Patent Publication Number: US-2022213834-A1

Title: Heat exchanger

Description:
TECHNICAL FIELD 
     The present invention relates to a heat exchanger, and more particularly, to a heat exchanger capable of cooling air compressed at a high temperature and a high pressure by a turbo charger in order to increase an output of an engine. 
     BACKGROUND ART 
     Among heat exchangers, an intercooler is a device that cools air compressed at a high temperature and a high pressure by a turbo charger in order to increase an output of an engine. 
     A temperature of the air rapidly compressed by the turbo charger becomes very high, such that a volume is expanded and an oxygen density is decreased, resulting in a decrease in filling efficiency in a cylinder. Therefore, the intercooler cools the high-temperature air compressed in the turbo charger to increase suction efficiency of the cylinder of the engine and improve combustion efficiency, thereby increasing fuel efficiency. 
     The intercooler playing such a role may be divided into a water-cooled intercooler and an air-cooled intercooler according to a cooling method. Among them, the water-cooled intercooler  10  is similar in principle to the air-cooled intercooler, but is different from the air-cooled intercooler in that it cools the compressed air using cooling water of a vehicle, water, or the like, instead of external air at the time of cooling the intercooler through which the high-temperature air passes. 
     A water-cooled intercooler  10  illustrated in  FIG. 1  includes: a first header tank  20  and a second header tank  30  spaced apart from each other by a predetermined distance and formed in parallel; a first inlet pipe  40  which is formed in the first header tank  20  and through which air is introduced and a first outlet pipe  50  which is formed in the second header tank  30  and through which air is discharged; a plurality of tubes  60  having both ends fixed to the first header tank  40  and the second header tank  50  to form an air passage; fins  70  interposed between the tubes  60 ; a cover member  80  accommodating an assembly of the tubes  60  and the fins  70  and opened at one side surface thereof on which one ends of the tubes  60  are positioned and the other side surface thereof; a second inlet pipe  41  which is formed on one side surface of the cover member  80  and through which cooling water is introduced and a second outlet pipe  51  which is formed on one side surface of the cover member  80  and through which the cooling water is discharged. 
     In addition, on the contrary, cooling water passes through the insides of tubes, and a core of a heat exchanger, which is an assembly in which header tanks, tubes and fins are assembled, is disposed inside, and a housing is formed to surround the core, such that air may be cooled by the core while passing through the inside of the housing. 
     However, when such a water-cooled intercooler is installed and used in the vehicle, vibrations are applied to the core disposed inside the housing due to vibrations of the engine or vibrations transferred from a road surface. As a result, a portion in which stress is concentrated may occur in the core, resulting in damage to the core. 
     RELATED ART DOCUMENT 
     Patent Document 
     
         
         KR 10-1116844 B1 (2012 Feb. 8) 
       
    
     DISCLOSURE 
     Technical Problem 
     An object of the present invention is to provide a heat exchanger with improved durability against vibrations of a vehicle by improving a support structure of a core portion of the heat exchanger to allow the core portion to be firmly coupled to a housing. 
     Technical Solution 
     In one general aspect, a heat exchanger includes: a core portion including an inlet tank portion and an outlet tank portion in which spaces in which cooling water is stored and flows are formed and a plurality of tubes each having one end connected to the inlet tank portion and the other end connected to the outlet tank portion to form a flow passage through which the cooling water flows; an upper reinforcing plate coupled to an upper end of the core portion, having an inlet pipe and an outlet pipe formed to communicate with the inlet tank portion and the outlet tank portion, respectively, and having coupling portions formed for fixation; a lower reinforcing plate coupled to a lower end of the core portion; a first support portion coupled to one side of the lower reinforcing plate in a length direction on a lower surface of the lower reinforcing plate and absorbing vibrations; and a second support portion coupled to the other side of the lower reinforcing plate in the length direction on a lower surface of the lower reinforcing plate and absorbing vibrations. 
     In addition, the first support portion may be formed to be longer in a width direction than in the length direction, and the second support portion may be formed to be longer in the length direction than the width direction. 
     In addition, an extension line of a long axis of the first support portion and an extension line of a long axis of the second support portion may intersect each other. 
     In addition, the extension lines may be perpendicular to a central axis direction of the coupling portions of the upper reinforcing plate. 
     In addition, the first support portion may include: a first bracket coupled to the lower reinforcing plate and a first anti-vibration member fitted onto the first bracket. 
     In addition, the first bracket may have a hooking protrusion protruding from a side surface of a portion onto which the first anti-vibration member is fitted and the first anti-vibration member may have a hooking groove formed at a position corresponding to the hooking protrusion, and the hooking protrusion may be inserted and hooked into the hooking groove. 
     In addition, the first bracket may include a reinforcing plate coupling portion coupled to the lower reinforcing plate and a protruding portion extending downward from the reinforcing plate coupling portion. 
     In addition, the first bracket may be formed by bending one flat plate. 
     In addition, the first bracket may have connection portions formed to connect the reinforcing plate coupling portion and the protruding portion to each other. 
     In addition, the first anti-vibration member may have a plurality of support protrusions protruding from at least one of side surfaces thereof in a width direction or the length direction, and the support protrusions may extend along a height direction. 
     In addition, the second support portion may include: a second bracket coupled to the lower reinforcing plate and a second anti-vibration member fitted onto the second bracket. 
     In addition, the second bracket may have a hooking protrusion protruding from a side surface of a portion onto which the second anti-vibration member is fitted and the second anti-vibration member may have a hooking groove formed at a position corresponding to the hooking protrusion, and the hooking protrusion may be inserted and hooked into the hooking groove. 
     In addition, the second bracket may include a reinforcing plate coupling portion coupled to the lower reinforcing plate and a protruding portion extending downward from the reinforcing plate coupling portion. 
     In addition, the second bracket may be formed by bending one flat plate. 
     In addition, the second bracket may have connection portions formed to connect the reinforcing plate coupling portion and the protruding portion to each other. 
     In addition, the second anti-vibration member may have a plurality of support protrusions protruding from at least one of side surfaces thereof in a width direction or the length direction, and the support protrusions may extend along a height direction. 
     In addition, the heat exchanger may further include a housing formed in a concave container shape, having an air inlet which is formed on one side thereof and through which air is introduced, and having an air outlet which is formed on the other side thereof and through which the air is discharged, wherein the core portion is inserted and accommodated into a concave inner portion of the housing, the upper reinforcing plate is coupled and fixed to an upper end portion of the housing, and the first support portion and the second support portion are in contact with and supported by an inner bottom of the housing. 
     In addition, the housing may have insertion grooves concavely formed in an inner bottom surface thereof at positions corresponding to the first support portion and the second support portion, and the first support portion and the second support portion may be inserted into and supported by the insertion grooves, respectively. 
     Advantageous Effects 
     In the heat exchange according to the present invention, a support structure of the core portion of the heat exchanger is improved, such that durability of the heat exchanger against vibrations of an engine or vibrations transferred from a road surface is improved when the heat exchanger is mounted and used in a vehicle. 
    
    
     
       DESCRIPTION OF DRAWINGS 
         FIG. 1  is an exploded perspective view illustrating a conventional water-cooled intercooler. 
         FIGS. 2 to 4  are an exploded perspective view and an assembled perspective view illustrating a heat exchanger according to an embodiment of the present invention. 
         FIG. 5  is a front cross-sectional view illustrating a heat exchanger according to an embodiment of the present invention. 
         FIG. 6  is a graph for comparing simulation results obtained by performing excitation tests on the heat exchanger according to an embodiment of the present invention and a base model. 
         FIG. 7  is a perspective view illustrating a second support portion of the heat exchanger according to an embodiment of the present invention. 
         FIG. 8  is a partial cross-sectional view illustrating a first support portion of the heat exchanger according to an embodiment of the present invention. 
     
    
    
     BEST MODE 
     Hereinafter, a heat exchanger according to the present invention having the configuration as described above will be described in detail with reference to the accompanying drawings. 
       FIGS. 2 to 4  are an exploded perspective view and an assembled perspective view illustrating a heat exchanger according to an embodiment of the present invention, and  FIG. 5  is a front cross-sectional view illustrating a heat exchanger according to an embodiment of the present invention. 
     As illustrated in  FIGS. 2 to 5 , the heat exchanger according to an embodiment of the present invention may largely include a core portion  100 , an upper reinforcing plate  500 , a lower reinforcing plate  400 , a first support portion  600 , and a second support portion  700 , and may further include a housing  800 . 
     The core portion  100  may include an inlet tank portion, an outlet tank portion, and tubes, and may further include fins interposed and coupled between neighboring tubes spaced apart from each other. The input tank portion is a portion in which cooling water introduced from the outside may be stored and may flow along the inside, and may be formed along a height direction to be connected to inlet pipes  111 . The outlet tank portion is a portion in which a space in which the cooling water heat-exchanged with air passing between the tubes may be collected and stored and may flow along the inside and be discharged to the outside is formed, and may be formed along the height direction so as to be connected to an outlet pipe  121 . The tube is a portion having one end connected to the inlet tank portion and the other end connected to the outlet tank portion to form a cooling water flow passage through which the cooling water may be heat-exchanged with the air while flowing, and a plurality of tubes may be arranged to be spaced apart from each other in the height direction and formed side by side. In this case, the inlet tank portion, the outlet tank portion, and the tubes may be formed in various shapes. For example, the inlet tank portion, the outlet tank portion, and the tubes may be formed in a stacked heat exchanger shape in which a plurality of plates are stacked and formed integrally or may be formed in an extruded tube-type heat exchanger shape in which a plurality of tubular tubes are connected and fixed to a tubular tank or header tanks. The fins for improving heat exchange efficiency may be interposed between the tubes. For example, the fins may be formed in a corrugated fin shape and coupled to the tubes. In addition, the inlet tank portion and the outlet tank portion may be disposed on one side or both sides in a length direction, but it has been illustrated in the drawings that the inlet tank portion and the outlet tank portion are formed on one side in the length direction. Here, the core portion  100  may be formed in a shape in which the cooling water introduced into the inlet tank portion flows in a form in which the cooling water makes a U-turn along the tubes and is then discharged to the outside through the outlet tank portion. Thus, the cooling water introduced from the outside through the inlet pipe  111  may be distributed to the tubes while flowing in the height direction along the inlet tank portion of the core portion  100 , flow along the tubes in the length direction, makes a U-turn, be collected in the outlet tank portion, flow in the height direction, and be then discharged to the outside through the outlet pipe  121 . In this case, the air may flow from a front side of the core portion  100  to a rear side of the core portion  100  in a width direction, and may be heat-exchanged and cooled while passing between the tubes. In addition, the core portion  100  may be formed in a rectangular hexahedron shape of which the length direction is longer than the width direction when viewed on a plane in the length direction and the width direction, and may be formed in a round shape at edges where the length side and the width direction meet each other. 
     The upper reinforcing plate  500  may be coupled to an upper end of the core portion  100 , such that the core portion  100  may be formed in a shape in which it is fixed to a lower surface of the upper reinforcing plate  500 . In addition, the upper reinforcing plate  500  is formed to be wider than the core portion  100  in the length direction and the width direction, and may thus be formed in a flange shape in which the upper reinforcing plate  500  protrudes outward of a circumference of an upper surface of the core portion  100 . In addition, a plurality of through holes penetrating through upper and lower surfaces of the upper reinforcing plate  500  may be formed at positions between edges of a circumference of the upper reinforcing plate  500  and side surfaces of the core portion  100  in the length direction or the width direction along the circumference of the upper reinforcing plate  500  so as to be spaced apart from each other. Thus, the upper reinforcing plate  500  may serve to reinforce a structural strength of an upper side of the core portion  100 , and may be coupled and fixed to a housing  800  to be described later through the through holes using separate fastening means. That is, a flange-shaped portion of the upper reinforcing plate  500  in which the through holes are formed may serve as coupling portions capable of being coupled to another component or structure. 
     The lower reinforcing plate  400  may be coupled to and fixed to a lower end of the core portion  100 , and may serve to reinforce a structural strength of a lower side of the core portion  100 . 
     The first support portion  600  and the second support portion  700  serve to absorb vibrations, and may be coupled to and fixed to a lower surface of the lower reinforcing plate  400 . In addition, the first support portion  600  may be disposed on one side of the lower reinforcing plate  400  in the length direction, the second support portion  700  may be disposed on the other side of the lower reinforcing plate  400  in the length direction, and the first support portion  600  and the second support portion  700  may be disposed to be spaced apart from each other in the length direction. In addition, the first support portion  600  and the second support portion  700  may be supported by a housing  800  to be described later or another component or structure. 
     The housing  800  may be formed in a concave container shape. In addition, the housing  800  may be formed in a shape in which an upper surface thereof is opened, may have an air inlet  810  which is formed on one side thereof in the length direction and through which air is introduced, and an air outlet  820  which is formed on the other side thereof in the length direction and through which the air is discharged. In addition, fastening holes to which the fastening means are coupled may be formed at positions of the housing  800  corresponding to the through holes formed along the circumference of the upper reinforcing plate  500  along a circumferential portion of an upper end of the housing  800 . Thus, the core portion  100  is inserted and accommodated into the housing  800 , and the upper reinforcing plate  500  may be fixed by a separate fastening means in a state in which the edge portion thereof is in contact with the upper end of the housing  800 . In addition, the housing  800  may have insertion grooves  830  and  840  concavely formed in an inner bottom surface thereof at positions corresponding to the first support portion  600  and the second support portion  700 , and the first support portion  600  and the second support portion  700  may be inserted into and supported by the insertion grooves  830  and  840 . 
     Thus, vibrations transferred to the lower side of the core portion  100  are decreased by the first support portion  600  and the second support portion  700 , such that durability of the core portion  100  may be improved. 
       FIG. 6  is a graph for comparing simulation results obtained by performing excitation tests on the heat exchanger according to an embodiment of the present invention and a base model. 
     As illustrated in  FIG. 6 , in an excitation simulation result tested using a base model in which only one support portion was formed at a lower end of a core portion in which a damage mode was reproduced, a resonance frequency of the core portion in a width direction was 580.6 Hz, while in an excitation simulation result test in the heat exchanger in which two support portions at the lower end of the core portion  100  as in the present invention, a resonance frequency of the core portion in the width direction was 1035.4 Hz. That is, the resonance frequency of the core portion  100  in the width direction according to the present invention was in a range of 1000 Hz or more, which is not relatively dangerous. In addition, in this case, as a result of testing a stress concentration in a specific portion where damage to the core portion occurs due to vibrations of the resonance frequency, while a stress of the specific portion of the base model in the width direction was 50.4 MPa, while a stress of the specific portion of the core portion according to the present invention was 10.1 MPa. That is, it may be seen that in the present invention, a stress concentration generated in the specific portion of the core portion according to a change of the resonance frequency is solved, such that damage to the core portion due to the vibrations may be prevented. 
     In addition, the first support portion  600  may be formed to be longer in the width direction than in the length direction, and the second support portion  700  may be formed to be longer in the length direction than the width direction. That is, as illustrated in the drawings, the first support portion  600  is formed to be elongated along the width direction, such that a long axis of the first support portion  600  in which a long side is formed may be disposed in parallel with the width direction, and the second support portion  700  is formed to be elongated along the length direction, such that a long axis of the second support portion  700  in which a long side is formed may be disposed in parallel with the length direction. Thus, the upper reinforcing plate  500  may be coupled to the housing  800  by fastening means such as bolts to absorb vibrations in the height direction, the first support portion  600  may absorb vibrations in the length direction, and the second support portion  700  may absorb vibrations in the width direction. In addition, rotational vibrations about the height direction axis may also be decreased by the first support portion  600  and the second support portion  700 . In addition, an extension line of the long axis of the first support portion  600  and an extension line of the long axis of the second support portion  700  may be formed to intersect each other, and may be formed to be perpendicular to each other. In addition, the extension lines may be formed to be perpendicular to a central axis direction of the coupling portions (through holes) of the upper reinforcing plate. 
     In addition, the first support portion  600  may include a first bracket  610  and a first anti-vibration member  620 . In addition, the first bracket  610  may be formed in a T shape and may be formed in a shape in which a protruding portion extends downward from a reinforcing plate coupling portion, which is a horizontal portion of an upper side, the reinforcing plate coupling portion may be coupled to and fixed to the lower reinforcing plate  400 , and the first anti-vibration member  620  may have a groove formed to be downwardly concave and may be fitted and fixed onto the protruding portion so that the protruding portion, which is a vertical portion extending downward from the reinforcing plate coupling portion of the first bracket  610 , is inserted into the groove. Here, the first bracket  610  may be formed of a metal material for structural rigidity, and the first anti-vibration member  620  may be formed of an elastic material such as rubber or resin so as to absorb vibrations. Similarly, the second support portion  700  may include a second bracket  710  and a second anti-vibration member  720 , the second bracket  710  may be formed in a T shape and may be formed in a shape in which a protruding portion extends downward from a reinforcing plate coupling portion, which is a horizontal portion of an upper side, the reinforcing plate coupling portion may be coupled to and fixed to the lower reinforcing plate  400 , and the second anti-vibration member  720  may have a groove formed to be downwardly concave and may be fitted and fixed onto the protruding portion so that the protruding portion, which is a vertical portion extending downward from the reinforcing plate coupling portion of the second bracket  710 , is inserted into the groove. Here, the second bracket  710  may also be formed of a metal material for structural rigidity, and the second anti-vibration member  720  may also be formed of an elastic material such as rubber or resin so as to absorb vibrations. 
     In this case, the first support portion  600  and the second support portion  700  are formed in the same configuration and shape, so that the first support portion  600  and the second support portion  700  may be manufactured and used in common as one type of component. Thus, the number of components may be decreased, such that manufacturing and management may be easily performed. 
       FIG. 7  is a perspective view illustrating a second support portion of the heat exchanger according to an embodiment of the present invention, and  FIG. 8  is a partial cross-sectional view illustrating a first support portion of the heat exchanger according to an embodiment of the present invention. 
     As illustrated in  FIGS. 7 and 8 , the first bracket  610  of the first support portion  600  may have a hooking protrusion  612  protruding in a hook shape from a side surface of the protruding portion, which is a portion onto which the first anti-vibration member  620  is fitted, and the first anti-vibration member  620  may have a hooking groove  622  formed at a position corresponding to the hooking protrusion  612  of the first bracket  610  in a concave shape or a shape in which it penetrates through inner and outer surfaces. Thus, the hooking protrusion  612  is inserted and hooked into the hooking groove  622 , such that the first anti-vibration member  620  may be coupled to the first bracket  610  so as not to be separated from the first bracket  610  in an opposite direction to a direction in which the first anti-vibration member  620  is fitted. Similarly, the second bracket  710  of the second support portion  700  may have a hooking protrusion  712  protruding from a side surface of the protruding portion, which is a portion onto which the second anti-vibration member  720  is fitted, and the second anti-vibration member  620  may have a hooking groove  722  formed at a position corresponding to the hooking protrusion  712 . Thus, the hooking protrusion  712  is inserted and hooked into the hooking groove  722 , such that the second anti-vibration member  720  may be coupled to the second bracket  710  so as not to be separated from the second bracket  710  in an opposite direction to a direction in which the second anti-vibration member  720  is fitted. 
     In addition, the first bracket  610  of the first support portion  600  may be formed by bending one flat plate. Thus, the first bracket  610  may be formed in a shape in which the reinforcing plate coupling portion is formed in parallel with a plane in the length direction and the width direction and the protruding portion extends downward from a central portion of the reinforcing plate coupling portion. In addition, in the first bracket  610 , connection portions  611  having the shape of connecting the reinforcing plate coupling portion and the protruding portion to each other in order to reinforce a strength at a portion where the reinforcing plate coupling portion and the protruding portion that are formed in a T shape meet each other may be formed. In this case, the connection portions  611  may be formed by pressing one flat plate using a mold for bending one flat plate when forming the first bracket  610  by bending one flat plate, and reinforcing ribs may be formed in a protruding shape between the reinforcing plate coupling portion and the protruding portion having the T shape through an additional pressing process after bending one flat plate in the T shape. Similarly, the second bracket  710  of the second support portion  700  may be formed by bending one flat plate, and connection portions  711  may be formed in a protruding shape between the reinforcing plate coupling portion and the protruding portion. 
     In addition, the first bracket  610  of the first support portion  600  and the second bracket  710  of the second support portion  700  may be formed in a T shape, and the reinforcing plate coupling portions of the first bracket  610  and the second bracket  710  may be fixed to the lower surface of the lower reinforcing plate  400  fixed to the lower end of the core portion  100  by welding or rivets. 
     In addition, the first anti-vibration member  620  of the first support portion  600  and the second anti-vibration member  720  of the second support portion  700  have support protrusions  621  and  721  protruding from at least one of side surfaces thereof in the width direction or the length direction, respectively. In addition, the support protrusions  621  and  721  may extend along the height direction in which the first anti-vibration member  620  and the second anti-vibration member  720  are inserted into the insertion grooves  830  and  840 , respectively. Thus, the first support portion  600  and the second support portion  700  may be easily inserted and assembled into the insertion grooves  830  and  840  formed in the housing  800 , respectively. In addition, in a state in which the first support portion  600  and the second support portion  700  are inserted into the insertion grooves  830  and  840  formed in the housing  800 , respectively, the support protrusions  621  and  721  of the first anti-vibration member  620  and the second anti-vibration member  720  may be in contact with and supported by surfaces of the insertion grooves in the width direction and the length direction, and lower surfaces of the first anti-vibration member  620  and the second anti-vibration member  720  may be in contact with and supported by insertion grooves  830  and  840 . In addition, in this case, surfaces of the first anti-vibration member  620  and the second anti-vibration member  720  in the width direction and the length direction are spaced apart from the surfaces of the insertion grooves  830  and  840  in the width direction and the length direction, and thus, contact areas are decreased by the support protrusions  621  and  721 , such that the first support portion  600  onto which the first anti-vibration member  620  is fitted and the second support portion  700  onto which the second anti-vibration member  720  is fitted may be easily inserted into the insertion grooves  830  and  840 , respectively. 
     In addition, the core portion  100  may have sealing member insertion grooves  150  concavely formed along the height direction in both side surfaces thereof in the length direction, and sealing members  200  may be inserted and coupled into the insertion grooves  150 . In addition, in the sealing members  200 , lip seals having a small thickness than portions inserted into the insertion grooves  150  may protrude outward from an outer surface of the core portion  100 . In addition, an internal space of the housing  800  is formed to be wider than the core portion  100 , such that the core portion  100  may be easily inserted into the housing  800  when it is inserted into the housing  800 , and in a state in which the core portion  100  is inserted into the housing  800 , the lip seals of the sealing members are in contact with and closely adhered to inner surfaces of side walls of the housing  800  in the length direction, such that spaces between the inner surfaces of the side walls of the housing  800  in the length direction and the side surfaces of the core portion  100  in the length direction may be sealed by the sealing members  200 . Thus, the air introduced into the air inlet  810  of the housing  800  may pass between the tubes of the core portion  100  and be then discharged through the air outlet  820 . 
     The present invention is not limited to the embodiments described above, and may be applied to various fields. In addition, the present invention may be variously modified by those skilled in the art to which the present invention pertains without departing from the gist of the present invention claimed in the claims. 
     
       
         
           
               
             
               
                   
               
               
                 [Detailed Description of Main Elements] 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 100: core portion 
                 111: inlet pipe 
               
               
                 121: outlet pipe 
                 150: sealing member insertion groove 
               
               
                 200: sealing member 
                 400: lower reinforcing plate 
               
               
                 500: upper reinforcing plate 
                 600: first support portion 
               
               
                 610: first bracket 
                 611: connection portion 
               
               
                 612: hooking protrusion 
                 620: first anti-vibration member 
               
               
                 621: support protrusion 
                 622: hooking groove 
               
               
                 700: second support portion 
                 710: second bracket 
               
               
                 711: connection portion 
                 712: hooking protrusion 
               
               
                 720: first anti-vibration member 
                 721: support protrusion 
               
               
                 722: hooking groove 
                 800: housing 
               
               
                 810: air inlet 
                 820: air outlet 
               
               
                 830, 840: insertion groove