Fresh air supply device of an international combustion engine

Abstract

A fresh air supply device for an internal combustion engine may include a suction module for conducting supercharged fresh air and a charge air cooler arranged in the suction module for cooling the supercharged fresh air. The suction module includes a housing with a charge air inlet for uncooled charge air and a charge air outlet for cooled charge air. The housing has a cooler shell, which may include the charge air inlet containing the charge air cooler and an assembly opening. With respect to a flow direction of the charge air the assembly opening may be arranged downstream of the charge air cooler and through which the charge air cooler is inserted into the cooler shell. The housing has a connecting shell, which includes the charge air outlet and which in the region of the assembly opening is attached to the cooler shell in an air-tight manner.

Claims

1. A fresh air supply device for an internal combustion engine, comprising: a suction module for conducting supercharged fresh air, a charge air cooler arranged in the suction module for cooling the supercharged fresh air, wherein the suction module includes a housing with a charge air inlet for uncooled charge air and a charge air outlet for cooled charge air, the housing includes a cooler shell, which includes the charge air inlet containing the charge air cooler and an assembly opening, which with respect to a flow direction of the charge air the assembly opening is arranged downstream of the charge air cooler and through which the charge air cooler is inserted into the cooler shell, and the housing has a connecting shell, which includes the charge air outlet and which in the region of the assembly opening is attached to the cooler shell in an air-tight manner, wherein the cooler shell in a region that is distal from the assembly opening includes at least one receiving contour that is open towards the assembly opening, into which a leading plug contour of the charge air cooler dips in the assembly direction when inserting the charge air cooler; wherein at least one tensile anchor is integrally formed on an onflow side of the cooler shell, which with respect to the flow direction of the charge air is arranged on an onflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the onflow side of the charge air cooler; wherein the at least one tensile anchor is configured as a guide blade for the charge air, which extends curved in an inlet region having the charge air inlet and redirects charge air coming from the charge air inlet in the direction of the charge air cooler; wherein the connecting shell contacts the cooler shell via a tongue and groove connection; wherein the cooler shell encloses the charge air cooler in a circumferential direction on three sides, while a fourth side is arranged in the region of the assembly opening; and wherein in the region of the charge air outlet a flap device is attached to the connecting shell via a closed circumferential tongue and groove connection.

2. The device according to claim 1, wherein the charge air cooler includes a plurality of tubes which in their longitudinal direction run parallel to one another and a plurality of cooling fins which are connected to the tubes in a heat-transferring manner, wherein an assembly direction, in which the charge air cooler is inserted into the cooler shell through the assembly opening, runs perpendicularly to the longitudinal direction of the tubes.

3. The device according to claim 2, wherein at least one tensile anchor is integrally formed on an outflow side of the connecting shell, which with respect to the flow direction of the charge air is arranged on an outflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the outflow side of the charge air cooler.

4. The device according to claim 2, wherein the main flow direction of the charge air in the charge air cooler runs parallel to and is oriented opposite of the assembly direction.

5. The device according to claim 4, wherein the cooler shell includes at least one fixing rib in a region that is distal from the assembly opening which extends parallel to the longitudinal direction of the tubes, the at least one fixing rib projecting opposite to the assembly direction and into the charge air cooler between adjacent tubes.

6. The device according to claim 2, wherein at least one of the charge air cooler includes an inlet connection for feeding in a coolant, the inlet connection formed by an inlet connector that is separate with respect to the charge air cooler and the suction module, the inlet connection projecting into an inlet opening formed on the charge air cooler through an inlet passage opening formed in the housing of the suction module, and the charge air cooler includes an outlet connection for discharging a coolant, the outlet connection formed by an outlet connector that is separate with respect to the charge air cooler and the suction module, the outlet connector projecting into an outlet opening formed on the charge air cooler through an outlet passage opening formed in the housing.

7. The device according to claim 1, wherein the connecting shell includes at least one stop contour facing the assembly opening, against which a support contour of the charge air cooler comes to bear opposite to the assembly direction.

8. The device according to claim 1, wherein on the connecting shell at least one tensile anchor is integrally formed on an outflow side, which with respect to the flow direction of the charge air is arranged on an outflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the outflow side of the charge air cooler.

9. The device according to claim 1, wherein at least one of: (1) the charge air cooler includes an inlet connection for feeding in a coolant, the inlet connection formed by an inlet connector that is separate with respect to the charge air cooler and with respect to the suction module, the inlet connector projecting into an inlet opening formed on the charge air cooler through an inlet passage opening formed in the housing of the suction module; and (2) the charge air cooler includes an outlet connection for discharging a coolant, the outlet connection formed by an outlet connector that is separate with respect to the charge air cooler and with respect to the suction module, the outlet connector projecting into an outlet opening formed on the charge air cooler through an outlet passage opening formed in the housing.

10. The device according to claim 1, wherein at least one of the suction module is plastic and the charge air cooler is metal.

11. The device according to claim 1, wherein the main flow direction of the charge air in the charge air cooler runs parallel to the assembly direction, and is orientated opposite the assembly direction.

12. The device according to claim 1, wherein the cooler shell in a region that is distal from the assembly opening includes at least one fixing rib, which extends parallel to the longitudinal direction of the tubes and projects opposite to the assembly direction, the at least one fixing rib projects into the charge air cooler between adjacent tubes.

13. A fresh air supply device for an internal combustion engine, comprising: a suction module for conducting supercharged fresh air, the suction module including a housing with a charge air inlet for uncooled charge air and a charge air outlet for cooled charge air, and a charge air cooler arranged in the suction module for cooling the supercharged fresh air, wherein the housing includes a cooler shell, which includes the charge air inlet containing the charge air cooler and an assembly opening, which with respect to a flow direction of the charge air the assembly opening is arranged downstream of the charge air cooler and through which the charge air cooler is inserted into the cooler shell, and the housing has a connecting shell, which includes the charge air outlet and which in the region of the assembly opening is attached to the cooler shell in an air-tight manner, wherein the connecting shell contacts the cooler shell via a tongue and groove connection, wherein at least one tensile anchor is integrally formed on an outflow side of the connecting shell, which with respect to the flow direction of the charge air is arranged on an outflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the outflow side of the charge air cooler, wherein at least one tensile anchor is integrally formed on an onflow side of the cooler shell, which with respect to the flow direction of the charge air is arranged on an onflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the onflow side of the charge air cooler, wherein the at least one tensile anchor on the onflow side of the cooler shell is configured as a guide blade for the charge air, which extends curved in an inlet region having the charge air inlet and redirects charge air coming from the charge air inlet in the direction of the charge air cooler, wherein the cooler shell in a region that is distal from the assembly opening includes at least one receiving contour that is open towards the assembly opening, into which a leading plug contour of the charge air cooler dips in the assembly direction when inserting the charge air cooler, wherein the cooler shell encloses the charge air cooler in a circumferential direction on three sides, while a fourth side is arranged in the region of the assembly opening, wherein the cooler shell in a region that is distal from the assembly opening includes at least one fixing rib, which extends parallel to the longitudinal direction of the tubes and projects opposite to the assembly direction, the at least one fixing rib projects into the charge air cooler between adjacent tube, and wherein in the region of the charge air outlet a flap device is attached to the connecting shell via a closed circumferential tongue and groove connection.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) It shows, in each case schematically,

(2) FIG. 1 an isometric view of a fresh air supply device,

(3) FIG. 2 an isometric sectional view of the fresh air supply device,

(4) FIG. 3 an isometric sectional view of a cooler shell of the fresh air supply device,

(5) FIG. 4 an enlarged detail IV in FIG. 3,

(6) FIG. 5 another isometric sectional view of the cooler shell,

(7) FIG. 6 a further isometric sectional view of the cooler shell,

(8) FIG. 7 an enlarged detail VII from FIG. 6,

(9) FIG. 8 a greatly simplified sectional view of a further embodiment of the fresh air supply device.

DETAILED DESCRIPTION

(10) According to the FIGS. 1 to 8, a fresh air supply device 1, with the help of which fresh air can be fed to an internal combustion engine, comprises a suction module 2, with the help of which supercharged fresh air can be conducted. The suction module 2 thus has an adequate pressure stability for charge air. The suction module 2 is located at an end of the fresh air supply device 1 assigned to the internal combustion engine and is connected to a charge air duct on the inlet side, which leads to a supercharging device, in particular to a compressor of an exhaust gas turbocharger. In the suction module 2, a charge air cooler 3 is arranged, with the help of which the supercharged fresh air, i.e. the charge air can be cooled. The suction module 2 has a housing 4 or is formed by a housing 4. The housing 4 comprises a charge air inlet 5 for uncooled charge air and a charge air outlet 6 for cooled charge air.

(11) The housing 4 comprises a cooler shell 7 and a connecting shell 8, which are assembled in a suitable manner, thus forming the housing 4. The housing 4 in the shown case is thus designed in two parts, so that it substantially only comprises the cooler shell 7 and the connecting shell 8.

(12) The cooler shell 7 comprises the charge air inlet 5 and contains the charge air cooler 3. Furthermore, the cooler shell 7 comprises an assembly opening 9, which with respect to the flow direction of the charge air is arranged downstream of the charge air cooler 3. The assembly opening 9 is dimensioned so that the charge air cooler 3 can be inserted into the cooler shell 7 through the assembly opening 9. The connecting shell 8 in the embodiment of the FIGS. 1 to 7 comprises the charge air outlet 6. In addition, the connecting shell 8 is attached to the cooler shell 7 in the region of the assembly opening 9 in an air-tight manner. The charge air thus flows from the charge air inlet 5 within the cooler shell 7 as far as to the assembly opening 9 where it enters the connecting shell 8, leaving it via the charge air outlet 6.

(13) The charge air cooler 3 is designed as a tube-fin heat exchanger and comprises a plurality of tubes 10 running parallel to one another in their longitudinal direction. In addition to this, a plurality of cooling fins 11 which are only indicated in FIG. 2 are provided, which are connected to the tubes 10 in a heat-transferring manner. Practically, tubes 10 and cooling fins 11, alternating one another, are stacked onto one another. An assembly direction 12, which is indicated by an arrow for example in FIG. 2, in which the charge air cooler 3 can be inserted into the cooler shell 7 through the assembly opening 9 runs perpendicularly to the longitudinal direction of the tubes 10, which is indicated for example in FIG. 2 by an arrow 13.

(14) As is evident in the FIGS. 2 and 3 and in particular FIG. 4, the cooler shell 7 can comprise at least one receiving contour 14 in a region that is distal from the assembly opening 9, i.e. on an onflow side of the charge air cooler 3 on the air side, which is open towards the assembly opening 9. Practically, the charge air cooler 3 now comprises a plug contour 15 that is complementary to the receiving contour 14, which is located on the onflow side of the charge air cooler 3, so that it leads during the inserting of the charge air cooler 3 into the cooler shell 7. In the assembled state, the respective plug contour 15 dips into the associated receiving contour 14 in the assembly direction 12. The receiving contour 14 and the plug contour 15 in this case interact as a tongue and groove connection. The plug contour 15 is formed through an edge of an end plate 16 on the onflow side, which delimits a cooler block formed of the tubes 10 and the cooling fins 11 on two sides facing away from one another. Through the positively joined engagement between plug contour 15 and receiving contour 14 an efficient bypass seal is obtained, which obstructs a flow bypassing the charge air cooler 3 with respect to the charge air. Since in this case two such receiving contours 14 and plug contours 15 are present, a bypass seal for the charge air cooler 3 can be realised on both sides, i.e. on both end plates 16.

(15) As is evident in particular from FIG. 2, the connecting shell 8 can comprise at least one stop contour 17, which faces the assembly opening 9. Following the inserting of the charge air cooler 3 into the cooler shell 7, the connecting shell 8 is attached to the cooler shell 7. In the process, the respective stop contour 17 comes to bear against the assembly direction 12 against a support contour 18 of the charge air cooler 3 that is complementary thereto. In the example, both the support contours 18 are each formed through an edge of the previously mentioned end plates 16 on the outflow side. Through the interaction of the stop contours 17 and the support contours 18, an intensive position fixing of the charge air cooler 3 within the housing 4 is obtained, which in particular can bring about a preloading of the charge air cooler 3 in the housing 4. The interaction of the respective stop contour 17 and the respective support structure 18 likewise brings about a bypass seal.

(16) In the embodiments shown here the charge air cooler 3 is entirely arranged within the cooler shell 7, so that the cooler shell 7 encloses the charge air cooler 3 in a circumferential direction, which in FIG. 2 is indicated by a double arrow 19, on three sides. In FIG. 2, these are the upper side, the lower side and the right-hand side. In contrast with this, the fourth side, i.e. in FIG. 2 the left-hand side of the charge air cooler 3 is arranged in the assembly opening 9.

(17) As is further evident from FIG. 2, the connecting shell 8 in this case is in contact with the cooler shell 7 via a tongue and groove connection 20. This tongue and groove connection 20 is embodied completely closed circumferentially along the assembly opening 9, in order to realise efficient sealing of the two shells 7, 8 on one another. The tongue and groove connection 20 also leads to an intensive stiffening of the housing 4 formed by the two shells 7, 8. In the region of the tongue and groove connection 20, in particular a welded connection between the two shells 7, 8 can be established. Optionally, a seal 21 can be arranged within the tongue and groove connection 20.

(18) As is evident in particular from the FIGS. 5 and 6, a plurality of tensile anchors 22 can be arranged on the cooler shell 7 on the onflow side, which are practically formed integrally on the cooler shell 7. These tensile anchors 22 are arranged on an onflow side 23 of the charge air cooler 3 on the air side. Here, the tensile anchors 22 connect two wall portions 24, 25 of the cooler shell 7 to one another, which are located opposite one another on the onflow side 23 of the charge air cooler 3. As is evident from FIG. 6, some of these tensile anchors 22 can be configured as guide blades for the charge air on the onflow side. The respective guide blade in FIG. 6 is designated 26. It is curved and extends into an inlet region 27 of the cooler shell 7, which comprises the charge air inlet 5. The guide blades 26 in this case are curved so that here they bring about an approximately 90 redirection of the charge air coming from the charge air inlet 5 in the direction of the charge air cooler 3. Arrows 28 in this case indicate the charge air flow.

(19) FIG. 2 indicates that tensile anchors 29 on the outflow side can also be present on the connecting shell 8, which can be practically formed integrally on the connecting shell 8. The respective tensile anchor 29 on the outflow side in this case is arranged with respect to the flow direction of the charge air on an outflow side 30 of the charge air cooler 3. Here, the respective tensile anchor 29 on the outflow side connects two wall portions 31, 32 of the connecting shell 8 to one another, which are located opposite one another on the outflow side 30 of the charge air cooler 3.

(20) The tensile anchors 22 on the onflow side and the tensile anchors 29 on the outflow side lead to an intensive stiffening of the housing 4 on both sides of the charge air cooler 3. Compressive forces, which can develop within the charge air cooler 3 during the operation, can thus be absorbed by the housing 4. For stabilising the housing 4, it can be additionally provided that the cooler shell 7 on its outside is equipped with a multiplicity of stiffening ribs 33, which can run perpendicularly to one another and thus bring about intensive stiffening of the cooler shell 7.

(21) As is evident from the FIGS. 6 and 7, the charge air cooler 3 comprises an inlet connection 34 for feeding in a coolant according to an arrow 35. An outlet connection 36 for discharging the coolant according to an arrow 37 is likewise provided. The inlet connection 34 in this case is formed by an inlet connector 38, which with respect to the charge air cooler 3 and with respect to the suction module 2 forms a separate component. The outlet connection 36 in this case is also formed by a separate component, namely by an outlet connector 39. The inlet connector 38 is inserted into an inlet opening 41 of the charge air cooler 3 through an inlet passage opening 40 formed in the housing 4. The outlet connector 39 is inserted into an outlet opening 43 which is formed on the charge air cooler 3 through an outlet passage opening 42 formed in the housing 4. A first seal 44 on the inlet side seals the inlet connector 38 against the charge air cooler 3 in the region of the inlet opening 41. A second seal 45 on the inlet side seals the inlet connector 38 against the housing 4 in the region of the inlet passage opening 40. A first seal 46 on the outlet side seals the outlet connector 39 against the charge air cooler 3 in the region of the outlet opening 43. A second seal 47 on the outlet side seals the outlet connector 39 against the housing 4 in the region of the outlet passage opening 42. The respective first seal 44, 46 thus separates the coolant from the charge air. The respective second seal 45, 47 thus separates the charge air from the ambient air.

(22) The inlet opening 41 opens into an inlet chamber 48 or distribution chamber 48, which is fluidically connected via a first group of tubes 10 to a redirection chamber 49 that is evident in FIG. 6. This redirection chamber 49 is then fluidically connected via a second group of tubes 10 to an upper chamber 50 or collecting chamber 50, into which the outlet opening 43 opens.

(23) As is evident from FIG. 1, the fresh air supply device 1 shown in the FIGS. 1 to 7 can be additionally equipped with a flap device 51, which is attached to the connecting shell 8 in the region of the charge outlet 6. The flap device 51 can be embodied as a tumble or swirl flap device. Corresponding flaps are marked with 58 in FIG. 2. Here, too, a completely closed circumferential tongue and groove connection 52 and/or a welded connection can again be provided along the charge air outlet 6 in order to connect the flap device 51 to the connecting shell 8 and thus to the housing 4 in an air and pressure-tight manner.

(24) In the embodiment shown in the FIGS. 1 to 7, the connecting shell 7 serves for connecting the suction module 2 to a cylinder head of an internal combustion engine or for connecting to the flap device 51, which in turn is provided for connecting to the cylinder head.

(25) The suction module 2 is produced from plastic. Accordingly, the housing 4 and consequently the cooler shell 7 and the connecting shell 8 are produced from plastic. The charge air cooler 3, by contrast, is produced from metal. In particular, the tubes 10, the fins 11 and the end plates 16 are thus produced from metal. Furthermore, a first cap 53 for realising the inlet chamber 48 and the outlet chamber 50 as well as a second cap 54 for realising the redirection chamber 49 can also be produced from metal. The connecting connectors 38, 39 can be preferably produced from plastic. In principle, however, metallic connecting connectors 38, 39 can also be used here.

(26) In the embodiment shown in the FIGS. 1 to 7, the main flow direction of the charge air in the charge air cooler 3, which is indicated for example in FIG. 6 by an arrow 55, is orientated parallel to the assembly direction 12, however opposite thereto.

(27) In contrast with this, FIG. 8 shows an embodiment in which the main flow direction 55 of the charge air is orientated perpendicularly to the assembly direction 12. In the embodiment shown in FIG. 8, the cooler shell 7, in a region that is distal from the assembly opening 9, comprises at least one fixing rib 56, which extends parallel to the longitudinal direction 13 of the tubes 10 and which projects from the cooler shell 7 opposite to the assembly direction 12. Here, the respective fixing rib 56 projects into the cooler block, namely into the charge air cooler 3 between two adjacent tubes 10. In the embodiment shown in FIG. 8, at least one such fixing rib 57 is likewise additionally provided on the connecting shell 8, which projects in the assembly direction 12 and likewise projects into the charge air cooler 3 between adjacent tubes 10. In the embodiment shown in FIG. 8, the charge air inlet 5 which is not shown and the charge air outlet 6 which is not shown are each arranged on the cooler shell 7.