EP2397788A1 - Heat exchanger and method for manufacturing a heat exchanger - Google Patents
Heat exchanger and method for manufacturing a heat exchanger Download PDFInfo
- Publication number
- EP2397788A1 EP2397788A1 EP10290330A EP10290330A EP2397788A1 EP 2397788 A1 EP2397788 A1 EP 2397788A1 EP 10290330 A EP10290330 A EP 10290330A EP 10290330 A EP10290330 A EP 10290330A EP 2397788 A1 EP2397788 A1 EP 2397788A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- heat exchanger
- potting compound
- elements
- heating unit
- filling
- 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.)
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Classifications
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- 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
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- 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
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- 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
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
- H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
- H05B3/262—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base the insulating base being an insulated metal plate
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/02—Heaters using heating elements having a positive temperature coefficient
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/022—Heaters specially adapted for heating gaseous material
- H05B2203/023—Heaters of the type used for electrically heating the air blown in a vehicle compartment by the vehicle heating system
Definitions
- the invention relates to a heat exchanger according to the preamble of claim 1, a method for producing a heat exchanger according to claim 14 and a method for producing a heat exchanger according to claim 15.
- Consumption-optimized motor vehicles generate less and less waste heat, which is available for heating the interior of the motor vehicle. Especially in the starting phase and at low outside temperatures, it is therefore necessary to heat for example by means of a Brennstoffzuloomers, an electric heater, an exhaust gas heat exchanger or the like.
- the electrical heater has proved to be particularly advantageous because they cost, spontaneously noticeable (ie the electrical power is immediately converted into noticeable heat) and space-saving can be installed, which allows easy integration into an air conditioner and the air ducts.
- the importance of the electric heater is even greater.
- electrical power of> 3 kW is needed, as a conventional coolant radiator is only conditionally or no longer applicable.
- the vehicle electrical system voltage is> 60 V, in some cases even> 300 V. Due to the high required heating power at the electric heater this is operated with a high voltage in order to keep the current as low as possible.
- PTC heaters are commonly used as electric heaters.
- the conversion of electrical energy from the electrical system into heat takes place in a PTC heating element, which comprises a ceramic thermistor, which is a very temperature-dependent semiconductor resistor.
- the resistance of the PTC element increases sharply with increasing temperature.
- a very uniform surface temperature at the PTC element ie applied voltage, nominal resistance, amount of air over the PTC element, etc.
- This prevents overheating, as z. B. would arise with a normal heating wire, since regardless of the boundary conditions or regardless of whether heat can be delivered, always the same resistance is present, and thereby electrical heating power is introduced.
- the electrical protection in the form of, for example, an overheating protection is not necessary because the PTC element is de-regulated by its own behavior, ie with increasing temperature, the electrical resistance increases proportionally.
- the high voltage unit should be dust and waterproof encapsulated to meet the requirements of IP 67 (dust and water resistance up to 1 meter depth) to avoid short circuits.
- IP 67 dust and water resistance up to 1 meter depth
- the penetration of dust and water into the high voltage unit is disadvantageous, since they can form a "current bridge", which can then cause a short circuit.
- the object of the present invention is therefore to provide a heat exchanger, in particular an electric heater for a motor vehicle and a method for its production, wherein the heat exchanger is provided with both a contact protection, so that none of the externally accessible electrically conductive components an electric Has potential, and wherein the contact protection process is reliable and the high-voltage heating unit also protects against dirt and moisture entry safely.
- a heat exchanger in particular an electric heater for a motor vehicle, which has a plurality of alternately juxtaposed corrugated fin elements and heating units and an upper end trough, which comprises a plurality of openings for receiving and fixing the heating units, each heating unit having two electrically conductive Contact plates and arranged between the two electrically conductive contact plates PTC heating elements, which are accommodated in a housing element, wherein at least one space between an inner wall of the housing member and the contact plates is filled with an electrically insulating potting compound, wherein in the housing element at least one positioning element for positioning the heating unit is arranged in the housing element, which has an integrated first filling channel for filling the intermediate space with potting compound.
- the positioning element with integrated first filling channel thus has two functions: on the one hand it ensures that the casting compound is reliably filled into the intermediate space, and on the other hand, the heating unit is securely positioned or fixed in the housing element. Without an integrated filling channel, a nozzle from which the potting compound flows would have to be applied to the bottom of the housing element, so that the potting compound penetrates from bottom to top into the intermediate space, and then move upwards during filling with the water level, which is very expensive would. However, the potting compound can flow downwards through the first filling channel and enter the intermediate space in the lower region of the first filling channel in order to fill it from bottom to top without bubbles. Depending on the design, the space between the individual PTC heating elements can also be used each heating unit to be completed.
- the gap is process reliable filled, so that the filling compound filled in the gap permanently, that is over the life of the heat exchanger, provides a secure contact protection. Also, filling the interstice with potting compound of the high-voltage heater unit provides protection against ingress of dirt and moisture since the high-voltage heater unit is "encapsulated" in itself. and all electrically conductive surfaces of accessible external components are potential-free.
- the housing element is a rectangular tube, an oval tube or a flow press.
- the rectangular tube is made as a extruded part, the upper end pan and the lower bottom plate may be integrally formed therewith.
- the rectangular tube or the oval tube or extruded part is used for retrofitting a prefabricated and provided with at least one positioning heating unit, which is inserted into the rectangular tube, the oval tube or the extruded part.
- the tube width of a rectangular tube is between 2.5 to 10 mm.
- the thickness of the contact sheets is preferably in the range between 0.2 to 1.5 mm and the thickness of the individual PTC heating elements between 0.8 to 3 mm.
- the positioning element is designed as a position bar, which is provided at a lower end portion with at least one opening through which the potting compound enters during filling of the heating unit in the intermediate space.
- the position bar is formed with an undercut.
- the undercut has the task in a possibly occurring demolition of the contact between the Potting compound and the contact plate to create no direct air gap between the contact plate and the housing element.
- a lower bottom plate is further provided, which is arranged spaced from a lower end portion of each heating unit of the plurality of heating units as a separate component.
- the lower bottom plate may also be formed integrally on each housing element or on each rectangular tube, which in this case is, for example, a flow-molded part.
- one, preferably two, side parts may be provided.
- the gap has a gap which is in a range of 0.3 to 2.0 mm. This range is particularly preferred because the thinner the gap, the higher the heat conduction. However, if the gap is too narrow, there is the risk that air pockets may occur in the potting compound, which results in the risk of a flashover. On the other hand, wider gaps can be filled better, but here the heat extraction is worse.
- the potting compound is electrically insulating and has a good thermal conductivity.
- the heat from the PTC heating elements must be transferred via the contact plates and the potting compound to the housing element and then to the air-side corrugated fins. The largest temperature response will be in the potting compound, which should therefore have a good thermal conductivity.
- the potting compound is curable, in particular by heat or by the addition of chemical curing agents, and heat stable, especially at continuous temperatures around 200 ° C.
- the potting compound, which serves as a heat transfer medium is particular viscous during processing and solid hardening during operation. The hardness during operation can go up to a Shore hardness of A to D.
- the potting compound contains thermally conductive fillers, in particular aluminum oxide, boron nitride and / or silicon carbide.
- the base of the potting compound of resin or silicone Preferably, the base of the potting compound of resin or silicone.
- the potting compound which is used as a heat transfer medium, advantageously separates electrical and thermal flows.
- the upper end trough is at least partially filled with potting compound.
- the potting compound When filling the gap, the potting compound, if it completely fills the gap, then also enters the top of the upper tundish, there to isolate the high voltage unit galvanic to "outside". In addition, this provides for improved heat transfer to the outside.
- the function of the upper end tray as "overflow basin" when filling with potting compound is also advantageous because the amount of potting compound is not precisely metered.
- the upper end pan also has the function of receiving the housing elements and provides an overall structure during the soldering of the blank.
- the ceramic elements have a 10 times higher thermal conductivity than the potting compound. Thus, the proportion of heat and thus energy transferring solids is significantly increased throughout the system.
- the at least one ceramic element is designed as a ceramic rod or as a ceramic plate, which defines a minimum distance of the inner wall of the housing member and the one of the two contact plates.
- the ceramic elements also ensure that the heating unit in the housing element is mechanically accurately positioned.
- the remaining film of potting compound between the surface of the ceramic element and the component surface compensates for unevenness in a flexible manner, thereby better admitting the hard inflexible ceramic surface to the metal surfaces of, for example, the housing element.
- the components of the heat exchanger made of metal, in particular made of aluminum.
- a gap is formed between the positioning and the PTC elements of the heating unit, which serves as a second filling channel for filling a cavity between the respective PTC heating elements of the heating unit with potting compound.
- the invention also provides a method for producing a heat exchanger, comprising the following steps: producing a blank for a heat exchanger, which has a multiplicity of alternatingly arranged corrugated rib elements and housing elements, in particular rectangular tubes, for receiving heating units and an upper terminating trough; Inserting a respective heating unit into each of the housing elements, wherein each heating unit comprises two electrically conductive contact plates and PTC heating elements arranged between the two electrically conductive contact plates and at least one position element with an integrated first filling channel for filling at least one intermediate space between an inner wall of the Housing element and the respective contact plates, and filling the first filling channel with a potting compound, wherein the potting compound enters through an opening at a lower end portion of the first filling channel into the intermediate space and fills it from bottom to top.
- the potting compound can flow down through the first filling channel, emerge at the lower region of the first filling channel in the intermediate space, where it is deflected and then fills the gap from bottom to top.
- the space between the PTC heating elements are filled.
- the inventive method is also very flexible, since a separate prefabrication of heat exchanger blank and heating unit is possible.
- Another inventive method for producing a heat exchanger comprises the following steps: producing a blank for a heat exchanger, which has a plurality of alternately juxtaposed corrugated fin elements and housing elements, in particular rectangular tubes, for receiving heating units and an upper end trough; at least partially filling each of the plurality of housing elements with a potting compound; and inserting a respective heating unit into each of the housing elements, wherein each heating unit has two electrically conductive contact plates and between the two electrically conductive contact plates arranged PTC heating elements and at least one position element to which a stop is disposed at a lower end portion.
- the stop guarantees to realize a defined distance of the heating unit and at the same time prevents the heating unit from slipping downwards. Since in the method according to the invention the prefabricated heating unit is introduced with the position elements in the potting compound, the potting compound fills by filling all to be filled gaps and gaps reliably.
- the insertion of the heating unit can be carried out under ambient pressure.
- the stop may be designed intgegral with the positioning element according to a preferred embodiment. Alternatively, however, the stop can also be arranged as a separate insert at the lower end portion of the positioning element.
- the heating unit including the positioning elements may preferably be designed to be streamlined in order to minimize the formation of air bubbles during insertion.
- the upper end trough is provided as a separate component.
- the upper end trough may also be formed integrally on each housing element, if this is produced, for example, as extruded part.
- the insertion can be realized in stages with small residence breaks.
- the potting compound can be given time to displace.
- Fig. 1 shows a perspective view of a prefabricated blank 1 for a heat exchanger according to one embodiment.
- the blank 1 consists essentially of a plurality of housing elements 2, which are formed here as rectangular tubes 3, and in which the heating units, not shown here, are insertable. Between each two rectangular tubes 3, a corrugated fin element 4 is arranged, so that the plurality of housing elements 2 arranged alternately side by side with a plurality of corrugated rib elements 4 form a block 5.
- the block 5 is fixed at its upper end by an upper end trough 6, which has a plurality of openings 9, through which respective upper end portions 8 of the housing elements 2 and rectangular tubes 3 can be passed, and fixed at its lower end by a lower bottom plate 7, which has a plurality of receptacles 10, in which the lower end portions 11 of the housing elements 2 and rectangular tubes 3 can be used.
- side parts not shown here may additionally be provided on the blank 1 in addition. All parts of the blank 1 are made of aluminum and fixed together by means of soldering. It thereby creates an intimate bond and good heat conduction to the air or to another medium to be heated, such as water.
- the parts of the blank 1 can also be fixed to one another by means of gluing or mechanical clamping.
- the upper end trough 6 and the lower bottom plate 7 can be retrofitted after soldering the rectangular tubes 3 and the corrugated fin elements 4, For example, in a case where these two components are made of plastic instead of aluminum.
- Fig. 2 shows an exploded view of the blank 1 of Fig. 1 which, as described above in the embodiment, consists of a plurality of rectangular tubes 3, a plurality of corrugated fin elements 4, an upper end trough 6 and a lower bottom plate 7.
- the rectangular tubes 3 are formed in the embodiment as open tubes, which are sealed down, for example by means of soldering to the bottom plate 7 through them.
- flow pressings can be used, which are closed on one side. In this case could then be dispensed with the lower bottom plate 7.
- Fig. 3 shows a perspective view of a finished and already filled with an electrically insulating and highly thermally conductive potting compound 13 heat exchanger 12 according to one embodiment. It can be seen that the potting compound 13 not only within the rectangular tubes 3, as later in connection with the FIGS. 5A to 5D is still described, and there the electrical high voltage unit galvanically separates to "outside", but at the same time provides the heat transfer, but also exits up into the upper end tray 6 and thus in the upper region for a galvanic isolation of the electrical from the outside touchable part, here the rectangular tubes 3, provides. As can still be seen, only the contact lugs 14, 14 'of the respective heating units protrude out of the potting compound 13.
- Fig. 4A, 4B show respective exploded views of a heating unit 15 according to one embodiment.
- Each heating unit 15 consists of a multiplicity of PTC heating elements 16, here three, and two contact plates 17, 17 ', which define the + and - pol, which are on both sides of the PTC heating elements 16 are arranged.
- the heating unit 15 comprises positioning elements 19, which in Fig. 4A as two positioning bars and in Fig. 4B as a one-piece positioning frame, on which at a lower end portion 28 a stop not shown here is arranged.
- the stop can also be provided as a separate insert. In both cases, it serves to space the heating unit 15 down, for example, from the lower base plate 7.
- the heating unit 15 is the current-carrying and heating unit of the heat exchanger 12. It must be electrically galvanically isolated to the outside and still ensure the best possible heat flow to the outside.
- Each heating unit 15 can be prefabricated.
- the heating unit 15 can be prefabricated with a silicone adhesive.
- Figs. 5A to 5D show respective representations of the process steps in a filling method according to an embodiment.
- a PTC heating elements 16, the contact plates 17, 17 'and the positioning elements 19 comprehensive heating unit 15 is already introduced into the housing element 2 and rectangular tube 3, which is completed by the lower bottom plate 7.
- Each of the positioning elements 19 is provided with a first filling channel 18, in which by means of the nozzles 20, the sealing compound 13 is filled filled from above.
- the potting compound 13 In order not to form any air pockets in the intermediate space 21 to be filled between the contact plates 17, 17 'and an inner wall of the housing element 2 or rectangular tube 3, the potting compound 13 must penetrate from the bottom to the top in the intermediate space 21.
- the positioning elements 19 thus have two functions: On the one hand, they ensure that the potting compound 13 penetrates from the bottom to the top and, on the other hand, they position the heating unit 15 in the rectangular tube 3. As in FIG Fig. 5B can be seen, the potting compound 13 first fills the respective positioning elements 19 from top to bottom, is then deflected at a gap between the lower bottom plate 7 and the heating unit 15 and then fills the gap 21 from bottom to top ( Fig. 5C .
- the intermediate space between the three PTC heating elements 16 can also be filled with potting compound 13.
- the potting compound 13 during processing is liquid and cures to a solid mass with a Shore hardness A to D, depending on the composition of.
- the potting compound 13 ensures a separation of the electrical current flows from the thermal fluxes.
- the base of the potting compound 13 consists of resin or alternatively also of silicone and contains heat-conductive particles of silicon carbide, boron nitride or aluminum oxide.
- the filling process described above takes place in a vacuum. Alternatively, it can also be carried out at atmospheric pressure. The selection of the prevailing pressure takes place in accordance with the gap dimension of the intermediate space 21 to be filled.
- An increase in the heat transfer from the inner wall of the rectangular tube 3 to the potting compound 13 can be achieved by the method described below.
- the inner wall of the rectangular tube 3 is provided with a rough boron nitride surface. This increases the heat transfer surface.
- the boron nitride is in this case baked into the aluminum surface of the rectangular tube 3, so that the thermal interface transition to the metal surface is further optimized.
- This special coating is produced during a CAB brazing process.
- a certain amount of boron nitride particles is added to a potassium aluminum flux, which is preferably between 2% and 20 ° C.
- the potassium aluminum flux melts during the soldering process and forms the matrix for the boron nitride particles
- a mixed phase of boron nitride, aluminum oxide and potassium aluminum fluoride is formed, while the flux crystallizes out with the boride particles on the surface, forming a rough, highly thermally conductive boron nitride -Surface.
- Fig. 6 shows a sectional view of a housed in a housing element 2 and rectangular tube 3 heating unit 15 according to one embodiment.
- each positioning element 19 is provided with a first filling channel 18, in which the potting compound 13 is filled to fill the gap 21 between an inner wall 22 of the rectangular tube 3 and the respective contact plates 17, 17 '.
- only one of the two positioning elements 19 may be equipped with the first filling channel 18.
- a gap 26 is provided, which serves as a second filling channel 27 to a cavity 29 (see Figs. 5A to 5D ) between the individual PTC heating elements 16 of each heating unit 15 to fill potting compound 13.
- the potting compound, which is arranged between the PTC heating elements 16, contributes to even better heat dissipation to the outside.
- the positioning elements 19 are each provided with an undercut 23, which serves that in a demolition of the contact between potting compound 13 and contact plate 17, 17 'no direct air gap between the contact plate 17, 17' and rectangular tube 3 arises.
- Fig. 7 shows a sectional view of a housed in a housing element 2 or rectangular tube 3 heating unit 15 according to a further embodiment, which differs from the in Fig. 6 illustrated embodiment differs in that additional ceramic elements 24 are provided in the intermediate space 21 in order to achieve an improvement in the transfer of heat energy, without increasing the P
- the ceramic elements 24 are formed as fine ceramic rods. Alternatively, they may also be formed as ceramic sheets, which after filling and the introduction of the heating unit 15 additionally between the inner wall 22 of the rectangular tube 3 and the respective contact plates 17, 17 'are introduced.
- the ceramic elements 24 are smaller in diameter than the gap of the gap 21, but define a minimum distance of the heating unit 15 to the inner wall 22 of the rectangular tube 3 over the entire tube length.
- the ceramic elements 24 have a tenfold higher heat conduction than the potting compound 13, so that the proportion of heat-transferring solids is thereby significantly increased.
- the heating unit 15 is thereby mechanically accurately positioned in the rectangular tube 3.
- the remaining film of potting compound 13 between the ceramic surface and the component surface compensates for unevenness in a flexible manner and thereby better adapts the hard inflexible ceramic surface to the metal surfaces.
- FIGS. 8A to 8E show respective representations of the process steps in a filling process according to another embodiment.
- the positioning elements 19, which are fixed to the heating unit 15 by means of clipping, gluing or mechanically fixed have no filling channel.
- the potting compound 13 is first filled in a prefabricated soldered blank 1 or in each of the rectangular tubes 3, so that it partially fills them ( Fig. 8A ).
- the filling level is dependent on the displacement amount of the heating unit 15 to be subsequently introduced.
- the heating unit 15 is introduced with the positioning elements 19 fixed thereto in a respective rectangular tube 3 ( Fig.
- the potting compound 13 fills all the gaps to be filled, especially the intermediate space 21.
- the insertion of the heating unit 15 can be carried out under ambient pressure. A brief, easy evacuation of the filled blank 1 can be carried out before the insertion and possibly after the complete insertion of the heating unit 15. So can still existing Air bubbles escape. The insertion can also be carried out in stages with small residence breaks to give the potting compound 13 time to displace.
- Fig. 9 shows a perspective view of the in Fig. 8D illustrated process step in which the heating unit 15 is already immersed in the potting compound 13, but not yet touches on the lower base plate 7.
- Fig. 10 shows a sectional view of a housed in a housing element 2 and rectangular tube 3 heating unit 15 according to a further embodiment, which differs from the in Fig. 6 illustrated embodiment distinguished by the formation of the positioning elements 19, which are formed here without the first filling channel 18 and without the undercut 23.
- Fig. 11 shows a perspective view of an end portion of a completed heat exchanger 12 and a single housing element 2 and rectangular tube 3. As can be seen here, occur at the upper end trough 6 of the potting compound 13, only the contact lugs 14, 14 'from. Also, by a joint 25 on the narrow longitudinal side of the rectangular tube 3, the potting compound 13 exits.
- FIG. 1 shows a sectional view of a heating unit 15 accommodated in a housing element 2 or rectangular tube 3 according to a further embodiment.
- the potting compound 13 has entered the upper end trough 6 upwards beyond the heating unit 15 and almost completely fills it, so that only the contact lugs 14, 14 'project out of it.
- Fig. 13A shows a sectional view through a housing member 2 with therein heating unit 15, while Fig. 13B a 90 ° rotated about the longitudinal axis L sectional view through the in Fig. 13A shown housing element 2 shows.
- the housing element 2 or rectangular tube 3 is produced as extruded part, wherein both upper end trough 6, which serves as an overflow for emerging from the rectangular tube 3 potting compound 13 and the lower bottom plate 7 are integrally formed therewith.
- both upper end trough 6 may be integrally formed on the rectangular tube 3, in which case a separate lower bottom plate 7 is provided.
- only the lower bottom plate 7 may be integrally formed on the rectangular tube 3, in which case a separate upper end trough 6 is provided.
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Abstract
Description
Die Erfindung betrifft einen Wärmeübertrager gemäß dem Oberbegriff des Anspruchs 1, ein Verfahren zur Herstellung eines Wärmeübertragers gemäß Anspruch 14 und ein Verfahren zur Herstellung eines Wärmeübertragers gemäß Anspruch 15.The invention relates to a heat exchanger according to the preamble of
Verbrauchsoptimierte Kraftfahrzeuge erzeugen immer weniger Abwärme, die für die Aufwärmung des Innenraums des Kraftfahrzeugs zur Verfügung steht. Vor allem in der Startphase und bei geringen Außentemperaturen ist es daher notwendig, beispielsweise mittels eines Brennstoffzuheizers, eines elektrischen Zuheizers, eines Abgas-Wärmeübertragers oder dergleichen zuzuheizen. Bei den verschiedenen zur Verfügung stehenden Zuheizmöglichkeiten hat sich die elektrische Zuheizung als besonders vorteilhaft erwiesen, da sie kostengünstig, spontan spürbar (d. h. die elektrische Leistung wird sofort in spürbare Wärme umgesetzt) und platzsparend einbaubar ist, was eine leichte Integration in ein Klimagerät und die Luftkanäle ermöglicht.Consumption-optimized motor vehicles generate less and less waste heat, which is available for heating the interior of the motor vehicle. Especially in the starting phase and at low outside temperatures, it is therefore necessary to heat for example by means of a Brennstoffzuheizers, an electric heater, an exhaust gas heat exchanger or the like. In the various available Zuheizmöglichkeiten the electrical heater has proved to be particularly advantageous because they cost, spontaneously noticeable (ie the electrical power is immediately converted into noticeable heat) and space-saving can be installed, which allows easy integration into an air conditioner and the air ducts.
Für hybridisierte Fahrzeuge oder rein elektrisch betriebene Fahrzeuge ist der Stellenwert der elektrischen Zuheizung noch größer. Hier werden elektrische Leistungen von > 3 kW benötigt, da ein konventioneller Kühlmittelheizkörper nur noch bedingt oder gar nicht mehr einsetzbar ist. Bei solchen Fahrzeugen ist die Bordnetzspannung > 60 V, teilweise sogar > 300 V. Aufgrund der hohen geforderten Heizleistungen am elektrischen Zuheizer wird dieser mit einer hohen Spannung betrieben, um die Stromstärke möglichst gering zu halten.For hybrid vehicles or purely electrically powered vehicles, the importance of the electric heater is even greater. Here electrical power of> 3 kW is needed, as a conventional coolant radiator is only conditionally or no longer applicable. In such vehicles, the vehicle electrical system voltage is> 60 V, in some cases even> 300 V. Due to the high required heating power at the electric heater this is operated with a high voltage in order to keep the current as low as possible.
Im Stand der Technik werden als elektrische Zuheizer üblicherweise PTC-Heizeinrichtungen verwendet. Die Umwandlung von elektrischer Energie aus dem Bordnetz in Wärme erfolgt in einem PTC-Heizelement, das einen Kaltleiter aus Keramik umfasst, der ein sehr stark temperaturabhängiger Halbleiter-Widerstand ist. Hierbei nimmt mit zunehmender Temperatur der Widerstand des PTC-Elements stark zu. Dadurch stellt sich unabhängig von den Randbedingungen, d. h. angelegte Spannung, Nominalwiderstand, Luftmenge über dem PTC-Element, etc., eine sehr gleichmäßige Oberflächentemperatur an dem PTC-Element ein. Dadurch wird eine Überhitzung verhindert, wie sie z. B. mit einem normalen Heizdraht entstehen würde, da hier unabhängig von den Randbedingungen bzw. unabhängig davon, ob Wärme abgegeben werden kann, immer der gleiche Widerstand vorhanden ist, und dadurch elektrische Heizleistung eingebracht wird. Auch ist die elektrische Absicherung in Form beispielsweise eines Überhitzungsschutzes nicht notwendig, da das PTC-Element sich durch sein Eigenverhalten abregelt, d. h. mit zunehmender Temperatur steigt der elektrische Widerstand proportional an.In the prior art, PTC heaters are commonly used as electric heaters. The conversion of electrical energy from the electrical system into heat takes place in a PTC heating element, which comprises a ceramic thermistor, which is a very temperature-dependent semiconductor resistor. In this case, the resistance of the PTC element increases sharply with increasing temperature. As a result, regardless of the boundary conditions, ie applied voltage, nominal resistance, amount of air over the PTC element, etc., a very uniform surface temperature at the PTC element. This prevents overheating, as z. B. would arise with a normal heating wire, since regardless of the boundary conditions or regardless of whether heat can be delivered, always the same resistance is present, and thereby electrical heating power is introduced. Also, the electrical protection in the form of, for example, an overheating protection is not necessary because the PTC element is de-regulated by its own behavior, ie with increasing temperature, the electrical resistance increases proportionally.
Ein solcher Zuheizer muss jedoch einen sicheren Berührungsschutz aufweisen, so dass eine Gefährdung der Insassen im Betrieb ausgeschlossen wird. Um dies zu gewährleisten und einen absoluten Berührungsschutz gemäß der Schutzklasse I der II zu realisieren, sollten alle elektrisch leitenden und von außen berührbaren Tele des elektrischen Zuheizers potentialfrei sein. Konventionelle aus dem Stand der Technik bekannte Zuheizer, die auf eine Betriebsspannung von 13 V ausgelegt sind, sind jedoch in der Regel so gestaltet, dass kein Berührungsschutz vorliegt, d. h. Teile des Zuheizers sind nicht potentialfrei bzw. liegen auf einen +-Potential. Oft haben die in einem Heiznetz vorhandenen Wellrippen auch ein alternierendes ― oder +-Potential. Wird ein derartiger elektrischer Zuheizer direkt oder indirekt berührt, kann es zu einem Stromschlag kommen.However, such a heater must have a secure contact protection, so that a risk to the occupants during operation is excluded. To ensure this and to realize an absolute protection against contact according to the protection class I of the II, all electrically conductive and externally accessible Tele of the electric heater should be potential-free. Conventional heaters known from the prior art which are designed for an operating voltage of 13 V, however, are generally designed so that there is no contact protection, ie. H. Parts of the auxiliary heater are not potential-free or lie on a + potential. Often, the corrugated fins present in a heating network also have an alternating - or + -potential. If such an electric heater is touched directly or indirectly, an electric shock may occur.
Zusätzlich sollte die Hochspannungseinheit staub- und wasserdicht gekapselt sein, um die Erfordernisse der IP-Schutzklasse 67 (Staub- und Wasserdichtigkeit bis 1 Meter Tiefe) zur Vermeidung von Kurzschlüssen zu erfüllen. Insbesondere ist das Eindringen von Staub und Wasser in die Hochspannungseinheit nachteilig, da sie eine "Strombrücke" bilden können, was dann einen Kurzschluss hervorrufen kann.In addition, the high voltage unit should be dust and waterproof encapsulated to meet the requirements of IP 67 (dust and water resistance up to 1 meter depth) to avoid short circuits. In particular, the penetration of dust and water into the high voltage unit is disadvantageous, since they can form a "current bridge", which can then cause a short circuit.
Als mögliche Lösung der obigen Probleme in Bezug auf die erforderlichen hohen elektrischen Leistungen, die zur Aufheizung des Innenraums des Kraftfahrzeugs notwendig sind, ist es jedoch nicht sinnvoll, die elektrische Spannung für den Zuheizer zu reduzieren, da hierbei die Stromstärken und damit die Kabeldicken und Spannungsabfälle zu groß werden.However, as a possible solution to the above problems with respect to the required high electrical power necessary to heat the interior of the motor vehicle, it is not useful to reduce the electrical voltage for the heater, since in this case the currents and thus the cable thickness and voltage drops get too big.
Eine andere aus dem Stand der Technik bekannte Lösung setzt bei luftseitigen Hochvolt-PTC-Zuheizern Folien ein, die die Heizeinheiten umschließen um so die äußeren elektrisch leitenden Teile, wie beispielsweise die Wellrippen, zu schützen. Diese sind dann potentialfrei. Ein Problem besteht bei dieser Lösung jedoch darin, dass diese Folien zur Trennung des elektrischen Potentials Wärme sehr schlecht leiten. Dadurch sinkt die Leistungsfähigkeit des elektrischen Zuheizers. Bei Verwendung eines elektrischen Zuheizers mit PTC-Heizelementen kommt es zur starken Abregelung, was bedeutet, dass mehr PTC-Heizelemente eingesetzt werden müssen, was wiederum höhere Kosten nach sich zieht. Ebenso ist die Folie prozesssicher schwer einzusetzen, da eine Rissbildung oder Vorschädigung nicht sicher auszuschließen ist. Darüber hinaus schützt die Folie auch nicht zu 100 % vor dem Eindringen von Schmutz und Feuchtigkeit in die Hochvolt-Heizeinheit. Würde man zur Lösung der obigen Probleme sowohl eine Wärmeleitfolie als auch eine "Kapselfolie" verwenden, dann würde dies wiederum eine Erhöhung in der Anzahl an Teilen und einen erhöhten Kostenfaktor nach sich ziehen.Another solution known from the prior art employs foils in air-side high-voltage PTC auxiliary heaters, which enclose the heating units so as to cover the outer electrically conductive parts, such as the corrugated fins, for example. to protect. These are then potential-free. A problem with this solution, however, is that these films conduct heat very poorly to separate the electrical potential. This reduces the efficiency of the electric heater. When using an electric heater with PTC heating elements, there is a great deal of regulation, which means more PTC heating elements have to be used, which in turn means higher costs. Likewise, the film is process reliable difficult to use because cracking or previous damage can not be ruled out safely. In addition, the film does not protect 100% from the ingress of dirt and moisture into the high-voltage heating unit. If one were to use both a heat-conducting film and a "capsule film" to solve the above problems, this would in turn entail an increase in the number of parts and an increased cost factor.
Auch ist bei der Verwendung von Folien ein klassisch gelöteter Wärmeübertrager mit Rechteckrohren nicht einsetzbar, da die Folie über die Länge des Rechteckrohrs nicht prozesssicher eingeschoben werden kann. Daher müsste ein geklebter, mechanisch gespannter Aufbau verwendet werden, bei dem es jedoch schwer ist, die oben genannte IP-Schutzklasse für die Heizeinheit zu erfüllen.Also, when using foils a conventionally brazed heat exchanger with rectangular tubes can not be used because the film over the length of the rectangular tube can not be inserted reliably. Therefore, a glued, mechanically stressed structure would have to be used, but it is difficult to meet the above-mentioned IP rating for the heating unit.
Die Aufgabe der vorliegenden Erfindung ist es daher, einen Wärmeübertrager, insbesondere einen elektrischen Zuheizer für ein Kraftfahrzeug und ein Verfahren zu dessen Herstellung zu schaffen, wobei der Wärmeübertrager sowohl mit einem Berührungsschutz versehen ist, so dass keines der von außen erreichbaren elektrisch leitenden Bauteile ein elektrisches Potential besitzt, und wobei der Berührungsschutz prozesssicher einsetzbar ist und die Hochvolt-Heizeinheit außerdem vor Schmutz- und Feuchtigkeitseintrag sicher schützt.The object of the present invention is therefore to provide a heat exchanger, in particular an electric heater for a motor vehicle and a method for its production, wherein the heat exchanger is provided with both a contact protection, so that none of the externally accessible electrically conductive components an electric Has potential, and wherein the contact protection process is reliable and the high-voltage heating unit also protects against dirt and moisture entry safely.
Diese Aufgabe wird erfindungsgemäß durch einen Wärmeübertrager mit den Merkmalen gemäß Anspruch 1 sowie durch ein Verfahren mit den Merkmalen gemäß Anspruch 14 und ein Verfahren mit den Merkmalen gemäß Anspruch 15 gelöst.This object is achieved by a heat exchanger with the features of
Erfindungsgemäß wird ein Wärmeübertrager, insbesondere ein elektrischer Zuheizer für ein Kraftfahrzeug, vorgesehen, welcher eine Vielzahl von abwechselnd nebeneinander angeordneten Wellrippenelementen und Heizeinheiten und eine obere Abschlusswanne aufweist, welche eine Vielzahl von Öffnungen zum Aufnehmen und Fixieren der Heizeinheiten umfasst, wobei jede Heizeinheit zwei elektrisch leitende Kontaktbleche und zwischen den zwei elektrisch leitenden Kontaktblechen angeordnete PTC-Heizelemente aufweist, welche in einem Gehäuseelement aufgenommen sind, wobei zumindest ein Zwischenraum zwischen einer Innenwandung des Gehäuseelements und den Kontaktblechen mit einer elektrisch isolierenden Vergussmasse ausgefüllt ist, wobei in dem Gehäuseelement zumindest ein Positionierelement zum Positionieren der Heizeinheit in dem Gehäuseelement angeordnet ist, welches einen integrierten ersten Befüllkanal zum Befüllen des Zwischenraums mit Vergussmasse aufweist. Das Positionsierelement mit integriertem ersten Befüllkanal hat somit zwei Funktionen: Einerseits stellt es sicher, dass die Vergussmasse prozesssicher in den Zwischenraum gefüllt wird, und andererseits wird die Heizeinheit im Gehäuseelement sicher positioniert bzw. fixiert. Ohne integrierten Befüllkanal müsste eine Düse, aus der die Vergussmasse strömt, bis auf den Grund des Gehäuseelements angesetzt werden, so dass die Vergussmasse von unten nach oben in den Zwischenraum dringt, und dann während der Befüllung mit dem Pegelstand nach oben wandern, was sehr aufwändig wäre. Durch den ersten Befüllkanal kann die Vergussmasse jedoch nach unten strömen und im unteren Bereich des ersten Befüllkanals in den Zwischenraum eintreten, um diesen so von unten nach oben blasenfrei zu befüllen. Je nach Auslegung kann dabei auch der Raum zwischen den einzelnen PTC-Heizelementen einer jeden Heizeinheit ausgefüllt werden. Durch diese Konfiguration ist der Zwischenraum prozesssicher füllbar, so dass die in den Zwischenraum gefüllte Vergussmasse dauerhaft, das heißt über die Lebensdauer des Wärmeübertragers, einen sicheren Berührungsschutz bietet. Auch bietet das Ausfüllen des Zwischenraums mit Vergussmasse der Hochvolt-Heizeinheit Schutz vor eindringendem Schmutz und Feuchtigkeit, da die Hochvolt-Heizeinheit in sich "gekapselt" ist. und alle elektrisch leitenden Oberflächen erreichbarer außenliegender Bauteile sind potentialfrei.According to the invention, a heat exchanger, in particular an electric heater for a motor vehicle, is provided, which has a plurality of alternately juxtaposed corrugated fin elements and heating units and an upper end trough, which comprises a plurality of openings for receiving and fixing the heating units, each heating unit having two electrically conductive Contact plates and arranged between the two electrically conductive contact plates PTC heating elements, which are accommodated in a housing element, wherein at least one space between an inner wall of the housing member and the contact plates is filled with an electrically insulating potting compound, wherein in the housing element at least one positioning element for positioning the heating unit is arranged in the housing element, which has an integrated first filling channel for filling the intermediate space with potting compound. The positioning element with integrated first filling channel thus has two functions: on the one hand it ensures that the casting compound is reliably filled into the intermediate space, and on the other hand, the heating unit is securely positioned or fixed in the housing element. Without an integrated filling channel, a nozzle from which the potting compound flows would have to be applied to the bottom of the housing element, so that the potting compound penetrates from bottom to top into the intermediate space, and then move upwards during filling with the water level, which is very expensive would. However, the potting compound can flow downwards through the first filling channel and enter the intermediate space in the lower region of the first filling channel in order to fill it from bottom to top without bubbles. Depending on the design, the space between the individual PTC heating elements can also be used each heating unit to be completed. By this configuration, the gap is process reliable filled, so that the filling compound filled in the gap permanently, that is over the life of the heat exchanger, provides a secure contact protection. Also, filling the interstice with potting compound of the high-voltage heater unit provides protection against ingress of dirt and moisture since the high-voltage heater unit is "encapsulated" in itself. and all electrically conductive surfaces of accessible external components are potential-free.
Gemäß einer bevorzugten Ausführungsform ist das Gehäuseelement ein Rechteckrohr, ein Ovalrohr oder ein Fließpressteil. Wenn das Rechteckrohr beispielsweise als Fließpressteil hergestellt ist, können vorteilhafterweise die obere Abschlusswanne und die untere Bodenplatte integral daran ausgebildet sein. Das Rechteckrohr bzw. das Ovalrohr oder Fließpressteil dient zur nachträglichen Aufnahme einer vorgefertigten und mit zumindest einem Positionierelement versehenen Heizeinheit, die in das Rechteckrohr, das Ovalrohr oder das Fließpressteil eingeschoben wird.According to a preferred embodiment, the housing element is a rectangular tube, an oval tube or a flow press. For example, if the rectangular tube is made as a extruded part, the upper end pan and the lower bottom plate may be integrally formed therewith. The rectangular tube or the oval tube or extruded part is used for retrofitting a prefabricated and provided with at least one positioning heating unit, which is inserted into the rectangular tube, the oval tube or the extruded part.
Vorzugsweise beträgt die Rohrbreite eines Rechteckrohrs zwischen 2,5 bis 10 mm. Darüber hinaus ist die Dicke der Kontaktbleche vorzugsweise im Bereich zwischen 0,2 bis 1,5 mm und die Dicke der einzelnen PTC-Heizelemente zwischen 0,8 bis 3 mm.Preferably, the tube width of a rectangular tube is between 2.5 to 10 mm. Moreover, the thickness of the contact sheets is preferably in the range between 0.2 to 1.5 mm and the thickness of the individual PTC heating elements between 0.8 to 3 mm.
Gemäß einer weiteren bevorzugten Ausführungsform ist das Positionierelement als Positionsleiste ausgebildet, welche an einem unteren Endabschnitt mit zumindest einer Öffnung versehen ist, durch welche die Vergussmasse beim Befüllen der Heizeinheit in den Zwischenraum eintritt.According to a further preferred embodiment, the positioning element is designed as a position bar, which is provided at a lower end portion with at least one opening through which the potting compound enters during filling of the heating unit in the intermediate space.
Gemäß noch einer weiteren bevorzugten Ausführungsform ist die Positionsleiste mit einem Hinterschnitt ausgebildet. Der Hinterschnitt hat die Aufgabe, bei einem möglicherweise auftretenden Abriss des Kontaktes zwischen der Vergussmasse und dem Kontaktblech keinen direkten Luftspalt zwischen Kontaktblech und Gehäuseelement entstehen zu lassen.According to yet another preferred embodiment, the position bar is formed with an undercut. The undercut has the task in a possibly occurring demolition of the contact between the Potting compound and the contact plate to create no direct air gap between the contact plate and the housing element.
Vorzugsweise ist weiterhin eine untere Bodenplatte vorgesehen, welche beabstandet zu einem unteren Endabschnitt einer jeden Heizeinheit der Vielzahl von Heizeinheiten als separates Bauteil angeordnet ist. Alternativ kann die untere Bodenplatte auch integral an jedem Gehäuseelement bzw. an jedem Rechteckrohr ausgebildet sein, welches in diesem Fall beispielsweise ein Fließpressteil ist. Gemäß einer weiteren Ausführungsform können darüber hinaus auch eines, vorzugsweise zwei Seitenteile vorgesehen werden.Preferably, a lower bottom plate is further provided, which is arranged spaced from a lower end portion of each heating unit of the plurality of heating units as a separate component. Alternatively, the lower bottom plate may also be formed integrally on each housing element or on each rectangular tube, which in this case is, for example, a flow-molded part. According to another embodiment, moreover, one, preferably two, side parts may be provided.
Es ist auch bevorzugt, wenn der Zwischenraum ein Spaltmaß aufweist, welches in einem Bereich von 0,3 bis 2,0 mm liegt. Dieser Bereich ist besonders bevorzugt, da, je dünner das Spaltmaß ist, umso höher ist die Wärmeleitung. Bei einem zu schmalen Spaltmaß besteht jedoch die Gefahr, dass Lufteinschlüsse in der Vergussmasse auftreten können, wodurch die Gefahr eines Spannungsüberschlags besteht. Breitere Spalte können dagegen zwar besser gefüllt werden, jedoch ist hier die Wärmeauskopplung schlechter.It is also preferable that the gap has a gap which is in a range of 0.3 to 2.0 mm. This range is particularly preferred because the thinner the gap, the higher the heat conduction. However, if the gap is too narrow, there is the risk that air pockets may occur in the potting compound, which results in the risk of a flashover. On the other hand, wider gaps can be filled better, but here the heat extraction is worse.
Gemäß einer weiteren bevorzugten Ausführungsform ist die Vergussmasse elektrisch isolierend und weist eine gute Wärmeleitfähigkeit auf. Die Wärme der aus den PTC-Heizelementen muss über die Kontaktbleche und die Vergussmasse auf das Gehäuseelement und dann auf die luftseitigen Wellrippen übertragen werden. Der größte Temperaturgang wird dabei in der Vergussmasse liegen, die daher eine gute Wärmeleitfähigkeit aufweisen sollte.According to a further preferred embodiment, the potting compound is electrically insulating and has a good thermal conductivity. The heat from the PTC heating elements must be transferred via the contact plates and the potting compound to the housing element and then to the air-side corrugated fins. The largest temperature response will be in the potting compound, which should therefore have a good thermal conductivity.
Gemäß noch einer weiteren bevorzugten Ausführungsform ist die Vergussmasse aushärtbar, insbesondere durch Wärme oder durch den Zusatz chemischer Härter, und wärmestabil, insbesondere bei Dauertemperaturen um 200°C. Die Vergussmasse, die als Wärmeleitmedium dient, ist insbesondere bei der Verarbeitung zähflüssig und im Betrieb fest aushärtend. Dabei kann die Härte im Betrieb bis zu einer Shore-Härte von A bis D gehen.According to yet another preferred embodiment, the potting compound is curable, in particular by heat or by the addition of chemical curing agents, and heat stable, especially at continuous temperatures around 200 ° C. The potting compound, which serves as a heat transfer medium is particular viscous during processing and solid hardening during operation. The hardness during operation can go up to a Shore hardness of A to D.
Besonders bevorzugt ist es, wenn die Vergussmasse wärmeleitfähige Füllstoffe, insbesondere Aluminiumoxid, Bornitrid und/oder Siliziumkarbid enthält.It is particularly preferred if the potting compound contains thermally conductive fillers, in particular aluminum oxide, boron nitride and / or silicon carbide.
Vorzugsweise besteht die Basis der Vergussmasse aus Harz oder Silikon. Die Vergussmasse, die als Wärmeübertragungsmedium verwendet wird, trennt vorteilhafterweise elektrische und thermische Flüsse.Preferably, the base of the potting compound of resin or silicone. The potting compound, which is used as a heat transfer medium, advantageously separates electrical and thermal flows.
Es ist darüber hinaus von Vorteil, wenn auch die obere Abschlusswanne zumindest teilweise mit Vergussmasse gefüllt ist. Beim Befüllen des Zwischenraums tritt die Vergussmasse, wenn sie den Zwischenraum vollständig ausfüllt, dann auch oben in die obere Abschlusswanne aus, um dort die Hochspannungseinheit galvanisch nach "außen" zu trennen. Darüber hinaus wird hierdurch für einen verbesserten Wärmetransport nach außen gesorgt. Die Funktion der oberen Abschlusswanne als "Überlaufbecken" beim Befüllen mit Vergussmasse ist zudem auch vorteilhaft, da die Menge der Vergussmasse nicht genau dosierbar ist. Darüber hinaus weist die obere Abschlusswanne auch die Funktion des Aufnehmens der Gehäuseelemente auf und sorgt für einen Gesamtaufbau beim Löten des Rohlings.It is also advantageous if the upper end trough is at least partially filled with potting compound. When filling the gap, the potting compound, if it completely fills the gap, then also enters the top of the upper tundish, there to isolate the high voltage unit galvanic to "outside". In addition, this provides for improved heat transfer to the outside. The function of the upper end tray as "overflow basin" when filling with potting compound is also advantageous because the amount of potting compound is not precisely metered. In addition, the upper end pan also has the function of receiving the housing elements and provides an overall structure during the soldering of the blank.
Gemäß noch einer weiteren bevorzugten Ausführungsform ist zwischen zumindest ein Keramikelement in dem Zwischenraum zwischen der Innenwandung des Gehäuseelements und einem der beiden Kontaktbleche angeordnet, welches einen Durchmesser aufweist, der kleiner ist als das Spaltmass des Zwischenraums. Durch diese Ausführungsform wird eine verbesserte Energieübertragung erzielt. Die Keramikelemente haben eine 10fach höhere Wärmeleitung als die Vergussmasse. So wird im gesamten System der Anteil von Wärme- und damit Energieübertragender Festkörper deutlich erhöht.According to yet another preferred embodiment is arranged between at least one ceramic element in the intermediate space between the inner wall of the housing member and one of the two contact sheets, which has a diameter which is smaller than the gap of the gap. This embodiment achieves improved energy transfer. The ceramic elements have a 10 times higher thermal conductivity than the potting compound. Thus, the proportion of heat and thus energy transferring solids is significantly increased throughout the system.
Gemäß noch einer weiteren bevorzugten Ausführungsform ist das zumindest eine Keramikelement als Keramikstab oder als Keramikplättchen ausgebildet, welches einen Mindestabstand der Innenwandung des Gehäuseelements und dem einen der beiden Kontaktbleche definiert. Die Keramikelemente sorgen außerdem dafür, dass die Heizeinheit im Gehäuseelement mechanisch genauer positioniert wird. Der verbleibende Film an Vergussmasse zwischen der Oberfläche des Keramikelements und der Bauteiloberfläche gleicht Unebenheiten flexibel aus, und pass dadurch die harte unflexible Keramikoberfläche den Metalloberflächen beispielsweise des Gehäuseelements besser an.According to yet another preferred embodiment, the at least one ceramic element is designed as a ceramic rod or as a ceramic plate, which defines a minimum distance of the inner wall of the housing member and the one of the two contact plates. The ceramic elements also ensure that the heating unit in the housing element is mechanically accurately positioned. The remaining film of potting compound between the surface of the ceramic element and the component surface compensates for unevenness in a flexible manner, thereby better admitting the hard inflexible ceramic surface to the metal surfaces of, for example, the housing element.
Vorzugsweise sind die Bauelemente des Wärmeübertragers aus Metall, insbesondere aus Aluminium hergestellt.Preferably, the components of the heat exchanger made of metal, in particular made of aluminum.
Gemäß noch einer bevorzugten Ausführungsform ist zwischen dem Positionierelement und den PTC-Elementen der Heizeinheit ein Spalt ausgebildet, der als zweiter Befüllkanal zum Befüllen eines Hohlraums zwischen den jeweiligen PTC-Heizelementen der Heizeinheit mit Vergussmasse dient.According to yet a preferred embodiment, a gap is formed between the positioning and the PTC elements of the heating unit, which serves as a second filling channel for filling a cavity between the respective PTC heating elements of the heating unit with potting compound.
Erfindungsgemäß wird auch ein Verfahren zum Herstellen eines Wärmeübertragers bereitgestellt, welches die folgenden Schritte umfasst: Herstellen eines Rohlings für einen Wärmeübertrager, welcher eine Vielzahl von abwechselnd nebeneinander angeordneten Wellrippenelementen und Gehäuseelementen, insbesondere Rechteckrohren, zur Aufnahme von Heizeinheiten und eine obere Abschlusswanne aufweist; Einbringen einer jeweiligen Heizeinheit in jedes der Gehäuseelemente, wobei jede Heizeinheit zwei elektrisch leitende Kontaktbleche und zwischen den zwei elektrisch leitenden Kontaktblechen angeordnete PTC-Heizelemente sowie zumindest ein Positionselement mit einem integrierten ersten Befüllkanal zum Befüllen zumindest eines Zwischenraums zwischen einer Innenwandung des Gehäuseelements und den jeweiligen Kontaktblechen aufweist, und Befüllen des ersten Befüllkanals mit einer Vergussmasse, wobei die Vergussmasse durch eine Öffnung an einem unteren Endabschnitt des ersten Befüllkanals in den Zwischenraum eintritt und diesen von unten nach oben füllt. Hierdurch wird eine prozesssichere Befüllung des Zwischenraums gewährleistet. Die Vergussmasse kann durch den ersten Befüllkanal nach unten strömen, am unteren Bereich des ersten Befüllkanals in den Zwischenraum austreten, wo er umgelenkt wird und dann den Zwischenraum von unten nach oben füllt Hierbei kann, wie bereits erwähnt, je nach Auslegung auch der Raum zwischen den PTC-Heizelementen gefüllt werden. Das erfindungsgemäße Verfahren ist darüber hinaus sehr flexibel, da eine separate Vorfertigung von Wärmeübertrager-Rohling und Heizeinheit möglich ist.The invention also provides a method for producing a heat exchanger, comprising the following steps: producing a blank for a heat exchanger, which has a multiplicity of alternatingly arranged corrugated rib elements and housing elements, in particular rectangular tubes, for receiving heating units and an upper terminating trough; Inserting a respective heating unit into each of the housing elements, wherein each heating unit comprises two electrically conductive contact plates and PTC heating elements arranged between the two electrically conductive contact plates and at least one position element with an integrated first filling channel for filling at least one intermediate space between an inner wall of the Housing element and the respective contact plates, and filling the first filling channel with a potting compound, wherein the potting compound enters through an opening at a lower end portion of the first filling channel into the intermediate space and fills it from bottom to top. As a result, a process-reliable filling of the gap is guaranteed. The potting compound can flow down through the first filling channel, emerge at the lower region of the first filling channel in the intermediate space, where it is deflected and then fills the gap from bottom to top. As already mentioned, depending on the design, the space between the PTC heating elements are filled. The inventive method is also very flexible, since a separate prefabrication of heat exchanger blank and heating unit is possible.
Ein weiteres erfindungsgemäßes Verfahren zum Herstellen eines Wärmeübertragers umfasst die folgenden Schritte: Herstellen eines Rohlings für einen Wärmeübertrager, welcher eine Vielzahl von abwechselnd nebeneinander angeordneten Wellrippenelementen und Gehäuseelementen, insbesondere Rechteckrohren, zur Aufnahme von Heizeinheiten und eine obere Abschlusswanne aufweist; zumindest teilweises Befüllen eines jeden der Vielzahl von Gehäuseelementen mit einer Vergussmasse; und Einschieben einer jeweiligen Heizeinheit in jedes der Gehäuseelemente, wobei jede Heizeinheit zwei elektrisch leitende Kontaktbleche und zwischen den zwei elektrisch leitenden Kontaktblechen angeordnete PTC-Heizelemente sowie zumindest ein Positionselement aufweist, an welchem an einem unteren Endabschnitt ein Anschlag angeordnet ist. Der Anschlag gewährleistet einen definierten Abstand der Heizeinheit zu realisieren und verhindert gleichzeitig ein Durchrutschen der Heizeinheit nach unten. Da bei dem erfindungsgemäßen Verfahren die vorgefertigte Heizeinheit mit den Positionselementen in die Vergussmasse eingeführt wird, füllt die Vergussmasse durch das Verdrägen alle zu füllenden Spalte und Zwischenräume zuverlässig aus.Another inventive method for producing a heat exchanger comprises the following steps: producing a blank for a heat exchanger, which has a plurality of alternately juxtaposed corrugated fin elements and housing elements, in particular rectangular tubes, for receiving heating units and an upper end trough; at least partially filling each of the plurality of housing elements with a potting compound; and inserting a respective heating unit into each of the housing elements, wherein each heating unit has two electrically conductive contact plates and between the two electrically conductive contact plates arranged PTC heating elements and at least one position element to which a stop is disposed at a lower end portion. The stop guarantees to realize a defined distance of the heating unit and at the same time prevents the heating unit from slipping downwards. Since in the method according to the invention the prefabricated heating unit is introduced with the position elements in the potting compound, the potting compound fills by filling all to be filled gaps and gaps reliably.
Vorzugsweise kann das Einschieben der Heizeinheit unter Umgebungsdruck durchgeführt werden.Preferably, the insertion of the heating unit can be carried out under ambient pressure.
Der Anschlag kann gemäß einer bevorzugten Ausführungsform intgegral mit dem Positionierelement ausgebildet sein. Alternativ kann der Anschlag jedoch auch als separates Einlegeteil an dem unteren Endabschnitt des Positionierelements angeordnet werden.The stop may be designed intgegral with the positioning element according to a preferred embodiment. Alternatively, however, the stop can also be arranged as a separate insert at the lower end portion of the positioning element.
Bei beiden erfindungsgemäßen Verfahren kann ein kurzes leichtes Evakuieren des befüllten Rohlings für einen Wärmeübertrager vor dem Einschieben und gegebenenfalls auch nach dem vollständigen Einschieben der Heizeinheit erfolgen. So können noch vorhandene Lufteinschlüsse ausdringen. Die Heizeinheit einschließlich der Positionierelemente kann vorzugsweise strömungsgünstig ausgelegt sein, um das Entstehen von Luftblasen beim Einschieben zu minimieren.In both methods according to the invention a short easy evacuation of the filled blank for a heat exchanger before insertion and possibly also after the complete insertion of the heating unit. This allows existing air pockets to escape. The heating unit including the positioning elements may preferably be designed to be streamlined in order to minimize the formation of air bubbles during insertion.
Gemäß einer bevorzugten Ausführungsform ist die obere Abschlusswanne als separates Bauteil vorgesehen. Gemäß einer alternativen Ausführungsform kann die obere Abschlusswanne jedoch auch integral an jedem Gehäuseelement ausgebildet sein, wenn dieses beispielsweise als Fließpressteil hergestellt wird.According to a preferred embodiment, the upper end trough is provided as a separate component. However, according to an alternative embodiment, the upper end trough may also be formed integrally on each housing element, if this is produced, for example, as extruded part.
Vorzugsweise kann bei beiden erfindungsgemäßen Verfahren das Einschieben stufenweise mit kleinen Verweilpausen realisiert werden. So kann der Vergussmasse Zeit zum Verdrängen gegeben werden.Preferably, in both methods of the invention, the insertion can be realized in stages with small residence breaks. Thus, the potting compound can be given time to displace.
Im Nachfolgenden wird ein Ausführungsformen der Erfindung unter Bezugnahme auf die beigefügten Zeichnungen näher beschrieben. Es zeigt:
-
Fig. 1 eine perspektivische Ansicht eines Rohlings für einen Wärmeübertrager gemäß einer Ausführungsform, -
Fig. 2 Explosionsdarstellung des Rohlings vonFig. 1 , -
Fig. 3 eine perspektivische Ansicht eines fertiggestellten Wärmeübertragers gemäß einer Ausführungsform, -
Fig. 4A, 4B jeweilige Explosionsdarstellungen einer Heizeinheit gemäß einer Ausführungsform, -
Fig. 5A bis 5D jeweilige Darstellungen der Prozessschritte bei einem Befüllungsverfahren gemäß einer Ausführungsform, -
Fig. 6 eine Schnittansicht einer in einem Gehäuseelement aufgenommenen Heizeinheit gemäß einer Ausführungsform, -
Fig. 7 eine Schnittansicht einer in einem Gehäuseelement aufgenommenen Heizeinheit gemäß einer weiteren Ausführungsform, -
Fig. 8A bis 8E jeweilige Darstellungen der Prozessschritte bei einem Befüllungsverfahren gemäß einer weiteren Ausführungsform, -
Fig. 9 eine perspektivische Darstellung des inFig. 8D dargestellten Prozessschrittes, -
Fig. 10 eine Schnittansicht einer in einem Gehäuseeelement aufgenommenen Heizeinheit gemäß einer weiteren Ausführungsform, -
Fig. 11 eine perspektivische Ansicht eines Abschnitts eines fertiggestellten Wärmeübertragers, -
Fig. 12 eine Schnittansicht eines in einem Gehäuseelement aufgenommenen Heizeinheit gemäß einer weiteren Ausführungsform; und -
Fig. 13A, 13B jeweils eine Schnittansicht einer in einem Gehäuseelement aufgenommenen Heizeinheit gemäß noch einer weiteren Ausführungsform.
-
Fig. 1 3 a perspective view of a blank for a heat exchanger according to an embodiment, -
Fig. 2 Exploded view of the blank ofFig. 1 . -
Fig. 3 a perspective view of a completed heat exchanger according to an embodiment, -
Fig. 4A, 4B respective exploded views of a heating unit according to an embodiment, -
Figs. 5A to 5D respective representations of the process steps in a filling method according to an embodiment, -
Fig. 6 3 a sectional view of a heating unit accommodated in a housing element according to an embodiment, -
Fig. 7 3 a sectional view of a heating unit accommodated in a housing element according to a further embodiment, -
FIGS. 8A to 8E respective representations of the process steps in a filling method according to a further embodiment, -
Fig. 9 a perspective view of the inFig. 8D represented process step, -
Fig. 10 1 is a sectional view of a heating unit accommodated in a housing element according to a further embodiment, -
Fig. 11 a perspective view of a portion of a completed heat exchanger, -
Fig. 12 a sectional view of a housed in a housing member heating unit according to another embodiment; and -
FIGS. 13A, 13B in each case a sectional view of a heating unit accommodated in a housing element according to yet another embodiment.
Darüber hinaus ist in der Figur erkennbar, dass die Positionierelemente 19 jeweils mit einem Hinterschnitt 23 versehen sind, der dazu dient, dass bei einem Abriss des Kontaktes zwischen Vergussmasse 13 und Kontaktblech 17, 17' kein direkter Luftspalt zwischen Kontaktblech 17, 17' und Rechteckrohr 3 entsteht.In addition, it can be seen in the figure that the
Insgesamt betrachtet wird durch den erfindungsgemäßen Wärmeübertrager 1 und die entsprechenden Verfahren auf prozesssichere Art und Weise ein effektiver Berührungsschutz erzielt.On the whole, effective contact protection is achieved by the
Claims (15)
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EP10290330A EP2397788A1 (en) | 2010-06-17 | 2010-06-17 | Heat exchanger and method for manufacturing a heat exchanger |
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