KIT FOR A HEAT EXCHANGER, A HEAT EXCHANGER CORE, AND HEAT EXCHANGER

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a kit for producing a heat exchanger in a plate design, particularly for motor vehicles, with a plurality of plate pairs and/or plate groups for forming flow paths, a heat exchanger core for forming heat exchangers, and a corresponding heat exchanger.

2. Description of the Background Art

Heat exchangers for motor vehicles are known in the conventional art. Thus, heat exchangers are already being used in many configurations and for many specific purposes in vehicles, for example, as evaporators, storage evaporators, oil coolers, condensers, charge air cooler, or coolant coolers. All of these heat exchangers have different configurations and types of construction, so that a different design is also often used for each type.

DE 102006028017, which corresponds to U.S. Pat. No. 8,495,894, which is incorporated herein by reference, and which discloses an evaporator with a cold store, a so-called storage evaporator, in which an evaporator part is formed with double-row flat tubes, whereby a storage part, which is formed as a single row, is provided adjacent to said evaporator part of the heat exchanger and through an arrangement of double tubes, on the one hand, a refrigerant can flow through an inner flat tube and, on the other, a cold store medium can be disposed in a space between the inner flat tube and the outer flat tube or can flow through this region.

In the conventional art, the production of a storage evaporator is a highly complex process, because a plurality of tubes and a plurality of parts must be fabricated and connected together. The evaporator part is typically a variation of a standard refrigerant evaporator, so that this structural element as well cannot be used as a standard version, but requires modification at least in regard to some structural elements. The storage evaporator therefore represents a special solution that cannot fall back on mass-produced parts.

EP 1817534 B1, which corresponds to U.S. Pat. No. 8,122,943, discloses a storage evaporator, whereby in a first exemplary embodiment flat tubes are again inserted into one another that can be connected by means of connecting members to different refrigerant or cold storage material-media circuits. The production of such a storage evaporator again has a high parts complexity, which results in considerable additional costs.

The embodiment of a storage evaporator in a plate design according to the second exemplary embodiment of EP 1817534 B1 also shows that a unique solution was again developed, which is of limited suitability for other applications.

The heat exchangers in the conventional art are therefore adapted very particularly to the requirements of the specific medium in the circuit, so that wide use for different applications is more likely to be ruled out.

SUMMARY OF THE INVENTION

It is therefor an object of the invention to provide a kit for producing a heat exchanger in a plate design, particularly for motor vehicles, with a plurality of plate pairs and/or plate groups for forming flow paths, which facilitates the production of different heat exchangers for different applications as well. Moreover, it is also as object of the invention to provide heat exchanger cores, which are used to form heat exchangers, and it is the object of the invention to provide such a heat exchanger.

For the kit, this is achieved in an embodiment, whereby a kit is provided for producing heat exchangers with at least two types of heat exchanger cores for producing more than two different heat exchangers, whereby the kit advantageously comprises a first type of heat exchanger core with a plurality of pairs of plates to create a plurality of parallel flow paths between the pairs of plates and, further, comprises a second type of heat exchanger core with a plurality of groups of three plates to create a plurality of two parallel flow paths, whereby in each case a flow path is formed between two of the three plates, whereby a first heat exchanger with a heat exchanger core of the first type can be produced, whereby a second heat exchanger with two heat exchanger cores of the first type can be produced, whereby a third heat exchanger with a heat exchanger core of the first type and with a heat exchanger core of the second type can be produced, whereby a fourth heat exchanger with two heat exchanger cores of the second type can be produced, and a fifth heat exchanger with a heat exchanger core of the second type can be produced. It is advantageous according to the invention that the heat exchanger cores are designed in such a way that they can be used alone, can be combined and used with another core of the same type, and also can be combined and used with a heat exchanger core of the other type.

As a result, when a heat exchanger core of the first type is used as a simple, narrow evaporator, it can thus be used as space-saving. This can occur advantageously in small vehicles with low required cooling capacities.

In the case of higher required cooling capacities, if two heat exchanger cores of the first type are used, these can be arranged in a series or parallel connection to one another and used so that an increased cooling capacity with a double space requirement can be realized.

When the heat exchanger is used as a storage evaporator, a heat exchanger core of the first type with a heat exchanger core of the second type can be used, whereby in this case the refrigerant can flow parallel or serially through flow paths of the first core and of the second core, whereby the cold store medium can flow through further flow paths of the second heat exchanger core.

Two heat exchangers of the second type can also be connected together, so that, for example, an increased cooling capacity can be realized with a simultaneous cold store effect.

Furthermore, the second type of heat exchanger core alone can be used, for example, as a two-row evaporator or as a one-row evaporator with a cold store. As a result, a storage evaporator with a lower cooling capacity is realized, for example.

The heat exchanger cores of the first and/or second type can be provided with connecting devices and/or interconnecting devices for introducing and/or discharging and/or transferring fluid into or between or out of the heat exchanger cores or between flow channels of the heat exchanger cores.

With respect to the heat exchanger core, in an embodiment, a heat exchanger core is provided in a plate design, particularly for use in a kit, for forming a heat exchanger, with a plurality of plate pairs for forming first flow paths, whereby in each case two plates of a plate pair form the first flow path between them and a region for second flow paths each is formed between adjacent plate groups.

With respect to the heat exchanger core, in an embodiment, a heat exchanger core is provided in a plate design, particularly for use in a kit, for forming a heat exchanger, with a plurality of plate pairs for forming third and fourth flow paths, whereby the third flow path is formed between a first and a second plate of a plate group and the fourth flow path is formed between a second plate and a third plate of the plate group, and in each case a region for the fifth flow path is formed between adjacent plate groups.

At least individual plates can have openings and/or wells as connecting and interconnecting regions and have channel-forming structures, such as embossings, for forming flow paths between connecting regions.

The first plate and second plate of the plate pair at two opposite end regions in each case can have a connecting region as an inlet or outlet of the first flow path and a channel-forming structure between the two connecting regions to form the first flow path.

The first plate and/or second plate of the plate pair at an end region can have two connecting regions as an inlet or outlet of the first flow path and a channel-forming structure between the two connecting regions to form the first flow path.

The first plate, the second and third plate of the plate group at two opposite end regions in each case can have two connecting regions as an inlet or outlet of the third flow path or of the fourth flow path, whereby the first and second plate in each case between an opposite connecting region have a channel-forming structure between one of the two connecting regions to form the third and fourth flow path, whereby the third plate is provided between the first and second plate as a partition wall between the third and fourth flow path.

In an embodiment, heat exchangers with at least two heat exchanger cores can have the distance of the plate pairs or the plate groups of a heat exchanger core to form the second and/or fifth flow paths selected in such a way that in the case of adjacent heat exchanger cores of a heat exchanger, it is the same or different, such as smaller or larger than in the adjacent heat exchanger core.

The depth of the flow channels perpendicular to the plane, defined by the plate pairs or plate groups, can be selected individually for each flow channel.

Further, plate pairs can be formed from a paired arrangement of plates and with a partition wall between adjacent plates, which form pairs of flow channels, characterized in that flow through the flow channels of a plate pair is a counterflow.

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 illustrates an arrangement of two heat exchanger cores, a heat exchanger of a first type, and a heat exchanger of a second type;

FIG. 2 illustrates an assembled arrangement of two heat exchanger cores;

FIG. 3 illustrates an arrangement of two heat exchanger cores of a first type;

FIG. 4 illustrates an arrangement of two heat exchanger cores of a second type;

FIG. 5 illustrates a heat exchanger core of a first type;

FIG. 6 illustrates a heat exchanger core of a second type;

FIG. 7 illustrates two plates of a plate pair;

FIG. 8 illustrates three plates of a plate group;

FIG. 9 illustrates a number of plate pairs;

FIG. 10 illustrates a number of plates and a detail of a plate;

FIG. 11
a illustrates a plate in detail;

FIG. 11
b illustrates a plate in a detail;

FIG. 11
c illustrates a pair of plates of a plate group in a detail;

FIG. 11
d illustrates a pair of plates of a plate group in a detail;

FIG. 12 illustrates an arrangement of plate pairs and plate groups in a view;

FIG. 13 illustrates an arrangement of plate pairs with plate groups in a view from the opposite side;

FIG. 14 illustrates an arrangement of plate pairs and plate groups in a sectional cut through the plate pairs and the plate groups;

FIG. 15 illustrates a plate with an overflow channel between adjacent passages;

FIG. 16 illustrates the plate of FIG. 15 from the back;

FIG. 17 illustrates a view of a heat exchanger;

FIG. 18 illustrates the view of plate pairs;

FIG. 19 illustrates a view of plates;

FIG. 20 illustrates a section of plates;

FIG. 21 illustrates a section of plates;

FIG. 22 illustrates a section of plate pairs;

FIG. 23 illustrates a sectional cut through the plate pairs according to FIG. 22;

FIG. 24 illustrates a sectional cut through the plate pairs according to FIG. 22;

FIG. 25 illustrates a section of plate pairs;

FIG. 26 illustrates a sectional cut through the plate pairs according to FIG. 25;

FIG. 27 illustrates a sectional cut through the plate pairs according to FIG. 25;

FIG. 28 illustrates a schematic view of a heat exchanger; and

FIG. 29 illustrates a schematic view of a plate pair.

DETAILED DESCRIPTION

FIG. 1 shows the arrangement of two heat exchanger cores 1, 2, which can be connected together to form a heat exchanger. In this case, heat exchanger core 1 has a plurality of plate pairs 3, which are arranged adjacent to one another, whereby corrugated fins 4 are arranged in free spaces between the particular adjacent plate pairs for better heat transfer during the flow of air between the particular adjacent plate pairs 3. As a feed and discharge, plates 3 at their opposite ends have connections or openings, formed as such as cups 5, 6, which are also used to connect plate pairs 3 to one another.

Heat exchanger core 2 is formed with a plurality of plate groups 7, whereby again adjacent plate groups 7 leave free spaces 8 for the flow of air, whereby a mount for corrugated fins can be provided for improved heat exchange for the flow of air.

FIG. 1 thus shows an arrangement of two heat exchanger cores 1, 2, whereby first heat exchanger core 1 is a heat exchanger core of a first type, formed with a plurality of pairs of plates to create a plurality of parallel flow paths between the pairs of plates. Within the plate pairs, a flow path is created for a fluid to flow through the plate, whereby entry and exit of the fluid into the plate or out of the plate is permitted through a connecting opening formed by a cup in the plate.

Second heat exchanger core 2 is a heat exchanger core of the second type, which is formed with a plurality of groups of three plates to create a plurality of two parallel flow paths, whereby in each case a flow path is formed between two of the three plates. To this end, the plate groups at their two opposite ends each have two connecting openings for an inlet and outlet for a first and/or a second fluid, so that either two different fluids can flow through this heat exchanger core 2 in the particular different flow channels, or also in a different application a fluid can flow in different flow paths in two flows through the heat exchanger core, whereby at one of the two heat exchanger core ends a redirection of the fluid from the one flow path to the other flow path is then provided. Said redirection is not shown in FIG. 1, however. In this regard, reference is made to FIGS. 15 and 16, which show a plate 200, where an overflow channel is provided as redirection between cups 201. Inlets and outlets in second heat exchanger core 2 are evident in the circular or substantially circular openings 10, 11, which are arranged at the top or bottom end region of the particular plate group. The plurality of adjacent plate groups form an inlet and outlet distribution channel via cup-shaped openings 10, 11 as connecting regions, so that a fluid flowing into the heat exchanger core through opening 10, 11 and the corresponding cup can be distributed over the length of the heat exchanger core before it can flow through the flow channels along the heat exchanger plate group, before it is again collected at the opposite end in the area of the cup connection, before the fluid can be conveyed out of the heat exchanger. This applies both to the flow channel between the first and the second plate and between the second and third plate. It is evident that opening 10 is adjacent to opening 11 and has a smaller cross section, so that different flow rates for the different media can be realized throughout. However, in a further exemplary embodiment it can also be expedient if openings 10, 11 of the flow paths are of the same size.

FIG. 2 shows the arrangement of the two heat exchanger cores 1, 2 in an arrangement in which the heat exchanger cores are connected to one another, whereby a heat exchanger is produced that has a first core with a plurality of parallel flow paths, and has a second core with a plurality of two adjacent flow paths.

Such a heat exchanger according to FIG. 2 can be used, for example, as a storage evaporator, whereby a first flow path 12 between opening 5 and opening 6 is used as a refrigerant flow path and then a redirection occurs to opening 11 as an inlet, so that the refrigerant can flow through the flow path between the two openings 11, 11a as connections and then can leave the evaporator. Flow path 13 can be used between the openings as connections 10, 10a as the storage medium flow path, so that during normal operation of the evaporator the storage medium in this flow path is cooled and in case that the refrigerant circuit of the climate control system is in a start/stop situation, for example, the flowing air, indicated by arrow 14, is cooled further by the heat exchange between the storage medium in flow path 13, so that also during a temporary standstill phase of the refrigerant circuit of the climate control system a certain cooling capacity can still be provided during the start/stop operation.

It is advantageous, if a heat exchanger core of FIG. 1, as labeled with reference character 1, can also be used as a single heat exchanger, see FIG. 5, whereby such a heat exchanger 20 can be used, for example, as a plate evaporator in a climate control system with little available installation space. Said heat exchanger 20 as an evaporator would in fact provide only a reduced cooling capacity, but in small vehicles such as, for example, in small electric vehicles, this might be completely sufficient. Heat exchanger 20 has a core 25 of a plurality of plate pairs 26, which are arranged spaced apart from one another, so that air can flow through interspaces 24 and can be cooled thereby. The airflow direction is indicated by arrow 27. Plate pairs 26 have connections formed by cups, which are used to form the header space and are used for the mutual attachment to adjacent plate pairs. A fluid can flow into one connecting region, see arrow 21, and the fluid can flow out again from an opposite connecting region, see arrow 22. Flow path 23, formed by the plate pair and through which the fluid flows lies between the two connecting regions.

Furthermore, two such heat exchanger cores according to reference character 1 of FIG. 1 can be used in a parallel connection or in a series connection, so that, for example, a two-row evaporator unit can be formed by two heat exchanger cores of the first type. This is shown in FIG. 3. FIG. 3 shows a heat exchanger 30 made up of two heat exchanger cores 31, 32 of the first type. Each of the two heat exchanger cores 31, 32 have a plurality of plate pairs 33, 34, each of which is arranged spaced apart from one another in a row in the particular core, so that, for example, air can flow through interspaces 35, 36 between plate pairs 33, 34 and can be cooled thereby. The airflow direction is indicated by arrow 37. Plate pairs 33 have cup-shaped connections 38, 39, which are also used to form header spaces 40, 41 and are used for the mutual attachment to adjacent plate pairs. Plate pairs 34 have cup-shaped connections 42, 43, which are also used to form header spaces 44, 45 and are used for the mutual attachment to adjacent plate pairs. For example, a fluid can flow into first core 31 in a connecting region 38. The fluid flows through flow channel 46 and can leave first core 31 at 39. It is redirected in order to enter the second core at 43. Next, the fluid flows through second flow channel 47 and out of an opposite connecting region 42 again flows out of second core 32. The redirection is not shown; it can occur through a tube or the like.

Alternatively, only one heat exchanger core according to reference character 2 of FIG. 1 can be used (see FIG. 6), whereby in this case a double flow is made possible, because each plate assembly group already forms two flow paths, through which flow can occur in different flow directions, so that this represents an alternative to an evaporator, for example, which can be used when only limited installation space is available. FIG. 6 shows a heat exchanger 50 having only one heat exchanger core 51 of the second type. Heat exchanger core 51 has a plurality of plate groups 52 which are arranged spaced apart from one another in a row, so that, for example, air can flow through interspaces 53 between plate groups 52 and can be cooled thereby. The airflow direction is indicated by arrow 54. Plate pairs 52 form two parallel flow channels 55, 56, each of which is formed by two of the three plates of plate group 52.

The connections of the two flow channels or flow paths 55, 56 are formed by connections 57, 58, 59, 60, which are formed as cups, which are also used to form the particular header spaces 61, 62, 63, 64 and are used for the mutual attachment to adjacent plate pairs or plate group. In a connecting region 57 a fluid can flow into first flow channel 55, for example. The fluid then flows through flow channel 55 and as an outlet at cup 58 can leave first flow channel 55. The fluid is then redirected in order to enter second flow channel 56 at cup 59. Next, the fluid flows through second flow channel 56 from cup 59 to cup 60 and there, at the outlet located opposite to the inlet, again flows out of the second flow channel. The redirection is not shown; it can occur through a tube or the like.

Furthermore, it would be possible to combine two heat exchanger cores according to reference character 2 of FIG. 1, i.e., two heat exchanger cores of the second type, to form a heat exchanger, which provides four flow paths, therefore two flow paths per heat exchanger core, in order to also enable four flows within the provided installation space, for example. FIG. 4 shows such a heat exchanger 70, which have only one first heat exchanger core 71 of the second type and one second heat exchanger core 72 of the second type. In order to avoid repetitions, the mode of action of the two heat exchanger cores 71, 72 will be explained according to the heat exchanger core of FIG. 6. In this case, for example, a fluid flows from a first core 71 and then is redirected to a second core 72, and then flows through this second core 72, before the fluid again leaves said core 72.

FIG. 7 shows two identically formed plates 80 and 81 of a plate pair 82 and are arranged laterally reversed to one another. The two plates each have a cup 83 and an opposite cup 84, which are formed at opposite end regions of the plate. The cups point from the base surface 85 of the plate in a direction perpendicular to it, so that they protrude from base surface 85 of the plate. Furthermore, the plate has a circumferential edge 86, which projects in the direction perpendicular to the plane of plate 85, whereby edge 86 projects in the opposite direction than cup 87 or 88 of openings 83, 84. If two plates are now connected to one another, they rest against one another at circumferential edges 86 and can there be sealingly soldered together. This has the effect that between the two plates a flow channel 89 arises that is used for flow through the plate and is in fluid communication with openings 83, 84.

FIG. 8 shows a plate group with plates 90, 91, and 92. In this case, plate 90 has a base plane 93 and a correspondingly projecting circumferential edge 94, whereby openings 95 and 96 formed by circumferential cups, are provided at the two opposite ends, whereby the cups in regard to base plane 93 are embossed perpendicular thereto and project in a different direction than circumferential edge 94.

As is evident, flow channel 97 is embossed between openings 95 and is in fluid communication with them, whereby the flow channel is separated from opening 96 and is not in communication with it.

Plate 91 is formed planar and at the two opposite ends each has openings 98, 99, which are formed without cups, whereby plate 91 is also formed planar and has no embossed structures. If plate 90 is now placed on plate 91, the two plates touch in the area of circumferential edge 94 and can be connected together fluid-tight so that, on the one hand, openings 98 are aligned with openings 95 and fluid channel 97 is defined between plate 90 and plate 91, whereby openings 96 are aligned with openings 99, but are not in communication with fluid channel 97.

Plate 92 also has openings 100, 101 at its opposite ends, whereby in base area 102 of the plate a fluid channel 103 is formed which communicates with openings 101, whereby a circumferential edge 104 is formed projecting in a direction perpendicular to the plane of base surface 102, whereby openings 100 are embossed in the circumferential edge and thus are not in fluid communication with flow channel 103. Openings 100 and 101 are designed with cups projecting perpendicular to the direction of base plane 102, whereby these project toward the back in FIG. 8 and thus project opposite to circumferential edge 104.

If plate 92 is connected to plate 91, a fluid-tight connection occurs in edge region 104 between the two plates, whereby openings 99 and 101 are each aligned and create a fluid communication to fluid channel 103, and openings 98 and 100 align with one another but these openings do not have any fluid communication with fluid channel 103. If plates 90, 91, and 92 are now connected to one another, two fluid channels 97 and 103 arise, which are separated from one another by the interposition of plate 91, and which are in communication with openings for the introduction and discharge of a fluid. Thus, openings 95, 98, and 100 connect fluid channel 97 and openings 96, 99, and 101 connect fluid channel 103.

FIG. 9 shows an arrangement of a plurality of plate pairs according to FIG. 7, whereby plate pairs 110 are soldered together and then connected to one another adjacently, so that they touch in the region of projecting cups 111 and thereby define a distance between the plate pairs that is greater than the extent of the plate perpendicular to the base plane of the plate, so that a region 112 remains open between the two neighboring plates for the flow, for example, of air.

FIG. 10 shows a similar example of the arrangement of plate groups 113 according to FIG. 8, whereby these plate groups are also again connected together and adjacent plate groups come into contact with one another via projecting cups 114, 115. A free space 116 is again opened between the plate groups for the flow, for example, of air.

FIG. 11
a shows a detail of a plate 82 according to FIG. 7, as does FIG. 11b, whereby plate 82 has a planar base region 85 compared with which circumferential edge 86 projects, whereby simultaneously opening 83 has a cup 87, which projects in a different direction compared with base surface 85. This can also be readily seen in FIG. 11b, so that cup 87 in FIG. 11b projects forward compared with base surface 85, whereby circumferential edge 86 in FIG. 11b projects backwards.

A similar situation can be seen in FIGS. 11c and 11d for plates 90 and 92, whereby plate 91 cannot be seen in this view of FIGS. 11c and 11d. Plates 92 and 90 each have at their opposite ends two openings 95 and 100 or 101 and 96, whereby these openings are surrounded by cups, which project compared with base region 97 or 102 of the plates. As can be seen, flow channel 103 or flow channel 97 is in fluid communication with another opening, so that flow channel 97 is connected to opening 95, whereas flow channel 103 is connected to opening 101. If these plates are now placed one on top of the other according to FIG. 8, small openings 95, 100 can be connected to one another, while large openings 96 and 101 can be connected to one another. Fluid channels 97 or 103 are designed as to allow flow in conjunction with the particular openings, whereby the two flow channels 97 and 103 are separated from one another by the interposition of plate 91 (not shown).

FIG. 12 shows the arrangement of plate pairs and plate groups in an adjacent arrangement, whereby the plate pairs of plates 82 are arranged in the air flow direction ahead of the arrangement of the plate groups of plates 90, 91, 92.

It can be seen that flow channel 85 is exposed to the air flow first before flow occurs around flow channel 97 or flow channel 103 (not shown). FIG. 13 shows this from the other side, so that it can be seen that air first flows around flow channel 85 before it flows around flow channel 103. FIG. 14 shows this again in a sectional cut, whereby it is evident that flow channel 85 is formed by two plates 82, whereby flow channels 97 and 103 are formed by plates 90, 91, and 92, whereby the two flow channels 90 and 103 in a direction perpendicular to the air direction together only occupy the region occupied by air channel 85 of the two plates 82.

FIG. 17 shows a heat exchanger 300 with a heat exchanger core, whereby heat exchanger core 301 is formed by a plurality of plate pairs, arranged in parallel and having two plates, which by the interposition of a partition wall form two flow paths between a plate and the partition wall.

Heat exchanger 300 has a plurality of plate pairs 302, arranged adjacent to one another, whereby corrugated fins 303 are preferably arranged between the plate pairs. Each plate pair (also see FIG. 18) has two inlet openings 304, 305, 306, 307, designed as cups, at a first end region and at a second end region. In this case, a cup of an end of region 304 or 305 forms an inlet-side cup, whereby the outlet-side cup associated with flow path 308 is arranged in the other end region. Accordingly, on each side in each end region, an inlet-side and an outlet-side cup is provided as a heat exchanger inlet or outlet.

FIG. 18 to this end shows three plate pairs, shown spaced apart and having two plates and a wall inserted between them, whereby these plate pairs are arranged to form a plate packet 310.

FIG. 19 shows the arrangement of a plate pair, having plates 311 and 312, whereby plate 311 forms a flow channel 313 and plate 312 a flow channel 314. These flow channels are formed by embossings between two cups, whereby only two of the four shown cups are connected to the flow channel. Thus, cup 315 and cup 316 are connected to flow channel 313, whereby cups 317 and 318 are not connected to flow channel 313. In the case of plate 312, cup 319 and cup 320 are connected to flow channel 314, whereby cup 321 and cup 322 are not connected to the flow channel. If the two plates 311 and 312 with the interposition of wall 323 are soldered together, a fluid communication occurs between cups 315 and 321 and 316 and 322 and 318 and 319 and 317 with 320, so that cups 315, 321 are an inlet cup for flow channel 313 and cups 317 and 320 are an outlet cup. The same applies to the arrangement of flow channel 314.

FIGS. 20 and 21 show the arrangements of cups 319, 321 of FIG. 19 in an enlarged illustration, whereby cups 319 and 321 in FIG. 20 are formed separated from one another and cup 319 is in fluid communication with flow channel 314, whereas cup 321 is separated from flow channel 314. FIG. 21 also shows two cups 330 and 331, whereby between the two cups 330 a crossover 332 is provided, allowing a fluid overflow from cup 330 to cup 331.

FIG. 22 shows a plate packet with three plate pairs in a perspective illustration with only the uppermost region of plate packet 340 being shown. FIG. 23 shows a sectional cut along line 1 of FIG. 22 and FIG. 24 shows a sectional cut along line 2 of FIG. 22. It is evident that a plate pair 350, 351 each is provided with an intermediate layer 352, whereby a flow channel 353 is arranged between plates 350 and 351 on one side of partition wall 352, while a second flow channel 354 is arranged on the other side of the partition wall. This pattern repeats for each plate pair of the three shown plate pairs, so that in each case two flow channels 354, 353 are arranged between the plate pairs on both sides of partition wall 352.

FIG. 24 shows flow channels 353 and 354 likewise arranged on one side of partition wall 352. FIG. 25 shows plate packet 340, whereby FIG. 26 shows a sectional cut along line 3 of FIG. 25, and FIG. 27 a sectional cut along line 4 of FIG. 25.

In FIGS. 26 and 27 plates 350 and 351 are shown with the interposition of partition wall 352, whereby flow channels 354 and 353 can be seen. In sectional cut 3 it can be observed that the flow channels do not run over the entire width of the plate, whereas the flow channels in FIG. 27 run substantially over the entire plate. This is so because the channel course toward the cup must be reduced from the substantially full width to about half the width.

A heat exchanger, has a row of plate pairs, can be formed by the design of the plate pairs, whereby each half forms both a first flow channel connected to an inlet header or to an outlet header and a second flow channel, which is likewise provided with an inlet header and an outlet header. In this case, the cups, connected together in series, constitute the particular inlet header or outlet header. The particular plate pair has two opposite plates, whereby a partition wall or a partition sheet separating the flow channels of the particular plates from one another, is provided between the two plates. If the flow to the flow channels is a counterflow, the partition sheet is used to separate the opposite fluid flows through the flow channels, whereby the cups of the individual plate pairs, arranged in series to one another, form the fluid inlet header or the fluid outlet header.

FIG. 28 shows the schematic arrangement of plate pairs 400, 401, having an inflow-side cup 402 and an outflow-side cup 403. The fluid flow occurs from the inlet-side cup 402 through flow channel 401 to a passover 404, from where the fluid can flow into second flow channel 400, in order to flow to cup 403. This is carried out with the plate pairs arranged next to one another in rows, whereby the two flow channels 400 and 401 can be operated in counterflow to one another.

FIG. 29 shows this in an enlarged illustration. Plate pair 401, 400 is provided with fins 405 on both sides for the flow of air.

The invention relates to a heat exchanger with an internally integrated heat transfer with two flow channels operated in counterflow in a tube.

The configuration of a heat exchanger in a plate design is described below; alternatively embodiments such as, e.g., those with a flat tube design are also possible.

The heat exchanger has a row of plate pairs, half of which in each case have both a first flow channel connected to the inlet header or cup and a second flow channel connected to the outlet header or cup. The plate pair is again made up of two opposite plates and a partition sheet located between them. The partition sheet is used to separate the opposite fluid flows; the connected cups of the plate pairs, arranged in series, on the one hand, form the fluid inlet header for distributing the fluid to the individual first flow channels and, on the other, the fluid outlet header for collecting the fluid from the individual two flow channels.

The two plates 311, 312 differ only in the transition region between the plate channel and cups; in fluid inlet plate 311 a flow connection is embossed between flow channel 313 and the fluid inlet cup, whereby in the case of fluid plate 312 a connection between flow channel 314 and the fluid outlet cup exists.

These connection embossings can be carried out alternately in the plate tool and thus both plates can be produced in one and the same tool with an interchangeable set. This reduces the tool costs and increases the number of identical parts.

The flow through the above-described heat exchanger is such that a fluid such as, for example, a refrigerant or coolant, etc., flows in over the first header as the inlet header, e.g., on the top block side into the first plate channel half 311, then is conveyed via a connecting element between the two opposite headers, designated as the inlet header and outlet header at the lower block side, into the second plate channel half 312, flows through it, and then again flows out of this second channel half via the second header, then again designated as an outlet header on the top block side.

The advantage of this type of flow is the homogenization of the temperature profile, e.g., as an evaporator, by an equalization of the different temperatures of the opposite fluid flows based on the heat transfer between the two channel halves, on the one hand, and by an equalization of the temperature of the air flowing around the two channel halves, on the other.

The connecting elements between the two opposite headers on the bottom block side can be a separate connecting part or can also be in a side part with an integrated redirection channel, or the like.

In the case of a two-block connection, the fluid is simultaneously distributed via the inlet header to all first plate channel halves 311, arranged in parallel, and is distributed further after the redirection by means of the connecting element to all second plate channel halves 312.

In a multiblock connection, the fluid is distributed simultaneously only to a certain number of first plate channel halves 311, arranged in parallel, after which the fluid passover occurs from one header to the neighboring header directly in the plates, e.g., over embossed connecting channels between the adjacent header cups of a plate, before—after flowing through the second plate channel halves 312—the fluid is conveyed further into the next block, and there the same distribution process continues as in the first block.

The flow channel exchanger, such as particularly the plate evaporator, alternatively can also be of a single-tank design, i.e., with only one tank on one side of the heat exchanger.

The interconnection of the individual modules can vary, depending on the arrangement and/or embodiment.

A pressure drop is produced in the evaporator depending on the mass flow or operating point.

Depending on the pressure drop, different absolute pressures arise and thereby different evaporation pressures between the evaporator inlet and outlet.

This may cause the evaporation temperature at the evaporator inlet at great pressure drops to be much higher than the temperature associated with the evaporation pressure at the outlet. Depending on the arising pressure drop across the heat exchanger, this leads to a temperature response of the evaporating refrigerant. In addition, overheating of the refrigerant at the end of the evaporation at the evaporator outlet is desirable in order to produce a stable overheating signal at the injection valve (e.g., 5K).

However, this creates local hot zones in the evaporator, which can be homogenized by suitable measures, such as, e.g., multiple interconnections one after the other in the air direction.

By integration of an inner heat transfer surface in the evaporator over substantially the entire height, local hot zones between the evaporator inlet and outlet can be minimized.

A stable overheating in the counterflowing refrigerant at the outlet can be produced between the incoming refrigerant by the heat transfer at the integrated inner heat transfer surface. Because of the much greater heat transfer, this occurs in a much smaller section of the evaporator than in conventional systems with multiple connections.

The temperature of the flowing refrigerant through the evaporator reaches a lower average temperature level much quicker and the overheating zone in the evaporator can be reduced to a minimum. This results in a high driving average temperature gradient and an increase in performance associated therewith.

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.

	Number	Date	Country
Parent	PCT/EP2012/076859	Dec 2012	US
Child	14319047		US

KIT FOR A HEAT EXCHANGER, A HEAT EXCHANGER CORE, AND HEAT EXCHANGER

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