The present invention relates to an evaporator heat exchanger for evaporating liquid working medium.
In order to further lower the fuel consumption in commercial vehicles and passenger cars, attempts are made to recover a part of the energy of the exhaust gas. This can take place thermally, i.e. the energy of the exhaust gas is used for example to heat a passenger compartment or to heat the internal combustion engine or the transmission. In a variant that has been discussed for some time, although thermal energy is removed from the exhaust gas, said thermal energy is returned to the internal combustion engine in a mechanical form. This method is based on a steam power process, in which a particular working medium is evaporated and superheated in an evaporator and is expanded in an adjoining expander, for example a turbine, with the result that mechanical energy is generated. The evaporation takes place here by means of heating via the exhaust gas. The working medium to be evaporated is in this case usually first heated up to boiling point in an evaporator, then evaporated and subsequently superheated. This can take place in principle at two different locations in a motor vehicle. Firstly, heat can be withdrawn from the exhaust gas in an evaporator, which is used instead of an exhaust gas cooler, in order to evaporate the working medium. In this case, the exhaust gas is cooled by the evaporation of the fluid to be evaporated and is then fed back to the motor together with the fresh air. Secondly, the main exhaust gas flow is also intended to be used as a heat source, in order likewise to evaporate working medium here in what is known as a main exhaust gas evaporator. Such a main exhaust gas evaporator is usually arranged by the vehicle manufacturers after the silencer or after the entire exhaust gas aftertreatment device in the exhaust gas system. Alternatively, the charge air in supercharged engines is used as a heat source.
WO 2012/010349 A1 discloses a generic evaporator heat exchanger for evaporating liquid working medium and for using waste heat from an internal combustion engine. In the known system, introduction of the working medium into the combustion air fed to the internal combustion engine on account of a sealing problem or leakage in the evaporator heat exchanger is intended to be substantially ruled out. To this end, at least one first flow channel is formed by at least one first delimiting component and at least one second flow channel is formed by at least one second delimiting component, wherein there is a fluid-conducting connection into the surroundings or into a receiving chamber from at least one of these delimiting components, such that in the event of a leakage at the delimiting components, the working medium is introducible into the surroundings or into the receiving chamber.
Concepts of a gas-operated evaporator heat exchanger that are described in the prior art provide for the risk of gas and working medium mixing to be reduced. If for example a fluorinated refrigerant flows into the exhaust gas and is fed together therewith into the internal combustion engine and combusted therein, hydrofluoric acid is produced, and this can pass out of the exhaust pipe and cause damage there. If, rather than this refrigerant, use is made for example of an alcohol, in the event of a leakage, the alcohol would be co-combusted in the internal combustion engine, and this would become noticeable on account of a sudden increase in power of the internal combustion engine. Under certain circumstances, this may be manageable only with difficulty, in particular for inexperienced drivers.
Therefore, the present invention deals with the problem of specifying an improved embodiment for an evaporator heat exchanger of the generic type, in which undesired mixing of working medium and gas, in particular exhaust gas or charge air, can be ruled out.
This problem is achieved according to the invention by way of the subject matter of the independent claim. Advantageous embodiments are the subject matter of the dependent claims.
The present invention is based on the general idea of providing a leakage channel and/or leakage space between a first flow channel that conducts working medium and a second flow channel that conveys gas, in particular exhaust gas or charge air, and in the process of configuring both the first flow channel and the leakage channel and/or the leakage space with a particularly simple structure by way of two cover plates and a profiled fluid plate arranged in between. The evaporator heat exchanger according to the invention for evaporating liquid working medium in this case has a housing in which said first flow channel for conducting the working medium and the second flow channel for conducting the gas are arranged. By way of heat transfer from the gas, for example charge air or exhaust gas, to the working medium, the latter is evaporated, with the result that it can subsequently be expanded in an expansion machine, for example in a turbine, and as a result exerts mechanical work. As mentioned, according to the invention, the first flow channel and at least one leakage channel and/or leakage space are formed by two comparatively thick cover plates and a profiled fluid plate arranged in between, wherein a plate pack formed from two cover plates and a fluid plate located in between thus accommodates the first flow channel and the at least one leakage channel and/or leakage space fluidically separated therefrom. The connection between the two cover plates and the fluid plate arranged in between is produced in a cohesive manner, for example via a soldered connection. Arranged in this case between two adjacent plate packs is in each case a second flow channel through which the heat transfer gas, for example exhaust gas or charge air, flows. If the fluid plate breaks and/or if the soldered seam between the fluid plate and the cover plate fails, the working medium passes from the first flow channel into the leakage channel and/or into the leakage space and can be discharged from there without being directly mixed with the gas, for example exhaust gas, flowing through the second flow channel. In the same way, the leakage channel and/or the leakage space can also be used to discharge gas passing undesirably out of the second flow channel, if for example detaching of a soldered connection between the fluid plate and the cover plate or breaking of a wall of the fluid plate would result in a fluidic connection between the leakage channel and the second flow channel. As a result of this, too, gas now flowing into the leakage channel and/or into the leakage space can be discharged and as a result direct mixing with the working medium in the first flow channel can be avoided. The leakage channel and/or leakage space thus forms a natural safety barrier located between the two flow channels. The leakage channel and/or the leakage space is usually filled with air.
Expediently, the strength of a material of the fluid plate is less than the strength of a cover plate arranged on the fluid plate. This brings about a kind of predetermined breaking point of the fluid plate, such that if the evaporator heat exchanger is overloaded in the region of the first flow channel, the working medium conducted through the first flow channel passes into the leakage channel. If, for example, the fluid plate breaks, the cover plate delimiting the first flow channel expands under certain circumstances and compresses the rib structure arranged for example in the second flow channel. During the expansion of the cover plate, a soldered seam connecting the fluid plate to said cover plate can be detached, with the result that a fluidic connection between the first flow channel and the leakage channel is created. From the latter, the working medium can be discharged without mixing with the gas flowing through the second flow channel. In the same way, such a predetermined breaking point can also be formed by a smaller wall thickness or material thickness of the fluid plate compared with the cover plates connected thereto. What is important here is always that, in the event of an overload, first of all the fluid plate breaks or ruptures and not the cover plates. In this way, regardless of the type of failure, it is always possible to ensure that the leakage channel and/or leakage space located between the first and the second flow channel can be used to discharge the working medium or the gas. The leakage channel and leakage space are preferably impressed in an encircling manner in the fluid plate, wherein larger areas are denoted leakage space and smaller areas are denoted leakage channel.
In a further advantageous embodiment of the solution according to the invention, the evaporator heat exchanger has a plurality of plate packs stacked on top of one another with in each case a second flow channel arranged in between, wherein the leakage channel and/or the leakage space in a fluid plate has a first opening and a plurality of cover plates, arranged opposite one another, of two adjacent plate packs each have a second opening, wherein a leakage bushing for forming a (leakage) outlet duct, is arranged between the second openings. In this way, the leakage fluid or gas can be reliably drained from the second flow channel or the working medium can be reliably drained from the first flow channel.
In an advantageous development of the solution according to the invention, the housing has a housing opening which is connected, via a housing leakage bushing, to the first or second opening in the cover plate of a plate pack arranged adjacent to the housing. In this case, the housing leakage bushing and all further leakage bushings form an outlet duct, also known as a leakage outlet duct, for conducting the leakage fluid, wherein a line into the surroundings or periphery is attachable to the housing leakage bushing, a sensor which is configured to measure the pressure and/or the flow rate and/or a chemical composition of the fluid in the line being arranged in the region of said line. Ambient air pressure usually prevails in the outlet duct. At the same time air with the usual quality is present. If, on account of an overload, the fluid plate breaks or ruptures and thus working medium passes out of the first flow channel or gas passes out of the second flow channel into the leakage channel, then the pressure, the temperature and/or the chemical composition changes therein, since the leakage fluid, regardless of whether it is exhaust gas or working medium, has different physical and/or chemical properties than air. If a corresponding change indicating a leakage is detected by the sensor, then the latter can for example control a pump delivering the working medium or an exhaust gas recirculation valve depending on the signal detected by the sensor. It is likewise conceivable for a warning signal, which visually and/or acoustically notifies a user of the motor vehicle of a malfunction in the evaporator heat exchanger, to be output. Ambient air pressure of about 1 bar is usually present—as described above—at the sensor. If the evaporator heat exchanger is put into operation, the pressure in the leakage channel and/or in the leakage space rises to about 1-1.5 bar on account of the temperature-related expansion, this being normal. However, if the pressure does not rise, then either the sensor is defective or the leakage channel and/or leakage space has a sealing problem via which a drop in pressure can occur. If the pressure rises considerably during operation of the evaporator heat exchanger, this usually indicates a leakage of the first flow channel or of the second flow channel. The operation of the leakage channel is thus tested each time the motor vehicle is restarted, in particular upon each cold start.
Further important features and advantages of the invention can be gathered from the dependent claims, from the drawings, and from the associated description of the figures with reference to the drawings.
It goes without saying that the abovementioned features and those yet to be explained in the following text are usable not only in the combination given in each case but also in other combinations or on their own, without departing from the scope of the present invention.
Preferred exemplary embodiments of the invention are illustrated in the drawings and are described in more detail in the following description, wherein identical reference signs refer to identical or similar or functionally identical components.
In the figures, in each case schematically,
According to
The leakage channel 10 according to the invention creates a barrier between the two flow channels 4, 5, such that it is not possible for the working medium 2 to mix directly with the gas 6 and as a result to damage an internal combustion engine. In the case of evaporator heat exchangers that are known from the prior art, the working medium to be evaporated flows into the exhaust gas in the event of a leakage and can, if for example a fluorinated refrigerant, for example R245fa, is used, be combusted in the internal combustion engine, thereby producing poisonous hydrofluoric acid. This would pass out of the exhaust pipe and cause damage there. If, rather than such a refrigerant, use is made of alcohol, for example ethanol or methanol, in the event of a leakage, the latter would be co-combusted in the internal combustion engine, and this would be reflected in a sudden increase in power of the internal combustion engine. In particular inexperienced drivers would be exposed to an increased risk of an accident as a result. However, as a result of the barrier according to the invention of the leakage channel 10 and leakage space 11 type, in the event of virtually any kind of failure of the fluid plate 9, mixing of the gas 6 with the working medium 2 can be reliably prevented.
In addition to the provision of the leakage channel 10 and/or of the leakage space 11 (cf. also
In
Considering the fluid plate 9 according to
Considering
Provision can likewise be made of an open-loop and/or closed-loop control device 30 which is configured to evaluate a signal detected by the sensor 29, in particular the pressure, the flow rate and/or the chemical composition of the fluid, in particular of the leakage fluid, in the line 28, and for the open-loop/closed-loop control of a pump (not shown) delivering the working medium and/or of an exhaust gas recirculation valve (likewise not shown) depending on the signal detected.
The ambient air pressure of about 1 bar is usually present at the sensor 29, as long as the evaporator heat exchanger 1 is switched off and is at ambient temperature. This is shown in
In general, the evaporation heat exchanger 1 according to the invention has the following advantages:
avoidance of undesired mixing of the working medium 2 with the gas 6, for example exhaust gas or charge air,
no health risk when refrigerant is used,
no safety risk when alcoholic working medium 2 is used,
ongoing testability of the function of the leakage concept.
This application is a US National Phase application of International Patent Application PCT/EP2013/066248, filed on Aug. 2, 2013, which is hereby incorporated by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/066248 | 8/2/2013 | WO | 00 |