DE102005053518A1 - Method for producing a heat exchanger - Google Patents

Abstract

The invention relates to a method for producing a heat exchanger (10) for an air heater (12) for integration into an air guiding housing, which has a heat exchanger body (14) having a longitudinal axis. According to the invention, the heat exchanger body (14) is produced at least partially in a die casting method using two cores, the cores being removed in opposite demolding directions (40, 42) extending along the longitudinal axis.

Description

The The invention relates to a method for producing a heat exchanger for a Air heater for Integration into a leading air Casing, which one a longitudinal axis comprising heat exchanger body.

Currently are fuel-operated auxiliary heaters for vehicles, in particular for commercial vehicles, mainly separate from the vehicle's heating-air conditioning unit, in this case also as a vehicle air conditioner designated, installed. Such additional heaters are for example realized as air heaters, which are used as auxiliary heaters and / or auxiliary heaters.

For quite some time efforts have been made to integrate air heaters in the vehicle's own heating-air conditioning unit. This saves space and required components. An example of such an arrangement is in DE 102 11 591 A1 shown.

The for the Integration of the air heater selected in the heating / air conditioning unit Position and structure of the air heater are for the function, the economy and the security of involvement significantly responsible. you is therefore endeavoring the various with the introduction of the air heater in the Detecting heating-air conditioning unit related problems and related solutions provide, so that ultimately a successful overall concept to disposal stands.

One Problem circle hangs combined with the high weight of the heat exchanger body, which is generally made by a die-casting technique. by virtue of In particular, the heavy weight must carry the vehicle heater Housing accordingly stable execution be.

Of the elongated in the axial direction extending heat exchanger should in the proposed concepts perpendicular to this direction flows around become. Such a flow inevitably leads to high air turbulence and thus high flow losses. Do you want this by an enlargement of the the heat exchanger unbalanced space, this has the consequence that overall the space for the heating air conditioning can be increased got to. They are therefore solutions required the flow behavior and the heat transfer favor the heat exchanger.

Farther There is a desire to have existing components of air heaters as well in connection with the concept of installation of the air heater in a Heating air conditioning continue to use. One is therefore anxious the heat exchanger preferably build variable so as to have the same concepts related to different types of air heaters to use. This Desire for variability also concerns the production of the heat exchanger.

Next the flow around of the heat exchanger from the one to be heated by him Air continues to play heat transfer from the combustion gases to the heat exchanger an important role. Also this heat transfer should be improved, thereby in particular a greater freedom in the construction of the heat exchanger to be able to provide.

A Another important requirement for an air heater is to do this to arrange that a transfer of combustion gases is excluded in the air heater flowing around the air. Farther It should be ensured that the combustion used Air outside of the Motor vehicle, that is especially is not removed from the interior. An improvement with regard to the localization of the various connecting pieces of the air heater is also desired.

Of the Invention is based on the object, the above-mentioned problems through appropriate solutions to overcome, especially with regard to the weight of the heat exchanger.

These The object is achieved with the features of the independent claim.

advantageous embodiments of the invention are in the dependent claims specified.

The Invention builds on the generic method thereby, that the heat exchanger body at least partially manufactured in a two-core die-casting process being, with the cores in opposite directions along the longitudinal axis be removed extending Entformungsrichtungen. hereby let the demolding forces for a given draft angle, given surface texture and reduce the given material. Ultimately, such a heat exchanger with reduced wall thickness and thus reduced weight can be produced.

The method shows its particular advantages in the case that the heat exchanger core has an internal profile. Since such an inner profile increases the Entformungskräfte, in this case, the inventions dungsgemäße reduction of the harvesting forces of particular advantage.

For example For example, the method of manufacturing a heat exchanger may be used that the inner profile in the longitudinal direction extending ribs includes.

By Such an inner profile may be the heat-transmitting inner surface of the Heat exchanger to be enlarged so that in turn the total space can be reduced in turn.

Usefully is provided that the heat exchanger body and a heat exchanger bottom be made separately. By the heat exchanger bottom and the heat exchanger head manufactured separately from the heat exchanger body can be, the heat exchanger body in total with the method according to the invention be made.

Out comparable reasons It makes sense that a separately manufactured heat exchanger head provided is. If such a heat exchanger head available is, lets its separate.Production the application of the die-casting method according to the invention to. Depending on the geometric design However, it is the burner head or the burner unit also possible, on the heat exchanger head completely to renounce.

The Special features of the preparation according to the invention a heat exchanger can in combination with numerous other properties of the heat exchanger, of air heaters, for the the heat exchanger is provided, and of manufacturing methods for heat exchangers advantageous features result.

It can be provided that the heat exchanger body a heat exchanger core and heat transfer surfaces and that the heat exchanger core and the surfaces of the Wärmeübertragerflä disposal adjusting components are at least partially manufactured separately. Also this separate production possibility is against the background of a possible Weight reduction and higher variability in terms of on the design of the components and the manufacturing processes as considered advantageous.

In In this context, it is particularly useful that the heat transfer surfaces for disposal placing components on the heat exchanger core shrunk and / or pressed on. While the heat exchanger head and the heat exchanger bottom preferably by welding, soldering, gluing and / or screwing to the heat exchanger core connected gas-tight, stands for example, the disc-like trained individual heat exchanger surfaces the Possibility to available Shrink this onto the heat exchanger core or press on, creating another way to vary the Manufacturing process available stands.

It can be provided that he a the reduction of the flow resistance favorable Has cross-sectional geometry.

This can be achieved, for example, that the cross-sectional geometry is oval.

A another possibility is that the cross-sectional geometry of the cross-sectional geometry an aircraft wing is similar.

Farther It may be advantageous that the cross-sectional geometry is spindle-shaped.

It can be provided that the heat exchanger body to its outside a variety of bars has, the heat exchanger surfaces for disposal put. By such a plurality of rods, a very large surface for heat transfer to be heated Air available be put.

there can be useful on the one hand be that the heat exchanger body a Heat exchanger core has and that the multitude of bars at least partially by means of a separate component on the heat exchanger core is applied.

on the other hand it is also possible that the heat exchanger body a Heat exchanger core has and that the multitude of bars at least partially in one piece formed with the heat exchanger core is. Depending on the design of the rods on a separate component or integral with the heat exchanger core can different advantages are recognized, for example, on the one hand in terms of variability and, on the other hand, in view of the simplicity of the overall manufacturing process.

It can be provided that the heat exchanger body to its outside having a plurality of corrugated fins, the heat transfer surfaces for disposal put.

On the one hand is it possible in this context that the heat exchanger body a heat exchanger core and that the plurality of corrugated ribs at least partially by means of a separate component or as separate components on the heat exchanger core is applied.

It is also conceivable that the heat exchanger body has a heat exchanger core and that the plurality of corrugated fins zumin at least partially formed integrally with the heat exchanger core. It is useful not to attach such heat transfer surfaces via screw or similar compounds to the heat transfer core, but by welding, soldering, shrinking or pressing of single or multiple deferred surface parts or whole packages.

It can be provided that the heat exchanger body off several heat exchanger body modules is constructed. This, in turn, increases the variability, since out individual heat exchanger body modules differently shaped and in particular different sized heat exchanger can be produced.

in the With regard to the modular production is further advantageous that the heat exchanger body modules at least partially identical. It is then, especially in the Trap of die casting process, no different tools required.

Further Advantages arise in connection with an air heater for integration in an air-conducting Casing, with a heat exchanger, which having a heat exchanger body, the air heater Has flow guide, the when burning in an at least partially inside the heat exchanger arranged combustion chamber resulting hot gases to the inside of the Steer heat exchange body. The resulting during combustion hot gases can be more efficient at the Inside of the heat exchanger be distributed.

In In this context, it is useful that the flow guide elements in the manner of a screw thread, as blades, meander-shaped components, Baffles and / or perforated pipes are executed. These and many other options overall improve the heat transfer.

Also There are advantages in connection with an air heater for integration in an air-conducting Casing, with a heat exchanger, where a flange plate is provided, which by means of sealing elements between a mounting point for the air heater and the flange plate and between the air heater and the Flange plate at least one exhaust discharge to the vehicle interior seals. Such a flange plate ensures that the exhaust gas on as possible short way to the outside air guided there is no risk of exhaust fumes in the air Get inside the vehicle.

In In this context, it is also useful that the flange plate a combustion air supply seals against the vehicle interior. Thus can be ensured be that the combustion air taken from the outside of the vehicle becomes.

Farther it is advantageous that the flange plate has a passage for a fuel supply. Thus, all are Connections, over the Gases and liquids transported, located in the area of the flange plate, what advantages for the connection of the air heater to the overall concept.

Of the Invention is based on the finding that an air heater in economic and in a manner suitable for the functionality Heating air conditioning system of a motor vehicle, in particular of a commercial vehicle, can be integrated. This let yourself in particular to the inventively provided high variability of the heat exchanger as well as on the positive characteristics of the heat exchanger in terms of to reduce his weight.

The Invention will now be described with reference to the accompanying drawings particularly preferred embodiments exemplified.

there shows:

1 a perspective view of an air heater;

2 a perspective view of an air heater without heat exchanger;

3 a perspective view of an air heater without heat exchanger, disassembled in the burner head and burner unit;

4 a perspective view of a heat exchanger;

5 a perspective view of individual components of a heat exchanger;

6 a perspective view of an air heater with a housing attached thereto;

7 a sectional view of a heat exchanger core with oval cross-section;

8th a sectional view of a heat exchanger core with wing-shaped cross-section;

9 a sectional view of a heat exchanger core with spindle-shaped cross section;

10 a heat exchanger and a separate component for heat transfer in a perspective view;

11 a heat exchanger in perspective view;

12 a heat exchanger in perspective view;

13 a heat exchanger in perspective view;

14 a plurality of identical heat exchanger body modules in perspective view;

15 a cutaway perspective view of a heat exchanger;

16 a perspective view of a combustion tube;

17 a perspective view of a combustion tube;

18 a perspective view of a combustion tube; and

19 a perspective view of a connection area of an air heater with flange plate.

at The following description of the drawings describe the same Reference numerals are the same or similar Component.

1 shows a perspective view of an air heater 12 , The air heater 12 includes a heat exchanger 10 standing on a burner unit 60 is attached, and a burner head 62 , The burner head 62 contains a blower motor 64 and a controller 66 , the essential components of a combustion air blower unit 68 form. At the burner head 62 is still a nozzle 56 intended for a combustion air supply. At the burner unit 60 are a fuel supply 58 as well as a nozzle 54 intended for an exhaust discharge. At the exhaust outlet 54 is a flange plate 48 arranged, the openings for the implementation of the fuel supply 58 and the combustion air supply 56 having. The function of the flange plate 48 is related to 19 explained in more detail. The on the burner unit 60 attached heat exchanger 10 has on its outside a rib structure to thereby the surface for heat transfer to the heat exchanger 10 to increase air flowing around. The air heater 12 is preferably so arranged with respect to the air flow of the air to be heated that the air is perpendicular to the axis of the heat exchanger 10 in and out and the heat exchanger 10 flows around it.

2 shows a perspective view of an air heater 12 without heat exchanger. In this illustration, the burner head 62 and the burner unit 60 to recognize. The burner unit 60 includes a burner tube 70 in which hot gases are created by flame formation, which heat their energy on the in 2 not shown heat exchanger 10 transfer. To allow the hot gases to reach the heat exchanger is a plurality of holes 72 in the jacket of the burner tube 70 brought in.

3 shows a perspective view of an air heater 12 without heat exchanger, disassembled in burner head and burner unit. At this representation it becomes clear that the burner head 60 via a flange connection 74 . 76 with the burner unit 60 connected is. Furthermore, it is clear in this illustration that the flange plate 48 firmly with the exhaust gas discharge 54 is connected while for the combustion air supply 56 a passage is provided in the flange plate.

4 shows a perspective view of a heat exchanger 10 , It can be seen a rib structure, the heat exchanger surfaces 22 provides.

5 shows a perspective view of individual components of a heat exchanger 10 , It can be seen that the heat exchanger 10 is executed in several parts. It includes a heat exchanger core 20 , Components 24 with heat exchanger surfaces 22 , a heat exchanger bottom 16 and a heat exchanger head 18 , Depending on the design of the burner head 62 and / or the burner unit 60 can the heat exchanger head 18 be dispensable. Inside the heat exchanger core 20 is an inner profile 30 provided for this purpose, the heat transfer from the burner tube 70 resulting hot gases on the heat exchanger 10 to improve. The heat exchanger head 18 and the heat exchanger bottom 16 can be produced by various techniques, for example by deep drawing, die casting or by machining. The individual parts can then be connected to each other by various joining techniques, for example by welding, soldering, gluing and / or screwing. Because inside the heat exchanger 10 Combustion gases occur, it is essential that a gas-tight connection between heat exchanger head 18 , Heat exchanger core 20 and heat exchanger bottom 16 is provided. In the context of the present disclosure, the heat exchanger core with components attached thereto 24 with heat transfer surfaces 22 also as a heat exchanger body 14 designated.

6 shows a perspective view of an air heater 12 with a housing fastening arranged thereon 74 , By means of this housing attachment 74 can the air heater 12 be attached to a surrounding housing. The housing attachment 74 is over the heat exchanger head 18 and the heat exchanger bottom 16 on the air heater 12 attached.

7 shows a sectional view of a heat exchanger core with oval cross-section. The heat exchanger core 20 has an inner profile 30 , The finer this inner profile 30 is configured, the larger the surface, which is responsible for heat transfer from the hot gases to the heat exchanger 10 is available. A heat exchanger core 20 as illustrated herein may be made, for example, by an extrusion process. As a result, small wall thicknesses can be ensured in order to ensure a low weight on the one hand and a large surface for the heat transfer on the other hand. In the heat exchanger core 20 are fasteners, such as openings 76 , arranged for attachment of the other components. The oval cross-sectional geometry 32 of the heat exchanger 20 can the flow conditions for the heat exchanger 20 improve air flowing around to be heated. As the heat exchanger bottom 16 one from the heat exchanger core 20 is separately manufactured component, is the production of the heat exchanger core 20 simplified.

8th shows a sectional view of a heat exchanger core with a wing-shaped cross-section. 9 shows a sectional view of a heat exchanger core with spindle-shaped cross-section. The cross-sectional geometries shown here, namely the wing-shaped cross-sectional geometry 34 and the spindle-shaped cross-sectional geometry 30 are as further examples of the flow around the heat exchanger 20 favoring geometry to understand.

10 shows a heat exchanger 10 as well as a separate component 24 for heat transfer in a perspective view. The illustrated component 24 is from the heat exchanger core 20 made separately. The already on the heat exchanger core 20 attached components 24 are there by shrinking or pressing on one or more deferred components 24 or whole packages attached.

11 shows a heat exchanger in perspective view. The heat exchanger shown here 10 has an extremely large surface area for the transfer of heat to the air flowing around it. This is realized in that the heat transfer surface 22 through a variety of bars 26 is made available.

12 shows a heat exchanger in perspective view. Again, there is an extremely large heat exchanger surface available, as well as rods here 26 in large numbers to provide this heat transfer surface 22 are provided. On the inside of the heat exchanger is again an inner profile 30 to recognize. In the present embodiment, this inner profile partially sets the outer rods 26 or rows of staff continues. The bars 26 both of the embodiment according to 12 as well as the embodiment according to 11 can either be mounted externally on the heat exchanger surface by a separately created component or be realized by the post-processing of an extruded profile by reshaping or machining process.

13 shows a heat exchanger 10 in perspective view. The components shown here 28 that the heat transfer surfaces 22 of the heat exchanger 10 are corrugated ribs that promote heat transfer.

14 shows several identical heat exchanger body modules 38 in perspective view. The embodiment shown here is of particular interest when the heat exchanger is not to be manufactured by extrusion, as mentioned above, but, as before, by a die casting process. Die casting methods have the disadvantage that large wall thicknesses can occur due to draft angles. In the present example, there are multiple heat exchanger body modules 38 provided, each individual heat exchanger body module 38 has only a small axial length. Consequently, wall thickness can be saved due to short Entungsungsschrägen.

15 shows a cutaway perspective view of a heat exchanger 10 , On the basis of this illustration, another method can be explained, can be kept short with the Entformungsschrägen. Namely, by the manufactured as a diecast heat exchanger 10 is made with two cores in two opposite demolding directions 40 . 42 can be removed, the wall thickness can also be kept low.

The 16 . 17 . 18 show a perspective view of combustion tubes 70 , 17 shows a perspective view of a combustion tube. 18 shows a perspective view of a combustion tube. In order to distribute the resulting hot gases during combustion as efficiently as possible for a good and even heat transfer to the inside of the heat exchanger NEN, it makes sense, the hot gas by means of Strömungsleitteilen within the heat exchanger 10 to the inner ribbing 30 or to direct its inner wall. In 17 is a helical flow guide 44 shown. Likewise, the flow guide can be realized in the form of a blade, meandering geometries, baffles and perforated tubes, wherein such a perforated tube having a plurality of holes 46 in addition to the hole profile that passes through the holes 72 formed, in 18 is shown.

19 shows a perspective view of a connection area of an air heater with flange plate 48 , The flange plate 48 serves to mount the air heater 10 on the vehicle body or a housing or other component attached to the vehicle. To ensure that the exhaust gases and the combustion air are supplied to or taken from the outer space, the flange plate is 48 against the air heater 12 and against the mounting location, that is, for example, the vehicle body, sealed. The seals can be realized for example by sealing rings.

The in the above description, in the drawings and in the claims disclosed features of the invention can both individually and also in any combination for the realization of the invention be essential.

LIST OF REFERENCE NUMBERS

10

heat exchangers

12

air heater

14

heat exchanger body

16

heat exchange floor

18

heat exchanger head

20

heat exchanger core

22

heat transfer surface

24

components with heat transfer surfaces (disk-shaped)

26

components with heat transfer surfaces (rods)

28

components with heat transfer surfaces (corrugated ribs)

30

internal profile

32

oval Cross-sectional geometry

34

wing-shaped cross-sectional geometry

36

spindle-shaped cross-sectional geometry

38

Heat exchanger body module

40

unmolding

42

unmolding

44

screw thread

46

hole in perforated tube

48

flange

54

exhaust system

56

Combustion air feed

58

fuel supply

60

burner unit

62

burner head

Claims (4)

Method for producing a heat exchanger ( 10 ) for an air heater ( 12 ) for integration into an air-guiding housing, which has a longitudinal axis of a heat exchanger body ( 14 ), characterized in that the heat exchanger body ( 14 ) is at least partially produced in a die-casting method using two cores, wherein the cores are formed in opposite demolding directions (along the longitudinal axis) (FIG. 40 . 42 ). Method according to claim 1, characterized in that the heat exchanger core ( 20 ) an inner profile ( 30 ) having. Method according to claim 2, characterized in that that the inner profile extending in the longitudinal direction Includes ribs. Method according to one of the preceding claims, characterized in that the heat exchanger body ( 14 ), a heat exchanger bottom ( 16 ) and a heat exchanger head are manufactured separately.