Heat exchanger, air intake system and method for mounting a heat exchanger

Abstract

A heat exchanger for cooling air by means of a coolant, comprising a first and a second front face as an inlet or an outlet for air, respectively, and a shell between the first and the second front face, the shell having at least one coupling element along a circumferential line of the shell, the circumferential line being spaced apart from the first front face by a predetermined distance, the shell having at least one port as an inlet or an outlet for the coolant, the port being arranged at a distance from the first front face, the distance being greater than the predetermined distance, wherein the at least one coupling element is adapted to be fixedly coupled with at least one corresponding coupling element of an air inlet duct or an air outlet duct, and wherein the shell comprises a tube arrangement connected to the port for the coolant. The tube arrangement is adapted to guide the coolant into an insertion section of the shell, the insertion section being located between the first front face and the circumferential line.

Description

Technical Field

[0001] This disclosure relates to a heat exchanger for cooling intake air (particularly intake air of a combustion engine), an air intake system, and a method for installing the heat exchanger in the air intake system. Background Technology

[0002] Vehicle combustion engines (especially turbocharged combustion engines) are sometimes equipped with heat exchangers to cool the intake air before it is supplied to the engine. EP 2 501 912 B1 discloses an intake manifold for an internal combustion engine with a heat exchanger, including an outer housing of the intake manifold, wherein a feed line for boost air leads to an inlet section of the housing. The heat exchanger is part of the intake manifold system and operates by means of a cooling fluid. The heat exchanger includes a plurality of flat exchanger tubes. An engine flange is directly fastened to the air outlet side of the heat exchanger, and the air inlet side of the heat exchanger is connected to the intake manifold. Boost air flows through the exchanger tubes in a water jacket formed by the outer housing surrounding the exchanger tubes.

[0003] Given limited space for installing and connecting heat exchangers, the size of the heat exchanger is typically reduced to fit within the available space. However, reducing the size of the heat exchanger may degrade its cooling efficiency. Furthermore, the connection between the heat exchanger and the air inlet and outlet ducts usually requires connection tools (e.g., crimping tools) to access the connection points. To provide sufficient space for the connection tools to access these connection points, the size of the heat exchanger is often further reduced, thereby further degrading its cooling efficiency.

[0004] In view of the above, an object of the present invention is to provide an improved heat exchanger and an improved air intake system. Another object is to provide a method for installing a heat exchanger in an air intake system. Summary of the Invention

[0005] Therefore, a heat exchanger for cooling air with a coolant is provided. The heat exchanger may be a plate-type or tubular heat exchanger. The heat exchanger includes: first and second front faces, respectively serving as an air inlet or outlet; and a shell between the first and second front faces. The shell has at least one connecting element along a circumferential line spaced from the first front face at a predetermined distance. Furthermore, the shell has at least one port serving as a coolant inlet or outlet, the port being arranged at a distance from the first front face greater than the predetermined distance. The at least one connecting element is adapted to be fixedly connected to at least one corresponding connecting element of an air inlet or air outlet duct, and the shell may include a pipe arrangement structure or internal piping system connected to the coolant and adapted to guide the coolant into an insertion section of the shell. Alternatively, the shell may include a plate-type arrangement structure. The insertion section is located between the first front face and the circumferential line.

[0006] By inserting at least part of the heat exchanger's volume into one of the air ducts, the installation space is reduced, and the connecting elements are made easier to access.

[0007] When installing a heat exchanger in a vehicle's air intake system, shifting the circumferential connecting element from the front face allows for an improved proximity between the connecting element and its corresponding connecting element.

[0008] The air can be at atmospheric pressure, or it can be compressed air (e.g., boosted air) compressed by a compressor of a turbocharger or electric supercharger. It should be understood that when referring to air, a mixture of air and redirected exhaust gas can also be considered. In operation, air flows, for example, from the first front face to the second front face of a heat exchanger.

[0009] The coolant can be a liquid coolant, such as water. Engine coolant fluid can be used as the coolant for the heat exchanger. The coolant flows from the (inlet) port of the heat exchanger to another (outlet) port, for example, through an internal pipe arrangement. The coolant flow within the pipe or plate arrangement provides an indirect method for cooling air flowing around the pipes (i.e., outside the pipes). The direction of the coolant flow within the heat exchanger can be perpendicular to the direction of the airflow to provide efficient cooling.

[0010] In one embodiment, the first front surface of the heat exchanger is an air-permeable surface. The second front surface of the heat exchanger may also be an air-permeable surface. The shell of the heat exchanger is airtight. The shell may comprise a metallic material.

[0011] The shell, the first front face, and the second front face are joined to form, for example, the housing of a heat exchanger. The combination of the shell, the first front face, and the second front face can, for example, have a rectangular block shape. In this case, the shell has four rectangular shell sides, and the first and second front faces are each rectangular in shape. The heat exchanger housing can form part of the housing of an intake system.

[0012] In one embodiment, the shell forms a sheath for the cooling fluid, and the air to be cooled is guided through the cooling fluid in the air duct. Thus, the volume enclosed by the sheath corresponds to the duct arrangement.

[0013] The insertion section of the shell may include a portion of the shell between the first front face and the circumferential line, and an internal volume surrounded by the front face and the portion of the shell. The insertion section houses a section through which coolant from a tubular arrangement is guided and around which air to be cooled flows. The tubular arrangement may include, for example, a curved section bent along the direction of the first front face. Therefore, coolant is guided into the insertion section to cool the air also within the insertion section. Thus, active heat exchange between the coolant and the air occurs within the insertion section of the shell.

[0014] It should be understood that embodiments with a pipe arrangement do not necessarily include cylindrical or oval pipes. However, the pipe arrangement can be achieved by a sheath that restricts the volume of coolant and a plate that separates air from the coolant. The function of the "pipe arrangement" is to guide the coolant into the insertion section in the direction of or against the airflow. It can also refer to the internal piping system of the coolant.

[0015] At least one connecting element of the heat exchanger may be a connecting element comprising a plurality of connecting elements arranged along the circumferential line of the shell. The connecting element is adapted to be fixedly connected to at least one corresponding connecting element (e.g., a plurality of corresponding connecting elements) of an air inlet or air outlet duct.

[0016] In an embodiment, at least one connecting element of the heat exchanger includes a deformable element. At least one connecting element of the heat exchanger is configured, for example, to engage with a non-deformable connecting element of an air inlet or air outlet duct. Alternatively or additionally, at least one connecting element of the heat exchanger includes a crimping element, a clip, a retaining ring, a sleeve, and / or a coupling element. At least one connecting element of the heat exchanger may also include sections or points configured for welding or brazing, such as weld points or brazed joints.

[0017] In an embodiment, at least one coupling element of the heat exchanger includes an element for screw connection, such as a screw hole or screw.

[0018] At least one connecting element of the heat exchanger, along a circumferential line spaced at a predetermined distance from the first front face, allows an air inlet or air outlet duct to be connected to the heat exchanger, such that the air inlet or air outlet duct partially accommodates the heat exchanger within its interior. In other words, a portion of the heat exchanger is inserted into the air inlet or air outlet duct. Therefore, the length of the heat exchanger from the first front face (e.g., the air inlet face) to the second front face (e.g., the air outlet face) is typically greater than the distance between at least one connecting element of the heat exchanger and the second front face. Consequently, the length of the heat exchanger in the direction of airflow can be greater than the available space for mounting the heat exchanger in the air intake system of a combustion engine.

[0019] Given the limited space available for installing the heat exchanger, a larger heat exchanger can be used because a portion of its volume can be accommodated within the air duct. Since, as mentioned above, active heat exchange also occurs within the insertion section of the heat exchanger, this larger heat exchanger also has a larger active heat exchange area compared to a heat exchanger with an effective volume only between the flanges of the air inlet and outlet. Therefore, for the limited space available for installing the heat exchanger, a heat exchanger with more efficient cooling can be provided.

[0020] Furthermore, the specific arrangement of at least one of the connecting elements of the heat exchanger can provide sufficient space for a connecting tool (e.g., a crimping tool) to approach the at least one connecting element of the heat exchanger and / or the at least one connecting element of the air inlet or air outlet duct without reducing the length of the heat exchanger and thus reducing cooling efficiency.

[0021] According to another embodiment, the heat exchanger includes at least one frame surrounding at least one of a first front face and a second front face, wherein at least one coupling element of the heat exchanger is attached to said at least one frame. The frame may be integrally formed with the at least one coupling element and / or a shell. Alternatively, the shell may be formed separately. The frame and at least one coupling element may comprise, for example, metal, while the shell may comprise, for example, a plastic material. The shell may also be formed of metal.

[0022] According to another embodiment, the tube arrangement includes flat tubes, particularly multiple stacked flat plates. The multiple stacked flat plates can be stacked along the direction of airflow. The flat plates can have a rectangular block shape, a small height along the direction of airflow, and a large surface area perpendicular to the direction of airflow. Thus, a large cooling surface can be provided, and therefore, efficient cooling is achieved.

[0023] According to another embodiment, the tube arrangement includes a bundle of tubes. This provides further flexibility in the tube arrangement to better accommodate the tubes within the insertion section.

[0024] The pipe arrangement can be any internal piping system that guides the coolant in a direction perpendicular to the specified airflow and at least partially guides it to the volume included by the insertion section. Thus, the air to be cooled can flow from the inlet front face and the outlet front face, thereby transferring heat to the coolant flowing through the piping system or pipe arrangement. The heat exchanger is preferably implemented to transfer heat from the air to the coolant in the insertion section.

[0025] In an embodiment, the internal piping system or pipe arrangement of the coolant is configured to redirect the flow of coolant from the respective inlet port toward the insertion section or from the insertion section toward the outlet port.

[0026] According to another embodiment, at least one connecting element of the heat exchanger includes a deformable element, particularly a deformable protrusion configured for crimping connections, clips, snap rings, sleeves, and / or engaging elements.

[0027] At least one connecting element of the heat exchanger may be configured to engage with a non-deformable connecting element of the air inlet or air outlet duct.

[0028] In one embodiment, at least one deformable connecting element is in direct contact with the shell of the heat exchanger. The deformable connecting element may be integrally formed with the shell. Both the deformable connecting element and the shell may, for example, comprise metal.

[0029] According to another embodiment, at least one connecting element includes a non-deformable element configured to connect, in particular, to a deformable element of an air inlet or air outlet duct by means of a crimp connection, clip connection, snap ring connection, and / or engagement connection.

[0030] At least one non-deformable connecting element of the heat exchanger may be configured, for example, to engage with a deformable connecting element of an air inlet or air outlet duct.

[0031] According to another embodiment, the housing includes at least one additional connecting element disposed at an edge of the housing adjacent to the second front face, the at least one additional connecting element being adapted to be fixedly connected to at least one corresponding additional connecting element of an additional air inlet or air outlet duct.

[0032] Therefore, additional air inlet or outlet ducts can be connected to the heat exchanger at the edge of the casing. An asymmetrical arrangement of circumferential connections with respect to the length of the heat exchanger facilitates assembly of the exchanger within the inlet duct.

[0033] According to another embodiment, the housing includes at least one additional connecting element along another circumferential line of the housing, the additional circumferential line being spaced apart from the second front face by another predetermined distance, wherein the at least one additional connecting element is adapted to be fixedly connected to at least one corresponding additional connecting element of another air inlet or air outlet duct, and wherein the duct arrangement is adapted to guide coolant into another insertion section of the housing, the additional insertion section being located between the second front face and the additional circumferential line.

[0034] Displace the two circumferential connecting elements from the front faces of the first and second inlets or outlets, which can facilitate access to the connecting elements by means of tools to connect the elements and / or activate a fixed connection with the air duct.

[0035] The port is, for example, a coolant inlet port. Similarly, another port is, for example, a coolant outlet port. A pipe arrangement connects, for example, the inlet and outlet ports, such that the coolant is guided from the inlet port to the outlet port through the pipes of the pipe arrangement inside the heat exchanger housing. Thus, the coolant is guided into insertion sections during its passage through the pipe arrangement and into other insertion sections of the housing. These insertion sections can be used for active heat transfer from air to coolant.

[0036] The first front face of the heat exchanger is, for example, the inlet face of the air to be cooled. The second front face is, for example, the outlet face of the cooled air. In this case, the inlet face of the heat exchanger is connected to an air inlet duct, and the outlet face of the heat exchanger is connected to an air outlet duct. Furthermore, in this case, the connecting elements of the heat exchanger are adapted to be fixedly connected to corresponding connecting elements of the air inlet duct. Similarly, other connecting elements of the heat exchanger are adapted to be fixedly connected to corresponding other connecting elements of the air outlet duct. Furthermore, in this case, the air inlet duct is adapted to accommodate the first front face and an insertion section of the housing. Similarly, the air outlet duct is adapted to accommodate the second front face and another insertion section.

[0037] Thus, an additional air inlet or air outlet duct can be connected to the heat exchanger such that the length of the heat exchanger from the first front face to the second front face is greater than the distance between at least one connecting element of the heat exchanger and at least one connecting element of the additional air inlet or air outlet duct.

[0038] Therefore, the length of the heat exchanger from the first front face to the second front face can even be greater than the available space for mounting the heat exchanger in the air intake system of the combustion engine. Thus, for a given limited space for mounting the heat exchanger, even larger heat exchangers with even larger active heat exchange areas can be provided. Therefore, heat exchangers with even more efficient cooling can be provided.

[0039] Furthermore, the location of the at least one additional connecting element of the heat exchanger provides sufficient space for the connecting tool (e.g., a crimping tool) to approach the at least one additional connecting element of the heat exchanger without reducing the length of the heat exchanger.

[0040] The predetermined distance and / or other predetermined distance can be obtained outside the corresponding air duct to employ tools for connecting the coupling elements. The connection may include crimping, welding, brazing, clamping, snapping, and / or deformation using specific tools.

[0041] According to another embodiment, the ratio of the predetermined distance to the distance between the first front surface and the second front surface is greater than 5%, preferably greater than 10%, and even more preferably greater than 20%.

[0042] The length of the heat exchanger between the first front face and the second front face can be greater than 5%, preferably greater than 10%, or even more preferably greater than 20%, than the distance between at least one connecting portion and the second front face.

[0043] Therefore, even when the available space for installing the heat exchanger is as small as 5%, 10%, or 20% less than the length of the heat exchanger, a heat exchanger with efficient cooling can still be installed in the air intake system.

[0044] According to another embodiment, the ratio of the additional predetermined distance to the distance between the first front surface and the second front surface is greater than 5%, preferably greater than 10%, and even more preferably greater than 20%.

[0045] Therefore, even when the available space for installing the heat exchanger is as small as 10%, 20%, or 40% less than the length of the heat exchanger, a heat exchanger with even more efficient cooling can be installed in the air intake system.

[0046] According to another embodiment, the distance between the circumferential line and another circumferential line is between 50 mm and 70 mm, and the distance between the first front face and the second front face is between 55 mm and 85 mm.

[0047] Thus, a heat exchanger with a length in the range of 55 mm to 85 mm can be installed in an air intake system, where the available space for installing the heat exchanger is only in the range of 50 mm to 70 mm.

[0048] In another embodiment, the heat exchanger is configured to cool the air compressed by the turbocharger. This provides the engine with better fuel efficiency due to the supply of cooled air.

[0049] According to another aspect of this disclosure, an air intake system for an internal combustion engine is provided. The air intake system includes a heat exchanger configured to cool air by a coolant. The heat exchanger includes first and second front faces, respectively serving as an air inlet or outlet, and a housing between the first and second front faces. The housing has at least one connecting element along a circumferential line spaced from the first front face at a predetermined distance. The housing also has at least one port serving as a coolant inlet or outlet, the port being arranged at a distance from the first front face greater than the predetermined distance. The air intake system further includes an air inlet or air outlet duct for guiding air to or from the first front face of the heat exchanger. The air inlet or air outlet duct has at least one corresponding connecting element adapted to be fixedly connected to at least one connecting element of the heat exchanger. The at least one connecting element and the at least one corresponding connecting element are fixedly connected to each other. The housing includes a pipe arrangement structure for connecting to a port of coolant and adapted to guide coolant into an internal piping system in an insertion section of the housing between the first front face and the circumferential line. In addition, the air inlet or air outlet duct accommodates the insertion section of the first front face and the shell.

[0050] The aspects and embodiments described regarding the heat exchanger also apply to air intake systems that include the corresponding heat exchanger.

[0051] Air inlet or outlet ducts are specifically configured to guide air to or from the first front face of the heat exchanger. For example, an inlet air duct is configured to guide air to the first front face (inlet surface) of the heat exchanger. An inlet air duct, for example, guides air compressed by the compressor of a turbocharger to the inlet face of the heat exchanger. An air outlet duct, for example, is configured to guide air from the second front face (outlet surface) of the heat exchanger. An air outlet duct, for example, guides air from the outlet face of the heat exchanger to the engine's intake manifold for supplying cooled air to the engine.

[0052] In the embodiments, the air inlet or air outlet air duct is at least partially formed of a plastic material, particularly a thermoplastic material such as polyamide.

[0053] In one embodiment, at least one connecting element of the heat exchanger and at least one corresponding connecting element of the air inlet duct achieve an airtight connection. Similarly, at least one additional connecting element of the heat exchanger and at least one corresponding additional connecting element of the air inlet duct can provide an airtight connection. In another embodiment, the connecting element further includes a circumferential seal for tightly connecting the heat exchanger to the air duct.

[0054] In the embodiments, the heat exchanger is implemented as explained above or below.

[0055] According to another embodiment, the intake system includes a turbocharger for compressing intake air into a heat exchanger. The heat exchanger may be arranged in the airflow path between the turbocharger and the engine.

[0056] According to another embodiment, at least one corresponding connecting element of the air inlet or air outlet duct is a non-deformable element, which is configured to be fixedly connected to at least one connecting element of the heat exchanger, particularly by means of a press-fit connection, wherein at least one connecting element of the heat exchanger specifically includes a deformable element.

[0057] In this embodiment, the air inlet and / or air outlet ducts are separate components, and in particular, the corresponding connecting elements are not part of the engine or engine flange.

[0058] In addition, a method is provided for installing a heat exchanger in an air intake system for a combustion engine.

[0059] The heat exchanger includes: first and second front faces, respectively serving as an air inlet or outlet; and a shell between the first and second front faces. The shell has at least one connecting element along a circumferential line spaced from the first front face at a predetermined distance. Furthermore, the shell has at least one port serving as a coolant inlet or outlet, the port being arranged at a distance from the first front face greater than the predetermined distance. The at least one connecting element is adapted to be fixedly connected to at least one corresponding connecting element of an air inlet or air outlet duct, and the shell includes a pipe arrangement or internal piping system connected to a port for guiding coolant into an insertion section of the shell. The insertion section is located between the first front face and the circumferential line.

[0060] The air intake system further includes an air inlet or air outlet duct configured to guide air to or from a first front face of a heat exchanger, and the air inlet or air outlet duct includes at least one corresponding connecting element.

[0061] The method includes at least one of the following steps: Insert the insertion section and the first front face of the shell into the interior of the air inlet or air outlet duct; At least one connecting element of the heat exchanger is brought into contact with at least one corresponding connecting element of the air inlet or air outlet duct; At least one connecting element of a fixedly connected heat exchanger and at least one corresponding connecting element of an air inlet or air outlet pipe are provided to provide a fluid connection between the heat exchanger and the air inlet or air outlet pipe.

[0062] In particular, the method has the advantage that a larger heat exchanger can be provided and fixedly connected for a given limited space for installing the heat exchanger (e.g., the space between two air ducts). This is because when the heat exchanger is fixedly connected within the air intake system, the heat exchanger matrix reaches into the air ducts. Furthermore, there may still be sufficient space to access the at least one connecting element of the heat exchanger and / or the at least one connecting element of the air inlet or air outlet duct using a connection tool (e.g., a crimping tool). This allows for easier and more stable connection of the heat exchanger.

[0063] In one embodiment, the method includes employing a crimping tool at an outer circumferential section of an air duct, wherein the outer circumferential section is opposite to an inner circumferential section of a surrounding insertion section of the air duct.

[0064] Contacting at least one connection portion of a heat exchanger with at least one corresponding connection portion of an air inlet or air outlet duct can be interpreted as making at least one connection portion of the heat exchanger adjacent to at least one corresponding connection portion of an air inlet or air outlet duct.

[0065] According to another embodiment, the fixed connection includes deforming at least one of at least one connecting element of the heat exchanger and at least one corresponding connecting element of the air inlet or air outlet duct.

[0066] The embodiments and features described above and below with reference to the heat exchanger, with necessary modifications, are also applicable to the air inlet pipe having a heat exchanger and the method for arranging the heat exchanger in the air inlet pipe.

[0067] Further possible embodiments or alternative solutions of the heat exchanger, the intake pipe, and the method for arranging the heat exchanger inside the intake pipe include combinations of features described above or below with reference to the embodiments that are not explicitly mentioned herein. Those skilled in the art can also add individual or isolated aspects and features to the most basic form of the invention. Attached Figure Description

[0068] Further embodiments, features, and advantages of this heat exchanger will become apparent from the accompanying drawings, the following description, and the dependent claims, wherein: Figure 1 A schematic view of an air intake system having a heat exchanger according to a first embodiment is shown; Figure 2 Show Figure 1 A perspective view of a heat exchanger; Figure 3 A schematic view of an air intake system having a heat exchanger according to a second embodiment is shown; and Figure 4 - Figure 7 The method steps for installing a heat exchanger in the air intake system of a combustion engine are shown.

[0069] In the figures, unless otherwise stated, similar reference numerals indicate similar or functionally equivalent elements. Detailed Implementation

[0070] Figure 1 A schematic cross-sectional view of an air intake system 100 is shown. The air intake system 100 includes a heat exchanger 1 according to a first embodiment. The heat exchanger 1 is provided for cooling intake air F1 by a coolant F2. The heat exchanger 1 includes a first front surface 3 (inlet surface) as an inlet for air F1 and a second front surface 4 (outlet surface) as an outlet for air F1'. The heat exchanger 1 further includes an airtight shell 2 between the inlet surface 3 and the outlet surface 4 to guide air F1 through the interior of the heat exchanger 1. The shell 2, the inlet surface 3, and the outlet surface 4 are combined to have a rectangular block shape. The shell 2 has four rectangular shell sides, and the inlet surface 3 and the outlet surface 4 each have a rectangular shape.

[0071] Heat exchanger 1 is connected to air inlet duct 12. Air inlet duct 12 is configured to guide intake air F1 to the inlet surface 3 of heat exchanger 1. In addition, heat exchanger 1 is connected to air outlet duct 13. Air outlet duct 13 is configured to guide cooled air F1' from the outlet surface 4 of heat exchanger 1 to the vehicle's engine (not shown).

[0072] The shell 2 has port 5 as an inlet for coolant F2 and port 6 as an outlet for coolant F2'. The coolant flows inside the shell along an internal piping system, which may be a pipe arrangement structure 7.

[0073] Therefore, the shell 2 includes a pipe arrangement structure 7 inside. The pipe arrangement structure 7 is connected to the inlet port 5 and the outlet port 6 of the coolants F2 and F2', such that the coolants F2 and F2' are guided from the inlet port 5 to the outlet port 6 through the pipes of the pipe arrangement structure 7.

[0074] The coolant flows F2, F2' within the pipe arrangement structure 7 provide an indirect method for cooling the air F1, F1' flowing around (i.e., outside) the pipes in the pipe arrangement structure 7. Figure 1 In the example, the direction of the airflow from the inlet surface 3 to the outlet surface 4 is basically transverse to the direction of the coolant flow, thereby providing efficient cooling of the air.

[0075] The shell 2 has at least one or more connecting elements 10 along its circumferential line 8. The circumferential line 8 is spaced from the inlet surface 3 by a predetermined distance d1. The connecting element 10 is adapted to be fixedly connected to the corresponding connecting element 14 of the air inlet duct 12 by means of a crimp connection. The corresponding connecting elements 14 of the air ducts 12, 13 are shown as solid blocks. For example, the connecting element 10 of the heat exchanger 1 is implemented as a deformable element, and the corresponding connecting element 14 of the air inlet duct 12 is a non-deformable element. The connecting element 10 of the heat exchanger 1 is configured to engage with the non-deformable connecting element 14 of the air inlet duct 12 during crimping. Multiple connecting elements may be arranged circumferentially along the shell 2 and / or the corresponding air ducts 13, 12.

[0076] In addition, Shell 2 Figure 1 The orientation is such that it has an additional connecting element or a second connecting element 11 on the left side. One or more additional (left-side) connecting elements 11 are adapted to be fixedly connected to at least one corresponding additional connecting element 15 of the air outlet duct 13 by means of a crimp connection. Figure 1 In this embodiment, an additional connecting element 11 is arranged at the edge of the shell 2 adjacent to the outlet surface 4. The additional connecting element 11 of the heat exchanger 1 is a deformable element, and the corresponding additional connecting element 15 of the air outlet duct 13 is a non-deformable element. The additional connecting element 11 of the heat exchanger 1 is configured to securely connect to the non-deformable connecting element 15 of the air outlet duct during crimping. Connecting elements 10, 11, 14, and 15 fasten the heat exchanger 1 to the air ducts 12 and 13 by means of form closures or form fittings.

[0077] Inlet port 5 and outlet port 6 are arranged between connecting elements 10 and 11. In particular, inlet port 5 is arranged at a distance from inlet surface 3, said distance being greater than a predetermined distance d1.

[0078] Shell 2 includes an insertion section 16 located between inlet face 3 and circumferential line 8. Insertion section 16 is indicated by a hash region and includes portions of shell 2 between inlet face 3 and circumferential line 8, as well as the internal volume between line 8 and inlet face 3. Insertion section 16 accommodates the section through which coolant F2, F2' of pipe arrangement structure 7 is guided. Air F1, F1' flows within shell 2 around pipe arrangement structure 7 and transfers heat to the coolant in pipe arrangement structure 7'. Figure 1In the example, the pipe arrangement structure 7 includes a curved section 21 that bends along the direction of the inlet face 3. Therefore, coolants F2, F2' are guided into the insertion section 16 of the shell 2 during their passage through the pipe arrangement structure 7 to cool the air F1, F1' also within the insertion section 16. Thus, active heat exchange between the coolants F2, F2' and the air F1, F1' also occurs within the insertion section 16 of the shell 2.

[0079] The arrangement of at least one connecting element 10 of heat exchanger 1 along a circumferential line 8 spaced d1 from the inlet face 3 allows for the connection of air inlet duct 12 to heat exchanger 1, such that air inlet duct 12 accommodates a portion of heat exchanger 1, namely insertion section 16, within its interior. Therefore, the length d3 of heat exchanger 1 from air inlet face 3 to air outlet face 4 is greater than the distance between connecting element 10 and outlet face 4 of heat exchanger 1. Thus, heat exchanger 1 is configured such that its length d3 in the direction of airflow can be greater than the available space for installing heat exchanger 1 in the air intake system of a combustion engine. The space available for installation is sometimes limited by the installation distance between the openings of air inlet and outlet ducts 12, 13. Therefore, for a given limited space for installing heat exchanger 1, a heat exchanger with a matrix greater than the installation distance can be used. Since, as described above, active heat exchange also occurs within the insertion section 16 of heat exchanger 1, this larger heat exchanger also has a larger active heat exchange area (matrix). Therefore, for a given limited space for installing heat exchanger 1, a heat exchanger 1 with more efficient cooling can be provided.

[0080] Furthermore, the arrangement of the connecting elements 10 of the heat exchanger 1, spaced apart from the front face 3, provides sufficient space for handling the connecting tool without reducing the length of the heat exchanger 1 and thus reducing cooling efficiency. Specifically, there is sufficient space for the crimping tool to approach at least one connecting element 10 of the heat exchanger 1 and / or at least one connecting element 14 of the air inlet duct 12. Figure 1 As shown, the heat exchanger 1 provides sufficient space in the area 22 left from the connection arrangement structures 10, 14 for processing crimping tools, for example, between at least one connection element 10 and the inlet pipe 5, and between at least one corresponding connection element 14 of the inlet pipe 12 and the edge of the shell 2 adjacent to the inlet surface 3.

[0081] Figure 2 Showing those without inlet and outlet pipes 12 and 13 Figure 1 A perspective view of a heat exchanger. (As shown from...) Figure 2 As can be seen, the connecting portion 10 of shell 2 is arranged circumferentially on the outer side of shell 2 and spaced apart from the entrance surface 3 of shell 2 by a distance d1. Thus, it can be seen that the portion extends beyond the connecting portion 10 (in... Figure 2An extension of shell 2 of length d1 (oriented upwards and to the left). This extension of shell 2 includes the aforementioned insertion section 16 and is configured to be inserted into air inlet or air outlet ducts 12, 13. Figure 1 In one embodiment, the insertion section 16 is configured to be inserted into the air inlet duct 12.

[0082] like Figure 2 As shown, another connecting element 11 is arranged at the edge of the shell 2 adjacent to the outlet surface 4. Figure 1 In one embodiment, it corresponds to an additional connecting element 11 adapted to be fixedly connected to another connecting element 15 corresponding to the air outlet duct 13 (see [link]). Figure 1 ).

[0083] Figure 3 A schematic cross-sectional view of an air intake system 200 having a heat exchanger 101 according to a second embodiment is shown. The second embodiment is similar to the first embodiment, except for the arrangement of the additional connecting elements 111 of the heat exchanger 101. Hereinafter, only those features of the second embodiment that differ from the first embodiment will be described. Descriptions of identical features will be omitted.

[0084] like Figure 3 As shown, in the second embodiment, additional connecting elements 111 of the housing 102 are arranged along additional circumferential lines 109 of the housing 102. The additional circumferential lines 109 are spaced from the outlet surface 104 by an additional predetermined distance d2'. The additional connecting elements 111 are adapted to be fixedly connected to corresponding additional connecting elements 115 of the air outlet duct 13. The pipe arrangement 107 is adapted to guide coolant F2, F2' into additional insertion sections 117 of the housing 102. The additional insertion sections 117 are located between the outlet surface 104 and the additional circumferential lines 109.

[0085] In the second embodiment, the air inlet duct 12 is further adapted to accommodate the insertion section 116 of the inlet face 103 and the housing 102. Similarly, the air outlet duct 13 is adapted to accommodate the additional insertion section 117 of the outlet face 104 and the housing 102.

[0086] The length d3' of heat exchanger 100 from inlet face 103 to outlet face 104 is greater than the distance d4' between connecting element 111 and other connecting elements 111 of heat exchanger 101.

[0087] Therefore, the length d3' of the heat exchanger 101 from the inlet face 103 to the outlet face 104 can even be greater than the available space for installing the heat exchanger 100 in the air intake system of the combustion engine. The installation space is typically limited by the distance between the openings of the air inlet and outlet ducts 12, 13. Therefore, for a given limited space for installing the heat exchanger 100, an even larger heat exchanger 100 with an even larger active heat exchange area can be provided. Thus, heat exchangers with even more efficient cooling can be used.

[0088] Furthermore, the specific arrangement of the connecting elements 110, 111 of the heat exchanger 101 provides sufficient space for connecting tools (e.g., crimping tools) to approach the connecting elements 110, 111 of the heat exchanger 101 and the air ducts 114, 115 without reducing the length d3' of the heat exchanger 100 or extending the installation distance between the air ducts 12, 13.

[0089] Figure 4 - Figure 7 Shown in the use of Figure 1 The steps involved in the method of installing a heat exchanger 1 inside the air intake system 200 of a combustion engine.

[0090] In the first step, such as Figure 4 As shown, an air inlet duct 12 and an air outlet duct 13 are provided, which are similar to Figure 1 The corresponding air inlet pipe 12 and air outlet pipe 13 are shown. Figure 4 An air intake system 300 without a heat exchanger is shown.

[0091] The air intake duct 12 of the air intake system 200 is connected to the turbocharger 19. The air intake duct 12 receives air F1 compressed by the compressor of the turbocharger 19. The air intake duct 12 guides the compressed air F1 to the inlet surface 3 of the heat exchanger 1 to be installed between the air ducts 12 and 13. Figure 5 The corresponding heat exchanger is shown. Figure 4 and Figure 5 The air outlet duct 13 of the air intake system 300 is further shown. The air outlet duct 13 is configured to guide the heat exchanger 1 (see [reference]) installed from the outlet surface 4 of the heat exchanger 1. Figure 5 Cooled air F1'. Air outlet duct 13 guides the cooled air F1' from the outlet surface 4 of the corresponding heat exchanger 1, for example, to the intake manifold of the engine (not shown) to provide the engine with cooled air.

[0092] The air inlet duct 12 includes a connecting element 14 corresponding to at least one connecting element 10 of the heat exchanger 1 to be installed. The at least one connecting element 14 of the air inlet duct 12 is configured to be fixedly connected to at least one connecting element 10 of the heat exchanger 1 by means of a crimp connection.

[0093] The air outlet duct 13 includes at least one additional connecting element 15, which corresponds to at least one additional connecting element 11 of the heat exchanger 1. The at least one connecting element 15 of the air outlet duct 13 is configured to be fixedly connected to at least one connecting element 11 of the heat exchanger 1 by means of a crimp connection.

[0094] The distance between the connecting element 14 of the air inlet duct 12 and the connecting element 15 of the air outlet duct 13 represents the available space for installing the heat exchanger. In other words, Figure 4 The configuration of the air inlet duct 12 and air outlet duct 13 shown allows for the installation of only this heat exchanger, for which the distance between its two (sets) of connecting elements 10, 11 corresponds to the distance between the two (sets) of connecting elements 14, 15 of the air inlet and air outlet ducts 12, 13.

[0095] like Figure 5 As shown, in the first step, a similar method is also provided. Figure 1 and Figure 2 Heat exchanger 1. For a detailed description of the features of heat exchanger 1, refer to... Figure 1 and Figure 2 The description states that the connecting elements 10 and 11 can be deformable metal flaps or latches that can be used for crimping connections with corresponding connecting elements 14 and 15 of the air ducts 12 and 13.

[0096] For reference Figure 1 and Figure 2 The connecting element 10 at the shell 2 of the heat exchanger 1 is advantageously arranged along the circumferential line 8 of the shell 2, which is spaced from the inlet surface 3 by a predetermined distance d1. In this way, an insertion section 16 is defined, which will be inserted into the air inlet duct 12. Therefore, the heat exchanger 1 has a length between the inlet surface 3 and the outlet surface 4 that is greater than the distance between the connecting elements 10 and 11. Furthermore, the advantageous arrangement of the connecting elements 10 provides sufficient space for the connecting tool to approach the connecting elements 10, 14, as will be described later.

[0097] In this example, an additional connecting element 11 of the shell 2 of the heat exchanger 1 is arranged at the edge of the shell 2 adjacent to the outlet surface 4.

[0098] Both connecting elements 10 and 11 of heat exchanger 1 are deformable elements. Both connecting elements 14 of air inlet pipe 12 and connecting element 15 of air outlet pipe 13 are non-deformable elements. Both connecting elements 10 and 11 are configured to be crimped or connected to the corresponding connecting elements 14 of air inlet pipe 12 and connecting elements 15 of air outlet pipe 13, respectively. Figure 5 The diagram shows the deformable connecting elements 10 and 11 in their undeformed state.

[0099] In the second step, such as Figure 6 As shown, the insertion section 16 and inlet surface 3 of the heat exchanger 1 are inserted into the interior of the air inlet pipe 12.

[0100] Next, as Figure 6 As shown, the connecting element 10 of the heat exchanger 1 is brought into contact with the corresponding connecting element 14 of the air inlet pipe 12. Furthermore, another connecting element 11 of the heat exchanger 1 is brought into contact with a corresponding other connecting element 15 of the air outlet pipe 13. Thus, connecting elements 10 and 14, and connecting elements 11 and 15, are adjacent to each other. Figure 6 The image shows the processing space 22 left from the flip-plate 10 that can be used for crimping tools.

[0101] In other steps, such as Figure 7 As shown, the connecting element 10 of the heat exchanger 1 and the corresponding connecting element 14 of the air inlet pipe 12 are fixedly connected to each other by deforming the flap 10 using a corresponding tool 20. Therefore, fluid connection between the heat exchanger 1 and the air inlet pipe 12 is achieved. Figure 7 As shown, a fixed connection is achieved by deforming the flap 10 using a crimping tool 20, so that it mates with the non-deformable connecting element 14 of the air duct 12.

[0102] like Figure 7 As shown, the advantageous arrangement of at least one connecting element 10 spaced d1 from the inlet surface 3 provides sufficient space 22 for the crimping tool 20 to approach the connecting elements 10 and 14 (see Figure 1). Figure 6 This allows for a simpler and more stable connection between the heat exchanger 1 and the air inlet pipe 12.

[0103] In addition, such as Figure 7As shown, an additional connecting element 11 on the left side of the heat exchanger 1 and a corresponding additional connecting element 15 of the air outlet pipe 13 are fixedly connected to each other to provide a fluid connection between the heat exchanger 1 and the air outlet pipe 13. The fixed connection of the connecting elements 11 and 15 is achieved by deforming at least one connecting element 11 using a crimping tool 20 so that it surrounds the indeformable connecting element 15. Other fixed connection methods are conceivable, such as brazing, welding, press-fitting, using clamps or snap rings. However, this has the advantage that the heat exchanger is partially inserted into the air pipe, thus leaving space for the use of the connecting tool.

[0104] Although the invention has been described with reference to preferred embodiments, it will be apparent to those skilled in the art that modifications are possible in all embodiments. For example, the heat exchanger may be a plate or tubular heat exchanger. Other forms of mating connections besides press-fit connections are conceivable. The heat exchanger can be used in applications other than turbocharger applications where installation space is limited.

Claims

1. A heat exchanger (1, 100) for cooling intake air (F1) with a coolant (F2), comprising: The first and second front surfaces (3, 4) respectively serve as the inlet or outlet of the air (F1), and A shell (2) located between the first and second front faces (3, 4), the shell (2) having at least one connecting element (10) along a circumferential line (8) spaced from the first front face (3) by a predetermined distance (d1), the shell (2) having at least one port (5) as an inlet or outlet for the coolant (F2), the port (5) being arranged at a distance from the first front face (3) greater than the predetermined distance (d1). The at least one connecting element (10) is adapted to be fixedly connected to at least one corresponding connecting element (14) of the air inlet pipe (12) or the air outlet pipe (13), and The shell (2) includes a pipe arrangement structure or internal piping system (7) connected to the port (5) of the coolant (F2) and adapted to guide the coolant (F2) into an insertion section (16) of the shell (2), the insertion section (16) being located between the first front face (3) and the circumferential line (8).

2. The heat exchanger according to claim 1, wherein, The at least one connecting element (10) of the heat exchanger (1) includes deformable elements, particularly deformable protrusions configured for crimping connections, clips, snap rings, sleeves and / or engaging elements.

3. The heat exchanger according to claim 1 or 2, wherein, The at least one connecting element (10) includes a non-deformable element configured to connect, in particular, to a deformable element of the air inlet duct (12) or air outlet duct (13) by means of a crimp connection, clip connection, snap ring connection and / or engagement connection.

4. The heat exchanger according to any one of claims 1-3, wherein, The housing (2) includes at least one additional connecting element (11) disposed at the edge of the housing (2) adjacent to the second front surface (4), the at least one additional connecting element (11) being adapted to be fixedly connected to at least one corresponding additional connecting element (15) of an additional air inlet or air outlet duct (13).

5. The heat exchanger (101) according to any one of claims 1-4, wherein, The housing (102) includes at least one additional connecting element (111) along an additional circumferential line (109) of the housing (102), the additional circumferential line (109) being spaced apart from the second front face (104) by an additional predetermined distance (d2'), wherein the at least one additional connecting element (111) is adapted to be fixedly connected to at least one corresponding additional connecting element (115) of an additional air inlet duct (12) or an air outlet duct (13), and wherein the pipe arrangement structure (107) is adapted to guide the coolant (F2) into an additional insertion section (117) of the housing (102) located between the second front face (104) and the additional circumferential line (109).

6. The heat exchanger according to any one of claims 1-5, wherein, The ratio of the predetermined distance (d1, d1') to the distance (d3, d3') between the first front surface (3, 103) and the second front surface (4, 104) is greater than 5%, preferably greater than 10%, and even more preferably greater than 20%.

7. The heat exchanger according to claim 5 or 6, wherein, The ratio of the additional predetermined distance (d2') to the distance (d3, d3') between the first front surface (3, 103) and the second front surface (4, 104) is greater than 5%, preferably greater than 10%, and even more preferably greater than 20%.

8. The heat exchanger according to any one of claims 5-7, wherein, The distance (d4') between the circumferential line (108) and the other circumferential line (109) is between 50 mm and 70 mm, and the distance (d3') between the first front surface (103) and the second front surface (104) is between 55 mm and 85 mm.

9. The heat exchanger according to any one of claims 1-8, wherein, The heat exchangers (1, 100) are configured to cool the intake air (F1) compressed by the turbocharger.

10. An air intake system (100) for an internal combustion engine, comprising: - A heat exchanger (1) for cooling intake air (F1) with coolant (F2) comprises: The first and second front surfaces (3, 4) respectively serve as the inlet or outlet of the air (F1), and A shell (2) located between the first and second front faces (3, 4), the shell (2) having at least one connecting element (10) along a circumferential line (8) spaced from the first front face (3) by a predetermined distance (d1), the shell (2) having at least one port (5) as an inlet or outlet for the coolant (F2), the port (5) being arranged at a distance from the first front face (3) greater than the predetermined distance (d1). as well as - An air inlet duct (12) or an air outlet duct (13) for guiding air (F1) to or from the first front surface (3) of the heat exchanger (1), the air inlet duct (12) or the air outlet duct (13) having at least one corresponding connecting element (14) adapted to be fixedly connected to at least one connecting element (10) of the heat exchanger (1), the at least one connecting element (10) and the at least one corresponding connecting element (14) being fixedly connected to each other. The shell (2) includes a pipe arrangement or internal piping system (7) connected to the port (5) of the coolant (F2) and adapted to guide the coolant (F2) into an insertion section (16) of the shell, the insertion section (16) being located between the first front face (3) and the circumferential line (8). The air inlet pipe (12) or air outlet pipe (13) accommodates the first front surface (3) and the insertion section (16) of the shell (2).

11. The air intake system according to claim 10, wherein, The heat exchanger (1) is implemented according to any one of claims 1-9.

12. The air intake system according to claim 10 or 11, further comprising a turbocharger device (19) for compressing intake air, wherein, The heat exchanger (1) is arranged in the airflow path between the turbocharger (19) and the combustion engine.

13. The air intake system according to any one of claims 10-12, wherein, The at least one corresponding connecting element (14) of the air inlet or air outlet duct (12) is a non-deformable element, which is configured to be fixedly connected to the at least one connecting element (10) of the heat exchanger (1) in particular by means of a crimp connection, which in particular includes a deformable element.

14. A method for installing a heat exchanger (1) according to any one of claims 1-9 in an air intake system (100) for a combustion engine, the air intake system (100) comprising an air inlet duct (12) or an air outlet duct (13) configured to direct air (F1) to or from the first front surface (3) of the heat exchanger (1), the air inlet duct (12) or the air outlet duct (13) comprising at least one corresponding connecting element (14). Includes the following steps: - Insert the insertion section (16) of the shell (2) and the first front surface (3) into the interior of the air inlet pipe (12) or the air outlet pipe (13). - To bring at least one connecting element (10) of the heat exchanger (1) into contact with at least one corresponding connecting element (14) of the air inlet pipe (12) or air outlet pipe (13), - A fixed connection is made between at least one connecting element (10) of the heat exchanger (1) and at least one corresponding connecting element (14) of the air inlet pipe (12) or air outlet pipe (13) to provide a fluid connection between the heat exchanger (1) and the air inlet pipe (12) or air outlet pipe (13).

15. The method according to claim 14, wherein, The fixed connection includes deforming at least one of the at least one connecting element (10) of the heat exchanger (1) and at least one corresponding connecting element (14) of the air inlet pipe (12) or air outlet pipe (13).

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