EP1690056B1 - Heat exchanger, in particular for motor vehicles - Google Patents

Heat exchanger, in particular for motor vehicles Download PDF

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Publication number
EP1690056B1
EP1690056B1 EP04765229.2A EP04765229A EP1690056B1 EP 1690056 B1 EP1690056 B1 EP 1690056B1 EP 04765229 A EP04765229 A EP 04765229A EP 1690056 B1 EP1690056 B1 EP 1690056B1
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EP
European Patent Office
Prior art keywords
heat exchanger
tubes
tube
housing
medium
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP04765229.2A
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German (de)
French (fr)
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EP1690056A1 (en
Inventor
Claus Augenstein
Karsten Emrich
Daniel Hendrix
Frank von Lützau
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Mahle Behr GmbH and Co KG
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Behr GmbH and Co KG
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Publication of EP1690056A1 publication Critical patent/EP1690056A1/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
    • F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
    • F28F21/081—Heat exchange elements made from metals or metal alloys
    • F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
    • F28D7/1684—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation the conduits having a non-circular cross-section
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F7/00—Elements not covered by group F28F1/00, F28F3/00 or F28F5/00
    • F28F7/02—Blocks traversed by passages for heat-exchange media
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
    • F28D2021/0082—Charged air coolers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes

Definitions

  • the invention relates to a heat exchanger, in particular for motor vehicles for a first and a second flow medium, in particular according to the preamble of claim 1.
  • this temperature threshold up to about 260 to 270 degrees Celsius, aluminum manifolds are used for intercoolers, which are more temperature-resistant. If you want to continue to use these conventional charge air cooler, ie at increased boost pressures and charge air temperatures, you need a pre-cooler, ie the charge air is cooled down in two stages, to preferably less than about 260 degrees through the precooler. This must therefore be particularly temperature resistant.
  • the charge air is cooled in the intercooler of motor vehicles usually by ambient air, wherein the intercooler is arranged in the front engine compartment of the motor vehicle in the region of a coolant / air cooler.
  • the coolant of the cooling circuit of the internal combustion engine cools the charge air.
  • a disadvantage of known charge air coolers is the deflection of the charge air in the air boxes, which leads to a pressure drop.
  • Other constructions, z. B. plate or stacked disk heat exchanger according to DE-A 195 11 991 have due to the double 90 degree deflection of the charge air on an increased pressure loss.
  • the tube bundle and one of the two tubesheets are integrally formed and produced by the extrusion molding method known per se.
  • Extrusion molding is a known technology, similar to extrusion and extrusion, with a blank being forced through a forming die (see FIG. Dubbel, paperback for mechanical engineering, 20th edition, S30).
  • the material used is preferably an aluminum extrusion alloy which is particularly suitable for extrusion.
  • the product thus produced by extrusion is a finished tube sheet, to which all tubes of the tube bundle connect seamlessly and in one piece.
  • the remaining parts such as the second tube sheet, the housing and the connecting pieces are made of aluminum materials and are conventionally connected to the extrusion, z. B. by soldering or welding. It is also advantageous that any pipe cross section, be it produced in round or square shape by the extrusion. It is also advantageous that the tubes of the tube bundle can be produced in any length and wall thickness. The temperature resistance is also achieved by a low-stress geometry of the Ganzaluminium Anlagenübertragers invention.
  • the housing is produced by extrusion, d. H. in one operation with the tubesheet and the tube bundle.
  • the transition region between the tubes and the tubesheets is designed round, ie provided with a radius.
  • the transition radius is preferably arranged on the tube outer side, but can also be provided in the inflow region of the tube on the tube plate. The latter would further reduce the primary-side pressure drop.
  • the heat exchanger according to the invention is used as a charge air cooler for internal combustion engines of motor vehicles, as a pre or intercooler of a charging system.
  • a charge air cooler for internal combustion engines of motor vehicles as a pre or intercooler of a charging system.
  • Fig. 1 shows in exploded view a charge air cooler 1 for an internal combustion engine, not shown, of a motor vehicle.
  • the intercooler 1 consists of the following parts, from left to right in the drawing: an inlet nozzle 2, a tube bundle 3 with tube sheet 4, designed as a housing shell, cylindrical housing 5 and an outlet nozzle 6.
  • the tube bundle 3 consists of a plurality of tubes 3a , which are formed integrally with the tube sheet 4 and each having a rectangular flow cross-section 3b.
  • the tubesheet 4 and the adjoining tubes 3a are made by extrusion, ie, a process similar to extruding or extrusion molding.
  • the starting material used is an aluminum extruded alloy, which is pressed by a die, not shown, with the geometry and the arrangement of the tubes 3a.
  • the cross section of the tubes 3a and their length and wall thickness can be freely selected by the extrusion process or the corresponding die.
  • the tubes 3a are thus firmly and tightly connected to the tubesheet 4 and require no post-treatment in principle.
  • the tube bundle 3 has a side facing away from the tube bottom 4 end face 3c, which is provided in a conventional manner with a second tube plate, not shown. All parts, preferably made of aluminum alloys exist are soldered together to form a complete heat exchanger.
  • the housing shell 5 has on its circumference an inlet nozzle 7 and this diagonally opposite to an outlet nozzle 8 - thus, a cooling chamber 9 is formed between the two tube sheets and the housing shell 5, which can be flowed through by the coolant of a non-illustrated cooling circuit of the internal combustion engine.
  • the coolant thus flows between the tubes 3a and around the tube bundle 3.
  • the hot charge air represented by an arrow LL, enters into the inlet connection 2, which is designed in the manner of a diffuser and thus distributes the charge air evenly to the surface of the tube bottom 4 and the individual tube cross-sections 3b.
  • the charge air flows through all the tubes 3a of the tube bundle 3 and exits on the opposite side 3c from the tube bundle 3 and into the outlet nozzle 6.
  • the fully assembled intercooler 1 is inserted into a charge air line, not shown, which is flush with the inlet nozzle 2 and the outlet nozzle 6.
  • the intercooler 1 is thus rectilinear, ie flows through the charge air without deflections, which has a low pressure loss result.
  • Fig. 2 shows a further embodiment of the invention, namely a charge air cooler 10 with a housing 11 which is integrally formed with a tubesheet 12 by extrusion, with the tubesheet 12, a non-visible tube bundle, represented by a dashed tube 13, integrally formed and also by extrusion is made.
  • a non-visible tube bundle represented by a dashed tube 13
  • three components or assemblies namely tube bundle, tubesheet and housing in one step by extrusion are made in one piece.
  • a conventionally manufactured tube sheet 14 is placed, which is connected to both the tubes 13 and the housing 14 and thus forms a cooling chamber for the coolant within the housing 11.
  • an inlet nozzle 15 and an outlet nozzle 16 are used, which are connected to the housing shell 11. All parts are made of aluminum alloys and are preferably soldered together.
  • the intercooler 1, 10 according to Fig. 1 and Fig. 2 are preferably used as pre-cooler or intercooler in a charging system for an internal combustion engine. Both intercoolers are all-aluminum radiators and thus withstand charge air temperatures of up to more than 300 degrees Celsius, which is also achieved by a voltage-optimized design. In the case of pre-cooling, the charge air is pre-cooled to about 260 degrees and can then be fed to a conventional intercooler for further cooling.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Description

Die Erfindung betrifft einen Wärmeübertrager, insbesondere für Kraftfahrzeuge für ein erstes und ein zweites Strömungsmedium insbesondere nach dem Oberbegriff des Patentanspruches 1.The invention relates to a heat exchanger, in particular for motor vehicles for a first and a second flow medium, in particular according to the preamble of claim 1.

Brennkraftmaschinen für Kraftfahrzeuge werden zur Erhöhung ihrer Leistung aufgeladen, wobei die Ladeluft nach ihrer Verdichtung im Lader zwecks Erhöhung des Liefergrades durch einen Ladeluftkühler gekühlt wird. Die Entwicklung moderner Verbrennungsmotoren geht in Richtung höherer Leistung und dabei auch in Richtung höherer Ladedrücke, was insbesondere durch verbesserte Lader, z. B. so genannte VTG-Lader (variable Turbinengeometrie) möglich wird. Teilweise erfolgt auch eine zweistufige Aufladung, wobei zwischen beiden Stufen eine Zwischenkühlung der Ladeluft vorgesehen ist. Demnach benötigen derartige Ladeluftsysteme einen Zwischen-Ladeluftkühler. Durch die verstärkte Aufladung werden erhöhte Ladelufttemperaturen erreicht, die mit herkömmlichen Ladeluftkühlern nicht mehr beherrschbar sind. Bekannte Ladeluftkühler weisen z. T. Kunststoffsammelkästen auf, die jedoch nur bis zu Temperaturen von ca. 200 Grad Celsius einsetzbar sind. Oberhalb dieser Temperaturschwelle bis zu etwa 260 bis 270 Grad Celsius werden Aluminium-Sammelkästen für Ladeluftkühler verwendet, die temperaturbeständiger sind. Will man diese herkömmlichen Ladeluftkühler weiter verwenden, d. h. bei erhöhten Ladedrücken und Ladelufttemperaturen, benötigt man einen Vorkühler, d. h. die Ladeluft wird in zwei Stufen heruntergekühlt, und zwar auf vorzugsweise unter etwa 260 Grad durch den Vorkühler. Dieser muss daher besonders temperaturbeständig sein.Internal combustion engines for motor vehicles are charged to increase their power, the charge air is cooled after its compression in the loader in order to increase the degree of delivery by a charge air cooler. The development of modern internal combustion engines goes in the direction of higher power and also in the direction of higher boost pressures, which in particular by improved loader, z. B. so-called VTG loader (variable turbine geometry) is possible. In some cases, there is also a two-stage charging, between two stages, an intermediate cooling of the charge air is provided. Accordingly, such charge air systems require an intermediate intercooler. Increased charging results in increased charge air temperatures that are no longer manageable with conventional intercoolers. Known intercoolers have z. T. plastic collection boxes, which, however, can only be used up to temperatures of about 200 degrees Celsius. Above this temperature threshold, up to about 260 to 270 degrees Celsius, aluminum manifolds are used for intercoolers, which are more temperature-resistant. If you want to continue to use these conventional charge air cooler, ie at increased boost pressures and charge air temperatures, you need a pre-cooler, ie the charge air is cooled down in two stages, to preferably less than about 260 degrees through the precooler. This must therefore be particularly temperature resistant.

Die Ladeluft wird im Ladeluftkühler von Kraftfahrzeugen in der Regel durch Umgebungsluft gekühlt, wobei der Ladeluftkühler im vorderen Motorraum des Kraftfahrzeuges im Bereich eines Kühlmittel/Luftkühlers angeordnet ist. Teilweise sind jedoch auch Ladeluftkühler mit Flüssigkeitskühlung im Einsatz, wobei das Kühlmittel des Kühlkreislaufes der Brennkraftmaschine die Ladeluft kühlt. Nachteilig bei bekannten Ladeluftkühlem (vgl. DE-A 199 53 787 und DE-A 199 53 785 ) ist die Umlenkung der Ladeluft in den Luftkästen, was zu einem Druckverlust führt. Auch andere Bauweisen, z. B. Plattenoder Stapelscheibenwärmeübertrager gemäß DE-A 195 11 991 weisen infolge der zweifachen 90 Grad-Umlenkung der Ladeluft einen erhöhten Druckverlust auf.The charge air is cooled in the intercooler of motor vehicles usually by ambient air, wherein the intercooler is arranged in the front engine compartment of the motor vehicle in the region of a coolant / air cooler. However, sometimes intercooler with liquid cooling in use, the coolant of the cooling circuit of the internal combustion engine cools the charge air. A disadvantage of known charge air coolers (see. DE-A 199 53 787 and DE-A 199 53 785 ) is the deflection of the charge air in the air boxes, which leads to a pressure drop. Other constructions, z. B. plate or stacked disk heat exchanger according to DE-A 195 11 991 have due to the double 90 degree deflection of the charge air on an increased pressure loss.

Auf dem Gebiet der Abgaswärmeübertrager wurden Bauweisen bekannt, bei welchen der Druckverlust auf der Primärseite durch Vermeidung von Umlenkungen reduziert wurde, z. B. durch die DE-A 199 07 163 der Anmelderin oder die WO 00/26514 . Diese Wärmeübertrager weisen jeweils Rohrbündel, Rohrböden, Gehäuse und Abgasstutzen auf, die miteinander verlötet oder verschweißt sind. Dies bedeutet eine Vielzahl von Teilen und eine Vielzahl von Fertigungsschritten, d. h. erhöhte Herstellkosten.In the field of exhaust gas heat exchanger constructions have been known in which the pressure drop on the primary side has been reduced by avoiding deflections, z. B. by the DE-A 199 07 163 the applicant or the WO 00/26514 , These heat exchangers each have tube bundles, tube sheets, housings and exhaust gas nozzles, which are soldered or welded together. This means a variety of parts and a variety of manufacturing steps, ie increased production costs.

Es ist Aufgabe der vorliegenden Erfindung, einen Wärmeübertrager der eingangs genannten Art zu schaffen, der eine Temperaturbeständigkeit bis etwa 300 Grad Celsius und gegebenenfalls darüber und einen vorzugsweise relativ niedrigen Druckabfall auf der Gasseite aufweist sowie vorzugsweise mit geringen Kosten herstellbar ist.It is an object of the present invention to provide a heat exchanger of the type mentioned, which has a temperature resistance up to about 300 degrees Celsius and optionally above and a preferably relatively low pressure drop on the gas side and is preferably produced at low cost.

Diese Aufgabe wird durch die Merkmale des Patentanspruches 1 gelöst. Erfindungsgemäß ist vorgesehen, dass das Rohrbündel und einer der beiden Rohrböden einstückig ausgebildet und durch das an sich bekannte Fließpressverfahren herstellbar sind. Das Fließpressen ist eine bekannte Technologie, ähnlich dem Extrudieren und Strangpressen, wobei ein Rohteil durch ein formgebendes Werkzeug (Matrize) hindurchgedrückt wird (vgl. Dubbel, Taschenbuch für den Maschinenbau, 20. Auflage, S30). Als Werkstoff wird bevorzugt eine Aluminiumstrangpresslegierung verwendet, die sich für das Fließpressen besonders eignet. Das dermaßen durch Fließpressen hergestellte Erzeugnis ist ein fertiger Rohrboden, an welchen sich sämtliche Rohre des Rohrbündels nahtlos und einstückig anschließen. Damit wird der Vorteil erreicht, dass erstens das separate Herstellen des Rohrbodens und der Rohre sowie zweitens die aufwendige Verbindung zwischen Rohren und Rohrböden, z. B. Schweißen oder Löten entfallen. Damit werden die Herstellkosten erheblich reduziert. Die übrigen Teile wie der zweite Rohrboden, das Gehäuse und die Anschlussstutzen bestehen aus Aluminiumwerkstoffen und werden konventionell mit dem Fließpressteil verbunden, z. B. durch Löten oder Schweißen. Vorteilhaft ist ferner, dass jeder beliebige Rohrquerschnitt, sei es in runder oder eckiger Form durch das Fließpressen herstellbar ist. Ferner ist von Vorteil, dass die Rohre des Rohrbündels in beliebiger Länge und Wandstärke herstellbar sind. Die Temperaturfestigkeit wird auch durch eine spannungsarme Geometrie des erfindungsgemäßen Ganzaluminiumwärmeübertragers erreicht.This object is solved by the features of claim 1. According to the invention it is provided that the tube bundle and one of the two tubesheets are integrally formed and produced by the extrusion molding method known per se. Extrusion molding is a known technology, similar to extrusion and extrusion, with a blank being forced through a forming die (see FIG. Dubbel, paperback for mechanical engineering, 20th edition, S30). The material used is preferably an aluminum extrusion alloy which is particularly suitable for extrusion. The product thus produced by extrusion is a finished tube sheet, to which all tubes of the tube bundle connect seamlessly and in one piece. Thus, the advantage is achieved that, firstly, the separate production of the tube plate and the tubes, and second, the complex connection between pipes and tube sheets, for. As welding or soldering omitted. This considerably reduces the production costs. The remaining parts such as the second tube sheet, the housing and the connecting pieces are made of aluminum materials and are conventionally connected to the extrusion, z. B. by soldering or welding. It is also advantageous that any pipe cross section, be it produced in round or square shape by the extrusion. It is also advantageous that the tubes of the tube bundle can be produced in any length and wall thickness. The temperature resistance is also achieved by a low-stress geometry of the Ganzaluminiumwärmeübertragers invention.

Nach einer vorteilhaften Ausgestaltung der Erfindung ist auch das Gehäuse durch Fließpressen herstellbar, d. h. in einem Arbeitsgang mit dem Rohrboden und dem Rohrbündel. Damit wird der Vorteil einer weiteren Herstellungsvereinfachung und Kostenreduzierung des erfindungemäßen Wärmeübertragers erreicht. Mit dem Fließteil werden zur Komplettierung des Wärmeübertragers nur noch der zweite Rohrboden und die Anschlussstutzen verbunden.According to an advantageous embodiment of the invention, the housing is produced by extrusion, d. H. in one operation with the tubesheet and the tube bundle. Thus, the advantage of further manufacturing simplification and cost reduction of erfindungemäßen heat exchanger is achieved. With the flow part, only the second tubesheet and the connecting pieces are connected to complete the heat exchanger.

Nach einer vorteilhaften Ausgestaltung der Erfindung ist der Übergangsbereich zwischen den Rohren und den Rohrböden rund gestaltet, d. h. mit einem Radius versehen. Damit werden der Vorteil einer erhöhten Festigkeit durch einen günstigen Faserverlauf und der Vorteil eines besseren Fließverhaltens des Materials erreicht. Der Übergangsradius ist vorzugsweise auf der Rohraußenseite angeordnet, kann jedoch auch im Einströmbereich des Rohres am Rohrboden vorgesehen werden. Letzteres würde den primärseitigen Druckabfall weiter verringern.According to an advantageous embodiment of the invention, the transition region between the tubes and the tubesheets is designed round, ie provided with a radius. Thus, the advantage of increased strength achieved by a favorable fiber flow and the advantage of better flow behavior of the material. The transition radius is preferably arranged on the tube outer side, but can also be provided in the inflow region of the tube on the tube plate. The latter would further reduce the primary-side pressure drop.

Nach einer weiteren vorteilhaften Ausgestaltung der Erfindung wird der erfindungsgemäße Wärmeübertrager als Ladeluftkühler für Verbrennungsmotoren von Kraftfahrzeugen eingesetzt, und zwar als Vor- oder Zwischenkühler eines Aufladesystems. Damit ist eine kostengünstige Lösung geschaffen, die auch bei hohen Aufladedrücken und dementsprechend hohen Temperaturen eine wirksame Kühlung der Ladeluft erlaubt und gleichzeitig die Weiterverwendung konventioneller Ladeluftkühler ermöglicht.According to a further advantageous embodiment of the invention, the heat exchanger according to the invention is used as a charge air cooler for internal combustion engines of motor vehicles, as a pre or intercooler of a charging system. For a cost-effective solution is created, which allows effective cooling of the charge air even at high Aufladedrücken and correspondingly high temperatures and at the same time allows the further use of conventional intercooler.

Ausführungsbeispiele der Erfindung sind in der Zeichnung dargestellt und werden im Folgenden näher beschrieben. Es zeigen

Fig. 1
ein erstes Ausführungsbeispiel der Erfindung mit fließgepresstem Rohrboden und Rohrbündel und
Fig. 2
ein zweites Ausführungsbeispiel der Erfindung mit fließgepresstem Rohrboden, Rohrbündel und Gehäuse.
Embodiments of the invention are illustrated in the drawings and will be described in more detail below. Show it
Fig. 1
a first embodiment of the invention with extruded tube plate and tube bundle and
Fig. 2
A second embodiment of the invention with extruded tube plate, tube bundle and housing.

Fig. 1 zeigt in Explosivdarstellung einen Ladeluftkühler 1 für eine nicht dargestellte Brennkraftmaschine eines Kraftfahrzeuges. Der Ladeluftkühler 1 besteht aus folgenden Teilen, von links nach rechts in der Zeichnung: ein Eintrittsstutzen 2, ein Rohrbündel 3 mit Rohrboden 4, ein als Gehäusemantel ausgebildetes, zylinderförmiges Gehäuse 5 und ein Austrittsstutzen 6. Das Rohrbündel 3 besteht aus einer Vielzahl von Rohren 3a, welche einstückig mit dem Rohrboden 4 ausgebildet sind und jeweils einen rechteckförmigen Strömungsquerschnitt 3b aufweisen. Der Rohrboden 4 und die sich daran anschließenden Rohre 3a sind durch Fließpressen hergestellt, d. h. ein dem Extrudieren oder Strangpressen ähnliches bekanntes Verfahren. Als Ausgangswerkstoff wird eine Aluminiumstrangpresslegierung verwendet, welche durch eine nicht dargestellte Matrize mit der Geometrie und der Anordnung der Rohre 3a gedrückt wird. Der Querschnitt der Rohre 3a sowie deren Länge und Wandstärke sind durch das Fließpressverfahren bzw. die entsprechende Matrize frei wählbar. Die Rohre 3a sind somit fest und dicht mit dem Rohrboden 4 verbunden und bedürfen prinzipiell keiner Nachbehandlung. Das Rohrbündel 3 weist eine dem Rohrboden 4 abgewandte Stirnseite 3c auf, welche auf konventionelle Art mit einem zweiten nicht dargestellten Rohrboden versehen wird. Alle Teile, die vorzugsweise aus Aluminiumlegierungen bestehen, werden miteinander zu einem kompletten Wärmeübertrager verlötet. Der Gehäusemantel 5 weist auf seinem Umfang einen Eintrittsstutzen 7 und diesem diagonal gegenüber einen Austrittsstutzen 8 auf - somit wird zwischen den beiden Rohrböden und dem Gehäusemantel 5 eine Kühlkammer 9 gebildet, die vom Kühlmittel eines nicht dargestellten Kühlkreislaufes der Brennkraftmaschine durchströmbar ist. Das Kühlmittel strömt somit zwischen den Rohren 3a und um das Rohrbündel 3 herum. Die heiße Ladeluft, dargestellt durch einen Pfeil LL, tritt in den Eintrittsstutzen 2 ein, der diffusorartig ausgebildet ist und die Ladeluft somit gleichmäßig auf die Fläche des Rohrbodens 4 und die einzelnen Rohrquerschnitte 3b verteilt. Die Ladeluft durchströmt sämtliche Rohre 3a des Rohrbündels 3 und tritt auf der gegenüberliegenden Seite 3c aus dem Rohrbündel 3 aus und in den Austrittsstutzen 6 ein. Der fertig montierte Ladeluftkühler 1 ist in eine nicht dargestellte Ladeluftleitung eingesetzt, welche sich bündig an den Eintrittsstutzen 2 und den Austrittsstutzen 6 anschließt. Der Ladeluftkühler 1 wird somit geradlinig, d. h. ohne Umlenkungen von der Ladeluft durchströmt, was einen geringen Druckverlust zur Folge hat. Fig. 1 shows in exploded view a charge air cooler 1 for an internal combustion engine, not shown, of a motor vehicle. The intercooler 1 consists of the following parts, from left to right in the drawing: an inlet nozzle 2, a tube bundle 3 with tube sheet 4, designed as a housing shell, cylindrical housing 5 and an outlet nozzle 6. The tube bundle 3 consists of a plurality of tubes 3a , which are formed integrally with the tube sheet 4 and each having a rectangular flow cross-section 3b. The tubesheet 4 and the adjoining tubes 3a are made by extrusion, ie, a process similar to extruding or extrusion molding. The starting material used is an aluminum extruded alloy, which is pressed by a die, not shown, with the geometry and the arrangement of the tubes 3a. The cross section of the tubes 3a and their length and wall thickness can be freely selected by the extrusion process or the corresponding die. The tubes 3a are thus firmly and tightly connected to the tubesheet 4 and require no post-treatment in principle. The tube bundle 3 has a side facing away from the tube bottom 4 end face 3c, which is provided in a conventional manner with a second tube plate, not shown. All parts, preferably made of aluminum alloys exist are soldered together to form a complete heat exchanger. The housing shell 5 has on its circumference an inlet nozzle 7 and this diagonally opposite to an outlet nozzle 8 - thus, a cooling chamber 9 is formed between the two tube sheets and the housing shell 5, which can be flowed through by the coolant of a non-illustrated cooling circuit of the internal combustion engine. The coolant thus flows between the tubes 3a and around the tube bundle 3. The hot charge air, represented by an arrow LL, enters into the inlet connection 2, which is designed in the manner of a diffuser and thus distributes the charge air evenly to the surface of the tube bottom 4 and the individual tube cross-sections 3b. The charge air flows through all the tubes 3a of the tube bundle 3 and exits on the opposite side 3c from the tube bundle 3 and into the outlet nozzle 6. The fully assembled intercooler 1 is inserted into a charge air line, not shown, which is flush with the inlet nozzle 2 and the outlet nozzle 6. The intercooler 1 is thus rectilinear, ie flows through the charge air without deflections, which has a low pressure loss result.

Fig. 2 zeigt ein weiteres Ausführungsbeispiel der Erfindung, nämlich einen Ladeluftkühler 10 mit einem Gehäuse 11, welches einstückig mit einem Rohrboden 12 durch Fließpressen hergestellt ist, wobei mit dem Rohrboden 12 ein nicht sichtbares Rohrbündel, dargestellt durch eine gestricheltes Rohr 13, einstückig ausgebildet und ebenfalls durch Fließpressen hergestellt ist. Somit sind bei diesem Ausführungsbeispiel drei Bauteile bzw. Baugruppen, nämlich Rohrbündel, Rohrboden und Gehäuse in einem Verfahrensschritt durch Fließpressen einstückig hergestellt. Auf das nicht sichtbare, stromabwärtige Ende des Rohrbündels 13 wird ein konventionell gefertigter Rohrboden 14 aufgesetzt, der sowohl mit den Rohren 13 als auch mit dem Gehäuse 14 verbunden wird und somit innerhalb des Gehäuse 11 eine Kühlkammer für das Kühlmittel bildet. Wie beim Ausführungsbeispiel gemäß Fig. 1 werden in das einlass- und das auslassseitige Ende des Gehäuses 11 ein Eintrittsstutzen 15 und ein Austrittsstutzen 16 eingesetzt, welche mit dem Gehäusemantel 11 verbunden werden. Sämtliche Teile bestehen aus Aluminiumlegierungen und werden vorzugsweise miteinander verlötet. Fig. 2 shows a further embodiment of the invention, namely a charge air cooler 10 with a housing 11 which is integrally formed with a tubesheet 12 by extrusion, with the tubesheet 12, a non-visible tube bundle, represented by a dashed tube 13, integrally formed and also by extrusion is made. Thus, in this embodiment, three components or assemblies, namely tube bundle, tubesheet and housing in one step by extrusion are made in one piece. On the invisible, downstream end of the tube bundle 13, a conventionally manufactured tube sheet 14 is placed, which is connected to both the tubes 13 and the housing 14 and thus forms a cooling chamber for the coolant within the housing 11. As in the embodiment according to Fig. 1 In the inlet and the outlet end of the housing 11, an inlet nozzle 15 and an outlet nozzle 16 are used, which are connected to the housing shell 11. All parts are made of aluminum alloys and are preferably soldered together.

Die Ladeluftkühler 1, 10 gemäß Fig. 1 und Fig. 2 werden vorzugsweise als Vorkühler oder Zwischenkühler in einem Aufladesystem für eine Brennkraftmaschine eingesetzt. Beide Ladeluftkühler sind Ganzaluminiumkühler und halten somit Ladelufttemperaturen bis zu über 300 Grad Celsius stand, was auch durch eine spannungsoptimierte Bauweise erreicht wird. Im Falle der Vorkühlung wird die Ladeluft auf ca. 260 Grad vorgekühlt und kann dann einem konventionellen Ladeluftkühler zur weiteren Abkühlung zugeführt werden. The intercooler 1, 10 according to Fig. 1 and Fig. 2 are preferably used as pre-cooler or intercooler in a charging system for an internal combustion engine. Both intercoolers are all-aluminum radiators and thus withstand charge air temperatures of up to more than 300 degrees Celsius, which is also achieved by a voltage-optimized design. In the case of pre-cooling, the charge air is pre-cooled to about 260 degrees and can then be fed to a conventional intercooler for further cooling.

Claims (14)

  1. A heat exchanger, in particular for motor vehicles, for a first flow medium and a second flow medium, having a tube bundle (3) which includes a multiplicity of tubes (3a), a first tube plate (4) and a second tube plate, a housing (5) and inlet and outlet connection pieces (2, 6) for the first flow medium, the tubes (3a) having tube ends which are held and sealed in the tube plates, and the housing (5) being connected on the one hand to the tube plates so as to form a cooling chamber (9) for the second flow medium and on the other hand at the end sides to the inlet and outlet connection pieces (2, 6), characterized in that the first tube plate (4) and the tubes (3a) are formed integrally.
  2. The heat exchanger as claimed in claim 1, characterized in that the first tube plate (12), the tubes (13) and the housing (11) are formed integrally.
  3. The heat exchanger as claimed in one of the preceding claims, characterized in that the integrally formed parts are produced by impact extrusion.
  4. The heat exchanger as claimed in one of the preceding claims, characterized in that the integrally formed parts are produced by impact extrusion, are preferably produced from an aluminum extrusion alloy.
  5. The heat exchanger as claimed in claim 1, 2, 3 or 4, characterized in that the cross section (3b) of the tubes (3a) is round, rectangular or polygonal.
  6. The heat exchanger as claimed in one of claims 1 to 5, characterized in that a rounded transition region is provided between the tubes (3a, 13) and the first tube plate (4, 12), in particular on the outer side of the tubes.
  7. The heat exchanger as claimed in one of claims 1 to 6, characterized in that the tubes (3a, 13) have fins or turbulence generators on their inner and/or outer side in order to improve the heat transfer.
  8. The heat exchanger as claimed in one of claims 1 to 7, characterized in that the inlet and outlet connection pieces (2, 6; 15, 16) and the tubes (3a, 13) of the tube bundle are arranged aligned with one another.
  9. The heat exchanger as claimed in one of claims 1 to 8, characterized in that the inlet and outlet connection pieces (2, 6; 15, 16), the second tube plate (14) and/or the housing (5) are cohesively joined to the integral, impact-extruded part (3, 4; 11, 12).
  10. The heat exchanger as claimed in one of claims 1 to 9, characterized in that the housing (5, 11) has an inlet and an outlet opening (7, 8) for the liquid flow medium.
  11. The heat exchanger as claimed in one of claims 1 to 10, characterized in that charge air can flow through the tubes (3a, 13) and coolant for an internal combustion engine of a motor vehicle can flow through the housing (5, 11).
  12. The heat exchanger as claimed in one of the preceding claims, characterized in that the first medium is a liquid or gaseous medium.
  13. The heat exchanger as claimed in one of the preceding claims, characterized in that the second medium is a liquid or gaseous medium.
  14. The use of the heat exchanger as claimed in one of claims 1 to 13 as a primary cooler or intercooler or cooler for the charge air or the exhaust gas of an internal combustion engine of a motor vehicle.
EP04765229.2A 2003-10-17 2004-09-15 Heat exchanger, in particular for motor vehicles Not-in-force EP1690056B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10349140A DE10349140A1 (en) 2003-10-17 2003-10-17 Heat exchanger, in particular for motor vehicles
PCT/EP2004/010315 WO2005038376A1 (en) 2003-10-17 2004-09-15 Heat exchanger, in particular for motor vehicles

Publications (2)

Publication Number Publication Date
EP1690056A1 EP1690056A1 (en) 2006-08-16
EP1690056B1 true EP1690056B1 (en) 2014-03-05

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Family Applications (1)

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EP04765229.2A Not-in-force EP1690056B1 (en) 2003-10-17 2004-09-15 Heat exchanger, in particular for motor vehicles

Country Status (4)

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US (1) US20070029076A1 (en)
EP (1) EP1690056B1 (en)
DE (1) DE10349140A1 (en)
WO (1) WO2005038376A1 (en)

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Also Published As

Publication number Publication date
WO2005038376A1 (en) 2005-04-28
DE10349140A1 (en) 2005-05-12
US20070029076A1 (en) 2007-02-08
EP1690056A1 (en) 2006-08-16

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