U.S. patent application number 15/104035 was filed with the patent office on 2016-12-29 for collection box and corresponding heat exchanger.
This patent application is currently assigned to Valeo Systemes Thermiques. The applicant listed for this patent is Valeo Systems Thermiques. Invention is credited to Jean-Marc Lesueur, Christian Riondet.
Application Number | 20160377357 15/104035 |
Document ID | / |
Family ID | 50289932 |
Filed Date | 2016-12-29 |
United States Patent
Application |
20160377357 |
Kind Code |
A1 |
Riondet; Christian ; et
al. |
December 29, 2016 |
COLLECTION BOX AND CORRESPONDING HEAT EXCHANGER
Abstract
The invention relates to a collection box (1) for a heat
exchanger comprising a header (5) having an at least partially
rounded shape and comprising: a plurality of openings (7) for the
passage of a plurality of heat-exchange tubes (3) of the heat
exchanger, and a plurality of flanges (9) surrounding the openings
(7). According to the invention, the header (5) comprises a
plurality of corrugations (11), and the flanges (9) are created at
the corrugations (11) of the header (5) and respectively have a
substantially flared shape directed away from the volume defined by
the collection box (1).
Inventors: |
Riondet; Christian;
(Bourgogne, FR) ; Lesueur; Jean-Marc; (Boult sur
Suippe, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Valeo Systems Thermiques |
Le Mesnil Saint-Denis |
|
FR |
|
|
Assignee: |
Valeo Systemes Thermiques
Le Mesnil Saint-Denis
FR
|
Family ID: |
50289932 |
Appl. No.: |
15/104035 |
Filed: |
October 14, 2014 |
PCT Filed: |
October 14, 2014 |
PCT NO: |
PCT/EP2014/071941 |
371 Date: |
September 21, 2016 |
Current U.S.
Class: |
165/173 |
Current CPC
Class: |
F28F 1/02 20130101; F28F
2275/04 20130101; F28F 9/04 20130101; F28F 9/0224 20130101; F28F
2275/00 20130101; F28F 2225/08 20130101; F28F 2280/00 20130101;
F28F 9/0243 20130101 |
International
Class: |
F28F 9/04 20060101
F28F009/04; F28F 1/02 20060101 F28F001/02; F28F 9/02 20060101
F28F009/02 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 13, 2013 |
FR |
1362571 |
Claims
1. A collection box for a heat exchanger comprising a header having
an at least partially rounded shape, the header comprising: a
plurality of openings for the passage of a plurality of
heat-exchange tubes of the heat exchanger; and a plurality of
flanges surrounding the openings; and a plurality of corrugations,
wherein the flanges are created at the corrugations of the header
and respectively have a substantially flared shape directed away
from the volume defined by the collection box.
2. The collection box as claimed in claim 1, in which the flanges
are formed at the crests of the corrugations facing away from the
volume defined by the collection box.
3. The collection box as claimed in claim 1, in which the header
has at least one wall, the shape of which is substantially dished
towards the outside of the volume defined by the collection
box.
4. The collection box as claimed in claim 3, in which the
corrugations are formed on the wall.
5. The collection box as claimed in claim 1, in which the
corrugations respectively have a top height of the order of 30% of
the pitch of the tubes.
6. The collection box as claimed in claim 1, in which the flanges
respectively have a substantially conical shape.
7. The collection box as claimed in claim 6, in which a cone formed
by a flange has an angle of the order of 30.degree..
8. The collection box as claimed in claim 1, in which the flanges
respectively have: a first width ; and a second width two times
greater than the first width.
9. The collection box as claimed in claim 8, in which the first
width is substantially equal to the width of a tube intended to be
inserted in the opening.
10. The collection box as claimed in claim 1, in which the flanges
respectively have two convex substantially flared edges with the
convexity facing toward the outside of the volume defined by the
collection box.
11. The collection box as claimed in claim 1, in which the flanges
have a height of the order of half the height of a corrugation.
12. The collection box as claimed in claim 1, in which the flanges
are thinned with respect to the corrugations on the header.
13. The collection box as claimed in claim 12, in which the
thinning of the material at a flange is at least greater than 30%
of the initial thickness of the material.
14. A heat exchanger for a motor vehicle, comprising a
heat-exchange core bundle of tubes, the ends of which are fixed to
at least one collection box in accordance with claim 1.
15. The heat exchanger as claimed in claim 14, in which the
heat-exchange tubes have a height comprised between 1.2 mm and 1.8
mm.
16. The heat exchanger as claimed in claim 14, in which the pitch
of the heat-exchange tubes is comprised between 6 mm and 8 mm.
Description
[0001] The invention relates to a collection box for a heat
exchanger, particularly for a motor vehicle. The invention also
relates to a corresponding heat exchanger. Such a heat exchanger
is, for example, used in a motor vehicle, notably as a radiator for
the cooling system, or in high-pressure applications, for example
as a condenser for an air conditioning system.
[0002] In general, such a heat exchanger comprises a core bundle of
tubes and at least one collection box. This collection box is
configured to accept the ends of the tubes of the heat
exchanger.
[0003] For that purpose, the collection box generally comprises a
header, for example in the form of a header plate. The collection
box generally also comprises a cover that fixes to the header plate
to close the collection box.
[0004] The header plate allows the fluid to be distributed to the
heat exchange tubes or allows the fluid from these heat exchange
tubes to be collected. The header plate is generally made of
aluminum and may for example be produced by stamping.
[0005] The header plate generally has a flat bottom.
[0006] However, in applications intended to withstand pressure, it
is known practice for the header to have an at least partially
rounded bottom in order to withstand the pressure. Moreover, the
flat-bottomed or dished-bottomed header plate is usually provided
with flanges surrounding openings through which the ends of the
tubes of the core bundle of the heat exchanger pass.
[0007] The openings such as slots are made in the header plate for
the introduction of the tubes, for example with a removal of
material or, on the other hand, without removing material. In the
latter case, the material is pushed by the tooling towards the
inside of the volume defined by the collection box, thus creating a
flange around the opening for the introduction of the tube. These
are referred to as standard flanges.
[0008] The flanges make it possible to ensure contact between the
tube and the opening in the header plate and to obtain high-quality
brazing in the case of brazed, for example all-aluminum,
exchangers.
[0009] The tubes are generally inserted into the opening in the
same direction as the tooling used to create the flanges around the
openings. The inserted tubes generally extend partially into the
collection box in order to guarantee correct brazing and firm and
leaktight assembly. With certain solutions, the tubes protrude into
the volume forming a reservoir for the fluid by almost half the
volume of the collection box.
[0010] However, having the tubes protruding into the volume defined
by the interior volume of the collection box that forms a reservoir
for the fluid creates an internal pressure drop in the fluid
circuit. This internal pressure drop entails increasing the pumping
power in order to maintain a certain fluid flow rate.
[0011] According to a known solution, a flat-bottomed collection
box may have flanges referred to as reverse flanges which means to
say flanges produced in the opposite direction to the direction of
insertion of a heat-exchange tube. The flanges than have a flared
shape facing away from the volume defined by the collection box.
However, such reverse flanges are only very slightly flared, which
in other words means that the known reverse flanges define a small
entry cone for the insertion of the heat-exchange tubes. The entry
cone may therefore not be enough to allow the heat-exchange tubes
to be inserted simply, and the solutions known from the prior art
may present difficulties with inserting the heat-exchange tubes
into the header.
[0012] Because of this difficulty of inserting the heat-exchange
tubes into the header that has such reverse flanges, such a
reverse-flanges solution for a round-bottomed header is not
envisioned in the prior art where so-called standard flanges take
preference.
[0013] It is an objective of the invention to propose a collection
box that allows these problems of the prior art to be solved.
[0014] To this end, one subject of the invention is a collection
box for a heat exchanger comprising a header having an at least
partially rounded shape and comprising a plurality of openings for
the passage of a plurality of heat-exchange tubes of the heat
exchanger, and a plurality of flanges surrounding the openings,
characterized in that the header further comprises a plurality of
corrugations, and in that the flanges are created at the
corrugations of the header and respectively have a substantially
flared shape directed away from the volume defined by the
collection box.
[0015] According to one preferred embodiment, the flanges are
formed at the crests of the corrugations facing away from the
volume defined by the collection box.
[0016] Such an at least partially rounded box is suited to
withstanding pressure in high-pressure applications, and the header
with such reverse flanges, namely flanges facing in the opposite
direction to the usual direction of insertion of the tubes, is able
to accept the ends of the tubes which, previously, would have
projected into the volume defined by the collection box.
[0017] The ends of the tubes therefore no longer open into the
volume defined by the collection box. This results in a significant
reduction in the pressure drop associated with the flow of a fluid
through the tubes of the heat exchanger.
[0018] In conclusion, by combining an at least partially rounded
header with a plurality of corrugations there is enough material to
form reverse flanges that are flared enough to facilitate the
introduction of the heat-exchange tubes. Specifically, the reverse
flanges according to the invention define a substantially
tulip-shaped inlet opening for the insertion of the heat exchange
tubes that is wide enough because of this addition of material.
[0019] Said collection box may further comprise one or more of the
following features considered separately or in combination: [0020]
the header has at least one wall, the shape of which is
substantially dished towards the outside of the volume defined by
the collection box, [0021] the corrugations are formed on the wall,
[0022] the corrugations respectively have a top height of the order
of 30% of the pitch of the tube, this height being sufficient to
form a flange, [0023] the flanges respectively have a substantially
conical shape, [0024] a cone formed by a flange has an angle of the
order of 30.degree., making it easier at the same time for the
plurality of heat-exchange tubes to be introduced into the header
openings surrounded by the flanges, [0025] the flanges respectively
have a first width and a second width greater than the first width,
for example of the order of twice the first width, thus offering an
opening that is wide enough to facilitate introduction of all the
heat exchange tubes into the openings in the header, [0026] the
first width is substantially equal to the width of a tube intended
to be inserted in the opening, [0027] the flanges respectively have
two convex substantially flared edges with the convexity facing
toward the outside of the volume defined by the collection box,
[0028] the flanges have a height of the order of half the height of
a corrugation, [0029] the flanges are thinned with respect to the
corrugations on the header so that the corrugations respectively
have a first thickness and the flanges respectively have a second
thickness smaller than the first thickness of the corrugation,
[0030] the thinning of the material at a flange is at least greater
than 30% of the initial thickness of the material, or even locally
greater than 50% of the initial thickness of the material. By
thinning the material the flanges can be lengthened in order to
obtain enough of a flare to facilitate the introduction of the
tubes.
[0031] The invention also relates to a heat exchanger, particularly
for motor vehicles, comprising a heat-exchange core bundle of
tubes, the ends of which are fixed to at least one collection box,
as defined hereinabove.
[0032] This may be a brazed heat exchanger.
[0033] As an alternative, it may be a heat exchanger of which the
elements that form the collection box are mechanically assembled to
one another.
[0034] According to one embodiment, the heat-exchange tubes have a
height comprised between 0.8 mm et 2.5 mm, preferably between 1.2
mm and 1.8 mm.
[0035] The pitch of the heat-exchange tubes, which means to say the
center-distance between two heat-exchange tubes, is, for example,
comprised between 5 mm and 10 mm, preferably between 6 mm and 8
mm.
[0036] Further features and advantages of the invention will become
more clearly apparent from reading the following description, given
by way of illustrative nonlimiting example, and from studying the
attached drawings among which:
[0037] FIG. 1 is a perspective view of a collection box according
to the invention for a heat exchanger,
[0038] FIG. 2 is a partial view in cross section of the collection
box of FIG. 1 accepting an end of a partially depicted tube of a
core bundle of tubes of the heat exchanger,
[0039] FIG. 3 is a side view in cross section of the header of FIG.
1,
[0040] FIG. 4a is a first perspective view of a header of the
collection box of FIGS. 1 to 3,
[0041] FIG. 4b is a second perspective view of the header of the
collection box of FIGS. 1 to 3,
[0042] FIG. 5 is a view in transverse section of the header of
FIGS. 4a and 4b, and
[0043] FIG. 6 is an enlarged view of the header of FIG. 5 accepting
ends of tubes of the heat exchanger.
[0044] In these figures, elements that are identical bear the same
references.
[0045] FIG. 1 schematically and in simplified form depicts a fluid
collection box 1 for a heat exchanger (not depicted), notably in
the automotive field. The heat exchanger may be used in particular
as a radiator or as a condenser for a motor vehicle.
[0046] In particular, the invention may be applied to a brazed heat
exchanger.
[0047] The heat exchanger comprises a core bundle of tubes 3. Only
one end of one tube 3 is visible in FIG. 2. The tubes 3 are for
example made of aluminum or aluminum alloy. They are, for example,
substantially flattened tubes 3.
[0048] The collection box 1 is configured to accept at least one
end of a tube 3 of the heat exchanger, more specifically to accept
the ends of a multiplicity of tubes 3 of the heat exchanger (which
is not illustrated). Only one end of one tube 3 is visible in FIG.
2.
[0049] The collection box 1 for this purpose comprises a header 5.
The collection box 1 also comprises a cover 6 fixed to the header 5
so as to close the collection box 1.
[0050] The header 5 is, for example, made of aluminum or of
aluminum alloy. The cover 6 for its part may be made of aluminum of
aluminum alloy or, as an alternative, of plastic.
[0051] The cover 6 may be fixed to the header 5 for example by
clip-fastening, by brazing or even by crimping.
[0052] Furthermore, the header 5 comprises a plurality of openings
7 for the passage of the ends of the tubes 3.
[0053] The openings 7 have, for example, a substantially elongate
shape, like slots.
[0054] The ends of the tubes 3 accepted into the openings 7 may
then be brazed for example to the header 5.
[0055] According to one embodiment, the heat exchange tubes 3 have
a height comprised between 0.8 mm and 2.5 mm, preferably between
1.2 mm and 1.8 mm.
[0056] The pitch of the heat-exchange tubes 3, which means to say
the center-distance between two heat-exchange tubes 3 is, for
example, comprised between 5 mm and 10 mm, preferably between 6 mm
and 8 mm.
[0057] According to the embodiment illustrated, the header 5 has a
wall 8 forming a box end. The collection box 1 additionally
comprises lateral walls 8' connected to this box end 8.
[0058] This is a box end 8 of at least partially rounded shape.
[0059] According to the embodiment illustrated, the wall 8 forming
the end of the box, also referred to as the end wall 8, has a shape
that is substantially dished toward the outside of the volume
defined by the collection box 1. Thus, the end wall 8 of the header
5 has a shape that is substantially concave with respect to the
interior volume defined by the collection box 1 and substantially
convex with respect to the core bundle of tubes 3 of the heat
exchanger, with the convexity facing toward the outside of the
volume defined by the collection box 1.
[0060] As visible in FIGS. 1 to 3, the collection box 1
additionally comprises a predefined number of flanges 9 formed on
the header 5 at the openings 7 for accepting the ends of the tubes
3. More specifically, each opening 7 is surrounded by a flange 9.
The flanges 9 are in this instance produced without the removal of
material.
[0061] The header 5 additionally comprises a plurality of
deformations 11. The deformations 11 are created at the
substantially dished end wall 8 of the header 5. The deformations
11 are produced for example in such a way as to form a regular
pattern.
[0062] According to the embodiment illustrated, this pattern is
made up of corrugations or waves 11.
[0063] The corrugations 11 may be produced symmetrically with
respect to the longitudinal axis of the end wall 8 of the header 5.
The corrugations 11 therefore have crests extending alternating on
one side and the other of the longitudinal axis of the end wall 8
of the header 5. In order words, the corrugations 11 have, for
example, a plurality of crests facing towards the inside of the
volume defined by the collection box 1 and a plurality of opposite
crests directed away from the volume defined by the collection box
and therefore toward the outside of the collection box 1 and toward
the core bundle of tubes 3 of the heat exchanger.
[0064] The flanges 9, better visible in FIGS. 4a and 4b, are formed
at the corrugations 11, more specifically at the crests of the
corrugations 11 facing away from the volume defined by the
collection box. In particular, the openings 7 are formed by
piercing or perforating the header 5 at the crests of the
corrugations 11 facing away from the volume defined by the
collection box, and the flanges 9 are produced by the material
around these openings 7.
[0065] In order to be able to have enough material from which to
form the flanges 9 at the corrugations 11, the corrugations 11 are
created with a sufficient height h (cf FIG. 5), for example with a
top height h of the order of 30% of the pitch of the tubes.
[0066] The flanges 9 thus formed face away from the volume defined
by the collection box 1, namely toward the core bundle of tubes 3
of the heat exchanger. They are then referred to as reverse flanges
9.
[0067] Thus, and referring once again to FIG. 2 and to FIG. 6, when
the end of a tube 3 of the heat exchanger is inserted into an
opening 7 surrounded by such a reverse flange 9, this end of tube 3
lies in a zone Z situated between the crests of the corrugations 11
which face toward the inside of the volume defined by the
collection box 1 and the level of the box end 8 of the header 5 but
does not protrude into the volume defined by the collection box 1.
The absence of tubes 3 opening into the volume of the collection
box 1 makes it possible to improve performance in terms of fluid
flow.
[0068] The flanges 9 have a sufficient height h' suited to allowing
the insertion of the ends of the tubes 3, for example of the order
of half the height h of a corrugation 11.
[0069] Furthermore, the flanges 9 have a flared overall shape, such
as a tulip shape.
[0070] More specifically, the flanges 9 respectively have a
substantially conical shape, for example of angle .alpha. of the
order of 30.degree. (cf. FIG. 5).
[0071] A flange 9 therefore has two flared edges 9a, 9b,
corresponding to the two long edges, joined together by two short
edges 9c, 9d.
[0072] This flared or substantially conical shape facilitates the
introduction of the ends of the tubes 3 into the header 5, from
outside the volume defined by the collection box 1 toward the
inside of the volume defined by the collection box 1.
[0073] The two flared edges 9a, 9b for example have a substantially
convex shape with the convexity facing toward the outside of the
volume defined by the collection box 1.
[0074] With reference to FIG. 5, the tulip-shaped flanges 9
respectively have: [0075] a first width l.sub.1 at the pierced or
perforated crest of the associated corrugation 11 which corresponds
to the shortest width of the flange 9, and [0076] a peripheral
second width l.sub.2 which corresponds to the greatest width of the
flange 9.
[0077] The first width l.sub.1 is substantially equal to or
slightly greater than the width of a tube 3 intended to be inserted
into the opening 7.
[0078] The greatest width l.sub.2 defines the opening 7 surrounded
by the flange 9 for the insertion of the end of a tube 3. The
second width l.sub.2 is made wide enough to allow simple and,
notably, simultaneous, insertion of the ends of all of the tubes 3
of the heat exchanger (which is not depicted) into the openings 7.
The second width l.sub.2 is, for example, of the order of twice the
first width l.sub.1 of the flange 9.
[0079] Furthermore, the flanges 9 may be thinned with respect to
the corrugations 11 on the header 5. Specifically, with reference
to FIG. 6, a corrugation 11 has, for example, a first thickness
e.sub.1, and the flange 9 has a second thickness e.sub.2 less than
the first thickness e.sub.1 of the corrugation 11.
[0080] The flange 9 may just as easily be thinned at the long
flared edges 9a, 9b as at the short connecting edges 9c and 9d.
[0081] By way of example, the thinning of material is performed at
the flange 9 and may range beyond 30% or even locally beyond 50% of
the initial thickness of the material.
[0082] By thinning the material at a flange 9, this flange 9 may be
lengthened.
[0083] It will therefore be appreciated that a header 5 comprising
such reverse flanges 9 facilitates the introduction of the ends of
the multiplicity of heat exchange tubes 3 of the heat exchanger
simultaneously and simply without requiring any special-purpose
tooling notably to guide each tube 3 into the associated opening
7.
[0084] Specifically, the reverse and flared flanges 9 offer enough
of an opening for introduction from outside the collection box 1
toward the inside of the volume defined by the collection box
1.
[0085] Finally, these reverse flanges 9 allow the insertion of the
ends of the tubes 3 without these ends opening into the volume
defined by the collection box 1, thus encouraging the flow of the
fluid inside the collection box 1.
* * * * *