DE102011005236A1 - Header, heat exchanger and method of making a header - Google Patents

Abstract

The present invention relates to a header pipe (300) for a heat exchanger having at least one through hole (350) for receiving a coolant tube of the heat exchanger, the through hole (350) being bounded by a collar (360) extending from one to an inner wall of the heat exchanger Collector (300) turned over edge region of the manifold (300) is formed, and wherein the collar (360) rests against the inner wall.

Description

The present invention relates to a manifold for a heat exchanger, to a heat exchanger with such a manifold and to a method for producing such a manifold, which can be used for example in the vehicle sector.

When operating a battery, eg. As a lithium-ion batteries, heat loss, which leads to the heating of the battery. Especially lithium-ion batteries age much faster from a design-related temperature, so that the life of the battery can shorten undesirable. To counteract this effect, therefore, battery coolers are used.

Frequently battery cells on the bottom - arresters or connections are therefore up - cooled by means of a flat radiator or a cooling plate. The battery cooler can contain internal channels, in which a cooling medium is guided. As constructions constructions of pipes are known, which are plugged into collectors. Furthermore, there are constructions that consist of laminated sheets or embossed sheets.

To ensure a Dichtlötung between pipes and the collector, usually "passages" are introduced for the pipes in the collector. Often a collector consists of two half-shells, the bottom and the lid, as the "passages" are easier to produce.

The DE 41 30 517 A1 relates to a connection box, in particular for a coolant condenser, which is formed from a bottom part and a cover part. The bottoms of the bottom part is provided with transverse, slot-shaped passages for the flat tubes, wherein the length of the passages corresponds approximately to the distance of the legs of the bottom part.

It is the object of the present invention to provide an improved manifold for a heat exchanger, an improved heat exchanger, and an improved method of manufacturing a manifold.

This object is achieved by a manifold, a heat exchanger and a method for producing a manifold according to the main claims.

The present invention is based on a partial use of flanks of a manifold as a template for a production of passages. This makes it possible to keep a height of a battery cooler low.

According to the structural solution presented here can thus be dispensed with in a Z-direction of the manifold, which may correspond to a direction of a height of the manifold, on a die for the production of the passages. This allows the smallest possible height.

Thus, advantageously, a collector can be made, in which a "solid" collar, which can ensure a Dichtlötung of the tube in the bottom or collector, rests directly against an outer wall of the bottom or collector. Based on the fact that this construction or procedure presented here is characterized by a solid collar, can, for a given material thickness of the bottom and a height of the flat tube, a production of a particularly flat collection tube, d. H. a manifold with the lowest possible height, can be achieved.

According to the approach proposed here can thus be avoided that the die, which determines the smallest possible design of the manifold, can adversely affect the height of a desired as low as possible height.

Thus, the arrangement presented here or the method presented here allow the production of a collector with passages, for secure Dichtlötung of inserted pipes, with the lowest possible height.

The constructive solution proposed here makes it possible to produce a battery cooler composed of tubes and collectors, in which the overall height of the collector is sufficiently low so that the collector, like the tubes, also has to be arranged below the battery cells and not next to them. In this way, space can be saved.

The present invention provides a manifold for a heat exchanger having at least one passage opening for receiving a coolant tube of the heat exchanger, wherein the passage opening is defined by a collar which is formed from a folded-over to an inner wall of the manifold edge portion of the manifold, wherein the collar rests against the inner wall.

The heat exchanger can be used for example for cooling an electrochemical energy storage unit such as a lithium-ion battery. The heat exchanger can, for. B. have two manifolds between which run a plurality of coolant tubes that communicate fluidly with the collection containers. Thus, a manifold for supplying cooled Cooling fluid serve to the coolant tubes and serve the further manifold for discharging heated by a heat exchange with the electrochemical energy storage unit cooling fluid from the coolant tubes. In addition, the headers may also be used to control a direction of the flow of cooling fluid through the individual coolant tubes. The manifold can be used as an elongated container with z. B. be formed a round or rectangular cross-section. The at least one passage opening can be arranged in a longitudinal side of the manifold. In addition, the manifold may have a further opening for supplying or removing the cooling fluid to and from the manifold. The at least one passage opening may have a shape which corresponds to a circumferential contour of the coolant pipe to be accommodated. In general, the coolant tube used is fluid-tightly connected to the manifold by one end of the coolant tube is inserted into the through hole and the adjoining material areas are then fluid-tightly interconnected, for. B. by means of a welding process. To simplify and improve this connection between the manifold and the coolant tube, the collar is provided. Due to the fact that here the collar rests on the inside of the collecting tube wall, the overall height of the collecting tube, and thus of the heat exchanger in which such a collecting tube is used, can be reduced to a minimum. The passage opening can also be referred to as "passage", since the collar can be formed by means of a "pulling through" of collecting pipe material from outside to inside in the direction of a collecting tube interior.

According to one embodiment, the collecting tube may have a base element and a cover element which is connected in a fluid-tight manner to the base element. In this case, the passage opening can be arranged in the bottom element. This embodiment of a two-part construction is advantageous in that the passage opening can be made easier. Thus, at first the bottom element can be provided with at least one passage opening and subsequently the bottom element can be closed on one of the at least one passage opening opposite side with the cover element. In this case, the cover element can be pushed into the bottom element. This saves production time and costs.

According to a further embodiment, the bottom element may have a bottom element base surface and two opposing bottom element edges. The lid member may include a lid member base and two opposing lid member flanks. The cover element flanks can be arranged between the bottom element flanks and connected in a fluid-tight manner to the bottom element flanks. This is a particularly simple and inexpensive construction for the manifold, since both the floor element and the lid member inexpensive and easily available in the market and in all sizes C-profiles can be used by simply plugging together to the manifold can be joined.

For example, the bottom element flanks and the bottom element base surface and the lid element base surface may form outer walls of the collection tube. This embodiment can advantageously be made particularly quickly and inexpensively, since only the steps of joining the bottom element and the cover element and then connecting both, for. B. need to be performed by means of a simple welding process.

The collar may surround an entire circumference of the through opening. Thus, due to the material redundancy along the entire circumference of the passage opening a particularly robust and durable fluid-tight connection between the coolant tube and the manifold can be created.

According to one embodiment, the passage opening may have a rectangular shape. For example, the passage opening may be arranged such that long sides of the rectangular passage opening extend parallel to the floor element edges. This embodiment is a low height of the manifold very contrary. Furthermore, the manifold presented here is advantageously particularly universally applicable, since an outer circumference of coolant tubes used particularly frequently has a rectangular outer peripheral contour. With this design can be made particularly space-saving.

According to a further embodiment, the collecting tube may have a plurality of passage openings. These may be arranged adjacent to each other along a longitudinal extension of the bottom element base. For example, the passage openings may be arranged in a row next to each other and evenly spaced from each other in the bottom element base. Thus, advantageously, even with a low overall height of the collecting tube, a cooling fluid flow sufficient for the functionality of the heat exchanger can be ensured.

The present invention further provides a heat exchanger having the following features:
a first manifold according to one of the preceding embodiments;
a second manifold according to one of the preceding embodiments; and
at least one coolant tube, wherein the coolant tube between the first manifold and the second manifold disposed and fluid-tightly connected to the collar of the first manifold and the collar of the second manifold.

For example, the heat exchanger may include a plurality of coolant tubes arranged in parallel between the first and second manifolds. Such a heat exchanger can be used for example in an electric or hybrid vehicle for cooling the drive battery. Alternatively, only one of the collectors may be configured according to an embodiment of the present invention.

According to one embodiment, the heat exchanger has a heat exchanger surface for arranging at least one battery on the heat exchanger surface. In this case, the heat exchanger surface may extend over the at least one coolant tube, at least a portion of the first manifold and at least a portion of the second manifold. The heat exchanger surface can be formed by wall regions of the headers and wall regions of the coolant tubes. Alternatively, the heat exchanger surface may be formed by an additional plate which rests on a wall region of the collecting pipes and additionally or alternatively on wall regions of the coolant pipes. In this case, the heat exchanger surface may extend over an entire length of the coolant tube and an entire width of one or both manifolds in the direction of a longitudinal direction of the coolant tube. Accordingly, the heat exchanger surface can extend only over one of the manifolds. By the heat exchanger surface is suitable for receiving at least one battery, the at least one battery can also be arranged in the region of the headers. It can thus be used as a heat exchanger surface for battery cooling, the entire areal extent of the heat exchanger.

The present invention further provides a method of manufacturing a manifold for a heat exchanger, comprising the following steps:
Providing a bottom member for the manifold, the bottom member having a bottom member base and two opposing bottom member edges;
Providing a U-shaped female mold with two opposite legs, wherein each one inner wall of the legs has a shoulder for forming a stop surface for the bottom element flanks of the floor element;
Assembling the die and the bottom member, wherein the bottom member flanks of the bottom member come to rest against the abutment surfaces of the die;
Aligning the die and the bottom member with a cutting punch, such that the cutting punch is directed toward an outside of the bottom member base surface of the bottom member to form the at least one through hole;
Pressing the cutting punch through the bottom member base to form the at least one through hole, wherein an edge portion of the header is turned to an inner wall of the header and abuts against the inner wall; and
Removing the die and the punch from the floor element.

The method may, for example, be performed by a numerically controlled machine tool. The template can z. B. be formed of a metal with high strength. A distance between legs of the die may correspond to a distance between the bottom element flanks of the bottom element. The stop surfaces formed by the paragraphs may correspond to bearing surfaces of the bottom element edges. The cutting punch may be a tool having a sharp point that has sufficient strength to cut through the material of the bottom element base. In the step of aligning, the cutting punch may be aligned with a center of the bottom member base with respect to the bottom member edges. The pushing of the cutting punch can be done in a direction of advance to a yoke of the die out. The cutting punch may have a sufficient material thickness in order to press the folded or continuous edge region of the collecting tube against the inner wall of the collecting tube with the penetration of the base element base surface so that it comes into contact there.

According to one embodiment, the method may comprise a step of providing a cover element for the collection tube. In this case, the cover element may have a cover element base surface and two opposite cover element flanks. Furthermore, the method may include a step of inserting the cover element flanks between the bottom element flanks of the base element and the fluid-tight connection of the cover element flanks to the bottom element flanks. Advantageously, this embodiment of the method allows a particularly quick and easy production of the manifold.

Advantageous embodiments of the present invention will be explained below with reference to the accompanying drawings. Show it:

1A a schematic diagram of a method step for producing passages of a manifold;

1B a schematic diagram of a further process step for the production of passages of a manifold;

2A a schematic representation of a process step for producing passages of a manifold, according to an embodiment of the present invention;

2 B a schematic representation of a further process step for producing passages of a manifold, according to an embodiment of the present invention;

3 a perspective view of a collecting tube with low height, according to an embodiment of the present invention;

4 a sectional view of the manifold 3 with exemplary dimensions, according to an embodiment of the present invention; and

5 a flow diagram of a method for producing a header with a low profile, according to an embodiment of the present invention.

In the following description of the preferred embodiments of the present invention, the same or similar reference numerals are used for the elements shown in the various drawings and similar, and a repeated description of these elements will be omitted.

On the basis of the following figures, designs of headers or process steps for the production of such headers are presented in which the "passages" are always introduced into the "bottom" or are. This z. B. material formed by a cutting punch inside in a die. In principle, a formation of passages in a cover of a manifold can be realized. Under the passage, a passage opening is to be provided, which is characterized in that an edge region of the passage opening to the inside, here in an interior of the floor or manifold into, is bent or turned over.

Based on 1A and 1B should be explained a production of passages for pipes in the bottom of a manifold.

1A shows a schematic diagram of a process step for the production of passages or through holes of a manifold. The passages are formed in a bottom element of the manifold. 1A shows a cross-sectional view of an arrangement of a bottom element 100 a manifold, a die 110 and a cutting punch 120 , The arrangement shown in the illustration can be realized, for example, by the floor 100 with the matrix 110 clamped in a tool and opposite the stamp 120 is suitably positioned. The representation in 1A shows that both the floor element 100 as well as the matrix 110 have a U-shape. There are ground element edges 130 so on thigh of the matrix 110 plugged that floor 100 opposite the die 110 is firmly positioned. End portions of the legs of the die 110 lie on a floor element base 140 of the floor element 100 at.

1B shows one on the in 1A shown following method step for producing a bottom element with passages for a battery cooler. Here is the stamp 120 the floor element base 140 of the floor element 100 intersected. Caused by a feed direction of the cutting punch 120 towards an interior of the die 110 became an edge portion of the cut bottom sheet material corresponding to a peripheral geometry of the punch 120 around the end portions of the legs of the die 110 bent around and with into the interior of the matrix 110 drawn. Like the illustration in 1B shows, the edge region of the cut forms an inner collar around the through hole. The illustration shows that a height of the die 110 a height indicated by a double arrow 170 determined in a Z-direction of the manifold to be manufactured.

The 2A and 2 B show a production of passages for pipes in the bottom of a manifold according to an embodiment of the present invention. The representations in the 2A and 2 B correspond to those from the 1A and 1B with the difference that a differently shaped die 110 is used and the floor element 100 has a lower height. The U-shaped die used here 110 has on the inner sides of each leg each have a shoulder for the formation of stop surfaces 200 for the floor element edges 130 of the floor element 100 on. So need the bottom element edges 130 So not, as in the 1A and 1B shown on the legs of the matrix 110 but can be attached to the stop surfaces 200 to the Inner sides of the thighs are applied, as shown in the illustration in 2A easy to recognize. About the stop surfaces 200 outwardly extending inner surfaces of the legs of the die 110 lie on outer surfaces of the bottom element edges 130 at. The floor element flanks 130 can completely into the matrix 110 be introduced. End areas of the floor element edges 130 lie on the stop surfaces 200 the matrix 110 at. A height of the stop surfaces 200 may be a thickness of the floor element flanks 130 correspond.

The cutting punch 120 is opposite an outer surface of a central region of the bottom element base 140 of the floor element 100 arranged. The cutting punch 120 can be configured to only a passage in the bottom element base 140 manufacture. Alternatively, the cutting punch 120 also be formed to form a plurality of passages, or it may be a plurality of cutting punches 120 be present, each of which each one a passage in the bottom element 100 can form. The manufactured passages can lie on one line. The passages can be evenly spaced from each other.

2 B shows one on the in 2A shown following method step for producing a bottom element with passages for a battery cooler. Here is the stamp 120 the bottom element base of the floor element 100 intersected. Caused by a feed direction of the cutting punch 120 towards an interior of the die 110 became an edge portion of the cut bottom sheet material corresponding to a peripheral geometry of the punch 120 bent inwards and into an interior of the floor 100 drawn. After removal of the stamp 120 is the formation of at least one passage opening or a passage in the bottom element 100 completed.

Like the illustration in 2 B shows, forms the edge area of the through the stamp 120 formed cut an inner collar around the passage opening around. The inner collar is adjacent in an overlap region to an inside of the now shortened bottom element edges 130 at. Thus, the ground points 100 in the region of the passage opening, a thickness which consists of a thickness of the collar and a thickness of the regions of the base element flanks that overlap with the collar and are in their original position 130 is determined. Thus, the ground points 100 in the region of the passage opening, a thickness which is twice the material thickness of the bottom element flanks 130 equivalent. The illustration shows that a height of the ground 100 a height indicated by a double arrow 170 determined in a Z-direction of the manifold to be manufactured.

This construction of the die 110 makes it possible that the die legs in the formation process of the passage or openings, in particular during the formation of the collar are not in the way. So how can it in 2 B clearly shown, a significantly flatter collar area are formed. Accordingly, the height 170 of according to the basis of 2 B shown method shaped bottom element 100 lower than the one in 1B shown. On an outer surface of at least one of the bottom element flanks 130 a battery can be arranged.

3 shows a perspective view of a manifold 300 with the lowest possible height and passages for flat tubes, according to an embodiment of the present invention. The manifold 300 has one according to the in 2A and 2 B shown bottom element manufactured 100 and a lid member 310 on. This in 3 shown floor element 100 includes four rectangular shaped passages 350 of which, for the sake of clarity, only one is provided with a reference numeral. In the illustration in 3 It can be clearly seen that the respective collar 360 around the passages 350 circulating around. The passages 350 are for connecting coolant tubes in flat design to the manifold 300 suitable. The cover element 310 is like the floor element 100 formed in a U-shape, wherein a distance between outer sides of cover element flanks 320 the lid element 310 equal to or slightly smaller than a distance between inner sides of the bottom element edges 130 of the floor element is such that the cover element 310 to close the manifold 300 between the floor element flanks 130 can be inserted and welded with these to the manifold 300 complete fluid-tight.

4 shows in a cross-sectional view of the manifold 300 out 3 with exemplary dimensions. All dimensions shown are indicated by double arrows. So is a width 400 of the manifold 300 20 to 40 cm and a height 410 of the manifold 300 6.5 cm. A material thickness 420 the lid element 310 like the floor element 100 is measured at 1 cm. A distance 430 between inner sides of the bottom element flanks is 4.5 cm, and a light measure 440 of the passage 350 is 3 cm. In the illustration in 4 is the collector pipe 300 with one in the passage 350 inserted coolant tube 450 shown. The dimensions mentioned are given by way of example and can be varied.

5 shows a flowchart of a method 500 for producing a floor element for a low-height header, according to an embodiment of the present invention. In a first step 510 a floor element is provided for the manifold, and in one step 520 For example, a female mold in a U-shape is provided with shouldered abutment surfaces for receiving the flanks of the floor element. The steps 510 and 520 can be done simultaneously. In a following step 530 the die and the bottom element are assembled so that the flank ends of the bottom element abut against the abutment surfaces of the die. In one step 540 The matrix-bottom element combination is then aligned with respect to a cutting punch, that the cutting punch is directed to an outer side of the bottom element base surface of the bottom element. Then in one step 550 the cutting punch is forced through the bottom member base to form one or more through holes in the bottom member base. Finally, in one step 560 removed the die and the punch from the bottom element.

In collecting pipes with high material thickness of the soil can alternatively openings for the pipes by punching, d. H. without "pulling through" a "collar" are produced. The punching process can be done from the inside out. As a result, the die can be arranged on the outside to achieve the lowest possible height. However, the soldering resistance depends on a sufficiently thick material thickness.

The described embodiments are chosen only by way of example and can be combined with each other.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 4130517 A1 [0005]

Claims (10)

Manifold ( 300 ) for a heat exchanger, the at least one passage opening ( 350 ) for receiving a coolant tube ( 450 ) of the heat exchanger, wherein the passage opening through a collar ( 360 ) is limited, which is formed from a folded-over to an inner wall of the manifold out edge region of the manifold, wherein the collar rests against the inner wall. Manifold ( 300 ) according to claim 1, comprising a floor element ( 100 ) and a fluid-tight connected to the bottom element cover element ( 310 ), wherein the passage opening ( 350 ) is arranged in the bottom element. Manifold ( 300 ) according to one of the preceding claims, in which the floor element ( 100 ) a floor element base ( 140 ) and two opposing floor element flanks ( 130 ) and the cover element ( 310 ) a cover element base surface and two opposite cover element flanks ( 320 ), wherein the cover element flanks are arranged between the bottom element flanks and are connected in a fluid-tight manner to the bottom element flanks. Manifold ( 300 ) according to claim 3, wherein the floor element flanks ( 130 ) and the floor element base ( 140 ) and the cover element base form outer walls of the collection tube. Manifold ( 300 ) according to one of the preceding claims, wherein the collar ( 360 ) a total circumference of the passage opening ( 350 ) surrounds. Manifold ( 300 ) according to one of the preceding claims, in which the passage opening ( 350 ) has a rectangular shape. Manifold ( 300 ) according to one of the preceding claims, which has a plurality of passage openings ( 350 ) adjacent to each other along a longitudinal extent of the bottom element base ( 140 ) are arranged. Heat exchanger having the following features: a first header ( 300 ) according to one of the preceding claims; a second manifold according to one of the preceding claims; and at least one coolant tube ( 450 ), wherein the coolant tube between the first manifold and the second manifold arranged and fluid-tight with the collar ( 360 ) of the first manifold and the collar of the second manifold is connected. Heat exchanger according to claim 8, having a heat exchanger surface for arranging at least one battery on the heat exchanger surface, wherein the heat exchanger surface extends over the at least one coolant tube, at least a portion of the first manifold and / or at least a portion of the second manifold. Procedure ( 500 ) for producing a collecting pipe ( 300 ) for a heat exchanger, comprising the following steps: 510 ) of a floor element ( 100 ) for the manifold, the floor member having a floor element footprint ( 140 ) and two opposing floor element flanks ( 130 ) having; Provide ( 520 ) of a U-shaped die ( 110 ) with two opposite legs, wherein each an inner wall of the legs has a shoulder for forming a stop surface ( 200 ) has for the bottom element flanks of the bottom element; Put together ( 530 ) of the die and the bottom member, wherein the bottom member flanks of the bottom member come to rest against the abutment surfaces of the die; Align ( 540 ) of the die and the bottom element with respect to a cutting punch ( 120 ), such that the cutting punch for forming the at least one passage opening ( 350 ) is directed to an outside of the bottom element base of the bottom element; Pressing ( 550 ) of the cutting punch through the bottom member base to form the at least one through hole, an edge portion of the header being turned to an inner wall of the header and abutting against the inner wall; and remove ( 560 ) of the die and the cutting punch from the bottom element.

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