US20230266075A1

US20230266075A1 - Non-vertical corrugated fins in a heat exchanger and method of manufacturing the same

Info

Publication number: US20230266075A1
Application number: US17/676,310
Authority: US
Inventors: David McDermott
Original assignee: Mahle International GmbH
Current assignee: Mahle International GmbH
Priority date: 2022-02-21
Filing date: 2022-02-21
Publication date: 2023-08-24

Abstract

An inclined heat exchanger for use in a motor vehicle. The heat exchanger contains at least two flat tubes and at least two corrugated fins. The flat tubes and the corrugated fins are stacked alternately one above the other in a height direction (HR) to form a stack. The corrugated fins include a rhombic cross-section. A corrugated fin is also provided for use in the heat exchanger, as well as a method for manufacturing the corrugated fin.

Description

FIELD

This disclosure relates generally to a heat exchanger for a motor vehicle. More specifically, this disclosure relates to non-vertical corrugated fins incorporated into a heat exchanger and a method of manufacturing the same.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
In modern motor vehicles, the space available for mounting a heat exchanger is often reduced in comparison to the space occupied by a heat exchanger mounted in an older vehicle model. This creates a problem that can be solved by the heat exchanger either being constructed with smaller dimensions or configured to be mounted at an angle. However, in both of these solutions, the amount of air that flows through the heat exchanger may be significantly reduced and not provide the desired performance. It is therefore desirable to provide a heat exchanger that may be mounted in a restricted space and maintain the degree of air flow that supports the required level of performance.

SUMMARY

The present disclosure generally provides a heat exchanger for use in a motor vehicle. This heat exchanger generally comprises at least two flat tubes through which a liquid flows in a width direction (BR), and at least two corrugated fins through which air flows in a depth direction (TR). The corrugated fins comprise a rhombic cross-section in a plane spanned transversely to the width direction (BR). The flat tubes and the corrugated fins are stacked one on top of the other alternately in a height direction (HR) to form a stack. The height direction (HR), the width direction (BR) and the depth direction (TR) are oriented perpendicular to each other.
According to another aspect of the present disclosure, the cross-section of the corrugated fins may comprise, in a plane spanned transversely to the width direction (BR), two edges aligned parallel to the depth direction (TR) and two edges aligned at an inclination angle (NW) to the height direction (HR). This inclination angle (NW) may be between 5° and 85°; alternatively, between 25° and 65°; alternatively, about 30° or about 60°.
According to yet another aspect of the present disclosure, the flat tubes separated by the corrugated fins overlap only in regions in the depth direction (TR) and completely in the width direction (BR). The corrugated fins and the flat tubes adjacent thereto overlap only in regions in the depth direction (TR) and completely in the width direction (BR). The flat tubes and the corrugated fins in the stack may be displaced one above the other in the depth direction (TR) in such a way that a height center axis (HMA) passing through the center of the stack is aligned with the height direction (HR) at an inclination angle (NW) that is greater than zero.
According to another aspect of the present disclosure, a corrugated fin for use in the heat exchanger described above and further defined herein is provided. This corrugated fin generally comprises a single piece of material with a plurality of folds extending in the depth direction (TR) and adjacent to each other in the width direction (BR), and a rhombic cross-section in a plane spanned transversely to the width direction (BR).
According to yet another aspect of the present disclosure, a method of manufacturing the corrugated fin for use in the heat exchanger is provided. This method generally comprises folding a single piece of material, such that the corrugated fin contains a rectangular cross-section in a plane spanned transversely to the width direction (BR), and cutting the single piece of material, such that the corrugated fin contains a rhombic cross-section in the plane spanned transversely to the width direction (BR). The material may be cut to form the corrugated fin in such a way that a cross-section of the corrugated fin in a plane spanned transversely to the width direction (BR) contains two edges aligned parallel to the depth direction (TR) and two edges aligned at an inclination angle (NW) to the height direction (HR). The material may be cut to form the corrugated fin on both sides at an angle that corresponds to an extension of the individual folds.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which each drawing is provided as a schematic representation.

FIG. 1 is a partial sectional view of a heat exchanger formed according to the teachings of the present disclosure.

FIG. 2 depicts a corrugated fin before the step of folding in the manufacturing process according to the teachings of the present disclosure.

FIG. 3 depicts the corrugated fin of FIG. 2 after the step of folding in the manufacturing process of the present disclosure.

FIG. 4 depicts the corrugated fin of FIG. 3 after the step of cutting in the manufacturing process of the present disclosure.

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. Various embodiments of the present disclosure are shown in the drawings and will be explained in more detail in the following description, wherein like reference signs refer to like or similar or functionally identical components or features.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no way intended to limit the present disclosure or its application or uses. For example, the heat exchanger made and used according to the teachings contained herein are described throughout the present disclosure in conjunction with a motor vehicle. The incorporation and use of such a heat exchanger in other heating, ventilation, air conditioning, and refrigeration applications wherein the space for mounting the heat exchanger is limited and the design set forther herein would be desirable is contemplated not to exceed the scope of the present disclosure.
For the purpose of this disclosure, the terms “at least one” and “one or more of” an element are used interchangeably and may have the same meaning. These terms, which refer to the inclusion of a single element or a plurality of the elements, may also be represented by the suffix “(s)” at the end of the element. For example, “at least one fin”, “one or more fins”, and “fin(s)” may be used interchangeably and are intended to have the same meaning.
Although specific terminology is used herein to describe particular embodiments within the disclosure, this terminology is not intended to limit any portion of the disclosure. For example, as used herein, singular forms of “a”, “an”, and “the” are intended to include various plural forms as well, unless the context of their use clearly indicates otherwise. Terms, such as “comprises”, “includes”, “comprising” or “including” are meant to specify the presence of stated features, integers, steps, operations, elements, and/or components, but are not meant to preclude the presence and/or addition of one or more other features, integers, steps, operations, elements, components, and/or groups associated therewith.
The present disclosure addresses the deficiency of the prior art by providing a design for an inclined heat exchanger having a corrugated fin that provides an improvement over or at least an alternative embodiment for a heat exchanger of the generic type, in which the described disadvantages are overcome. The present disclosure also provides a method for manufacturing the corrugated fin incorporated into the heat exchanger.
The heat exchanger according to the present disclosure may be provided for a motor vehicle. The heat exchanger contains at least two flat tubes through which a liquid can flow in a width direction and at least two corrugated fins through which air can flow in a depth direction. The flat tubes and the corrugated fins are stacked alternately one above the other in a height direction to form a stack. The height direction, the width direction and the depth direction are thereby aligned perpendicularly to one another. According to one aspect of the present disclosure, the respective corrugated fin contains a rhombic cross-section in a plane spanned transversely to the width direction.
The respective flat tube rests on a contact surface of the respective adjacent corrugated fin and is connected to the respective corrugated fin by a material bond. The two opposing contact surfaces of the respective corrugated fin are aligned transversely to the height direction. Due to the rhombic cross-section of the respective corrugated fin, the two opposing contact surfaces of the corrugated fin are displaced relative to one another transversely to the height direction in the depth direction, so that the adjacent flat tubes abutting the respective corrugated fin on both sides are displaced relative to one another transversely to the height direction in the depth direction. As a result, the stack of the heat exchanger deviates in its shape from a cuboid and is formed to be inclined transversely to the height direction in the depth direction. The respective corrugated fin is further aligned transversely to the height direction. Accordingly, the air flow in the heat exchanger is not negatively affected despite the inclined shape of the stack.
In a plane spanned transversely to the width direction, the cross-section of the respective corrugated fin may contain two edges aligned parallel to the depth direction and two edges aligned at an inclination angle to the height direction. In other words, the respective corrugated fin may be formed inclined to the height direction. The flat tubes and the corrugated fins in the stack may be displaced one above the other in the depth direction such that a central height axis of the stack passing through the center of the stack is oriented at the inclination angle greater than zero to the height direction. The inclination angle may be between 5° and 85°, alternatively, between 25° and 65°, alternatively, at either about 30° or about 60°. The inclination angle may be adapted to the desired inclination of the heat exchanger and/or to the available installation space in the motor vehicle.
Advantageously, the respective adjacent flat tubes may overlap each other only in regions in the depth direction and completely in the width direction. In other words, the respective flat tubes may be arranged displaced to each other transversely to the height direction. Moreover, the respective corrugated fin and the respective adjacent flat tube may overlap each other only in regions in the depth direction and completely in the width direction. In other words, the respective flat tube and the respective corrugated fin may be arranged displaced to each other transversely to the height direction.
The present disclosure also relates to a corrugated fin for use in the heat exchanger described above. The corrugated fin is folded from a single piece of material and contains a plurality of folds extending in the depth direction and adjacent to each other in the width direction. The corrugated fin contains a rhombic cross-section in a plane spanned transversely to the width direction. In order to avoid repetition, reference is made at this point to the above explanations.
The present disclosure also relates to a method of manufacturing the corrugated fin described above. The corrugated fin is folded from a single piece of material in such a way that the corrugated fin contains a rectangular cross-section in a plane spanned transversely to the width direction. Thereafter, the folded material is cut on both sides such that the corrugated fin contains a rhombic cross-section in the plane spanned transversely to the width direction. In other words, the rhombic cross-section of the corrugated fin is produced only after folding, which simplifies the production of the corrugated fin.
The corrugated fin can be cut off from the material on both sides in such a way that a cross-section of the corrugated fin in a plane spanned transversely to the width direction contains two edges aligned parallel to the depth direction and two edges aligned at an inclination angle to the height direction. Thus, the corrugated fin may be formed inclined to the height direction. In this case, the corrugated fin can be cut on both sides at an angle to the extension of the individual folds in the corrugated fin.
Other important features and advantages of the present disclosure will be apparent hereafter, from the drawings and from the accompanying figure description with reference to the drawings. It is understood that the above features, and those to be explained below, may be used not only in the combination indicated in each case, but also in other combinations or alone, without departing from the scope of the present invention.
FIG. 1 shows a sectional view of a heat exchanger 1 according to one aspect of the present disclosure. In FIG. 1 , only a section of the heat exchanger 1 is shown. Here, the heat exchanger 1 contains a plurality of flat tubes 2 through which a fluid can flow in a width direction (BR) and a plurality of corrugated fins 3 through which air can flow in a depth direction (TR). The flat tubes 2 and the corrugated fins 3 are formed flat and extend transversely to a height direction (HR). The flat tubes 2 and the corrugated fins 3 are stacked alternately one above the other in the height direction (HR) to form a stack 4. The height direction (HR), the width direction (BR) and the depth direction (TR) are aligned perpendicularly to each other.
According to another aspect of the present disclosure, the respective corrugated fin 3 contains a rhombic cross-section transversely to the width direction (BR). In particular, the cross-section of the respective corrugated fin 3 contains, in a plane spanned transversely to the width direction (BR), two edges aligned parallel to the depth direction (TR) and two edges aligned at an inclination angle (NW) - in this case (FIG. 1 ) approximately 30° - to the height direction (HR). As a result, the respective corrugated fin 3 is formed inclined to the height direction (HR) and two opposing contact surfaces 3 a and 3 b of the corrugated fin 3 are displaced to each other in the depth direction (TR). However, air can still flow through the corrugated fins 3 in the depth direction (TR).
Still referring to FIG. 1 , since the respective flat tube 2 rests on the corresponding contact surface 3 a or 3 b of the corrugated fin 3, the mutually adjacent flat tubes 2 are also displaced relative to one another in the depth direction (TR). As a result, the heat exchanger 1 or the stack 4 has a rhombic cross-section in the plane spanned transversely to the width direction (BR). Thereby, a height center axis (HMA) of the heat exchanger 1 in the plane spanned transversely to the width direction (TR) is oriented at the inclination angle (NW) - here about 30° as shown - to the height direction (HR). In this case, the central height axis (NMA) is an axis which always passes through the center of the stack 4 in a plane spanned transversely to the height direction (HR). Advantageously, the heat exchanger 1 can be mounted inclined in a motor vehicle without air flow through the corrugated fins 3 being negatively affected.
Referring now to FIG. 2 and FIG. 3 , several views of the corrugated fin 3 are shown during the manufacturing process. During manufacture, the corrugated fin 3 is folded in a process and then cut off. In the process, the corrugated fin 3 having a plurality of folds 5 is folded from a single piece of material 6. In FIG. 2 , the corrugated fin 3 is shown not folded and not cut off. In FIG. 3 , the corrugated fin 3 is shown folded and not cut off. The piece of material 6 or corrugated fin 3 is shown with solid lines before being cut off, while the broken lines provide a view of what the corrugated fin 3 looks like after being cut off. FIG. 4 shows a view of the corrugated fin 3 after cutting. Here, lateral portions of the piece of material 6 or corrugated fin 3 are cut off so that initially rectangular cross-section becomes rhombic. FIGS. 2-4 also show a louver bank region 7 with dotted lines. The single piece material 6 may be cut to form the corrugated fin on both sides at an angle that corresponds to an extension of the individual folds. This angle may be the same as the inclination angle in the range of 5° to 85°; alternatively, between 25° and 65°; alternatively, at about 30° or about 60°.
Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that all preferred features described herein are applicable to all aspects of the invention described herein.
The foregoing description of various forms of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications or variations are possible in light of the above teachings. The forms discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various forms and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

What is claimed is:

1. A heat exchanger for use in a motor vehicle, the heat exchanger comprising:

at least two flat tubes through which a liquid flows in a width direction (BR), and

at least two corrugated fins through which air flows in a depth direction (TR), the corrugated fins comprising a rhombic cross-section in a plane spanned transversely to the width direction (BR),

wherein the flat tubes and the corrugated fins are stacked one on top of the other alternately in a height direction (HR) to form a stack,

wherein the height direction (HR), the width direction (BR) and the depth direction (TR) are oriented perpendicular to each other.

2. The heat exchanger according to claim 1, wherein the cross-section of the corrugated fins comprise, in a plane spanned transversely to the width direction (BR), two edges aligned parallel to the depth direction (TR) and two edges aligned at an inclination angle (NW) to the height direction (HR).

3. The heat exchanger according to claim 2, wherein the inclination angle (NW) is between 5° and 85°.

4. The heat exchanger according to claim 3, wherein the inclination angle (NW) is between 25° and 65°.

5. The heat exchanger according to claim 4, wherein the inclination angle (NW) is about 30° or about 60°.

6. The heat exchanger according to claim 1, wherein the flat tubes separated by the corrugated fins overlap only in regions in the depth direction (TR) and completely in the width direction (BR).

7. The heat exchanger according to claim 1, wherein the corrugated fins and the flat tubes adjacent thereto overlap only in regions in the depth direction (TR) and completely in the width direction (BR).

8. The heat exchanger according to claim 1, wherein the flat tubes and the corrugated fins in the stack are displaced one above the other in the depth direction (TR) in such a way that a height center axis (HMA) passing through the center of the stack is aligned with the height direction (HR) at an inclination angle (NW) greater than zero.

9. A corrugated fin for use in the heat exchanger according to claim 1, the corrugated fin comprising:

a single piece of material with a plurality of folds extending in the depth direction (TR) and adjacent to each other in the width direction (BR), and

a rhombic cross-section in a plane spanned transversely to the width direction (BR).

10. A method of manufacturing the corrugated fin according to claim 9, the method comprising:

folding a single piece of material, such that the corrugated fin contains a rectangular cross-section in a plane spanned transversely to the width direction (BR), and

cutting the single piece of material, such that the corrugated fin contains a rhombic cross-section in the plane spanned transversely to the width direction (BR).

11. The method according to claim 10, wherein the material is cut to form the corrugated fin in such a way that a cross section of the corrugated fin in a plane spanned transversely to the width direction (BR) contains two edges aligned parallel to the depth direction (TR) and two edges aligned at an inclination angle (NW) to the height direction (HR).

12. The method according to claim 10, wherein the material is cut to form the corrugated fin on both sides at an angle that corresponds to an extension of the individual folds.

13. The method according to claim 11, wherein the material is cut to form the corrugated fin on both sides at an angle that corresponds to an extension of the individual folds.

14. The method according to claim 12, wherein the angle is between 5° and 85°.

15. The method according to claim 13, wherein the angle is between 25° and 65°.

16. The method according to claim 12, wherein the angle is about 30° or about 60°.