Indirect-Type Air Cooler

Abstract

The invention relates to an indirect-type air cooler by way of which compressed charge air for an internal-combustion engine is cooled by means of a liquid, wherein the air cooler is constructed from stacked pairs of plates having fins which are disposed therebetween, and the brazed stack is disposed in a housing into which the charge air flows, flows through the fins and exits the housing again. The charge air exchanges heat with the liquid which flows in the plate pairs and which is introducible into the plate pairs via at least one inlet and via inlet-side plate openings which are flush in the stack and is dischargeable via at least one outlet by means of flush outlet-side plate openings. In order to further improve the performance potential of the air cooler, at least one venting element which extends to the exterior through an opening of the housing is connected to a liquid space within the stack.

Claims

1. An indirect-type air cooler comprising: a brazed stack of plates arranged in plate pairs with air fins disposed between the plate pairs, the plate pairs enclosing a liquid space for a liquid coolant; a housing into which the brazed stack of plates is disposed, having an air inlet and an air outlet, wherein air passing through the housing from the air inlet to the air outlet passes over the air fins to exchange heat with the liquid coolant flowing through the liquid space; and a venting element extending through an opening of the housing such that a first end of the venting element is disposed exterior to the housing, a second end opposite the first end being fluidly connected to the liquid space.

2. The indirect-type air cooler of claim 1, further comprising: an inlet space portion of the liquid space, formed by a first plurality of openings in the plate pairs; an outlet space portion of the liquid space, formed by a second plurality of openings in the plate pairs; a plurality of liquid flow passages extending between and fluidly connecting the inlet space portion and the outlet space portion of the liquid space, each one of said liquid flow passages being arranged within one of the plate pairs, the plurality of liquid flow passages and the inlet and outlet space portions together defining the liquid space; a first connector piece extending through the housing and fluidly coupled to the inlet space portion; a second connector piece extending through the housing and fluidly coupled to the outlet space portion; and a third connector piece extending through the housing, wherein the third connector piece is part of the venting element and is arranged at the first end of the venting element.

3. The indirect-type air cooler of claim 2, wherein the first, second, and third connector pieces extend through a common side of the housing.

4. The indirect-type air cooler of claim 3, wherein said common side of the housing is a lower side of the housing when the air cooler is in operation.

5. The indirect-type air cooler of claim 2, wherein the venting element includes a venting pipe fluidly coupled to the third connector piece.

6. The indirect-type air cooler of claim 5, wherein the venting pipe is manufactured from plastic material.

7. The indirect-type air cooler of claim 5, wherein the venting pipe extends approximately the full height of the brazed stack of plates.

8. The indirect-type air cooler of claim 7, wherein a portion of the venting pipe is at a location above the brazed stack of plates when the air cooler is in operation.

9. The indirect-type air cooler of claim 8, wherein said portion of the venting pipe is between the first and second ends of the venting element.

10. The indirect-type air cooler of claim 5, wherein the venting pipe includes the second end of the venting element.

11. The indirect-type air cooler of claim 10, wherein the second end of the venting element is located within one of the inlet space portion and the outlet space portion.

12. The indirect-type air cooler of claim 11, wherein at least a portion of the venting pipe is arranged outside of the liquid space.

13. The indirect-type air cooler of claim 12, wherein at least a portion of the venting pipe is arranged in a free space between the inlet space portion and the outlet space portion.

14. The indirect-type air cooler of claim 11, wherein the entirety of the venting pipe is located within said one of the inlet space portion and the outlet space portion.

15. The indirect-type air cooler of claim 5, wherein the venting pipe is entirely located within the housing.

16. The indirect-type air cooler of claim 5, wherein the venting pipe is metallic and is joined to the stack of plates during the brazing of the stack.

17. The indirect-type air cooler of claim 2, wherein the second end of the venting element is located within one of the inlet space portion and the outlet space portion.

18. The indirect-type air cooler of claim 1, wherein the brazed stack of plates extends in a height direction and wherein the first end of the venting element is below the brazed stack of plates when the air cooler is in operation.

19. The indirect-type air cooler of claim 18, wherein at least a portion of the venting element extends above the brazed stack of plates.

20. The indirect-type air cooler of claim 18, wherein at least a portion of the venting element is arranged within the housing and extends approximately the full height of the brazed stack of plates.

21. The indirect-type air cooler of claim 20, wherein at least portion of the venting element within the housing is located external to the liquid space.

22. The indirect-type air cooler of claim 18, wherein the venting element comprises a metallic venting pipe that is joined to the stack of plates during the brazing of the stack.

23. The indirect-type air cooler of claim 22, wherein the metallic venting pipe is entirely located within the liquid space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 is a sectional elevation view of a first embodiment of an indirect-type air cooler according to the present invention.

[0030] FIG. 2 is a perspective view of the air cooler of FIG. 1.

[0031] FIG. 3 is an exploded perspective view of the air cooler of FIG. 1.

[0032] FIG. 4 is a sectional elevation view of a second embodiment of an indirect-type air cooler according to the present invention.

[0033] FIG. 5 is a perspective view of the air cooler of FIG. 4.

[0034] FIG. 6 is another perspective view of the air cooler of FIG. 4, with select elements removed from view.

[0035] FIG. 7 is an exploded perspective view of the air cooler of FIG. 4.

[0036] FIG. 8 is a schematic view illustrating a coolant circuit in which an air cooler according to the present invention is located

[0037] FIG. 9 is a perspective view of a third embodiment of an indirect-type air cooler according to the present invention.

[0038] FIG. 10 is a partially sectioned perspective view of the air cooler of FIG. 9.

[0039] FIGS. 11 and 12 are schematic diagrams of a venting element for use in an indirect-type air cooler according to embodiments of the present invention.

DETAILED DESCRIPTION

[0040] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

[0041] FIGS. 1 to 3 illustrate a first and possibly preferred exemplary embodiment in which venting is carried out within the liquid space 10 which is enclosed by the plate pairs 1a, 1b of the stack.

[0042] FIGS. 4 to 7 show another exemplary embodiment in which a venting element 6 is likewise connected to the mentioned liquid space 10, wherein the element 6 per se, however, is mainly disposed outside the stack. As compared with the first exemplary embodiment, this exemplary embodiment has the disadvantage that the venting element 6 has to extend through two plate openings 1c. In the first exemplary embodiment, only a single plate opening 1c is necessary.

[0043] FIGS. 9 and 10 show a further exemplary embodiment which, borrowing from that of FIGS. 4 to 7, has been refined in terms of design of the stack. In contrast to the preceding embodiments, the inlet 4 and the outlet 5 are located so as to be approximately in the center of the stack. However, the venting element 6 is between the inlet 4 and the outlet 5 also here.

[0044] FIGS. 1 to 7 and 9 and 10 show indirect-type air coolers by way of which compressed charge air for an internal-combustion engine is cooled by means of a liquid, wherein the air cooler is constructed from stacked pairs 1a, 1b of plates 1 having fins 2 which are disposed therebetween, and the brazed stack is disposed in a housing 3 into which the charge air flows, flows through the fins 2 and exits the housing 3 again. A corresponding inlet and an outlet for the charge air have the reference signs 31 and 32 in FIG. 2. The charge air exchanges heat with the liquid which flows in the plate pairs 1a, 1b. Via an inlet 4 and via inlet-side plate openings 1d which are flush in the stack, the liquid flows into the plate pairs 1a, 1b, and flows out again via an outlet 5 by means of flush outlet-side plate openings 1e.

[0045] A venting element 6 is connected to a liquid space 10 which is embedded in the plate pairs 1a, 1b of the stack. The venting element 6 further extends to the exterior through an opening 30 of the housing 3.

[0046] Depending on the design of the coolant circuit, the venting element 6 may be routed further by means of a line 61 to an expansion tank AGB, as is shown in FIG. 8.

[0047] With regard to the opening 30, it should also be stressed that this does not necessarily have to be a separate opening 30 for the venting element 6. In some embodiments, the opening 30 may also be unified with an inlet opening 4 or an outlet opening 5, which is present in the housing 3 in any case. It is to be essential only that the venting element 6 extends to the exterior of the housing 3.

[0048] In other cases it may already be sufficient for the venting element 6 to be incorporated in a return line for the liquid. However, it is unfavorable for the liquid which is enriched with gas bubbles to be fed to a pump 62 (FIG. 8). If incorporation in the return line is nevertheless planned, this should take place outside the housing 3, that is to say after the venting element 6 has traversed the housing opening 30, since such a design has advantages in terms of compactness and assembly.

[0049] A simple bypass 66 between an inlet space 10b which is described in more detail below and an outlet space 10a, disposed so as to be opposite the inlet 4 and the outlet 5, has a certain venting effect. This alternative, which could offer adequate results for many applications, is shown in FIG. 12 and described in more detail further below.

[0050] The venting element 6 comprises at least one venting pipe. There may also be a plurality of pipes. Most figures show that a connector element, such as a connector piece 60, also belongs to the venting element 6.

[0051] FIGS. 1 to 7 show the air cooler having the mentioned inlet-side and outlet-side plate openings 1d, 1e, which are located in protrusions on a plate side and which between the protrusions provide a free space along the height of the stack.

[0052] Such a preferred design embodiment allows for the venting element 6 to be routed through the free space 7 outside the stack, such that no additional installation space is required. This is shown in FIGS. 4 to 7.

[0053] As mentioned, the first exemplary embodiment according to FIGS. 1 to 3 at present could be seen as being preferred. The venting element 6 has been disposed within the stack in a preferred liquid space 10b. A plate opening 1c for the venting element 6 is located in a base plate 9. The liquid space 10b is an inlet space for the liquid. Said liquid space 10b is formed by the plate inlet openings 1d which are flush in the stack. Accordingly, an outlet space 10a is formed by the plate outlet openings 1e which are flush in the stack. The inlet space 10b and the outlet space 10a are merely part of an entire liquid space 10 which is embedded in the plate pairs.

[0054] It is also highly preferable for one end of the venting element 6 to be disposed opposite the outlet 4, as is shown, for example, in FIG. 1 which illustrates a cross section through the air cooler, specifically in the region of the inlet space 10b and of the outlet space 10a.

[0055] The venting pipe as part of the venting element 6 may at least be a conjointly brazed component part of the stack.

[0056] As opposed thereto, the venting element 6 may also be manufactured from plastics or from another material. This element 6, which may be composed integrally of the pipe and the connector piece 60, is then conjointly installed in the housing 3 in the process of the assembly of the brazed stack.

[0057] The housing 3 is preferably a plastics housing. According to the images, said housing 3 is composed of a trough-like part and a planar cover part which is connected to the former. In embodiments which are not shown, these parts are two trough-like parts which are interconnected halfway up the stack. In particular, the housing 3 is an intake pipe for an internal combustion engine, which for this purpose may be designed in a different manner from the one shown. For example, said intake pipe may have a plurality of outlets 32 for the cooled charge air, which are assigned to individual cylinders of the internal combustion engine.

[0058] As is often the case, a prescribed installation position of the air cooler in an engine bay (not shown) of a motor vehicle is provided. On account thereof, the inlet 4 and the outlet 5 for the liquid have to be located on a lower side of the air cooler, or on the corresponding lower housing side, respectively. The already mentioned connector element 60 of the vent has also to be located on the lower side. In these cases which are shown, the venting element 6 extends along approximately the height of the stack. The opening 30 in the housing 3 and further openings for the inlet 4 and the outlet 5 are disposed in the lower side of the housing 3.

[0059] A connector piece 40, 50, 60 is provided in all of the openings. According to FIG. 5, a single common flange plate 33 may be provided for the three connector pieces.

[0060] The second exemplary embodiment provides a bulge 8 in the upper side of the housing 3, as is shown in FIGS. 4 and 7. The bulge 8 ensures the already mentioned compactness of the air cooler. The two mentioned plate openings 1c are located at the bottom in the base plate 9 and in an upper plate, as is shown by FIG. 4, for example.

[0061] FIG. 9 shows a view of the stack of a further exemplary embodiment, and FIG. 10 shows the same stack but with a section through the inlet-side plate openings 1d. In this exemplary embodiment the illustration of the housing 3 has been dispensed with. Therefore, the opening 30 in the housing 3, which in fact exists, is also omitted. The arrows included in the drawing for the throughflow on the liquid side clarify the mode of functioning of this embodiment. The stream which enters into the liquid space 10 is divided into two part-streams T1, T2, which is intended to be shown by the two arrows.

[0062] As is furthermore derived from the illustrations, on account of the central inlet 4 and the central outlet 5, there is presently another configuration of the plates 11. However, the stack likewise has plate pairs 1a, 1b, and also fins 2 which are disposed between the plate pairs 1a, 1b. This embodiment also has the mentioned free space 7 between the inlet-side and the outlet-side plate openings 1d, 1e. The free space 7 serves for positioning the venting element 6.

[0063] In a further embodiment (not shown) having plates, as in FIGS. 9 and 10, the venting element 6 has been disposed so as to be largely within the liquid space 10.

[0064] FIG. 11 is a rather abstract diagram which is intended to show that the venting element 6 may be configured so as to simultaneously extract air bubbles from various points 10a, 10b of the liquid space 10.

[0065] FIG. 12 is another abstract diagram which is intended to show that the venting element 6 may be configured so as to be merely a bypass 66 between two liquid part-spaces.

[0066] FIG. 11 may clarify that the effectiveness of venting can be further improved by a corresponding design of the venting element 6. The venting element 6 may extend into a plurality of the liquid space parts and simultaneously vent all the part-spaces. Only the part-spaces 10a and 10b are shown.

[0067] FIG. 12 shows that a certain venting effect may be achieved by merely one single bypass 66 which directly, that is to say along a short path, connects a liquid entry space 10b to a liquid exit space 10a of the air cooler. The two arrows to the left and to the right of the bypass 66 are intended to indicate the same. This allows gas inclusions which enter into the entry space 10b to be directly conveyed into the exit space 10a, which means that said gas bubbles need not flow through the air cooler. Since the position of the bypass 66 should be opposite the entry 4 and the exit 5, it is sensible for a bulge 8 to also be planned in the upper housing wall 3 for this purpose.

[0068] Finally, in FIG. 12, a further pipe 67, which branches off from the bypass 66 and which can be routed through the opening 30, which is located here in the bulge 8 of the housing 3, to the exterior to the expansion tank AGB has been added by means of dashed lines. On account thereof, the venting effect is significantly improved in relation to the single bypass 66 as described in the preceding paragraph, since gas inclusions may be extracted by means of the pipe 67 both from the space 10a as well as from the space 10b. The provision of the pipe 67 has caused the bypass function to assume a background role.

[0069] Features which are not shown in the diagrams according to FIGS. 11 and 12 correspond to those features which have been shown in the other figures and have previously already been described in detail.

[0070] Various alternatives to the certain features and elements of the present invention are described with reference to specific embodiments of the present invention. With the exception of features, elements, and manners of operation that are mutually exclusive of or are inconsistent with each embodiment described above, it should be noted that the alternative features, elements, and manners of operation described with reference to one particular embodiment are applicable to the other embodiments.

[0071] The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention.