Heat exchanger
By improving the baffle design and sealing the coolant passage bypass area, the problems of temperature difference and thermal shock in WCAC are solved, the durability and mechanical strength of the heat exchanger are improved, and the failure rate is reduced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-26
- Publication Date
- 2026-03-27
AI Technical Summary
Traditional water-cooled booster air coolers (WCACs) exhibit significant temperature differences and thermal shock at the pipe-to-manifold connections, leading to heat exchanger failures. Improvements to the baffles are needed to prevent coolant bypass flow and enhance resistance to thermal shock.
An improved spoiler design is employed, including crest and trough structures with twisted outer edges, which, by brazing to the bend between the tube and the shell plate, closes the coolant passage bypass area, ensuring coolant flow through the core area, and increases the brazing area to enhance the mechanical connection.
It effectively eliminates the high temperature difference area between the coolant side and the air side, reduces thermal stress, improves the durability and mechanical strength of the heat exchanger, reduces the failure rate, and improves temperature uniformity and mechanical resistance.
Smart Images
Figure CN121752865A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present invention relates to a heat exchanger. More particularly, the present invention relates to an improved spoiler for a heat exchanger. BACKGROUND
[0002] It is known that, in order to achieve high volumetric efficiency, improved performance and power of a combustion engine of a motor vehicle, the combustion engine is supplied with charge air that has been compressed using a turbocharger or a supercharger. However, such compression has the effect of raising the temperature of the charge air and reducing its density. For this reason, the charge air must be cooled before being introduced into the combustion chambers of the engine. Cooling is usually performed in an air cooler or heat exchanger known as a charge air cooler or intercooler. The drop in temperature of the charge air allows the risk of self-ignition to be reduced and can increase the density of the charge air, thus increasing the combustion yield.
[0003] A conventional charge air cooler, such as a water-cooled charge air cooler (WCAC), can include a housing defined by walls, such as side walls 102, to receive a plurality of tubes, such as tubes 104 and 106, as shown in Figure 1 The opposite ends of the tubes are inserted into the tube slots of the headers and further brazed to the respective headers. The housing is usually open at both of its ends so that the tubes can be connected to a fluid inlet tank and a fluid outlet tank. Fluid to be cooled, such as air, flows through the air flow passages defined by the tubes 104 and 106. Typically, air spoilers, such as air spoiler 107, are disposed in the air flow passages of the tubes. In addition, coolant spoilers, such as spoiler 108, are disposed between adjacent tubes, i.e., the adjacent tubes are separated by the coolant spoilers. The charge air flows in the tubes from the inlet tank to the outlet tank, and the coolant fluid, such as water, flows through the gaps between the adjacent tubes separated by the coolant spoilers from the inlet tube to the outlet tube and exchanges heat with the charge air to cool the charge air. Such coolant spoilers 108 are formed from a sheet material comprising a monolithic row of alternating crests and troughs to turn the laminar flow of the coolant into turbulent flow, in turn, increasing the heat exchange efficiency.
[0004] Furthermore, with the need for engine downsizing and improved engine performance, the mechanical load on engine components is becoming more severe. The thermal shock load experienced by engine components is increasing due to more stringent targets and / or requirements. With the tube design of a WCAC, one of the main failure modes is due to thermal shock at the location where the tube and header are connected. More specifically, on the hot side of the WCAC, i.e., the air inlet and coolant outlet side, there is a location of thickness change between the tube and the header slot. As shown in Figure 1As shown, there is a gap or bypass area 110 between the side wall 102 of the housing, the edge of the tube 104 / 106 and the coolant spoiler 108, where the coolant can flow without any physical restriction and avoid passing through the coolant spoiler 108, which results in a significant temperature difference between the air side and the coolant side of the tube. The thickness variation along with the significant temperature difference between the air side and the coolant side of the tube can create local stress concentration at high loads during thermal shock phenomena in the WCAC, which can lead to failure of the heat exchanger.
[0005] Therefore, there is a need for a solution to prevent eliminating the area with a significantly high local temperature difference between the air and the coolant side to reduce thermal stress on the tube. Moreover, there is a need to increase the resistance of the tube portion corresponding to the air inlet side and the coolant outlet side to the thermal shock phenomena. SUMMARY
[0006] The present invention discloses a simple, efficient and robust heat exchanger for a motor vehicle, such as a water-cooled charge air cooler (WCAC). In particular, the present invention discloses an improved spoiler for a WCAC.
[0007] According to an embodiment of the present invention, the disclosed spoiler comprises a sheet of material, the sheet comprising a plurality of integral rows along a first axis, the integral rows formed by an alternation of first peaks and second peaks. The first peaks protrude beyond a first plane in a first direction. The second peaks protrude beyond the first plane in a second direction opposite the first direction. At least a portion of each first peak of at least one of the plurality of rows protrudes beyond a second plane, the second plane offset from the first plane and coplanar with the first peaks of an adjacent row.
[0008] Further, an outer edge portion of each first peak of the row is twisted and protrudes beyond the second plane in the first direction.
[0009] In an embodiment, at least a portion of each second peak of the row protrudes beyond a third plane, the third plane offset from the first plane and coplanar with the second peaks of an adjacent row.
[0010] Further, an outer edge portion of each second peak of the row is twisted and protrudes beyond the third plane in the second direction.
[0011] Further, adjacent first peaks and second peaks in each of the plurality of rows are connected by a stepped sidewall.
[0012] Still further, adjacent first peaks and second peaks of each row are arranged in an inverted manner with respect to each other.
[0013] Further, at least one perforation is disposed between two adjacent ones of the plurality of rows such that a second peak in each row is in fluid communication with an adjacent first peak in any immediately adjacent row, and a first peak in the row is in fluid communication with an adjacent second peak in the immediately adjacent row.
[0014] A first peak in one of the rows is configured to be adjacent to a second peak in any immediately adjacent row, and a second peak in one of the rows is configured to be adjacent to a first peak in the immediately adjacent row.
[0015] In an embodiment, the first plane extends in a manner that divides the spoiler into two symmetrical halves.
[0016] According to another embodiment, a heat exchanger for a motor vehicle is disclosed. The heat exchanger comprises a housing defined by at least two housing plates and a heat exchanger core adapted to be received in the housing. The heat exchanger core comprises at least two tubes arranged one above the other with a space therebetween to define a fluid flow passage for a fluid, wherein opposite minor side walls of the two tubes are in abutment with inner surfaces of the corresponding housing plates. The heat exchanger further comprises at least one spoiler located between the tubes. The spoiler comprises a sheet of material. The sheet comprises a plurality of integral rows along a first axis, the integral rows being formed of an alternation of first peaks and second peaks. The first peaks protrude beyond a first plane in a first direction. The second peaks protrude beyond the first plane in a second direction opposite to the first direction. The first peaks and the second peaks are adapted to be in abutment with adjacent outer surfaces of the respective tubes.
[0017] At least a portion of each first peak of at least one of the plurality of rows protrudes beyond a second plane, the second plane being offset with respect to the first plane and coplanar with the first peaks of the adjacent row. In addition, an outer edge portion of each first peak of the at least one row is twisted and protrudes beyond the second plane. The twisted outer edge portion is adapted to be received in a first gap between a curved portion of the corresponding tube and the corresponding housing plate.
[0018] In addition, the twisted outer edge portion of each first peak of the at least one row has a curved profile complementary to the curved portion of the corresponding tube.
[0019] In an embodiment, at least a portion of each second peak of the at least one row protrudes beyond a third plane, the third plane being offset with respect to the first plane and coplanar with the second peaks of the adjacent row.
[0020] In addition, an outer edge portion of each second peak of the at least one row is twisted and protrudes beyond the second plane. The twisted outer edge portion is adapted to be received in a second gap between the curved portion of the corresponding tube and the corresponding housing plate.
[0021] The twisted outer edge portion of each second wave peak of the side lane has a curved profile complementary to the curved portion of the corresponding tube.
[0022] In this specification, some elements or parameters can be indexed, such as a first element and a second element. In that case, unless otherwise stated, this indexing only means to distinguish and name similar but not identical elements. No concept of priority should be inferred from this indexing, as these terms can be interchanged without departing from the invention. In addition, this indexing does not imply any order of installation or use of the elements of the invention. BRIEF DESCRIPTION OF DRAWINGS
[0023] Other features, details and advantages of the invention can be inferred from the following description of the invention. A more complete understanding of the present invention, and the many attendant advantages of it, will be had by reference to the following detailed description when considered in conjunction with the drawings, which become better understood as the description is considered, in which:
[0024] Figure 1 A conventional heat exchanger according to an embodiment of the present invention is shown, showing the coolant bypass area between the side wall of the housing, the tubes and the edge of the coolant spoiler;
[0025] Figure 2 An isometric view of a heat exchanger according to an embodiment of the present invention is shown;
[0026] Figure 3 A cross-sectional view of the heat exchanger of Figure 2 is shown;
[0027] Figure 4 A spoiler of the heat exchanger of Figure 2 is shown; and
[0028] Figure 5 The arrangement of the spoiler between two tubes of the heat exchanger of Figure 2 is shown. DETAILED DESCRIPTION
[0029] It must be noted that the attached drawings disclose the invention in sufficient detail to enable its implementation, if necessary, said drawings helping to better define the invention. However, the invention should not be limited to the embodiments disclosed in the specification.
[0030] In the following description and drawings, the present application is explained by way of example with reference to a heat exchanger such as a water-cooled charge air cooler for a motor vehicle. More specifically, the present application discloses an improved spoiler for a heat exchanger, wherein the shape of a portion of the spoiler is modified to close the coolant passage bypass area to prevent bypass flow of coolant and force the coolant to flow through the main core area of the spoiler and / or heat exchanger. Thus, in terms of thermal shock phenomenon, the coolant temperature is greatly improved in the most critical areas, i.e. air inlet side and coolant outlet side, thereby eliminating the areas with significantly high local temperature difference, which reduces the thermal stress during normal vehicle operation, thereby reducing the failure caused by thermal shock phenomenon and improving the durability of the WCAC. Further, the mechanical core resistance is also improved as the brazing area between the spoiler and tube extends to the tube radius.
[0031] It will be appreciated that the concept of the present application can be applicable to any other application in vehicle and non-vehicle environments, wherein a modified spoiler is required to close the coolant passage bypass area in a heat exchanger.
[0032] With reference to Figure 2 and Figure 3 According to an embodiment, the present application discloses a heat exchanger 200, such as a water-cooled charge air cooler, for a motor vehicle. The heat exchanger 200 comprises a housing 202, a first tank 203a (e.g. inlet tank) and a second tank 203b (e.g. outlet tank). The first tank 203a and the second tank 203b are fluidly connected to the housing 202 through two opposite open ends of the housing 202. The housing 202 is configured to house a heat exchanger core 206. The housing 202 is defined by two side housing plates 204a and 204b configured on two opposite sides of the heat exchanger core 206, and two closing plates 205a and 205b configured on the other two sides of the heat exchanger core 206 adjacent to the housing plates 204a and 204b to cover the heat exchanger core 206 from the other two opposite sides. The longitudinal side ends of the closing plates 205a and 205b are in abutment with the adjacent longitudinal side ends of the housing plates 204a and 204b.
[0033] The heat exchanger core 206 includes a plurality of tubes 208-1, 208-2,... 208-N (hereinafter collectively referred to as tubes 208), and a plurality of coolant baffles 250 disposed between the tubes 208. The plurality of tubes 208 and the plurality of coolant baffles 250 are arranged alternately such that at least one coolant baffle 250 is disposed between adjacent tubes, and a space or flow passage for fluid / coolant is established between the adjacent tubes. Each tube 208 has opposite large flat walls 211 connected at their ends by a circular / curved and smaller side wall 209. A portion of the smaller side wall 209 of the tube 208 abuts the inner surface of the respective housing plates 204a and 204b. In addition, the opposite open ends of the tube 208 are inserted into the tube slots of the headers 223a and 223b disposed on the two open ends of the housing 202, and further brazed to the respective headers 223a and 223b. The first and second tanks 203a and 203b are fixed to the respective headers 223a and 223b such that the fluid to be cooled (e.g., charge air) flows from the first tank 203a to the second tank 203b through the air flow passage defined by each tube 208.
[0034] In addition, one or more air baffles 213 are inserted into the air flow passage of each tube 208. The air baffles 213 can be cut and biased fins. Typically, the peaks of the air baffles 213 are bonded to the inner surface of the respective tube 208 by a suitable bonding process, such as but not limited to, soldering, brazing, and welding.
[0035] The fluid / coolant (e.g., water) is received within the housing 202 through the inlet pipe 225a, and flows around the tubes 208 through the spaces / fluid flow passages between adjacent tubes separated by the coolant baffles 250, exchanges heat with the charge air to cool the charge air, and further flows out of the housing 202 through the outlet pipe 225b. For example, the inlet pipe 225a is disposed on the housing plate 204b, and the outlet pipe 225b is disposed on the housing plate 204a.
[0036] With this arrangement of the tubes 208 separated by the baffles 250, the air flows through the air flow passages in the tubes 208 and the coolant / water flows through the spaces between the tubes 208, the coolant flow passages being adjacent to the air flow passages. This configuration enables heat exchange between the air flowing through the air flow passages in the tubes 208 and the coolant flowing through the coolant flow passages around the tubes. The air baffles 213 and the coolant baffles 250 are made of thermally conductive material, and serve as means to enhance the heat exchange between the air flow and the coolant / water. In addition, the air baffles 213 and the coolant baffles 250 are adapted to convert the laminar flow of the air and the coolant, respectively, into turbulent flow, in turn increasing the heat exchange efficiency of the heat exchanger 200.
[0037] It should be understood that the construction and function of spoilers 250 are similar, so one of the spoilers will be described below, and this will be sufficient to describe all similar spoilers.
[0038] refer to Figure 4 The spoiler 250 comprises a sheet 210 of a material with good thermal conductivity, such as a sheet of steel, copper, brass, aluminum, etc. For example, the spoiler 250 can be manufactured by a stamping process. The sheet 210 comprises a plurality of integral rows 212-1, 212-2…212-N (hereinafter collectively referred to as rows 212) along a first axis 214, with alternating first peaks 216 and second peaks 218. The first peak 216 protrudes beyond a first plane in a first direction (indicated by the dotted line 215), while the second peak 218 protrudes beyond the first plane 215 in a second direction opposite to the first direction. The first plane 215 may extend in a manner that divides the spoiler 250 into two symmetrical halves. Furthermore, adjacent first peaks 216 and second peaks 218 of each row 212 may be arranged in an inverted manner relative to each other. For example, in each row of row 212, the first peak 216 and the second peak 218 protrude in opposite directions, thus forming alternating ridges and valleys.
[0039] Furthermore, adjacent first peaks 216 and second peaks 218 in each of the plurality of rows 212 are connected by stepped sidewalls 234. The stepped sidewalls 234 may have one or more bends. The length of the stepped sidewalls 234 may vary in different rows. For example, the length of the stepped sidewalls 234 in row 212-1 may be longer than the length of the stepped sidewalls 234 in row 212-2.
[0040] Furthermore, the first peak 216 and the second peak 218 are adapted to abut against the adjacent outer surfaces of the corresponding tubes 208. For example, the first peak 216 abuts against the outer surface of tube 208-1, and the second peak 218 abuts against the outer surface of tube 208-2, as shown below. Figure 4 As shown. In addition, the first peak 216 and the second peak 218 can be bonded / brazed to the outer surface of the corresponding tube 208.
[0041] In one embodiment, at least a portion of each first peak 216 of at least one lateral row (e.g., but not limited to lateral rows 212-1 and 212-N) protrudes beyond the second plane 220 (by...). Figure 4(Represented by solid line 220 in the diagram). The second plane 220 is offset relative to the first plane 215 and is coplanar with the first crests 216 of the adjacent rows of side rows 212-1 and 212-N. The outer edge portion 217 of each first crest 216 of side rows 212-1 and 212-N is twisted and protrudes beyond the second plane 220. Furthermore, the twisted outer edge portion 217 of the first crest 216 is adapted to be received in a first gap between the curved portion 226 of the small sidewall 209 of the corresponding tube (e.g., tube 208-1) and the corresponding housing plates 204a, 204b, as shown. Figure 5 As shown. Furthermore, the twisted outer edge portion 217 of each first crest 216 of the lateral rows 212-1 and 212-N has a curved profile complementary to the curved portion 226 of the corresponding tubes 208-1 / 208-2, as shown. Figure 5 shown.
[0042] In another embodiment, at least a portion of each second peak 218 of the lateral rows 212-1 and 212-N may protrude beyond the third plane (by...). Figure 4 (Indicated by dashed line 228 in the diagram). The third plane 228 is offset relative to the first plane 215 and is coplanar with the second crests 218 of the adjacent rows of side rows 212-1 and 212-N. The outer edge portion 219 of each second crest 218 of side rows 212-1 and 212-N may be twisted and protrude beyond the second plane 218. The twisted outer edge portion 219 of the second crest 218 is adapted to be received in a second gap between the bend 226 of the corresponding tube (such as tube 208-2) and the corresponding housing plates 204a, 204b, as shown in the diagram. Figure 5 As shown. In addition, the twisted outer edge portion 219 of each second crest 218 of the side rows 212-1 and 212-N has a curved profile that is complementary to the curved portion 226 of the small sidewall 229 of the corresponding tube 208-1 / 208-2.
[0043] When the twisted outer edge portion 217 of the first peak 216 and the twisted outer edge portion 219 of the second peak 218 are inserted into the gaps (including the first and second gaps) between the side housing plates 204a and 204b and the bent portions 226 of the corresponding pipes 208, the spoiler 250 closes the coolant passage bypass area to prevent bypass flow of coolant and forces coolant / water flow through the core area of the heat exchanger core 2 06 and / or the spoiler 250. This configuration of the spoiler 250 helps to completely eliminate areas with high temperature differences generated by the bypass coolant flow in a conventional heat exchanger. Therefore, thermal stress during normal vehicle operation can be reduced, thereby reducing failures caused by thermal shock phenomena of the heat exchanger 200. Furthermore, a more uniform temperature distribution can be achieved at the edge of the spoiler 250 on the outlet side. In addition, a uniform temperature distribution along the length of the heat exchanger core can be achieved, i.e., improved temperature uniformity and reduced temperature gradient.
[0044] Furthermore, the spoiler 250 simplifies the assembly process because the spoiler deformation (i.e., the twisted outer edge portions 217 and 219 of the first crest 216 and the second crest 218) aligns with the bent portion 226 of the tube 208, ensuring proper positioning of the spoiler during assembly and brazing. Additionally, the increased brazing area between the spoiler 250 and the tube 208 due to the extended twisted outer edge portions 217 and 219 of the tube bend 226 improves the mechanical resistance of the heat exchanger core 206 to thermal shock. This also increases the heat exchanger core's resistance to mechanical loads (e.g., but not limited to air pressure cycling and coolant pressure cycling), thereby increasing the heat exchanger's lifespan.
[0045] Refer again Figure 4 At least one perforation is provided between two adjacent rows in the plurality of rows 212, such that a second peak 218 in each row 212 is in fluid communication with an adjacent first peak 216 in any immediately adjacent row, and a first peak 216 in that row is in fluid communication with an adjacent second peak 218 in an immediately adjacent row. Furthermore, a first peak 216 in one of the rows 212 is configured to be adjacent to a second peak 218 in any immediately adjacent row, and similarly, a second peak 218 in one of the rows 212 is configured to be adjacent to a first peak 216 in an immediately adjacent row.
[0046] In no event should the invention be limited to the embodiments specifically described herein, as other embodiments may exist. The invention should be extended to any equivalent means and any combination of technical operations of those means.
Claims
1. A spoiler (250), comprising: Material sheet (210), the sheet (210) includes a plurality of integral rows (212) along a first axis (214), the integral rows being formed by alternating first crests (216) and second crests (218), the first crests (216) protruding beyond a first plane (215) in a first direction, and the second crests (218) protruding beyond the first plane (215) in a second direction opposite to the first direction. In this plurality of rows (212), at least a portion of each first peak (216) of at least one side row (212-1, 212-N) protrudes beyond a second plane (220), which is offset relative to the first plane (215) and coplanar with the first peak (216) of the adjacent row.
2. The spoiler (250) according to the preceding claim, wherein, The outer edge portion (217) of each first peak (216) of the lateral rows (212-1, 212-N) is distorted and protrudes beyond the second plane (220) in the first direction.
3. The spoiler (250) according to any one of the preceding claims, wherein, At least a portion of each second peak (218) of the side rows (212-1, 212-N) protrudes beyond a third plane (228), which is offset relative to the first plane (215) and coplanar with the second peak (218) of the adjacent row.
4. The spoiler (250) according to any one of the preceding claims, wherein, The outer edge portion (219) of each second peak (218) of the lateral rows (212-1, 212-N) is distorted and protrudes beyond the third plane (228) in the second direction.
5. The spoiler (250) according to any one of the preceding claims, wherein, The adjacent first peak (216) and second peak (218) in each of the plurality of rows (212) are connected by stepped sidewalls (234).
6. The spoiler (250) according to any one of the preceding claims, wherein, The adjacent first peak (216) and second peak (218) of each row (212) are arranged in a manner that is inverted relative to each other.
7. The spoiler (250) according to any one of the preceding claims, wherein, At least one perforation is provided between two adjacent rows in the plurality of rows (212) such that the second peak (218) in each row (212) is in fluid communication with the adjacent first peak (216) in any immediately adjacent row, and the first peak (216) in the row is in fluid communication with the adjacent second peak (218) in the immediately adjacent row.
8. The spoiler (250) according to any one of the preceding claims, wherein, The first peak (216) in one of the rows (212) is configured to be adjacent to the second peak (218) in any adjacent row, and wherein the second peak (218) in one of the rows (212) is configured to be adjacent to the first peak (216) in the adjacent row.
9. The spoiler (250) according to any one of the preceding claims, wherein, The first plane (215) extends in such a way that it divides the spoiler (250) into two symmetrical halves.
10. A heat exchanger (200) for a motor vehicle, comprising: A housing (202) defined by at least two housing plates (204a, 204b); A heat exchanger core (206) adapted to be received in the housing (202) includes at least two tubes (208-1, 208-2), one tube (208-1, 208-2) arranged on top of the other, with a space between them to define a fluid flow channel for fluid, and the relatively smaller sidewalls (209) of the two tubes (208-1, 208-2) abutting against the inner surfaces of the corresponding housing plates (204a, 204b); and At least one spoiler (250) positioned between the tubes (208-1, 208-2), the spoiler (250) comprising a sheet of material (210) comprising a plurality of integral rows (212) along a first axis (214), the integral rows (212) being formed by alternating first crests (216) and second crests (218), the first crests (216) protruding beyond a first plane (215) in a first direction, and the second crests (218) protruding beyond the first plane (215) in a second direction opposite to the first direction, wherein the first crests (216) and the second crests (218) are adapted to abut against adjacent outer surfaces of the respective tubes (208-1 and 208-2); In this plurality of rows (212), at least a portion of the first peak (216) of at least one side row (212-1, 212-N) protrudes beyond the second plane (220), the second plane (220) being offset relative to the first plane (215) and coplanar with the first peak (216) of the adjacent row; and The outer edge portion (217) of each first crest (216) of the side rows (212-1, 212-N) is twisted and protrudes beyond the second plane (220), and the twisted outer edge portion (217) is adapted to be received in a first gap between the curved portion (226) of the corresponding tube (208-1, 208-2) and the corresponding housing plate (204a, 204b).
11. The heat exchanger (200) according to the preceding claim, wherein, The twisted outer edge portion (217) of each first peak (216) of the side rows (212-1, 212-N) has a curved profile that is complementary to the curved portion (226) of the corresponding tube (208-1, 208-2).
12. The heat exchanger (200) according to any one of the preceding claims, wherein, At least a portion of each second peak (218) of the side rows (212-1, 212-N) protrudes beyond a third plane (228), which is offset relative to the first plane (215) and coplanar with the second peak (218) of the adjacent row.
13. The heat exchanger (200) according to any one of the preceding claims, wherein, The outer edge portion (219) of each second crest (218) of the side rows (212-1, 212-N) is twisted and protrudes beyond the second plane (218), and the twisted outer edge portion (219) is adapted to be received in a second gap between the curved portion (226) of the corresponding tube (208-1, 208-2) and the corresponding shell plate (204a, 204b).
14. The heat exchanger (200) according to any one of the preceding claims, wherein, The twisted outer edge portion (219) of each second peak (218) of the side rows (212-1, 212-N) has a curved profile that is complementary to the curved portion (226) of the corresponding tube (208-1, 218-2).