Air-conducting housing with sealing arrangement of a heat exchanger

Abstract

Air-conducting housing (11), comprising - at least one air inlet (12) and one air outlet (13), - a heat exchanger (20) with at least a plurality of heat-exchanging elements (23) which are aligned parallel to each other and through which a fluid can flow in a first direction (Z), and a lamellar structure (25) arranged between them which is in physical contact with the respective adjacent heat-exchanging elements (23), wherein in the installed state the first direction (Z) is aligned perpendicular to the airflow in the air-conducting housing (11), so that the lamellar structure (25) can be flowed through by air from an upstream side (LA), and - a sealing arrangement (30) between the heat exchanger (20) and the air-conducting housing (11), - wherein the sealing arrangement (30) comprises engagement means (32, 33) which engage in the lamellar structure (25) in such a way that it is plastically deformed at least in sections, characterized in that - the heat exchanger (20) is designed as a flat tube heat exchanger with opposing tanks (21A, 21B) and an intermediate plate-shaped tube block (22) which includes the heat-exchanging elements (23) and the fin structure (25), - the intervention means (32, 33) engage from the upstream side (LA) in the air-conducting housing (11) into the lamellar structure (25) and - the lamellar structure (25) is plastically deformed in an area along a deformation line (34) parallel and adjacent to the heat-exchanging elements (23) at two opposite edges (24B, 24D) of the heat exchanger (20).

Description

[0001] The present invention relates to an air-conducting housing with a heat exchanger and a sealing arrangement between the air-conducting housing and the heat exchanger. The invention further relates to an air conditioning unit with such an air-conducting housing.

[0002] Air-conducting housings of this type typically comprise at least one air inlet and one air outlet, as well as a heat exchanger with at least a plurality of heat-exchanging elements, which are aligned parallel to one another and through which a fluid can flow in a first direction, and an intermediately arranged lamellar structure, which is in physical contact with the respective adjacent heat-exchanging elements. In the installed state, the first direction is oriented perpendicular to the airflow in the air-conducting housing, so that the lamellar structure is permeable to air.

[0003] Typically, several air inlets (for example, a fresh air inlet and a recirculated air inlet), several air outlets, and several heat exchangers (for example, at least one evaporator and one heating heat exchanger) are arranged in such an air-conducting housing, as is well known in the prior art. The heat-exchanging elements are, in particular, tubes or flat tubes, but can also be designed differently, for example, as plates. The fluid flowing through is, in particular, a refrigerant from a refrigerant circuit driven by a compressor. Furthermore, depending on the design, the fluid can also be a cooling liquid or a gas. A finned structure is, in particular, a composite or network of fins, which are typically made of the same or a similar material as that of the heat-exchanging elements, for example, aluminum or another suitable metal, as is also known in the prior art.

[0004] The seal between the air-conducting housing and the heat exchanger installed within it is important for several reasons. The heat exchanger must be securely and vibration-free mounted within the air-conducting housing, and the sealing assembly must be easy to install and fit securely. Particularly with evaporators, it is crucial to prevent warm, humid air from flowing between the edges of the heat exchanger and the air-conducting housing, as this would impair the air conditioning process. If the heat-exchanging elements are designed as flat tubes, sealing them at the parallel edges is especially challenging.

[0005] Known solutions include a sealing arrangement using foam, which, however, tends to become damp and consequently has problems with bacterial growth and odor formation. The use of two-component plastic gaskets is complex to manufacture and comparatively expensive. EP 2 739 493 A1 describes a sealing arrangement with horizontal and vertical ribs. It is also known to apply sealing ribs to the flat tubes of the heat exchanger. However, this requires stricter adherence to manufacturing tolerances and precise positioning during assembly. Further sealing arrangements are known, for example, from JP H10-29 424 A and JP 2007-1 329 A.

[0006] The object of the present invention is to provide an air-conducting housing with a sealing arrangement of the type mentioned above, which further reduces these disadvantages mentioned in the prior art and in particular allows for simple and cost-effective assembly without neglecting the other requirements for embedding the heat exchanger in the air-conducting housing.

[0007] This problem is solved according to the invention by an air-conducting housing with the features of claim 1 and an air conditioning unit with the features of claim 8. Advantageous embodiments and further developments are described in the dependent claims.

[0008] The air-conducting housing according to the invention is characterized in that the sealing arrangement comprises engagement means which engage in the fin structure. Engaging in the space between the heat-exchanging elements offers several advantages. Since the space is typically larger than the width of the heat-exchanging elements, assembly is simpler and more generous tolerances can be used during manufacturing. Furthermore, the heat exchanger is not directly supported by the heat-exchanging elements. This prevents surface damage and eliminates direct pressure on the heat-exchanging elements, thereby reducing the risk of leakage.

[0009] According to the invention, the lamellar structure is plastically deformed, at least in sections, by the intervention means. In automotive applications of the air-conducting housing, the lamellars provide secure retention of the heat exchanger in a defined position and an improved buffer zone in the event of a vehicle collision.

[0010] In one embodiment, the lamellar structure between the heat-exchanging elements is formed in layers from bent or folded metal sheets, such that the surface normals of the metal sheets span a plane through the bending or folding, and the engagement means engage in the lamellar structure perpendicular to this plane.

[0011] According to the invention, the lamellar structure is plastically deformed only in an area adjacent to heat-exchanging elements at the edges of the heat exchanger, preferably completely at two opposite edges. The slight plastic deformation then results in practically no functional limitation because the disturbance of the airflow passing through the heat exchanger is minimal.

[0012] According to one embodiment of the invention, the engagement means are designed as a rib (or several ribs), which are preferably pointed in an arrow-shaped or semicircular form in the direction of engagement. This enables stable engagement with the lamellar structure. Alternatively, the rib profile can also have other shapes, e.g., it can be rectangular, hexagonal, or octagonal in the direction of engagement.

[0013] In typical configurations, the primary direction determined by the heat-exchanging elements and the fins run vertically in the installed state, meaning the tanks are horizontal and stacked on top of each other. However, other orientations are also possible, for example, the tanks running vertically, side by side, with the heat-exchanging elements and fins running horizontally.

[0014] Depending on the embodiment of the invention, the engagement means can be provided in various ways. In an advantageous embodiment, the engagement means are integrally formed within the air-conducting housing. This is typically manufactured using a plastic injection molding process, so that the engagement means can then be produced from the same plastic in a single process step. Alternatively, the engagement means can also be formed on an insert, which is arranged as a separate component between the heat exchanger and the air-conducting housing. This allows for subsequent adaptation to an existing design.

[0015] According to the invention, the heat exchanger is designed as a flat-tube heat exchanger with opposing tanks and an intermediate plate-shaped tube block comprising the heat-exchanging elements and the fin structure. The engagement elements engage the fin structure from the upstream side within the air-conducting housing. This ensures a good seal. Depending on the heat exchanger design and installation requirements, in a non-inventive variant, the engagement can also be located laterally or on the downstream side.

[0016] According to the invention, an air conditioning unit, in particular for a motor vehicle air conditioning system, comprises a previously mentioned arrangement of an air-conducting housing, wherein the heat exchanger is in particular an evaporator, condenser, heating heat exchanger or gas cooler.

[0017] The invention will now be described using exemplary embodiments and with reference to the Fig. 1 to 8 explained in more detail. The Fig. Figure 1 schematically shows a generic air conditioning unit with a sealing arrangement between the air-conducting housing and a heat exchanger arranged therein. the Fig. Figure 2 schematically shows the structure of a heat exchanger as it can be used in connection with the present disclosure. the Fig. Figure 3 schematically shows a section of an air-conducting housing according to a first embodiment of the present disclosure, the Fig. 4 and Fig. Figure 5 shows two embodiments of the sealing arrangement according to the present disclosure, the Fig. Figures 6 to 8 schematically show design variants and intended deformation areas of the lamellae usable in connection with the present disclosure and the Fig. Figure 9 schematically shows a section of an air-conducting housing with a sealing arrangement according to a second, non-inventive embodiment of the present disclosure.

[0018] In the Fig. Figure 1 schematically depicts an air conditioning unit 10 for a motor vehicle air conditioning system with a sealing arrangement 30 between the air-conducting housing 11 and a heat exchanger arranged therein, here an evaporator 20, as is known from the prior art. The airflow enters the evaporator 20 at an acute angle via an air inlet 12 on the upstream side LA. The air inlet 12 can be configured in any way and typically includes a fresh air inlet, a recirculation inlet, and a fan (not shown). After the airflow L passes through the evaporator 20, the air continues to flow in the air-conducting housing 11 towards the air outlet 13, which typically includes several air outlets, e.g., a footwell outlet, a headroom outlet, and a defrost duct with an outlet at the base of the windshield (not shown). Between the evaporator 20 and the air outlet 13, there are typically other components, such as...A heat exchanger and an air mixing device are provided (not shown).

[0019] In the Fig. Figure 2 schematically illustrates the structure of an evaporator 20 as known from the prior art and typically usable in connection with the present disclosure. According to the intended installation position, the evaporator 20 is shown in the left-hand illustration in the Y direction (along the vehicle's transverse axis) and in the right-hand illustration in the X direction (along the vehicle's longitudinal axis).

[0020] The evaporator 20 has a tube block 22 between an upper tank 21A and a lower tank 21B. When installed, the tube block 22 is subjected to refrigerant flow in the X direction. It consists of numerous heat-exchanging elements in the form of flat tubes 23, which are aligned parallel to each other and through which a refrigerant flows vertically (in the Z direction). A finned structure 25 is in physical contact with the adjacent flat tubes 23. When installed, the upper and lower edges 24A, 24C are received in a corresponding recess in each half-shell of the air-conducting housing 11, thus achieving a sufficient seal against the airflow at these edges.

[0021] The lateral edges 24B, 24D are then sealed against the airflow with a sealing arrangement 30 according to an embodiment of the invention, as is now shown with reference to the Fig. 3 to 5 will be explained.

[0022] In the Fig. Figure 3 is a schematic section of an air-conducting housing 11 analogous to the Fig. Figure 1 shows the airflow on the upstream side LA striking the evaporator 20 at an acute angle. The evaporator is shown in plan view (Z-direction) in this illustration. The sealing arrangement 30 at the leading edge extends as a vertical rib 32 (i.e., perpendicular to the plane of the drawing) near the left edge of the evaporator 20 – as is best seen in the illustration. Fig. 4 and Fig. 5 can be seen. The sealing arrangement at the rear leading edge is designed analogously, so that the evaporator 20 is completely sealed at the opposite vertical edges.

[0023] The vertical rib 32 with an engagement profile 33 engages the lamellar structure 25 of the evaporator 20 from the upstream side LA. The engagement profile 33 is pointed in an arrow shape in the direction of engagement, penetrates the lamellar structure 25 in its installed state, and plastically deforms it. In the two embodiments shown according to the Fig. 4 and Fig. 5 engages the rib 32 between the outermost and second outermost flat tube 23, with the intermediate lamellar structure 25 extending over the entire height of the tube block 22 along the deformation line 34 (see Fig. 2) is deformed. Instead of the outermost flat tube, a side wall can also be provided. In this case, the rib 32 engages between the side wall and the outermost flat tube 23 in the lamellar structure 25 (not shown).

[0024] During the Fig. In the embodiment shown in Figure 4, the vertical rib 32 with the engagement profile 33 is integrally formed with the air-conducting housing 11. A web 31 extends from the wall of the housing 11, which is angled next to the evaporator 20, parallel to the front of the evaporator 20, up to the level of the first gap between the first two flat tubes 23 (or between the side wall and the outermost flat tube 23). From there, the vertical rib 32 extends vertically into the finned area.

[0025] During the Fig. In the embodiment shown in Figure 5, the vertical rib 32 is formed on an insert 35. The vertical rib 32 with the engagement profile 33 is analogous to the Fig. 4. For the sake of clarity, these reference symbols were included in the Fig. 5 omitted. The insert 35 is arranged as a separate component between the evaporator 20 and the air-conducting housing 11. For assembly, the insert 35 is attached, for example, to fastening means (e.g., snap-in fasteners - not shown) on the inner wall of the housing 11 or in another known manner.

[0026] With reference to the Fig. Figures 6 to 8 schematically illustrate design variants and intended deformation ranges of the usable lamellae. The lamellae can have any design shape. In their simplest form, they consist of folded or bent metal strips or metal sheets 26. The set of surface normals N (in the plane of the drawing) spans the entire plane of the drawing through the folds or creases 27. The deformation direction along the deformation line 34, which is generated by the engagement of the rib 32, is then perpendicular to this plane. Alternatively, any other known lamella structures 25 and a different deformation direction can be used.

[0027] In the Fig. Figure 9 schematically shows a section of an air-conducting housing 11 according to a second, non-inventive embodiment of the disclosure. Unlike in the first embodiment, the airflow on the upstream side LA strikes the front face of the evaporator 20 at a right angle, which, as in the Fig. Figure 3 shows the top view (Z-direction). The vertical rib 32 with the engagement profile 33 engages in the metal sheets 26 of the lamellar structure 25 provided laterally on the evaporator 20.

[0028] The features shown in the disclosure can be combined in any way. Thus, various embodiments are conceivable in which the airflow on the upstream side LA impinges frontally on the evaporator 20 and the sealing arrangement 30 engages laterally in any suitable fin structure of the evaporator 20. Furthermore, the extent of the engagement (whether only at a single point or along the entire length) and the specific type of heat exchanger are irrelevant, without being limited to an evaporator 20. REFERENCE MARK 10 air conditioner 11 air-conducting housing 12 Air inlet 13 Air outlet 20 evaporators, heat exchangers 21A, 21B Tank 22 pipe block 23 flat tubes (heat-exchanging elements) 24A - 24D Edges 25 lamella structure 26 sheet metal 27. Crease, fold 30 Sealing arrangement 31 Bridge 32 vertical ribs 33 Intervention profile 34 Deformation line 35 deployment L Airflow LA Inflow side N surface normal X, Y, Z 3-D coordinate system

Claims

[1] Air-conducting housing (11) comprising - at least one air inlet (12) and one air outlet (13), - a heat exchanger (20) with at least a plurality of heat-exchanging elements (23) which are aligned parallel to each other and through which a fluid can flow in a first direction (Z), and a lamellar structure (25) arranged between them which is in physical contact with the respective adjacent heat-exchanging elements (23), wherein in the installed state the first direction (Z) is aligned perpendicular to the airflow in the air-conducting housing (11), so that the lamellar structure (25) can be flowed through by air from an upstream side (LA), and - a sealing arrangement (30) between the heat exchanger (20) and the air-conducting housing (11), - wherein the sealing arrangement (30) comprises intervention means (32, 33) which engage in the lamellar structure (25) in such a way that it is plastically deformed at least in sections, characterized by , that - the heat exchanger (20) is designed as a flat tube heat exchanger with opposing tanks (21A, 21B) and an intermediate plate-shaped tube block (22) which includes the heat-exchanging elements (23) and the fin structure (25), - the intervention means (32, 33) engage from the upstream side (LA) in the air-conducting housing (11) into the lamellar structure (25) and - the lamellar structure (25) is plastically deformed in an area along a deformation line (34) parallel and adjacent to the heat-exchanging elements (23) at two opposite edges (24B, 24D) of the heat exchanger (20). [2] Air-conducting housing (11) according to claim 1, characterized by , that - the lamellar structure (25) between the heat-exchanging elements (23) is formed in layers from bent or folded metal sheets (26), such that the surface normals (N) of the metal sheets (26) span a plane (Y, Z) through the bending or folding, and - the intervention means (32, 33) engage perpendicularly to this plane (Y, Z) in the lamellar structure (25). [3] Air-conducting housing (11) according to claim 2, characterized by , that the lamellar structure (25) is completely plastically deformed at two opposite edges (24B, 24D). [4] Air-conducting housing (11) according to any of the preceding claims, characterized by , that the engagement means (32, 33) are designed as a rib (32) which is preferably arrow-shaped or semicircular in the direction of engagement (X). [5] Air-conducting housing (11) according to claim 4, characterized by, that the first direction (Z) specified by the heat-exchanging elements (23) and the ribs (32) run vertically in the installed state. [6] Air-conducting housing (11) according to any of the preceding claims, characterized by , that the intervention means (32, 33) are integrally formed in the air-conducting housing (11). [7] Air-conducting housing (11) according to one of claims 1 to 5, characterized by , that the intervention means (32, 33) are formed on an insert (35) which is arranged as a separate component between the heat exchanger (20) and the air-conducting housing (11). [8] Air conditioning unit (10), in particular for a motor vehicle air conditioning system with an arrangement of an air-guiding housing (11) according to one of the preceding claims, wherein the heat exchanger (20) is an evaporator, condenser, heating heat exchanger or gas cooler.

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