Charge air cooler and method for providing a heat exchanger device

Abstract

Charge air cooler (10) for a motor vehicle, with a heat exchanger device (12) surrounded by a housing (14), which is designed to be flowed through by charge air in a flow direction (16) which extends from an air inlet end (18) of the heat exchanger device (12) to an air outlet end (20) of the heat exchanger device (12), wherein the heat exchanger device (12) has, in a longitudinal section along the flow direction (16), the shape of its circumference as a parallelogram with angles other than 90 degrees, wherein the heat exchanger device (12) has a plurality of heat exchanger tubes arranged parallel to one another and the heat exchanger tubes have oblique cut surfaces at their respective ends.

Description

The invention relates to a charge air cooler for a motor vehicle and to a method for providing a heat exchanger device for a charge air cooler of a motor vehicle. The charge air cooler is a heat exchanger which is designed to cool compressed charge air flowing into an intake tract of a supercharged internal combustion engine. The cooled charge air is to be supplied to the internal combustion engine of the motor vehicle having the charge air cooler. The charge air cooler may be arranged in the intake tract of the motor vehicle between a compressor, in particular a turbocharger, and an inlet valve for the internal combustion engine. By means of the charge air cooler, heat arising during the compression of the charge air in the turbocharger can be dissipated from the charge air.DE 10 2015 204 014 A1 discloses a heat exchanger having a plurality of first fluid paths for a first fluid to flow through and a plurality of second fluid paths for a second fluid to flow through, which are fluidically separated from the first fluid paths and are thermally coupled thereto. The heat exchanger is produced by means of an additive production method and has, in a cross section perpendicular to a predetermined direction of extent along which the heat exchanger extends, a round, in particular circular, geometry or the geometry of a polygon, in particular of a triangle. By means of the heat exchanger, fresh air supercharged by an exhaust gas turbocharger can be cooled.DE 35 14 474 A1 discloses a heat exchanger, preferably an air / air, air / oil or air / water heat exchanger, in particular for internal combustion engines. The heat exchanger consists of alternately layered lamellae in plate form for the cooling and the medium to be cooled, which together form a pressure-resistant cooling unit.Furthermore, DE 603 13 477 T2 discloses a tube for a heat exchanger, formed from a flat tube, the two ends of which are open and in which a flow path for a heat exchange medium and an inner rib are arranged in the flow path of the flat tube, which rib is formed separately from the flat tube and thinner than the thickness of the flat tube. Here, the flat tube is formed of a flat tube material plate, and the tube is formed by cutting the flat tube together with the inner fin.Furthermore, DE 10 2013 205 267 A1 discloses an air-liquid heat exchanger with a fin and tube block.The object of the present invention is to provide a solution which enables charge air to be conducted in a heat exchanger device of a charge air cooler for a particularly long heat exchanger section, wherein the charge air cooler is integrated in a particularly compact manner with further components in a motor vehicle.This object is achieved according to the invention by the subject matter of the independent claims. Further possible embodiments of the invention are disclosed in the dependent claims, the description and the figures.The invention relates to a charge air cooler for a motor vehicle, in particular for a motor vehicle, having a heat exchanger device surrounded by a housing. The heat exchanger device is configured to be flowed through by charge air in a flow direction. The flow direction extends from an air inlet end of the heat exchanger device to an air outlet end of the heat exchanger device. In a longitudinal section along the flow direction, the heat exchanger device has with its circumference the shape of a parallelogram with angles not equal to 90 degrees. In a lateral plan view of the heat exchanger device or of the housing surrounding the heat exchanger device, the housing or the heat exchanger device has the shape of the parallelogram with angles not equal to 90 degrees. In the parallelogram, mutually opposite sides are respectively of equal length and are aligned parallel to one another. The provision of the heat exchanger device with the parallelogram-shaped longitudinal section makes it possible for respective heat exchanger tubes of the heat exchanger device, which extend in the flow direction, to be designed to be particularly long at a given height of the charge air cooler from the air inlet end to the air outlet end, as a result of which the charge air covers a particularly long heat exchanger section when it flows through the respective heat exchanger tubes. As a result, the charge air can be cooled particularly well when flowing through the heat exchanger device.The heat exchanger device has a plurality of heat exchanger tubes arranged parallel to one another. The charge air can flow through each of the heat exchanger tubes in the flow direction. The charge air flowing through the respective heat exchanger tubes is cooled when it flows through the heat exchanger tubes. By distributing the charge air to the plurality of heat exchanger tubes, the charge air can be cooled over a particularly large heat exchanger surface when flowing through the heat exchanger device. As a result, by means of the particularly compact heat exchanger device, a particularly large amount of heat can be transported away from the charge air.It is furthermore provided that the heat exchanger tubes have oblique cut surfaces at their respective ends. By means of the respective cut surfaces, a particularly large inflow surface or outflow surface of the respective heat exchanger tubes is thus provided for the inflow of the charge air into the respective heat exchanger tubes or the outflow of the charge air from the respective heat exchanger tubes. As a result, the charge air can flow particularly quickly into the respective heat exchanger tubes or can flow particularly quickly out of the respective heat exchanger tubes. Moreover, the respective oblique cut surfaces of the heat exchanger tubes at their respective ends make it possible to provide the heat exchanger device with the parallelogram-shaped longitudinal section.In a further embodiment of the invention, it is provided that the charge air cooler has a rectangular cross section running perpendicular to the flow direction at the height of the heat exchanger device. As a result, a space requirement of the charge air cooler is particularly small on account of its at least substantially rectangular cross section perpendicular to the flow direction, as a result of which installation space in the motor vehicle can be used particularly efficiently.In a further embodiment of the invention, it is provided that each of the heat exchanger tubes is provided by a rolled flat strip. This means that, for the provision of the respective heat exchanger tubes, at least one flat strip is rolled and in particular connected, in particular welded, to form a base tube. For this base pipe, the at least one heat exchanger pipe can in turn be provided. The provision of the respective heat exchanger tubes from the rolled flat strip enables a particularly simple and cost-effective provision of the respective heat exchanger tubes. Furthermore, the provision of the respective heat exchanger tubes from the rolled flat strip enables a particularly precise setting of a respective flow cross section of the respective heat exchanger tubes.In a further embodiment of the invention, it is provided that the heat exchanger tubes of the heat exchanger device are fixed relative to one another and to the housing by means of at least one frame which is oriented parallel to the cut surfaces of the heat exchanger tubes. In particular, the respective heat exchanger tubes can be held on the frame, as a result of which the heat exchanger tubes are fixed relative to one another by means of the frame. The at least one frame can in particular hold and fix respective ends of the heat exchanger tubes having the cut surfaces to one another. Due to the at least substantially parallel orientation of the frame relative to the cut surfaces of the heat exchanger tubes, the frame can hold the heat exchanger tubes in each case at an identical distance from the ends of the respective heat exchanger tubes having the respective cut surfaces. As a result, the respective ends of the heat exchanger tubes are fixed in a particularly stable manner relative to one another.In a further embodiment of the invention, it is provided that the heat exchanger tubes have a round, flattened cross section. In this case, the cross section of the respective heat exchanger tubes runs perpendicular to a respective direction of longitudinal extent of the respective heat exchanger tubes. The cross section can have two mutually parallel sides, which are each connected on both sides via a radius. Due to the flattened, round cross section, the heat exchanger tubes have a particularly large outer circumference and consequently a particularly large outer surface compared to a volume enclosed by the respective heat exchanger tubes. As a result, a particularly large heat transfer surface can be provided by the respective heat exchanger tubes, by means of which the charge air flowing through the respective heat exchanger tubes can be cooled particularly efficiently.In a further embodiment of the invention, it is provided that the housing enclosing the heat exchanger device outwards along the flow direction is designed to be open to an underside assigned to the air outlet end and to an upper side assigned to the air inlet end, an air outlet funnel is arranged on the underside of the housing, and an air inlet funnel is arranged on the upper side of the housing. The air outlet funnel is configured to collect charge air flowing out of the heat exchanger device. This collected charge air may be supplied to the engine of the motor vehicle. The air inlet funnel is configured to supply charge air to the heat exchanger device. In particular, the air inlet funnel is configured to receive, collect and feed the charge air compressed by means of the compressor to the respective heat exchanger tubes of the heat exchanger device. The air inlet funnel makes it possible, via the collection of the charge air, to distribute the charge air to be cooled uniformly to the respective heat exchanger tubes of the heat exchanger device. By means of the air outlet funnel on the underside of the housing, the charge air is to be collected after flowing through the heat exchanger tubes of the heat exchanger device, whereby the charge air can be supplied to the engine in a collected manner. Due to the parallelogram-shaped longitudinal section of the heat exchanger device, the air inlet funnel and the air outlet funnel can be aligned obliquely to a vertical direction of the heat exchanger device, whereby a particularly fluidically favorable inflow and outflow of the charge air into the heat exchanger device or out of the heat exchanger device is made possible, in particular with limited installation space.The invention furthermore relates to a method for providing a heat exchanger device for a charge air cooler of a motor vehicle, as has already been described in connection with the charge air cooler according to the invention. In the method, at least one base tube is trimmed obliquely to its direction of longitudinal extent to form at least one heat exchanger tube.Furthermore, it is provided in the method that a plurality of heat exchanger tubes trimmed at an identical angle are assembled parallel to one another to form a heat exchanger device. In this case, the respective heat exchanger tubes can be fixed relative to one another in their parallel orientation by means of a frame. By obliquely cutting the respective heat exchanger tubes from the base tube, the respective heat exchanger tubes have oblique cut surfaces at their respective ends. When the heat exchanger tubes are arranged in parallel, these oblique cut surfaces of a first end of the respective heat exchanger tubes are arranged in a first common plane and the respective oblique cut surfaces of the second end of the respective heat exchanger tubes are arranged in a second common plane parallel to the first plane. As a result, the heat exchanger device comprising the plurality of heat exchanger tubes has a parallelogram-shaped circumference in its longitudinal section, with respective internal angles of not 90 degrees. At a given height of the heat exchanger device along a vertical direction of the heat exchanger device, the heat exchanger tubes thus have a length which is greater than the height of the heat exchanger device, as a result of which a particularly long heat exchanger section for the charge air is provided when flowing through the heat exchanger device.In a further embodiment of the invention, it is provided that the heat exchanger tubes are cut from a base tube designed as a piece of meter material. This means that a plurality of heat exchanger tubes are cut off one behind the other from the base tube, as a result of which the heat exchanger tubes can be provided with particularly little waste, in particular without waste, being produced.Advantages and advantageous refinements of the charge air cooler according to the invention are to be regarded as advantages and advantageous refinements of the method according to the invention, and vice versa.Further features of the invention can be derived from the claims, the figures and the description of the figures. The features and combinations of features mentioned above in the description and the features and combinations of features shown below in the description of the figures and / or in the figures alone can be used not only in the respectively specified combination but also in other combinations or alone without departing from the scope of the invention.The drawing shows in: FIG. 1 shows a schematic perspective view of a charge air cooler for a motor vehicle, in particular a motor vehicle, by means of which charge air compressed by a compressor is to be cooled, as a result of which the cooled charge air can be supplied to an engine of the motor vehicle.FIG. 1 shows a charge air cooler 10 for a motor vehicle, in the present case a motor vehicle. By means of the charge air cooler 10, charge air received from a compressor and to be supplied to an engine of the motor vehicle is to be cooled. In order to achieve a particularly advantageous extended lambda-1 operating range for a Miller combustion method of the engine, it is provided that the charge air can be cooled particularly efficiently by means of the charge air cooler 10. The charge air cooler 10 provides a particularly long heat exchanger path for the charge air when flowing through a heat exchanger device 12 of the charge air cooler 10, wherein the charge air cooler 10 is configured to be integrated in the motor vehicle in a particularly space-saving manner, in particular in packaging of the motor vehicle.The charge air cooler 10 comprises the heat exchanger device 12 and a housing 14 surrounding the heat exchanger device 12 In the present case, the charge air cooler 10 comprises two heat exchanger devices 12 each surrounded by a housing 14. The respective flow direction 16 extends from an air inlet end 18 of the respective heat exchanger device 12 to a respective air outlet end 20 of the respective heat exchanger device 12. By means of the air inlet funnel 24, charge air received by the compressor can be divided into respective heat exchanger tubes of the heat exchanger device 12. On an underside 22 of the respective heat exchanger device 12 or of the respective housing 14 assigned to the air outlet end 20, an air outlet funnel 28 likewise indicated by dashed lines can be arranged. By means of the air outlet funnel 28, the respective charge air flowing through the associated heat exchanger device 12 can be collected and provided collected for the engine of the motor vehicle. Thus, by means of the air outlet funnel 28, charge air flowing out of all heat exchanger tubes of the associated heat exchanger device 12 can be collected and thus combined.In order to enable a particularly large length of respective heat exchanger tubes of the respective heat exchanger devices 12 at a given height 30 in a vertical direction 32 of the respective heat exchanger devices 12, it is provided that the respective heat exchanger device 12 has the shape of a parallelogram with angles not equal to 90 degrees in a longitudinal section along the flow direction 16. Thus, the flow direction 16 and the vertical direction 32 are aligned obliquely to one another. Respective heat exchanger tubes of the heat exchanger devices 12 thus extend in their longitudinal extension direction obliquely to the vertical direction 32 of the respective heat exchanger device 12, whereby at a given height 30 of the respective heat exchanger device 12 the respective heat exchanger tubes assigned to the heat exchanger device 12 have a particularly large length. As a result, when the respective heat exchanger tubes of the heat exchanger devices 12 are flowed through, a particularly large amount of heat can be absorbed by the charge air flowing through the heat exchanger tubes and therefore the charge air can be cooled particularly efficiently.For a particularly compact design of the respective heat exchanger devices 12 or of the housings 14 surrounding the respective heat exchanger devices 12 on the circumference, it is provided that the charge air cooler 10 has a rectangular cross section running perpendicular to the flow direction 16 at the height of the respective heat exchanger devices 12.In the present case, it is provided that each heat exchanger device 12 has a plurality of heat exchanger tubes, which are each arranged parallel to one another. For a particularly simple provision of the respective heat exchanger tubes, the heat exchanger tubes can each be provided by a rolled flat strip. For a particularly large outer surface of the respective heat exchanger tubes and thus a particularly large heat transfer, the respective heat exchanger tubes can have a flat, rounded cross section perpendicular to the flow direction 16. In order to provide the parallelogram-shaped periphery of the heat exchanger device 12 in its longitudinal section, the respective heat exchanger tubes of the associated heat exchanger device 12 can have respective oblique cut surfaces at their ends. This means that the respective inflow openings or outflow openings of the heat exchanger tubes have a cross section which extends in a plane running obliquely to the flow direction 16. Thus, the flow direction 16 encloses an angle α with the lower side 22 or with the upper side 26, which angle is not equal to 90 degrees. In order to be able to hold the respective heat exchanger tubes at their ends and fix them relative to one another, a frame 34 is provided both on the underside 22 and on the upper side 26 of each of the heat exchanger devices 12, by means of which frame the respective heat exchanger tubes of the respective heat exchanger device 12 are fixed relative to one another.For providing the respective heat exchanger devices 12 for the charge air cooler 10, it is provided that at least one base tube, which is provided in particular by a rolled flat strip, is trimmed obliquely to its longitudinal extension direction to form at least one heat exchanger tube. In particular, the base pipe can be produced in the form of goods from which a plurality of heat exchanger pipes are cut. For the provision of the respective heat exchanger device 12, a plurality of heat exchanger tubes trimmed at an equal angle are aligned and fixed parallel to one another.By configuring the respective heat exchanger devices 12 with the parallelogram-shaped longitudinal section, wherein the parallelogram has angles not equal to 90 degrees, a particularly large heat exchanger surface can be achieved, wherein only particularly little installation space is required by the respective heat exchanger device 12 and wherein particularly few pressure losses occur when the charge air flows through the heat exchanger devices 12.In the charge air cooler 10 described, it is provided that respective closed heat exchanger boxes, comprising the respective heat exchanger devices 12 surrounded circumferentially by the respective housing 14, have the shape of the parallelogram with angles not equal to 90 degrees in front view. In this case, the air inlet funnel 24 and the air outlet funnel 28 can be arranged at an angle on the respective heat exchanger device 12, as a result of which a particularly fluidically favorable inflow and outflow of the charge air from the respective heat exchanger device 12 or into the respective heat exchanger device 12 is made possible with a limited available installation space for the charge air cooler 10. The respective frame 34, which is designed to receive the respective obliquely trimmed heat exchanger tubes, can be oriented with its extension plane running perpendicular to the vertical direction 32 parallel to the respective cut surfaces of the held heat exchanger tubes. For the provision of the heat exchanger devices 12, the internal flat heat exchanger tubes can be cut to length obliquely to their longitudinal extension direction from the base tube designed as a piece of material. The plurality of heat exchanger tubes can be cut off from the base tube designed as a piece of material, in particular by cuts parallel to one another, as a result of which the heat exchanger tubes can be provided with particularly little, in particular at least substantially without waste.Overall, the invention shows how a closed internal charge air cooler 10 can be provided in the form of a parallelogram.List of reference characters10 Charge air cooler 12 Heat exchanger device 14 Housing 16 Flow direction 18 Air inlet end 20 Air outlet end 22 Underside 24 Air inlet funnel 26 Upper side 28 Air outlet funnel 30 Height 32 Vertical direction 34 Frame

Claims

Charge air cooler (10) for a motor vehicle, having a heat exchanger device (12) which is surrounded by a housing (14) and is configured to be flowed through by charge air in a flow direction (16) which extends from an air inlet end (18) of the heat exchanger device (12) to an air outlet end (20) of the heat exchanger device (12), wherein the heat exchanger device (12) has, in a longitudinal section along the flow direction (16), with its circumference the shape of a parallelogram with angles unequal to 90 degrees, wherein the heat exchanger device (12) has a plurality of heat exchanger tubes arranged parallel to one another and the heat exchanger tubes have oblique cut surfaces at their respective ends.Charge air cooler (10) according to Claim 1, characterized in that the charge air cooler (10) has a rectangular cross section running perpendicular to the flow direction (16) at the level of the heat exchanger device (12).The charge air cooler (10) according to any one of the preceding claims, characterized in that each of the heat exchanger tubes is provided by a rolled flat band.Charge air cooler (10) according to one of the preceding claims, characterized in that the heat exchanger tubes of the heat exchanger device (12) are fixed relative to one another and to the housing (14) by means of at least one frame (34) which is oriented parallel to the cut surfaces of the heat exchanger tubes.Charge air cooler (10) according to one of the preceding claims, characterized in that the heat exchanger tubes have a round, flattened cross section.Charge air cooler (10) according to one of the preceding claims, characterized in that the housing (14) which encloses the heat exchanger device (12) outwards along the flow direction (16) is designed to be open to an underside (22) assigned to the air outlet end (20) and to an upper side (26) assigned to the air inlet end (18), an air outlet funnel (28) which is designed to collect charge air flowing out of the heat exchanger device (12) is arranged on the underside (22), and an air inlet funnel (24) which is designed to guide charge air to the heat exchanger device (12) is arranged on the upper side (26).Method for providing a heat exchanger device (12) for a charge air cooler (10) of a motor vehicle according to one of the preceding claims, in which at least one base pipe is trimmed obliquely to its longitudinal extent direction to form at least one heat exchanger pipe and a plurality of heat exchanger pipes trimmed at an identical angle are assembled parallel to one another to form a heat exchanger device (12).Method according to claim 7, characterised in that the heat exchanger tubes are cut from a basic tube designed as a piece of material.

Images