Heat exchanger unit with removable cassettes for air conditioning in motor vehicles

Abstract

A heat exchanger unit that enables a quick interchanging of function, form and size of the different heat exchanger modules. The interchanging may be possible in regard to the sequence of the individual heat exchanger modules. The heat exchanger unit in includes inserts configured such that appropriately configured cassettes can be inserted, and an inner shape of the cassettes is configured so that different heat exchanger modules can be accommodated therein. The cassettes are thus designed specific to the heat exchanger, while the outer shape of all cassettes conforms to the shape of the uniformly configured inserts.

Claims

1. A heat exchanger unit for an air conditioner in a motor vehicle, the heat exchanger unit comprising: a housing; a plurality of inserts formed in the housing, the plurality of inserts arranged in series in a direction of a flow of air; and a plurality of cassettes configured to receive a plurality of heat exchanger modules therein, each of the plurality of cassettes configured to be received in one of the plurality of inserts, wherein an outer shape of the plurality of cassettes corresponds to a shape of the plurality of inserts and an inner shape of the plurality of cassettes corresponds to an outer shape of the plurality of heat exchanger modules, wherein each of the plurality of cassettes has the same external dimension so the plurality of cassettes are interchangeable in position in the housing, wherein a first one of the plurality of cassettes includes a bevel portion formed between a first heat exchanger module of the plurality of heat exchanger modules and a second heat exchanger module of the plurality of heat exchanger modules.

2. The heat exchanger unit according to claim 1, wherein each of the plurality of heat exchanger modules is one of a heat pump condenser, a heat pump evaporator, a heating heat exchanger, an electrical heating element, and an electrical cooling element.

3. The heat exchanger unit according to claim 1, wherein the housing is part of an air conditioner.

4. The heat exchanger unit according to claim 1, wherein each of the plurality of cassettes is a unitary structure.

5. The heat exchanger unit according to claim 1, wherein each of the plurality of cassettes is formed from a plurality of pieces.

6. The heat exchanger unit according to claim 1, wherein the plurality of inserts include guiderails for aligning the plurality of cassettes.

7. The heat exchanger unit according to claim 6, wherein the plurality of cassettes include a groove formed therein configured to receive the guiderails.

8. The heat exchanger unit according to claim 1, wherein an inner shape of the plurality of cassettes correspond to an outer shape of the plurality of heat exchanger modules.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further details, features and advantages of embodiments of the invention will emerge from the following description of sample embodiments making reference to the accompanying drawings. There are shown:

(2) FIG. 1: air conditioner with permanently installed heat exchanger according to the prior art,

(3) FIG. 2: air conditioner with several heat exchanger modules;

(4) FIG. 3: detail view of the inserts with cassettes and

(5) FIG. 4: sectional view of the inserts with cassettes and heat exchanger modules,

(6) FIG. 5: cassette with PTC,

(7) FIG. 6: cassette with condenser,

(8) FIG. 7: installation diagram for an air conditioner with cassette for PTC auxiliary heater, and

(9) FIG. 8: installation diagram for an air conditioner with cassette for a condenser.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

(10) The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

(11) FIG. 1 shows an air conditioner 9 with a permanently installed heating heat exchanger 4 of the prior art. A fan 10 transports air flow 11 at first through an evaporator 5, where it is dehumidified and cooled down. After this, the air flows through the heating heat exchanger 4, where the air is heated to the desired temperature. Like the evaporator 5, the heat exchanger 4 is likewise permanently installed in the air channel formed by a housing 2.

(12) FIG. 2 shows a configuration of an air conditioner 9 according to the invention, in which several heat exchangers 4, 6, 7 are modularly arranged in inserts 3 of the housing 2. The heat exchangers 4, 6, 7 are received in cassettes 8, shown in FIGS. 3-8, which act as adapters. The replacing of the heat exchangers 4, 6, 7 is done by replacing the cassettes 8 with the heat exchangers 4, 6, 7 arranged therein. The outer shape of the cassettes 8 corresponds to the configuration of the inserts 3.

(13) FIG. 3 shows the detail of the inserts 3 in the housing 2 with cassettes 8 inserted into the inserts 3. The cassettes 8 have an outer shape that is compatible with the inserts 3 in the housing 2 of the air conditioner. The cassettes 8, similar to drawers, are received in the inserts 3 of the housing 2. As the content of the drawer is independent of the inserts, different heat exchangers (not shown)—especially those with different height—can be placed in the cassettes 8. The rastering in the most elementary case can be realized by the height of the cassettes 8. The criterion is that the overall height of the inserted cassettes 8 corresponds to the overall height of the insert 3 or the inserts 3. For an overall height of the insert 3 of, say, 12 cm and a rastering of 2 cm, a cassette 8 with 6 cm, one with 2 cm and one with 4 cm can be placed in the insert 3, for example. The sequence of the cassettes 8 of different height is variable. For sealing against the housing 2, the inserts can be sealed by a cover 12, such as a door. Likewise, the cassettes 8 can be configured such that a cover is integrated in the housing 2, including the seal.

(14) FIG. 4 shows the detail of the inserts 3 in the housing 2 with the heat exchangers 4, 6, 7 and the cassettes 8 in cross section.

(15) The heat exchanger modules 4, 6, 7 here are, for example, a heat pump condenser 4, a heating heat exchanger 6, and an electrical heating or cooling element 7.

(16) For this, the inner shape of the cassettes 8 is configured according to the outer shape of the heat exchangers 4, 6, 7. The inner shape of the cassettes 8 corresponds to the outer shape of the heat exchanger modules 4, 6, 7. In this way, a close-fitted and tight insertion of the different heat exchangers 4, 6, 7 in the housing 2 can be realized. In addition, sealing elements such as sealing lips (not shown) are arranged appropriately between the different cassettes 8, between the cassettes 8 and the inserts 3, in the housing 2, and on the heat exchanger modules 4, 6, 7.

(17) One should strive for a standardization of the heat exchanger modules 4, 6, 7, so that the cassettes 8 can be used each time for several of the heat exchanger modules 4, 6, 7 of similar size.

(18) The heat exchanger modules 4, 6, 7 can be introduced, for example, by inserting them in or placing them in the cassettes 8. Likewise, the cassettes 8 can be in two or more pieces (not shown), such that a top part and a bottom part of the cassettes 8 can be connected by clips, or screws, thus receiving and holding the heat exchanger modules 4, 6, 7.

(19) Since the heat exchangers 4, 6, 7 can have different heights, the associated cassettes 8 are designed according to the height of the particular heat exchangers 4, 6, 7. The inserts 2 are configured so as to have a raster dimension that corresponds to the height graduation of the cassettes 8. In this way, it is possible to arrange the cassettes 8 and thus the heat exchangers 4, 6, 7 in the housing 2 regardless of their height.

(20) For example, if only one heat exchanger 4, 6, 7 with 8 cm height is required, a cassette 8 with 4 cm height without heat exchanger can be inserted. By the removal of unneeded heat exchangers, flow noises, pressure loss, and the resulting power uptake of the fan can be reduced.

(21) A rastering of the inserts 3 can be realized, for example, by guide rails 13 at corresponding distance in the inserts 3. Accordingly, corresponding guide grooves 14 are arranged in the cassettes 8.

(22) The rastering of the inserts 3 makes it possible to change the sequence of heat exchangers 4, 6, 7.

(23) The cassettes 8 are advantageously configured such that the airflow is optimized. This can be accomplished, for example, by appropriately arranged leading-edge bevels 15. This enables an optimal heat transfer while at the same time reducing the flow noises and the power uptake of the fan (not shown). The inner shape of the cassettes 8 is configured such that corresponding connection elements such as pipelines or cables can be integrated in it. The connection lines of the respective heat exchanger modules 4, 6, 7 are laid out at the factory. The cable laying can be simplified by plug connections and that of media lines by screw connections.

(24) FIG. 5 shows a cassette with PTC heating element 7. One notices here that the PTC heating element 7 which is considerably smaller in terms of flow cross section of the heat exchanger unit (not shown) is adapted to the size of the insert (not shown) by the cassette 8.

(25) FIG. 6 shows the cassette 8 with the condenser 4. The condenser 4 here has a size that corresponds almost to that of the cassette 8. The cassette 8 here only has the task of functioning as an adapter for the shape of the inserts (not shown).

(26) FIG. 7 and FIG. 8 show installation options for an air conditioner 9 with the cassette 8 for the PTC auxiliary heater 7, or the condenser 4. The exploded diagrams illustrate that the outer shape of the cassettes 8 is configured each time so that they are interchangeable with each other in the insert 3 of the housing of the air conditioner 9. The inner shape of the cassettes 8 is configured so that it corresponds to the outer shape of the heat exchanger the PTC auxiliary heater 7 or the condenser 4. Thus, the heat exchangers 4, 7 are interchangeable with each other.

(27) The glycol heating heat exchanger 6 here is permanently installed in the air conditioner 9. It is also possible for the heat exchangers 4, 6, 7 to be configured already so that the outer shape corresponds to the inserts 3 of the housing of the air conditioner 9. The cassette 8 is de facto integrated in these specially fabricated heat exchangers 4, 6, 7. Thus, these heat exchangers 4, 6, 7 can also be interchanged, like the ones integrated in the cassettes 8.

(28) The condenser 4 in FIG. 8 is arranged upstream from the glycol heating heat exchanger 6. However, the sequence can also easily be reversed.

(29) Thanks to the arrangement and number of the inserts 3, the heat exchangers 4, 6, 7 can be changed in their sequence and thus, for example, be positioned upstream or downstream from permanently installed heat exchangers.

(30) From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, make various changes and modifications to the invention to adapt it to various usages and conditions.

LIST OF REFERENCE SYMBOLS

(31) 1 heat exchanger unit 2 housing 3 inserts 4 heat exchanger, heat pump condenser, heating heat exchanger 5 heat exchanger, heat pump evaporator 6 heat exchanger, heating heat exchanger 7 heat exchanger, electrical heating or cooling element, PTC heating element 8 cassette 9—air conditioner 10 fan 11 airflow 12 cover 13—guide rail 14 guide groove 15 leading-edge bevel