JP2011133198A - Vehicular intercooler - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a header structure for an intercooler suppressing deformation of a header due to high-temperature high-pressure compressed air and sympathetic vibration and sympathetic resonance with respect to vibration of a supercharger, minimizing flow resistance of compressed air and enabling efficient flowing to a core part. <P>SOLUTION: The intercooler 10 includes: the core part 1 exchanging heat between the compressed air and cooling air; an inlet header 2 formed by smoothly continuing an inlet pipe part 2b connected to the supercharger side and a header part 2a expanded to approximately correspond to an end plate 6 of the core part 1 by a curved surface part 2c, mounted to the upwind side of the core part 1 and supplying the compressed air; and an outlet header formed by smoothly continuing a header part expanded to approximately correspond to the end plate 6 of the core part 1 and an outlet pipe part connected to the engine side by a curved surface part, mounted to the downwind side of the core part 1, collecting the compressed air and supplying the compressed air to the engine side. Reinforcement plates 7 formed along the flowing direction of the compressed air are installed within each of the curved surface parts of the inlet header 2 and the outlet header by integral molding. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an intercooler used for a vehicle or the like, and more particularly, to a structure of an intercooler header.

An intercooler for a vehicle has a function of cooling by heat exchange and supplying the compressed air, which has been compressed by a supercharger and heated to the inside, to the intake side of the engine.
As shown in FIG. 1, the intercooler 10 is arranged in series on the upstream side of the cooling air of a radiator 11 that cools the cooling water of the engine by heat exchange with the cooling air.

As shown in FIG. 2, the intercooler 10 includes a core portion 1 in which a number of hollow flat tubes 4 and outer fins 5 are stacked and both ends thereof are respectively inserted into end plates 6 and 6. Yes. In the core portion 1, as shown by the thick arrows in FIGS. 2 and 7, the compressed air is allowed to flow through the flat tube 4, and the outer fin 5 is caused to flow in the crossing direction to cool the compressed air.
The headers 2 and 3 are fixed to the end plates 6 and 6 by welding or caulking.

  The headers 2 and 3 attached to both ends of the core portion 1 for introducing and derivatizing compressed air are generally made of iron or aluminum press, cast aluminum or resin, but are mounted on a large truck. When the compressed air becomes extremely hot and high pressure and a large intercooler is required, for example, aluminum casting is mainly used.

As shown in FIGS. 2 and 7, the headers 2 and 3 have header portions 2a and 3a formed with one end expanded for attachment to the end plate 6, and the other end formed into a tubular shape with a pipe portion. 2b and 3b, and the pipe parts 2b and 3b are smoothly connected to the header parts 2a and 3a by R (curved surface) parts 2c and 3c, and the pipe parts 2b and 3b are integrally formed or as a separate body. There is a molded one.
Hereinafter, what is attached to the compressed air upstream side of the core part 1 may be called an inlet header 2, and what is attached to the compressed air downstream side of the core part may be called an outlet header 3.

In recent years, there has been a tendency to increase the supercharging pressure of an engine in order to tighten exhaust gas regulations and improve fuel efficiency, and the temperature of compressed air compressed by a supercharger has increased accordingly.
The high-temperature compressed air flows into the inlet header 2 from the inlet pipe portion 2b. In order to improve the cooling performance of the intercooler and improve the fuel efficiency by reducing the resistance of the intake air of the engine, it is necessary to reduce the resistance of compressed air (hereinafter referred to as gas resistance) in the intercooler.

In order to reduce gas resistance, there are pipes 2b and 3b of the headers 2 and 3 that are smoothly connected to the header parts 2a and 3a by curved R parts 2c and 3c. Depending on the pressure of the compressed air (100 to 250 kPa), the R portions 2c and 3c and the header portions 2a and 3a in the range shown in the B portion of FIG.
As a result, stress concentrates on the welded portion between the end plates 6 and 6 and the headers 2 and 3, the brazed portion between the end plate 6 and the flat tube 4, the headers 2 and 3, and cracks may occur. It was.
Further, in addition to the above-described problem of strength, resonance and resonance may occur in the intercooler due to vibration and supercharging sound of the turbine of the supercharger that compresses air.

  Conventionally, in order to solve these problems, the end cross section of the pipe portion connected to the header portion is made into a flat oval shape, thereby reducing the thickness of the header to suppress the flow of compressed air and the core portion. There is an intercooler that can improve the cooling performance by taking a long length (length of the flat tube) (Patent Document 1).

In addition, there is one that improves rigidity by installing plate-like or columnar reinforcing parts on the pipe part or the header part.
When installing reinforcement parts on the pipe part, install it parallel to the front or back of the core part so as to connect both flat parts of the pipe part, and when installing it on the header part, In order to suppress the deformation, it is installed in parallel to the end plate so as to connect both wall surface portions which are the long sides of the header portion.

In the case of casting, the reinforcing part is formed integrally with the header or prepared as a separate part and fixed by brazing, welding, bolts, screws, or the like.
As this reinforcing component, for example, a perforated partition plate perpendicular to the diffusion direction of the compressed air is arranged at a required portion inside the header portion to partition the inside (Patent Documents 2 to 4). Thereby, in each space part partitioned by the perforated partition plate, the vibration that causes the generation of sound is small, and the generation of noise can be reduced as a whole header.

JP-A-6-159971 Japanese Utility Model Publication No. 6-12390 JP-A-6-201291 JP-A-6-213591

In this way, the installation of reinforcing parts on the pipe or header increases the rigidity of the header and suppresses distortion, cracks, resonance, and resonance, but all of them are reinforced perpendicular to the flow of compressed air. Since the parts were installed, the gas resistance of the header was increased, making it difficult to improve the cooling performance of the intercooler, and wind noise was generated when compressed air passed.
Furthermore, when the reinforcing part is molded after being formed separately, it takes time for the mounting.

  The present invention has been made to solve the above-mentioned problems, and in a vehicle intercooler, while suppressing an increase in cost, the header is deformed due to high-temperature and high-pressure of compressed air, and resonance due to vibration of a supercharger. An object of the present invention is to provide an intercooler header structure that can suppress the resonance, minimize the flow resistance of the compressed air, and flow efficiently to the core of the intercooler.

In the present invention, means for solving the above problems are as follows.
A first aspect of the present invention is a structure in which a plurality of hollow flat tubes through which compressed air is circulated and outer fins through which cooling air is circulated are alternately stacked, and both ends are fixed by a pair of end plates. The header portion is formed by smoothly connecting a core portion that exchanges heat with the inlet pipe portion connected to the supercharger side and a header portion that is expanded so as to substantially match the end plate with a curved surface portion. An inlet header that is joined to the end plate and attached to the core portion to supply compressed air to the flat tubes, a header portion that is expanded so as to substantially match the end plate, and an outlet pipe that is connected to the engine side Are joined to the end plate by the header part and attached to the core part, and the compressed air is collected and sent to the engine side. An intercooler for a vehicle comprising an outlet header, wherein a reinforcing plate along the flow direction of the compressed air is erected in an integral manner inside each curved surface portion of the inlet header and the outlet header. .

  In the second invention, the reinforcing plate is installed from the inlet pipe portion of the inlet header to the curved surface portion and the header portion, or from the outlet pipe portion of the outlet header to the curved surface portion and the header portion. It is characterized by.

  The third invention is characterized in that the longitudinal cross-sectional shape of the reinforcing plate in the gas flow direction is formed into a rectangular shape, an oval shape, or a spindle shape.

According to the first aspect of the present invention, the reinforcing plate extending in the flow direction of the compressed air is installed in the curved surface portions of the inlet header and the outlet header by integral molding. The deformation of the header portion due to the pressure of the supercharger can be suppressed, and the resonance and resonance of the turbocharger can be suppressed. In addition, since the reinforcing plate is integrally formed with the header body, it is possible to reduce the man-hours for manufacturing and attaching the reinforcing plate as separate members.
In addition, when hot compressed air passes through the inside of the inlet header, the flow is dispersed by the reinforcing plate, so that the compressed air can flow into each flat tube of the core portion evenly and efficiently. The difference in temperature distribution due to can be reduced.

  Further, since the curved surface portion is a portion where the flow of compressed air is disturbed by hitting the header wall surface, according to the second aspect, the reinforcing plate is extended from the inlet pipe portion of the inlet header to the curved surface portion and the header portion. Or, by installing from the outlet pipe part of the outlet header to the curved surface part and the header part, it is possible to minimize the turbulence in the flow of compressed air due to the installation of the reinforcing plate, and to reduce the gas resistance. The increase can be reduced, the compressed air can be efficiently flowed to the core portion, and the cooling performance can be improved.

  According to the third invention, since the longitudinal cross-sectional shape of the reinforcing plate in the gas flow direction is formed in a rectangular shape, an oval shape, or a spindle shape, the reinforcing plate has a shape that does not hinder the flow of compressed air. Therefore, an increase in gas resistance can be suppressed, compressed air can be efficiently flowed into the core portion, and cooling performance can be improved.

It is a perspective view of the intercooler for vehicles concerning the embodiment of the present invention. It is a front view of the intercooler. It is a side view of the intercooler. It is the sectional view on the AA line in FIG. It is a partial cutaway perspective view of the intercooler. (A) is a graph which shows the result of having measured the resonant acceleration of the Example and (b) of the comparative example. It is a side view of the conventional vehicle intercooler.

Hereinafter, a header structure of a vehicle intercooler according to an embodiment of the present invention will be described.
As shown in FIG. 1, the intercooler 10 includes an inlet header 2 that introduces compressed air from a supercharger (not shown) at both ends of a core portion 1 that performs heat exchange between compressed air and cooling air. An outlet header 3 for attaching the cooled compressed air to the intake system (not shown) of the engine is attached.

As shown in detail in FIG. 2, the core portion 1 is formed by alternately laminating hollow flat tubes 4 that allow compressed air to pass therethrough and outer fins 5 that bend the plate material and allow cooling air to pass. 4 is formed by penetrating both ends of a pair of end plates 6 and fixing them.
The end plate 6 is formed in a rectangular shape, and a large number of long holes are formed in order to penetrate the flat tube 4.

  As shown in FIGS. 2 and 3, the inlet header 2 attached to the compressed air upstream side of the core portion 1 includes a header portion 2 a that expands in accordance with the shape of the end plate 6, and the opposite side of the header portion 2 a. An inlet pipe portion 2b formed on the (supercharger side) and connected to a pipe (not shown) from the supercharger, and an R (curved surface) portion that smoothly connects the header portion 2a and the inlet pipe portion 2b with a curved surface. 2c is integrally formed, and is formed in a shape in which the funnel is bent as a whole.

  Similarly, the outlet header 3 attached to the compressed air downstream side of the core portion 1 is formed on the header portion 3a that expands in accordance with the shape of the end plate 6, and on the opposite side (engine side) of the header portion 3a. The outlet pipe portion 3b connected to the piping (not shown) to the engine and the R (curved surface) portion 3c that smoothly connects the header portion 3a and the outlet pipe portion 3b with a curved surface are integrally formed. It is formed in a shape in which a substantially funnel is bent.

In the inlet header 2 and the outlet header 3, the header portions 2a and 3a have rectangular openings that match the shape of the end plates 6 and 6, and can be joined to the end plates 6 and 6 by welding or caulking. Yes.
The inlet pipe portion 2b and the outlet pipe portion 3b are formed in a cylindrical shape and can be connected to other pipes.
The R portions 2c and 3c gradually increase in diameter and bend at a substantially right angle, and smoothly between the inlet pipe portion 2b and the header portion 2a and between the outlet pipe portion 3c and the header portion 3a, respectively. Are connected.

  As shown by the thick arrows in FIGS. 1 to 3, the compressed air that has been compressed by a supercharger (not shown) and has reached a high temperature flows in from the inlet pipe portion 2b of the inlet header 2, and the R portion 2c and the header. It is diffused by the part 2 a and flows into each flat tube 4 of the core part 1. When compressed air passes through each flat tube 4, heat exchange is performed with the cooling air flowing through the outer fins 5 in the crossing direction, and the air is cooled. The compressed air merged at the header portion 3a and the R portion 3c of the outlet header 3 is sent from the outlet pipe portion 3b to the intake system (not shown) of the engine.

As shown in FIG. 4 and FIG. 5, the inside of the inlet header 2 and the outlet header 3 includes an outer R portion (curved portion outside the portion bent at a substantially right angle) and an inner R portion of the respective R portions 2 c and 3 c. A reinforcing plate 7 is laid along the flow of compressed air between (the curved surface inside the portion bent at a substantially right angle).
The thickness of the reinforcing plate 7 is preferably about 3 to 20 mm. As shown in FIGS. 4 and 5, from the inlet pipe portion 2b or the outlet pipe portion 3b to the vicinity of the portion bent at a substantially right angle of the R portions 2c and 3c. Extend to the range.

  The number of reinforcing plates 7 may be increased in accordance with the size and shape of the inlet header 2 and the outlet header 3. When two or more reinforcing plates 7 are installed, they are installed with an interval of 30 mm or more between them. At that time, when the radial parallel arrangement is used as shown in FIG. 3, the compressed air is uniformly diffused and the flow rate of each flat tube 4 becomes uniform as shown by the broken line arrows in the figure, and the cooling performance of the intercooler 10 is improved. It becomes good.

  The longitudinal cross-sectional shape obtained by cutting the reinforcing plate 7 in the gas flow direction may be a shape that does not hinder the flow of compressed air, such as a rectangular shape or a spindle shape, in addition to the oval shape shown in FIG.

  The inlet header 2 and the outlet header 3 provided with such a reinforcing plate 7 can be integrally formed by aluminum casting or resin molding. Thereby, the man-hour of manufacture and attachment can be reduced compared with the case where the reinforcement board 7 is shape | molded as another component.

<Confirmation of effect by simulation analysis>
A header portion 2a that is expanded to match the end plate 6 of the core portion 1, a cylindrical inlet pipe portion 2b that is formed on the opposite side of the header portion 2a and is connected to a pipe from the supercharger, and the header portion 2a and an inlet pipe portion 2b, and an R header 2c that is bent at a substantially right angle, and an inlet header in which a reinforcing plate 7 is integrally formed in the R portion 2c along the flow of compressed air. 2 was attached to the supercharger side of the core part 1, and the same outlet header 3 was attached to the engine side of the core part 1 to form an intercooler. In this embodiment, as shown in FIG. 3, the two reinforcing plates 7 and 7 are arranged vertically near the center of the height of the inlet header 2 and are arranged slightly in a radial pattern. The thicknesses of the reinforcing plates 7 and 7 are substantially the same as the other portions of the inlet header 2.
Moreover, the comparative example of the intercooler according to an Example was prepared except not having provided the reinforcement board 7 in each R part of the inlet header 2 and the outlet header 3. FIG.
In this example and comparative example, simulation analysis of stress, resonance acceleration, and gas resistance was performed to confirm the effect.

In the example and the comparative example, the stress applied to the joint portion between the flat tube 4 of the core portion 1 and the inlet header side end plate 6 when the compressed air of the supercharging pressure at the time of traveling of the vehicle is caused to flow is analyzed by simulation. did.
In this simulation, the flat tube 4 is made of aluminum and is completely fixed on the center side of the core 1, and the inner wall of the inlet header 2, the end plate 6, etc. The stress applied to the joint portion when a predetermined supercharging pressure was applied to the surface was calculated.
As a result, when the stress of the comparative example was 100, the stress ratio of the example was about 39. In other words, in the embodiment, the rigidity of the inlet header 2 is increased by the installation of the reinforcing plate 7 and the deformation is suppressed. As a result, the stress applied to the joint portion between the flat tube 4 and the end plate 6 is reduced to half or less.

Further, in the example and the comparative example, the resonance acceleration of the R portion 2c of each inlet header 2 with respect to the supercharging sound of the supercharger generated when the vehicle travels was analyzed by simulation.
In this simulation, the natural frequency of the inlet header 2 was analyzed in each of the example and the comparative example, and the resonance acceleration generated in the outer R portion with respect to the vibration near the resonance frequency was analyzed.
As a result, as shown in FIG. 6, the resonance acceleration of the comparative example was about 2.40E + 05 mm / s ^{2 in} the band of 1500 to 2000 Hz where the resonance acceleration of the inlet header 2 is the largest (FIG. 5 ( b)), the resonance acceleration of the example was lower than 1.20E + 05 mm / s ² (FIG. 5A). Assuming that the resonance acceleration of the comparative example is 100, the resonance acceleration ratio of the example is about 48.7, and the resonance and resonance are suppressed by installing the reinforcing plate 7.

Further, in the example and the comparative example, the gas resistance when the compressed air having the supercharging pressure during running of the vehicle was supplied to each was analyzed by simulation.
In this simulation, the gas flow when the compressed air having a predetermined pressure flows into the inlet header 2 was analyzed, and the gas flow when the compressed air having a predetermined pressure flowed into the outlet header 3 was analyzed.
As a result, assuming that the gas resistance of the comparative example is 100, the gas resistance ratio of the example was about 105, and the increase in the gas resistance of the intercooler due to the installation of the reinforcing plate 7 was slight.

As described above, in the vehicle intercooler 10 according to the embodiment of the present invention, the reinforcing plate 7 is installed on the inner surfaces of the R portions 2c and 3c of the inlet header 2 and the outlet header 3 along the flow of compressed air. As a result, the rigidity of the headers 2 and 3 can be increased, and the deformation of the header portions 2a and 3a due to the pressure of the compressed air can be suppressed, and the resonance and resonance of the turbocharger can be suppressed.
Further, since the reinforcing plate 7 is integrally formed with the headers 2 and 3, man-hours for manufacturing and mounting as separate members of the reinforcing plate are not required.
Further, when high-temperature compressed air flows into the inlet header 2, the flow is dispersed by the reinforcing plate 7 in the vicinity of the portion where the flow of the compressed air bends. It can be made to flow into the flat tube 4, and the difference of the temperature distribution by the position for every flat tube 4 can be reduced.

  Further, the R portions 2c and 3c are portions where the flow of compressed air is disturbed by hitting the header wall surface, so that the reinforcing plate 7 is extended from the inlet pipe portion 2b to the R portion 2c and the header portion 2a, or from the outlet pipe portion 3b to the R portion 3c. In addition, since it is installed over the header portion 3a, it is possible to minimize the increase in gas resistance by minimizing the turbulence in the flow of compressed air due to the installation of the reinforcing plate 7, and to efficiently compress the compressed air. The heat exchange performance can be improved by flowing to the core portion 1.

  Further, since the reinforcing plate 7 has a longitudinal, cross-sectional shape in the gas flow direction that is rectangular, oval, or spindle-shaped, the reinforcing plate 7 has a shape that does not hinder the flow of compressed air, thereby suppressing an increase in gas resistance. Therefore, the compressed air can efficiently flow into the core portion 1 and the cooling performance can be improved.

DESCRIPTION OF SYMBOLS 1 Core part 2 (Inlet) header 2a Header part 2b (Inlet) Pipe part 2c R part 3 (Outlet) Header 3a Header part 3b (Outlet) Pipe part 3c R part 4 Flat tube 5 Outer fin 6 End plate 7 Reinforcement plate 10 Intercooler 11 Radiator

Claims (3)

A large number of hollow flat tubes through which compressed air is circulated and outer fins through which cooling air is circulated are alternately stacked, and both ends are fixed by a pair of end plates to exchange heat between the compressed air and the cooling air. The core,
An inlet pipe portion connected to the supercharger side and a header portion expanded so as to substantially coincide with the end plate are smoothly continuous at a curved surface portion, and the core portion is joined to the end plate at the header portion. An inlet header for attaching compressed air to each of the flat tubes,
The header portion that is expanded so as to substantially match the end plate and the outlet pipe portion that is connected to the engine side are smoothly connected at the curved surface portion, and joined to the end plate at the header portion to the core portion. A vehicle intercooler comprising an outlet header that collects and sends the compressed air to the engine side,
A vehicular intercooler characterized in that a reinforcing plate extending in the flow direction of the compressed air is installed in the curved surface portions of the inlet header and the outlet header by integral molding.
The reinforcing plate is constructed from the inlet pipe portion of the inlet header to the curved surface portion and the header portion, or from the outlet pipe portion of the outlet header to the curved surface portion and the header portion. The intercooler according to 1.
  2. The intercooler for a vehicle according to claim 1, wherein a longitudinal cross-sectional shape of the reinforcing plate in the gas flow direction is formed in a rectangular shape, an oval shape, or a spindle shape.

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