Heat exchanger device, method for manufacturing a heat exchanger device, and internal combustion engine

Abstract

The invention relates to a heat exchanger device (100) having a heat exchanger (10) surrounded by a housing (52), wherein the housing (52) is traversable by a fluid and has a fluid inlet (54) and a fluid outlet (56) for the fluid, wherein the heat exchanger (10) is arranged between the fluid inlet (54) and the fluid outlet (56) such that the fluid can be traversed through the heat exchanger. The housing (52) has a sealing profile (80) with which the heat exchanger (10) is connected form-lockingly at its fluid inlet or at its fluid outlet.

Description

Technical Field

[0001] The present invention relates to a heat exchanger device, a method for manufacturing a heat exchanger device, and an internal combustion engine having a heat exchanger device. Background Technology

[0002] US2014326222A1 discloses a heat exchanger device in the form of an intake manifold for an internal combustion engine, the intake manifold having an integrated boost air cooler. The boost air cooler is surrounded by the intake manifold and sealed relative to the intake manifold with a surrounding elastomeric seal to prevent heated boost air from undesirably bypassing the boost air cooler. Summary of the Invention

[0003] One objective of this invention is to provide an improved heat exchanger device.

[0004] Another task is to provide a method for manufacturing such a heat exchanger device.

[0005] Another task is to provide an internal combustion engine with such a heat exchanger device.

[0006] According to one aspect of the invention, the aforementioned task is solved by a heat exchanger device having a heat exchanger surrounded by a housing through which fluid can flow and having a fluid inlet and a fluid outlet for the fluid, wherein the heat exchanger is arranged between the fluid inlet and the fluid outlet such that fluid can flow through the heat exchanger. The housing has a sealing profile through which the heat exchanger is form-fitted at its fluid inlet or fluid outlet.

[0007] According to another aspect of the invention, the task is accomplished by a method for manufacturing such a heat exchanger device having a housing and a heat exchanger, wherein the sealing surface of a sealing profile in the housing is melted and extruded onto the sealing surface of the heat exchanger. Through plastic deformation, the sealing profile is sealed onto the sealing surface of the heat exchanger and remains in a sealed position.

[0008] In the context of this application, "sealing" means that, in the prescribed operating conditions of the internal combustion engine, air flowing through the housing is guided through the heat exchanger and flows past the heat exchanger from the outside, not inside the housing. Therefore, the sealing profile can prevent bypass flow around the heat exchanger inside the housing in the prescribed operating conditions of the internal combustion engine.

[0009] According to another aspect of the invention, the task is accomplished by an internal combustion engine having such a heat exchanger device.

[0010] The advantageous design and benefits of the present invention are evident from the description and drawings.

[0011] A heat exchanger device is proposed, comprising a heat exchanger surrounded by a housing. The housing is permeable by fluid and has a fluid inlet and a fluid outlet for the fluid, wherein the heat exchanger is arranged between the fluid inlet and the fluid outlet to allow fluid to flow through the heat exchanger. The housing has a sealing profile to which the heat exchanger is form-fitted at its fluid inlet or fluid outlet.

[0012] The heat exchanger may have a single fluid inlet and / or fluid outlet. The sealing profile may then be configured such that it surrounds the inner wall of the housing. Alternatively, the heat exchanger may include multiple cooling zones, such that the sealing profile is configured to surround the corresponding fluid inlet or outlet of each cooling zone.

[0013] If the sealing profile of the housing and the sealing area of ​​the heat exchanger are made of different materials, a form-locking connection can be achieved. For example, the sealing profile can be formed of plastic and the sealing area of ​​the heat exchanger can be formed of metal.

[0014] Advantageously, the sealing profile can be an integral part of the housing, and in particular, the sealing profile can be formed in a locking manner with the housing material.

[0015] The sealing profile can be integrally formed from the housing as a single profile material. The sealing profile can be formed on the housing in a manner similar to a sealing lip. Preferably, the sealing profile can be provided in the form of ribs, which have no function other than sealing.

[0016] Advantageously, individual seals can be eliminated during the assembly process of the heat exchanger unit. This avoids incorrect assembly and thus prevents potentially undetected leaks. Furthermore, it is advantageous to save costs by eliminating the need for separate elastomeric seals and the separate seal assembly process.

[0017] The form-locking connection between the heat exchanger and the sealing profile allows for the compensation of tolerances between the heat exchanger and the housing. Furthermore, it significantly reduces the necessary structural space within the housing for the heat exchanger. This reduced structural space requirement advantageously enables optimal design in terms of housing rupture pressure and pressure pulsation.

[0018] According to an advantageous design of the heat exchanger device, the housing can be formed of at least two shells, which follow each other sequentially along the direction of fluid flow during intended use. In particular, one shell can be joined to another at the contact point, especially by welding. Advantageously, the plastic deformation of the sealing profile can be integrated into the welding process.

[0019] According to an advantageous design of the heat exchanger assembly, the sealing profile can be arranged, in particular formed, on the inner wall of a shell. The location and geometry of the sealing profile can be selected to be advantageous for the installation of the heat exchanger. For example, the sealing profile can be configured as surrounding ribs that enclose the fluid outlet or fluid inlet of the heat exchanger.

[0020] According to an advantageous design of the heat exchanger assembly, at least the sealing profile can have a region with a sealing surface that contacts the heat exchanger, wherein at least this region can be formed of plastic. In particular, the housing and the sealing profile can be formed of plastic, preferably thermoplastic, such as polyamide, which may contain fillers, such as glass fiber or other known additives. The sealing profile can be suitably arranged inside a connecting flange of the housing. Advantageously, the ribs of the housing can melt on their end sides during the initial welding process used to hermetically connect the housings to each other and during the joining process, sealably connect with the sealing area, such as the flange, on the heat exchanger side. Through additional welding, that is, melting or plastic deformation of the material on the end sides of the ribs, the component tolerances between the sealing area of ​​the heat exchanger and the sealing profile can be easily compensated. The different thermal expansions of the materials of the heat exchanger and the housing can also be compensated by the seal. Furthermore, the reduced structural space requirements for the heat exchanger enable an optimized design in terms of housing rupture pressure and pressure fluctuations.

[0021] According to an advantageous design of the heat exchanger assembly, the sealing surface of the sealing profile relative to the heat exchanger is coplanar with the sealing surface of one shell relative to another. This allows for an advantageous engagement process between the heat exchanger and the sealing profile when the shells of the housings are connected to each other. Alternatively, the heat exchanger may also be tilted relative to the sealing surface of the shell and / or offset, and / or one or both sealing surfaces may be configured as wavy.

[0022] According to an advantageous design of the heat exchanger assembly, the sealing surface of the sealing profile relative to the heat exchanger is aligned with the sealing surface of one shell relative to another. This allows for an advantageous engagement process between the heat exchanger and the sealing profile when the shells are joined together. Alternatively, the heat exchanger may also be tilted relative to the sealing surface of the shell and / or offset, and / or one or both sealing surfaces may be configured as wavy.

[0023] According to an advantageous design of the heat exchanger device, the heat exchanger can be completely enclosed by a housing. Advantageously, a reliable seal relative to the housing on the inner surface of the housing allows for the fluid to undesirably bypass the heat exchanger. In particular, the heat exchanger can be completely integrated into one of the housings. Alternatively, the heat exchanger can be integrated into both housings. The arrangement of the heat exchanger within the housing can be selected based on the available structural space.

[0024] According to an advantageous design of the heat exchanger assembly, the heat exchanger can have a metal flange, for example, made of aluminum, for connection to a housing. The plastic-metal connection supports the sealing of the connection throughout the service life of the heat exchanger assembly. Unlike common elastomeric seals, the connection cannot be exposed to temperature effects and / or the effects of fluids within the housing.

[0025] According to an advantageous design of the heat exchanger device, the heat exchanger can be configured as a pressurized air cooler, and the housing can be configured as an intake manifold or pressurized air distributor. This allows for cost-effective provision of a reduced structural space requirement for the intake manifold or pressurized air distributor along with the heat exchanger, and long-term stable sealing of the heat exchanger in the intake manifold. Undesirable leakage of pressurized air within the housing surrounding the pressurized air cooler can be avoided.

[0026] According to another aspect of the invention, a method for manufacturing a heat exchanger device is provided, the heat exchanger device comprising a housing and a heat exchanger surrounded by the housing, wherein the housing is permeable by fluid and has a fluid inlet and a fluid outlet for the fluid, wherein the heat exchanger is arranged between the fluid inlet and the fluid outlet such that fluid can permeate through the heat exchanger. Here, the housing has a sealing profile, and the heat exchanger is form-fitted to the sealing profile at its fluid inlet or fluid outlet. The sealing surface of the sealing profile constructed in the housing is melted and pressed against the sealing area of ​​the heat exchanger.

[0027] Advantageously, no separate seal is required during the assembly process. This avoids incorrect assembly and thus prevents undetected leaks. Cost savings are achieved by eliminating the need for additional elastomeric seals and the additional installation process for them. Advantageously, tolerances between the components can be compensated for. The structural space requirements for the heat exchanger can be significantly reduced. This enables a long-term stable seal between the heat exchanger and the housing.

[0028] According to an advantageous design of the method, the sealing surfaces can be melted during the connection process, particularly the welding process, to connect the shells of the housing to each other during the connection. This achieves cost savings through a compact connection process, in which the housing and heat exchanger can be joined in one process step. Alternatively, the shells can also be threaded, riveted, or clamped together.

[0029] According to another aspect of the invention, an internal combustion engine having a heat exchanger device according to the invention is provided, wherein the heat exchanger device includes a housing and a heat exchanger, wherein the housing is configured as an intake manifold for pressurized air, and the heat exchanger is configured as a pressurized air cooler in the intake manifold.

[0030] Advantageously, it achieves a long-term, stable seal between the booster air cooler and the intake manifold. The structural space requirement of the booster air cooler is reduced. It can meet the specific requirements for the airtightness of the internal interface of the booster air cooler relative to the intake manifold. It can prevent hot air from bypassing the booster air cooler, or it can guide air through the booster air cooler as completely as possible to ensure cooling efficiency, i.e., heat transfer from hot air to cooling water. Attached Figure Description

[0031] Other advantages are illustrated in the following figures. Embodiments of the invention are shown in the figures. The figures, description, and claims contain a large number of features in combination. Those skilled in the art will also suitably consider these features individually and conclude other meaningful combinations. The figures are illustrated exemplary as follows:

[0032] Figure 1 A cross-sectional view of an intake manifold with an integrated booster air cooler, according to the prior art, is shown, the intake manifold having an elastomeric seal;

[0033] Figure 2 A cross-sectional view of a heat exchanger device according to an embodiment of the present invention is shown;

[0034] Figure 3 It shows according to Figure 2 Details of the interface of the heat exchanger unit;

[0035] Figure 4 A schematic process flow for manufacturing a heat exchanger device is shown;

[0036] Figure 5 An exploded view shows an intake pipe with a boosted air cooler according to an embodiment of the invention;

[0037] Figure 6 It shows in Figure 5 A top view of the intake manifold shell along with the outlined stepped section A;

[0038] Figure 7 It shows Figure 5 The top view of the intake manifold and the booster air cooler corresponding to section A, together with the outlined section B of the intake manifold; and

[0039] Figure 8 Section B is shown Figure 5 A top view of the pressurized air cooler in the middle. Detailed Implementation

[0040] In the accompanying drawings, the same or similar parts are indicated by the same reference numerals. The drawings are merely illustrative and should not be interpreted restrictively.

[0041] Figure 1 A cross-sectional view of an intake pipe 50 with an integrated booster air cooler, according to the prior art, is shown. The intake pipe has an embedded, separate elastomeric seal 22 located between the booster air cooler 12 and the intake pipe 50. The elastomeric seal 22 must be installed in a separate assembly step.

[0042] Figure 2 A cross-sectional view of a heat exchanger device 100 according to an embodiment of the present invention is shown. Figure 3 It shows according to Figure 2 Details of the interface of the heat exchanger device 100.

[0043] The heat exchanger assembly 100 includes a heat exchanger 10 surrounded by a housing 52. The housing 52 is permeable by fluid and has a fluid inlet 54 and a fluid outlet 56 for the fluid. The heat exchanger 10 is arranged between the fluid inlet 54 and the fluid outlet 56 to allow fluid to flow through it. The housing 52 has, for example, a partially or completely surrounding sealing profile 80 to which the heat exchanger 10 is form-fitted.

[0044] The housing 52 is configured, for example, as an air intake 50 and the heat exchanger 10 is configured as a booster air cooler 12.

[0045] The housing 52 is formed by two shells 58 and 60, which follow each other sequentially along the fluid flow direction 90 during intended use. One shell 58 is welded to the other shell 60 at a contact point 70 between the flange 72 of the first shell 58 and the flange 74 of the second shell 60. However, the shells may also be optionally connected to each other by thread, riveting, or clamping.

[0046] The heat exchanger 10 is completely surrounded by a housing 52 and fully inserted into a housing 58, which is opposite to a housing 60 having a sealing profile 80. Here, the heat exchanger 10 is inserted into the receiving portion 62 of the housing 58 at its end away from the sealing profile 80, with element 24.

[0047] In this embodiment, the sealing profile 80 is formed as a surrounding rib on the inner side of a shell 60 and completely surrounds the fluid outlet of the heat exchanger 10. The sealing surface 82 of the sealing profile 80 relative to the heat exchanger 10 is constructed coplanarly with the sealing surface 76 of one shell 60 relative to another shell 58. This facilitates the engagement of the components. Of course, the arrangement can also be chosen such that the sealing profile 80 surrounds the fluid inlet of the heat exchanger.

[0048] In this embodiment, the sealing surface 82 of the sealing profile 80 relative to the heat exchanger 10 inside the housing is aligned outward with the sealing surface 76 of one housing 60 relative to another housing 58.

[0049] The housing 52 with the sealing profile 80 is, for example, formed of plastic.

[0050] The heat exchanger 10 is equipped with a flange 16 on its end side 14 and is pressed against a sealing profile 80. The end side 14 is, for example, the outlet end of the heat exchanger from which fluid flows out of the heat exchanger 10.

[0051] The flange 16 is, for example, a metal flange, which is made of aluminum. The sealing profile 80 contacts the flange 16 at the sealing surface 18 with a sealing surface 82.

[0052] Advantageously, the sealing surface 82 of the sealing profile 80 is melted, plasticized, and pressed onto the sealing region 18 of the heat exchanger 10 during the welding process, where the sealing profile solidifies. During this welding process, the two shells 58, 60 are joined at their flanges 72, 74. If the shells 58, 60 are joined together, the heat exchanger 10 is clamped between the receiving portion 62 and the sealing profile 80.

[0053] Figure 4 The method and process are explained schematically.

[0054] In step S100, two housings 58 and 60 are provided, one housing having a sealing profile 80 and the heat exchanger 10 being inserted into the other housing 58.

[0055] In step S102, the sealing surface 82 of the sealing profile 80 is melted and pressed onto the flange 16 of the heat exchanger 10 by engaging the shells 58 and 60. This compensates for component tolerances.

[0056] In step S104, the flanges 72 and 74 of the shells 58 and 60 are connected to each other, especially welded together, and an airtight connection is established between the shells 58 and 60.

[0057] Figures 5 to 8 A different view of the intake pipe 50 with a pressurized air cooler 12, corresponding to the heat exchanger device 100 described above, is shown.

[0058] Figure 5 An exploded view shows an intake pipe 50 with two housings 58 and 60, between which the booster air cooler 12 is arranged. The booster air cooler 12 has two separate cooling zones separated by a gap 26 through which the flow is not penetrating. The sealing profile 80 is arranged in housing 60 and is outlined with an interrupted reference line.

[0059] Figure 6 A top view of the housing 58, which serves as the intake pipe 50, is shown. The housing 58 has four outlets (not shown in detail) through which air cooled in the booster air cooler 12 is discharged from the intake pipe 50. The airflow direction 90 is indicated by a thick arrow.

[0060] The stepped cross section A, as outlined, extends through the shell 60 and the pressurized air cooler 12.

[0061] Figure 7 A top view of section A is shown along with the outlined section B. In the left half of the figure, section A extends through the flow region of the shell 60, while in the right half of the figure, the booster air cooler 12 located inside the intake manifold 50 can be seen.

[0062] The boosted air cooler 12 abuts against a sealing profile 80 in the housing 60 at the fluid inlet of the corresponding cooling area. At the fluid outlet, the boosted air cooler 12 is supported on a shoulder of the housing 58 (not shown in detail).

[0063] The sealing profile 80 surrounds the fluid inlet of the booster air cooler 12 according to the fluid flow direction 90 in this embodiment. The section B is arranged such that the connecting flange 74 of the housing 60 is separated from the housing 60.

[0064] However, it goes without saying that the sealing profile 80 can also be arranged such that the fluid outlet of the boosted air cooler 12 is surrounded.

[0065] As in Figure 8 As can be seen in the top view of section B, the booster air cooler 12 is divided into two cooling zones by a non-through gap 26, each of which has a fluid inlet. The sealing profile 80 completely surrounds each fluid inlet.

Claims

1. A heat exchanger assembly (100) having a heat exchanger (10) surrounded by a housing (52), through which a fluid can flow and having a fluid inlet (54) and a fluid outlet (56) for the fluid, wherein the heat exchanger (10) is arranged between the fluid inlet (54) and the fluid outlet (56) such that a fluid can flow through the heat exchanger. Its features are, The housing (52) is formed of at least two shells (58, 60) that are arranged sequentially along the direction of fluid flow (90) when used as intended, and the housing (52) has a sealing profile (80) to which the heat exchanger (10) is form-fitted at its fluid inlet or fluid outlet, wherein the sealing profile (80) is arranged on the inner wall of one of the shells (58), and the sealing surface (82) of the sealing profile (80) relative to the heat exchanger (10) is coplanar with the sealing surface (76) of the shell (60) relative to the other shell (58).

2. The heat exchanger device according to claim 1, characterized in that, One of the shells (58) is connected to the other shell (60) at the contact point (70).

3. The heat exchanger device according to claim 1, characterized in that, The sealing profile (80) is formed on the inner wall of the shell (58).

4. The heat exchanger device according to any one of the preceding claims, characterized in that, The sealing profile (80) has a region with a sealing surface (82), wherein at least the region is formed of plastic.

5. The heat exchanger device according to claim 1, characterized in that, The sealing surface (82) of the sealing profile (80) relative to the heat exchanger (10) is aligned with the sealing surface (76) of one shell (60) relative to the other shell (58).

6. The heat exchanger device according to any one of claims 1 to 3, characterized in that, The heat exchanger (10) is completely surrounded by the housing (52).

7. The heat exchanger device according to any one of claims 1 to 3, characterized in that, The heat exchanger (10) has a metal flange (16) for connection to the sealing profile (80) of the housing (60).

8. The heat exchanger device according to any one of claims 1 to 3, characterized in that, The heat exchanger (10) is configured as a pressurized air cooler (12), and the housing (52) is configured as an air inlet pipe (50).

9. The heat exchanger device according to claim 2, characterized in that, One of the shells (58) is welded to the other shell (60) at the contact point (70).

10. The heat exchanger device according to claim 4, characterized in that, The housing (52) and the sealing profile (80) are made of plastic.

11. The heat exchanger device according to claim 6, characterized in that, The heat exchanger (10) is fully inserted into one of the shells (58, 60) of the housing (52).

12. A method for manufacturing a heat exchanger device (100) according to any one of claims 1 to 11, the heat exchanger device comprising a housing (52) and a heat exchanger (10), characterized in that, A sealing profile (80) is constructed in the housing (52), and the sealing surface (82) of the sealing profile is melted and pressed onto the sealing area (18) of the heat exchanger (20).

13. The method according to claim 12, characterized in that, The sealing surface (82) is melted during the connection process, during which the shells (58, 60) of the housing (52) are connected to each other.

14. The method according to claim 13, characterized in that, The sealing surface (82) is melted during the welding process.

15. An internal combustion engine having a heat exchanger device (100) according to any one of claims 1 to 11, wherein the heat exchanger device (100) comprises a housing (52) and a heat exchanger (10), wherein the housing (52) is configured as an intake manifold for pressurized air, and the heat exchanger (10) is configured as a pressurized air cooler (12) in the intake manifold (50).

Images