KR20100056709A - Intercooler for vehicle - Google Patents

Abstract

PURPOSE: An intercooler for a vehicle is provided to prevent damage due to the concentration of stress on the edge because the edge between the extension part and the main body of upper and lower headers does not contact with the tube. CONSTITUTION: An intercooler for a vehicle comprises an upper header(16) coupled with an upper tank connected to an inlet port, a lower header coupled with a lower tank connected to an outlet, and a plurality of tubes(20) which are installed between the upper header and the lower header at certain intervals. Each header includes a main body(161), a plurality of openings formed in the main body in the longitudinal direction of the tube, and an extension part(163) surrounding the openings on one side of the body facing the tube. Both ends of the tube are embedded in the extension part, with a distance to one side of the main body facing the upper and lower tanks, and do not contact with the edge of the extension part connected to the main body.

Description

Automotive Intercooler {INTERCOOLER FOR VEHICLE}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automotive intercooler, and more particularly, to an automotive intercooler capable of dispersing stress applied to a tube and a head, thereby preventing component breakage due to stress concentration.

In general, the intake air supplied to the engine is introduced into the air duct, purified by the air cleaner, and then pressurized by a turbocharger rotating to the discharge pressure of the exhaust gas. The pressurized air in the turbocharger, however, is less dense due to excessive temperature rise, which does not help to improve engine power. Therefore, an intercooler is installed between the turbocharger and the intake manifold to lower the temperature of the intake air.

A typical intercooler includes an upper tank having an inlet, a lower tank having an outlet, a header coupled to each of the upper tank and the lower tank, and a plurality of rows of tubes connecting both the upper tank and the lower tank with both ends fixed to the header. And a heat dissipation fin installed in the space between the tube and the tube through which the outside air passes. Therefore, the intake air discharged from the turbocharger flows into the tube through the upper tank, and is cooled by heat exchange with outside air through the heat dissipation fin while passing through the tube.

In the above-described intercooler structure, the header forms a plurality of openings, the tube is inserted into the opening, and the tube and the header are fixed by the adhesive force by the adhesive. In this case, the header may be a flat plate type to form only an opening or an extension part surrounding the opening on one surface of the header facing the upper tank and the lower tank. In the latter case, the tube is arranged to overlap the extension to enlarge the joint area with the header.

In both cases, however, high pressure air passing through the inside of the tube exerts a repetitive load on the tube and the header, thereby causing stress concentration on the tube and the header. In the former case, the stress is concentrated at the edge of the header surrounding the opening, and in the latter, the stress is concentrated at the edge between the header and the extension. If such stress concentration is prolonged for a long time, the weak strength part may be broken.

The present invention is to solve the above problems, an object of the present invention is to provide an intercooler for automobiles that can suppress the damage caused by stress concentration by dispersing the stress applied to the tube and the header.

An automotive intercooler according to an embodiment of the present invention includes an upper header coupled to an upper tank connected to an inlet, a lower header coupled to a lower tank connected to an outlet, and installed between the upper header and the lower header at a distance from each other. And a plurality of tubes. The upper header and the lower header each include a main body, a plurality of openings formed in the main body to face each other in the longitudinal direction of the tube, and an extension part formed to surround the opening on one surface of the main body facing the tube. Both ends of the tube are built into the extension.

Both ends of the tube may be positioned at a distance from one surface of the main body toward the upper and lower tanks so as not to contact the edges of the extension portion leading to the main body. The extension may be formed to a thickness thinner than the body. The ends of the extension may be formed to have curvature. The distance between one side of the body and the tube toward the upper and lower tanks may be greater than or equal to the thickness of the body.

In the intercooler for automobiles according to an embodiment of the present invention, since the edge between the main body and the extension part of the upper and lower headers does not contact the tube, it is possible to prevent the stress from being concentrated on the edge. And the extension part in contact with the tube is flexibly deformed by the air pressure of the tube can effectively distribute the stress. Therefore, it is possible to prevent stress breakdown of the tube and header to prevent component breakage.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art may easily implement the present invention. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention.

1 is a front view of an automotive intercooler according to an exemplary embodiment of the present invention, and FIG. 2 is a partial cutaway perspective view illustrating an upper header, a plurality of tubes, and a plurality of heat dissipation fins included in the automotive intercooler shown in FIG. 1.

1 and 2, the vehicle intercooler 100 of the present embodiment includes an upper tank 12, a lower tank 14, an upper header 16, a lower header 18, a plurality of tubes 20, and It includes a plurality of heat radiation fins (22).

The upper tank 12 is formed with an inlet 24 connected to a turbocharger (not shown), and the lower tank 14 is formed with an outlet 26 connected with an intake manifold (not shown). The upper header 16 is coupled to the lower end of the upper tank 12, and the lower header 18 is coupled to the upper end of the lower tank 14. A plurality of openings are formed in the upper header 16 and the lower header 18, and a plurality of tubes 20 are installed between the upper header 16 and the lower header 18 corresponding to each opening.

The upper end of the tube 20 is fixed to the upper header 16 so as to run through the opening of the upper header 16, and the lower end of the tube 20 runs to the opening of the lower header 18. Is fixed to. The fixing of the tube 20 and the upper and lower headers 16 and 18 may be made by a conventional method using an adhesive.

Accordingly, a plurality of tubes 20 connect the upper tank 12 and the lower tank 14, and an air passage leading to the upper tank 12, the plurality of tubes 20, and the lower tank 14 is formed. An inner heat dissipation fin 201 (see FIGS. 3 and 4) may be located inside the tube 20. Outside air flows into the space between the tube 20 and the tube 20, and a plurality of heat dissipation fins 22 are installed in the space to maximize the contact area with the outside air.

Intake air compressed from a turbocharger (not shown) is introduced into the upper tank 12 through the inlet 24, and passes through the plurality of tubes 20. In this process, the intake air passing through the inside of the tube 20 is cooled by heat exchange with outside air through the heat dissipation fin 22. The cooled intake air is discharged to the intake manifold (not shown) through the lower tank 14 and the outlet 26.

In the above-described process, the high-pressure inlet air passing through the tube 20 exerts a repetitive load on the tube 20 and the upper and lower headers 16 and 18, and in particular, since a sudden change in air pressure occurs due to output variation, This change causes a thermal shock or pressure change to generate stress in each part of the intercooler 100. Therefore, the vehicle intercooler 100 of the present embodiment is a combination of the tube 20 and the upper and lower headers 16 and 18 that can distribute the stress applied to the tube 20 and the upper and lower headers 16 and 18. Provide structure.

3 is a partially enlarged cross-sectional view of an upper header and a tube included in the automotive intercooler illustrated in FIG. 1, and FIG. 4 is a partially enlarged cross-sectional view of a lower header and a tube included in an automotive intercooler illustrated in FIG. 1.

2 and 3, the upper header 16 includes a main body 161, a plurality of openings 162 formed in the main body 161, and one surface of the main body 161 facing the tube 20 (FIG. 3, an extension 163 having a predetermined height formed on the lower surface of the main body 161 and surrounding the opening 162. In addition, the tube 20 may be partially extended while maintaining a predetermined distance d1 (see FIG. 3) from one surface (the upper surface of the body 161 in FIG. 3) of the body 161 facing the upper tank 12. It is positioned inside the extension part 163 so as to overlap with the 163.

Referring to FIG. 4, the lower header 18 includes a main body 181, a plurality of openings 182 formed in the main body 181, and one surface of the main body 181 facing the tube 20 (the main body in FIG. 4). And an extension 183 of a predetermined height formed on the upper surface 181 and surrounding the opening 182. In addition, the tube 20 maintains a predetermined distance d2 (refer to FIG. 4) from one surface of the main body 181 facing the lower tank 14 (the lower surface of the main body 181 in FIG. 4) and an extension portion thereof. Located inside the extension to overlap.

The separation distances d1 and d2 between one surface of the main body 161 and 181 facing the upper and lower tanks 12 and 14 and the tube 20 may be set to the same value.

The extensions 163 and 183 may be formed to have a thickness thinner than those of the main bodies 161 and 181, and may be molded integrally with the main bodies 161 and 181. As the extensions 163 and 183 are formed to be thinner than the bodies 161 and 181, the extensions 163 and 183 have flexibility to bend outward of the tube 20 when air pressure is generated in the tube 20. can do. In addition, the ends of the extension parts 163 and 183 are formed to have a predetermined curvature, and as the curvature increases, the concentration of stress on the end parts of the extension parts 163 and 183 can be suppressed.

In addition, since the tube 20 is spaced apart from one surface of the main body 161 and 181 facing the upper and lower tanks 12 and 14, the edge between the main body 161 and 181 and the extension parts 163 and 183 (Fig. Dashed circles in FIGS. 3 and 4) do not overlap the tube 20.

When compressed air flows into the intercooler 100 and air pressure is generated in the tube 20, a repeated load is applied to the tube 20 and the upper and lower headers 16 and 18 to generate stress. In the intercooler 100 of the present exemplary embodiment, the upper and lower headers 16 are not in contact with the tube 20 because the corners between the main bodies 161 and 181 and the extension parts 163 and 183 of the upper and lower headers 16 and 18 do not contact the tube 20. , It is possible to prevent the concentration of stress in the corner of (18).

At this time, the distance (d1, d2) between the one surface of the main body (161, 181) and the tube 20 toward the upper and lower tanks (12, 14) is greater than or equal to the thickness of the main body (161, 181), and satisfies this condition. When corners can be effectively protected from stress concentration.

In addition, since the extension portions 163 and 183 contacting the tube 20 are formed to have a thickness thinner than those of the main bodies 161 and 181, the extension portions 163 and 183 may be flexibly deformed by the air pressure of the tube 20 to disperse the stress. Therefore, due to the coupling structure of the above-described tube 20 and the upper and lower headers 16 and 18, stress concentration of the tube 20 and the upper and lower headers 16 and 18 can be prevented, thereby effectively suppressing breakage of components. have.

Table 1 shows the analysis results of the thermal load and the pressure load in the intercooler of the present embodiment, the intercooler of Comparative Example 1 and the intercooler of Comparative Example 2. In the following table, the numerical values of Comparative Examples 1 and 2 mean relative values with respect to the results of the Examples when the results of the Examples are assumed to be 1.

5 is a partially enlarged cross-sectional view of the upper header and the tube included in the intercooler of Comparative Example 1. FIG. Referring to FIG. 5, the upper header 28 of Comparative Example 1 forms only the opening 281 without an extension, and the upper end of the tube 20 ′ is inserted into the opening 281 and fixed to the upper header 28. do. The coupling structure of the lower header and the tube, not shown, is also made in the same way as the upper header 28.

6 is a partially enlarged cross-sectional view of the upper header and the tube included in the intercooler of Comparative Example 2. FIG. Referring to FIG. 6, the upper header 30 of Comparative Example 2 surrounds the opening 302 on one surface (the upper surface of the body 301 in FIG. 6) facing the upper tank as opposed to the intercooler of the present embodiment. Forms an extension 303. And the upper end of the tube 20 'is protruded out of the extension portion 303 is located. The coupling structure of the lower header and the tube, not shown, is also made in the same way as the upper header 30.

The height of the extension in the intercooler 100 of the embodiment used in the experiment is 2.286mm, the thickness of the upper header 28 in the intercooler of Comparative Example 1 is 0.4064mm, the height of the extension 303 in the intercooler of Comparative Example 2 is 3.175 mm.

In the intercooler of Comparative Example 1, when the air pressure is generated in the tube 20 ', stress concentration occurs at an edge of the upper header 28 in contact with the tube 20' (see the dotted circle in FIG. 5). In the intercooler of Comparative Example 2, when the air pressure is generated in the tube 20 ', stress concentration occurs at an edge between the main body 301 and the extension 303 (see the dotted line in FIG. 6).

On the other hand, in the intercooler 100 of the present embodiment, stress concentration does not occur at the corners between the main bodies 161 and 181 and the extension parts 163 and 183, and the extension parts 163 and 183 are flexibly deformed by the load. Therefore, the stress applied to the tube 20 and the upper and lower headers 16 and 18 can be effectively dispersed.

Therefore, as shown in the above table, the thermal load value and the pressure load value measured in the intercooler 100 of the present embodiment show lower results than those measured in the intercoolers of Comparative Examples 1 and 2.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited thereto, and various modifications and changes can be made within the scope of the claims and the detailed description of the invention and the accompanying drawings. Naturally, it belongs to the range of.

1 is a front view of an intercooler for a vehicle according to an embodiment of the present invention.

FIG. 2 is a partially cutaway perspective view illustrating an upper header, a plurality of tubes, and a plurality of heat dissipation fins included in the intercooler for an automobile shown in FIG. 1.

FIG. 3 is a partially enlarged cross-sectional view of the upper header and the tube included in the automotive intercooler shown in FIG. 1.

4 is a partially enlarged cross-sectional view of a lower header and a tube included in the automotive intercooler shown in FIG. 1.

5 is a partially enlarged cross-sectional view of the upper header and the tube included in the intercooler of Comparative Example 1. FIG.

6 is a partially enlarged cross-sectional view of the upper header and the tube included in the intercooler of Comparative Example 2. FIG.

Claims (5)

An upper header coupled to the upper tank connected to the inlet; A lower header coupled to the lower tank connected to the outlet; And It includes a plurality of tubes installed between the upper header and the lower header at a distance from each other, Each of the upper header and the lower header includes a main body, a plurality of openings formed to face each other along the longitudinal direction of the tube, and an extension part formed to surround the opening on one surface of the main body facing the tube. Including, Both ends of the tube is a vehicle intercooler in the extension portion. The method of claim 1, Both ends of the tube is positioned at a distance from one surface of the main body toward the upper and lower tanks so as not to contact the edge of the extension portion connected to the main body. The method of claim 2, The extension part is formed in the car thinner than the main body cooler. The method of claim 3, An end portion of the extension is a vehicle intercooler is formed to have a curvature. The method of claim 2, The distance between the one surface of the main body and the tube toward the upper, lower tank is greater than the thickness of the main body.

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