Indirect charge-air cooler

Patent metadata

Field	Value
Publication number	US-10240872-B2
Application number	US-201615334852-A
Country	US
Kind code	B2
Filing date	Oct 26, 2016
Priority date	Oct 27, 2015
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

A heat exchanger, such as an indirect charge-air cooler for an internal combustion engine, may include a first duct system including a plurality of pipes, a second duct system, a collector including a base part and a box part, and at least two opposite side parts. The plurality of pipes may be arranged between the side parts, and the first duct system may be fluidically separated from the second duct system. The box part may bear against at least one of the side parts via a first contact surface. At least one frame part may be provided and coupled in a non-positively locking connection and/or a cohesive connection, for example by pressing and/or brazing, to a respective outer edge of the side parts, a respective outer edge of the base part, and/or a respect outer edge of the box part.

First claim

The invention claimed is:

1. A heat exchanger for an internal combustion engine, comprising:
a plurality of pipes defining a first duct system for a first fluid which flows in a first flow direction;
a second duct system disposed between the plurality of pipes for a second fluid to flow through in a second flow direction, the second duct system fluidically separated from the first duct system;
at least two collectors fluidically separated from the second duct system, wherein at least one collector of the at least two collectors includes a base part and a box part that defines a collecting chamber fluidically connected to at least one pipe of the plurality of pipes;
the base part of the at least one collector including at least one opening connected to the at least one pipe such that the collecting chamber is fluidically separated from the second duct system;
at least two opposite side parts for fluidic delimitation of the second duct system, wherein the plurality of pipes are arranged between the at least two side parts and the base part transitions into at least one side part of the at least two side parts in a surface-flush manner;
the box part of the at least one collector engaging via a first contact surface against at least one side part of the at least two side parts;
the box part and the at least one side part are cohesively joined to one another via the first contact surface; and
at least one frame part coupled in at least one of a non-positively locking connection and a cohesive connection to at least one of a respective outer edge of the at least two side parts, a respective outer edge of the base part, and a respective outer edge of the box part.

2. The heat exchanger according to claim 1 , wherein at least one of:
the respective outer edge of at least one of the at least two side parts includes a bent-over lug configured as an edge reinforcement, the bent-over lug of the respective outer edge connecting the at least one side part to the at least one frame part; and
the at least one frame part is cohesively connected to the respective outer edge of the at least two side parts, the respective outer edge of the base part, and the respective outer edge of the box part.

3. The heat exchanger according to claim 1 , wherein the at least one frame part is connected via a pressed connection to the respective outer edge of the at least side parts, the respective outer edge of the base part and the respective outer edge of the box part.

4. The heat exchanger according to claim 1 , wherein the at least one frame part is structured a closed tetragonal frame including two longitudinal sides and two transverse sides, wherein each longitudinal side is connected to the respective outer edge of one side part, and each transverse side is connected to the respective outer edge of the base part and of the box part.

5. The heat exchanger according to claim 1 , wherein the at least one frame part has an S-shaped cross section including a first receptacle and a second receptacle, the second receptacle open oppositely to the first receptacle, and wherein the respective outer edge of at least one side part, of the base part or of the box part is received in the first receptacle.

6. The heat exchanger according to claim 1 , further comprising at least one of:
a plurality of heat exchanger elements arranged in the second duct system and in heat-exchanging contact with at least one of the plurality of pipes; and
a heat exchanger element is arranged between at least one of the at least two side parts and at least one of the plurality of pipes.

7. The heat exchanger according to claim 6 , wherein at least one of the plurality of heat exchanger elements is brazed to the at least one of the plurality of pipes.

8. The heat exchanger according to claim 6 , wherein at least one of the plurality of heat exchanger elements is spaced apart from the base part such that a free bypass section is defined at an edge of the second duct system, and wherein the at least one frame part includes a projecting collar section which at least partially covers the free bypass section to reduce a bypass flow of the second fluid through the free bypass section.

9. The heat exchanger according to claim 1 , wherein the base part engages via a linear second contact surface against the at least one side part, the linear second contact surface including a lug disposed on the at least one side part engaging into a recess disposed on the base part, wherein the recess includes at least two lateral protrusions and the lug is clamped between the at least two lateral protrusion in the recess.

10. An internal combustion engine, comprising:
a heat exchanger configured as a charge-air cooler, the heat exchanger including:
a first duct system including a plurality of pipes for a first fluid which flows in a first flow direction;
a second duct system disposed between the plurality of pipes for a second fluid to flow through in a second flow direction, the second duct system fluidically separated from the first duct system;
a collector fluidically separated from the second duct system, the collector including a base part and a box part defining a collecting chamber fluidically connected to at least one pipe of the plurality of pipes;
the base part of the collector including at least one opening connected to the at least one pipe such that the collecting chamber is fluidically separated from the second duct system;
at least two opposite side parts for fluidic delimitation of the second duct system, wherein the plurality of pipes are arranged between the at least two side parts and the base part transitions into at least one side part of the at least two side parts in a surface-flush manner;
the box part of the collector engaging via a first contact surface against at least one side part of the at least two side parts;
the box part and the at least one side part are cohesively joined to one another via the first contact surface; and
at least one frame part coupled in at least one of a non-positively locking connection and a cohesive connection to at least one of a respective outer edge of the at least two side parts, a respective outer edge of the base part, and a respective outer edge of the box part.

11. The internal combustion engine according to claim 10 , further comprising a fresh-air system, wherein the at least two side parts of the heat exchanger define an outer wall portion of the fresh-air system.

12. The internal combustion engine according to claim 11 , wherein the fresh-air system includes a first duct section arranged upstream of the heat exchanger and a second duct section arranged downstream of the heat exchanger, and wherein the heat exchanger is mechanically and fluidically connected to at least one of the first duct section the second duct section via the at least one frame part.

13. The internal combustion engine according to claim 12 , wherein the first duct section or the second duct section includes a diffuser having an outer edge that is received in a receptacle of the at least one frame part.

14. The internal combustion engine according to claim 10 , wherein the at least one frame part is structured a closed tetragonal frame including two longitudinal sides and two transverse sides, wherein each longitudinal side is connected to the respective outer edge of an associated side part, and each transverse side is connected to the respective outer edge of the base part and of the box part.

15. The internal combustion engine according to claim 10 , wherein the at least one frame part has an S-shaped cross section including a first receptacle an

Assignees

• Mahle Int Gmbh

Inventors

• Ferrand Nicolas
• Schoettle Olaf

Classifications

• F02B29/0462

  Liquid cooled heat exchangers · CPC title

• F28F9/0219

  Arrangements for sealing end plates into casing or header box; Header box sub-elements (F28F9/0236 takes precedence) · CPC title

• F28D2021/0082

  Charged air coolers · CPC title

• F28F3/025

  the means being corrugated, plate-like elements · CPC title

• F28F2275/04

  by brazing · CPC title