U.S. patent application number 15/512155 was filed with the patent office on 2017-09-14 for heat exchanger and method for producing a heat exchanger.
This patent application is currently assigned to MAHLE INTERNATIONAL GMBH. The applicant listed for this patent is MAHLE INTERNATIONAL GMBH. Invention is credited to Stefan HIRSCH, Michael MOSER, Nic SAUTTER.
Application Number | 20170261266 15/512155 |
Document ID | / |
Family ID | 54065367 |
Filed Date | 2017-09-14 |
United States Patent
Application |
20170261266 |
Kind Code |
A1 |
HIRSCH; Stefan ; et
al. |
September 14, 2017 |
HEAT EXCHANGER AND METHOD FOR PRODUCING A HEAT EXCHANGER
Abstract
The invention relates to a heat exchanger for a motor vehicle,
comprising a heat exchanger block and at least one collection box
with a tube plate. The heat exchanger block is made of a plurality
of adjacent tubes and corrugated rib elements arranged between the
tubes, and one of the end regions of the tubes is received in the
tube plate of the collection box in a fluid-tight manner. The tube
plate of the collection box is made of plastic and is injection
molded onto the heat exchanger block. A spacer element through
which the tubes are guided is arranged between the tube plate of
the collection box and the heat exchanger block, and the corrugated
rib elements are spaced from the tube plate of the collection box
by the spacer. The invention further relates to a method for
producing a heat exchanger.
Inventors: |
HIRSCH; Stefan; (Stuttgart,
DE) ; MOSER; Michael; (Ellwangen, DE) ;
SAUTTER; Nic; (Plochingen, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MAHLE INTERNATIONAL GMBH |
Stuttgart |
|
DE |
|
|
Assignee: |
MAHLE INTERNATIONAL GMBH
Stuttgart
DE
|
Family ID: |
54065367 |
Appl. No.: |
15/512155 |
Filed: |
September 8, 2015 |
PCT Filed: |
September 8, 2015 |
PCT NO: |
PCT/EP2015/070471 |
371 Date: |
March 17, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28F 9/0224 20130101;
F28F 2255/14 20130101; F28F 2255/143 20130101; F28D 1/053 20130101;
F28F 2009/0297 20130101; F28F 2240/00 20130101; F28F 9/0229
20130101; F28D 1/05316 20130101; F28F 1/126 20130101 |
International
Class: |
F28D 1/053 20060101
F28D001/053; F28F 1/12 20060101 F28F001/12; F28F 9/02 20060101
F28F009/02 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 17, 2014 |
DE |
10 2014 218 677.3 |
Claims
1. A heat exchanger for a motor vehicle, comprising a heat
exchanger block and at least one collection box, wherein the heat
exchanger block is made of a plurality of tubes adjacent to one
another and corrugated fin elements arranged therebetween, and one
of the end regions of the tubes is received in the tube plate of
the collection box in a fluid-tight manner, wherein the tube plate
of the collection box is made of plastic and is molded onto the
heat exchanger block by injection molding, wherein a spacer element
is arranged between the tube plate of the collection box and the
heat exchanger block, through which the tubes are conducted,
wherein the corrugated fin elements are spaced apart from the tube
plate of the collection box by the spacer element.
2. The heat exchanger as claimed in claim 1, wherein the tube plate
of the collection box is connected to a cover of the collection box
to form the collection box.
3. The heat exchanger as claimed in claim 1, wherein the spacer
element is formed by a perforated plate exhibiting openings that
match the tubes in the heat exchanger block in such a manner that
they project through the openings with an accurate fit.
4. The heat exchanger as claimed in claim 1, wherein the tube plate
of the collection box is injection-molded onto the heat exchanger
block using a plastic injection-molding process.
5. The heat exchanger as claimed in claim 1, wherein the tubes have
at the end an at least partially circumferential groove and/or are
surface-treated and/or coated at the end.
6. The heat exchanger as claimed in claim 1, wherein the heat
exchanger has two collection boxes, wherein the tubes each open out
at the ends into one of the collection boxes and are connected in a
fluid-tight manner thereto, wherein a spacer element is arranged
between each of the collection boxes and the heat exchanger
block.
7. The heat exchanger as claimed in claim 1, wherein the spacer
element is coated with plastic on the side turned away from the
heat exchanger block, which forms the tube plate of the collection
box, wherein the tubes are connected to the injection-molded tube
plate of the collection box in a substance-bonded and/or
positive-locking manner.
8. The heat exchanger as claimed in claim 1, wherein the spacer
element forms a reinforcement of the plate region of the collection
box facing the heat exchanger block, wherein the spacer element is
connected to the tube plate of the collection box in a
positive-locking and/or substance-bonded manner.
9. The heat exchanger as claimed in claim 1, wherein the spacer
element is soldered and/or welded and/or clamped and/or adhered to
the tubes and/or the corrugated fin elements.
10. A method for producing a heat exchanger as claimed in claim 1,
wherein a heat exchanger block is produced from a plurality of
tubes adjacent to one another and corrugated fin elements arranged
therebetween, wherein a spacer element is placed on the tubes at
the ends and the tube plate of the collection box is
injection-molded integrally to the heat exchanger block and/or the
spacer element.
11. The method for producing a heat exchanger as claimed in claim
10, wherein the tubes penetrate the spacer element through precise
openings formed in it and the corrugated fin elements are
completely covered by the spacer element.
12. The method as claimed in claim 10, wherein the tube plate of
the collection box is injection-molded onto the tubes projecting
through the spacer element, wherein the tube plate is connected to
the projecting sections of the tubes and/or the spacer element in a
substance-bonded and/or positive-locking manner.
Description
TECHNICAL FIELD
[0001] The invention relates to a heat exchanger for a motor
vehicle, comprising a heat exchanger block and at least one
collection box with a tube plate, wherein the heat exchanger block
is made of a plurality of tubes adjacent to one another and
corrugated fin elements arranged therebetween, and one of the end
regions of the tubes is received in the tube plate of the
collection box in a fluid-tight manner. Moreover, the invention
relates to a method for producing a heat exchanger.
STATE OF THE ART
[0002] Heat exchangers by means of which a heat transfer is
produced between a first fluid and a second fluid are used for
cooling or heating fluids in motor vehicles.
[0003] A wide variety of heat exchanger designs is known in the
art. Known designs also include, among other things, heat
exchangers which exhibit a so-called tube/fin construction. In
designs of this kind when there is a plurality of tubes, the tube
ends are received in openings in a tube plate at the end, said tube
plate in turn being connected to a cover-like element to form a
collection box. Corrugated fin elements may be arranged between the
tubes, said elements promoting the heat transfer between a fluid
flowing in the tubes and a fluid flowing around the tubes.
[0004] The tubes, the corrugated fin elements and the tube plates
are produced from a metallic material in some embodiments known in
the art. The cover-like elements in this case are either made from
a metallic material, such as aluminum, or from a plastic.
[0005] The disadvantage of the heat exchangers known in the art is,
in particular, that due to the large range of variants, tubes with
different geometries are used, the tubes are arranged at different
distances from one another and the number of tubes used also
varies. It is therefore only possible with some difficulty for
modular components to be used for the production of heat
exchangers, which means that the production of heat exchangers is
time-consuming and expensive.
[0006] In the state of the art, heat exchangers are furthermore
known which have a collection box made of plastic which is
injection-molded straight onto the tubes and corrugated fin
elements.
[0007] A disadvantage of the heat exchangers known in the art with
a collection box injection molded onto them is, in particular, that
the heat exchanger block formed from tubes and corrugated fin
elements is not sufficiently protected against contact with plastic
during the injection process. The sensitive corrugated rib elements
are also not adequately protected against the pressures occurring
during the injection process, which means that damage can occur,
particularly to the corrugated fin elements. The heat exchangers
with a collection box injection-molded onto them therefore often
have only a very small number of tubes, as a result of which the
performance of the heat exchanger is greatly limited.
Representation of the Invention, Problem, Solution, Advantages
[0008] The problem addressed by the present invention is therefore
that of creating a heat exchanger which is an improvement on the
state of the art and exhibits means which protect the heat
exchanger block formed from tubes and corrugated fin elements
during the injection process from plastic and the resulting working
pressure. Moreover, the problem addressed is that of creating a
method of producing a heat exchanger.
[0009] The problem in relation to the heat exchanger is solved by a
heat exchanger having the features of claim 1.
[0010] An exemplary embodiment of the invention relates to a heat
exchanger for a motor vehicle, having a heat exchanger block and
having at least one collection box with a tube plate, wherein the
heat exchanger block comprises a plurality of tubes arranged
adjacent to one another and corrugated fin elements arranged
therebetween, and the end regions of the tubes are received in the
tube plate of the collection box in a fluid-tight manner, wherein
the tube plate of the collection box is made of plastic and is
molded onto the heat exchanger block by injection molding, wherein
a spacer element is arranged between the collection box and the
heat exchanger block, through which the tubes are conducted,
wherein the corrugated fin elements are spaced apart from the tube
plate of the collection box by the spacer element.
[0011] The tubes and the corrugated fin elements are made of a
metallic material and are connected to one another by a soldering
method or a welding method. Alternatively, the tubes and corrugated
fin elements may also be held by means of a tool device, until an
adequate connection is produced between the elements by
injection-molding the tube plate of the collection box.
[0012] The heat exchanger may only exhibit a collection box or, in
an alternative exemplary embodiment, also two collection boxes. In
only one collection box, the tubes may either be received therein
at the ends, while the other end region in each case is received in
another structure, or the tubes may be of U-shaped configuration,
for example, so that the tubes are each received with both end
regions in the on collection box.
[0013] The tube plate of the collection box is advantageously made
of plastic and molded onto the heat exchanger block by injection
molding. This is particularly advantageous, since the tube plate of
the collection box can be produced quickly and easily and can be
adapted to different heat exchangers particularly easily. For this
purpose, only the mold need be adapted for the production of the
injection-molded tube plate of the collection box. The tube plate
of the collection box or else of the collection box or the heat
exchanger can therefore easily be produced in a wide variety of
variants.
[0014] It is particularly preferable for a spacer element to be
arranged between the heat exchanger block and the tube plate of the
collection box. This primarily performs a separating function and a
protective function. The spacer element advantageously prevents the
plastic of the tube plate of the collection box from penetrating
between the corrugated fin elements and damaging them. Moreover,
the heat exchanger block is protected by the spacer element from
the high pressures that occur during the injection-molding of the
plastic and, in particular, can damage the partially thin-walled
tubes and likewise very thin-walled corrugated fin elements.
[0015] It is also advantageous for the spacer element to be formed
by a perforated plate exhibiting openings that match the tubes in
the heat exchanger block in such a manner that they project through
the openings with an accurate fit.
[0016] A configuration of the spacer element as a perforated plate
is particularly advantageous, as in this way the end regions of the
tubes can be guided through the spacer element, on the one hand,
while the corrugated fin elements are otherwise covered by the
spacer element. In this way, the collection box can easily be
injection-molded onto the heat exchanger block, without the
corrugated fin elements being damaged in the process.
[0017] The openings in the spacer element are preferably configured
with only a small amount of play in respect of the tubes, so as to
allow the best possible fit of the tubes in the spacer element.
This is particularly advantageous in preventing plastic from
penetrating through between the tubes and the openings during the
injection-molding of the tube plate of the collection box and
thereby damaging the corrugated fin elements.
[0018] It is also preferable for the tube plate of the collection
box to be injection-molded onto the heat exchanger block using a
plastic injection-molding process. A plastic injection-molding
process is particularly advantageous for production of the tube
plate of the collection box, as on the one hand it allows high
dimensional freedom and, on the other hand, the production of a
collection box with an adequately great pressure resistance is made
possible.
[0019] Moreover, it is advantageous for the tubes to have at the
end an at least partially circumferential groove and/or to be
roughened at the end.
[0020] An at least partially circumferential groove and/or a
surface-pretreated and/or coated, also roughened, for example, end
region are advantageous in producing a better connection between
the tubes and the injection-molded tube plate of the collection
box. The groove may form an edge which is engaged behind by a
partial region of the tube plate of the collection box, as a result
of which the connection is improved. Roughness in the region of the
tube end may improve the toothing between the plastic of the tube
plate of the collection box and the tubes.
[0021] Furthermore, it is advantageous for the heat exchanger to
exhibit two collection boxes, wherein the tubes each open out at
the ends into one of the collection boxes and are connected in a
fluid-tight manner thereto, wherein a spacer element is arranged
between each of the collection boxes and the heat exchanger
block.
[0022] Particularly advantageous is a heat exchanger with two
collection boxes opposite one another, which are connected to one
another fluidically by the tubes of the heat-exchanger block. The
heat exchanger can thereby be flowed through conventionally from a
collection box through the tubes to the opposite connection box.
Depending on the embodiment of the collection boxes, a single or
multiple deflection of the fluid flowing through the heat exchanger
may also be achieved in this way, as a result of which different
through-flow principles can be achieved. The different through-flow
principles in this case substantially correspond to the
through-flow principles of conventional heat exchangers.
[0023] It is also advantageous for the spacer element to be coated
with plastic on the side turned away from the heat exchanger block,
which forms the tube plate of the collection box, wherein the tubes
are connected to the injection-molded tube plate of the collection
box in a substance-bonded and/or positive-locking manner.
[0024] It is particularly advantageous for the collection box to be
limited on all sides by the injection-molded plastic. This is
particularly advantageous if the spacer element is not connected to
the tubes in a fluid-tight manner. This means that the spacer
element forms a surface onto which the tube plate of the collection
box is injection-molded. However, the tube plate of the collection
box in this case is preferably connected to the tube sections
protruding through the spacer element, as a result of which the
tube plate of the collection box is directly attached to the heat
exchanger block and the tubes are connected to the tube plate of
the collection box in a fluid-tight manner. Depending on the
embodiment of the tubes and/or the tube plate of the collection
box, a substance-bonded and/or positive-locking connection may be
produced in this case between the tubes and the tube plate of the
collection box.
[0025] Moreover, it is advantageous for the spacer element to form
a reinforcement of the plate region of the collection box facing
the heat exchanger block, wherein the spacer element is connected
to the collection box in a positive-locking and/or substance-bonded
manner.
[0026] In an advantageous embodiment, the spacer element which may
be formed from a metallic material, for example, may form a
reinforcement of the plate region of the collection box facing the
heat exchanger block. This increases the stability of the
collection box and therefore also the durability of the heat
exchanger. The spacer element may, for example, exhibit ledges,
edges or roughened regions for this purpose, which improve the
connection between the plastic of the collection box and the spacer
element.
[0027] Furthermore, it is advantageous for the spacer element to be
soldered and/or welded and/or clamped and/or adhered to the tubes
and/or the corrugated fin elements. Depending on the choice of
material for the spacer element, this may be connected to the tubes
and/or the corrugated fin elements, as a result of which the
strength of the heat exchanger can be increased.
[0028] The problem in respect of the method is solved by a method
having the features of claim 9.
[0029] An exemplary embodiment of the invention relates to the
method of producing a heat exchanger, wherein a heat exchanger
block is produced from a plurality of tubes adjacent to one another
and corrugated fin elements arranged therebetween, wherein a spacer
element is placed on the tubes at the ends and the tube plate of
the collection box is injection-molded integrally to the heat
exchanger block and/or the spacer element.
[0030] The heat exchanger block can preferably be produced in a
conventional manner, in that the tubes are soldered to the
corrugated fin elements, for example. An independent component is
thereby produced which can be selectively further processed. The
addition of the spacer element is advantageous in preventing damage
to the corrugated fin elements by plastic parts during the
subsequent injection-molding of the tube plate of the collection
box. The tube plate of the collection box is advantageously
injection-molded onto the heat exchanger block in such a way that a
fluid-tight and pressure-tight connection is produced between the
tube ends projecting through the spacer element and the inside of
the injection-molded tube plate of the collection box.
[0031] It is also advantageous for the tubes to penetrate the
spacer element through precise openings formed in it and the
corrugated fin elements are completely covered by the spacer
element. This is particularly advantageous in achieving a play-free
fit of the spacer element on the heat exchanger block wherever
possible and to avoid the injection of plastic into the region
filled by the corrugated fin elements.
[0032] Furthermore, it is preferable for the tube plate of the
collection box to be injection-molded to the tubes projecting
through the spacer element, wherein the tube plate of the
collection box is connected to the projecting sections of the tubes
and/or the spacer element in a substance-bonded and/or
positive-locking manner.
[0033] This is particularly advantageous, since a fluid-tight and
pressure-tight connection must be produced between the tubes and
the tube plate, in order to guarantee the functionality of the heat
exchanger. The corrugated fin elements are regularly embodied in a
very delicate manner, which means that they are particularly prone
to mechanical deterioration. The connection of the tube plate of
the collection box to the heat exchanger block should therefore
preferably not be produced via the corrugated fin elements.
[0034] The collection box is formed or sealed by connecting a tube
plate of the collection box to a cover of the collection box. In
this case, the tube plate and the cover can be produced separately
and connected to one another or they may be jointly produced by
injection-molding.
[0035] Advantageous developments of the present invention are
described in the dependent claims and in the following figure
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] In the following, the invention is explained in detail with
the help of exemplary embodiments with reference to the drawings.
In the drawings:
[0037] FIG. 1 shows a sectional view through an end region of a
heat exchanger block, wherein the tubes open out into a tube plate
of the collection box injection-molded onto the heat exchanger
block and a spacer element is arranged between the tube plate of
the collection box and the corrugated fin elements, and
[0038] FIG. 2 shows a plan view of a spacer element, as was used in
FIG. 1 for the spacing of the tube plate of the collection box from
the corrugated fin elements.
PREFERRED EMBODIMENT OF THE INVENTION
[0039] FIG. 1 shows a sectional view through a heat exchanger 1.
The heat exchanger 1 has a heat exchanger block 7, which is formed
by a plurality of tubes 2 and corrugated fin elements 3 arranged
therebetween. The heat exchanger block 7 is conventional in design,
the tubes 2 being arranged parallel to one another and spaced apart
from one another. In the gaps between the tubes 2, corrugated rib
elements 3 are arranged and are in thermally conductive contact
with the tubes 2.
[0040] The tubes 2 exhibit a longer extension than the corrugated
fin elements 3, which is why the corrugated fin elements 3 project
laterally from the heat exchanger block 7. A spacer element 4 is
placed on the projecting tubes 2, which spacer element exhibits a
plurality of openings 6. The tubes 2 project through the openings
6. The cross sections of the openings 6 are adapted to the cross
sections of the tubes 2, as a result of which a play-free fit of
the spacer element 4 on the tubes 2 is achieved. The spacer element
4 or else the openings 6 is/are adapted to the arrangement of the
tubes 2 within the heat transmission block 7.
[0041] A collection box 5 with a tube plate 8 is attached to the
spacer element 4, which is produced by an injection method. The
tube plate 8 of the collection box 5 is injection-molded straight
onto the heat exchanger block 7. The tube plate 8 of the collection
box 5 is injection-molded around the sections of the tubes 2
projecting through the spacer element 4, as a result of which,
depending on the configuration of the tubes 2, a positive-locking
and/or substance-bonded connection is produced.
[0042] The spacer element 4 may likewise be spray-coated completely
or partially with the plastic of the tube plate 8 of the collection
box 5, as a result of which a positive-locking and/or
substance-bonded connection is likewise produced. The spacer
element 4 may either be fitted onto the tubes 2 of the heat
exchanger block or connected to the tubes 2 and/or the corrugated
fin elements 3. This may be achieved by, among other things,
conventional joining techniques, such as welding or soldering.
[0043] The main purpose of the spacer element 4 is to prevent
plastic from penetrating the region of the corrugated fin elements
3 during the injection-molding process, in which the collection box
5 or the tube plate 8 of the collection box 5 is configured, and
causing damage to or obstruction of the corrugated fin elements 3
there. In this case, with a separate configuration of the tube
plate 8, said tube plate can be joined to a cover to form the
collection box 5.
[0044] The collection box 5 is depicted is a box-shaped body in
FIG. 1 which receives the regions at the ends of the tubes 2 of the
heat exchanger block 7. In alternative exemplary embodiments, the
tube plate 8 of the collection box 5 and also the collection box 5
may also assume different shapes. In particular, the shape of the
tube plate 8 and of the collection box 5 must be adapted to the
planned application. The collection box 5 may be formed by a single
section on the inside or be divided into several sections by
partition walls which are co-produced during the injection-molding
process.
[0045] A change in the shape of the collection box 5 and/or of the
tube plate 8 may be achieved by simply influencing the tool used
for injecting the plastic. By using a suitable tool and the spacer
element 4, a functional heat exchanger 1 can be produced which, in
particular, can be produced without damage to the heat exchanger
block 7, putting the available installation space to the best
possible use. Furthermore, time-consuming sealing work and
additional sealing elements are not necessary, as the tube plate 8
of the collection box 5 is integrally formed. Through the use of
suitable plastics, adequate and satisfactory durability can be
achieved.
[0046] FIG. 2 shows a plan view of a spacer element 4. The spacer
element 4 has a rectangular, plate-shaped form. Along the spacer
element 4 are arranged several openings 6 which are used to guide
through the end regions of the tubes 2. The openings 6 are, as
already mentioned, adapted to the arrangement of the tubes 2 and
have a cross section that corresponds to the outer diameter of the
tubes 2 in such a manner that the smallest possible play is
produced between the spacer element 4 and the tubes 2.
[0047] In FIG. 2, the corrugated fins 3 arranged behind the spacer
element 4 are indicated by dotted lines 3. The spacer element 4 may
be formed from the same material as the tubes 2 and the corrugated
fins 3 or likewise from a plastic, like the tube plate 8 of the
collection box 5, for example.
[0048] The exemplary embodiments in FIGS. 1 and 2 are exemplary and
explain the basic idea underlying the invention. They do not
exhibit a limiting character, particularly with regard to the
shape, material choice and embodiment of the individual elements.
The heat exchanger block 7, in particular, may be configured in a
variety of ways deviating from the exemplary embodiment shown in
FIG. 1, in that the tubes and/or the corrugated fins are
differently configured and the arrangement differs relative to one
another.
* * * * *