
  • the terminals 9e and 9f are connected to an outside circuit (not shown) so that the electric heaters 9 can be energized by a vehicle electric source.
  • Reference numerals 12 and 13 indicate fastening members or bands made of anticorrosion metal respectively disposed on a surface of the air inlet side and on a surface of the air outlet side of the core unit 3.
  • Each of the fastening members 12 and 13 has hook portions at the opposite ends thereof to engage grooves 8c and 8d formed at middle of the upper and lower side plates 8a and 8b.
  • the fastening members 12 and 13 provides the support plates 10 and 11 with fastening force to hold the electric heater 9.
  • the tubes 6 and corrugated fins 7 are alternately stacked on one another, and the support plates 10 and 11 are inserted between the corrugation summits of the corrugated fins 7 which are located in four hatched portions.
  • a dummy spacer (not shown) is inserted into the support plate 10.
  • the spacer is made of material (such as carbon) which is resistant to the soldering heat and is not soldered to aluminum.
  • the tanks 1 and 2, the pipes 4 and 5 and the side plates 8a and 8b are also assembled in a well-known manner.
  • the above assembled unit is held by an assembling tool (not shown) and sent to a brazing furnace to be brazed or soldered.
  • the assembled unit is heated at a soldering temperature (600 °C) to melt solder in aluminum clad members of the core unit 3.
  • the assembled unit is taken out from the furnace and is cooled until the temperature of the assembled unit goes down to the ambient temperature. Then, the flat heating element 9a is inserted between the electrodes 9b and 9c to form the three-layered sandwich unit, which is covered by the insulating cover 9d.
  • the dummy spacers are removed from the support plates 10 and 11, and each of the electric heaters 9 is inserted thereto in a manner that the insulating cover 9d is press-fitted to the support member 10. Thereafter, the hooks of the fastening members 12 and 13 are engaged with the grooves 8c and 8d of the upper and lower side plates 8a and 8b to fasten the core unit 3 tight.
  • the motor-driven fan 15 is operated to pass air through the spaces between the flat tubes 6 and the corrugated fins 7 in the direction indicated by the arrow A in Fig. 1.
  • a water pump (not shown) is operated and hot water flows into the inlet tank 1 from the inlet pipe 4.
  • the hot water is distributed to a plurality of flat tubes 6 and transfer the heat thereof to the air to be heated while the water flows along the flat tubes. All the water flowing along the flat tubes 6 are collected in the outlet tank 2 and goes out of the outlet pipe 5 to the engine.
  • the electric source voltage of the vehicle is applied across the terminals 9e and 9f of the electrodes 9b and 9c. consequently, the heating elements 9a are energized to generate heat, which is conducted to the corrugated fins 7 via the electrodes 9b and 9c, the insulating cover 9d and the support plates 10 and 11. Therefore, the air is heated in a short time even if the water is not sufficiently hot.
  • a preset temperature e.g. 80 °C
  • the heating element 9a is composed of a PTC element which has a positive temperature characteristic the resistance of which increases sharply at a preset temperature T0, it regulates the temperature thereof to the preset temperature by itself.
  • the solder melts in the subsequent soldering step of the core is guided by the capillarity to the gaps between the summits of the corrugation of the corrugated fins 7 and support plate and fills the gaps even though the gaps forms due to irregular height of the corrugation.
  • the insulating cover 9d of the electric heater 9 can be made of adhesive resinous material to bond the electric heater 9 to the support plates 10 and 11. In this case, the fastening members can be omitted.
  • each of the portions of the heat exchanger core unit 3 where the electric heaters are installed has a U-shaped support member 100 extending in the longitudinal direction of the flat tubes 6 between the summits of the corrugation of adjacent two of the corrugated fins.
  • a U-shaped closing portion 10a of the support member 100 is located at the air inlet side of the heat exchanger core unit 3, and the opening portion 10b thereof is located at the air outlet side of the heat exchanger core unit 3.
  • the support member 100 has plates 10 and 11 extending in parallel at a distance L1, and they are soldered to the summits of the corrugations in the same manner as in the first embodiment.
  • the electric heater 9 is inserted from the opening portion 10b into the inside of the support member 100 to be held therein.
  • the electric heater 9 is held by an insulating member as described before.
  • Total thickness L2 of the support member 100 is same as thickness L3 of the flat tube 6 so that the support member 100 can be installed between the corrugated fins 7 instead of the flat tube 6.
  • D is the thickness of the core unit 3 as well as the width of the flat tubes 6 and the corrugated fins 7 in the air flow direction.
  • Each of the support members 100 is made of a thin sheet having thickness between 0.1 and 0.5 mm and width (in the direction of the hot air) having nearly the same size as the core thickness D.
  • the length (in the horizontal direction in Fig. 1) of the support member 100 is nearly the same as the distance between the sheet metals 1b and 2b.
  • the electric heater 9 has a three-layered sandwich structure composed of a flat heating element 9a and long flat electrodes 9b and 9c disposed on the opposite surfaces of the heating element 9a as shown in Figs. 5 and 6.
  • An insulating cover 9d covers the electrodes 9b and 9c.
  • the heating element 9a is a PTC heater element which has a positive temperature characteristic to increase the resistance sharply at a prescribed temperature T0 (e.g. around 200 °C).
  • the thickness of the heating element 9a is between 1.0 - 2.0 mm.
  • the electrodes 9b and 9c of the heating element 9a is made of aluminum, copper, stainless or the like and has the thickness between 0.1 - 0.5 mm.
  • the length of the electrodes 9b and 9c (horizontal size-in Fig. 1) is nearly equal to the length of the support member 100.
  • the electric heater can be held by a single fastening member 12 disposed on the opening portions 10b.
  • Fig. 7 illustrates an air conditioner to which a heat exchanger of a heater H according to this embodiment is installed.
  • Outside air or inside air is introduced by a motor-driven fan 15 disposed in the upstream side of a resinous case 14 and sent to an evaporator 16 of the refrigerating cycle to be cooled and dried.
  • the cooled air is separated by an air-mix door 17 into a flow passing the heat exchanger H for cooling air and a flow passing a bypass 18 so that the air heated by the heat exchanger H and the air passing the bypass 18 can be mixed and adjusted by turning the air-mix door 17, thereby controlling temperature of the air blown into the compartment of a vehicle.
  • the present invention can be applied to an air conditioner for a vehicle in which hot water supplied to the heat exchanger H is controlled by a hot-water control valve to control the temperature of the air blown into the vehicle compartment instead of the air-mix door 17.
  • the heat exchanger core is assembled first.
  • the tubes 6 and corrugated fins 7 are alternately stacked on one another, and one of the U-shaped support member 100 which extends along the tubes 6 is inserted between the corrugation summits of the corrugated fins 7 which are located in portions (four hatched portions).
  • Other steps are substantially the same as those of the first embodiment.
  • the motor-driven fan 15 is operated to pass air to be heated through the spaces between the flat tube and the corrugated fins.
  • a water pump (not shown) is operated and hot water flows into the inlet tank 1 from the inlet pipe 4.
  • the hot water is distributed to a plurality of flat tubes 6 and transfer the heat thereof to the air to be heated while the water flows along the flat tubes. All the water flowing along the flat tubes 6 are collected in the outlet tank 2 and goes out of the outlet pipe 5 to the engine.
  • the electric source voltage of the vehicle is applied in the same manner as described before.
  • the heat exchanger H for heating air is disposed at a downstream side of the heat exchanger 16 for cooling air in the case of the vehicle air conditioner. Therefore, condensed water generated in the heat exchanger 16 may be carried by the cooled air to the heat exchanger H and may adhere to the surface of the heat exchanger H . Snow may come from the air inlet into the case 14, melt and adhere to the upstream surface of the heat exchanger H .
  • the U-shaped closing portions 10a of the support member 100 are located at the air inlet side of the heat exchanger H , and the opening portions 10b are located at the air outlet side thereof. Even if the condensed water adheres to the upstream side of the heat exchanger H of the heater, the closing portions 10a keep off water or snow from the electric heater 9.
  • the opening portion 10b projects a little from the downstream side of the electric heater 9. Even if water moves along the outer surface of the support members 100 to the opening portion 10b, the water can not adhere to the surface of the electric heater 9.
  • the electric terminals 9e and 9f of the electric heater 9 project from the downstream side of the heat exchanger core unit 3 in the air flow A , water does not adhere to the terminals 9e and 9f. Therefore, deterioration of the terminals 9e and 9f, short-circuiting and electric leakage can be prevented. Since the electric heaters 9 can be held in the U-shaped support members 100, the electric heater 9 can be positioned accurately.
  • the heating element 9a and the electrodes 9b and 9c of the electric heater 9 are covered by the insulating cover 9d and insulated from the support plate 10, electric current can not flow into the metal members of the heat exchanger H , and the electric corrosion of the metal members such as tubes or fins can be prevented.
  • Fig. 8 shows a variant of the second embodiment.
  • the opening portion 10b of the support member 100 projects slightly from the end of the electric heater 9.
  • the opening portion 10b is positioned at the downstream side of the corrugated fins in the air flow and is expanded at the end thereof like a skirt. Accordingly, the water moving along the surface to the opening portion 10b of the support member 100 is prevented from adhering to the electric heater with more sure.
  • Fig. 9 shows a second variant of the second embodiment.
  • the heat exchanger H according to the second variant is a type in which hot water is returned as compared with the heat exchanger H according to the first embodiment, so called full-pass (one way) type, in which the hot water flows in one way direction in all the flat tubes from the hot water inlet tank 1 to the hot water outlet tank 2.
  • the tank disposed on a side of the core unit 3 is divided into the hot water inlet tank 1 and the hot water outlet tank 2, and a connecting tank 19 is disposed to return the water to the opposite side of the tanks 1 and 2.
  • Hot water is introduced from the inlet tank 1 through the flat tubes 6 on the left side of the core unit 3 into the connecting tank 19. From the connecting tank 19, the hot water is introduced to the outlet tank 2 through the flat tubes 6 on the right side of the core unit 3 and goes out from the outlet 5.
  • the electric heater 9 can be installed in this type in the same manner as in the first embodiment.
  • Fig. 10 shows a third variant of the second embodiment.
  • Two rows of the flat tubes 6 are disposed in the thickness of the core and, therefore, the thickness D of the core unit 3 is about twice as thick as the thickness of electric heater.
  • a stopper portion 10e is formed at the middle of the support member 100 to hold the electric heater 9 in position. The middle portions of the support member 100 are pinched to be in contact with each other.
  • the same electric heater 9 can be used to any heat exchanger H of a heater having core with different thickness.
  • Fig. 11 shows a fourth variant of the second embodiment.
  • a separate stopper member (made of resin or metal) 10f is disposed inside the support member 100.
  • Fig. 12 shows a fifth variant of the second embodiment.
  • the plate 10 of the support member 100 is pinched to form the stopper 10e.
  • Fig. 13 shows a sixth variant of the second embodiment.
  • the support member 100 has a reinforcement rib 10g between the stopper portion 10e and the closing portion 10a.
  • the reinforcement rib 10g is formed by pinching middle portions of the plates 10 and 11.
  • the reinforcement rib 10g increases the stiffness of the portion between the stopper portion 10e and the closing portion 10a.
  • the reinforcement rib 10g of the seventh embodiment can be formed on either one of the two plates 10 and 11.
  • the stopper 10e and the reinforcement rib 10g can be formed along the whole length of the tubes of the core continuously or intermittently
  • the PTC heater 9 shown in Fig. 14 is composed of a flat heating element 9a and long flat electrodes 9b and 9c disposed on the opposite surfaces of the heating element 9a.
  • the heating element 9a is a PTC heater element which has a positive temperature characteristic to increase the resistance sharply at a prescribed temperature T0.
  • the electrodes 9b and 9c of the PTC heater element 9a are bonded by adhesive insulating material 10 to the summits of corrugation of the corrugated fins 7.
  • the opposite ends of the PTC heater element 9a (horizontal direction in Fig. 1) are bonded by adhesive insulating material 10 to the sheet metals 1b and 1c.
  • the adhesive insulating material 10 is made of adhesive, electrically insulating and heat conductive resin. Heat generated by the PTC heater element 9a is conducted by the corrugated fins 7 to heat the heating air.
  • Fig. 15 shows an electric driving circuit of the PTC heater 9.
  • the four PTC heaters 9 are parallelly connected to a vehicle electric source 12 via a switch 9.
  • the switch 11 is controlled by a control circuit 13.
  • the control circuit 13 receives signals from a water temperature sensor 14 for detecting temperature of the water flowing from the engine into the heat exchanger of a heater and a switch 15 operated when the heater operates. If the water temperature is lower than a certain temperature (e.g. 80 °C), the control circuit 13 turns on the switch 11 to power the PTC heaters 9.
  • a certain temperature e.g. 80 °C
  • an air blower operates and drive air to the spaces between the flat tubes 6 and the corrugated fins 7.
  • hot water is driven by a water pump (not shown) installed in the engine to flow from the engine through the inlet pipe 4 into the inlet tank 1. Then, the hot water is distributed into a plurality of the flat tubes 6 to heat the heating air via the corrugated fins while passing the tubes 6. Thereafter, the hot water flows into the outlet tank 2, gets together, flows out of the outlet pipe 5 of the heat exchanger and returns to the engine.
  • the switch 11 of the electric circuit closes to power the four PTC heaters 9.
  • the PTC heaters 9 self-controls the temperature and rises to the temperature T0, which is transmitted to the heating air through the adjacent corrugated fins 7. Thus, the heating air is heated in a short time even if the water temperature is low.
  • the set temperature T0 is an important factor.
  • Fig. 16 shows temperature distribution of the corrugated fin 7 disposed between the surface of the PTC heater 9 and the surface of the adjacent corrugated fin 6.
  • E1 and E2 The following relations expressed by E1 and E2 are known, where temperature of the heating air flowing in the direction vertical to the drawing is Tair, set temperature (surface temperature) of the PTC heater 9 is T0, height of the corrugated fin 7 is hf, height of a certain position of the corrugated fin 7 is x, and temperature of the fin at the height x of the certain position is ⁇ :
  • E1: ( ⁇ -Tair)/(T0-Tair) cosh[m(hf-x)]/cosh(m ⁇ hf)
  • E2: ⁇ cosh[m(hf-x)]/cosh(m ⁇ hf) ⁇ (T0-Tair) + Tair, where m is a dimensionless number expresses in the following expression E3.
  • E3: m 2h 0 / ⁇ f ⁇ b, where h 0 is a coefficient of heat transfer of the fin surface, b is a thickness of the fin, and ⁇ f is a coefficient of
  • the temperature ⁇ of the portions of the corrugated fins 7 adjacent to the flat tubes 6 is made equal to the temperature Tw of the peripheral surface of the tubes (or the water temperature in the tubes) in order to prevent the heat generated by the PTC heater 9 from transferring to the water.
  • T0 (Tw-Tair) cosh (m ⁇ hf) + Tair
  • m 227.626
  • Tair is the outside temperature in winter. Because a recent highly-efficient-engine can provide hot water of 60 °C at the highest in winter, 60 °C is selected as Tw.
  • Fig. 18 shows relationship between the height hf of the fin and the set temperature T0 of the PTC heater 9 with various heating air temperatures Tair when Tw is 80 °C under the same conditions as above.
  • Fig. 19 shows relationship between the set temperatures T0 and the heating air temperatures Tair at various water temperatures Tw with the height of the corrugated fins being 4.5 mm.
  • the set temperature of the PTC heater 9 changes from 96 °C to 126 °C.
  • Fig. 20 shows relationship between the set temperatures T0 and the heating air temperatures Tair at various water temperatures Tw when the height of the fins hf is 4.0 mm.
  • the set temperature of the PTC heater 9 changes from 87 °C to 118 °C.
  • Fig. 21 is a graph showing relationship between temperatures on the fin surfaces and distances x of the fin surfaces from the PTC heater 9 with following conditions:
  • the height hf is 4.5 mm
  • the water temperature Tw is 60 °C
  • the heating air (outside air) temperature Tair is 0 °C.
  • the heat of the corrugated fins, which is transferred from the PTC heater 9 is transferred to water and the heat generated by the PTC heater 9 is not utilized efficiently.
  • the shorter width of the elliptic opening of the flat tube 6 is about 1.4 mm. It is found preferable that the height of the corrugated fins 7 is equal to or larger than 3.9 mm in combination with the above sized tubes. If the height of the fins is less than 3.9 mm, the ratio of the heat conduction area of the corrugated fins to the number of the flat tubes 6 is too small to have a sufficient heat radiation capacity.
  • the height hf of the fins is, preferably, smaller than 5 mm. Otherwise, temperature of the middle portions of the corrugated fins becomes excessively lower than the temperature of the portions of the corrugated fins 7 adjacent to the tubes. This reduces the difference between the fin temperature, and the heating air temperature becomes too small for efficient heat transfer.
  • the desirable height hf of the corrugated fins 7 is between 3.9 and 5.0 mm.
  • the set temperature T0 of the PTC heater 9 is between 80 °C and 120 °C if the height hf of the fins being between 3.9 and 5.0.
  • the heater element 9a has positive temperature characteristic sharply changing the resistance thereof at temperature between 120 °C and 170 °C.
  • the position of the PTC heater 9 can be changed in accordance with various specifications of the heat exchanger of the heaters.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Geometry (AREA)
  • Air-Conditioning For Vehicles (AREA)
  • Resistance Heating (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Claims (19)

  1. Unité de noyau d'un échangeur de chaleur, ladite unité de noyau comprenant :
    une pluralité de tubes plats parallèles (6) ;
    une pluralité d'ailettes ondulées (7) dont chacune est disposée entre deux tubes adjacents des tubes plats (6) ;
    et un réchauffeur électrique (9), caractérisé en ce que
    un élément de support (100) est disposé entre deux desdites ailettes ondulées (7) au lieu d'un desdits tubes plats, dans lequel
    ledit réchauffeur électrique (9) est disposé à l'intérieur dudit élément de support (100),
    ledit élément de support (100) comporte une paire de plaques parallèles (10, 11) liées auxdites ailettes ondulées (7) au niveau du somme d'ondulation, et
    ledit réchauffeur électrique (9) comporte un élément de chauffage (9a) et un élément d'isolation (9b) inséré entre l'élément chauffant (9a) et lesdites plaques parallèles (10, 11).
  2. Unité de noyau selon la revendication 1, ledit échangeur de chaleur ayant un côté orifice d'entrée d'air et un côté orifice de sortie d'air, dans lequel
    la pluralité des tubes plats (6) parallèlement disposés conduit un thermoconducteur ;
    la paire de plaques (10, 11) s'étend en parallèle suivant lesdits tubes plats (6), l'élément de support (100) comporte une partie d'extrémité d'ouverture (10b) et une partie d'extrémité de fermeture (10a) en forme de U, et ladite partie d'extrémité de fermeture (10a) en forme de U est disposée au niveau dudit côté orifice d'entrée d'air.
  3. Unité de noyau selon la revendication 2, dans laquelle
    ladite partie d'extrémité d'ouverture (10b) dépasse d'une extrémité dudit réchauffeur électrique (9).
  4. Unité de noyau selon la revendication 2, dans laquelle
    ladite partie d'extrémité d'ouverture (10b) s'étale en forme de jupe.
  5. Unité de noyau selon la revendication 2, dans laquelle
    ledit élément de support (100) a la même épaisseur que ladite unité de noyau dans la direction d'écoulement d'air,
    ledit réchauffeur électrique (9) a une épaisseur plus faible dans la direction de l'épaisseur du noyau que ledit élément de support (100), et
    ledit élément de support (100) comprend des moyens (10e, 10f) destinés à y positionner ledit réchauffeur électrique (9).
  6. Unité de noyau selon la revendication 5, dans laquelle
    lesdits moyens (10e, 10f) destinés au positionnement comprennent une butée dépassant à l'intérieur d'au moins l'une desdites deux plaques (10, 11).
  7. Unité de noyau selon la revendication 6, dans laquelle
    une desdites plaques (10, 11) comporte une nervure de renforcement disposée entre ladite butée et ladite partie d'extrémité de fermeture (10a).
  8. Unité de noyau selon la revendication 6, dans laquelle
    ledit moyen (10e, 10f) pour le positionnement comprend un élément de butée disposé entre ledit réchauffeur électrique (9) et ladite partie d'extrémité de fermeture (10a).
  9. Unité de noyau selon l'une quelconque des revendications 1 et 2, dans laquelle
    chacun desdits tubes plats (6), des ailettes ondulées (7) et de l'élément de support (100) ou des plaques de support (10, 11) est constitué d'aluminium et sont brasés les uns aux autres.
  10. Unité de noyau selon l'une quelconque des revendications 1 et 2, dans laquelle
    ledit réchauffeur électrique (9) comporte une électrode plus (9b), une électrode moins (9c), l'élément de chauffage (9a) disposé entre lesdites deux électrodes (9b, 9c), l'élément de couvercle isolant (9d) couvrant lesdites deux électrodes, dans laquelle
    ledit élément de couvercle (9d) est inséré ou est ajusté de manière serrée entre lesdites plaques (10, 11) pour y maintenir le réchauffeur électrique (9).
  11. Unité de noyau selon la revendication 10, dans laquelle
    chacune de ladite électrode plus (9b) et de ladite électrode moins (9c) comporte une borne de raccord solidairement formée sur leur surface et/ou dépassant de celle-ci.
  12. Unité de noyau selon la revendication 11, dans laquelle
    chacune desdites bornes de raccord dépasse de l'une correspondante de ladite électrode plus (9b) et de ladite électrode moins (9c) dans une direction d'épaisseur dudit noyau de l'échangeur de chaleur.
  13. Unité de noyau selon la revendication 11, comprenant, en outre, un moyen (12, 13) pour maintenir ledit réchauffeur électrique (9) sous pression entre lesdites deux plaques de support (10, 11).
  14. Unité de noyau selon la revendication 27, comprenant, en outre,
    un élément de fixation (12, 13), disposé sur ledit côté orifice de sortie d'air de ladite unité de noyau, destiné à maintenir ledit réchauffeur électrique (9) dans ledit élément de support (100).
  15. Unité de noyau selon l'une quelconque des revendications 1 à 14, dans laquelle
    ladite pluralité de tubes plats (6) disposés parallèlement conduit un thermoconducteur ;
    ladite pluralité d'ailettes ondulées (7) ayant ses sommets d'ondulation disposés entre deux desdits tubes plats (6) ; et
    ledit réchauffeur électrique (9) est disposé entre deux desdits sommets d'ondulation au lieu d'un desdits tubes plats (6),
    ledit réchauffeur électrique (9) ayant une caractéristique de température positive changeant finement sa résistance au niveau d'une température établie, dans laquelle
    ledit réchauffeur électrique (9) avec ladite température établie chauffe des parties desdites ailettes (7) adjacentes auxdits tubes plats (6) à une température égale à la température de l'eau dans lesdits tubes plats (6) si ladite température de l'eau est égale ou supérieure à 60° C et la température de l'air à chauffer est égale à ou inférieure à 0° C.
  16. Unité de noyau selon l'une quelconque des revendications 1 à 15, dans laquelle
    ladite pluralité de tubes plats (6) parallèlement disposés conduit un thermoconducteur ;
    chacune de ladite pluralité d'ailettes ondulées (7) est disposée entre deux desdits tubes plats (6) ;
    ledit réchauffeur électrique (9) est disposé au niveau d'une partie de ladite unité de noyau (3) au lieu desdits tubes plats (6), ledit réchauffeur électrique (9) ayant une caractéristique de température positive changeant finement sa résistance à une température établie, dans laquelle
    lesdites ailettes ont des sommets d'ondulation disposés entre deux desdits tubes plats (6) qui ont une hauteur d'entre 3,9 mm et 5 mm, et
    ladite température établie dudit réchauffeur électrique (9) est située entre 80° C et 110° C.
  17. Unité de noyau selon la revendication 15, dans laquelle
    ladite unité de noyau est constituée d'un alliage d'aluminium,
    ledit réchauffeur électrique (9) est une structure en sandwich à trois couches composée d'un élément (9a) du réchauffeur électrique et de deux électrodes plates (9b, 9c) sur des côtés opposés dudit élément (9a) du réchauffeur électrique et est inséré entre lesdites ailettes ondulées (7) et lesdites deux électrodes, et
    lesdites deux électrodes sont ajustées de manière serrée auxdits sommets de l'ondulation.
  18. Unité de noyau selon la revendication 1, dans laquelle
    ledit élément (9a) du réchauffeur électrique a une caractéristique de température positive changeant finement sa résistance à une température établie qui est entre 120° C et 170° C.
  19. Procédé de fabrication d'une unité de noyau selon l'une quelconque des revendications 1 à 18,
    le procédé comprenant les étapes consistant à :
    empiler lesdits tubes plats (6) et lesdites ailettes ondulées (7) de manière alternative, et placer ladite paire de plaques de support (10, 11) ente lesdits sommets d'ondulation à une partie où ledit réchauffeur électrique (9) doit être disposé ;
    braser lesdits tubes plats (9), lesdites ailettes ondulées (7) et lesdites plaques de support (10, 11) en une unité ; et
    insérer ledit réchauffeur électrique (9) entre lesdites deux plaques (10, 11).
EP98102091A 1997-02-06 1998-02-06 Noyau d'un échangeur de chaleur avec réchauffeur électrique Expired - Lifetime EP0857922B1 (fr)

Applications Claiming Priority (9)

Application Number Priority Date Filing Date Title
JP2415497 1997-02-06
JP02415497A JP3812031B2 (ja) 1997-02-06 1997-02-06 車両暖房用熱交換器
JP24154/97 1997-02-06
JP9241797A JP3812045B2 (ja) 1997-04-10 1997-04-10 暖房用熱交換器
JP9241797 1997-04-10
JP92417/97 1997-04-10
JP21504297 1997-08-08
JP215042/97 1997-08-08
JP21504297A JP3794117B2 (ja) 1997-08-08 1997-08-08 暖房用熱交換器

Publications (3)

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EP0857922A2 EP0857922A2 (fr) 1998-08-12
EP0857922A3 EP0857922A3 (fr) 1999-12-08
EP0857922B1 true EP0857922B1 (fr) 2003-04-23

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KR (1) KR100334619B1 (fr)
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CN206061176U (zh) * 2015-10-18 2017-03-29 谢彦君 一种ptc电加热装置
CN106568189A (zh) * 2015-10-18 2017-04-19 谢彦君 一种电加热装置
CN106658774A (zh) * 2015-11-01 2017-05-10 谢彦君 一种液体介质加热设备
CN106711109A (zh) * 2015-11-17 2017-05-24 谢彦君 一种功率模块
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JPS569732A (en) 1979-07-04 1981-01-31 Sadao Nakamura Preventing method of camera-shake at hand-held photographing in portable camera
JP2833620B2 (ja) 1987-02-19 1998-12-09 株式会社デンソー 車両用空調装置
DE4433814B4 (de) * 1994-09-22 2006-05-24 Behr Gmbh & Co. Kg Kraftfahrzeug

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DE69813650T2 (de) 2003-10-16
CN1194364A (zh) 1998-09-30
DE69813650D1 (de) 2003-05-28
EP0857922A3 (fr) 1999-12-08
KR19980071083A (ko) 1998-10-26
KR100334619B1 (ko) 2002-06-20
EP0857922A2 (fr) 1998-08-12
CN1145777C (zh) 2004-04-14

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