WO2012120059A1

WO2012120059A1 - Collector pipe, heat exchanger and method for manufacturing a collector pipe

Info

Publication number: WO2012120059A1
Application number: PCT/EP2012/053942
Authority: WO
Inventors: Stefan Hirsch
Original assignee: Behr Gmbh & Co. Kg
Priority date: 2011-03-08
Filing date: 2012-03-07
Publication date: 2012-09-13
Also published as: DE102011005236A1

Abstract

The present invention relates to a collector pipe (300) for a heat exchanger which has at least one through-opening (350) for receiving a coolant pipe of the heat exchanger, wherein the through-opening (350) is bounded by a collar (360) which is formed from an edge region of the collector pipe (300), said edge region being turned over to form an inner wall of the collector pipe (300), and wherein the collar (360) bears against the inner wall.

Description

Header, heat exchanger and method of manufacture

a manifold

The present invention relates to a manifold for a heat exchanger, to a heat exchanger with such a manifold and to a method for producing such a manifold, which can be used for example in the vehicle sector.

When operating a battery, e.g. A lithium-ion batteries, heat loss, which leads to the heating of the battery. Especially lithium-ion batteries age much faster from a design-related temperature, so that the life of the battery can shorten undesirable. To counteract this effect, therefore, battery coolers are used.

Often battery cells on the bottom - Abieiter or connections are therefore up - cooled by means of a flat radiator or a cooling plate. The battery cooler can contain internal channels, in which a cooling medium is guided. As constructions constructions of pipes are known, which are plugged into collectors. Furthermore, there are constructions that consist of laminated sheets or embossed sheets. To ensure a Dichtlötung between pipes and the collector, usually "passages" are introduced for the pipes in the collector. Often a collector consists of two half-shells, the bottom and the lid, as the "passages" are easier to produce.

DE 41 30 517 AI relates to a terminal box, in particular for a coolant condenser, which is formed from a bottom part and a cover part. The bottom of the bottom part is provided with transverse, slot-shaped passages for the flat tubes, wherein the length of the passages corresponds approximately to the distance of the legs of the bottom part.

It is the object of the present invention to provide an improved manifold for a heat exchanger, an improved heat exchanger, and an improved method of manufacturing a manifold.

This object is achieved by a manifold, a heat exchanger and a method for producing a manifold according to the. Main claims solved.

The present invention is based on a partially use of flanks of a manifold as a template for a production of passages. This makes it possible to keep a height of a battery cooler low.

According to the structural solution presented here can thus be dispensed in a Z direction of the manifold, which may correspond to a direction of a height of the manifold, to a die for the production of the passages. This allows the smallest possible height.

Thus, advantageously, a collector can be made, in which a "solid" collar, which can ensure a Dichtlötung of the tube in the bottom or collector, rests directly against an outer wall of the bottom or collector. Assuming that this type of construction or Hensweise is characterized by a solid collar _» can, for a given material thickness of the bottom and a height of the flat tube, a production of a particularly flat manifold, ie a manifold with the lowest possible height, can be achieved.

According to the approach proposed here can thus be avoided »that the die, which determines the smallest / possible design of the manifold, can adversely affect the height of a desired as small as possible height.

Thus, the arrangement presented here or the method presented here make it possible to produce a collector with passages for the reliable sealing soldering of inserted pipes, with the lowest possible overall height.

The constructive solution proposed here makes it possible to produce a battery cooler composed of tubes and collectors, in which the overall height of the collector is sufficiently low so that the collector, like the tubes, also has to be arranged below the battery cells and not next to them. In this way, space can be saved.

The present invention provides a header for a heat exchanger having at least one through hole for receiving a coolant tube of the heat exchanger, wherein the through hole is bounded by a collar which is formed from an edge of the header pipe turned towards an inner wall of the header, wherein the collar rests against the inner wall.

The heat exchanger can be used for example for cooling an electrochemical energy storage unit such as a lithium-ion battery. The heat exchanger may, for example, have two manifolds, between which run a plurality of coolant tubes that communicate fluidically with the reservoirs. Thus, a collecting pipe for supplying cooled cooling Serve fluid to the coolant tubes and serve the other manifold for discharging heated by a heat exchange with the electrochemical energy storage unit cooling fluid from the coolant tubes. In addition, the headers may also be used to control a direction of the flow of cooling fluid through the individual coolant tubes. The manifold may be formed as an elongated container with, for example, a round or rectangular cross-section. The at least one passage opening can be arranged in a longitudinal side of the manifold. In addition, the collecting tube can have a further opening for supplying or removing the cooling fluid to or from the collecting tube. The at least one passage opening may have a shape which corresponds to a circumferential contour of the coolant pipe to be accommodated. In general, the coolant tube used is fluid-tightly connected to the collecting tube by inserting one end of the coolant tube into the passage opening and then connecting the adjoining material regions to one another in a fluid-tight manner, for example by means of a welding process. To simplify and improve this connection between the manifold and the coolant tube, the collar is provided. Due to the fact that here the collar rests on the inside of the collecting tube wall, the overall height of the collecting tube, and thus of the heat exchanger in which such a collecting tube is used, can be reduced to a minimum. The passage opening can also be referred to as a "passage", since the collar can be formed by means of a "pull-through" of Sarnmelrohrmatehal from outside to inside in the direction of a Sammelrohrein- ren.

According to one embodiment, the collecting tube may have a base element and a cover element which is connected in a fluid-tight manner to the base element. In this case, the passage opening can be arranged in the bottom element. This embodiment of a two-part construction is advantageous in that the passage opening can be made easier. Thus, first of all, the floor element can be provided with at least one passage opening and subsequently the floor element can be provided on one of the at least one NEN through opening opposite side are closed with the lid member. In this case, the cover element can be pushed into the bottom element. This saves production time and costs.

According to a further embodiment, the bottom element may have a bottom element base surface and two opposing bottom element flanks. The cover element may have a cover element base surface and two opposing cover element flanks. The cover element flanks can be arranged between the bottom element flanks and connected in a fluid-tight manner to the bottom element flanks. This is a particularly simple and inexpensive construction for the manifold, since both the bottom element and the lid member inexpensive and easily available in the market and in all sizes C-profiles can be used by simply plugging together to the manifold can be joined.

For example, the bottom element flanks and the bottom element base surface and the lid element base surface may form outer walls of the collection tube. This embodiment can advantageously be made particularly quickly and inexpensively, since only the steps of joining the bottom element and the cover element and then connecting both, e.g. need to be performed by means of a simple welding process.

The collar may surround an entire circumference of the through opening. Thus, due to the material redundancy along the entire circumference of the passage opening a particularly robust and durable fluid-tight connection between the coolant tube and the manifold can be created.

According to one embodiment, the passage opening may have a rectangular shape. For example, the passage opening may be arranged such that that long sides of the rectangular passage opening are parallel to the bottom element edges. This embodiment is a low height of the manifold very contrary. Furthermore, the collection tube presented here is advantageously particularly universally applicable, since an outer circumference of frequently used Kühimittelrohre has a rectangular outer peripheral contour. With this design can be made particularly space-saving.

According to a further embodiment, the collecting tube may have a plurality of passage openings. These may be arranged adjacent to each other along a longitudinal extension of the base element base. For example, the through holes may be arranged in a row next to one another and evenly spaced from each other in the base element base. Thus, advantageously, even with a low overall height of the collecting tube, a cooling fluid flow sufficient for the functionality of the heat exchanger can be ensured.

The present invention further provides a heat exchanger having the following features: a first manifold according to one of the preceding embodiments; a second manifold according to one of the preceding embodiments; and at least one coolant tube, wherein the coolant tube is disposed between the first manifold and the second manifold and fluidly connected to the collar of the first manifold and the collar of the second manifold.

For example, the heat exchanger can convert a plurality of coolant tubes arranged in parallel between the first and the second manifold. believe it. Such a heat exchanger can be used for example in an electric or hybrid vehicle for cooling the drive battery. Alternatively, only one of the collectors may be configured according to an embodiment of the present invention.

According to one embodiment, the heat exchanger has a heat exchanger surface for arranging at least one battery on the heat exchanger surface. In this case, the heat exchanger surface may extend over the at least one coolant tube, at least a portion of the first manifold and at least a portion of the second manifold. The Wärmetauscherfiäche can be formed by wall portions of the manifolds and wall portions of the coolant tubes, Alternatively, the Wärmetauscherfiäche can be formed by an additional plate which rests on a wall portion of the manifolds and additionally or alternatively on wall portions of the coolant tubes. In this case, the heat exchanger surface can extend over an entire length of the coolant tube and an entire width of one or both manifolds in the direction of a longitudinal direction of extension of the coolant tube. Accordingly, the heat exchanger surface may extend only over one of the manifolds. By the Wärmetauscherfiäche is suitable for receiving at least one battery, the at least one battery can also be arranged in the region of the headers. It can thus be used as Wärmetauscherfiäche for battery cooling the entire areal extent of the heat exchanger.

The present invention further provides a method of manufacturing a manifold for a heat exchanger, comprising the following steps:

Providing a bottom member for the manifold, the bottom member having a bottom member base and two opposing bottom member flanks; Providing a U-shaped female mold with two opposite legs, wherein each of an inner wall of the legs has a shoulder for forming a stop surface for the Bodenefementflanken the floor element;

Assembling the die and the bottom member, wherein the bottom member flanks of the bottom member come to rest against the abutment surfaces of the die;

Aligning the die and the bottom member with a cutting punch, such that the cutting punch is directed toward an outside of the bottom member base surface of the bottom member to form the at least one through hole;

Pressing the cutting punch through the bottom member base to form the at least one through hole, wherein an edge portion of the header is turned to an inner wall of the header and abuts against the inner wall; and

Removing the die and the punch from the floor element.

The method may, for example, be performed by a numerically controlled machine tool. For example, the die may be formed of high strength metal. A distance between legs of the die may correspond to a distance between the bottom element flanks of the bottom element. The stop surfaces formed by the paragraphs may correspond to bearing surfaces of the bottom element edges. The cutting punch may be a tool having a sharp point that has sufficient strength to cut through the material of the bottom element base. In the aligning step, the cutting punch can be aligned with a center of the bottom member base with respect to the bottom member flanks. The pressing of the cutting punch can take place in a feed direction towards a yoke of the die. The cutting nozzle can have a sufficient material thickness in order to press the folded or continuous edge region of the collecting tube against the inner wall of the collecting tube with the penetration of the base element base surface so that it comes into contact there.

According to one embodiment, the method may comprise a step of providing a cover element for the collection tube. In this case, the cover element may have a cover element base surface and two opposite cover element flanks. Further, the method may include a step of inserting the cover element flanges between the bottom element flanks of the bottom element and the fluid-tight connection of the cover element flanks to the bottom element flanks. Advantageously, this embodiment of the method allows a particularly quick and easy production of the manifold.

Advantageous embodiments of the present invention will be explained below with reference to the accompanying drawings. Show it:

1A is a schematic diagram of a method step for the production of

Pulling through a collecting pipe;

FIG. 1B is a schematic representation of a further method step for producing passages of a collecting tube; FIG.

2A is a schematic diagram of a method step for the production of

Passing through a manifold, according to an embodiment of the present invention;

2B is a schematic diagram of a further method step for producing passages of a collecting tube, according to an embodiment of the present invention; 3 is a perspective view of a collecting tube with a low overall height, according to an embodiment of the present invention;

4 is a sectional view of the collection tube of FIG. 3 with exemplary dimensions, according to an embodiment of the present invention; and

5 is a flowchart of a method for producing a low-height manifold, according to an embodiment of the present invention.

In the following description of the preferred embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various drawings and similar, and a repeated description of these elements will be omitted.

On the basis of the following figures, designs of headers or process steps for the production of such headers are presented in which the "passages" are always introduced into the "bottom" or are. In doing so, e.g. Material formed by a cutting punch inside in a die. In principle, a formation of passages in a cover of a manifold can be realized. Under the passage, a passage opening is to be provided, which is characterized in that an edge region of the passage opening to the inside, here in an interior of the floor or manifold into, is bent or turned over.

With reference to the figures 1A and 1B, a production of passages for pipes in the bottom of a manifold will be explained. 1A shows a schematic representation of a method step for producing passages or passage openings of a collecting tube. The passages are formed in a bottom element of the manifold. 1A shows a cross-sectional view of an arrangement comprising a bottom element 100 of a collection tube, a die 110 and a cutting punch 120. The arrangement shown in the illustration can be realized, for example, by clamping the base 100 with the die 110 into a tool and opposite the punch 120 is suitably positioned. The illustration in FIG. 1A shows that both the bottom element 100 and the die 110 have a U-shape. Here Bodenelementflanken 130 are so on tavern! attached to the die 110, that the bottom 100 against the die 1 10 is firmly positioned. End regions of the legs of the die 110 rest against a bottom element base surface 140 of the bottom element 100.

FIG. 1B shows a subsequent process step shown in FIG. 1A for producing a bottom element with passages for a battery cooler. Here, the punch 120 has cut through the bottom element base 140 of the bottom element 100. Due to a feed direction of the cutting punch 120 toward an inner portion of the die 110, an edge portion of the cut bottom face material corresponding to a circumferential geometry of the punch 120 was bent around the end portions of the legs of the die 110 and drawn into the inner portion of the die 110. As the illustration in FIG. 1B shows, the edge region of the cut forms an inner collar around the passage opening. The illustration shows that a height of the die 110 determines a height 170 indicated by a double arrow in a Z-direction of the collecting tube to be manufactured.

FIGS. 2A and 2B show a production of passages for pipes in the bottom of a collecting pipe according to an embodiment. of the present invention. The illustrations in FIGS. 2A and 2B correspond to those from FIGS. 1A and 1B, with the difference that a differently shaped die 110 is used and the bottom element 100 is a smaller height having. The U-shaped female mold 110 used here has on each of the inner sides of each leg a shoulder for the formation of abutment surfaces 200 for the floor element flanks 130 of the floor element 100. Thus, the bottom element flanks 130 need not, as shown in Figures 1A and 1B, are attached to the legs of the die 110, but can be applied to the stop surfaces 200 on the inner sides of the legs, as in the illustration in Fig. 2A easy to recognize. Inner surfaces of the legs of the female mold 110 that extend beyond the abutment surfaces 200 bear on outer surfaces of the floor element flanks 130. The bottom element flanks 130 can be completely inserted into the die 1 10. End regions of the bottom element flanks 130 abut against the abutment surfaces 200 of the die 1 10. A height of the stop surfaces 200 may correspond to a thickness of the bottom element edges 130.

The cutting punch 120 is disposed opposite to an outer surface of a central portion of the bottom member base 140 of the bottom member 100. The cutting punch 120 may be configured to produce only a draft in the bottom element base 140. Alternatively, the cutting punch 120 may also be formed to form a plurality of punctures, or there may be a plurality of cutting punches 120, each of which may each form a passage in the bottom member 100. The manufactured passages can lie on one line. The passages can be evenly spaced from each other.

FIG. 2B shows a subsequent process step, shown in FIG. 2A, for producing a bottom element with passages for a battery cooler. Here, the punch 120 has cut through the bottom member bottom surface of the bottom member 100. Caused by a feed direction of the cutting punch 120 toward an inner portion of the die 10, an edge portion of the cut bottom sheet material has been bent inward in accordance with a circumferential geometry of the punch 120 and into an inner portion of the bottom 100 pulled, After removal of the punch 120 is the formation at least one passage opening or a passage in the bottom element 100 completed.

As the illustration in FIG. 2B shows, the edge region of the cut formed by the punch 120 forms an inner collar around the passage opening. The inner collar adjoins an inside of the now shortened bottom element edges 130 in an overlapping region. Thus, the bottom 100 has a thickness in the region of the passage opening, which thickness is determined from a thickness of the collar and a thickness of the regions of the bottom element flanks 130 which overlap with the collar and are in their original position. Thus, the bottom 100 in the region of the passage opening has a thickness which corresponds to a double material thickness of the bottom element edges 130. The illustration shows that a height of the floor 100 determines a height 170 indicated by a double arrow in a Z-direction of the collecting pipe to be manufactured.

This construction of the die 110 allows the die legs to be out of the way in the formation process of the passage orifices, particularly during the formation of the collar. Thus, as clearly shown in Fig. 2B, a much flatter collar portion can be formed. Correspondingly, the overall height 170 of the bottom element 100 shaped according to the method shown with reference to FIG. 2B is less than that of that shown in FIG. 1B. On an outer surface of at least one of the bottom element edges 130, a battery can be arranged.

Fig. 3 shows a perspective view of a manifold 300 with the lowest possible height and passages for flat tubes, according to an embodiment of the present invention. The collecting tube 300 has a bottom element 100 manufactured according to the method shown in FIGS. 2A and 2B and a cover element 310. The bottom element 100 shown in FIG. 3 comprises four rectangular-shaped passages or through-openings 350, of which, for the sake of clarity, only one with a reference number is provided. In the illustration in FIG. 3, it can be clearly seen that the respective collar 360 is circumferential around the passages 350. The passages 350 are suitable for connecting coolant tubes in a flat construction to the manifold 300. The cover element 310 is formed like the bottom element 100 in a U-shape, wherein a distance between outer sides of cover element flanks 320 of the cover element 310 is equal to or slightly smaller than a distance between inner sides the bottom element flanks 130 of the bottom element is such that the cover element 310 can be inserted between the bottom element flanks 130 for closing the collecting tube 300 and can be welded thereto in order to seal the collecting tube 300 in a fluid-tight manner.

4 shows a cross-sectional view of the collection tube 300 from FIG. 3 with exemplary dimensions. All dimensions shown are indicated by double arrows. Thus, a width 400 of the manifold 300 20 to 40 cm and a height 410 of the manifold 300 8.5 cm. A material thickness 420 of the lid member 310 as the bottom member 100 is dimensioned 1 cm. A distance 430 between inner sides of the bottom element flanks is 4.5 cm, and a clear dimension 440 of the passage 350 is 3 cm. In the illustration in Fig. 4, the manifold 300 is shown with a pushed into the passage 350 coolant tube 450. The dimensions mentioned are given as examples and can be varied.

FIG. 5 shows a flowchart of a method 500 for producing a bottom element for a low-height collector tube, according to one exemplary embodiment of the present invention. In a first step 510, a bottom member is provided for the manifold and, in a step 520, a female mold is provided in a U-shape with shouldered stop surfaces for receiving the flanks of the bottom member. Steps 510 and 520 may be concurrent. In a following step 530, the die and the bottom element are assembled so that the flank ends of the bottom element abut against the abutment surfaces of the die. In a step 540, the die-floor element combination is then so opposed aligned with a cutting punch that the cutting punch is directed to an outer side of the bottom element base surface of the bottom element. Then, in a step 550, the cutting punch is pushed through the bottom member base to form one or more through holes in the bottom member base. Finally, in a step 560, the die and the punch are removed from the bottom member

Alternatively, in the case of headers of high material thickness of the floor, openings for the tubes may be punched, i. without "pulling through" a "collar" are produced. The punching process can be done from the inside out. As a result, the die can be arranged on the outside to achieve the lowest possible height. However, the soldering resistance depends on a sufficiently thick material thickness.

The described embodiments are chosen only by way of example and can be combined with each other.

Claims

Patent claims

A manifold (300) for a heat exchanger having at least one port (350) for receiving a coolant tube (450) of the heat exchanger, the port being defined by a collar (360) extending to an inner wall of the manifold folded over edge region of the manifold is formed, wherein the collar rests against the inner wall.

2. collecting tube (300) according to claim 1, which has a bottom element (100) and a fluid-tightly connected to the bottom element cover element (3 0), wherein the passage opening (350) is arranged in the bottom element.

3. collecting tube (300) according to one of the preceding claims, wherein the bottom member (100) has a bottom element base (140) and two opposite bottom element flanks (130) and the lid member (310) has a lid member base and two opposite cover member flanks (320) Cover element edges are arranged between the bottom element flanks and connected in a fluid-tight manner to the bottom element flanks.

4. collecting tube (300) according to claim 3, wherein the Bodenelementflanken (130) and the Bodenelementgrundfläche (140) and the cover element base surface outer walls of the collecting tube form.

A manifold (300) according to any one of the preceding claims, wherein the collar (360) surrounds an entire circumference of the passage opening (350).

6. collecting tube (300) according to one of the preceding claims, wherein the passage opening (350) has a rectangular shape.

A collection tube (300) according to any one of the preceding claims, comprising a plurality of through holes (350) disposed adjacent to one another along a longitudinal extent of the bottom element base (140).

8. A heat exchanger having the following features: a first manifold (300) according to one of the preceding claims; a second manifold according to one of the preceding claims; and at least one coolant tube (450), the coolant tube being disposed between the first manifold and the second manifold r and fluidly connected to the collar (360) of the first manifold and the collar of the second manifold.

9. Heat exchanger according to claim 8, with a heat exchanger surface for arranging at least one battery on the heat exchanger surface, wherein the heat exchanger surface via the at least one Kü hl medium r, at least a portion of the first manifold and / or at least a portion of the second manifold extends.

10. A method (500) for producing a header pipe (300) for a heat exchanger, comprising the following steps; Providing (510) a manifold floor element (100), the floor element having a floor element base (140) and two opposing floor element edges (130);

Providing (520) a U-shaped female mold (110) with two opposing legs, wherein each inner wall of the legs has a shoulder for forming a stop surface (200) for the bottom element flanks of the floor element;

Assembling (530) the die and the bottom member, wherein the bottom member flanks of the bottom member abut against the abutment surfaces of the die;

Aligning (540) the die and the bottom member with a cutting punch (120) such that the cutting punch is directed toward an outside of the bottom member base of the bottom member to form the at least one through hole (350);

Pressing (550) the cutting punch through the bottom member base to form the at least one through hole, wherein an edge portion of the header is turned to an inner wall of the header and abuts against the inner wall; and

Removing (560) the die and the punch from the floor element,