HEAT EXCHANGER FOR INTERNAL COMBUSTION ENGINES

Abstract

Provided are heat exchangers for internal combustion engines wherein a first fluid, preferably a hot gas, gives off its heat to a second fluid, preferably a coolant liquid. The presently disclosed heat exchangers include caps that limit the heat exchange capacity of the exchanger without causing differential expansions between elements or parts of these elements that may damage the device or reduce its service life due to thermal fatigue. A device of the presently disclosed subject matter can be sized for the engine having a higher rated power, and the same heat exchanger, can be adapted for operating with engines having a lower rated power without the velocity of the gas to be cooled being reduced, thereby preventing the accumulation of particles therein or fouling.

Claims

1. A heat exchanger for internal combustion engines, comprising a bundle of exchange tubes (3) for the exchange of heat between a hot gas and a coolant fluid; wherein the exchange tubes (3) are tubes configured as planar tubes, with inner fins (3.1.1), extending according to a longitudinal direction (X-X), and wherein the inner fins (3.1.1) internally configure a plurality of channels extended according to said longitudinal direction (X-X) and distributed according to a transverse direction (Y-Y) with respect to said longitudinal direction (X-X), characterized in that it comprises at least one element configured as a plurality of caps (1) consecutively connected and attached by means of a connecting segment (1.6), each of the caps (1) housed in one end of a different exchange tube (3), covering one or more of the channels thereof to reduce the passage section thereof.

2. The heat exchanger of claim 1, wherein at least one cap (1) comprises: a closure surface (1.1) configured for being housed inside the exchange tube (3) limiting its passage section; and a side surface (1.2, 1.3) configured for fitting snugly against the inner surface of the exchange tube (3).

3. The heat exchanger of claim 2, wherein at least one cap (1) has a supporting surface (1.5) configured for being outside the exchange tube (3) and being supported on either the securing baffle (2) for securing the end of the exchange tube (3) where the cap (1) is housed or on the outer edge of said exchange tube (3).

4. The heat exchanger of claim 3, wherein the closure surface (1.1) and the supporting surface (1.5) in at least one cap (1) are separated from one another by means of the side surface (1.2, 1.3).

5. The heat exchanger according to claim 2, wherein the side surface (1.2, 1.3) is configured for being adapted to a planar exchange tube (3) with a cross-section according to two straight parallel segments connected at their ends by means of two arcs; where said side surface (1.2, 1.3) comprises a curved surface (1.2) adapted for fitting snugly against one of the curved ends of the section of the exchange tube (3).

6. The heat exchanger of claim 2, wherein the side surface (1.2, 1.3) comprises respective planar side surfaces (1.3) configured for fitting snugly against a portion of the inner surface of the wall of the exchange tube (3) corresponding to the cross-sectional straight segments of said exchange tube (3), where both side surfaces (1.3) are arranged in opposition.

7. The heat exchanger of claim 5, wherein the curved surface (1.2) and the side surfaces (1.3) configure a continuous connecting surface.

8. The heat exchanger of claim 2, wherein in at least one cap (1) the closure surface (1.1) has a tab (1.4) that is oblique or perpendicular to said closure surface (1.1), configured for at least partially entering one of the channels of the exchange tube (3) in which it is housed to establish better closure of said channels.

9. The heat exchanger of claim 1, wherein the channels of the exchange tubes (3) are configured by a plate (3.1) die cut and bent configured for forming fins (3.1.1), these fins (3.1.1) being the fins that demarcate the channels of said exchange tube (3).

10. The heat exchanger of claim 1, wherein at least one of the connecting segments (1.6) is configured according to an elastically deformable element to allow the insertion of each cap (1) in its corresponding exchange tube (3) with different positions according to the longitudinal direction (X-X).

11. The heat exchanger of claim 2, wherein the closure surface (1.1) comprises indentations (1.7) projected towards the side where the inner fins (3.1.1) are located to improve the closure of the channels.

12. A method for manufacturing a heat exchanger, the method comprising: providing a heat exchanger for internal combustion engines, comprising a bundle of exchange tubes (3), wherein said exchange tubes (3) are tubes configured as planar tubes, with inner fins (3.1.1), extending according to a longitudinal direction (X-X), and wherein the inner fins (3.1.1) internally configure a plurality of channels extended according to said longitudinal direction (X-X) and distributed according to a transverse direction (Y-Y) with respect to said longitudinal direction (X-X), the exchange tubes (3) being extended between a first baffle (2) and either a second baffle or the shell (4); providing a flow-limiting element configured as a plurality of caps (1) consecutively connected and attached by a connecting segment (1.6); arranging the heat exchanger in a support; arranging the flow-limiting element in a plurality of punches (5), movable in the longitudinal direction (X-X) established by the exchange tubes (3) of the heat exchanger once it is fixed in the support, such that: each cap (1) is housed on a different punch (5); and each cap (1) housed on a punch (5) is aligned with a different exchange tube (3); moving the punches (5) in the longitudinal direction until inserting all the caps (1) in their corresponding heat exchange tube (3); removing the punches (5); and releasing the heat exchanger.

13. The method of claim 12, wherein: the movement of each of the punches (5) is independent such that after imparting an insertion force, each cap (1) is allowed to be housed in its corresponding exchange tube (3) even if the exchange tubes (3) are not aligned according to the transverse direction (Y-Y) with respect to the longitudinal direction (X-X) of insertion.

14. The method of claim 12, one or more punches (5) have a pressure rib on the tab (1.4) of the cap (1) to force deformation thereof against the separations between channels of the exchange tube (3) to establish better closure of said channels.

15. The method of claim 13, wherein one or more punches (5) have a pressure rib on the tab (1.4) of the cap (1) to force deformation thereof against the separations between channels of the exchange tube (3) to establish better closure of said channels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The foregoing and other features and advantages of the invention will be more clearly understood based on the following detailed description of a preferred embodiment, given only by way of illustrative and non-limiting example, in reference to the attached drawings.

[0048] FIG. 1 shows a first embodiment of an element with caps intended for limiting the passage section of a plurality of exchange tubes.

[0049] FIG. 2 shows a section of an end of a heat exchanger. The drawing partially shows a heat exchange tube, the baffle to which the heat exchanger is attached and a section of a cap according to the first embodiment housed in the end of the heat exchange tube.

[0050] FIG. 3 shows a section like that in the preceding drawing where the configuration of the inner fins of the exchange tube has a termination in a different position with respect to the cap.

[0051] FIG. 4 shows a second embodiment of an element with caps attached by a connecting segment configured for being elastically deformable.

[0052] FIG. 5A shows a side view of the end of the heat exchanger where at least two heat exchange tubes projecting from the baffle as well as an elastically deformable connecting segment can be seen. The A-A plane through which the section of the following figure is formed is indicated in this figure.

[0053] FIG. 5B shows section A-A identified in preceding FIG. 5A.

[0054] FIGS. 6A-6C show the sequence followed during the method for inserting caps in the ends of the exchange tubes.

[0055] FIG. 7 shows a perspective view of the same end of the heat exchanger in order to see in detail the caps housed in the ends of the exchange tubes and particularly their internally housed closure surface.

[0056] FIG. 8 shows the same detail as in the preceding figure but now the perspective almost coincides with the longitudinal direction of the exchanger.

[0057] FIG. 9 shows the same detail as in the preceding figure in a cross-section view according to a plane central to one of the heat exchange tubes.

DETAILED DESCRIPTION

[0058] According to the first inventive aspect, the present invention relates to a heat exchanger for internal combustion engines which is capable of being configured for different flow rate requirements for a flow to be cooled according to the rated power of the engine in which it is installed.

[0059] The heat exchanger comprises planar exchange tubes. According to the embodiments shown in FIGS. 2, 3, 5A, 5B, 6A, 6B, 6C, 7, 8, and 9, the configuration of the planar tubes comprises two parallel plates connected laterally by a semicylindrical segment. This sectional configuration results in two straight segments connected at their ends by respective arcs. This configuration is clearly shown for example in FIG. 7, where the ends of the exchange tubes (3) project from a baffle (2) closing the heat exchanger on the hot gas intake side.

[0060] Although the invention can be applied to heat exchangers without a shell, when the coolant fluid is air for example, the heat exchangers described in these embodiments comprise a shell (4) housing the bundle of exchange tubes (3). The coolant fluid is liquid and has an inlet (4.1), and it comes out of the shell after immersing the heat exchange tubes. The heat exchangers used for the sole purpose of suitably understanding the elements of the invention and various alternatives with specific solutions have been chosen for the purpose of serving as heat exchangers for an EGR system.

[0061] The manner in which the heat exchanger is configured for different flow rate requirements is by making use of a heat exchanger sized for being capable of expelling heat according to the most demanding requirement. Without any adaptation, this exchanger will be oversized for lower heat expulsion requirements. The adaptation is carried out by reducing the passage section of the heat exchange tubes (3) with a plurality of caps (1).

[0062] FIG. 1 shows an embodiment of a plurality of caps (1), connected consecutively by means of a connecting segment (1.6). Each of the caps (1) is an element configured for being housed in the intake end of a heat exchange tube (3) covering part of its section, as will be described below.

[0063] The heat exchange tubes (3) are planar tubes, as indicated above, and furthermore have inner fins (3.1.1) extending according to a longitudinal direction (X-X), the longitudinal direction of the exchange tube (3). The inner fins (3.1.1) configure inside the exchange tube (3) a plurality of channels also extended in the longitudinal direction X-X. The presence of these channels allows the situation where if a cap (1) occludes the inlet of one of the channels, the entire channel is disabled, and it is equivalent to the passage section of the exchange tube (3) being reduced along its entire length.

[0064] Longitudinal direction X-X is the main direction along which the exchange tube (3) extends. Of all the possible transverse or essentially perpendicular directions, the direction extending in the direction parallel to the main plane of the exchange tube (3) will be identified as transverse direction Y-Y.

[0065] Having described the configuration of the exchange tubes (3) for these embodiments, according to the section of the tube and the transverse direction Y-Y, there is at least one channel located at the end demarcated by the side arcuate segments of the exchange tube (3).

[0066] In contrast, the inner fins (3.1.1) form a plurality of channels distributed along the transverse direction Y-Y.

[0067] In the selected embodiments of the invention, the caps (1) are configured for covering the first end channel, the one coinciding with the arcuate segment of the cross-section of the exchange tube (3) and at least one or more channels adjacent to this end channel reducing the effective section of the exchange tube. Given that all the exchange tubes (3) attached at their ends to the same baffle (2) have the same reduction in section, the temperatures of all of them are very close to one another such that there are no different longitudinal expansions causing thermal fatigue.

[0068] The embodiment of FIG. 1 shows each of the caps (1) with a closure surface (1.1) configured for being housed inside the exchange tube (3) covering the ends of the channels. Part of this closure surface (1.1) is configured as a half disc for covering the end channel and then extends in the form of a rectangular flat bar for covering the part of the end channel not covered by the half disc, if that is the case, and one or more adjacent channels.

[0069] In addition to the closure surface (1.1), each of the caps (1) shows a side surface (1.2, 1.3) configured for fitting snugly against the inner surface of the exchange tube (3). A first side surface (1.2) in the form of a cylindrical sector and two second planar side surfaces (1.3). The first side surface (1.2) in the form of a cylindrical sector internally fits snugly against the wall in the form of a cylindrical sector of the exchange tube (3), and the second planar side surfaces (1.3) prolong the side wall through the planar wall corresponding to the segments having a straight section.

[0070] In these embodiments, the channels extending along the longitudinal direction X-X of the exchange tube (3) show a winding configuration, as can be seen in FIG. 2. This winding configuration of the inner fins (3.1.1) is achieved by means of a specific bending of a metal plate (3.1). The bends of the metal plate (3.1) are the inner fins (3.1.1) and instead of making them straight, these bends are made such that they are winding. The inner fins (3.1.1) emerge from the rest of the bent metal plate (3.1) such that said metal plate (3.1) continues to have an essentially planar face. This planar face is what is braze-welded to the inner planar wall of the exchange tube (3). The inner fins (3.1.1) emerge from an inner face of an exchange tube (3) until reaching the opposite inner face. A channel is thereby limited by two consecutive fins (3.1.1) according to the transverse direction Y-Y; and between a planar inner wall of the exchange tube (3) and the metal plate (3.1) supporting the inner fins (3.1.1) which in turn is welded to the opposite planar inner wall of the same exchange tube (3), these last two spaced from one another according to a direction perpendicular to the main plane of the planar exchange tube (3).

[0071] The winding configuration of the fins (3.1.1) gives rise to the position of the walls of the inner fins (3.1.1) at the end thereof according to the direction X-X, where the cap (1) is supported, not being predictable. Especially in those cases in which the bent metal plate (3.1) giving rise to the inner fins (3.1.1) being manufactured continuously and cut into segments having a given length.

[0072] In these cases, the closure surface (1.1) of the cap (1) can only partially cover one of the channels, not suitably determining the degree of reduction in section of the exchange tube (3). The embodiment shown in FIGS. 2 and 3 shows a tab (1.4), which can be oblique or perpendicular, facing the inner fins (3.1.1), closing to a greater extent the passage to the partial opening that the closure surface (1.1) may leave.

[0073] The embodiment shown in FIGS. 1 to 3 also shows a supporting surface (1.5) configured for being outside the exchange tube (3) and being supported either on the securing baffle (2) for securing the end of the exchange tube (3) where the cap (1) is housed or on the outer edge of said exchange tube (3).

[0074] FIGS. 2 and 3 show the exchange tube (3) projecting from the surface of the baffle (2). In this case, the supporting surface (1.5) is the end edge of the exchange tube (3), and in this embodiment the supporting surface (1.5) is configured in the form of a semicircular flat bar for being supported on the free edge of the arcuate segment of the exchange tube (3).

[0075] If the exchange tube (3) ends flush with the baffle (2) or projects very little, support can be established directly on the baffle (2).

[0076] The walls of the cap (1), the curved surface (1.2) and the side surfaces (1.3) configure a continuous surface, assuring the leak-tight closure with the wall of the exchange tube (3) in the contact area.

[0077] When manufacturing heat exchangers with planar exchange tubes (3), one of the difficulties arising is the different position according to the longitudinal direction X-X of the ends of the exchange tubes (3).

[0078] According to the first inventive aspect, given that a plurality of caps (1) is connected through a connecting segment integrally connecting them, the insertion of the caps (1) in the tubes would give rise to some caps (1) being inserted all the way in and other caps (1) only being partially inserted.

[0079] To solve this problem, a second embodiment of an element with caps (1) is proposed and shown separately in FIG. 4. In this element, the connecting segment (1.6) is arc-shaped and is configured as an elastically deformable element. With this configuration, it is possible to insert each cap (1) in an exchange tube (3) even if each of the exchange tubes (3) emerges from the baffle (2) a different distance. The elastically deformable element adapts by deformation to allow this different position according to the longitudinal direction X-X.

[0080] FIG. 5A shows the end of a heat exchanger with exchange tubes (3) emerging from the baffle (2) a different distance according to the longitudinal direction X-X. Reference number 3 refers to two different corners, the corners corresponding to the ends of two exchange tubes (3) seen from the side and located in a different position according to the longitudinal direction X-X.

[0081] Said FIG. 5A and FIG. 5B show the transverse direction Y-Y, and according to this direction the width of the exchange tube (3), i.e., the distance between the ends of its section, and its thickness, i.e., the separation between planar plates, can be seen. The section plane giving rise to the section shown in FIG. 5B where each of the exchange tubes (3) clearly emerges from the baffle (2) a different distance according to the longitudinal direction X-X is also indicated.

[0082] A manufacturing method for manufacturing a heat exchanger like the one described up until now is also object of this invention. The different steps of the method are schematically shown in FIGS. 6A, 6B and 6C. The method comprises the following steps: [0083] providing a heat exchanger for internal combustion engines, comprising a bundle of exchange tubes (3), wherein said exchange tubes (3) are tubes configured as planar tubes, with inner fins (3.1.1), extending according to a longitudinal direction (X X), and wherein the inner fins (3.1.1) internally configure a plurality of channels extended according to said longitudinal direction (X-X) and distributed according to a transverse direction (Y-Y) with respect to said longitudinal direction (X X), the exchange tubes (3) being extended between a first baffle (2) and either a second baffle or the shell (4) [0084] providing a flow-limiting element configured as a plurality of caps (1) consecutively connected and attached by means of a connecting segment (1.6).

[0085] Up to this point elements suitable for assembly are provided. The heat exchanger with the described configuration of planar exchange tubes (3) and the flow-limiting element with caps (1). [0086] arranging the heat exchanger in fixing means, [0087] arranging the flow-limiting element in a plurality of punches (5), movable in the longitudinal direction (X-X) established by the exchange tubes (3) of the heat exchanger once it is fixed in the fixing means, such that: [0088] each cap (1) is housed on a different punch (5), [0089] each cap (1) housed on a punch (5) is aligned with a different exchange tube (3).

[0090] The heat exchanger is fixed such that a plurality of punches (5) are distributed leaving each punch (5) to coincide according to the longitudinal direction X-X with one of the exchange tubes (3), one punch (5) per cap (1) to be inserted.

[0091] FIG. 6A shows a section view of the fixed heat exchanger and above it, according to the orientation of the drawing, the plurality of punches (5) already housed inside each corresponding cap (1). [0092] moving the punches (5) in the longitudinal direction until inserting all the caps (1) in their corresponding heat exchange tube (3).

[0093] The downward movement of the punches (5) also causes the downward movement of the limiting element with each of its caps (1). In this embodiment where the caps (1) are linked by the elastically deformable connecting segment, a set of punches (5) in which movement of each punch (5) is independent has also been provided. In other words, each punch (5) exerts force independently of others and its movement does not impart the same movement in other punches (5). FIG. 6B shows the insertion of the caps (1) pushed by the punches (5) entering to a greater or lesser extent depending on how much their corresponding exchange tube (3) projects. Therefore, an exchange tube (3) that projects significantly does not prevent the entrance of the caps (1) that are inserted in the remaining exchange tubes (3) until reaching their end position, assuring the closure against the inner channels. [0094] removing the punches (5), [0095] releasing the heat exchanger.

[0096] The punches (5) are released with these operations, as shown in FIG. 6C, leaving the caps (1) inserted in their end position. Friction with the exchange tube (3) keeps this insertion position stable.

[0097] In this embodiment, the weld between the different elements making up the heat exchanger has been formed by using a brazing paste and with passage through a furnace to get this brazing paste to melt. In the case of the bent metal plate (3.1) configuring the inner fins (3.1.1), the attachment with one of the inner faces of the exchange tube (3) has been formed by means of a brazing foil. In this embodiment, this brazing foil has been spread out and has also been used for attaching each of the caps (1) to the exchange tube (3).

[0098] In FIGS. 6A to 6C, the punches (5) are shown in a section view, filling the inner cavity of each of the caps (1). Nevertheless, according to other embodiments, these same punches (5) have projections pressing against the tab (1.4) in order to deform it, fitting more snugly against the inner fins (3.1.1), assuring the closure between the cap (1) and the inner fins (3.1.1). The best closure of the channels is assured with this deformation.

[0099] FIGS. 7 and 8 show perspective views of the final position of the limiting element comprising the plurality of caps (1) inserted in the end of the exchange tubes (3), closing several channels, i.e., the channels located at the end according to the transverse direction Y-Y.

[0100] These same views of FIGS. 7 and 8 and the section view shown in FIG. 9 show a specific configuration that can be applied to any one of the preceding embodiments, where a plurality of indentations (1.7) is projected against the final ends of the inner fins (3.1.1), improving the closure of the channels.

[0101] A third aspect of the invention relates to a flow-limiting device for heat exchangers identified as embodiment #1; said device is configured for being installed in heat exchangers for internal combustion engines formed by means of exchange tubes (3) for the exchange of heat between a hot gas and a coolant fluid; wherein the exchange tubes (3) are tubes configured as planar tubes, with inner fins (3.1.1), extending according to a longitudinal direction (X-X), and where the inner fins (3.1.1) internally configure a plurality of channels extended according to said longitudinal direction (X-X) and distributed according to the transverse direction (Y-Y) with respect to said longitudinal direction (X-X), wherein said device is configured as a plurality of caps (1) aligned with one another and attached by means of a connecting segment (1.6), each of the caps (1) being insertable in one end of a different exchange tube (3) for covering one or more of the channels.

[0102] An embodiment identified as #2 is formed like the device of embodiment #1, wherein at least one cap (1) comprises: [0103] a closure surface (1.1) configured for being housed inside the exchange tube (3); and [0104] a side surface (1.2, 1.3) configured for fitting snugly against the inner surface of the exchange tube (3).

[0105] An embodiment identified as #3 is formed like the device of embodiment #1 or the device of embodiment #2, wherein at least one cap (1) has a supporting surface (1.5) configured for being outside the exchange tube (3) and being supported either on a securing baffle (2) for securing the end of the exchange tube (3) or on the outer edge of the exchange tube (3).

[0106] An embodiment identified as #4 is formed like the device of embodiment #2 or the device of embodiment #3, wherein, in at least one cap (1), the closure surface (1.1) and the supporting surface (1.5) are separated from one another by means of the side surface (1.2, 1.3).

[0107] An embodiment identified as #5 is formed like the device according to any of embodiments #2 to #4, wherein the side surface (1.2, 1.3) is configured for being adapted to a planar exchange tube (3) with a cross-section according to two straight parallel segments connected at their ends by means of two arcs; where said side surface (1.2, 1.3) comprises a curved surface (1.2) adapted for fitting snugly against one of the curved ends of the section of the exchange tube (3).

[0108] An embodiment identified as #6 is formed like the device according to any of embodiments #2 to #4 and embodiment #5, wherein the side surface (1.2, 1.3) comprises respective planar side surfaces (1.3) configured for fitting snugly against a portion of the inner surface of the wall of the exchange tube (3) corresponding to the cross-sectional straight segments of said exchange tube (3), where both side surfaces (1.3) are arranged in opposition.

[0109] An embodiment identified as #7 is formed like the device according to embodiment #6, wherein the curved surface (1.2) and the side surfaces (1.3) configure a continuous connecting surface.

[0110] An embodiment identified as #8 is formed like the device according to any of embodiments #1 to #7, wherein the closure surface (1.1) has a tab (1.4) oblique or perpendicular to said closure surface (1.1), configured for at least partially entering one of the channels of the exchange tubes (3) to establish better closure of said channels.

[0111] An embodiment identified as #9 is formed like the device according to any of embodiments #1 to #8, wherein at least one of the connecting segments (1.6) is configured according to an elastically deformable element to allow the insertion of each cap (1) in its corresponding exchange tube (3) with different positions according to the longitudinal direction (X-X).