HEAT EXCHANGER

Abstract

A heat exchanger, in particular a heat exchanger for a motor vehicle, which is constructed from modular heat exchanger components can include the following types of heat exchanger components: a plurality of tubes, in particular flat tubes, a plurality of plates and at least one connecting piece having an inlet opening for introducing a fluid and/or an outlet opening for discharging the fluid, the outer contour of the heat exchanger being at least partially formed by the outer contours of the heat exchanger components, the reliable arrangement of the same type of heat exchanger component in the designated location within the heat exchanger is reliably guaranteed. Thus, the heat exchanger components of the same type have different outer contours which form an outer contour of the heat exchanger so that heat exchanger components of the same type but having different functions may be distinguished from each other on the basis of their different outer contours.

Description

This nonprovisional application claims priority under 35 U.S.C. §119(a) to German Patent Application No. DE 10 2008 053 308.4, which was filed in Germany on Oct. 27, 2008, and which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a heat exchanger and to a method for manufacturing a heat exchanger. The invention also relates to a motor vehicle air conditioning system and a motor vehicle.

2. Description of the Background Art

Heat exchangers are used to transfer heat from one fluid to another fluid. For example, heat is transferred from a cooling liquid to the ambient air by a heat exchanger. This is used, in particular, in motor vehicles, in which the heat exchanger is used to discharge the waste heat released by the internal combustion engine into the ambient air. The heat exchanger generally includes two manifolds between which a plurality of tubes are arranged. Furthermore, heat exchangers may be used in motor vehicles in order, for example, to cool motor or transmission oil or air, for example charge air, or they may be used to cool a refrigerant in air conditioning systems for motor vehicles, i.e. the heat exchanger acts as a condenser within a refrigerant circuit.

Different manufacturing methods are know for manufacturing heat exchangers. In the so-called modular design, different heat exchanger components are assembled into a heat exchanger in a core builder. The heat exchanger components are generally flat tubes, plates with and without openings as well as two connecting pieces in which an inlet opening and an outlet opening for the fluid are provided. Turbulence inserts are generally arranged in the flat tubes, and the ends of the flat tubes are each closed by an insert part. Recesses are provided in the area of the ends of the flat tubes. The plates having openings that are placed on the end area of each flat tube. The recesses in the flat tubes are covered by the openings in the plates. A flat tube is again placed on both plates, and this process continues to repeat until the recesses and openings form a manifold of the heat exchanger. The flat tube includes a top and bottom wall, in each of which the recess is provided in the end area. The fluid may flow into the flat tube between the top and bottom walls. The fluid flows into the flat tubes from the manifold formed by the recesses and openings.

The plates also perform different functions as a type of heat exchanger component. For example, a plate without an opening may be provided with a vertical threaded bore. In addition, horizontal threaded bores, for example, may be provided at different points on the plates having openings. The threaded bores are used, for example, to fasten the heat exchanger to the body of a motor vehicle or to fix other components to the heat exchanger via the threaded bores. One type of heat exchanger component, i.e. a plate, thus has different functions.

In manufacturing the heat exchanger, the individual plates are each placed on the flat tubes. Errors may arise if the wrong plates, i.e. the plates having an incorrect function, are placed in the wrong location within the heat exchanger. This results in considerable damage because the heat exchanger is generally no longer suitable for its usual application if the error is not detected, or if a portion of an already assembled heat exchanger must be removed in a costly and time-consuming manner if the incorrect stacking of the plates is detected during manufacture, in particular while the plates and the flat tubes are being arranged.

EP 0 961 095 B1, which is incorporated herein by reference, shows a generic heat exchanger. An outer contour of the plates forms an outer contour of the heat exchanger. However, the outer contours of all plates are identical, making it impossible to distinguish between different plates on the basis of the outer contour.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to reliably guarantee that a single type of heat exchanger component is reliably arranged in its designated location within the heat exchanger in the case of a heat exchanger, a motor vehicle air conditioning system, a motor vehicle and a method for manufacturing a heat exchanger. During manufacture, the heat exchanger and the motor vehicle air conditioner as well as the motor vehicle should be able to perform the provided functions economically and during operation. In addition, it should be possible to carry out the method for manufacturing the heat exchanger easily and economically.

This object is achieved by a heat exchanger for a motor vehicle which can be constructed from modular heat exchanger components, including the following types of heat exchanger components: a plurality of tubes, in particular flat tubes, a plurality of plates and at least one connecting piece having an inlet opening for introducing a fluid and/or an outlet opening for discharging the fluid, the outer contour of the heat exchanger being at least partially formed by the outer contours of the heat exchanger components, heat exchanger components of the same type having different outer contours which form an outer contour of the heat exchanger, so that heat exchanger components of the same type, in particular those having different functions, are distinguishable by their different outer contours. In the case of different functions, the heat exchanger components have different outer counters which also form an outer contour of the heat exchanger. This makes it possible to distinguish between heat exchanger components of the same type based on the geometry of the outer contour.

In particular, the heat exchanger components of the same type having the different outer contours have different functions or properties.

In a further embodiment, the plates can be designed with or without openings. Plates with openings are used to form a manifold within the heat exchanger by stacking plates with openings on top of each other. Plates without openings are generally arranged on the top and bottom ends of the heat exchanger in order to close the manifold formed by the plates with openings and recesses in tubes, in particular flat tubes.

In a further embodiment, a closing member is arranged on a first, e.g. upper, and preferably also on a second, e.g. lower, end of the heat exchanger.

The different outer contours can be formed by at least one projection and/or at least one recess.

In a further variant, the at least one projection and/or the at least one recess can have/has a rectangular cross section. In particular, the at least one projection and/or the at least one recess is/are also designed with a square cross section. In addition, the at least one projection and/or the at least one recess may also have the shape of a knob, a cone or a part of a cone.

A recess can be suitably provided in the area of an end of the tubes.

In a further embodiment, a partial section of the tubes can be arranged between the plates in the area of the end of the tubes, and the openings in the plates can at least partially cover the recesses in the flat tubes, so that the openings and the recesses form a manifold.

In particular, turbulence inserts are provided in the tubes and/or the ends of the tubes are closed by an insert part.

In a further embodiment, the surface of the heat exchanger components, in particular the plates, flat tubes and connecting pieces as well as the closing members can be solder-plated. This enables the heat exchanger components joined to form a structural unit to be soldered in a furnace at temperatures of, for example, 600° C., thereby enabling the heat exchanger components to be connected to each other in a fluid-tight manner.

In a method according to the invention, heat exchangers are manufactured in a modular design from heat exchanger components, using, for example, the following steps: producing heat exchanger components, including tubes, plates and at least one connecting piece, in particular at least two connecting pieces; arranging the heat exchanger components into a structural unit; establishing a fluid-tight connection between the heat exchanger components contained in the structural unit, heat exchanger components of the same type having different outer contours which form an outer contour of the heat exchanger, so that when the different types of heat exchanger components are arranged into a structural unit, heat exchanger components of the same type having different functions may be distinguished from each other by a test component on the basis of their different outer contours to avoid incorrect arrangement of heat exchanger components of the same type having different functions.

The test component can be a mechanical component whose surface or geometry has a complementary design in relation to the outer contours or geometries of the heat exchanger components. As a result, when arranging the heat exchanger components, which is generally carried out by stacking the components in a core builder, e.g. manually, semi-automatically or automatically, the heat exchanger components which are arranged in a location other than the designated one have a position other than the designated one. The heat exchanger components are generally stacked on an inclined table. A heat exchanger component of the same type which performs a different function thus occupies a different position when arranged in a location other than its designated one. This other position may be detected and the heat exchanger component then replaced by a heat exchanger component of the correct type. Production errors are avoided thereby. Moreover, the test component may also detect or scan the surface or geometry, i.e. the outer contours of the heat exchanger components, in a different manner, e.g. optically, electrically or magnetically. The location of a heat exchanger component is thus determined by the construction plan of the heat exchanger component. An incorrect position of the heat exchanger component is determined by an arrangement of the heat exchanger component in the non-designated, i.e. incorrect, location.

In a further embodiment, a plate can be arranged between two tubes, in the area of an end of the tubes in each case.

In an embodiment, two plates can be laid on one tube.

In a further embodiment, the plates can be provided with openings, and recesses can be provided in the tubes in the area of one end of the tube, and when the tubes and plates are arranged, the openings and recesses at least partially cover each other.

In a further embodiment, corresponding sections of the test component have a shape which is complementary to the type of heat exchanger component provided in this position, so that when a type not designated for this position is arranged therein, the incorrect type of heat exchanger component occupies a different location that the designated heat exchanger component.

In an additional embodiment, the position of the different types of heat exchanger components is detected, for example, by a monitoring sensor when the heat exchanger components are arranged, and if a type of heat exchanger component assumes a non-designated position during arrangement, an error message occurs or the manufacturing method is terminated and/or the non-designated type of heat exchanger component is replaced by the designated type of heat exchanger component. The monitoring sensor may be, for example, an optical and/or a mechanical and/or an electrical monitoring sensor. In addition, the location of the heat exchanger components may also be checked by operators if a manual core builder is used.

In a further embodiment, the positions of the different types of heat exchanger components are detected, for example, by an operator, in particular visually, when the heat exchanger components are arranged, and if a type of heat exchanger component assumes a non-designated position, an error message occurs or the manufacturing method is terminated and/or the non-designation type of heat exchanger component is replaced by the designated type of heat exchanger component.

In manufacturing the heat exchanger, the individual heat exchanger components are arranged into a structural unit. This is generally carried out by stacking the individual heat exchanger components on a table in a core builder. After the individual heat exchanger components have been assembled into a structural unit, they are pressed together under pretension in a clamping apparatus. The surfaces of the individual heat exchanger components are provided with solder, i.e. they are solder-plated. The pretensioned structural unit is subsequently heated to temperatures in the range of approximately 600° C. in a soldering furnace. The individual heat exchanger components are soldered together thereby, connecting them to each other in a fluid-tight manner. A cooling liquid or air, for example, is used as the fluid.

A motor vehicle air conditioning system or a motor vehicle includes the heat exchanger described in this application.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

FIG. 1 shows a schematic, perspective and partially cut-away view of a heat exchanger;

FIG. 2 shows a schematic, perspective view of a plate without a representation of the special outer contour;

FIG. 2 a shows a perspective view of the plate without an opening, but having a vertical threaded bore in a first embodiment;

FIG. 2 b shows a perspective view of the plate with an opening and having a front horizontal threaded bore in a second embodiment;

FIG. 2 c shows a perspective view of the plate with an opening and having a rear horizontal threaded bore in a third embodiment;

FIG. 2 d shows a perspective view of the plate without an opening in a fourth embodiment;

FIG. 2 e shows a perspective view of the plate with an opening in a fifth embodiment;

FIG. 3 shows a perspective partial view of a flat tube;

FIG. 4 shows a perspective view of a connecting piece;

FIG. 5 shows a cross-sectional view V-V according to FIG. 4, including the flat tube; and

FIG. 6 shows a cross-sectional view VI-VI according to FIG. 3.

DETAILED DESCRIPTION

FIG. 1 shows a schematic, perspective and partially cut-away view of a heat exchanger 1. Heat exchanger 1 is used to cool a cooling liquid for the internal combustion engine of a motor vehicle, and an air flow 16, whose flow direction is marked by the arrow, flows through the heat exchanger for this purpose.

Tubes 3 designed as flat tubes 4, between which wavy fins 13 are provided, are stacked in heat exchanger 1. Wavy fins 13 are used, on the one hand, to mechanically connect flat tubes 4 to each other, and also to elevate the surface of heat exchanger 1 in order to thereby improve the cooling capacity. A recess 5 is provided at an end 10 of flat tubes 4 (FIG. 3). Flat tube 4 includes a top wall 20, a bottom wall 21 and two side walls 22. Top wall 20 and bottom wall 21 are positioned a short distance above one another and connected to each other by the two curved side walls 22. Recess 5 is thus present in both top wall 20 and bottom wall 21. In the area of recess 5 of flat tube 4, a fluid may thus flow inside flat tube 4 between top wall 20 and bottom wall 21. End 10 of flat tube 4 is closed in a fluid-tight manner by an insert part 12 (FIGS. 3 and 6). A turbulence insert 11 is provided inside flat tube 4. Turbulence insert 11 has a fin-like design and generates a turbulent flow inside the flat tube by mixing the cooling liquid. When fluid is flowing through flat tube 4, the latter largely has the same temperature on its surface, thereby increasing the cooling capacity of heat exchanger 1.

In addition to flat tubes 4, plates 6 are also provided in heat exchanger 1 as different types of heat exchanger components 2. Plates 6 are provided with an opening 7 (FIG. 2). Within heat exchanger 1, one plate 6 is provided between two flat tubes 4 in the area of end 10 of flat tube 4. In the interest of simplicity, FIG. 1 shows only heat exchanger components 2 in the upper and lower areas. Plates 6 stacked in heat exchanger 1 and having openings 7 as well as flat tubes 4 having recesses 5 thus form a manifold with the aid of recesses 5 and openings 7.

In addition, a connecting piece 8 is present in the upper and lower areas of heat exchanger 1. Lower connecting piece 8 has an outlet opening 15 and upper connecting piece 8 has an inlet opening (not illustrated). The cooling liquid is introduced into the inlet opening for cooling purposes, and the cooled cooling liquid is discharged from heat exchanger 1 via outlet opening 15. Connecting piece 8 is provided with a slot 17 (FIG. 5), in which a flat tube 4 is arranged in each case. Connecting pieces 8 also have an opening 7 (FIG. 5). Opening 7 in connecting piece 8 is thus also used to form the manifold within heat exchanger 1. Instead of arranging the two connecting pieces on the upper left and lower left sides of heat exchanger 1, it is possible, for example, to arrange a first connecting piece 8 on the lower left side and a second connecting piece 8 on the upper right side of heat exchanger 1 (not illustrated).

The upper and lower ends of heat exchanger 1 are sealed by a connecting part 14. Connecting part 14 is thus connected to a plate 6, a connecting piece 8 and wavy fin 13. Flat tube 4, plates 6, connecting pieces 8, insert parts 12, wavy fins 13 and closing members 14 are heat exchanger components 2 of heat exchanger 1. Heat exchanger 1 is manufactured from these heat exchanger components 2 in a core builder.

Plates 6 as an equivalent type of heat exchanger component 2 may perform different functions for heat exchanger 1. For example, plates 6 may also be designed without an opening 7 (FIGS. 2a and 2d). A plate 6 without an opening 7 may be provided, for example, with a vertical threaded bore 18 (FIG. 2a). In addition, plates 6 having an opening 7 may be provided with a horizontal threaded bore in different locations (FIGS. 2b, 2c). Plates 6 with and without a recess may also be provided without a vertical or horizontal threaded bore 18, 19 (FIGS. 2d and 2e). Threaded bores 18, 19 are used to attach heat exchanger 1 to a body of the motor vehicle or to fix other components to heat exchanger 1.

The same type of heat exchanger component 2, i.e. plate 6, thus has a different function for heat exchanger 1. In manufacturing heat exchanger 1 in the core builder, individual plates 6 must be stacked. Plates 6 having the different functions, in particular also a function without an additional fixing means according to plates 6 in FIGS. 2d and 2e, have a different outer contour 9. Outer contour 9 is formed by projections 23 and recesses 24, which have a largely rectangular cross section (FIGS. 2a and 2e). When individual plates 6 are stacked in the core builder (not illustrated), different plates 6 according to FIGS. 2a through 2e may be placed in the incorrect location. The core builder is provided with a test component (not illustrated). The test component has a shape or geometry which is complementary to outer contour 9 of plates 6. If an incorrect plate 6 is inserted, incorrect plate 6 assumes a different position on a table of the core builder. In each case, the test component is designed for a specific heat exchanger 1. The five different plates 6 used each have different outer contours 9. The corresponding section of the test component has a complementary design in relation to outer contour 9 of plate 6 provided in this location. If an incorrect plate 6 is placed in this position, plate 6 is unable to penetrate far enough into the test component because the complementary shape of the test component prevents it from doing so. All plates 6 have the same length. This means that an incorrect plate 6 sticks out from the other plates 6 when manufacturing heat exchanger 1 on a core builder table. This is both manually detectable by an operator and automatically detectable by a monitoring sensor, and the manufacturing method may be either terminated automatically or the operator may replace incorrect plate 6 with correct plate 6 designated for this location.

From an overall perspective, heat exchanger 1 according to the invention and the method according to the invention for manufacturing a heat exchanger 1 are associated with considerable advantages. Production errors due to incorrectly arranged plates 6 or heat exchanger components 2 may be easily avoided during the manufacture of heat exchanger 1. Different outer contours 9 of heat exchanger components 2 make it possible to easily detect the arrangement of heat exchanger components 2 of the same type but having different functions in the incorrect location within heat exchanger 1 during manufacture. Errors during manufacture may be avoided thereby and the costs of heat exchanger 1 as well as the costs of the method for manufacturing heat exchanger 1 may be reduced.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.

Claims

1. A heat exchanger formed of modular heat exchanger components, comprising: a plurality of tubes;a plurality of plates; andat least one connecting piece having an inlet opening configured to introduce a fluid and/or an outlet opening configured to discharge the fluid, an outer contour of the heat exchanger being at least partially formed by outer contours of the heat exchanger components,wherein the modular heat exchanger components of the same type have different outer contours that form the outer contour of the heat exchanger such that heat exchanger components of the same type are distinguished from each other based on their different outer contours.

2. The heat exchanger according to claim 1, wherein the heat exchanger components of the same type, but having different outer contours, are configured to function differently.

3. The heat exchanger according to claim 1, wherein the plates are configured with or without openings.

4. The heat exchanger according to claim 1, wherein the different outer contours are formed by at least one projection and/or at least one recess.

5. The heat exchanger according to claim 4, wherein the at least one projection and/or the at least one recess have/has a rectangular cross section.

6. The heat exchanger according to claim 1, wherein a recess is provided in an area of one end of the tubes.

7. The heat exchanger according to claim 6, wherein a partial section of the tubes is arranged between the plates in the area of the end of the tubes, and wherein the openings in the plates at least partially cover the recesses in the flat tubes such that the openings and the recesses form a manifold.

8. The heat exchanger according to claim 1, wherein turbulence inserts are provided in the tubes and/or ends of the tubes are closed by an insert part.

9. A method for manufacturing a heat exchanger from heat exchanger components in a modular design, the method comprising: providing heat exchanger components having tubes, plates and at least one connecting piece;arranging the heat exchanger components into a structural unit; andestablishing a fluid-tight connection between the heat exchanger components contained in the structural unit,wherein the heat exchanger components of the same type have different outer contours that form an outer contour of the heat exchanger such that when the different types of heat exchanger components are arranged into a structural unit a test component distinguishes between heat exchanger components of the same type that have different functions based on the different outer contours to avoid incorrect arrangement of heat exchanger components of the same type having different functions.

10. The method according to claim 9, wherein a plate is arranged between two tubes in an area of an end of the tubes.

11. The method according to claim 9, wherein two plates are placed on one tube.

12. The method according to claim 9, wherein corresponding sections of the test component have a shape that is complementary to the outer contour of the type of heat exchanger component designated for this location so that when a type of heat exchanger component not designated for this position is arranged therein, the non-designated type of heat exchanger component assumes a different position than the designated heat exchanger component.

13. The method according to claim 12, wherein the positions of the different types of heat exchanger components are detected by a monitoring sensor when the heat exchanger components are arranged, and if a type of heat exchanger component assumes a non-designated position during arrangement, an error message occurs and/or the manufacturing method is terminated and/or the non-designated type of heat exchanger component is replaced by the designated type of heat exchanger component.

14. The method according to claim 12, wherein the positions of the different types of heat exchanger components are detected visually by an operator when the heat exchanger components are arranged, and if a type of heat exchanger component assumes a non-designated position, the manufacturing method is terminated and/or the non-designated type of heat exchanger component is replaced by the designated type of heat exchanger component.

15. A motor vehicle air conditioning system or a motor vehicle, wherein the motor vehicle air conditioning system or motor vehicle includes a heat exchanger according to claim 1.

16. The heat exchanger according to claim 1, wherein the heat exchanger is a motor vehicle heat exchanger.

17. The heat exchanger according to claim 1, wherein the tubes are configured as flat tubes.