Heat exchanger

Abstract

The present disclosure relates to a heat exchanger, for example an indirect charge air cooler for an internal combustion engine. The heat exchanger includes a heat exchanger block including a first channel system for a first fluid and a second channel system for a second fluid that is fluidically separate from the first channel system. Two opposite side parts and two opposite end parts are structured and arranged to fluidically delimit the second channel system. At least one frame part is connected with a respective edge of the two side parts and of the two end parts. An air inlet box is connected to the at least one frame part via a seal. The heat exchanger block has a width b1 and a height h1, and the seal has a width b.sub.2 and a height h.sub.2, where b.sub.1≥b.sub.2 and h.sub.1≥h.sub.2.

Claims

1. A heat exchanger for an internal combustion engine, comprising: a heat exchanger block including a first channel system for a first fluid and a second channel system, fluidically separate from the first channel system, for a second fluid, two opposite side parts and two opposite end parts, structured and arranged to fluidically delimit the second channel system, wherein the heat exchanger block has a width b1 and a height h1, at least one frame part, the at least one frame part connected in at least one of a force-fitting manner and a materially bonded manner with a respective edge of the two side parts and with a respective edge of the two end parts, and an air inlet box connected to the at least one frame part via a seal, wherein the seal is configured as a rectangular ring seal and has a width b.sub.2 and a height h.sub.2, and wherein b.sub.1≥b.sub.2 and h.sub.1≥h.sub.2, so that the seal is maximally as wide and as high as the heat exchanger block, wherein the at least one frame part has a first mount structured and arranged to receive an edge of the air inlet box, and the seal is arranged in the first mount, and wherein the air inlet box has an outwardly projecting first edge portion that is engaged from behind by the respective edge of at least one of the two side parts or by the frame part, and the seal is further configured as an axial seal.

2. The heat exchanger according to claim 1, wherein one of: the first mount has a deep receiving region and a raised receiving region relative to the deep receiving region, wherein the seal configured as the axial seal is clamped between the first edge portion of the air inlet box and the deep receiving region of the first mount, and wherein the edge of the air inlet box has a second edge portion structured as a stop that supports the edge of the air inlet box on the raised receiving region, and the first mount has a flat receiving region, wherein the seal configured as the axial seal is clamped between the first edge portion of the air inlet box and the flat receiving region of the first mount, and wherein the edge of the air inlet box has a second edge portion structured as a stop that supports the edge of the air inlet box on the flat receiving region.

3. The heat exchanger according to claim 1, wherein the frame part has an edge that is S-shaped in cross-section.

4. The heat exchanger according to claim 3, wherein the edge has a second mount facing the heat exchanger block, and wherein a respective one of the two side parts or a respective one of the two end parts is fixed in the second mount.

5. The heat exchanger according to claim 4, wherein the respective edge of at least one of the respective side part and the respective edge of the respective end part is bent around and has a double edge region that is fixed in the second mount.

6. The heat exchanger according to claim 3, wherein the edge has a free leg facing the air inlet box, and wherein the air inlet box is fixed to the at least one frame part via the free leg.

7. A heat exchanger for an internal combustion engine, comprising: a heat exchanger block including a first channel system for a first fluid and a second channel system, fluidically separate from the first channel system, for a second fluid, two opposite side parts and two opposite end parts, structured and arranged to fluidically delimit the second channel system, wherein the heat exchanger block has a width b1 and a height h1, at least one frame part, the at least one frame part connected in at least one of a force-fitting manner and a materially bonded manner with a respective edge of the two side parts and with a respective edge of the two end parts, an air inlet box connected to the at least one frame part via a seal, wherein the seal is configured as a rectangular ring seal and has a width b.sub.2 and a height h.sub.2, and wherein b.sub.1≥b.sub.2 and h.sub.1≥h.sub.2, so that the seal is maximally as wide and as high as the heat exchanger block, wherein one of: the heat exchanger block includes a plurality of tubes that define the first channel system, and two collectors are provided fluidically separate from the second channel system, and wherein at least one of the two collectors includes a base part and a box part together delimiting a collecting chamber fluidically connected to at least one of the plurality of tubes, and the heat exchanger block includes a plurality of plates that define the first channel system.

8. The heat exchanger according to claim 7, wherein the at least one frame part has a first mount structured and arranged to receive an edge of the air inlet box.

9. The heat exchanger according to claim 8, wherein the seal is arranged in the first mount.

10. The heat exchanger according to claim 9, wherein: the air inlet box has an outwardly projecting first edge portion with an undercut groove, at least one of a respective side part of the two side parts and a respective end part of the two end parts has a lug that surrounds the first edge portion of the air inlet box and engages into the undercut groove in a mounted state, the seal is further configured as a radial seal, the first mount has an outer groove wall, a groove base and a curved inner groove wall, and the air inlet box has a second edge portion provided on the edge, the second edge portion structured and arranged complementary to the groove base and to the inner groove wall of the first mount.

11. The heat exchanger according to claim 10, wherein the seal configured as the radial seal is clamped in the mounted state between the outer groove wall and the first edge portion and the second edge portion.

12. The heat exchanger according to claim 7, wherein the heat exchanger block includes the plurality of tubes, and wherein at least one of: at least one of the base part and the box part define at least one of the two end parts, and the second channel system includes a plurality of heat exchanger elements arranged therein, and wherein the plurality of heat exchanger elements are in heat-transmitting contact with at least one of the plurality of tubes.

13. The heat exchanger according to claim 12, wherein the plurality of heat transfer elements comprise ribs.

14. An internal combustion engine, comprising: a heat exchanger configured as a charge air cooler, the heat exchanger including: a heat exchanger block including a first channel system for a first fluid and a second channel system for a second fluid, the second channel system fluidically separate from the first channel system; two opposite side parts and two opposite end parts, structured and arranged to fluidically delimit the second channel system; at least one frame part connected in at least one of a force-fitting manner and a materially bonded manner with a respective edge of the two side parts and with a respective edge of the two end parts; an air inlet box connected to the at least one frame part via a seal; wherein the heat exchanger block has a width b1 and a height h1; wherein the seal is configured as a rectangular ring seal and has a width b.sub.2 and a height h.sub.2, and wherein b.sub.1≥b.sub.2 and h.sub.1≥h.sub.2, so that the seal is maximally as wide and as high as the heat exchanger block; and wherein the at least one frame part has a first mount structured and arranged to receive an edge of the air inlet box, and an S-shaped edge providing a second mount facing the heat exchanger block.

15. The internal combustion engine according to claim 14, wherein the seal is arranged in the first mount.

16. The internal combustion engine according to claim 15, wherein the air inlet box has an outwardly projecting first edge portion that is engaged from behind by the respective edge of at least one of the two side parts or by the frame part; and wherein the seal is further configured as an axial seal.

17. The internal combustion engine according to claim 16, wherein the first mount has a deep receiving region and a raised receiving region relative to the deep receiving region, wherein the seal configured as the axial seal is clamped between the first edge portion of the air inlet box and the deep receiving region of the first mount, and wherein the edge of the air inlet box has a second edge portion structured as a stop that supports the edge of the air inlet box on the raised receiving region.

18. The internal combustion engine according to claim 16, wherein the first mount has a flat receiving region, wherein the seal configured as the axial seal is clamped between the first edge portion of the air inlet box and the flat receiving region of the first mount, and wherein the edge of the air inlet box has a second edge portion structured as a stop that supports the edge of the air inlet box on the flat receiving region.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) There are shown here, respectively diagrammatically,

(2) FIG. 1 a heat exchanger in a view according to the prior art,

(3) FIG. 2 a side view onto the heat exchanger shown according to FIG. 1 according to the prior art,

(4) FIG. 3 a sectional illustration through the heat exchanger according to the prior art along the section plane A-A,

(5) FIG. 4 a detail illustration of FIG. 3,

(6) FIG. 5 a view onto a heat exchanger according to the invention,

(7) FIG. 6 a side view onto the heat exchanger according to the invention,

(8) FIG. 7 a sectional illustration along the section plane B-B,

(9) FIG. 8 a detail illustration of FIG. 7,

(10) FIG. 9 a detail illustration of FIG. 8,

(11) FIG. 10 a detail illustration as in FIG. 9, but not with an axial seal, but rather with a radial seal,

(12) FIGS. 11A to 11C different method steps for production a heat exchanger according to the invention with tubes in the heat exchanger block,

(13) FIGS. 12A to 12E individual method steps for producing a heat exchanger according to the invention with a heat exchanger block having plates,

(14) FIG. 13 a side view onto a heat exchanger according to the invention,

(15) FIG. 14 a sectional illustration through a frame part,

(16) FIG. 15 a sectional illustration in a connection region of an air inlet box with a frame part and with a side part using a seal which is rectangular in cross-section,

(17) FIG. 16 a sectional illustration analogous to FIG. 15, but using a seal which is round in cross-section,

(18) FIG. 17 a partial section illustration along the section plane A-A of FIG. 13,

(19) FIG. 18 an illustration as in FIG. 16, but with dimensioning,

(20) FIG. 19 an illustration as in FIG. 15, but with dimensioning.

DETAILED DESCRIPTION

(21) According to FIGS. 5 to 7, 12e and 13 and 17, a heat exchanger 1 according to the invention, which can be configured for example as a charge air cooler or as a coolant cooler, configured in the present case as a charge air cooler, has a heat exchanger block 2 with a first channel system 3 for a first fluid, coolant for example, and a second channel system 4, fluidically separate from the first channel system 3, for a second fluid, charge air or air for example. Two opposite side parts 5 and two opposite end parts 6 are also provided for the fluidic delimiting of the second channel system 4. The heat exchanger block 2 has here a width b.sub.1 and a height h.sub.1. Resulting herefrom is a cross-sectional area Q.sub.1 of the heat exchanger block 2 with Q.sub.1=b.sub.1×h.sub.1.

(22) Furthermore, the heat exchanger 1 according to the invention has at least one frame part 7 (cf. also FIG. 14), which is connected to a respective edge 8 of the side parts 5 and to a respective edge of the end parts 6 in a force-fitting and/or materially bonded manner. An air inlet box 9 is arranged on the frame part 7 and is connected in a fluid-transmitting manner with the second channel system 4, wherein the air inlet box 9 is connected to the frame part 7 via a seal 13, wherein the seal 13 is configured as a ring seal which is rectangular or round in cross-section and has a width b.sub.2 and a height h.sub.2, so that a cross-sectional area Q.sub.2=b.sub.2×h.sub.2 results herefrom. According to the invention here b.sub.1≥b.sub.2 and h.sub.1≥h.sub.2, so that the seal 13 is maximally as wide and as high as the heat exchanger block 2. Hereby, it can be achieved that the air inlet box 9 projects distinctly less far beyond the heat exchanger block 2 than in the case of heat exchangers 1′ of the prior art, and in particular even remains within the cross-sectional area of the heat exchanger block 2 (cf. in particular FIGS. 5 to 8).

(23) Observing the heat exchanger 1′, known from the prior art, according to FIGS. 1 to 4, the proportions are thus entirely the other way round, so that the height h.sub.2 of the seal 13′ is greater than the height h.sub.1 of the heat exchanger block 2′, whereby an interface between the air inlet box 9′ and the heat exchanger block 2′, in particular its side parts 5′, lies outside the cross-section Q.sub.1 of the heat exchanger block 2′. This can be clearly seen in particular from FIGS. 1 and 3 and 4.

(24) In FIGS. 1 to 4, the respective components of the heat exchanger 1′, known from the prior art, are designated with the same reference numbers, but additionally with an apostrophe, in order to be able to clearly distinguish between the heat exchanger 1′ of the prior art and the heat exchanger 1 according to the invention.

(25) By comparison, the heat exchanger 1 according to the invention in accordance with FIGS. 5 and 7 and 8 behaves entirely differently, because here a connection site lies between the air inlet box 9 and the heat exchanger block 2 preferably within the cross-sectional area Q.sub.1 of the heat exchanger block 2. Hereby, installation space can be saved in the region of the air inlet box 9 or on the opposite side in the region of a flange 10, or else the heat exchanger block 2 can be configured higher with regard to its height h.sub.1 and thereby for example can have more tubes 26 for the heat exchange, whereby its efficiency can be increased.

(26) Observing FIGS. 8 to 10 more closely, it can be seen that the frame part 7 has a first mount 11, in which an edge 12 of the air inlet box 9 is received. This first mount 11 lies here in the heat exchanger 1′ known from the prior art according to FIG. 4 outside the heat exchanger block 2′, whereas in the heat exchanger 1 according to the invention in accordance with FIGS. 5 to 12 it lies within the heat exchanger block 2, so that the seal 13 in this case has a smaller height h.sub.2 than the heat exchanger block 2 with its height h.sub.1 and thereby the air inlet box 9 in this case has a smaller height than the heat exchanger block 2. In the first mount 11, the seal 13 is arranged here, which brings about a sealing of the second channel system 4 with respect to the environment.

(27) In FIGS. 9 and 10 two different seal designs of the heat exchanger 1 according to the invention are now described.

(28) According to FIG. 9, the air inlet box 9 has an outwardly projecting first edge portion 14, which is engaged behind by at least one edge 8 of the at least one side part 5. The engaging behind of the edge 8 of the side part 5 is brought about here via a crimp connection 15. In this case, the seal 13 is configured as an axial seal 13a. The first mount 11 has a deep receiving region 16 and a receiving region 17 which is raised with respect thereto, wherein the axial seal 13a is clamped between the first edge portion 14 of the air inlet box 9 and the deep receiving region 16 of the first mount 11, and wherein the edge 12 of the air inlet box 9 has a second edge portion 18, which is configured as a stop and can be supported via the edge 12 of the air inlet box 9 at the raised receiving region 17. In the same way or alternatively hereto, a support of the second edge portion 14 can of course also take place on an outer edge of the first mount 11.

(29) If one observes in this respect the embodiment according to FIG. 10, the air inlet box 8 thus also has here an outwardly projecting first edge portion 14 which, however, unlike the first edge portion 14 according to FIG. 9, has an undercut groove 19. At least one side part 5 or respectively at least one end part 6 has here a lug 20, which in the mounted state surrounds the first edge portion 14 of the air inlet box 9 and at the same time engages into the undercut groove 19. The seal 13 is configured here as a radial seal 13b. The first mount 11 has, in addition, an outer groove wall 21, a groove base 22 and a curved inner groove wall 23, wherein the edge 12 of the air inlet box 9 has a second edge portion 24, which is configured in a complementary manner to the groove base 22 and to the inner curved groove wall 23. In this case, the seal 13, configured as radial seal 13b, is therefore clamped in the installed state between the outer groove wall 21 and the first and second edge portion 14, 24 of the edge 12 of the air inlet box 9.

(30) The frame part 7 can be pressed with the respective edge 8 of the side parts 5 and with a respective edge of the end parts 6, and soldered, wherein the edges 8 are received either as for example in FIG. 4, 13-19 in a second mount 25, or lie externally on the edge 12 of the air inlet box 9 at least in certain areas (cf. FIG. 5-12).

(31) The heat exchanger block 2 of the heat exchanger 1 according to the invention can have for example tubes 26, in particular flat tubes, which form the first channel system 3. Furthermore, two collectors 27, fluidically separate from the second channel system 4, are provided, at least one of which collectors has a base part 28 and a box part 29, which delimit a collecting chamber of the collector 27 which is fluidically connected with at least one of the tubes 26. The base part 28 and/or the box part 29 can form the end part 6 here. In the second channel system 4, furthermore heat exchanger elements 30, for example rib structures, can be arranged, which are in heat-transmitting contact with at least one of the tubes 26 and thereby improve the heat exchange.

(32) Such a heat exchanger 1, having tubes 26, is shown with regard to production for example in the method steps 11 a to 11c, wherein according to FIG. 11 a firstly the individual tubes 26, for example flat tubes, with corresponding heat exchanger elements 30, for example corresponding rib structures. According to FIG. 11b, the frame parts 7 are then arranged laterally, after which according to the method step in FIG. 11c the end parts 6 and the side parts 5 are arranged. In this case, the end part 6 is configured as a base part 28, wherein the side part 5 is connected with its edge 8 and the end part 6, i.e. here the base part 28, is connected by its edge with the frame part 7. In the following step, the joining with the air inlet box 9 or respectively with the flange 10 takes place.

(33) According to FIG. 12, the individual method steps for the production of a heat exchanger 1 according to the invention are shown in an embodiment of the heat exchanger block 2 with plates 31 and with heat exchanger elements 30 arranged therebetween. According to FIG. 12a, firstly the heat exchanger block 2 with plates 31 and heat exchanger elements 30, for example corrugated ribs, is stacked, after which in the method step 12b the frame parts 7 are put on. Subsequently, the side parts 5 according to the method step 12c and the end parts 6 according to the method step 12d are put on. In the last method step 12e, the air inlet box 9 and the flange 10 is now connected with the side parts 5 or respectively the end parts 6, wherein it can also be seen here that the height of the air inlet box 9 is smaller than the height h.sub.1 of the heat exchanger block 2.

(34) Observing 13-19, it can be seen that the first mount 11 has a flat receiving region 16a, wherein the axial seal 13a is clamped between the first edge portion 14 of the air inlet box 9 and the receiving region 16a of the first mount 11, and wherein the edge 12 of the air inlet box 9 has a second edge portion 18, which is configured as a stop via which the edge 12 of the air inlet box 9 is able to be supported on the flat receiving region 16a.

(35) According to FIGS. 13 to 19, it can be further seen that the frame part 7 has an edge 33 which is S-shaped in cross-section. The S-shaped edge 33 has a second mount 25, facing the heat exchanger block 2, in which mount the side part 5 or the end part 6 is fixed, in particular soldered. The edge 8 of the side part 5 and/or the edge of the end part 6 is, in addition, bent around and has a double edge region 34, via which it is fixed in the second mount 25, in particular pressed and/or soldered. Via the double edge region 34 with double wall thickness, a particularly rigid and resilient connection can be created.

(36) The S-shaped edge 33 on the frame part 7 has in addition a free leg 35, facing the air inlet box 9, via which the air inlet box 9 is fixed on the frame part 7. As a whole, the frame part 7 has four legs 35, which are bent slightly outwards at their free end in order to facilitate an introduction of the edge 12 of the air inlet box 9.

(37) Observing FIGS. 18 and 19, example dimensions X1, X2, Y1, Y2 and Z can be seen there, wherein by way of example the following measurements can be assumed: X1=3 mm, X2=6.3 mm, Y1=2.9 mm and Y2=5.4 mm. A further important measurement is the distance Z between the frame part 7 and the heat exchanger block 2, wherein the following is to apply: Z<10 mm, in order to prevent a breaking of the side part 5 under compressive stress.

(38) All the embodiments of the heat exchanger 1 according to the invention have in common here that a cross-sectional area Q.sub.2 of the seal 13 and thereby also of the air inlet box 9 is smaller or maximally as great as a cross-sectional area Q.sub.1 of the heat exchanger block 2. Hereby, installation space can be saved in particular in the region of the air inlet box 9, or with the use of an air inlet box 9 of the same size, a size of the heat exchanger block 2 can be increased and thereby the efficiency of the heat exchanger 1 can be increased. Such a heat exchanger 1 is usually used in the field of an internal combustion engine 32.