Vehicle radiator

Abstract

A vehicle radiator with a plurality of flat tubes, fins, two tube plates having an upright continuous edge and collars around tube plate openings soldered to tube ends, and two collecting tanks. The tanks have a continuous edge protrusion with a recess, the upright edge of the tube plates being bent into the edge protrusion. A continuous seal protrusion on the edge protrusion of the collecting tanks and supported on the flat tube plates define a space between the collecting tanks and the tube plates about their periphery or, alternatively, an insert is provided in the tube plates and includes an edge strip soldered on one side to the tube plate upright edge and a member supporting the inside of the edge protrusion. A seal is between the tube plate and the collecting tank.

Description

CROSS REFERENCE TO RELATED APPLICATION(S)

[0001] Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

[0003] Not applicable.

TECHNICAL FIELD

[0004] The present invention is directed toward heat exchangers, and more particularly to vehicle radiators having tubes between tube plates and plastic collecting tanks.

BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART

[0005] Vehicle radiators having flat tubes, corrugated ribs and tube plates with an upright continuous edge and with openings that match the cross-section of the flat tubes, into which the ends of the flat tubes discharge are well known in the art. In many such radiators, the plate openings are designed with collars to which the tube ends are soldered, and with plastic collecting tanks that are fastened mechanically on their edge protrusion to the edge of the tube plates with insertion of a seal, the edge of the tube plates being bent onto the edge protrusion of the collecting tanks by clamping.

[0006] A vehicle radiator with these features is known, for example, from FIG. 2 of DE 34 40 489 C2, which has only one essentially flat tube plate with a collecting tank on one end of the flat tubes, with the flat tubes having an elongated connector so that the cooling water on the other end of the flat tube is deflected and flows back to the collecting tank. Ordinarily, for clamping of the collecting tank on the tube plate, a continuous groove is formed in the tube plate in which the seal is mounted and therefore cannot slide, as is also shown in FIG. 6 of DE 34 40 489 C2, such tube plates therefore not being viewed as being designed essentially flat.

[0007] DE 100 16 029 A1 is another example of a structure in which the tube plates are not essentially flat, as is EP 1 273 864 A2, which addresses the desire to equip vehicle radiators with smaller core depths (depths of the flat tubes and corrugated ribs) while minimizing the change in periphery by providing a second tube plate or intermediate plate. However, use of metal collecting tanks may be relatively costly, particularly where additional functional elements are required of the tank by design considerations. Further, the edge of the collecting tank protrudes beyond the core, and therefore requires more space for the radiator than required by the core.

[0008] Still further, in radiators in which the tank is clamped on a tube plate, not only during clamping but also during operation of the radiator there are often problems because the wall of the collecting tank or the edge protrusion does not remain stable but falls inward or slides.

[0009] The present invention is directed toward overcoming one or more of the problems set forth above.

SUMMARY OF THE INVENTION

[0010] In one aspect of the present invention, a vehicle radiator is provided including a plurality of flat tubes with corrugated fins therebetween, two tube plates having an upright continuous edge, collars in the tube plates around tube plate openings, the collars being soldered to ends of the flat tubes, and two plastic collecting tanks. The tanks have a continuous edge protrusion with a recess therein, the upright edge of the tube plates being bent into the edge protrusion recess to mechanically fastened the collecting tanks to the tube plates. A continuous seal protrusion is on the edge protrusion of the collecting tanks and supported on the flat tube plates to define a space between the collecting tanks and the tube plates about their periphery. A seal is in the defined space between the tube plate upright edge and the collecting tank edge protrusion.

[0011] In one form of this aspect of the present invention, the edge protrusion recess is substantially continuous and reinforced with connectors arranged at intervals defining a series of compartments. In a further form, flanges are at intervals about the upright edge of the tube plates, where the intervals correspond to the connector intervals.

[0012] In another form of this aspect of the present invention, tabs on the continuous edge protrusion are adapted to position the seal in the recess.

[0013] In yet a further form of this aspect of the present invention, a device is provided for clamping the collecting tank to the tube plate to produce the vehicle radiator, wherein the tube plate includes protrusions and the device includes first punches adapted to engage the edge protrusion recess of the tank to hold down the tank on the tube plate, and second punches between the first punches and adapted to bend the tube plate protrusions into the recess. In a still further form, the first and second punches engage the recess and the plate protrusions respectively from a direction perpendicular to tube plate.

[0014] In still another aspect of the present invention, a vehicle radiator is provided, including a plurality of flat tubes with corrugated fins therebetween, two tube plates having a continuous upright edge, collars in the tube plates around tube plate openings, the collars being soldered to ends of the flat tubes, and two plastic collecting tanks having a continuous edge protrusion with a recess therein. The upright edge of the tube plates is bent into the edge protrusion recess to mechanically fasten the collecting tanks to the tube plates. An insert in the tube plates includes an edge strip soldered on one side to the tube plate upright edge and a member supporting the inside of the edge protrusion A seal is between the tube plate and the collecting tank.

[0015] In one form of this aspect of the present invention, stops on the insert support the collecting tank edge protrusion.

[0016] In another form of this aspect of the present invention, cross connectors between sides of the insert support the collecting tank edge protrusion.

[0017] In still another form of this aspect of the present invention, deformed edge strips on the insert support the collecting tank edge protrusion.

[0018] In yet another form of this aspect of the present invention, a groove is provided in the tank edge protrusion, and the other side of the insert edge strip is received in the groove.

[0019] In still another form of this aspect of the present invention, the tank edge protrusion is supported in a groove in the insert edge strip. In a further form, the insert edge strip groove has an inner wall and an outer wall, and the outer wall is secured to the tube plate upright edge.

[0020] In yet another form of this aspect of the present invention, protrusions on the other side of the insert edge strip engage tube plate openings to secure the insert part in the tube plate.

[0021] In a still further form of this aspect of the present invention, the collars are aligned in the direction of the flat tubes and the tube plates are flat.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIGS. 1-5 are perspective cutaway views of the connection of a collecting tank and flat plate of a vehicle radiator according to a first aspect of the present invention;

[0023] FIGS. 6-28 variously illustrate a second aspect of the present invention, where:

[0024] FIGS. 6-7 illustrate one embodiment of pre-attachment of a tank and plate;

[0025] FIGS. 8-9 illustrate another embodiment of pre-attachment of a tank and plate, with FIG. 9 being a cross-sectional view along line 9-9 of FIG. 8;

[0026] FIGS. 10-12 illustrate various embodiments of an insert part usable with the present invention;

[0027] FIG. 13 is a cross-sectional view illustrating another embodiment of pre-attachment of a tank and plate;

[0028] FIGS. 14-16 variously illustrate collecting tanks which may be used with the present invention;

[0029] FIG. 17 is a partial view and FIGS. 18-23 are cross-sectional views of the edge of a tube plate and the edge strips of various insert parts usable with the present invention;

[0030] FIG. 24 is a front view and

[0031] FIG. 25 a side view of an end of a charge air cooler with which the present invention may be used;

[0032] FIG. 26 is a top view of a tube plate of a coolant radiator, and

[0033] FIG. 27 is a top view of a tube plate of a charge air cooler, which may be used in accordance with the present invention; and

[0034] FIG. 28 is a cross-sectional view of yet another embodiment illustrating the edge of a tube plate and the edge strips of an insert part usable with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0035] A vehicle radiator 30 according to one embodiment illustrated in FIGS. 1-5 may be constructed of a suitable cooling grate or core including a series of flat tubes 32 and corrugated fins or ribs 34. Two tube plates 36 include a plurality of openings 38 and are secured to opposite ends of the tubes 32 whereby the flow may occur through the plate openings 38 and the tubes 32. The tube plates 36 are each connected to a collecting tank 40.

[0036] FIG. 1 shows a cutout of one side of the vehicle radiator 30 with one part of a tube plate 36, with only two flat tubes 32 of the mentioned row, with as many openings 38, and with part of the corrugated ribs 34 arranged between the flat tubes 32 and traversed by the cooling air (dashed arrows). The openings 38 are formed with collars 42 facing the flat tubes 32 and corrugated ribs 34, onto which the ends of the flat tubes 32 are tightly and firmly soldered. The ends of the flat tubes 32 may end beneath the surface of tube plate 38 in order to keep the pressure loss of the cooling medium flowing through the flat tubes 32 low (solid arrows).

[0037] Part of a collecting tank 40 is also apparent in FIG. 1. The tank 40 may be produced from plastic in an injection molding process, and is mechanically fastened on its continuous edge protrusion 44 to the continuous deformed edge 46 of the essentially flat tube plate 38. The deformed edge 46 of the tube plate 38 is bent onto the edge protrusion 44 of the collecting tank 40 by clamping. The opposite side of the vehicle radiator (not shown) is designed identically.

[0038] A continuous protrusion 50 on the edge protrusion 44 of the collecting tank 40 is supported on the flat tube plate 36 and defines a space 54 to accommodate a seal 56 on the deformed edge 46 of tube plate 36. The seal 56 in the practical example in its uncompressed condition has a round cross-section which would protrude above the cross-section of the space 54, and is broadly pinched during clamping so that the sealing effect is produced by substantially filling the space 54 with the seal 56.

[0039] The openings 38 in the tube plates 36 extend on both ends roughly to the continuous protrusion 50 on the edge protrusion 44 of collecting tanks 40 so that only a slight protrusion of the deformed edge 46 beyond the periphery of the core (the flat tubes 32 and corrugated ribs 34) is created. It is apparent in FIGS. 1 and 2 that the protrusion 50 lying on the flat tube plate 36 is arranged roughly perpendicular over one end of the openings 38. The other end of openings 38 and the opposite side of the collecting tanks 40 are not shown, but are designed identically, which is expressed by the "continuous" edge 46 of the tube plate 38 and the "continuous" edge protrusion 44 of the collecting tank 40.

[0040] The edge protrusions 44 of the collecting tanks 40 are formed with a recess 60 into which the deformed edge 46 of the tube plates 36 engages. While the protrusion 50 on the bottom of edge protrusion 44 of the collecting tanks 40 is formed, the recess 60 on the top of the edge protrusion 44 of the collecting tanks 40 is formed as a continuous groove. The deformed edge 46 of the tube plate 36 engaging in recess 60 requires bending of this edge 46 inward by much more than 90.degree. so that the securing function of the deformed edge 46 relative to the wall of collecting tank 40 is satisfied. In the practical example, the edge 46 was bent inward by about 130.degree. from the vertical into the recess 60 of the edge protrusion 44. The collecting tank 40 has no other stop on the tube plate 36, since essentially flat tube plates 36 are provided. According to FIG. 1, the deformed edge 46 was fully bent into the recess 60.

[0041] FIGS. 2 and 3 show a modification wherein the deformed edge 46 of the tube plates 36 are formed with protrusions 66 arranged at intervals. These protrusions 66 are bent into the recess 60 which, as is apparent from FIG. 3, may be divided into compartments 68 by means of connectors 70. The connectors 70 lead to higher rigidity in the recess 60, which can therefore be designed with smaller wall thickness so that the protrusion 72 above the core is further minimized.

[0042] A device for clamping the collecting tanks 40 with the tube plates 36 can also be deduced from FIG. 3, and includes a forming punch 76 alternates in series with a hold-down punch 78. The hold-down punches 78 each engage in a compartment 68 of the recess 60 and hold the collecting tank 40 in the desired position. The forming punch 76 bends a protrusion 66 on the deformed edge 46 into the adjacent compartment 68. (Only one forming punch 76 and one hold-down punch 78 are depicted in FIG. 3). In order to satisfy its hold-down function, the hold-down punch 78 should be active somewhat earlier in time than the forming punch 76. The device may be advantageously situated in a metal-forming machine indicated functionally in FIG. 3 by reference number 80. Punches 76, 78 act at roughly right angles to flat tube plate 36 on the deformed edge 46 and the edge protrusion 44.

[0043] It can be deduced from FIG. 4 that the vehicle radiator may be equipped with a core of smaller depth (<T) without changes, for example, in the connection between tube plate 36 and collecting tank 40. For this reason, the collar 42 of a smaller opening 38' in tube plate 36 is indicated with reference number 42', which pertains to a core with the smaller depth (<T). The greater depth is marked with >T in FIG. 4.

[0044] Tabs 84 may also be provided to ensure support desired positioning of seal 56. The tabs 84 may be formed on the protrusion 50 of edge protrusion 44 of collecting tanks 40 at a spacing from each other (see FIG. 4 and 5).

[0045] Reference will now be had to FIGS. 6-27, in which comparable components to those just described have been given reference numbers which are increased by one hundred.

[0046] As is apparent from the partial views of FIGS. 24 and 25, the plastic collecting tanks 140 have an air inlet or outlet connector 200 (only one of the two collecting tanks is shown). The edge protrusion 144 of the collecting tanks 140 is fastened to the edge 146 of the tube plates 136 by clamping. The charge air cooler has a series of flat tubes 132 with corrugated ribs 134 arranged in-between, and the tube plates 136 each have openings 138, each of which is provided with a collar 142, aligned with the core.

[0047] The radiator also has a side part 204 on each narrow side, one of the side parts being apparent in FIGS. 24-25. In the practical examples described below, an insert part 210 is used, which is inserted into tube plate 136, where different variants of the insert part 210 are shown in FIGS. 10-12.

[0048] The insert part 210 may advantageously be made from aluminum sheet by deformation, and have differently configured edge strips 212 according to the different variants, which impart a frame-like configuration to insert part 210. Cross-connectors 216 are provided in FIGS. 10-12 between the two long sides of insert part 210 and its deformed edge strip 212.

[0049] The cross-connectors 216 may advantageously improve the stability of the insert part 210, and an effect in which the gas or liquid streams are guided may also be imparted by the cross-connectors 216 by appropriate design of the setting angle a (FIG. 12). The size of setting angle a can vary from cross-connector 216 to cross-connector 216 as a function of the position of the inlet or outlet connector 200. For this purpose, the cross-connectors 165 on both ends are only connected via a relatively narrow and therefore rotatable connector 218 to the edge strips 212. It should be understood, however, that the cross-connectors 216 are an option which may or may not be used within the broad scope of the present invention, and can also be dispensed with, for example, with smaller radiator sizes.

[0050] Protrusions 220 may also be provided on the lower edge of the edge strips 212, with the protrusions 220 passing into openings 224 in tube plate 136. The protrusions 220 and openings 224 together may be used to temporarily secure the edge strips 212 in the tube plate 136 so that the soldering process can be conducted (see FIGS. 8, 11, 27).

[0051] The same task with reference to pre-attachment may also be solved, for example, in the practical example from FIG. 13, which shows a section through the clamping, by bent protrusions or legs 166 which act on the edge strips 212 of the insert part 210.

[0052] FIGS. 6-7 illustrate yet another example of suitable pre-attachment, in which cutouts 228 are provided at intervals on the edge of tube plate 136 into which a protrusion 226 on the edge strip 212 is bent. In addition, the edge strip 212 of the insert part 210 is deformed groove-like with inner and outer walls 230, 231 in this practical example. The seal 156 is inserted into this groove, on which the edge protrusion 144 of the collecting tank 140 can lie (not shown in FIGS. 6-7). The outer wall of the groove or the edge strip 212 is soldered on the inside to the edge 146 of the tube plate 136, and clamping can occur as repeatedly shown in the other figures.

[0053] Still another advantageous practical example is shown in FIGS. 8-9, in which the seal 156 is situated in a continuous recess of the edge protrusion 144 of the collecting tank 140. The seal 156 itself is a rubber strip of roughly rectangular cross-section produced by extrusion and cut to the corresponding length. The recess in the edge protrusion 144 has cross-sectional constrictions 232 arranged at intervals (see FIG. 9). These serve to impart the corresponding support to the seal 156 by clamping it there and, consequently, it cannot fall out of the recess during assembly of the collecting tank 140, when the sealing effect is achieved by pressing the seal 156 against the edge strip 212 of the insert part 210. On the inside, the edge protrusion 144 lies against the already described cross-connectors 216 of the insert part 210 and therefore cannot slide. In another practical example (not shown) the cross-connectors 216 omitted with only individual deformations in the insert part 210 arranged in a row and serving as means to support the edge protrusion 144.

[0054] Still another structure which may be advantageously used to avoid sliding and to guarantee stability of the position of edge protrusion 144 is the provision of a groove 236 in edge protrusion 144, into which one edge or side of the edge strip 212 engages (FIGS. 17-20). This practical example requires a correspondingly adjusted deformation of the edge strip 212, as shown by the cuts in the mentioned figures. Such a groove may be omitted, as illustrated in FIGS. 13, 21 and 23, in which case the deformation of the edge strip 212 and the edge protrusion 144 may be modified so that a support of the edge protrusion 144 on the edge strip 212 is present.

[0055] FIGS. 14-16 particularly illustrate universal and cost-effective collecting tanks 140 which are made of plastic and may be advantageously used with the present invention. A partition 240 may be provided in the plastic collecting tank 140, whereby flow through the radiator can be chosen advantageously for specific applications. The seal 156 includes a cross-connection 242 on which the partition 240 lies during assembly of the collecting tank 140. Complete flow deflection can be achieved by an additional insert part 244 beneath the partition 240 or cross-connection 242.

[0056] Already-discussed FIGS. 17-23 are partial views or sections through the edge 146 of the tube plate 136 and the edge strips 212 of the insert part 210 in different practical examples from which, among other things, the clamping is also apparent. As particularly shown in FIG. 17, the outer edge of the edge protrusion 144 has cutouts, which are provided where the protrusions 166 are present on the edge 146 of the tube plate 136. Because of this, a somewhat smooth (i.e., continuous) connection edge is obtained on the outside. The protrusions 166, as already described above, are bent inward and produce the clamping although it should be appreciated that, with this alternative, it is not necessary to bend the protrusions 166 into the recesses since the stability of the position of edge protrusion 144 here is produced by the other expedients described above.

[0057] FIGS. 21-23 and 26-27 illustrate yet another feature which may be used to position the insert part 210 in the tube plate 136, with knobs or indentations 246 are embossed at intervals on the edge of the edge strip 212 on the bottom of tube plate 136. A precise positioning of the insert part 210 is achieved with this than might otherwise be possible because of the bending radius on the edge 146 of the tube plate 136.

[0058] FIGS. 26 and 27 each show the inside of an essentially flat tube plate 136, with FIG. 26 showing the tube plate 136 of a coolant radiator and FIG. 27 showing the tube plate 136 of a charge air cooler. The openings 138 for the ends of the flat tubes are apparent there as well as the described knobs or indentations 246. The openings 168 accommodate the protrusions 220 on the lower edge of the edge strip 212, and the edge 146 of tube plate 136 is only bent (i.e., aligned). The tube plates 36, 136 require no groove to accommodate the seal.

[0059] FIG. 28 shows another modified variant in which the collar 142 is formed on the openings 138 in the tube plate 136 facing the direction of the collecting tank 140. The insert part 210 may be as previously described in FIGS. 19-20.

[0060] It follows from the preceding description and from the figures that the present invention lead to a minimal and therefore tolerable protrusion 72 of collecting tank 40, 140 above the core, and that the core itself may be further reduced in size further the at least some aspects of the present invention. Moreover, at least some aspects of the present invention permit provision of a cooling grate of smaller depth T. In addition, despite the essentially flat tube plates 36, 136, a stable position of the wall of the collecting tank 40, 140 may be provided.

[0061] Further, vehicle radiators designed according to the present invention may be made with a conceivably small modification expense to a radiator of a smaller block depth. More cost-effective production of the tube plates required for this purpose with smaller openings may also be achieved, since this is possible in principle with the existing tube plate die in which only the hole punch set for larger openings integrated in the die need be replaced with a hole punch set for smaller openings.

[0062] Moreover, a vehicle radiator in which the openings extend to the protrusion on the collecting tank requires a relatively small incorporation space because the bulge of the edge protrusion of the collecting tank beyond the flat tubes is conceivably small, since no space-demanding groove is provided in the tube plates. In prior art designs, the groove is not only provided to accommodate the seal, but represents a stop for the edge protrusion of the collecting tank, which therefore cannot fall inward during the clamping process or during operation of the vehicle radiator. This function is otherwise provided by the present invention in that a recess is provided on the edge protrusion of the collecting tank into which the edge of the tube plate engages so that the collecting tank remains stable and cannot fall inward even though the tube plate is essentially flat (i.e., it has no continuous groove and no other essential deformations between the openings that extend above the surface of the tube plate and could form a stop for the collecting tank).

[0063] In accordance with the present invention, falling inward of the edge protrusion or the wall of the collecting tank having the edge protrusion may also be advantageously prevented during the clamping process through appropriate configuration of the clamping tool.

[0064] Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.

Claims

1. A vehicle radiator comprising: a plurality of flat tubes with fins therebetween; two tube plates having an upright continuous edge; collars in said tube plates around tube plate openings, said collars being soldered to ends of said flat tubes; two plastic collecting tanks having a continuous edge protrusion with a recess therein, said upright edge of the tube plates being bent into the edge protrusion recess to mechanically fastened the collecting tanks to the tube plates; a continuous seal protrusion on the edge protrusion of the collecting tanks and supported on the flat tube plates to define a space between the collecting tanks and the tube plates about their periphery; and a seal in said defined space between said tube plate upright edge and said collecting tank edge protrusion.

2. The vehicle radiator of claim 1, wherein said edge protrusion recess is substantially continuous and reinforced with connectors arranged at intervals defining a series of compartments.

3. The vehicle radiator of claim 2, further comprising flanges at intervals about the upright edge of the tube plates, said intervals corresponding to said connector intervals.

4. The device of claim 1, further comprising tabs on the continuous edge protrusion adapted to position said seal in said recess.

5. A device for clamping the collecting tank to the tube plate to produce a vehicle radiator according to claim 1, wherein said tube plates include protrusions, said device comprising: first punches adapted to engage said edge protrusion recess of said tank to hold down said tank on said tube plate; and second punches between said first punches and adapted to bend said tube plate protrusions into the recess.

6. The device of claim 5, wherein said first and second punches engage said recess and said plate protrusions respectively from a direction perpendicular to tube plate.

7. A vehicle radiator comprising: a plurality of flat tubes with fins therebetween; two tube plates having a continuous upright edge; collars in said tube plates around tube plate openings, said collars being soldered to ends of said flat tubes; two plastic collecting tanks having a continuous edge protrusion with a recess therein, said upright edge of the tube plates being bent into the edge protrusion recess to mechanically fasten the collecting tanks to the tube plates; inserts in said tube plates, said inserts including an edge strip soldered on one side to the tube plate upright edge and a member supporting the inside of said edge protrusion; and a seal between said tube plate and said collecting tank.

8. The vehicle radiator of claim 7, further comprising stops on said insert supporting said collecting tank edge protrusion.

9. The vehicle radiator of claim 7, further comprising cross connectors between sides of said insert, said cross connectors supporting said collecting tank edge protrusion.

10. The vehicle radiator of claim 7, further deformed edge strips on said insert, said deformed edge strips supporting said collecting tank edge protrusion.

11. The vehicle radiator of claim 7, further comprising a groove in said tank edge protrusion, wherein said other side of said insert edge strip is received in said groove.

12. The vehicle radiator of claim 7, wherein said tank edge protrusion is supported in a groove in said insert edge strip.

13. The vehicle radiator of claim 12, wherein said insert edge strip groove has an inner wall and an outer wall, and said outer wall is secured to the tube plate upright edge.

14. The vehicle radiator of claim 7, further comprising protrusions on the other side of the insert edge strip, said protrusions engaging tube plate openings to secure the insert part in the tube plate.

15. The vehicle radiator of claim 7, wherein said collars are aligned in the direction of the flat tubes and the tube plates are flat.