HEAT EXHANGER

Abstract

A heat exchanger, for example an intercooler or a coolant radiator, may include at least two floors each having a passage for accommodating a longitudinal end region of a plurality of fluid-conducting tubes. The heat exchanger may further include at least one side part having a longitudinal end region at least one of at least partially accommodated in a passage at an end of an associated floor and adjoining the associate floor. The at least one side part may include at least two segments having a different cross-section from one another.

Description

TECHNICAL FIELD

The present invention relates to a heat exchanger, in particular an intercooler or a coolant radiator. The invention further relates to a side part for such a heat exchanger.

BACKGROUND

Heat exchangers are typically made up of a large number of tubes, in particular flat tubes with or without turbulators, two floors and typically two side parts, on which plenums are mounted to make a complete collector. The side parts used for this are typically made from a single piece, usually in a stamping or embossing process. In addition, in order to reduce thermally induced stresses these side parts are either furnished with local expansion sections or they are split into two parts mechanically in a manufacturing step after joining.

A heat exchanger in which each of the side parts is equipped with an expansion bead is known from DE 197 53 408 A1, for example.

A species-related heat exchanger with two floors, each of which has two passages for accommodating the longitudinal end regions of fluid conducting tubes is known from EP 0 748 995 B1. In this case too, side parts are provided, and the longitudinal end region of each is at least partly accommodated in a passage at the end of the respective floor. These side parts are also equipped with expansion beads to compensate for thermal stresses.

A heat exchanger for exchanging heat between a gas-phase first fluid and a liquid second fluid, having a plurality of tubes that extend through a first fluid path for conducting the first fluid, is known from DE 10 2012 223 644 A1. The tubes are coupled so as to allow thermal exchange with cooling fins arranged in the first fluid path so that the first fluid can flow through them and form a second fluid path in the interior thereof for conducting the second fluid. The radiator core formed by the tubes and corresponding floors has one side part on each of two external sides farthest from each other in the direction of the stack to serve as the lateral limitation of the first fluid path. Such an arrangement is intended to increase the stability of the radiator core since both side parts are connected fixedly to each other via at least one tie rod, which is a separate component from the cooling fins and the tubes and which enables a tensile force to be transmitted in the direction of the stack.

Generally in the manufacture of heat exchangers according to the prior art, side parts of different lengths necessitated the constant use and purchase of new tools. Side parts made as a single piece, stamped from a metal sheet for example, are designed with identical wall thickness over their entire length, which may occasionally result in the unnecessary use of too much material in regions where high strength or bending stiffness values are not required. This is particularly the case in the middle region, whereas greater bending stiffness is required in the longitudinal end regions of the respective side parts. Accordingly, a single-piece side part must be constructed either with stiffening over its entire length, or the stiffening is introduced only locally, and results in increased material waste in the region that is not stiffened.

The present invention therefore addresses the problem of creating an improved or at least alternative embodiment of a heat exchanger of the species-related kind, which is characterised particularly by lighter weight and the use of less material in the region of the side parts.

This problem is solved according to the invention with the objects of the independent claims. Advantageous embodiments are the object of respective dependent claims.

SUMMARY

The present invention is based on the general idea of forming a side part from at least two segment parts with differing cross-sections in terms of bending stiffness to serve as lateral delimitation of the heat exchanger radiator core and satisfy the respective requirements therefor regarding bending stiffness. The heat exchanger according to the invention, which may have the form of a coolant radiator or intercooler for example, has two floors in the classic manner, each of which has passages for accommodating the longitudinal end regions of fluid-conducting tubes. The floors are delimited laterally by side parts, wherein one longitudinal end region of each is at least partially accommodated in a passage at the end of the respective floor. Alternatively, the longitudinal end region of the side parts may also be soldered or welded to the floors, and accordingly not accommodated in the passages. According to the invention, the side part then includes at least two separate segments having differing cross-sections, wherein at the same time the differing cross-sections give rise to different bending stiffness properties. A variant with three separate segments yields the particular advantages that the two end segments may be constructed identically, while the middle part has a different shape. This in turn makes it possible to construct the longitudinal end regions of the respective side parts (longitudinal end segments) more rigidly than for example a centre section (middle part) located between the two longitudinal end regions, so that the greater bending stiffness required in the longitudinal end region is achieved easily, while material and thus also weight can be saved in the middle section. Accordingly, with the heat exchanger according to the invention and a side part according to the invention it is possible to achieve sufficient stiffness, particularly bending stiffness in the region close to the floor, i.e., in the area of the floor, with minimal use of material. The longitudinal end region of the side part is thus provided with a cross-section of greater bending stiffness in the region close to the floor, while the middle section located between the end regions has a more flexible cross-section and/or reduced material thickness. Theoretically, it is of course also possible to dispense with the middle section entirely, so that in this case a zero cross-section would exist.

The middle section is expediently created in the form of a metal strip. This offers the simple and inexpensive option of manufacturing the metal strip economically, without sophisticated manufacturing equipment and processes. The longitudinal end regions of the respective side parts may have a cross-section with U-shape, U-wedge shape, an L-shape, a W-shape or a tubular shape consisting of one or more chambers, for example. Even this incomplete listing already suggests that the longitudinal end regions shaped in this way have significantly greater bending stiffness than the middle section in the form of a metal strip for example. Longitudinal end regions with such shapes are thus easily able to dissipate forces that occur on this region, while the middle section not only uses less material but can also be of lightweight construction, since in this region high stiffness or strength values are not required.

According to an advantageous development, one longitudinal end region and the middle section are materially bonded to each other, for example by welding, adhesion or soldering. This makes it possible to assemble a one-piece side part consisting of multiple segments with differing cross-sections, and to handle it relatively easily in the assembled state. Alternatively, it may also be provided that a gap is provided between the middle section and a longitudinal section, so that they do not touch each other. In this case, the gap would compensate for the effects of thermal expansion.

The present invention is further based on the general idea of producing a side part for a previously described heat exchanger from at least two segments with differing cross-sections and bending stiffness properties, that making it possible to ideally satisfy the different requirements in terms of bending stiffness in a middle section and in the respective longitudinal end regions of the side part. The cross-section used in the longitudinal end region exhibits good bending stiffness, while the middle section weighs less and at the same time helps to conserve resources due to its more flexible construction and/or reduced material thickness. The side part designed in this way is lighter overall, which also represents a considerable advantage particularly when it is used in a motor vehicle heat exchanger, yet still satisfies all requirements regarding bending stiffness. A further decisive advantage is the lower cost entailed by variations in the length of the side part, since only the middle section must be changed.

Further important features and advantages of the invention are described in the subordinate claims, the drawing and the associated description of the figures with reference to the drawing.

Of course, the features described in the preceding text and those which will be explained below are usable not only in the combinations described but also in other combinations, or alone, without departing from the scope of the present invention.

Preferred embodiments of the invention are illustrated in the drawing, and will be explained in greater detail in the following description, wherein the same reference signs refer to the same or similar or functionally equivalent components.

BRIEF DESCRIPTION OF THE DRAWINGS

In the schematic drawing:

FIG. 1 is a cross-sectional view through a heat exchanger according to the invention,

FIG. 2 shows a side part according to the invention with a middle section and two longitudinal end segments,

FIGS. 3 to 7 show various views of a side part with a middle section and differing longitudinal end segments,

FIG. 8 is a view of a side part with a longitudinal end segment having a first contour and a middle section having a second contour that complements the first.

DETAILED DESCRIPTION

According to FIG. 1, a heat exchanger 1 according to the invention, which may be realised as an intercooler for example, includes two floors 2, each of which has passages 3 for accommodating the longitudinal end regions of fluid-conducting tubes 4, flat tubes, for example. Floors 2 are connected to plenums 5 to form a collector, for coolant for example. The respective longitudinal end regions 7 of the two side parts 6 are at least partially accommodated in a passage 8 at the end of the associated floor 2, wherein the passage 8 at the end is constructed identically with the passages 3 provided for tubes 4. Side parts 6 may pass partially or all the way through passages 8, but do not have to. Alternatively, of course, they can also be joined to floors 2 in some other way, for example by soldering, welding, etc.

Now in order to be able to produce a side part 6 that not only satisfies the more demanding bending stiffness requirements that arise in the longitudinal end region 7 but can otherwise be produced with minimal material consumption, it is suggested according to the invention that side part 6 includes at least two different segments 9, 10 with differing cross-section and therewith also different bending stiffness characteristics. The side part 6 represented according to FIG. 2 has a total of three segments 9, 10, that is to say two identical longitudinal end segments 13 and a middle section 14 arranged between them. Middle section 14 has lower bending stiffness and/or a lower material thickness than longitudinal end segments 13 and can consequently be constructed particularly economically in terms of materials and with less weight. On the other hand, the longitudinal end segments 13 not only have differing cross-sections, enabling greater bending stiffness, but may also have greater material thickness, which also contributes to greater bending stiffness.

Middle section 14 may be in the form of a metal strip, which can be constructed simply and inexpensively, whereas the longitudinal end segments 13 may have for example a W-shaped cross-section (see FIGS. 2 and 5), a U-shaped cross-section (see FIG. 3), a U-wedge shaped cross-section (see FIG. 4) or a tubular cross-section consisting of one or more chambers 15 (see FIGS. 6 and 7). A common feature of all longitudinal end segments 13 shown is that they have relatively high bending stiffness moments by virtue of their cross-sections alone.

It is also conceivable that at least one longitudinal end segment 13 and the middle section 14 are materially bonded to each other, for example by welding or soldering, or that a gap 16 is provided between the middle section 14 and a longitudinal end segment 13, so that they do not touch each other. Theoretically, of course, the individual segments 9, 10 may be arranged so that they both overlap and abut each other. However, it is particularly advantageous if the two segments 9, 10 do not touch each other and the gap 16 between two segments 9, 10 is larger than 0.5 mm. A butt joint with gap 16 is shown for the side parts 6 according to FIGS. 2 to 7, whereas in FIG. 8 longitudinal end segment 13 has a first contour 11 and middle section 14 has a second contour 12 complementary thereto. Accordingly, in this case the longitudinal end segments 13 of side part 6 are given a convex or arrow-like shape directed towards the middle section 14 (see left and right images in FIG. 8), which makes it possible to ensure that each rib ridge can be joined to side part 6.

Side part 6 according to the invention and heat exchanger 1 according to the invention make it possible to produce heat exchangers 1 with differing tube lengths and identical longitudinal end segments 13 of side parts 6, which are simply combined with middle section 14 of different lengths depending on the tube length. In this way, the complex parts of side part 6, i.e. the longitudinal end segments 13 and segments 10 can always be used inexpensively and with excellent results using the same tool. Moreover, the simple design of middle section 14 helps to minimise material consumption, and in extreme cases even the middle section 14, i.e. segment 9, can be omitted entirely. At the same time, the complex shape of the longitudinal end segment 13 still affords firm bracing for tubes 4 in the region of the floor 2 close to the floor.

Claims

1. A heat exchanger, comprising: at least two floors each having a passage for accommodating a longitudinal end region of a plurality of fluid-conducting tubes;at least one side part having a longitudinal end region at least one of at least partially accommodated in a passage at an end of an associated floor and adjoining the associated floor; andwherein the at least one side part includes at least two segments having a different cross-section from one another.

2. The heat exchanger according to claim 1, wherein the at least two segments of the at least one side part includes two substantially identical longitudinal end segments and a middle section arranged between the two longitudinal end segments.

3. The heat exchanger according to claim 2, wherein the middle section has at least one of a material thickness and a bending stiffness that is lower than the two longitudinal end segments.

4. The heat exchanger according to claim 2, wherein the middle section is structured as a metal strip.

5. The heat exchanger according to claim 2, wherein the two longitudinal end segments have at least one of a U-shaped cross-section, a U-wedge shaped cross-section, a L-shaped cross-section, a W-shaped cross-section and a tubular cross-section with one or more chambers.

6. The heat exchanger according to claim 2, wherein a gap is provided between the middle section and at least one longitudinal end segment of the two longitudinal end segments to space the same from each other.

7. The heat exchanger according to claim 2, wherein at least one of the two longitudinal end segments and the middle section are materially bonded to each other at least in one region.

8. The heat exchanger according to claim 2, wherein at least one of the two longitudinal end segments and the middle section are at least partially connected to each other via a positive locking connection.

9. The heat exchanger according to claim 8, wherein the at least one longitudinal end segment and the middle section are at least partially connected to each other via a clipped connection.

10. The heat exchanger according to claim 2, wherein at least one of the two longitudinal end segments has a first contour and the middle section has a second contour complementing the first contour.

11. The heat exchanger according to claim 2, wherein the two longitudinal end segments have a tubular cross-section with one or more chambers.

12. The heat exchanger according to claim 2, wherein the two longitudinal end segments have at least one of a U-shaped cross-section, a U-wedge shaped cross-section, and a W-shaped cross-section.

13. The heat exchanger according to claim 2, wherein the middle section has a lower material thickness than that of the two longitudinal end segments.

14. The heat exchanger according to claim 2, wherein the middle section has a lower bending stiffness than that of the two longitudinal end segments.

15. The heat exchanger according to claim 3, wherein the middle section is structured as a metal strip.

16. The heat exchanger according to claim 4, wherein the middle section and at least one of the two longitudinal end segments are spaced apart from one another to define a gap therebetween.

17. A heat exchanger, comprising: a plurality of fluid-conducting tubes;at least two floors each having a passage for accommodating a longitudinal end region of the plurality of fluid-conducting tubes;at least one side part having a longitudinal end region coupled to an associated one of the at least two floors; andwherein the at least one side part includes at least two segments having a different cross-section from one another, the at least two segments including two longitudinal end segments and a middle section arranged between the two longitudinal end segments.

18. The heat exchanger according to claim 17, wherein the middle section is structured as a flat strip and the two longitudinal end segments are structured substantially identical to one another.

19. The heat exchanger according to claim 17, wherein the middle section has at least one of a material thickness and a bending stiffness that is lower than that of the two longitudinal end segments.

20. The heat exchanger according to claim 17, wherein at least one of the two longitudinal end segments has one of a U-shaped cross-section, a U-wedge shaped cross-section, a L-shaped cross-section, a W-shaped cross-section, and a tubular cross-section with one or more chambers.