Profile for a header of a cooler, a header having such a profile and a cooler having a header

Abstract

A profile for a header of a cooler which also includes numerous parallel tubes. The parallel tubes have a cross-sectional shape between slots for the tubes which further include at least two wave troughs Further, the header is also included having such a profile. A cooler may also be provided, wherein the cooler has such a header.

Claims

1. A header of a cooler which also comprises a plurality of parallel tubes, the header including a base having a plurality of slots formed therethrough with each of the slots receiving a corresponding one of the tubes therein, the slots spaced apart from each other along the base with respect to a longitudinal direction of the header and the tubes extending through the slots with respect to a height direction of the header arranged perpendicular to the longitudinal direction thereof, the base having a cross-sectional shape between adjacent ones of the slots which comprises at least two wave troughs and at least three wave crests with the wave crests and the troughs alternatingly formed in the base with respect to a width direction of the header arranged perpendicular to the longitudinal direction and the height direction thereof, wherein from outside to inside an outer radius (R1) of a first one of the wave crests, an inner radius (R2) of the first one of the wave crests, an outer radius (R3) of a first one of the wave troughs, an inner radius (R4) of the first one of the wave troughs and a radius (R5) of a second one of the wave crests measure as follows: R1=1.5-3.5 mm, R2=2-4 mm, R3=1.9-5 mm, R4=1.9-40 mm, R5=3-50 mm, and wherein each of the slots extends in the width direction of the header from a first end disposed at a highest point of the first one of the wave crests with respect to the height direction of the header to a second end disposed at a highest point of a third one of the wave crests with respect to the height direction of the header with the first one of the wave crests and the third one of the wave crests forming outermost ones of the at least three wave crests with respect to the width direction of the header, and wherein the wave crests and the wave troughs are formed along an entirety of the base of the header with respect to the width direction of the header.

2. The header according to claim 1, wherein at least one of the wave crests or at least one of the wave troughs has at least one flat portion.

3. The header according to claim 1, wherein the header consists of aluminum or an aluminum alloy.

4. A cooler for an air-conditioning system of a motor vehicle, the cooler having the header according to claim 1.

5. The cooler according to claim 4, wherein the tubes consist of aluminum or an aluminum alloy, and are soldered to the header.

6. The header according to claim 1, wherein the first one of the wave crests forms an outermost portion of the base to a first side of the base and with respect to the width direction of the header, and wherein the third one of the wave crests forms an outermost portion of the base to a second side of the base and with respect to the width direction of the header.

7. The header according to claim 1, wherein the header further includes a perimeter trough extending around a perimeter of the base, and wherein the first one of the wave crests transitions directly to the perimeter trough at a first side of the base with respect to the width direction of the header and wherein the third one of the wave crests transitions directly to the perimeter trough at a second side of the base with respect to the width direction.

8. The header according to claim 1, wherein the highest point of the first one of the wave crests with respect to the height direction of the header is formed where a first portion of the first one of the wave crests defining the outer radius (R1) thereof intersects a second portion of the first one of the wave crests defining the inner radius (R2) thereof, and wherein the highest point of the third one of the wave crests with respect to the height direction of the header is formed where a first portion of the third one of the wave crests defining the outer radius (R1) thereof intersects a second portion of the third one of the wave crests defining the inner radius (R2) thereof.

9. The header according to claim 1, wherein each of the slots is surrounded by a corresponding web projecting from the base with respect to the height direction, and wherein each of the webs projects the same distance from the base with respect to the height direction across each of the wave crests and wave troughs of the base.

10. The header according to claim 1, wherein each of the slots is surrounded by a corresponding web projecting from the base with respect to the height direction, and wherein each of the webs has a profile shape corresponding to the cross-sectional shape of the base of the header between adjacent ones of the slots.

11. The header according to claim 1, wherein each of the slots is surrounded by a corresponding web projecting from the base with respect to the height direction, and wherein each of the webs includes a profile shape having wave crests corresponding to the wave crests formed in the base and wave troughs corresponding to the wave troughs formed in the base.

12. A header of a cooler which also comprises a plurality of parallel tubes, the header including a base having a plurality of slots formed therethrough with each of the slots receiving a corresponding one of the tubes therein, the slots spaced apart from each other along the base with respect to a longitudinal direction of the header and the tubes extending through the slots with respect to a height direction of the header arranged perpendicular to the longitudinal direction thereof, the base having a cross-sectional shape between adjacent ones of the slots which comprises at least two wave troughs and at least three wave crests with the wave crests and the troughs alternatingly formed in the base with respect to a width direction of the header arranged perpendicular to the longitudinal direction and the height direction thereof, wherein the wave crests extend in a direction of an interior of the header, wherein each of the slots extends in the width direction of the header from a first end disposed at a highest point of the first one of the wave crests with respect to the height direction of the header to a second end disposed at a highest point of a third one of the wave crests with respect to the height direction of the header with the first one of the wave crests and the third one of the wave crests forming outermost ones of the at least three wave crests with respect to the width direction of the header, wherein the wave crests and the wave troughs are formed along an entirety of the base of the header with respect to the width direction of the header, wherein webs surrounding the slots are provided, and wherein the slots and the webs are formed by burring.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) In the following, embodiments of the invention that are shown in the drawings will be described in more detail. In the drawings:

(2) FIG. 1 shows a perspective view of a header according to the invention in a first embodiment;

(3) FIG. 2 shows a sectional view of the header shown in FIG. 1 with a detail enlargement;

(4) FIG. 3 shows a view of a further embodiment of the header according to the invention that corresponds to FIG. 2;

(5) FIG. 4 shows a view of a further embodiment of the header according to the invention that corresponds to FIG. 2;

(6) FIG. 5 shows a view of a further embodiment of the header according to the invention that corresponds to FIG. 2;

(7) FIG. 6 shows a further sectional view of the header shown in FIG. 2;

(8) FIG. 7 shows a partial sectional view of the header shown in FIG. 2; and

(9) FIG. 8 shows a partial sectional view of the header shown in FIG. 4.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(10) As can be seen from FIG. 1, a profile according to the invention for a header 10 of a cooler has the form of a shallow dish with an elongated rectangular shape and rounded corners and edges. According to FIG. 1, the header 10 shown is closed on the upper side by a further header, such that the header 10 is formed, which is typically vertically oriented during operation. According to the orientation in FIG. 1, underneath the header 10 shown and when installed, typically in a horizontal direction, numerous flat tubes are inserted in slots 16 which are formed in the base of the header 10. The invention relates to the cross-sectional shape of the base, which effectively remains between the slots 16. The dimensions of the remaining base portions in a direction from bottom left to top right according to FIG. 1 are slightly larger, in particular 1.5 to 2.5 times as large as the dimensions of the slots 16 in the same direction.

(11) FIG. 2 shows the wave shape of the base, and also the circumferential web 18 which surrounds each slot 16 and which essentially has a shape that corresponds to the flat tube to be inserted therein. As can be seen more clearly in FIG. 6, the web 18 has a considerable height H which preferably remains the same over the circumference and which ensures a secure soldered connection to the flat tubes to be inserted. The slots 16 and the webs 18 are typically formed by burring.

(12) FIG. 2 shows the wave shape according to the invention of the header 10 between the slots 16, which in the case shown has two wave troughs 12, which are aligned with the flat tubes that are not shown, and three wave crests 14. The slots 16 extend approximately to the highest point of the two outer wave crests 14.

(13) FIG. 2 shows the profile of the header 10 for flat tubes having a width (measured in FIG. 2 from left to right) of 18.5 mm, and FIG. 3 shows a profile for a width of 14 mm, FIG. 4 for a width of the flat tubes of 25.2 mm and FIG. 5 for a width of the flat tubes of 36.4 mm. As can be seen from FIG. 3, the waves here are slightly flatter, and in the embodiments according to FIG. 4 the wave crests are slightly drawn apart, as will be explained in more detail below with reference to FIG. 7 and FIG. 8.

(14) In FIG. 6 the radiuses R1 to R5 are marked out, wherein it should first of all be stressed that these are always to be measured on the side facing away from the flat tubes (that are not shown). An exterior or outer radius is therefore to be understood to be a radius measured on the (lateral) outer side, in other words in FIG. 6 for the first wave crest 14.1 to the left. In contrast, an internal or inner radius, such as R2 in the case of the first wave crest 14.1 and R4 in the case of the first wave trough 12.1, is measured at a point further inwards (further to the right in FIG. 6). It should also be noted that the cross-sectional shape of the header 10 according to the invention, which can be seen in FIG. 6, is typically symmetrical to the center of the second, middle wave crest 14.2, such that the directions described (left/right) can be reversed for the right-hand half of the header 10 according to FIG. 6. The presently preferred values for a header profile for flat tubes having a width of 18.5 mm are: R1=2.3 mm, R2=2.6 mm, R3=1.9 mm, R4=1.9 mm and R5=4 mm.

(15) The flat portions specified in claim 6 are labelled in FIG. 7 and are shown for the profile in FIG. 6.

(16) The profile in FIG. 8 corresponds to that in FIG. 4, in which there is a wider flat portion W3 corresponding to the preferred configuration.

(17) The invention relates to a profile for a header of a coolerin particular for a motor vehicle, having at least one header.