EP3246646A1

EP3246646A1 - Cooler, in particular gas cooler to a cooling system

Info

Publication number: EP3246646A1
Application number: EP16170580.1A
Authority: EP
Inventors: Dominik Sporna; Boleslaw Kurowski; Dariusz BUREK; Wojciech MATYSZKOWICZ
Original assignee: Valeo Systemes Thermiques SAS
Current assignee: Valeo Systemes Thermiques SAS
Priority date: 2016-05-20
Filing date: 2016-05-20
Publication date: 2017-11-22
Anticipated expiration: 2036-05-20
Also published as: EP3246646B1

Abstract

A cooler, preferably a gas cooler for a cooling system, comprising an inlet zone (I) and an outlet zone (II) of the cooling medium, each of which contains a set of flat tubes (6) located parallel to each other and an inlet/outlet manifold (1a) and an inner manifold (1b), wherein said flat tubes (6) of the inlet and outlet zones (I,II) are connected at opposite ends to the inlet/outlet manifold (1a) and the inner manifold (1b) for supplying from the inlet zone (I), guiding it to the outlet zone (II)and discharging it from the outlet zone. The cooler is characterised in that it comprises an insulating tube (5) having first and second ends and disposed between the inlet and outlet zones (I,II) of the cooling medium, and extended longitudinally to said flat tubes (6) of the zones (I,II) to separate and isolate the cooler zones, an inlet/outlet manifold (1a) comprising two segments (4a, 4b) of the inner housing (4). Segments (4a,4b) having the inner ends facing each other, and said inner ends are closed by means of baffles (3) and are arranged at a distance to each other and the cover (2) mounted on said inner housing (4) in the form of one part. Said cover (2) having a central slot (8) formed and arranged for receiving the first end of said insulating tube (5) and placing it between the segments (4a, 4b) of the inner housing (4);wherein said second end of the insulating tube (5) is located in front of outer surface of the cover (2') of said inner housing (4) of said inner manifold (1b).

Description

Technical Field

The present invention relates to a cooler, in particular gas cooler to a cooling system.

Background Art

There is known from the description EP 14461546.5 a gas cooler for a cooling system comprising an inlet and outlet zone of a cooling medium, each of which contains a set of flat tubes of a cooling assembly arranged parallel to each other and an inlet/outlet manifold and an inner manifold. The flat tubes of inlet and outlet zones are connected at opposite ends to the inlet/outlet and inner manifolds for supplying a cooling medium from the inlet zone, guiding it to the outlet zone and discharging it from the outlet zone.
Typically, the manifold consists of two elements in the form of the inner housing and the cover which is applied on and bent over the inner housing. The inner housing which is an uniform element having a closed profile is provided with at least one longitudinal channel defined therein and plurality slots on one of the surfaces of the housing. The slots are in fluid communication with at least one longitudinal channel. However the slots formed in the cover are in a position corresponding to positions of slots of the housing and are adapted for inserting flat tubes of the cooling assembly into them.
In above mentioned patent description EP 14461546 the gas cooler assembly of the cooling system was disclosed in which two separate manifolds are arranged on one side of the gas cooler, wherein one of them is used for supplying the cooling medium into the cooler, while the other is for discharging that medium. These manifolds are provided on their exposed surfaces, uncovered by the cover, with openings/ports for connection to an external circuit of a cooling medium. These openings are in fluid communication with channels of the inner housing. However, on the opposite side of the cooler the manifold free of such ports is arranged, therefore it is only an intermediate element in the gas cooler assembly, i.e. the cooling medium enters through one of the manifolds, flows through a part of the flat tubes, flows into the manifold, next re-enters into flat tubes and exits through the other of the manifolds on the opposite side of the assembly.
The object of the present invention is to provide a cooler, in particular a gas cooler to a cooling system to be able to achieve optimum performance and drop of internal pressure in the cooler.
Furthermore, the object of the invention is to improve the level of a cooler efficiency.

Disclosure of the invention

The above objects are achieved by a cooler to a gas system according to claim 1 and the following dependent claims.
A cooler that uses a separation of an inlet and outlet zones of the cooling medium through the insulating tube, which is not included into the cooling circuit ensured achieving optimal performance of the cooler and the internal pressure drop. With this solution, the heat conduction between the inlet and outlet zones has been limited. In order to reduce the cost the insulating tube having the same length as all the other tubes through which the cooling medium flows was used. Due to the fact that one end of the insulating tube will be fixed only on the inlet/outlet manifold side, while the opposite end of the insulating tube will be not inserted into the inner housing of the inner manifold, the additional length of the tube is equalized in the outlet zone of the inlet/outlet manifold.
The inner housing of the inlet/outlet manifold was divided into two separate segments ended with plugs (baffles). All these elements were attached on one cover of the inlet/outlet manifold.
As it will be explained below it was proposed two types of cover : one with an additional slot (central slot) for the insulating tube necessary for the inlet/outlet manifold and the other one, without central slot at the place in which the isolating tube is arranged and necessary for inner manifold. According to the invention the slot stamped in a conventional manner cannot be used due to observed collision with the inner housing of the manifolds.
Moreover, it was noted that during attempts of connecting and sealing of a cover and the inner housing with brazing, that, in the area where a slot is not formed on the cover of the inner manifold, a level of porosity is higher because of the small distance of the area to be soldered without degassing, i.e. the distance between the last slot of the inlet zone and the first slot of the outlet zone is 2.5 times larger than between the standard slots. This problem was simply solved, namely it was proposed a special cover with a central slot, which can be used for both inlet/outlet and inner manifolds.
According to the invention for the inner manifold a degassing and leak detection function was introduced in the attaching area of the insulating tube.
Preferably only one kind of the cover for both manifolds can be used, according to the invention.
Moreover, a central slot is formed by cutting (not stamping) in the opposite direction than the other stamped slots of the cover. This is very important because of the integration of the cover to the inner housing so as to form the inner manifold. In this case, an additional slot collar cannot be used because of the possibility of collision with the inner housing. Both of these elements have to be good fitted together. Cutting the slot profile in the same direction is not acceptable because there is a risk of burrs on the edges of the slot (at the slot exit).

Brief description of the drawings

The present invention is illustrated in its embodiments in the accompanying drawings, in which:

Fig. 1 shows schematically the gas cooler assembly with the manifolds and the indicated insulating tube according to the invention.
Fig. 2 shows the cooler assembly of Fig. 1 and a view of a fragment of the inlet/outlet manifold in a view in the direction indicated by the arrow A and a view of a fragment of the inner manifold in a view indicated by the arrow B.
Fig. 3 shows a detail of the attachment of one end of the insulating tube in the inlet/outlet manifold in a perspective view and the cover with a central slot at the location of the end of the insulating tube and the detail of the location of the opposite end of the insulating tube in the inner housing of the inner manifold together with the cover.
Fig. 4 shows a detail of the attachment of one end of the insulating tube in the inlet/outlet manifold in a perspective view and a cover with a central slot at the location of the end of the insulating tube and the detail of the location of the opposite end of the insulating tube in the inner housing of the inner manifold together with the cover in the second embodiment of the invention.
Fig. 5 shows the cooler in a side view.
Fig. 6 shows a fragment of the cover with a central slot for an insulating tube in a top view.

Embodiments of the invention

Figs. 1 and 2 show the gas cooler 1 for a cooling system comprising the inlet zone I and the outlet zone II of a cooling medium, each of which contains a set of flat tubes 6 arranged parallel to each other. The flat tubes 6 of the inlet and outlet zones I, II are connected at opposite ends to the inlet/outlet manifolds 1a and the inner manifold 1b for supplying a cooling medium from the inlet zone I, guiding it to the outlet zone II and discharging it from the outlet zone II.
The manifolds 1a and 1b used herein comprise the cover 2, 2' and the inner housing 4, 4'. The cover 2, 2' is manufactured from the plate of the thickness in range 0,8 to 2 mm, preferably of aluminium and/or its alloys by means of the stamping process and is bent in such manner that it substantially replicates the external shape of the inner housing 4, 4'. Preferably the cover 2, 2' can be plated on one or both sides.
The cover 2, 2' shown in fig. 3 and 4 and fig. 5 has many slots 7 arranged in a single row, through which, during the application of the manifold 1a and 1b, the flat tubes 6 of the gas cooler 1 are inserted. The cover 2,2' slots 7 are precisely made slots, so that the flat tubes 6 having inner passages are tightly received in these slots 7.
The inner housing 4, 4' is of known from the prior art hollow profile and is made by an extrusion process. It has a thick and solid walls which make it capable of withstanding high pressure, and it includes in its interior separate longitudinal channels (not shown) for the flow of a cooling medium.
The inner housing 4, 4' is also provided in its interior with stopping elements (not shown), against which the inserted flat tubes 6 abut. In addition, the inner housing 4, 4' has also a plurality of slots (not shown) at positions corresponding to the positions of slots 7 in the cover 2. The slots ( not shown) of the inner housing 4, 4' need not be made with such accurate dimensions as the slots 7 of the cover 2, 2', that is, their dimensions did not have to be exactly matched to the dimensions of the flat tubes 6;it is sufficient that the slots of the inner housing 4, 4' will have a size larger, or at least the same, as the size of flat tubes 6, and hence also the slots 7 of the cover 2, 2'. This results in that the flat tubes 6 are received loosely into slots of the inner housing 4, 4' and tightly into the slots 7 of the cover 2, 2'. The slots of the inner housing 4,4' can be made by a process using a saw milling, which process does not have to be precise. The slots(not shown) of the inner housing 4, 4' are further in fluid communication with the channels (not shown) of the inner housing 4, 4'. Like the cover 2, 2', the inner housing 4, 4' is also preferably made of aluminium and/or its alloys. The cover 2, 2' is so applied on the inner housing 4,4' that one surface of the inner housing 4,4' is exposed as it is known from the prior art.
As illustrated in fig. 1, between the inlet zone I and outlet zone II of the cooling medium the insulating tube 5 was inserted which is located longitudinally in relation to said flat tubes 6 of these zones for their separation and isolation. The insulating tube 5 has two opposite ends. One end of the insulating tube 5 is disposed in the inlet/outlet manifold 1a while the other end, opposite end is disposed in the inner manifold 1b. According to the invention, the inner housing 4' of the inner manifold 1b is a uniform element ( see right sides of figs.2-4).
In order to attach the insulating tube 5 in the inlet/outlet manifold 1a, the inner housing 4 according to the invention was divided in two segments 4a, 4b (see left sides of the figs.2-4). The segments have two inner ends facing each other. The inner ends are closed by means of baffles 3 and are arrange at a distance to each other as is best seen in fig. 2, fig. 3 and fig. 5 (see left side). The cover 2 which attached on the inner housing 4 of the inlet/outlet manifold 1a is formed in one piece.
The cover 2 is provided with the central slot 8 formed and positioned at the location of the insulating tube 5 for receiving one end of said insulating tube 5 and placing it between the segments 4a and 4b of the inner housing 4 of the inlet/outlet manifold 1a. According to the invention said central slot 8 of the cover 2 is the slot cut from its inner side, which is intended to come into contact with the housing 4.
According to the invention, an opposite other end of the insulating tube 5 is located in the inner manifold 1b in front of the outer surface of the cover 2' and in front of the central slot 8 of the cover 2'( see fig.4).
According to another embodiment illustrated in fig. 3 the cover 2' of the inner manifold 1b in the location area of the insulating tube 5 has a continuous surface free of the slot 8.
In order to reduce the cost, the insulating tube 5 has the same length as the flat tubes 6 through which the cooling medium flows. Due to the fact that one end of the insulating tube 5 will be attached only to the inlet/outlet manifold 1a side, while the opposite end of the insulating tube 5 is not inserted into the inner housing 4' of the inner manifold 1b, the additional length of the tube 5 was equalized in the outlet zone of the inlet/outlet manifold 1a.
The central slot 8 cannot be a slot stamped in a conventional manner due to the observed collision with the inner housing 4' of the inner manifold 1b (see fig. 6) . Moreover, it was noted during attempts of integrating and sealing of the cover 2' and the inner housing 4' by means of brazing, that, in the area where a central slot 8 is not formed on the cover 2' of the inner manifold 1b, the level of porosity is higher because of the small distance of the area to be soldered without degassing, i.e. the distance between the last slot 7 for the inlet zone I and the first slot 7 of the outlet zone II is 2.5 times larger than between the standard slots. This problem was resolved in a simply manner, namely it was proposed special cover 2' provided with the central slot 8 intended for both types of the manifolds 1a and 1b. Owing to the new solution of the present invention only one type of the cover 2 can be applied to both manifolds 1a and 1b. This ensures a degassing and leak detection function in this area for the inner manifold (see fig.4).
According to the invention, the central slot 8 is formed by cutting (not stamping) in the opposite direction than the other stamped slots 7 of the cover 2,2' . This is very important because of the integration of the cover 2' to the inner housing 4' so as to form the inner manifold 1b. In this case, an additional slot collar cannot be used because of the possibility of collision with the inner housing 4'. Both of these elements have to be good fitted together. Cutting the central slot 8 of the cover 2,2' in the same direction is not acceptable because there is a risk of burrs on the edges of the central slot 8.
According to the preferred embodiment the said central slot 8 has a width from 0.5 to 3.0 mm. However, the size of slots (not shown) in the inner housing 4 is at least equal to or greater than the size of slots 7 in the cover 2 and 2'.
It is obvious that the embodiments described herein does not limit that invention.

Claims

A cooler, preferably a gas cooler for a cooling system, comprising an inlet zone (I) and an outlet zone (II) of the cooling medium, each of which contains a set of flat tubes (6) parallel to each other and an inlet/outlet manifold (1a) and an inner manifold (1b), wherein said flat tubes (6) of the inlet and outlet zones (I,II) are connected at opposite ends to the inlet/outlet manifolds (1a) and the inner manifold (1b) for supplying from the inlet zone (I), guiding it to the outlet zone (II) and discharging it from the outlet zone, wherein each of said manifolds (1a,1b)comprises:
a inner housing (4,4') having a closed profile and having at least one longitudinal channel defined therein and

having a plurality of slots on one of its surfaces being in fluid communication to said at least one longitudinal channel; and

a cover (2,2') applied on said inner housing (4,4') and having a plurality of slots (7) located at positions corresponding to the positions of said slots of said inner housing (4,4') for introduction flat tubes (6) of the cooler to them,

characterised in that it comprises

an insulating tube (5) having first and second ends and disposed between the inlet and outlet zones (I,II) of the cooling medium, and extended longitudinally to said flat tubes (6) of the zones (I,II) to separate and isolate the cooler zones,

an inlet/outlet manifold (1a) comprising two segments (4a, 4b) of the inner housing (4), said segments (4a,4b) having the inner ends facing each other, and said inner ends are closed by means of baffles (3) and are arranged at a distance to each other, and the cover (2) mounted on said inner housing (4) in the form of one part, having a central slot (8) formed and arranged for receiving the first end of said insulating tube (5) and placing it between the segments (4a, 4b) of the inner housing (4);

wherein said second end of the insulating tube (5) is located in front of outer surface of said cover (2') of said inner housing (4') of the inner manifold (1b).
The cooler according to claim 1, characterized in that said cover (2') of said inner manifold (1b) is provided with a formed central slot (8) and said other end of said insulating tube (5) is arranged in front of said central slot (8) of said cover (2').
The cooler according to claim 1, characterized in that said cover (2') of said inner manifold (1b) has continuous surface free of slots in a location of the insulating tube (5).
The cooler according to claim 1 or 2, characterized in that the said central slot (8) of said cover (2,2') is the slot cut from its inner side, which is intended to come into contact with said inner housing (4,4').
The cooler according to claim 1 or 2 or 4, characterized in that said central slot (8) has a width from 0.5 to 3.0 mm.
The cooler according to any one of the preceding claims, characterized in that the size of slots of said inner housing (4,4') is at least equal to or greater than the size of said slots (7) of said cover (2,2').
The cooler according to any one of the preceding claims, characterized in that said cover (2,2') is applied to said inner housing (4,4') that one surface of said inner housing (4,4') is exposed.
The cooler according to any one of the preceding claims, characterized in that both said cover (2,2') and said inner housing (4,4') are made of aluminium and/or its alloys and are connected by means of brazing to each other.
The cooler according to any one of the preceding claims, characterized in that said cover (2,2') is made from the plate which has thickness ranging from 0.8 to 2 mm.