The present invention relates to a heat shield for shielding of hot areas of a part. Such heat shields are for instance used for shielding hot areas of combustion engines, especially of catalysts, exhaust manifolds, turbo chargers and the like or also in the conditioning of batteries. Conventionally, they comprise at least one metallic sheet layer. In addition to this metal sheet layer, which renders stability to the heat shield, typically an insulating layer made of insulating material, e.g. porous material is provided as a further layer.
As far as the insulating layer is not embedded between the two metal sheets, the insulating layer is applied with its entire surface to the part to be shielded so that it rests to the latter.
The operation of combustion engines and the like are subject to variations in load, which results in a varying heat production over the operation time. It is for instance necessary to heat up the combustion engine immediately after its cold start to high temperatures, in order to keep emissions and consumption at a minimum. To this end, an insulation is provided which prevents the heat radiation and convection of the hot or heating part to the widest extent. On the other hand, when the combustion engine reaches its full load operating condition, it is necessary to provide for a heat radiation or convection as high as possible in order to prevent the hot part or its elements from overheating. This is of particular importance if these parts are not durable against high temperatures.
Given the priority of the protection against overheating for the shielded part and of the durability of the heat shield itself, it is often necessary in the heat shield arrangements according to the state of the art, to design them in such a manner that the emission reduction at cold starting cannot be considered at all or only to a small extent. However, with newer vehicles, especially also with hybrid vehicles, operational conditions with partial load and operational phases with frequent new starts predominate. For this reason, it is important to consider these operational conditions to a larger extent in the design.
This is the starting point of the present invention, which objects on providing a heat shield with which an excellent insulation can be achieved in all operational conditions but at the same time allows for a sufficient heat removal at high heat load. The present invention also relates to a component assembly with a heat-emitting part, which is arranged at a heat shield according to the present invention.
This object is solved by a heat shield according to claim 1 and the component assembly according to claim 19. Advantageous embodiments of the heat shield according to the invention are given in the dependent claims.
The present invention solves the problems described above by providing a heat shield for shielding of hot areas of a part, which comprises at least one metallic layer. Adjacent to this metallic layer, a further insulating layer is arranged which extends in the plane of the layer essentially parallel to the metallic layer. Thus, the insulating layer extends between the part to be shielded and the metallic layer. Both of these layers preferably follow the outer shape of the part to be shielded. The insulating layer consists of porous insulating material or comprises such. Advantageously, on the surface of the insulating layer which faces away from the metallic layer, no further layers are arranged or only layers which are formed according to the contour of the insulating layer, so that the insulating layer comes to rest on the hot part directly or indirectly. The insulating layer on its surface which faces away from the metallic layer comprises at least one flow channel. The flow channel is formed as a groove into the surface of the insulating layer.
If the insulating layer with its entire surface—the one surface pointing towards the hot part—rests on the hot part, the hot part together with the walls of the groove delimits the flow channels in the insulating layer. At high temperatures of the hot part, convection between the hot part and the insulating layer takes place through these flow channels, which guides the heat between the hot part and the insulating layer to the outside, especially if the part shows a high temperature.
Thus, the flow channels according to the invention are directly integrated into the porous insulating material. As they are formed as grooves which are closed when the heat shield comes to rest on the hot part and thereby build up the flow channels, it becomes possible to introduce the flow channels in a simple manner into the insulating layer. With the heat shield according to the invention, it is advantageous that for instance with a cold part, the convection between this part and the heat shield is small and therefore only little heat is discharged. If the part has however reached a high temperature, an increased heat removal takes place via the integrated flow channels of the heat shield.
With regard to a most simplified manufacturing and fastening of the heat shield, it is preferred if it consists in several partial shells, which are connected to each other to form a heat shield which annularly surrounds the part. It is especially advantageous if the heat shield is constructed from two half-shells which each consists in a metallic layer on their outside and an insulating layer on their inside. It is however also possible to combine a larger number of partial shells to an annularly closed heat shield. It is particularly preferred if the housing formed by the partial shells is closed in such a manner that at least a part of the flow channels at the interface, at which the housing is closed, pass over in a flush manner. The partial shells are for instance connected to each other after having been mounted around the part. In this case, connection is in particular performed at the collar-shaped protrusions which are provided in all partial shells at their edge regions. In the same way, it is possible to install the partial shells individually. In a further advantageous embodiment, at least two half-shells are connected to each other via a kind of hinge, so that the heat shield can be mounted as a whole. The hinges used in this context can be separately produced parts via which the partial shells are connected to each other. It is however also possible, that the heat shield comprises bending areas which are provided as integral structure in the metallic layer of the heat shield. In this case, the partial shells directly cohere with each other and therefore are no separate parts.
It is preferred if at least one of the flow channels comprises at least one device for active or passive opening and closing or ventilation. In advantageous embodiments, the flow channels at their entrances and outlets can have a closing and opening function and this way can be switched on or off. This enables a control of the surface temperature of the hot part. To this end, one advantageously uses a control circuit with a temperature sensor, e.g. at the hot part or at the heat shield, especially at its surface. In order to control the flow channels, it is also possible to use actuators or thermo-sensitive materials which are able to close or open the channels due to their temperature-controlled agility. An opening of the channels has to be ascertained especially under full load conditions in order to achieve an improved heat removal.
The passage of gas or air through the flow channels is either achieved in a passive manner using natural convection or in case of an engine of a vehicle or additionally using the slip stream or by an active blowing of the gases, e.g. using a fan. It is further possible to condition the gas in advance. To this end, it can be heated using an electrical heating or using phase change materials. As an alternative, it can be cooled using the air condition of the vehicle prior to passing through the channels of the heat shield.
Advantageously, the insulating material consists in a fleece, which is for instance reinforced with a ceramic binder. Such a fleece can be molded to a preform. It is also possible to simultaneously mold the flow channels into the surface of the fleece which faces away from the metallic layer. If desired, an additional surface treatment can be provided for, e.g. using a ceramic-based high-temperature adhesive or a ceramic-based high-temperature coating or lacquer, in order to reinforce the surface of the insulation layer by forming a kind of skin. Such high-temperature adhesive, coatings and lacquers can for instance be materials, which at temperatures between 150° C. and 250° C. tend to form a skin.
As insulation materials, glass mats, especially made from SiO2, Al2O3 and/or CaO with a binder; expanded mica, basalt rock wool, all kinds of ceramic masses, expanded clay or high-temperatures such as polyimide or melamine are suited. Sandwich constructions, especially with at least one of the materials mentioned before are possible, too.
Formation and arrangement of the flow channels can be done in different manners, which have to be adapted to the thermal needs, which may be assessed using thermography of the hot part to be shielded. In this respect, the flow channels have to be adapted to the requirements in removal of heat in the hot part and in cases also to the need of heat removal in particular areas of the hot part, the so-called hot spots. The flow channels can show various patterns on the surface of the insulating layer, e.g. along the longitudinal extension of the heat shield or also transverse to it, helical in the shape of a one-level thread or a two-level winding and/or in the shape of several flow channels which are oriented in counter flow relative to each other. In most cases, it is preferable if the heat shield does not comprise a single flow channel only but that at least two flow channels are formed in the insulating layer which channels surround the part independent of each other. The distances of the flow channels can be adapted to the respective need in heat removal. Thus, they may be arranged closer to each other in the area of hot spots. The cross sections of the flow channels may be constant over their course or can be varied along their course with respect to their height and/or width, resulting in an adaptation to the local requirements. The total length of the flow channels, the pattern of the flow channels, a possible pooling of several flow channels at their inlet or outlet to a single channel and the like can be adapted to the respective requirements. It is especially advantageous if the channels in the partial shells are formed flush to each other, so that the flow of the gas is realized all around the entire part. If only such channels are given which extend in the longitudinal extension direction of the heat shield, this is of course not required.
Especially in areas of a hot spot, it can be advantageous to enlarge the width of a channel extending in this area, and preferably to simultaneously reduce its height. With this, the contact area between gas and part is increased and the heat transfer to the gas and the heat removal are improved. The cross section of the flow channels can in particular in the area of hot spots can also considerably vary in the flow direction of the gas, showing varying cross sections, so that the gas experiences turbulences, which improves the heat transfer to the gas.
To improve cooling performance and to homologize the outside thermal map of the entire heat shield, it can be advantageous to provide at least a first winding on the hot side of the insulating layer (as already described) and a at least a second winding on the outer surface of the insulating layer resulting at least in a first cooling circuit on the inner surface of the insulating layer and at least a second cooling circuit on the outer surface of the insulating layer. This enables to run the first and second cooling circuits in different directions or in the same direction. The first cooling circuits can run in parallel to the second cooling circuits, thus without shift relative to the plane of the surface of the insulating layer or be staggered. Further, they can extend relative to each other like a double helix or in a manner crossing each other in a projection into the middle of the insulating layer at several places. It is particularly preferred if the airflow passes the second cooling circuit(s) resulting from the second winding(s) on the outer surface of the insulating layer, as this guarantees for a simple and permanent cooling during operation of the vehicle while no cooling takes place during rest phases of the vehicle which facilitates the warm-up. Using first and second cooling circuits on the inner and outer surface of the insulating layer allows for further opportunities in designing the thermal map according to the requirements of each special operation condition.
Instead of forming the at least one first winding on the inner surface of an insulating layer and the at least one second winding on the outer surface of the same insulating layer, it is also possible to achieve a comparable design using a sequence of at least three insulating layers, the inner one with recesses for the at least one first winding, the second one being continuous and the outer one with recesses for the at least one second winding.
Cross sections with an area of 10 to 500 mm2, advantageously of 30 to 200 mm2 are particularly suited for the flow channels. The distances between individual flow channels can advantageously range between 5 and 100 mm, further advantageously between 10 and 50 mm.
In case of flow channels arranged in a thread-like manner, which continue over several partial shells, their slope can be between 25 and 100 mm, in particular about 50 mm. The width of the channel advantageously ranges between 3 and 30 mm, more advantageously between 4 and 20 mm and most advantageously between 8 and 12 mm. For the channel height, 2 to 20 mm, advantageously 5 to 15 mm and more advantageously 5 to 10 mm are especially suited.
The cross sectional shape of the flow channels can vary as well and be adapted to the actual requirements, e.g. by use of a semi-circular, rectangular or a trapezoidal cross section. In case of a trapezoidal cross-section, the longer basic side can either be arranged on the side of the hot part or opposite to it. Omega-shaped cross sections are possible, too. The arrangement of the flow channels along the hot part is especially preferred, as this results in a good cooling. However, an inclined orientation, at an angle of between 5 and 45°, advantageously about 20° relative to the longitudinal direction of the part is suited, too. In a preferred embodiment, the groove forming a flow channel at least on a section of its longitudinal extension can show a cross section that tapers, advantageously tapers in a conical manner. Further, this cross section can taper and widen in sections along the groove.
It is not necessary that the insulating layer shows the same extension as the at least one metallic layer. Rather, edge areas may be free of insulating material especially if they only aim on the fixation of the heat shield via its metallic layer to the hot part. However, it is preferred that the insulating extends over at least 50%, preferably at least 80%, preferably at least 90% of the planar extension of the metallic layer.
The at least one metallic layer comprises or consists in a steel sheet, in particular a stainless-steel sheet, an aluminated steel sheet, in particular a fire-aluminated steel sheet and/or an aluminum-plated steel sheet or the like. The metal sheet can have the form of a smooth metal sheet or it can be dimpled at least in sections. It is most preferred that the outer surface of the at least one metallic layer has a good reflectivity. As a consequence, the heat shield according to the invention combines reflection, convection and insulating properties and allows for a tailored design to the particular application.
The heat shield according to the invention is used for shielding of hot parts, in particular of parts of an internal combustion engine, especially in vehicles, thus mainly in passenger cars and utility vehicles. The heat shield is thus particular suitable for applications in the exhaust line, in particular at the exhaust manifold or for the unit for exhaust treatment, the unit for supercharging as well as for heat exchangers, for instance heat exchangers for the heating of transmission oil, in the additional heating for the passenger room and/or in the battery conditioning.
In the following, some examples of heat shields according to the invention are given. In all these examples the same or similar reference numbers are used for identical or similar elements, so that their repetition may be avoided. In the following examples, several elements according to the invention are represented in combination with an example. Each of these elements according to the invention can however also represent an advantageous embodiment of the present invention independent of the other elements of the respective example.
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Number | Date | Country | Kind |
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20 2012 010 993.6 | Nov 2012 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/073870 | 11/14/2013 | WO | 00 |