COOLER

Description

[0001] The invention relates to a cooler comprising: a fan with a substantially rigid fan housing enclosing a fan airflow chamber, a heat exchanger with a substantially rigid heat exchanger housing enclosing a heat exchanger airflow chamber, and an air guide element that connects the fan airflow chamber within the fan housing to the heat exchanger airflow chamber within the heat exchanger housing in a substantially fluid-tight manner, the air guide element extending from a heat exchanger air outlet opening of the heat exchanger to a fan air inlet opening of the fan or from a fan air outlet opening of the fan to a heat exchanger air inlet opening of the heat exchanger, wherein the air guide element is formed from a flexible, rubber-elastic material and is bendable.

[0002] Cooling devices are used in the prior art for a wide variety of applications, for example as engine radiators. A cooling system is known from DE 10 2012 018 571 B3. The cooling system has a fan for generating a cooling airflow and a heat exchanger for cooling a medium, for example cooling water, using the cooling airflow. A connecting channel for conveying cooling air to the heat exchanger is provided between the fan and the heat exchanger.

[0003] While this type of cooler has generally proven effective, it has the disadvantage that the connecting channel between the heat exchanger and fan must be designed and dimensioned for each specific application. Consequently, suitable connecting channels had to be provided for each size and shape of the respective fan and heat exchanger housing, which unfortunately resulted in high manufacturing and planning costs. Furthermore, the flow conditions in the existing connecting channel are not optimal. There is also room for improvement regarding noise levels.

[0004] The AT 515 865 B1, for example, offers a solution for achieving greater variability in the modular manufacturing of fans. To avoid expensive injection-molded parts, the fan housing is made from a textile element. This textile element has several overlapping textile segments arranged circumferentially to form an air guide jacket that surrounds the fan wheel.

[0005] US Patent 2,198,420 A also discloses a fan housing made of a flexible fabric. In this design, the flexible fabric bridges the gap between an opening in a floor slab and a ring surrounding the fan.

[0006] These approaches involve manufacturing the fan housing from flexible materials. However, significant stability problems can arise in practice. Neither document discloses the use of a heat exchanger, and therefore no connection between a fan housing and a heat exchanger housing.

[0007] DE 10 2017 200 222 A1 relates to a cooling device for motor vehicle engines comprising a heat exchanger and a fan wheel, which are connected to each other by fan shrouds made of rubber-elastic material. In this prior art, the flexible connecting section can only have a short axial extension in order to just withstand the loads during operation – including vibrations.

[0008] JP H 02 196 198 A reveals a radiator cover located between a radiator inlet opening and a fan bracket. The radiator cover is made of an elastic material.

[0009] CN 205 047 290 U relates to a radiator housing comprising a radiator frame, a rubber ring, and a mounting frame, with a cooling fan located inside the radiator frame. The radiator frame is made of plastic, the rubber ring of flexible, elastic rubber material, and the mounting frame of sheet steel. The top of the rubber ring is secured in the groove of the mounting frame. The mounting frame is connected to the engine block using combination screws.

[0010] Furthermore, fan casings and sleeves for fans, cooling fans or the like made of rubber-elastic material are known in the prior art, cf. DE 40 15 259 A1, US 4 774 911 A and CN 104 747 266 A, for example from documents which create simple assembly conditions through their design.

[0011] US 2017 275 458 A1 discloses the use of polyamide resin compositions for the manufacture of cooler housings, wherein these compositions may contain conductive additives.

[0012] EP 0 098 397 A1 discloses a water cooler for an internal combustion engine, to which a funnel-shaped radiator hood is attached on the engine side, transitioning into a cylindrical radiator frame. The radiator hood and the radiator frame form a common housing. A fan wheel is arranged within the radiator frame, in a flow opening. The inside of the radiator frame is lined with an elastic plastic. If relative movements occur between the radiator frame and the fan wheel, the fan wheel will scrape or mill away the elastic plastic at the points where it contacts it until it can rotate freely within the flow opening.

[0013] In contrast, the object of the present invention is to eliminate or at least mitigate some of the disadvantages of the prior art. The invention therefore aims in particular to create a cooler of the type mentioned above in which a fluid-tight connection between different fan and heat exchanger housings is achieved with minimal design effort. Furthermore, the invention aims to improve the flow conditions between the fan and the heat exchanger and / or to reduce the noise generated during operation of the cooler.

[0014] This problem is solved by a cooler having the features of claim 1. Preferred embodiments are specified in the dependent claims.

[0015] Accordingly, at least a rigid connection between the fan housing and the heat exchanger housing is provided.

[0016] The air guide element, through its flexible, rubber-elastic design, can achieve a structurally simple, yet stable and durable connection between the fan airflow space of the fan housing and the heat exchanger airflow space of the heat exchanger housing.

[0017] The air guide element directs the airflow axially (relative to the fan's central axis) between the fan airflow chamber of the fan housing and the heat exchanger airflow chamber of the heat exchanger housing. For this purpose, the air guide element extends from a heat exchanger air outlet opening of the heat exchanger to a fan air inlet opening of the fan. Depending on the application, the airflow can also be directed in the opposite direction, so that the heat exchanger air outlet opening of the heat exchanger is configured as a heat exchanger air inlet opening and the fan air inlet opening of the fan is configured as a fan air outlet opening. The flexible air guide element can be adapted to different installation situations with particular ease. Unlike the injection-molded or sheet metal parts of prior art components, the air guide element is so flexible that...The air guide element is essentially freely deformable, thus significantly facilitating the adaptation of the transition from the fan housing to the heat exchanger housing. For the purposes of this disclosure, the flexible design of the air guide element means that it can be manually bent, folded, or otherwise deformed in any direction. The use of a rubber-elastic material for the air guide element results in both high tear resistance and particularly effective airtightness. Furthermore, it is advantageous that favorable flow conditions are achieved within the air guide element because a continuous, flow-optimized transition between the different housing shapes of the fan and heat exchanger housings can be created. In addition, the air guide element exhibits low wear, even in humid environments.A particular advantage is that the flexible, rubber-elastic material of the air guide element can absorb and dampen mechanical vibrations from the fan. This results in exceptionally low noise levels during operation of the cooler. Unlike injection-molded or sheet metal parts, the inner surface of the rubber-elastic air guide elements has a sound-dampening effect when exposed to, for example, dust particles. Additional sound insulation can be achieved by selecting a thicker wall thickness for the air guide element. In contrast, the fan housing and the heat exchanger housing are essentially rigid, i.e., dimensionally stable, and therefore significantly less deformable than the air guide element. One aspect of the invention is thus based on the surprising realization that it is not the fan or heat exchanger housing that is designed to withstand the pressure.Instead of using flexible materials to design the heat exchanger housing for different applications, the rigid design of the fan and heat exchanger housing was retained, with only the intervening air guide element being made flexible. This allows for increased versatility of the cooler without compromising its stability.

[0018] To permanently withstand the loads occurring during operation of the cooler and to keep the fan housing in the intended position relative to the heat exchanger housing, the invention provides at least one rigid connection between the fan housing and the heat exchanger housing. Thus, the rigid connection allows the fan housing and the heat exchanger housing to be held in the predetermined position relative to each other, regardless of the operating loads. Advantageously, the rigid connection makes it possible to design the flexible air guide element to be comparatively long, thereby achieving even greater adaptability and also significantly improving the flow characteristics.

[0019] Depending on the design, the fan may have a fan wheel with attached fan blades and a motor to drive the fan wheel.

[0020] In a preferred embodiment, the fan housing has a fan air inlet opening with a first cross-section and the heat exchanger housing has a heat exchanger air outlet opening with a second cross-section, wherein the first cross-section is different from the second cross-section.

[0021] Advantageously, the assembly consisting of the fan housing, the heat exchanger housing, and the air guide element can be designed for different cross-sectional dimensions and / or geometries of the fan and / or heat exchanger by appropriately stretching the flexible air guide element. For example, an air inlet opening of the fan with a comparatively small cross-sectional area can be connected to an air outlet opening of the heat exchanger with a comparatively larger cross-sectional area via the same air guide element, just as with two air inlet and outlet openings of equal cross-sectional area. This variable applicability allows for cost savings, eliminating the need to manufacture different injection-molded or sheet metal parts for the various air guide elements.

[0022] With regard to manufacturing that is simple and cost-effective, the first cross-section is preferably essentially circular and / or the second cross-section is preferably essentially rectangular, in particular essentially square.

[0023] The different geometries of the individual airflow chambers, in addition to simple and cost-effective manufacturing, ensure excellent airflow within the air guide element. The flexible, rubber-elastic air guide element allows for a smooth and seamless transition between the different cross-sections. This increases the cooler's performance and reduces noise.

[0024] The heat exchanger housing preferably has a flange, particularly a substantially square one, projecting towards the fan housing, to which one end of the flexible air guide element is attached. Preferably, one end of the flexible air guide element is slipped over the outside of the flange. In a preferred embodiment, the flange is substantially rectangular, particularly a substantially square one, with rounded corners optionally provided. The flange encloses the air outlet opening of the heat exchanger.

[0025] Accordingly, the fan can have a mounting flange, in particular with a circular cross-section, to which the other end of the flexible air guide element is attached.

[0026] In a structurally simple, stable and easily assembled embodiment, the rigid connection between the fan housing and the heat exchanger housing comprises a rod, in particular a threaded rod.

[0027] Preferably, the rod extends essentially parallel to the central axis of the fan air inlet opening.

[0028] Preferably, several, in particular four, rods are arranged parallel to each other between the fan housing and the heat exchanger housing. The flange of the heat exchanger housing may have projecting tabs to which one end of the rods is attached. The other ends of the rods are preferably attached to corner regions of a square mounting plate of the fan housing.

[0029] To optimize flow conditions, it can be advantageous if the central axis of the fan air inlet opening of the fan housing is radially offset from the central axis of the heat exchanger air outlet opening of the heat exchanger housing. This design allows for a particularly flexible arrangement of the fan housing relative to the heat exchanger housing. For example, the cooler according to the invention is advantageously suited for use as an engine cooler in confined and angled engine compartments of a motor vehicle.

[0030] To prevent electrostatic charging within the air guide element, the air guide element is preferably electrically conductive. This counteracts potential sparking that can occur due to contact between aspirated particles, such as dust particles, and the inner surface of the air guide element. Therefore, the cooler according to the invention can also be used in strictly explosion-proof environments.

[0031] In a preferred embodiment, the air guide element is made of conductive rubber. For example, the conductive rubber of the elastic air guide sheath comprises a mixture of at least one elastomer and at least one electrically conductive metal and / or an electrically conductive alloy of two or more metals. The electrically conductive metals and / or alloys are incorporated into the elastomer in the form of particles and / or wires. A combination of at least one of the following is particularly suitable for producing conductive rubber: silicone, fluorosilicone, ethylene propylene diene monomer (EPDM) rubber, or neoprene, and at least one of the following: Monel, aluminum, silver-aluminum, silver-glass, silver-copper, or nickel-graphite.

[0032] The invention is further explained below with reference to preferred embodiments, to which it is not limited. The drawing shows in detail: Fig. 1 schematically a graphical view of a cooler according to the invention, in which a flexible air guide element connects a rigid fan housing with a rigid heat exchanger housing. Fig. 2 schematically a graphical view of the cooler according to the invention, in which the flexible air guide element has been removed to reveal a fan air inlet opening of the fan housing and a heat exchanger air outlet opening of the heat exchanger housing. Fig. 3 a side view of another cooler according to the invention, in which the fan air inlet opening of the fan housing is smaller than the heat exchanger air outlet opening of the heat exchanger housing and the central axes of the fan air inlet opening and the heat exchanger air outlet opening coincide. Fig. 4 a sectional view of another cooler according to the invention, in which the fan air inlet opening of the fan housing has a larger radius than the height of the heat exchanger air outlet opening of the heat exchanger housing and the central axes of the fan air inlet opening and the heat exchanger air outlet opening are radially offset from each other.

[0033] In Fig. 1 A cooler 1 with an air guide element 2 is shown, which connects a fan housing 4 to a heat exchanger housing 6. The fan housing 4 surrounds a fan element 3, which generates an airflow. The heat exchanger housing 6 surrounds a heat exchanger 5 in which a medium to be cooled is cooled by the airflow from the fan element 3. The fan housing 4 has a fan air inlet opening 7 and a fan air outlet opening 8, which define a fan airflow chamber 9 on both sides. The heat exchanger housing 6 encloses a heat exchanger airflow chamber 12 between a heat exchanger air inlet opening 10 and a heat exchanger air outlet opening 11.

[0034] The air guide element 2 is essentially flexible and rubber-elastic, whereas the heat exchanger housing 6 and the fan housing 4 are essentially rigid, i.e., dimensionally stable. The fan air inlet opening 7 of the fan housing 4 and the second air outlet opening 11 of the heat exchanger housing 6 are essentially fluid-tightly connected to each other by the flexible air guide element 2.

[0035] In the embodiment shown, the fan air inlet opening 7 of the fan housing 4 has a substantially circular cross-section, and the heat exchanger air outlet opening 11 has a substantially rectangular, here substantially square, cross-section. One end of the flexible air guide element 2 is fitted onto a substantially square flange 19 surrounding the heat exchanger air outlet opening 11. The other end of the flexible air guide element 2 is attached to a mounting flange 13 of the fan housing 4. The mounting flange 13 is substantially cylindrical, corresponding to the fan air inlet opening 7.

[0036] In the embodiment shown, the cooler 1 has four rigid connections 14 between the fan housing 4 and the heat exchanger housing 6. Threaded rods 14 are provided as rigid connections. The heat exchanger housing 6 has lugs 15 projecting from the flange 19 to receive one end of the threaded rods 14. The other ends of the threaded rods 14 are preferably attached to the corner regions 16 of a square mounting plate of the fan housing 4.

[0037] As from Fig. 2 (Without showing the air guide element 2), the heat exchanger housing 6 has a series of cooling elements 17 inside the airflow chamber 12. In the embodiment shown, several parallel lines 17 are provided for a fluid to be cooled. The lines 17 extend essentially perpendicular to the airflow with which the fluid is cooled. The fan housing 4 may have an air-permeable protective cover.

[0038] Fig. 3 shows a cooler 1 in which the central axis M1 of the fan air inlet opening 7 coincides with the central axis M2 of the heat exchanger air outlet opening 11.

[0039] In Fig. 4A cooler 1 is shown in which the central axis M1 of the fan air inlet opening 7 is offset radially from the central axis M2 of the heat exchanger air outlet opening 11. Due to the offset of the two central axes M1, M2, the air guide element 2 is designed as an asymmetric body of revolution with respect to the respective central axes M1, M2. The flexible air guide element 2 widens from the flange 19 on the heat exchanger housing towards the mounting flange 13 with respect to the central axis M2.

Claims

1. Cooler (1), comprising: - a fan with a substantially rigid fan housing (4), which encloses a fan air flow space (9), - a heat exchanger with a substantially rigid heat exchanger housing (6), which encloses a heat exchanger air flow space (12), and - an air guiding element (2), which connects the fan air flow space (9) within the fan housing (4) with the heat exchanger air flow space (12) within the heat exchanger housing (6) in a substantially fluid-tight manner, - which air guiding element (2) extends from a heat exchanger air outlet opening (11) of the heat exchanger to a fan air inlet opening (7) of the fan or extends from a fan air outlet opening (8) of the fan to a heat exchanger air inlet opening (10) of the heat exchanger, - wherein the air guiding element (2) is formed from a flexible, elastomeric material and is bendable, characterized in that at least one rigid connection (14) between the fan housing (4) and the heat exchanger housing (6) is provided.

2. Cooler (1) according to claim 1, characterized in that the fan housing (4) comprises a fan air inlet opening (7) with a first cross-section and the heat exchanger housing (6) comprises a heat exchanger air outlet opening (11) with a second cross-section, wherein the first cross-section is different from the second cross-section.

3. Cooler (1) according to claim 2, characterized in that the first cross-section is substantially circular and / or that the second cross-section is substantially rectangular, in particular substantially square.

4. Cooler (1) according to any one of claims 1 to 3, characterized in that the heat exchanger housing (6) comprises a flange (19) protruding in the direction of the fan housing (4), in particular a substantially square flange, to which one end of the flexible air guiding element is attached.

5. Cooler (1) according to any one of claims 1 to 4, characterized in that the rigid connection (14) between the fan housing (4) and the heat exchanger housing (6) comprises a rod, in particular a threaded rod.

6. Cooler (1) according to any one of claims 1 to 5, characterized in that the central axis (M1) of the fan air inlet opening (7) of the fan housing (4) is offset in the radial direction relative to the central axis (M2) of the heat exchanger air outlet opening (11) of the heat exchanger housing (6).

7. Cooler (1) according to any one of claims 1 to 6, characterized in that the air guiding element (2) is electrically conductive.

8. Cooler (1) according to claim 7, characterized in that the material of the air guiding element (2) is a conductive rubber.