U.S. patent application number 11/916264 was filed with the patent office on 2008-10-09 for charge air intercooler.
This patent application is currently assigned to BEHR GMBH & CO. KG. Invention is credited to Daniel Hendrix, Klaus Moderau.
Application Number | 20080245514 11/916264 |
Document ID | / |
Family ID | 36969192 |
Filed Date | 2008-10-09 |
United States Patent
Application |
20080245514 |
Kind Code |
A1 |
Hendrix; Daniel ; et
al. |
October 9, 2008 |
Charge Air Intercooler
Abstract
The invention relates to a charge air intercooler (1), in
particular for a private car, in which charge air can be cooled by
a coolant flowing through flow channels, whereby the flow channels
for the coolant are formed from flat tubes (6).
Inventors: |
Hendrix; Daniel; (Stuttgart,
DE) ; Moderau; Klaus; (Stuttgart, DE) |
Correspondence
Address: |
FOLEY AND LARDNER LLP;SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Assignee: |
BEHR GMBH & CO. KG
Stuttgart
DE
|
Family ID: |
36969192 |
Appl. No.: |
11/916264 |
Filed: |
June 1, 2006 |
PCT Filed: |
June 1, 2006 |
PCT NO: |
PCT/EP2006/005224 |
371 Date: |
January 22, 2008 |
Current U.S.
Class: |
165/152 |
Current CPC
Class: |
Y02T 10/12 20130101;
Y02T 10/146 20130101; F01P 2060/02 20130101; F02B 29/0462 20130101;
F28D 2021/0082 20130101; F28D 1/05383 20130101 |
Class at
Publication: |
165/152 |
International
Class: |
F28D 1/02 20060101
F28D001/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 3, 2005 |
DE |
10 2005 025 959.6 |
Claims
1. A charge air intercooler, in particular for a passenger vehicle,
in which charge air can be cooled by a coolant flowing in flow
channels, wherein the flow channels for the coolant are formed by
flat tubes.
2. The charge air intercooler as claimed in claim 1, wherein the
flat tubes are arranged in at least one row.
3. The charge air intercooler as claimed in claim 1, wherein two or
more rows of flat tubes are provided one behind the other in the
flow direction of the charge air.
4. The charge air intercooler as claimed in claim 1, wherein at
least two rows of flat tubes are provided, and flow can take place
through these in crosscurrent operation or in cross-counter current
operation in relation to the charge air which is to be cooled,
and/or in that flow can take place through individual chambers of
the flat tubes in crosscurrent operation.
5. The charge air intercooler as claimed in claim 1, wherein the
individual components of the charge air intercooler are soldered
together.
6. The charge air intercooler as claimed in claim 1, wherein
turbulence inserts are arranged in the flat tubes.
7. The charge air intercooler as claimed in claim 1, wherein the
flat tubes terminate in at least one collector tank.
8. The charge air intercooler as claimed in claim 7, wherein the
collector tank has a base with openings which correspond to the
external dimensions of the flat tubes, and the flat tubes are
soldered thereto.
9. The charge air intercooler as claimed in claim 1, wherein
corrugated ribs are provided between the flat tubes.
10. The charge air intercooler as claimed in claim 1, wherein the
coolant is a liquid, in particular water.
11. The charge air intercooler as claimed in claim 1, wherein the
charge air intercooler is arranged in a compressor housing or an
intake housing.
12. The charge air intercooler as claimed in claim 1, further
comprising at least one air tank for guiding the charge air.
13. The charge air intercooler as claimed in claim 1, wherein the
ratio of charge air channel height (HL) to coolant channel height
(HK) is 1:1 to 10:1, in particular 2:1 to 8:1.
Description
[0001] The invention relates to a charge air intercooler according
to the preamble of claim 1.
[0002] In order to increase engine performance, turbochargers are
used for the purpose of compressing the air. In this case, however,
the air, referred to hereinbelow as charge air, is heated to
temperatures of above 150.degree. C. as a result of the compression
in the turbocharger. In order to reduce such air heating, use is
made of air coolers which are arranged at the front of the cooling
module and serve for cooling the charge air. The charge air here
flows through a heat-transfer means which has ambient air flowing
through it in order to cool it.
[0003] This allows the charge air to be cooled to a temperature of
approximately 10-90 K above the temperature of the ambient air. The
cooling of the charge air makes it possible to increase the engine
performance.
[0004] In order to allow improved cooling, use is being made more
and more, in the case of passenger vehicles, of coolant-cooled
charge air intercoolers. In the case of compressor charging, and to
some extent also in the case of turbocharging, these charge air
intercoolers are arranged directly in the intake region (and/or in
the compressor housing). An example of such a known charge air
intercooler is illustrated in detail form in section in FIG. 4. The
charge air intercooler comprises a plurality of metal plates and
profiled elements which are connected to form flow channels for the
coolant and have their ends projecting into collector tanks.
Between the flow channels for the coolant, the charge air which is
to be cooled flows transversely to the flow direction of the
coolant in the flow channels. On account of the high weight and of
the relatively complex production, however, these charge air
intercoolers are expensive. Furthermore, the transfer of heat
leaves something to be desired.
[0005] Taking this prior art as the departure point, it is an
object of the invention to provide an improved charge air
intercooler. This object is achieved by a charge air intercooler
having the features of claim 1. Advantageous configurations form
the subject matter of the subclaims.
[0006] The invention provides a charge air intercooler, in
particular for a passenger vehicle, in which charge air can be
cooled by a coolant flowing in flow channels, the flow channels for
the coolant being formed by flat tubes. In contrast to conventional
charge air intercoolers, the use of flat tubes reduces the number
of parts required, in which case more straightforward production is
possible.
[0007] The flat tubes are preferably arranged in at least one row.
In this case, the coolant flow is preferably deflected over the
width and/or the depth of the charge air intercooler.
[0008] In order for a high level of efficiency to be made possible,
the ratio of charge air channel height to coolant channel height is
preferably 1:1 to 4:1, in particular 2:1 to 3:1. In another
advantageous configuration, the ratio of charge air channel height
to coolant channel height is 1:1 to 10:1, in particular 2:1 to
8:1.
[0009] In order to improve the heat transfer, preferably at least
two rows of flat tubes are provided, and flow can take place
through these in crosscurrent operation or in cross-counter current
operation in relation to the charge air which is to be cooled. As
an alternative, flow can take place through individual chambers of
the flat tubes in crosscurrent operation, in particular if just one
row of flat tubes is provided.
[0010] Production is additionally simplified in that the individual
components of the charge air intercooler including the coolant
tanks are soldered together, soldering preferably taking place in
one operation.
[0011] Turbulence inserts are preferably arranged in the flat tubes
in order to mix the coolant and thus to improve the exchange of
heat.
[0012] The flat tubes terminate in at least one collector tank, and
this may preferably be a deep-drawn collector tank which is
produced from a metal plate and may have a sheet-metal base with
openings for the flat tubes. Directing elements and/or partition
walls may be provided in the collector tank in order to direct the
coolant and distribute it to the flat tubes.
[0013] The openings in the base preferably correspond to the
external dimensions of the flat tubes, and the bases are soldered
to the flat tubes, which are plugged into the openings.
[0014] Corrugated ribs are preferably provided between the flat
tubes, these ribs increasing the heat-transfer surface area and
thus improving the exchange of heat.
[0015] The coolant used is preferably a liquid, in particular
water.
[0016] The charge air intercooler is preferably arranged directly
in a compressor housing or an intake housing, but may also have a
dedicated housing.
[0017] In order to provide for optimum charge air flow, at least
one charge air tank, through which the charge air flows, is
preferably provided.
[0018] The invention is explained in detail hereinbelow by way of
an exemplary embodiment and with reference to the drawing, in
which:
[0019] FIG. 1 shows a schematic perspective illustration, in
exploded form, of a charge air intercooler according to the
invention, without side panels in some areas,
[0020] FIG. 2 shows a schematic perspective illustration of the
charge air intercooler from FIG. 1 with a fastening plate in the
region of the coolant inlet and outlet,
[0021] FIG. 3 shows a schematic section, illustrated in detail
form, through the charge air intercooler from FIG. 1, and
[0022] FIG. 4 shows a schematic section, illustrated in detail
form, through a charge air intercooler from the prior art.
[0023] A charge air intercooler 1 has a first collector tank 2
comprising a deep-drawn first part 3 with a coolant inlet 4 and a
coolant outlet 5 and a flat second part 7 (base) which is provided
with slots for flat tubes 6 and via which coolant (in this case
water) is fed to, and discharged from, the charge air intercooler
1, as is indicated by arrows.
[0024] A partition wall (not illustrated) is provided in the
interior of the first collector tank 2, approximately in the
center, in order to prevent crossflow of the coolant directly from
the coolant inlet 4 to the coolant outlet 5. Arranged between the
flat tubes 6, which are plugged into the slots and in which
turbulence inserts are arranged, are corrugated ribs 8, for the
purpose of increasing the heat-transfer surface area.
[0025] A second collector tank 9 is arranged on that side of the
flat tubes 6 which is located opposite the first collector tank 2.
The second collector tank 9, corresponding to the first collector
tank 2, has a deep-drawn first part 10 and a flat second part 11
(base) which is provided with slots for flat tubes 6, it being the
case that, rather than having a coolant inlet 4 and coolant outlet
5, the deep-drawn first part 10 merely deflects the coolant from
one row of flat tubes to the next row of flat tubes.
[0026] Throughout the region between the two bases of the collector
tanks 2 and 9, as is indicated by a large arrow in FIG. 1, charge
air which is to be cooled flows through the charge air intercooler
1, and in the present case the coolant flows in
cross-countercurrent operation essentially perpendicularly to the
flow direction of the charge air through the rows of flat
tubes.
[0027] In order to achieve the highest possible level of
efficiency, the height of the charge air channel HL here is
approximately 2.5 times the height of the coolant channel HK.
[0028] It is the case here, within the production framework, that
all the parts of the charge air intercooler 1, once assembled, are
soldered together in a single operation.
[0029] According to a variant which is not illustrated in the
drawing, just a single row of flat tubes is provided. Turbulence
inserts are arranged in the flat tubes here, and these ensure
better mixing of the coolant.
[0030] According to a second variant which is not illustrated in
the drawing, corresponding to the first variant, just one row of
flat tubes with turbulence inserts is provided, but in this case
the flat tubes are subdivided so as to allow cross-countercurrent
operation in conjunction with partition walls in the collector
tanks.
[0031] In the present case, as described in the exemplary
embodiment and the variants thereof, such a charge air intercooler
is integrated directly in the intake housing, but it is also
possible for it to be arranged, for example, in the compressor
housing or in a dedicated housing.
* * * * *