阅读说明：本技术 用于气体的热交换器，特别用于来自发动机的排气，以及制造所述交换器的方法 (Heat exchanger for gases, in particular for exhaust gases from an engine, and method for manufacturing said exchanger ) 是由 B.格拉西亚拉扎罗 A.马伦纳瓦雷特 R.罗梅罗佩雷兹 T.孔特奥利维罗斯 于 2018-02-16 设计创作，主要内容包括：一种用于气体的热交换器,包括：界定用于冷却剂流体流通的回路的热交换壳体(1)；多个气体流通管(2),其布置在壳体(1)内以与所述冷却剂流体交换热量；和至少两个结构部件(3),设置有多个孔(4),用于接收热交换器壳体(1)的相应端部中的气体流通管(2)的端部,其中每个管(2)具有设计成彼此相对安装的两个开口半管(2a,2b),所述气体流通管(2)的端部的横截面的形状在结构部件(3)的接收所述气体流通管(2)的端部的孔(4)中留下连接空间(e),其特征在于,所述结构部件(3)的孔(4)具有与所述气体流通管(2)的横截面的几何形状互补的形状,其被调整为能够至少部分地阻挡所述连接空间(e)。(A heat exchanger for gases comprising: a heat exchange casing (1) defining a circuit for the circulation of a coolant fluid; a plurality of gas circulation pipes (2) arranged within the housing (1) to exchange heat with the coolant fluid; and at least two structural parts (3) provided with a plurality of holes (4) for receiving the ends of the gas circulation tubes (2) in the respective ends of the heat exchanger shell (1), wherein each tube (2) has two open half-tubes (2a, 2b) designed to be mounted opposite each other, the shape of the cross-section of the ends of the gas circulation tubes (2) leaving a connection space (e) in the holes (4) of the structural parts (3) receiving the ends of the gas circulation tubes (2), characterized in that the holes (4) of the structural parts (3) have a shape complementary to the geometry of the cross-section of the gas circulation tubes (2) adapted to be able to block at least partially the connection space (e).)

1. A heat exchanger for gases, in particular for exhaust gases from an engine, comprising:

a heat exchange casing (1) defining a circuit for the circulation of a coolant fluid,

a plurality of gas circulation tubes (2) arranged inside the casing (1) to exchange heat with the coolant fluid, and

at least two structural parts (3) provided with a plurality of holes (4) for receiving the ends of said gas circulation tubes (2) in the respective ends of the heat exchanger shell (1),

wherein each of the tubes (2) comprises two open half-tubes (2a, 2b) designed to be mounted opposite each other so that the side of one half-tube (2b) overlaps a portion of the corresponding side of the other half-tube (2a), the cross-sectional shape of the end of the gas flow-through tube (2) leaving a connecting space (e) in the hole (4) of the structural component (3) receiving the end of the gas flow-through tube (2),

it is characterized in that the preparation method is characterized in that,

the holes (4) of the structural part (3) have a shape complementary to the shape of the cross-section of the gas flow-through pipe (2) adapted to be able to at least partially block the connection space (e).

2. The heat exchanger according to claim 1, wherein the complementary shape of the hole of the structural component (3) defines a protrusion (8) adapted to at least partially obstruct the connection space (e) in the hole (4).

3. The heat exchanger according to any of claims 1 to 2, wherein the holes (4) of the structural component (3) define an irregular pattern of rectangular shape.

4. The heat exchanger according to any of claims 1 to 3, wherein the structural component (3) is provided in the form of a support plate provided with a plurality of holes (4) for inserting the ends of the gas circulation tubes (2).

5. The heat exchanger according to any of the preceding claims, wherein the two open half-tubes (2a, 2b) are arranged in the manner of a U-shaped plate.

6. The heat exchanger according to any of claims 1 to 5, wherein the end of each gas flow-through tube (2) has at least two tabs (6) arranged to overlap a same number of portions (7) of the side of one of the half-tubes (2a), said tabs being able to define the longitudinal position of the structural component (3) receiving the end of the gas flow-through tube (2).

7. The heat exchanger according to any of claims 1 to 6, comprising a plurality of tabs (6) in the form of projections, which extend separately along each side of one half-tube (2b) and are arranged to overlap the same number of side portions of the other half-tube (2 a).

8. The heat exchanger according to any of claims 1 to 6, comprising at least two tabs, each tab being formed by a single projection extending continuously along each side of one half-tube (2b) and arranged to overlap the same number of side portions of the other half-tube (2 a).

9. The heat exchanger according to any of claims 7 to 8, wherein at least two of the protrusions act as locking tabs at the end of each gas flow tube (2), and wherein the end of each gas flow tube (2) can be inserted into the same number of holes (4) of the structural component (3) of the exchanger until it stops against one of the locking tabs.

10. The heat exchanger of any of claims 6 to 8, wherein the length of the protrusion or tab is in the range of 0.5mm to 15 mm.

11. A method for manufacturing a heat exchanger and a gas flow-through pipe according to any one of claims 1 to 10, comprising the steps of:

a. stacking two open half-tubes (2a, 2b) to form each gas flow-through tube (2),

b. mechanically fixing the two half-tubes (2a, 2b) together,

c. inserting the end of each gas flow-through tube (2) in some holes (4) of a structural component (3) of the exchanger, said holes (4) having a shape complementary to the cross-section of the gas flow-through tube (2) and being adapted to at least partially block said connecting spaces (e),

d. filling the joint space (e) with a brazing filler material, and

e. brazing the end of the gas flow tube (2) and the structural member (3) together using the brazing filler material.

12. Method according to claim 11, wherein in step b the end of the side of one of the half-pipes (2b) comprises at least two tabs (6) arranged to overlap the same number of portions of the side of the other half-pipe (2a), and said step b comprises the step of folding said tabs (6) on the same number of side portions of the other half-pipe (2 a).

13. Method according to claim 12, wherein in step c the end of each gas flow tube (2) is inserted in a hole (4) of a structural component (3) until it stops against one of the locking tabs according to claim 11, so that the locking tabs delimit the position of the structural component (3).

14. Method according to any of claims 11 to 13, wherein in step a gas turbulator element (5) is arranged between two open half-tubes (2a, 2 b).

15. Method according to any one of claims 11 to 14, wherein the shape of the hole (4) of the structural component (3) defines a protrusion (8), which protrusion (8) is adapted to at least partially obstruct the connecting space (e) in the hole (4).

Technical Field

The present invention according to a first aspect relates generally to a heat exchanger for gases, in particular for exhaust gases from an engine, comprising a plurality of gas flow tubes and a casing to exchange heat between said gases and a coolant fluid contained in the casing around the gas flow tubes.

A second aspect of the invention relates to a method for manufacturing the heat exchanger according to the first aspect.

The invention is particularly useful in an Exhaust Gas Recirculation Cooler (EGRC) for an engine.

Background

The primary function of the EGRC exchanger is to exchange heat between the exhaust gas and the coolant fluid to cool the gas. Nowadays, EGRC heat exchangers are widely used in diesel applications to reduce emissions and in gasoline applications to reduce fuel consumption.

The current commercial EGRC exchanger layouts include metal heat exchangers, typically made of stainless steel or aluminum. There are basically two types of EGR heat exchangers: the first type has a housing containing a bundle of parallel tubes for conveying the gas, with coolant flowing through the housing outside the tubes, and the second type has a series of parallel plates forming heat exchange surfaces, so that the exhaust gas and the coolant flow in alternating layers between the two plates.

In a tube bundle heat exchanger, the connections between the tubes and the shell may be of different types. Typically, the ends of the tubes are attached between two support members coupled to each end of the housing, the two support members having a plurality of holes designed to receive the ends of the respective tubes.

Disclosure of Invention

In order to overcome the above drawbacks, according to a first aspect, the present invention relates to a heat exchanger for gases, in particular for the exhaust gases from an engine, comprising:

-a heat exchange casing delimiting a circuit for the circulation of a coolant fluid,

-a plurality of gas flow-through tubes arranged inside the housing to exchange heat with the coolant fluid, and

at least two structural parts provided with a plurality of holes for receiving the ends of the gas circulation tubes in the respective ends of the heat exchanger shell,

-wherein each of the tubes comprises two open half-tubes, preferably two U-shaped half-tubes, designed to be mounted opposite each other so that the side of one half-tube overlaps a portion of the corresponding side of the other half-tube, the cross-sectional shape of the end of the gas tube leaving a connecting space (e) in the hole of the structural component receiving the end of the gas flow-through tube,

it is characterized in that the preparation method is characterized in that,

-the holes of the structural component have a shape complementary to the shape of the cross-section of each gas flow-through pipe, suitable for at least partially blocking the connecting space (e).

Since the gas flow-through tubes of the exchanger are made of two open half-tubes, the flow-disturbing elements (e.g. heat transfer fins) of the exchanger can be easily installed in the gas flow-through tubes without risk of damage. Thus, the thickness of these flow perturbation elements can be significantly reduced, thereby also reducing the overall manufacturing costs of the exchanger.

The complementary shape of the holes of the structural component makes it possible to internally block the connection space (e) in the hole of the end of the structural component receiving the gas flow-through pipe, which acts as a barrier for the brazing filler material. This makes the sealing of the two elements (tube and component) more effective, ensuring a complete seal without risk of leakage.

Preferably, the shape of the holes of the structural component defines a projection adapted to at least partially obstruct said connecting space (e) in the hole, and advantageously, the holes of said structural component define an irregular figure of rectangular form.

In fact, in the present invention, the complementary shape of the holes of the structural component defines a pattern that adapts to the profile of the cross-sectional pattern of the end of the gas flow-through pipe. Thus, the sealing of the two parts (part and tube) can be achieved in a more optimal manner.

According to a preferred embodiment, the structural element is provided as a support plate provided with a plurality of holes for the insertion of the ends of said gas circulation tubes housed inside the shell of the exchanger.

According to the same preferred embodiment, the end of each gas flow-through tube comprises at least two tabs arranged to overlap a same number of portions of the side of one of the half-tubes, said tabs being able to define the longitudinal position of the structural component receiving the end of the gas flow-through tube.

Advantageously, the exchanger comprises a plurality of tabs in the form of projections, which extend separately along each side of one half-pipe and are arranged to overlap the same number of side portions of the other half-pipe.

Alternatively, however, according to another embodiment, the exchanger comprises at least two tabs, each tab being formed by a single projection extending continuously along each side of one half-tube and arranged to overlap the same number of lateral portions of the other half-tube.

The tabs forming the tabs may be folded and made to overlap portions of the sides of one of the half-tubes to ensure contact between the two half-tubes and the gas turbulator during the assembly and brazing stages of the components. This provides a more robust and compact exchanger with a lower risk of leakage.

Advantageously, at least two of said projections act as locking tabs at the end of each gas flow tube, and the end of each gas flow tube can be inserted into the same number of holes of the structural component of the exchanger until it stops against one of the locking tabs.

According to one embodiment, the length of the protrusion or tab is in the range of 0.5mm to 15 mm.

Advantageously, the half-pipe forming the gas flow-through pipe is a U-shaped plate and the tab is formed on the side of one of the U-shaped plates, preferably as a projection.

According to a second aspect, the invention provides a method of manufacturing a claimed exchanger, comprising the steps of:

a. two open half-tubes are stacked to form each gas flow-through tube,

b. the two half-pipes are mechanically fixed together,

c. inserting the end of each gas flow-through tube in some holes of the structural components of the exchanger, said holes having a shape complementary to the cross-section of said gas flow-through tube, adapted to at least partially block said connection space (e),

d. filling the joint space (e) with a brazing filler material, and

e. the brazing filler material is used to braze the gas flow tubes and the structural members together.

Preferably, in step c, the shape of the hole of the structural component defines a protrusion adapted to at least partially block internally said connecting space (e) in the hole of the structural component.

Advantageously, the end of the side of one of the half-tubes comprises at least two tabs arranged to overlap a same number of portions of the side of the other half-tube, and said step b comprises a step of folding said tabs on a same number of side portions of the other half-tube.

According to one embodiment of the method, in step c, the end of each gas flow tube is inserted into a hole of the structural component until it stops against two of the tabs, so that the tabs delimit the position of the structural component.

According to a preferred embodiment, in step a, the gas turbulator element is arranged between two open half-tubes.

The claimed manufacturing method ensures and improves the contact between the components, in particular between the half-pipe and the flow perturbation element, and between the gas flow-through pipe formed by said open half-pipe and the structural component receiving the end of the gas flow-through pipe. This ensures a good quality of brazing or welding and therefore a more robust exchanger with a longer service life.

Drawings

The accompanying schematic drawings illustrate a practical embodiment, provided by way of non-limiting example to assist understanding of the foregoing, and in which:

FIG. 1 is an exploded view of a gas heat exchanger comprising a heat exchange housing, a plurality of gas flow-through tubes made of open half-tubes containing flow perturbation elements, and structural components receiving the ends of the gas tubes located within the housing;

FIG. 2 is a schematic perspective view of a structural component provided with holes having a shape complementary to the shape of the cross-section of a gas flow-through tube inserted into one of the holes;

FIG. 3 is a detail of the front view of FIG. 2, showing a protrusion defining the shape of the hole of the structural part to adapt to the shape of the cross section of the gas flow-through pipe formed by two open "U" -shaped half-pipes;

figure 4 shows a prior art exchanger similar to that of figure 3. The figure shows the connecting space (e) formed by the cross-sectional shape of the gas flow-through pipe made of two U-shaped open half-pipes.

Detailed Description

Preferred embodiments of a heat exchanger for gas and a gas circulation pipe according to the present invention are described below with reference to fig. 1 to 4.

The gas exchanger according to the present invention comprises:

a heat exchange casing 1 defining a circuit for the circulation of a coolant fluid,

a plurality of gas circulation tubes 2 arranged inside the casing 1 to exchange heat with the coolant fluid, and

two structural parts 3 provided with a plurality of holes for receiving the ends of the gas circulation tubes 2 in the respective ends of the heat exchanger shell 1,

fig. 1 is an exploded schematic view of the claimed gas exchanger, which exemplarily shows a gas flow-through tube 2 made of two open half-tubes 2a, 2b, said two open half-tubes 2a, 2b being formed by two U-shaped plates containing flow perturbation elements 5 to improve the transfer of heat from the gas. Each gas flow-through pipe 2 is assembled by mounting the two half-pipes 2a, 2b opposite each other so that the side of one half-pipe 2b overlaps with the portion 7 of the corresponding side of the other half-pipe 2a, the shape of the cross-section of the gas pipe 2 leaving a connecting space (e) in the hole 4 of the structural component 3 receiving the end of said gas flow-through pipe 2.

Fig. 4 shows a cross section of the end of a gas flow-through pipe 2 according to the prior art, made of two U-shaped open half-pipes 2a, 2b and mounted in a hole 4 in the structural part 3 receiving the end of the gas flow-through pipe 2. The figure shows the connecting space (e) left by the particular shape of the cross-section of the gas tube 2.

The claimed exchanger has the advantage that the holes 4 of the structural component 3 have a shape complementary to the shape of the cross-section of the end of the gas flow-through tube 2, in particular a shape suitable for at least partially blocking said connection space (e) and for acting as a barrier for the brazing filler material. In the described embodiment, the shape of the hole is adapted by providing a protrusion 8 extending towards the side wall of one half-pipe 2a to at least partially block the connecting space (e) (see fig. 4). The size and shape of the projections 8 can vary according to the final design of the cross section of the gas flow-through pipe 2 and the shape of the holes 4 of the structural part 3 receiving the ends of said pipe 2.

In the same embodiment described and shown in the figures, in the gas flow-through pipe 2 there are a plurality of tabs 6, which extend partway along the side of the open half-pipe 2b, except for a part of the end of the half-pipe 2 b. These tabs 6 take the form of projections in the side of one half-tube 2b in the form of a U-shaped plate. These projections can be folded and overlapped with portions 7 of the side of the other plate or open half-tube 2a to form the gas flow-through tube 2. In the described embodiment, the length of the protrusion is about 15 mm. However, the length may vary depending on the design of the exchanger.

Although not shown in the figures, at least one pair of the above-mentioned projections can be positioned at the end of the gas flow pipe 2 so as to act as a stop in the manner of a locking tab and delimit the position of the structural component 3. For example, two projections or locking tabs may be positioned at a distance of 0.5mm from the ends of the plate or half-tube 2b and act as stops to define the position of each structural component 3. The width of these projections, which act as locking tabs, may be, for example, about 0.5mm, to internally block the connection space (e) of the hole 4 of the structural component 3 and to act as a barrier for the brazing filler material. The remaining projections extending along the sides of the plate or half-tube 2b are designed to ensure contact between the parts during the sealing operation.

The steps of a method of manufacturing the claimed heat exchanger are described below with reference to the accompanying drawings.

In a first step, two open half-tubes 2a, 2b are stacked to form each gas flow-through tube 2. Alternatively, the inner cavity of the gas tube 2 may contain a flow perturbation element 5, which flow perturbation element 5 is inserted between the open half-tubes 2a, 2b without risk of being damaged. As a result, the thickness of the component can be reduced, which contributes to reducing the final cost of the exchanger.

In a second step, the tabs 6 of the end of each gas tube 2 are folded to overlap the same number of portions 7 of the side of one half-tube 2a, ensuring the contact of the spoiler 5 during the sealing step. In a subsequent third step, the end of each gas flow tube 2 is inserted into a hole 4 in the respective structural component 3 receiving the end of said gas tube 2, partially blocking in the connecting space (e) a protrusion (8) having the shape of the hole 4 (see fig. 3).

In the fourth step, the sealing operation is performed by filling the connection space (e) of the hole 4 in the structural member 3 receiving the end of the gas tube 2 with a brazing filler material. All parts are then brazed.

As mentioned in the description of the invention, the claimed manufacturing method ensures a good quality of brazing or welding and therefore a more robust exchanger with a longer service life.

Although reference has been made to a particular embodiment of the invention, it is apparent to a person skilled in the art that numerous variations and modifications can be made to the heat exchanger, the gas flow ducts and the method described, and that all the details mentioned can be substituted by other technically equivalent details without thereby departing from the scope of protection defined by the appended claims. For example, although the description of the example refers to the tab 6 being formed by a plurality of projections, said tab may be formed by a single projection extending continuously along the side of one plate or half-tube 2a, 2b and overlapping the same number of lateral portions of the end of the other half-tube 2a, 2b to internally block the connection space (e) of the hole 4 of the structural component 3.