EP2410277A1 - Heat exchanger, in particular charge air cooler for motor vehicles - Google Patents

Abstract

A commercial vehicle has an air intake to an aggregate requiring force-fed cool air. The incoming air is cooled by a two-part (2, 3) heat exchanger within a surrounding housing (8). The heat-exchanger sections (2, 3) are separated by a gap from the surrounding housing.

Description

The invention relates to a heat exchanger, in particular intercooler for motor vehicles, preferably for commercial vehicles, with a first header and a second header for a first medium, wherein the two header boxes each having a first media connection for the first medium and communicating with each other via at least one heat exchanger element are and with a, the heat exchanger element receiving, inside a second medium leading housing having second media ports for the second medium.

Such heat exchangers are known. They serve in motor vehicles for the provision of cooled charge air. The charge air is cooled by means of cooling air, the cooling air used being the wind of the vehicle or ambient air conveyed by a fan. The two header boxes of the known heat exchanger are connected to each other for example via charge air pipes, wherein -zur Oberflächenvergrößerung- are arranged between the charge air tubes cooling fins. These cooling fins are flowed through by the cooling air, wherein the charge air ducts receiving housing is provided The housing is formed by housing walls, which bridge the gap between the two manifolds. The cooling air occurs transversely to the longitudinal extent of the charge air pipes in the Housing with a lateral distance to a collection box, where it is deflected by 90 °, flows through the housing in the direction of the charge air pipes and leaves the housing at a distance from the other collection box in a direction that is perpendicular to the longitudinal extent of the charge air ducts. The mentioned air deflection of the cooling air leads to a relatively large pressure loss, Further, the cooling air does not come in contact with the entire length of the charge air pipes, that is, the adjacent to the respective collection box sections of the charge air pipes are not or not sufficiently cooled by the cooling air. Overall, therefore, there is an unsatisfactory efficiency.

The invention is based on the object to provide a heat exchanger of the type mentioned above, which provides a very good heat exchange function, in particular cooling performance, without increasing the size and with only a small cooling air requirement.

This object is achieved in that the housing is designed such that in its interior at least one collecting box, preferably both headers, is at least partially taken with at least partially present distance to the housing inner wall with / are. This construction according to the invention makes it possible to place the second holedienanschlüsse such that the full or nearly full length of the heat exchanger element, in particular the charge air Rolire, are acted upon by the second medium and therefore a correspondingly high efficiency is achieved. The second media connections can, for example, be arranged in the region of the collecting boxes such that the second medium first flows along the outside of a tell of the associated collecting tank or along the entire collecting tank, then hits the heat exchanger element and carries out the heat exchange there over a correspondingly large distance. If the medium then arrives in the area of the other collecting tank, then at least part of it flows along the outside and vents the arrangement via the second media connection. By the at least partially present distance of the housing inner wall to at least one, preferably two collecting tank, it is ensured that the second medium via the second media connection can flow into the housing and can get to the heat exchange element. The same applies to the outflow of the second medium from the housing, that is, the second medium can flow in such a case, the heat exchanger element to its end and is only then discharged.

After rather development of the invention it is provided that the housing accommodates the headers understandably. This arrangement on the one hand offers the mentioned largest possible contact distance of the second medium with the heat exchanger element and also opens up the possibility of arranging the second media connections for the supply and the discharge of the second medium so that the lowest possible pressure loss occurs, that is, the second medium is possible In particular, it can be provided that the two media connections are assigned to the two header boxes in such a way that the first header box between the second medium connection and the heat exchanger element and the second header box lies between the other second media connection and the heat exchange element. In such a case, the inflowing second medium first strikes the collecting box, flows past it or flows around it, and then reaches the heat exchanger element, from there to the other collecting box, flows there or flows around it and then reaches the second medium connection, the second medium dissipates. The flow directions are selected such that the second medium in the region of the second media connections the same or about the same direction as in the heat exchanger element, that is, they are not as in the prior art transversely to the flow in the heat exchanger element and removed, but in the same direction. Accordingly, only a slight pressure loss occurs, in particular if the flow profile of the respective header tank is designed in such a way that the flow along or around the respective header tank takes place, that is, there is a substantially vortex-free flow of the second medium.

According to a development of the invention, it is provided that the flow direction of the first medium in the collecting box transversely, in particular at right angles, to the flow direction of the first medium in the heat exchanger element. The first medium therefore flows into the first collection box and leaves it transversely to the flow direction in the collection box, that is deflected in the collection box, in particular deflected at right angles, flows through the heat exchanger element and impinges on the second collection box. In this, in turn, a deflection takes place in the direction of the longitudinal extent of the collecting tank, in particular a rectangular deflection. The first medium then exits from the second collection box. The deflection or deflections of the first medium are less important, since it is preferably the charge air of the heat exchanger forming charge air cooler, which is pending at high pressure and therefore deflection-induced pressure losses can be accepted. This does not apply according to the invention for the second medium, for example for cooling air of the intercooler, since this cooling air has a lower pressure, for example when it comes to airstream or to ambient air conveyed by a fan.

It is advantageous if the second media connections point in the direction of or approximately in the direction of the flow direction of the first medium in the heat exchanger element. This has already been described above, that is, the second medium flows around the two headers when flowing or outflow of the heat exchanger element.

It can be provided that the first media connections point transversely, in particular at right angles to the flow direction of the first medium in the heat exchanger element. This has already been discussed, the first medium is deflected after passing the first media connection in the first collection box, then passes through the heat exchanger element and enters the second collection box and by repeated deflection to the other first Medienanschfuss, which derives the first medium.

In particular, it may be provided that the housing - seen in cross-section - has a bone shape or in its shape of a bone shape is approximated, in the region of the two thickenings of the bone shape of the first and the second collection box are arranged, that is, each thickening has an associated collection box, the housing to the respective collection box leaves a distance, so that inside the housing the second medium on the outside Can flow along collecting tank. Between the two, the bone shape forming thickenings of the housing is a less thick area in which the heat exchanger element is located.

According to a development of the invention, it is provided that the walls of the housing closely abut the heat exchanger element. These are side walls of the housing and also floor and ceiling walls. This close concern causes the second medium to come into intense heat exchange contact with the second medium, without creating a faulty medium flow that flows along the inner wall of the housing, but does not receive sufficient heat exchange contact with the first medium

According to a development of the invention can be provided that the housing forms a housing portion of a fan housing of a fan. Thus, the heat exchanger according to the invention is integrated in the housing of the fan, that is, the entire air housing has the fan of the fan and the heat exchanger, whereby a very space-saving design is achieved, the fan housing may preferably be formed as a spiral housing.

It is particularly preferred if the heat exchanger is designed as a countercurrent heat exchanger, that is, in the region of the heat exchanger element, the first and the second medium flow in opposite directions to each other, so that a high degree of heat exchange at low cooling air volume flow is achieved. Alternatively, however, it is also possible that the heat exchanger is designed as a DC heat exchanger, that is, the first and the second medium flow in the same direction in the heat exchanger element. Finally, there may be a mixed design of the two options mentioned, that is, sections are in countercurrent and flows through other sections in the DC. Additionally or alternatively, it is also conceivable that a cross-flow heat exchanger is formed.

Figur 1

einen Längsschnitt durch einen Wärmetauscher, dessen Formgebung einer Knochenform angenähert ist,

Figur 2

eine Draufsicht auf die Scheibenkontur eines Wärmetauscherelements eines Wärmetauschers, teilweise im Schnitt,

Figur 3

eine weitere Ausführungsform eines Wärmetauschers, teilweise aufgeschnitten,

Figur 4

eine vergrößerte Detailansicht des Wärmetauschers der Figur 3,

Figur 5

ein Schnitt entlang der Linie V-V in Figur 2,

Figur 6

ein Schnitt entlang der Linie VI-VI in Figur 2 und

Figur 7

ein weiteres Ausführungsbeispiel eines Wärmetauschers integriert in das Lüftergehäuse eines Lüfters.

The drawings illustrate the invention by means of exemplary embodiments, in which:

FIG. 1

a longitudinal section through a heat exchanger whose shape is approximated to a bone shape,

FIG. 2

a plan view of the disk contour of a heat exchanger element of a heat exchanger, partially in section,

FIG. 3

another embodiment of a heat exchanger, partially cut open,

FIG. 4

an enlarged detail view of the heat exchanger of FIG. 3 .

FIG. 5

a section along the line VV in FIG. 2 .

FIG. 6

a section along the line VI-VI in FIG. 2 and

FIG. 7

Another embodiment of a heat exchanger integrated into the fan housing of a fan.

The FIG. 1 shows a heat exchanger 1, which serves as a charge air cooler of a commercial vehicle. The heat exchanger 1 has a first collecting tank 2 and a second collecting tank 3 spaced apart from it for a first medium 4. The first medium 4 is charge air 5. The charge air 5 is to be cooled by means of a second medium 6. The second medium 6 is cooling air 7, which is formed by the wind and / or air sucked by a blower, not shown. The two header boxes 2 and 3 are tubular, formed with an oval cross section; their longitudinal extent is perpendicular to the plane of the FIG. 1 ,

The heat exchanger 1 has a housing 8, which in the longitudinal section of FIG. 1 seen- has a bone shape. Between two thickened areas 9 and 10 of the housing 8 is a less thick area 11, in which the housing 8 has two planar walls 12, 13. In the thickened areas 9 and 10, the respective flat wall 12 and 13 is in convexly curved walls 14, 15 and 16, 17 via. The housing 8 extends at its ends in areas 18, 19, which in the longitudinal section of FIG. 1 considered thinner than the region 11 and each having an end face 20 and 21 respectively. The convexly curved walls 14, 15, 16 and 17 extend at a distance a to the respective collection box 2 or 3, so that flow paths 22 to 25 are formed in the region of the header boxes 1 and 2 such that the latter can be flowed around inside the housing 8 outside , The thickened areas 9 and 10, which lead to the formation of the bone shape, make this possible.

The second collection box 3 is -senkrecht the plane of the FIG. 1 - The charge air 5 is supplied by means of a first, not shown media port 26. The charge air 5 thus rises in the second collection box 3 and is then deflected by 90 ° in the direction of the first collection box 2. It passes through a lying between the two headers 3, 2 heat exchanger element 27. This is indicated by the dashed arrow 28. After passing through the heat exchanger element 27, the charge air 5 enters the first collection box 2, is deflected there by 90 ° downwards and leaves the collection box 2 by means of a non-illustrated first media connection 29. The heat exchanger element 27 can run parallel to each other, the two Collecting boxes 2, 3 communicatively connecting charge air ducts to be formed (not shown). The charge air ducts extend at right angles to the longitudinal extent of the collecting tanks 2 and 3. Between the individual, spaced apart charge air ducts can be arranged for Oberflächenvergrößerung- cooling air ribs, which are opposite to the direction of the charge air 5 flows through the cooling air 7, so that an intense heat exchange in Heat exchanger element 27 takes place, which causes the charge air 5 is cooled by the cooling air 7. For this purpose, the cooling air 7 by means of a second media connection 30, located on the end face 20 of the area 18 is inserted into the interior of the housing 8, such that it passes through the two flow paths 22 and 23 and thus at least partially surrounds the second collection box 3. The cooling air 7 then enters the heat exchanger element 27 and flows countercurrently through this component, that is, the flow direction of the charge air 5 runs opposite to the flow direction of the cooling air 7. The cooling air 7 leaves the heat exchanger element 27 in the region of the second header 3 and flows into the Flow paths 24 and 25, that is, the collection box 3 is flowed around on both sides. The cooling air 7 then reaches the end face 21 of the region 19, where a second media connection 31 is formed for the removal of the cooling air 7.

Of the FIG. 1 It can be seen very clearly that the cooling air 7 undergoes no significant deflection in the region of the heat exchanger 1 and certainly not in the region of the heat exchanger element 27. Although the flow around the two header tanks 2 and 3 takes place with a certain change in direction of the cooling air 7, which does not bring about a significant pressure loss, since a laminar flow can be formed. The two second media connections 30 and 31 thus point in the direction of flow of charge air 5 of cooling air 7 within the heat exchanger element 27.

The FIG. 2 shows a plan view of a disk contour of the heat exchanger element 27, that is, the heat exchanger element 27 is realized in stacked disk design. For this purpose, individual slices (profiled aluminum sheets) are stacked alternately, which are provided to form the Anschusses and the formation of the two manifolds 2 and 3 with cups and passages. This is known in principle. When stacking, put cup / thread on cup / thread and then the next pair of edge on edge, etc. and soldered. By this stacking is in the heat exchanger element 27 according to FIG. 5 alternately formed a cooling air rib 32, a charge air rib 33 and then again a cooling air rib 32 and -following a charge air rib 33 and so on. From the FIG. 5 It can be seen that, by placing two half-shells 34, 35 on one another, the flow path for the charge air 5 in the region of Heat exchanger element 27 is created. The adjacent charge air rib 33 has a distance from the first-mentioned charge air rib 33, so that a cooling air rib 32 is formed between them, which can be flowed through by the cooling air 7 in countercurrent. In order to perform in the field of collecting tanks 2 and 3, the charge air 5 and the cooling air, 7 their respective flow paths within the heat exchanger element 27 is, according to the disc design of FIG. 6 - Provided that the charge air ribs 33 there-to form the header 2 and 3 are connected to each other, so that the charge air 5, the cooling air ribs 32 sealed penetrates and flows into the areas of the charge air ribs 33 and then - almost into the leaf level of FIG. 6 Divided into it, the heat exchanger element 27 passes through. The same happens in the area of the other header tank, where the charge air is brought together again and discharged together. The cooling air fins 32 communicate with the flow paths 22 to 25, that is, they are passed by the cooling air 5.

From the Figures 3 and 4 the overall structure of a heat exchanger 1 described above in stacked disk design is more apparent. The FIG. 3 shows the housing 8, which surrounds the heat exchanger element 27, wherein the housing 8 at diametrically opposite ends of the second media ports 30 and 31 has. Furthermore, the first media connections 26 and 29 can be seen leading to the collecting tanks 2, 3.

Of the FIG. 4 can be seen that coming from the heat exchanger element 27 charge air 5 is brought from the charge air ribs 33 and-corresponding to the arrows 35- is discharged from the collecting box 2. The lying between the charge air ribs 33 cooling air ribs 32, however, lead-according to the Gegenstromprinzip- cooling air 7 according to the arrows 36th

Also in the embodiment of FIGS. 2 to 4 ensures that the cooling air 7 for entry into the heat exchanger element 27 does not have to be deflected or only insignificantly, so that only small pressure losses occur.

The FIG. 7 shows a fan 37 with fan housing 38 and impeller 39. In the fan housing 38, a heat exchanger element 27 according to the embodiments described above is integrally at least partially accommodated such that within the fan housing 38 guided cooling air 7, the heat exchanger element 27 according to the FIG. 7 can flow through the arrows. The heat exchanger element 27 has integrated manifolds 2 and 3 and intermediate cooling air ribs 32 and charge air ribs 33 due to the stacked construction, so that a charge air flow guided there is cooled by the cooling air 7. The housing 38 is preferably formed as a spiral housing 40

Claims (14)

Heat exchangers, in particular intercoolers for motor vehicles, preferably for commercial vehicles, with a first header and with a second header for a first medium, wherein the two header boxes each having a first media connection for the first medium and communicating with each other via at least one heat exchanger element and with a , the heat exchanger element receiving, inside a second medium leading housing having second media connections for the second medium, characterized in that the housing (8) is formed such that in its interior at least one collecting box (2,3), preferably both Collecting boxes (2,3), at least partially with at least partially present existing distance to the housing inner wall is / are included. Heat exchanger according to claim 1, characterized in that the housing (8) sensibly receives the collecting boxes (2, 3). Heat exchanger according to one of the preceding claims, characterized in that the second media connections (30, 31) are assigned to the two collecting boxes (2, 3) such that the first collecting box (2) is connected between a second media connection (30) and the heat exchanger element (27 ) and the second collecting box (3) lies between the other second media connection (31) and the heat exchanger element (27). Heat exchanger according to one of the preceding claims, characterized in that the flow direction of the first medium (4) in the collecting boxes (2,3) transversely, in particular at right angles, to the flow direction of the first medium (4) in the heat exchanger element (27) extends. Heat exchanger according to one of the preceding claims, characterized in that the second media connections (30, 31) point in the direction of or approximately in the direction of flow of the first medium (4) in the heat exchanger element (27). Heat exchanger according to one of the preceding claims, characterized in that the first media connections (26,29) transversely, in particular at right angles, to the flow direction of the first medium (4) in the heat exchanger element (27). Heat exchanger according to one of the preceding claims, characterized in that the first media connections (26, 29) point in the direction of or approximately in the direction of the longitudinal extension of the collecting boxes (2, 3). Heat exchanger according to one of the preceding claims, characterized in that the respective first media connection (26,29) is aligned with the longitudinal extent of the associated first and second header tank (2,3). Heat exchanger according to one of the preceding claims, characterized in that the housing (8) seen in longitudinal section has a bone shape or in its shape approximates a bone shape. Heat exchanger according to one of the preceding claims, characterized in that the walls (12,13) and associated bonding and Deckenwandungen of the housing (8) create close to the heat exchanger element (27). Heat exchanger according to one of the preceding claims, characterized in that the housing (8) forms a housing section of a fan housing (38) of a fan (37). Heat exchanger according to one of the preceding claims, characterized in that the fan housing (38) as a spiral housing (40) is formed. Heat exchanger according to one of the preceding claims, characterized in that it is designed as a counterflow heat exchanger. Heat exchanger according to one of the preceding claims, characterized in that it is designed as a DC heat exchanger.

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