EP1912035B1 - Motor vehicle cooler - Google Patents

Description

The invention relates to a motor vehicle radiator, consisting of flat tubes, corrugated fins and tubesheets with an erected peripheral edge, and with openings corresponding to the cross section of the flat tubes, in which open the ends of the flat tubes, wherein the openings are formed with collars, and with collecting boxes made of plastic, which are mechanically fastened at its edge bead to the edge of the substantially flat tubesheets with the addition of a seal, wherein the edge of the tubesheets is bent onto the edge bead of the collecting boxes in the manner of a clamping.

A motor vehicle radiator is out of the Fig. 2 of the DE 34 40 489 C2 known. However, the known motor vehicle radiator has only at one end of the flat tubes a substantially flat tube plate with a collecting box. The flat tubes are formed there with a longitudinal ridge, so that the cooling water is deflected at the other end of the flat tubes and flows back to the collection box. Since in the document a completely different from the invention described below task has been solved, seems the Fig. 2 only randomly, ie not purposefully, to show the characteristics of the generic term.

Usually, a circumferential groove is formed for clamping the collecting tank on the tube plate in the tube plate, in which the seal is their recording and therefore can not slip, as well as in the Fig. 6 of the mentioned document. Such tube sheets are then not considered to be substantially flat.

In addition, be the DE 100 16 029 A1 just mentioned here for example. In contrast to this prior art, the present invention is based on a motor vehicle radiator with a substantially planar tube sheet.

By doing EP 1 273 864 A2 are also no substantially flat tube sheets available, but there the object was achieved, which also plays a role in the present invention and which is to be able to equip the motor vehicle radiator with the smallest possible amount of change with smaller block depths of the cooling network (flat tubes and corrugated fins). The solution takes place there by the provision of a second tube plate or an intermediate bottom. It is for reasons of cost still advantageous collecting boxes made of plastic - not made of metal - to use because additional functional elements can be easily realized by appropriate design of the injection molding tool. The projection of the edge of the collecting tank over the cooling grid, which coincides with the edge of the tubesheet If it is clamped, something could be reduced there, in the EP'864, in order to reduce the required installation space of the cooler.

Furthermore, there are often problems in the production of the clamping but also in the operation of the radiator, because the wall of the collecting tank or the edge bead is not stable but falls inward or slips. These problems occur when a substantially flat tube sheet is to be used, which therefore has no circumferential groove in which the edge bead could find support.

The WO 00/33009 A1 agrees with the preamble of claim 1, because there are substantially flat tube sheets available. There, a seal was further provided which extends over the entire tube sheet and is therefore also designed to seal the pipe ends in the openings of the tube sheet. The lateral projection of the tube sheets on the cooling network is quite large there, which is unfavorable in terms of the required installation space. If a cooling network with a different depth dimension is to be used, which is desired in many cases, then inevitably another, adapted thereto, gasket is needed, whereby the cost is increased. Further, the pipe ends protrude far into the interior of the header, which is also unfavorable in terms of pressure loss.

In the FR 2 750 484 For example, the tube ends were soldered in the openings of the tube bottom, so that a planar seal formed as described above is not required. However, the heat exchanger from this publication with respect to pressure loss is also not advantageous. In order to prevent the wall of the collecting tank from falling in during clamping, two rows of indentations were formed in the tube bottom, ie incorporated into the non-planar tubesheet, which serve as a stop for the wall of the collecting box. The seal assembly could be improved here.

In the heat exchanger, with the US 5,758,721 B was released, there are no such beads. In order to prevent the wall of the collecting tank from falling inwards when being clamped, two rows of protrusions have been worked into the otherwise flat tubesheet which protrude inwards and serve as a stop for the wall of the collecting box. The installation of the seal is also a bit difficult here.

The object of the present invention is to design the motor vehicle radiator so that the seal assembly is simplified, that the supernatant of the Cylinder box is further reduced over the cooling network, but with the option to provide the cooler in case of need in an economical manner with a cooling network of smaller block depth, and that the internal pressure loss is comparatively reduced

The solution according to the invention is achieved with the features of independent claim 1.

According to claim 1, a circumferential projection is provided at the bead of the collecting tanks, which is supported on the flat tube sheets and provides a space for receiving the seal to the edge of the tube sheet down. At the edge of the edge bead of the header box spaced lugs were formed, which take care of a better positioning of the seal.

The openings in the tubesheets extend approximately to the projection on the manifolds. The edge bead of the manifolds is formed with a recess into which engages the bent edge of the tube sheets.

Such a trained motor vehicle radiator can be designed with a very small change effort with a cooling network lesser block depth. In a motor vehicle radiator with a smaller block depth, the above-mentioned feature, according to which the openings in the tubesheets extend to the projection on the collecting boxes is not realized. The preparation of the required tube plates with smaller openings is also conceivable cost, since this is possible in principle with the existing tube bottom tool, with only the integrated in the tool punching kit for the larger openings must be replaced by a punching kit for smaller openings.

In addition, a motor vehicle radiator, in which the openings extend to the projection on the collecting box requires a relatively small installation space, because the projection of the edge bead of the collecting tank on the flat tubes is conceivable low, since no space-filling channel is provided in the tube sheet. In known embodiments, the channel is not only provided for receiving the seal, but it represents a stop for the edge bead of the header, which therefore can not occur in the Verklammerungsvorgang and during operation of the motor vehicle radiator to the inside. This function is ensured here by the fact that a recess has been provided at the edge bead of the header, in which engages the edge of the tube sheet. That is why the Collecting box does not fall inward, but he remains stable in position, although the tube sheet is substantially flat, ie it has no circumferential groove and no significant other deformations between the openings that protrude above the surface of the tube sheet and a stop for could form the collection box. The recess, which is preferably arranged in the entire peripheral edge bead of the collecting tank, can be further reinforced by spaced webs. The webs form quasi "fan" in the recess. The edge of the tube sheet is, as is known, likewise formed with projections arranged at intervals. The supernatants are designed so that they each fit into a "compartment" in the recess into which they are bendable by more than 90 ° inwards.

In addition, provision is made to prevent that during the Verklammerungsvorganges the edge bead or the edge bead having wall of the header into the interior. These precautions consist in the corresponding design of the clamping tool. The Verklammerungswerkzeug has punches, which act in the nature of hold-down and interposed Umformstempel that perform the transformation of the supernatants. The hold-down punches take time shortly before the Umformstempeln and cause the Umformstempel not change the position of the edge during the forming process or during the clamping. After reshaping the supernatants, the position, as already mentioned, secured by the deformed supernatants.

The invention will be described below in exemplary embodiments. Also from this description, the features of the dependent claims.

The Fig. 1 to 5 show partial perspective sections of the motor vehicle radiator according to the invention, which may be, for example, a cooled by cooling air coolant radiator or a charge air cooler.

The others FIGS. 6-28 show not inventive embodiments.

The Fig. 24 shows a front view and the Fig. 25 a side view of an essential part of a charge air cooler.

The motor vehicle radiator according to the invention ( Fig. 1-5 ) is known from a cooling network consisting of a series of flat tubes 1 and corrugated fins 2, and from two tube sheets 3, in whose openings 4 the opposite ends of the flat tubes 1 open, constructed. The tube sheets 3 are each connected to a collecting box 6 . The Fig. 1 shows a section of a side of the motor vehicle radiator, with a part of a tube sheet 3, with only two flat tubes 1 of the mentioned series, with as many openings 4, and with a piece of corrugated fins 2, which are arranged between the flat tubes 1 and by the cooling air ( dashed arrows) flows through. The openings 4 are formed with pointing to the flat tubes 1 and the corrugated fins 2 collar 5 , where the ends of the flat tubes 1 are soldered tight and durable. The ends of the flat tubes 1 terminate below the surface of the tube bottom 3 in order to keep the pressure loss of the flowing through the flat tubes 1 , to be cooled medium (solid arrows) low. Furthermore, a part of a collecting box 6 can be seen, which was made of plastic by injection molding. The collecting box 6 is mechanically fastened at its peripheral edge bead 7 with the peripheral deformed edge 8 of the substantially flat tube plate 3 with the addition of a seal 9 , wherein the deformed edge 8 of the tube plate 3 is bent on the edge bead 7 of the collecting box 6 in the manner of a clamping , The opposite side of the motor vehicle radiator, not shown, is of identical design.

At the edge bead 7 of the manifolds 6 , a circumferential projection 10 is provided, which is supported on the flat tube sheets 3 and provides a space 11 for receiving the seal 9 to the deformed edge 8 of the tube sheets 3 out. In the exemplary embodiment, the seal 9 has a round cross section projecting beyond the cross section of the space 11 , which is squeezed wide in the course of the clamping, whereby the sealing effect arises, or the space 11 is filled with the seal 9 .

The openings 4 in the tubesheets 3 extend at both ends approximately to the circumferential projection 10 on the edge bead 7 of the manifolds 6, whereby only a slight projection of the rim 8 over the circumference of the cooling network (flat tubes / corrugated fins) was created. In the Fig. 1 and 2 It can be seen that the projection 10 resting on the flat tubesheet 3 is arranged approximately perpendicularly above the one end of the openings 4 . The other end of the openings 4 or the opposite side of the collecting tank 6 is not shown, but is identical, which is also expressed by the "circumferential" edge 7 of the tube bottom and the "peripheral" edge bead 7 of the collecting box shall be. The edge bead 7 of the manifolds 6 is formed with a recess 12 into which the deformed edge 8 of the tube plates 3 engages. While the projection 10 is formed on the underside of the edge bead 7 of the collecting tank 6 , the recess 12 is formed on the upper side of the edge bead 7 of the collecting box 6 in the manner of a circumferential groove. The engaging in the recess 12 formed edge 8 of the tube sheet requires a bend of this edge 8 inwardly by much more than 90 °, so that the holding function of the deformed edge 8 relative to the wall of the collecting tank 6 is to be fulfilled. In the exemplary embodiment, the edge 8 was bent inwards by approximately 130 ° from the vertical inwards, into the recess 12 of the edge bead 7 . The collecting box 6 has no other stop on the tube sheet 3, since substantially flat tube sheets 3 are provided. According to Fig. 1 the reshaped edge 8 has been bent as a whole in the recess 12 into it.

The Fig. 2 and 3 In contrast, show a change, which consists in that the deformed edge 8 of the tube sheets 3 is formed with known at intervals spaced projections 20 . These projections 20 have been bent into the recess 12 . Like from the Fig. 3 can be seen, the recess 12 can be divided by means of webs 14 into compartments 15 . The webs 14 lead to a higher rigidity in the recess 12, which can therefore be formed with a smaller wall thickness, whereby the supernatant ü on the cooling network is further reduced. From the Fig. 3 Furthermore, in principle, a device for clamping the collecting tank 6 to the tube bottom 3 can be seen. The device has a series of punches. In the series, a forming punch 40 alternates with a holding-down punch 30 . The hold-down punches 30 each engage in a compartment 15 of the recess 12 and hold the collection box 6 in the desired position. In each case, a forming die 40 bends a supernatant 20 on the deformed edge 8 in the adjacent compartment 15 into. Only a forming punch 40 and a holding-down punch 30 were shown. In order to be able to fulfill the hold-down function, the hold-down punches 30 have to take effect somewhat earlier than the forming punches 40 in terms of time. The device is located in a forming machine, which was simply provided with the reference numeral 50 . The punches 30 and 40 act approximately perpendicular to the flat tubesheet 3 on the deformed edge 8 and the edge bead 7 a.

From the Fig. 4 It can be seen that the motor vehicle radiator, without changes, z. B. with regard to the connection between the tube sheet 3 and collecting tank 6, make, with a cooling network lesser depth <T can be equipped. Therefore, by the reference numeral 5 'of the collar 5 a smaller opening 4' in the tube sheet 3 was indicated, which belongs to a cooling network with a smaller depth <T. The greater depth was in the Fig. 4 marked with > T.

Further, lugs 21 spaced at intervals on the projection 10 of the edge bead 7 of the collecting tank 6 were formed, which can take care of a better positioning of the seal 9 care. ( Fig. 4 and 5 )

In the FIGS. 6 27 which show no embodiments protected by this invention, the components of the motor vehicle radiator already described above were nevertheless assigned reference numerals which are extended by one hundred. Other components, which have not been described above or are not present, have also received one hundred reference numerals. It can be seen from the partial views of FIGS. 24 and 25 in that the plastic collecting tanks 106 have an air inlet or outlet nozzle 190 . (only one of the two manifolds drawn) The edge bead 107 of the manifolds 106 is fixed at the edge 108 of the tube plates 103 by clamping. The intercooler has a series of flat tubes 101 with corrugated fins 102 arranged therebetween. The tube plates 103 have openings, which are each provided with a collar 105 , which are aligned with the cooling network. The cooler also has on each narrow side a side part 180. One of them can be seen in the pictures.

In the examples of the prior art described below, an insert 160 is used, which is inserted into the tube plate 103 . Various embodiments of the insert 160 are in the 10, 11 and 12 shown. The insert 160 is made of aluminum sheet by forming. The insert 160 has an edge strip 161 of different design according to the various embodiments , which gives the insert 160 a frame-like configuration. In the Fig. 10-12 transverse webs 165 were provided between the two longitudinal sides of the insert 160 and its deformed marginal strip 161 , respectively. The transverse webs 165 can improve the stability of the insert 160 and can also impart a gas or liquid flow directing effect by correspondingly forming the angle of attack α ( Fig. 12 ). The size of the Angle of attack α can change from transverse web 165 to transverse web 165 as a function of the position of the inlet or outlet connection 190 . For this purpose, the transverse webs 165 are connected at both ends only via a relatively narrow and therefore rotatable web 166 with the edge strip 161 . Nevertheless, the transverse webs 165 only represent an option that can be dispensed with, especially with smaller radiator sizes.

Also an option are the protrusions 167 located at the lower edge of the trim strip 161 . These projections 167 fit into openings 168 which are present in the tube plate 103 . Projections 167 and openings 168 together constitute a suitable measure for provisionally fixing the edge strip 161 in the tube sheet 103 so that the soldering process can be carried out. ( Fig. 8 . 11 . 27 ) This caused concerns about tightness are unfounded in view of the level of development of the soldering technology.

The same task regarding prefixing is described in the Fig. 13 shown showing a section through the clamping, solved by bent tabs 120 which act on the edge strip 161 of the insert 160 .

Another possibility according to the prior art for prefixing is the 6 and 7 shown. There are at intervals cutouts 170 at the edge of the tube sheet 103, in each of which a projection 169 is bent into the edge strip 161 . Incidentally, in this embodiment, the edge strip 161 of the insert 160 is deformed like a channel. In this groove, the seal 109 is inserted, on which the edge bead 107 of the collecting tank 106 comes to lie, which in the 6 and 7 not shown. The outer wall of the channel or the edge strip 161 is soldered to the inside of the edge 108 of the tube sheet. The bracketing can happen as it is shown several times in other figures.

The Fig. 9 the section A - A shows, in the Fig. 8 was drawn. There, the seal 109 is located in a circumferential recess of the edge bead 107 of the collecting tank 106. The seal 109 itself is a manufactured by extrusion rubber band approximately rectangular cross-section, which is cut to appropriate length. The recess in the edge bead 107 has at intervals arranged cross-sectional constrictions 171, which in the Fig. 9 are recognizable. These serve to give the seal 109 appropriate hold because it is trapped there.

Therefore, it can not fall out of the recess during assembly of the collecting tank 106 . The sealing effect is achieved by pressing the seal 109 on the edge strip 161 of the insert 160 . Inwardly, the edge bead 107 rests against the already described transverse webs 165 of the insert part 160 and thus can not slip. In another example, not shown, according to the prior art was dispensed with the transverse webs 165 and therefore only individual in-line formations were formed in the insert 160 , which serve as a means for supporting the edge bead 107 .

Another possibility or a further means to avoid slipping or to ensure the stability of the position of the edge bead 107 is the provision of a groove 175 in the edge bead 107 in which the one edge or side of the edge strip 161 engages. ( Fig. 17 - 20 This prior art example requires a correspondingly adapted deformation of the marginal strip 161, as the sections in the mentioned figures show.

In the Fig. 13 . 21 and 23 was waived on the groove 175 . For this purpose, the deformation of the edge strip 161 and the edge bead 107 have been changed so that an abutment of the edge bead 107 on the edge strip 161 is present.

With regard to the universal and cost-effective use of plastic collecting tanks 106 already mentioned in the introduction, reference is hereby made to the FIGS. 14, 15 and 16 be pointed out. There, a partition wall 188 was formed in the plastic collection box 106 as its component, with which, as is known, the flow through the radiator can be selected as it is advantageous for certain applications. It was further provided there, the seal 109 with a cross-connection 187 form , on which the partition wall 188 comes to rest during assembly of the collecting tank 106 . Below the partition wall 188 or the transverse connection 187 , the complete flow deflection can be achieved by a further insertion part 189 .

The already mentioned FIGS. 17 to 23 show partial views or sections through the edge 108 of the tube sheet 103 and the edge strip 161 of the insert 160 in various examples according to the prior art from which inter alia, the clamping closer. As the Fig. 17 shows particularly well, has the outer edge of the edge bead 107 cutouts, which are provided where the projections 120 are present at the edge 108 of the tube sheet 103 . This results in an approximately smooth, ie continuous end edge on the outside. The Supernatants 120 are, as described above, bent inwards and cause the clamping. In this alternative solution proposal, it is not necessary to bend the projections 120 into recesses since the stability of the position of the edge bead 107 is effected here by the other measures described above.

Attention is still to another feature that serves to position positioning of the insert 160 in the tube plate 103 . This feature goes from the FIGS. 21-23 and 26 and 27. At the bottom of the tube sheet 103 knobs 176 were impressed at intervals, on which the other edge of the edge strip 161 rests. This achieves a more accurate positioning of the insert 160, which otherwise, due to the bending radius at the edge 108 of the tube sheet 103, would not exist.

The Fig. 26 and 27 each show a view of the inside of a substantially flat tube bottom 103, wherein in the Fig. 26 the tube plate 103 of a Kühlflüssigkeitkühlers and in the Fig. 27 the tube plate 103 of a charge air cooler is shown. The openings 104 for the ends of the flat tubes can be seen there as well as the nubs described 176 and those openings 168 which receive the projections 167 at the lower edge of the edge strip 161 . The edge 108 of the tube plate 103 is merely bent, ie erect. The tube plates 3, 103 have no groove for receiving the seal.

The Fig. 28 shows a modified embodiment of the second proposed solution, in which the collar 105 are formed at the openings 104 in the tube sheet 103 in the direction of the collecting tank 106 pointing. With respect to the formation of the insert 160 may be described on FIGS. 19 and 20 to get expelled.

It is from the above description and from the FIGS. 1 to 6 clearly shows that the proposed solution has a minimum and therefore acceptable supernatant ü the collection box 6 via the cooling network result.

Claims (4)

1. Motor vehicle cooler, composed of flat tubes (1), corrugated fins (2) and two tube plates (3) having a turned-up encircling edge (8) and having openings (4) which are matched to the cross section of the flat tubes (1) and into which the opposite ends of the flat tubes (1) open out, with the openings (4) being formed with collars (5) which are designed so as to point in the direction of the cooling network, and having two collecting tanks (6) which are composed of plastic and which, at their encircling edge bead (7), are mechanically fastened to the turned-up edge (8) of the substantially planar tube plates (3) with the addition of a seal (9), with the edge bead (7) of the collecting tanks (6) being formed with a recess (12) into which the turned-up edge (8) of the tube plates (3) is bent in the manner of a clamp, with an encircling projection (10) being provided on the edge bead (7) of the collecting tanks (6), which encircling projection (10) is supported on the tube plates (3) and provides a space (11) for receiving the seal (9) towards the turned-up edge (8) of the tube plates (3),
   characterized in that lugs (21) are arranged at intervals on the encircling projection (10), which lugs (21) serve for positioning of the seal (9), and in that the tube ends are integrally soldered onto the collars (5) and do not project into the interior of the collecting tank (6).
2. Motor vehicle cooler according to Claim 1, characterized in that the recess (12) is of encircling design and is stiffened by means of webs (14) which are arranged at intervals, such that the recess (12) appears as a row of compartments (15).
3. Motor vehicle cooler according to Claim 2, characterized in that the turned-up edge (8) of the tube plates (3) is formed with protrusions (20) arranged at intervals, with said intervals corresponding to the intervals of the webs (14) in the recess (12), such that the protrusions (20) on the turned-up edge of the tube plate engage into every second compartment (15) of the recess (12).
4. Motor vehicle cooler according to one of Claims 1-3, characterized in that the openings (4) in the tube plates (3) end approximately at the encircling projection (10) of the collecting tanks (6).

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