Housing for heat exchanger having exchange tube bundle

Abstract

The invention relates to a heat exchanger (1) comprising an exchange tube bundle (2) intended to be passed through by a heat transfer liquid and a gas flow, comprising a plurality of plates (21) stacked on top of one another in a stacking direction (A), comprising a shell (3) surrounding the exchange tube bundle (2) and having at least one upper wall (31), a lower wall (32) and at least one main side wall (33), the main side wall (33) is arranged in the continuation of the upper wall (31) and / or the lower wall (32), characterized in that the housing (3) comprises at least one intermediate side wall (35) between the exchange tube bundle (2) and the main side wall (33).

Description

Technical Field

[0001] The present invention relates to the field of heat exchangers, more particularly to those equipped with an exchange core bundle formed by stacked plates. Background Art

[0002] Such heat exchangers are intended, for example, to equip vehicles, in particular motor vehicles, in which they thermally regulate a first fluid (for example an airflow) circulating through the heat exchanger in a dedicated circulation space by means of a second fluid (for example a coolant) circulating in dedicated channels in the heat exchanger.

[0003] Furthermore, motor vehicles are increasingly equipped with turbochargers for increasing the power of the internal combustion engine of said vehicle. These turbochargers direct an air flow to the intake manifold and compress it before it reaches the combustion chamber. This air flow, often referred to as "charge air", makes it possible to supercharge the engine, enabling it to burn fuel more efficiently.

[0004] It is known practice to connect a heat exchanger to a turbocharger, which heat exchanger is intended to cool the airflow or "charge air" in order to increase the density of the intake air of the turbocharged engine. These heat exchangers, also called "charge air coolers", generally have an exchange core formed by a stack of plates between which the charge airflow circulates. The fluid in communication with each plate passes through the stack of plates via channels formed in the plates. The exchange of thermal energy can take place between the plates or, if appropriate, between a radiating element arranged between two adjacent plates and the charge airflow.

[0005] This exchange core bundle is accommodated in a housing that surrounds it. This housing is usually formed by four parts forming a cover plate, which are joined to each other to form a parallelepiped that clamps the exchange core bundle, and whose two opposite faces, unlike the cover plate, are open and are intended to be passed by the charge air flow. The cover plates are fixed to each other by brazing their ends arranged against each other. Over time, this solution tends to experience wear at these brazed joints. Under the effect of the pressure of the charge air circulating through the heat exchanger, this wear can lead to openings through which the charge air flow can escape, reducing the effectiveness of the turbocharger in increasing the power of the internal combustion engine. Summary of the invention

[0006] The present invention proposes to overcome the drawbacks of the prior art, in particular the formation of openings which are limited at the brazing points joining the two cover plates to the housing. The invention also proposes to increase the mechanical strength of the cover plates relative to the pressure exerted by the charge air flow and to make the brazed joint used to form the housing more robust.

[0007] In this case, the main subject of the present invention is a heat exchanger, which includes an exchange core bundle intended to be traversed by a heat transfer liquid and an air flow, the exchange core bundle including a plurality of plates stacked one on top of the other in a stacking direction and defining at least one flow duct for the heat transfer liquid between at least two adjacent plates, each flow duct being connected to a first channel of the exchange core bundle via a first end and to a second channel of the exchange core bundle via a second end, the heat exchanger including a shell which surrounds the exchange core bundle and has at least one upper cover plate, a lower cover plate and at least one main side cover plate, the main side cover plate being arranged in a continuation of the upper cover plate and / or the lower cover plate, characterized in that the shell includes at least one intermediate side cover plate between the exchange core bundle and the main side cover plate.

[0008] The shell of the heat exchanger partially surrounds the exchange core bundle. The shell is a parallelepiped, open on two opposite faces, allowing the airflow to circulate through the exchange core bundle. The other four faces forming the sides of the parallelepiped are formed by the main side cover plate, the upper cover plate and the lower cover plate. The flow duct through which the heat transfer fluid circulates in the exchange core bundle is defined by a pair of plates, and between each pair of plates, the exchange core bundle includes a flow space containing heat sinks. These heat sinks are formed by fins for increasing the exchange surface area between the heat exchanger and the airflow.

[0009] The primary side cover is arranged in the continuation of the upper and lower cover plates so that the housing is sealed at the junction between these cover plates. More specifically, the primary side cover is arranged in the continuation of the upper and lower cover plates by aligning the inner surface of each of these cover plates, which is the surface of the cover plates intended to face the exchange core bundle.

[0010] According to one feature of the invention, the first channel and the second channel are formed by stacking the plates in the stacking direction. The channels are formed by the stacking of the plates; more specifically, a flange for forming the channels is formed at each plate. It should be understood that each plate comprises two flanges for forming the first channel and the second channel when the plates are stacked on each other.

[0011] According to one feature of the invention, the intermediate side cover has dimensions greater than the dimensions of the primary side cover against which it bears, these dimensions being measured parallel to the stacking direction. It will be understood that the intermediate side cover extends beyond the primary side cover in a direction parallel to the stacking direction of the plates. It will be noted that the intermediate side cover bears against the primary side cover such that these side covers are pressed against each other.

[0012] According to one feature of the invention, the housing has at least one junction between at least one main side cover and the upper and / or lower cover, and the intermediate side cover extends along the main side cover, the lower and / or upper cover and the junction. It should be understood that the intermediate side cover completely covers the junction between the main side cover and the lower and / or upper cover. This covering of the junction between these cover plates forms a physical barrier that protects the junction between the main side cover and the upper and / or lower cover.

[0013] According to one feature of the invention, the joining area comprises at least one first brazed joint between the intermediate side cover plate and the upper and / or lower cover plate, the joining area comprises a second brazed joint between the intermediate side cover plate and the main side cover plate, and the joining area comprises a third brazed joint between the main side cover plate and the upper and / or lower cover plate. Compared to the first and second brazed joints, the third brazed joint is an edge-to-edge brazed joint between the main side cover plate and the lower and / or upper cover plate. The edge-to-edge brazed joint enables the main side cover plate to be aligned in the continuation of the upper and / or lower cover plate.

[0014] According to one feature of the invention, the housing comprises preassembly means for preassembly between the intermediate side cover and the primary side cover against which said intermediate side cover bears. Such preassembly means advantageously make it possible to assemble the primary side cover and the intermediate side cover simultaneously during assembly of the heat exchanger. Furthermore, it will be appreciated that the preassembly means make it possible to ensure the precise positioning of each of said cover plates relative to the other.

[0015] According to one feature of the invention, the preassembly means comprises the interaction between at least one protruding element and a hole, the protruding element being integral with one of the side cover plates and the hole being formed in the other side cover plate. It should be noted that the protruding element and the hole may be formed on either the intermediate side cover plate or the primary side cover plate without departing from the scope of the invention, as long as the protruding element is formed on one of the side cover plates and the hole is formed on the other.

[0016] According to one feature of the present invention, the middle side cover plate includes a first edge in contact with the upper cover plate and a second edge in contact with the lower cover plate.

[0017] According to one feature of the present invention, the upper cover plate and / or the lower cover plate include at least one edge provided with a rounded corner, and the first edge and / or the second edge of the intermediate side cover plate have a rounded corner complementary to the rounded corner. It should be understood that the first edge and / or the second edge have a shape that allows the primary side cover plate to fit closely against the upper cover plate and / or the lower cover plate.

[0018] According to one feature of the invention, the casing comprises two intermediate side covers, each of which is connected to a main side cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other characteristics, details and advantages of the invention will become more apparent on reading the following description and a number of exemplary embodiments, which are given by way of non-limiting indication with reference to the attached schematic diagram, in which:

[0020] Figure 1 A heat exchanger intended to equip a motor vehicle is shown;

[0021] Figure 2 Shows Figure 1 The heat exchanger core bundle shown;

[0022] Figure 3 Shows the accommodation Figure 2 Two side covers of the housing of the exchange core bundle shown;

[0023] Figure 4 shows a design designed to accommodate Figure 2 The housing of the exchange core bundle is shown;

[0024] Figure 5 Shows Figure 4 An exploded view of the joint area of ​​the housing is shown. DETAILED DESCRIPTION

[0025] Features, variations and different embodiments of the present invention can be combined with each other in various combinations, as long as they are not mutually incompatible or mutually exclusive. In particular, variations of the present invention can be envisioned, which only include some of the features described below that are separated from the other described features, if these features are sufficient to provide technical advantages or distinguish the present invention from the prior art.

[0026] In the figures, elements common to several figures retain the same reference numerals.

[0027] In the following description, reference will be made to Figures 1 to 5 The trihedron L, V, T shown arbitrarily defines the orientation of the longitudinal axis L, the vertical axis V and the transverse axis T.

[0028] Figure 1 A heat exchanger 1 is shown through which a gas flow is to pass. In the embodiment shown, this gas flow is a gas flow compressed upstream of the heat exchanger 1, that is to say compressed by a turbocharger before it enters the heat exchanger 1 and is intended to be delivered to the intake manifold of an internal combustion engine at the outlet of the heat exchanger 1.

[0029] The heat exchanger 1 comprises an exchange core bundle 2 formed by a plurality of plates 21 stacked on one another in a stacking direction A substantially parallel to an axis V. Each of the plates 21 extends in a longitudinal direction substantially parallel to the main extension of the axis L. It will be understood that the plates 21 are stacked on one another in a direction perpendicular to the longitudinal direction of their main extension.

[0030] The exchange core bundle 2 is accommodated in a shell 3, and as shown in the cross-sectional view, the shell 3 is isolated from other components of the heat exchanger 1, such as Figure 4 As shown, the housing 3 has an upper cover plate 31, a lower cover plate 32 opposite to the upper cover plate 31, and at least one main side cover plate 33. The at least one main side cover plate 33 is arranged in a continuation of the upper cover plate 31 and the lower cover plate 32.

[0031] It should be noted that, in the embodiment shown, the housing 3 has two main side covers 33 assigned to each longitudinal end of the plate 21, that is to say, on both sides of the exchange core bundle 2 in the longitudinal direction of the main extension of the plate 21. It should be understood that the housing 3 at least partially surrounds the exchange core bundle 2 and forms a parallelepiped, the four faces of which are formed by the upper cover 31, the lower cover 32 and the two main side covers 33.

[0032] Of the faces of the housing 3 forming a parallelepiped, two opposite faces are open and allow the airflow to circulate through the exchange core bundle 2. The two open opposite faces are each connected to an arch 34 through which the airflow is guided so as to circulate through the exchange core bundle 2.

[0033] The exchange core bundle 2 is intended to be passed through by a heat transfer liquid that can exchange heat with the airflow. To this end, the upper cover plate 31 includes an inlet opening 311 for the heat transfer liquid, through which the heat transfer liquid can enter the exchange core bundle 2. The inlet opening 311 is connected to a first channel 22 formed in the exchange core bundle 2 in the stacking direction A of the plate 21. The upper cover plate 31 includes an outlet opening 312 for the heat transfer liquid, through which the heat transfer liquid can leave the exchange core bundle 2. The outlet opening 312 is connected to a second channel 23, which is similar to the first channel 22 and is formed in the exchange core bundle 2 in the stacking direction A of the plate 21.

[0034] Two adjacent plates 21 of the exchange core bundle 2 are stacked against each other in the stacking direction A, which helps to define a circulation duct 24 for the heat transfer liquid. The circulation duct 24 is connected to the first channel 22 through a first end or inlet end 241, and is connected to the second channel 23 through a second end or outlet end 242. It should be understood that the heat transfer liquid entering the heat exchanger 1 through the inlet opening 311 in the upper cover plate 31 circulates in the exchange core bundle 2 via the first channel 22 and is distributed in each circulation duct 24 formed between two adjacent plates 21. The heat transfer liquid circulates from the inlet end 241 of the circulation duct 24 to the outlet end 242 of the circulation duct 24, which is connected to the second channel 23 connected to the outlet opening 312 in the upper cover plate 31, and the heat transfer liquid can leave the heat exchanger 1 through the outlet opening 312.

[0035] Furthermore, according to the invention, the housing 3 comprises at least one intermediate side cover 35, which is interposed between the exchange core bundle 2 and the at least one primary side cover 33 shown. In the embodiment shown, the housing 3 comprises two primary side covers 33, each of which is connected to an intermediate side cover 35 between one of the primary side covers 33 and the exchange core bundle 2. At these side covers 33 and 35, the interaction ( Figure 3 ) makes it possible to position the main side cover plate 33 relative to the intermediate side cover plate 35.

[0036] Figure 2 A view of the exchange core bundle 2 in the transverse direction is shown, that is to say in a direction parallel to the axis T. As described above, the exchange core bundle 2 comprises a plurality of plates 21 stacked on top of one another in a stacking direction A. Two adjacent plates 21 delimit between them a flow duct 24, which are separated from two other plates 21 which also delimit the flow duct 24 by a flow space 25 for the gas flow. In the embodiment shown, this flow space 25 is partially filled with a radiant element 26.

[0037] The radiation element 26 is formed by a corrugated metal sheet extending mainly in the longitudinal direction L, that is to say along the axis L, substantially parallel to the plates 21. When the heat exchanger 1 is in operation and when the airflow passes through the circulation space 25, a heat exchange occurs between the metal wall forming the radiation element 26 and the airflow, so that the heat from the metal wall is exchanged with the heat transfer liquid circulating in the circulation duct 24 defined between two adjacent plates 21. It should be noted that the shape of the radiation element 26 makes it possible to increase the exchange surface area between the metal wall and the airflow. Of course, the radiation element 26 can take other forms, as long as these forms are able to increase the exchange surface area between the metal wall and the airflow, thereby increasing the amount of heat that can be transferred to the heat transfer liquid.

[0038] As mentioned above, the exchange core bundle 2 comprises two intermediate side covers 35, each of which is connected to a main side cover 33. These intermediate side covers 35 extend in the vertical direction, i.e. parallel to the stacking direction A, over the entire height of the exchange core bundle 2, the height being defined as the elongation of the object in the vertical direction parallel to the axis V.

[0039] More specifically, these intermediate side covers 35 have an inner surface 351 intended to face the exchange core bundle 2 and an outer face 352 intended to face at least partially the connected main side covers 33 and opposite to the inner surface 351 .

[0040] Each main side cover plate 33 is arranged in the continuation of the lower cover plate 32 and / or the upper cover plate 31. To this end, in the embodiment shown, the upper cover plate 31 and the lower cover plate 32 extending in the longitudinal direction of the main extension between the first longitudinal end 36 and the second longitudinal end 37 have at least one edge forming a rounded corner 38, which allows the first longitudinal end 36 and the second longitudinal end 37 to extend in a vertical direction perpendicular to the stacking direction A. Such a rounded corner 38 allows the main side cover plates 33 to be arranged in the continuation of the upper cover plate 31 and the lower cover plate 32.

[0041] The middle side cover plate 35 contacts the upper cover plate 31 and the lower cover plate 32, more specifically at the rounded corners 38. Figure 5 As shown, the portion of the intermediate side cover plate 35 that contacts the upper cover plate 31 and the lower cover plate 32 at the rounded corner 38 has a shape complementary to the rounded corner 38. More specifically, each intermediate side cover plate 35 includes a first edge 353 that forms a rounded corner having a shape complementary to the rounded corner 38 of the upper cover plate 31 and is intended to contact the rounded corner 38. Each intermediate side cover plate 35 also includes a second edge 354 that is opposite to the first edge 353 and is formed into a rounded corner having a shape complementary to the rounded corner 38 of the lower cover plate 32 and is intended to contact the rounded corner 38.

[0042] Furthermore, it should be understood that each intermediate side cover plate 35 extends beyond the connected primary side cover plate 33 in a vertical dimension measured parallel to the stacking axis A. In other words, the dimensions of the intermediate side cover plates 35 in the stacking direction A of the plates 21 are greater than the dimensions of the primary side cover plates 33 against which they are supported.

[0043] Figure 3 An intermediate side cover 35 and a main side cover 33 against which the intermediate side cover 35 bears are shown. The housing 3, more specifically the main side cover 33 and the intermediate side cover 35, have a preassembly device 4. The preassembly device 4 is formed by the interaction between at least one hole and one protruding element. More specifically, in the embodiment shown, the preassembly device 4 is formed by the interaction between two holes 41 formed in the main side cover 33 and two protruding elements 42 of the intermediate side cover 35. The protruding elements 42 of the intermediate side cover 35 are intended to be housed in the holes 41 of the main side cover 33. To this end, the holes 41 advantageously have a circular shape complementary to the shape of the protruding elements 42 and a diameter substantially equal to the diameter of the protruding elements 42.

[0044] The preassembly device 4 advantageously makes it possible to precisely position the intermediate side cover 35 so as to bear against the main side cover 33. It will be understood that the preassembly device 4 comprising two holes 41 interacting with two protruding elements 42 advantageously makes it possible to prevent the movement of one of the sides 33, 35 relative to the other in a direction parallel to the axis L and in a direction parallel to the axis V.

[0045] It should be noted that in the illustrated embodiment, the protruding elements 42 extend from the outer face 352 of the intermediate side cover 35 towards the primary side cover 33. Of course, these protruding elements 42 may extend from either of the side cover 33, 35 towards the connected side cover 33, 35 including the aperture 41 capable of receiving the protruding elements 42.

[0046] Figure 4 Schematically shows a cross section of a housing 3 isolated from a heat exchanger 1. More specifically, Figure 4 The intermediate side cover plate 35, the main side cover plate 33 and the upper cover plate 31 and / or the lower cover plate 32 are fixed to each other in the bonding areas 5. These bonding areas 5 are located at the first longitudinal end 36 and the second longitudinal end 37 of the upper cover plate 31 and the lower cover plate 32.

[0047] As described above, the main side cover plate 33 is arranged in the continuation of the lower cover plate 32 and the upper cover plate 31. This arrangement is such that the face of the main side cover plate 33 intended to contact the intermediate side cover plate 35 is located in the continuation of the face of the lower cover plate 32 or the upper cover plate 31 intended to contact the intermediate side cover plate 35, more specifically, in the continuation of the inner surface 352 of the intermediate side cover plate 35.

[0048] It should be understood that the combination between the main side cover plate 33 and the upper cover plate 31 or the lower cover plate 32 makes it possible to form a smooth surface against which the outer face 352 of the intermediate side cover plate 35 bears.

[0049] At each bonding area 5 , the main side cover plate 33 , the intermediate side cover plate 35 and the lower cover plate 32 or the upper cover plate 31 are brazed to each other at a very high temperature through a brazing process.

[0050] Figure 5 The joint area 5 between the main side cover plate 33, the connected intermediate side cover plate 35 and the lower cover plate 32 is shown. More specifically, Figure 5 An exploded view of the joint area 5 is shown, wherein the intermediate side cover plate 35, the main side cover plate 33 and the lower cover plate 32 are separated from each other. It should be noted that the following description of the joint area 5 of the housing 3 applies, mutatis mutandis, to each joint area 5 of the housing 3.

[0051] The brazing of the intermediate side cover plate 35, the main side cover plate 33 and the lower cover plate 32 is performed by heating the coating between two of the cover plates 33, 35, 32 to a high temperature. To this end, the bonding area 5 includes a first coating 51 arranged between the intermediate side cover plate 35 and the main side cover plate 33 and a second coating 52 arranged between the lower cover plate 32 and the intermediate side cover plate 35. It should be understood that Figure 5The bonding zone 5 is shown before the shell 3 is heated to a very high temperature. When the shell 3, including the coatings 51 and 52, is heated to a very high temperature, a third coating 53 is formed by migration, in particular by migration of a portion of the first coating 51 and the second coating 52, said third coating 53 being arranged between the main cover plate 33 and the lower cover plate 32. Each of the coatings 51, 52 and 53 then forms a polymeric layer fixed between two adjacent cover plates. The melting of the sacrificial layer, i.e. the first coating 51 and the second coating 52, the formation of the third coating 53 and the mixing of the first, second and third coatings 51, 52, 53 ensure the fixing of the components once they have cooled.

[0052] The first coating 51 is arranged to contact the outer face 352 of the intermediate side cover plate 35 and the face of the main side cover plate 33 facing the outer face 352 of the intermediate side cover plate 35. The second coating 52 is arranged at the first longitudinal end 36 of the lower cover plate so as to contact the outer face 352 of the intermediate side cover plate 35 and the lower cover plate 32 and is located between the fillet 38 of the lower cover plate and the second edge 354 of the intermediate side cover plate 35, which forms a rounded corner complementary to the fillet 38. In contrast to the first coating 51 and the second coating 52, the third coating 53 is formed between the first longitudinal end 36 of the main side cover plate 33 and the lower cover plate, so that the brazed joint formed by the third coating 53 is an edge-to-edge brazed joint between the main side cover plate 33 and the lower cover plate 32.

[0053] It should be understood that the housing 3 includes at least at each joint area 5 a first brazed joint between the intermediate side cover plate 35 and the upper cover plate 31 and / or the lower cover plate 32, a second brazed joint between the intermediate side cover plate 35 and the main side cover plate 33, and a third brazed joint between the main side cover plate 33 and the upper cover plate 31 and / or the lower cover plate 32. The fixing of different cover plates at each joint area 5 allows the housing 3 to be sealed at each different face through which the airflow enters the exchange core bundle 2.

[0054] As described above, the present invention does achieve its stated purpose and makes it possible to propose a heat exchanger in which the side cover of the housing is sealed and reinforced. Without departing from the context of the present invention, variants not described here can also be implemented, as long as they include a heat exchanger in which, according to the present invention, the intermediate side cover is interposed between the exchange core bundle and the main side cover.

Claims

1. A heat exchanger (1), the heat exchanger (1) comprising an exchange core bundle (2) intended to be passed by a heat transfer liquid and an air flow, the exchange core bundle (2) comprising a plurality of plates (21) stacked one on top of the other in a stacking direction (A), and defining at least one flow duct (24) for the heat transfer liquid between at least two adjacent plates (21), each flow duct (24) being connected to a first channel (22) of the exchange core bundle (2) through a first end (241) and connected to a second channel (23) of the exchange core bundle (2) through a second end (242), the heat exchanger (1) comprising a shell (3), the shell (3) surrounding the exchange core bundle (2) and having at least one upper cover plate (31), a lower cover plate (32) and at least one main side cover plate (33), the main side cover plate (33) being arranged in a continuation of the upper cover plate (31) and / or the lower cover plate (32), characterized in that The housing (3) comprises at least one intermediate side cover plate (35) between the exchange core bundle (2) and the primary side cover plate (33).

2. The heat exchanger (1) according to claim 1, characterized in that The first channel (22) and the second channel (23) are formed by stacking the plates (21) in a stacking direction (A).

3. The heat exchanger (1) according to claim 2, characterized in that The dimensions of the intermediate side cover (35) are greater than the dimensions of the main side cover (33) against which the intermediate side cover (35) bears, these dimensions being measured parallel to the stacking direction (A).

4. A heat exchanger (1) according to any one of the preceding claims, characterised in that The shell (3) has at least one joining area (5) between at least one main side cover plate (33) and the upper cover plate (31) and / or the lower cover plate (32), and the intermediate side cover plate (35) extends along the main side cover plate (33), the lower cover plate (32) and / or the upper cover plate (31) and the joining area (5).

5. The heat exchanger (1) according to claim 4, characterized in that The bonding area (5) includes at least one first brazed bonding portion between the intermediate side cover plate (35) and the upper cover plate (31) and / or the lower cover plate (32), the bonding area (5) includes a second brazed bonding portion between the intermediate side cover plate (35) and the main side cover plate (33), and the bonding area (5) includes a third brazed bonding portion between the main side cover plate (33) and the upper cover plate (31) and / or the lower cover plate (32).

6. A heat exchanger (1) according to any one of the preceding claims, characterised in that The housing (3) comprises a preassembly device (4) for preassembly between the intermediate side cover plate (35) and the main side cover plate (33) against which the intermediate side cover plate (35) is supported.

7. The heat exchanger (1) according to claim 6, characterized in that The preassembly device (4) comprises the interaction between at least one protruding element (42) integral with one of the side cover plates (33, 35) and a hole (41) formed in the other side cover plate (33, 35).

8. A heat exchanger (1) according to any one of the preceding claims, characterised in that The middle side cover plate (35) comprises a first edge (353) in contact with the upper cover plate (31) and a second edge (354) in contact with the lower cover plate (32).

9. The heat exchanger (1) according to claim 8, characterized in that The upper cover plate (31) and / or the lower cover plate (32) include at least one edge provided with a rounded corner (38), and the first edge (353) and / or the second edge (354) of the middle side cover plate (35) have a chamfered corner complementary to the rounded corner (38).

10. A heat exchanger (1) according to any one of the preceding claims, characterised in that The housing (3) comprises two intermediate side cover plates (35), each of which is connected to a main side cover plate (33).

Images