Patent Description:
Combustion engines for vehicles, in particular turbocharged combustion engines, are sometimes provided with a heat exchanger for cooling the intake air before it is supplied to the engine. <CIT> discloses an intake pipe for an internal combustion engine with a heat exchanger, comprising an outer housing of the intake pipe, wherein a feed line for charge air opens into an inlet section of the housing. The heat exchanger is part of the intake pipe system and operated with a cooling fluid. The heat exchanger includes a plurality of flat exchanger tubes. An engine flange is directly fastened to the air outlet side of the heat exchanger, and the air inlet side of the heat exchanger is connected to the intake pipe. The charge air flows through the exchanger tubes in a water jacket formed by an outer housing surrounding the exchanger tubes.

The <CIT> shows an air supply system for supplying fresh air to at least one combustion chamber of an internal combustion engine which includes a housing having a fresh air path and a lateral introduction opening. A charge-air cooler may be insertable into the housing via the introduction opening along an introduction direction. The charge-air cooler may be arranged in the housing and the fresh air path may extend through the charge air cooler. The charge air cooler may include an outer end region closing the introduction opening. The outer end region of the charge-air cooler may be secured to the housing.

<CIT> shows a heat exchanger for cooling intake air.

For a given limited space for mounting and coupling the heat exchanger, often the size of the heat exchanger is reduced in order to fit into the available space. However, reducing the size of the heat exchanger can deteriorate its cooling efficiency. Furthermore, the coupling between the heat exchanger and the air inlet and air outlet duct usually requires that a coupling tool, e.g. a crimping tool, accesses the coupling portions of the heat exchanger and the air inlet and air outlet duct. In order to provide sufficient space for a coupling tool to access said coupling portions, often the size of the heat exchanger is further reduced, thereby further deteriorating the cooling efficiency of the heat exchanger. In view of the above, it is an object of the present invention to provide an improved heat exchanger as well as an improved air intake system. It is a further object to provide a method for mounting a heat exchanger in an air intake system.

Accordingly, a heat exchanger for cooling air with a coolant is provided. The heat exchanger can be a plate type or a tube type heat exchanger. The heat exchanger comprises: a first and a second front face as an inlet or outlet for the air, respectively, and a shell between the first and the second front face. The shell has at least one coupling element along a circumferential line of the shell, the circumferential line being spaced apart from the first front face by a predetermined distance. Further, the shell has at least one port as an inlet or an outlet for the coolant, the port being arranged at a distance from the first front face that is larger than the predetermined distance. The at least one coupling element is adapted to fixedly couple with at least one corresponding coupling element of an air inlet or air outlet duct, and the shell can comprise a tube arrangement or an internal duct system connected to the port for the coolant and adapted to guide the coolant into an insertion section of the shell. Alternatively the shell can comprise a plate type arrangement. The insertion section is located between the first front face and the circumferential line.

By at least partially inserting the volume of the heat exchanger into one of the air ducts the installation space is reduced and the coupling elements can be easier accessed.

Having the circumferential coupling elements displaced from the front face may allow for an improved access to the coupling elements and corresponding coupling elements when mounting the heat exchanger in an air intake system of a vehicle.

The air can have atmospheric pressure or can be compressed air (e.g. charged air) that is compressed by a compressor of a turbocharger or an e-booster. It is understood that when referring to air one can also contemplate of a mixture of air and redirected exhaust gas. In operation, the air flows, for example, from the first front face to the second front face of the heat exchanger.

The coolant may be a liquid coolant, e.g. water. As coolant for the heat exchanger the coolant fluid of the engine may be used. The coolant flows for example from the (inlet) port of the heat exchanger through the internal tube arrangement to the further (outlet) port of the heat exchanger. The coolant flow within the tube or plate arrangement provides an indirect means to cool the air that flows around the tubes, i.e. that flows at the outside of the tubes. The direction of the coolant flow within the heat exchanger may be perpendicular to the direction of the air flow to provide efficient cooling.

In embodiments, the first front face of the heat exchanger is a face that is permeable to air. The second front face of the heat exchanger may be a face that is permeable to air. The shell of the heat exchanger is air-tight. The shell can comprise a metal material.

The shell, the first front face and the second front face in conjunction form, for example, a housing of the heat exchanger. The shell, the first front face and the second front face in conjunction can for example have a rectangular block shape. In this case, the shell has four rectangular shaped shell sides, and the first front face and the second front face have each a rectangular shape. The shell of the heat exchanger can form a portion of the housing of an intake system.

In embodiments the shell forms a jacket for the cooling fluid, and the air to be cooled is guided through the cooling fluid in air tubes. Then, the volume enclosed by the jacket corresponds to the tube arrangement.

The insertion section of the shell may comprise portions of the shell between the first front face and the circumferential line as well as the interior volume encompassed by said front face and said portions of the shell. The insertion section accommodates a section of the tube arrangement through which the coolant is guided and around which the air to be cooled flows. The tube arrangement can include for example a bent section that is bent in the direction of the first front face. Thus, the coolant is guided into the insertion section in order to cool air also within the insertion section. Thus, active heat exchange between the coolant and the air is taking place within the insertion section of the shell.

It is understood that the embodiment with a tube arrangement not necessarily includes cylindrical or oval tubes. However, the tube arrangement can be implemented by a jacket limiting a volume for the coolant and plates separating the air from the coolant. It is a function of the "tube arrangement" to guide coolant into the insertion section in the direction of the air flow or against the direction of the air flow. One may also refer to an internal duct system for the coolant.

The at least one coupling element of the heat exchanger can be a coupling element comprising a plurality of coupling elements arranged along the circumferential line of the shell. Said coupling element(s) is/are adapted to fixedly couple with at least one corresponding coupling element, e.g. a plurality of corresponding coupling elements, of an air inlet or air outlet duct.

In embodiments, the at least one coupling element of the heat exchanger comprises a deformable element. The at least one coupling element of the heat exchanger is, for example, configured to engage with a non-deformable coupling element of the air inlet or the air outlet duct. Alternatively, or additionally, the at least one coupling element of the heat exchanger comprises a crimp element, a clip, a buckle, a lag and/or an engagement element. The at least one coupling element of the heat exchanger can also comprise a section or a spot configured for welding or soldering such as a weld spot or a solder joint.

In embodiments, the at least one coupling element of the heat exchanger comprises an element for a screw connection such as a screw hole or a screw.

The at least one coupling element of the heat exchanger along the circumferential line that is spaced apart from the first front face by a predetermined distance allows to couple the air inlet or air outlet duct to the heat exchanger such that the air inlet or air outlet duct accommodates partially the heat exchanger in its interior. In other words, a part of the heat exchanger is inserted into the air inlet or air outlet duct. Thus, a length of the heat exchanger from the first front face (e.g. the air inlet face) to the second front face (e.g. the air outlet face) is generally larger than the distance between the at least one coupling element of the heat exchanger and the second front face. Thus, the length of the heat exchanger in the direction of the air flow can be larger than the available space for mounting the heat exchanger in an air intake system of a combustion engine.

For a given limited space for mounting the heat exchanger, a larger heat exchanger can be used because a part of the volume of the heat exchanger can be accommodated in the air duct. As there is active heat exchange taking place also within the insertion section of the heat exchanger, as described above, this larger heat exchanger also has a larger area of active heat exchange compared to a heat exchanger that has an active volume only between the flanges of an air inlet and an air outlet. Thus, for a given limited space for mounting the heat exchanger, a heat exchanger with a more efficient cooling can be provided.

Furthermore, the specific arrangement of the at least one said coupling element of the heat exchanger may provide sufficient space for a coupling tool, e.g. a crimping tool, to access said at least one coupling element of the heat exchanger and/or said at least one coupling element of the air inlet or air outlet duct without reducing the length, and thus the cooling efficiency, of the heat exchanger.

According to further embodiments, the heat exchanger comprises at least one frame surrounding at least one of the first front face and the second front face, wherein the at least one coupling element of the heat exchanger is attached to the at least one frame. The frame can be integrally formed with the at least one coupling element and/or the shell. Alternatively, the shell can be formed separately. The frame and the at least one coupling element, for example, comprise metal, while the shell, for example, comprises a plastic material. The shell can be formed of a metal as well.

According to further embodiments, the tube arrangement includes flat tubes, in particular a plurality of stacked flat plates. The plurality of stacked flat plates can be stacked in the direction of the air flow direction. The flat plates can have rectangular block shapes with a small height in the direction of the air flow and a large surface area perpendicular to the direction of the air flow. Thereby, large cooling surfaces can be provided and, thus, an efficient cooling is achieved.

According to further embodiments, the tube arrangement includes a bundle of tubes. Thereby, a further flexibility in the tube arrangement can be provided to better accommodate the tubes in the insertion section.

The tube arrangement can be any internal duct system that guides the coolant in a direction perpendicular to the designated air flow and at least partially into the volume comprised by the insertion section. Hence, air to be cooled may flow from the inlet front face and the outlet front face thereby transferring heat to the coolant running through the duct system or tube arrangement. The heat exchanger is preferably implemented to transfer heat from the air to the coolant in the insertion section.

In embodiments, the internal duct system or tube arrangement for the coolant is implemented to divert inflowing or outflowing coolant from a respective inlet port towards the insertion section or from the insertion section towards the outlet port.

According to further embodiments, the at least one coupling element of the heat exchanger comprises a deformable element, in particular a deformable projection configured for crimp coupling, a clip, buckle, lag and/or engagement element.

The at least one coupling element of the heat exchanger may be configured to engage with a non-deformable coupling element of the air inlet or air outlet duct.

In embodiments, the at least one deformable coupling element is in direct contact with the shell of the heat exchanger. The deformable coupling element may be integrally formed with the shell. The deformable coupling element and the shell, for example, both comprise metal.

According to further embodiments, the at least one coupling element comprises a non-deformable element configured to couple with a deformable element of the air inlet or air outlet duct, in particular by means of a crimp connection, clip connection, buckle connection and/or engaging connection.

The at least one non-deformable coupling element of the heat exchanger can for example be configured to engage with a deformable coupling element of the air inlet or air outlet duct.

According to further embodiments, the shell comprises at least one further coupling element arranged at the edge of the shell adjacent to the second front face, the at least one further coupling element being adapted to fixedly couple with at least one corresponding further coupling element of a further air inlet or air outlet duct.

Thereby, a further air inlet or air outlet duct can be coupled to the heat exchanger at the edge of the shell. Having an asymmetric arrangement of circumferential coupling means with respect to the length direction of the heat exchanger may facilitate the assembly of the exchanger in the intake duct.

According to further embodiments, the shell comprises at least one further coupling element along a further circumferential line of the shell, the further circumferential line being spaced apart from the second front face by a further predetermined distance, wherein the at least one further coupling element is adapted to fixedly couple with at least one corresponding further coupling element of a further air inlet or air outlet duct, and wherein the tube arrangement is adapted to guide the coolant into a further insertion section of the shell, the further insertion section being located between the second front face and the further circumferential line.

Having both circumferential coupling elements displaced from the first and second inlet or outlet front face may facilitate the access to the coupling elements with a tool to connect the elements and/or activate the fixed coupling with the air ducts.

The port is, for example, an inlet port for the coolant. Then, the further port is, for example, an outlet port for the coolant. The tube arrangement is connected, for example, to the inlet port and the outlet port such that the coolant is guided from the inlet port through the tubes of the tube arrangement inside the shell of the heat exchanger to the outlet port. Thereby, the coolant is guided on its way through the tube arrangement into the insertion section and into the further insertion section of the shell. The insertion section can be used for an active heat transfer from the air to the coolant.

The first front face of the heat exchanger is, for example, an inlet face for the air to be cooled. The second front face is, for example, an outlet face for the cooled air. In this case, the inlet face of the heat exchanger is connected to an air inlet duct, and the outlet face of the heat exchanger is connected to an air outlet duct, respectively. Furthermore, in this case, the coupling element of the heat exchanger is adapted to fixedly couple to a corresponding coupling element of the air inlet duct. Similarly, the further coupling element of the heat exchanger is adapted to fixedly couple to a corresponding further coupling element of the air outlet duct. Further, in this case, the air inlet duct is adapted to accommodate the first front face and the insertion section of the shell. Similarly, the air outlet duct is adapted to accommodate the second front face and the further insertion section.

Thereby, a further air inlet or air outlet duct can be coupled to the heat exchanger such that the length of the heat exchanger from the first front face to the second front face is larger than the distance between the at least one coupling element of the heat exchanger and the at least one coupling element of the further air inlet or air outlet duct.

Thus, the length of the heat exchanger from the first front face to the second front face can be even larger than the available space for mounting the heat exchanger in the air intake system of a combustion engine. Thus, for a given limited space for mounting the heat exchanger, an even larger heat exchanger with an even larger area of active heat exchange can be provided. Thus, a heat exchanger with an even more efficient cooling can be provided.

Furthermore, the position of said at least one further coupling element of the heat exchanger provides sufficient space for a coupling tool, e.g. a crimping tool, to access said at least one further coupling element of the heat exchanger without reducing the length of the heat exchanger.

The predetermined distance, and/or the further predetermined distance may be available at the outside of the respective air duct to employ a tool for connecting the coupling elements. Connecting may include crimping, welding, soldering, clipping, snapping and/or deforming using a specific tool, respectively.

According to the invention, a ratio of the predetermined distance and a distance between the first front face and the second front face is more than <NUM>%, preferably more than <NUM>%, even more preferably more than <NUM>%.

The length of the heat exchanger between the first front face and the second front face may be larger than the distance between the at least one coupling portion and the second front face by more than <NUM>%, preferably more than <NUM>%, even more preferably more than <NUM>%.

Thus, a heat exchanger with an efficient cooling can be mounted in an air intake system even when the available space for mounting a heat exchanger is by up to <NUM>%, or even up to <NUM>%, or even up to <NUM>% smaller than the length of the heat exchanger.

According to further embodiments, a ratio of the further predetermined distance and the distance between the first front face and the second front face is more than <NUM>%, preferably more than <NUM>%, even more preferably more than <NUM>%.

Thereby, a heat exchanger with an even more efficient cooling can be mounted in an air intake system even when the available space for mounting a heat exchanger is by up to <NUM>%, or even up to <NUM>%, or even up to <NUM>% smaller than the length of the heat exchanger.

According to further embodiments, a distance between the circumferential line and the further circumferential line is between <NUM> and <NUM>, and the distance between the first front face and the second front face is between <NUM> and <NUM>.

Thereby, a heat exchanger having a length ranging between <NUM> and <NUM> can be mounted in an air intake system in which the available space for mounting a heat exchanger is only in the range of <NUM> and <NUM>.

According to further embodiments, the heat exchanger is configured to cool air compressed by a turbocharger. Thereby, a better fuel efficiency for the engine supplied with the cooled air is provided.

According to another aspect of this disclosure an air intake system for an internal combustion engine is provided. The air intake system comprises a heat exchanger configured to cool air with a coolant. The heat exchanger comprises a first and a second front face as an inlet or outlet for the air, respectively, and a shell between the first and the second front face. The shell has at least one coupling element along a circumferential line of the shell, the circumferential line being spaced apart from the first front face by a predetermined distance. The shell also has at least one port as an inlet or an outlet for the coolant, the port being arranged at a distance from the first front face that is larger than the predetermined distance. The air intake system further comprises an air inlet or air outlet duct for guiding air to or from the first front face of the heat exchanger. The air inlet or air outlet duct has at least one corresponding coupling element adapted to fixedly couple with the at least one coupling element of the heat exchanger. The at least one coupling element and the at least one corresponding coupling element are fixedly coupled to one another. The shell comprises a tube arrangement for an internal duct system connected to the port for the coolant and adapted to guide the coolant into an insertion section of the shell, the insertion section being between the first front face and the circumferential line. Furthermore, the air inlet or air outlet duct accommodates the first front face and the insertion section of the shell.

Aspects and embodiments described with respect to the heat exchanger also apply to the intake system including a respective heat exchanger.

The air inlet or outlet duct is in particular configured to guide air to or from the first front face of the heat exchanger. An inlet air duct is, for example, configured to guide air to the first front face (the inlet face) of the heat exchanger. The inlet air duct, for example, guides air compressed by a compressor of a turbocharger to the inlet face of the heat exchanger. An air outlet duct is, for example, configured to guide air from the second front face (the outlet surface) of the heat exchanger. The air outlet duct, for example, guides air from the outlet face of the heat exchanger to an intake manifold of an engine for providing cooled air to the engine.

In embodiments, the air inlet or air outlet air duct is at least partially formed by a plastic material, in particular thermoplastic material like polyamide.

In embodiments, the at least one coupling element of the heat exchanger and the at least one corresponding coupling element of the air inlet duct realize an air-tight coupling. Similarly, the at least one further coupling element of the heat exchanger and the at least one corresponding further coupling element of the air inlet duct can provide an air-tight coupling. In embodiments, the coupling elements further include a circumferential sealing for tightly coupling the heat exchanger with the air ducts.

In embodiments, the heat exchanger is implemented as explained above or below.

According to further embodiments, the intake system comprises a turbocharger for compressing the intake air for the heat exchanger. The heat exchanger may be arranged in an air flow path between the turbocharger and the engine.

According to further embodiments, the at least one corresponding coupling element of the air inlet or air outlet duct is a non-deformable element configured to fixedly couple, in particular by means of a crimp connection, with the at least one coupling element of the heat exchanger, wherein the at least one coupling element of the heat exchanger comprises in particular a deformable element.

In embodiments, the air inlet and/or air outlet duct are separate parts, in particular the corresponding coupling elements are not part of the engine or an engine flange.

Further, a method for mounting a heat exchanger in an air intake system for a combustion engine is provided.

The heat exchanger comprises: a first and a second front face as an inlet or outlet for the air, respectively, and a shell between the first and the second front face. The shell has at least one coupling element along a circumferential line of the shell, the circumferential line being spaced apart from the first front face by a predetermined distance. Further, the shell has at least one port as an inlet or an outlet for the coolant, the port being arranged at a distance from the first front face that is larger than the predetermined distance. The at least one coupling element is adapted to fixedly couple with at least one corresponding coupling element of an air inlet or air outlet duct, and the shell comprises a tube arrangement or an internal duct system connected to the port for the coolant and adapted to guide the coolant into an insertion section of the shell. The insertion section is located between the first front face and the circumferential line.

The air intake system further comprises an air inlet or air outlet duct configured to guide air to or from the first front face of the heat exchanger, and the air inlet or air outlet duct comprises at least one corresponding coupling element.

The method comprises at least one of the steps of:.

In particular, the method has the advantage that for a given limited space for mounting the heat exchanger, e.g. the space between two air ducts, a larger heat exchanger can be provided and fixedly coupled. This is because the heat exchanger matrix reaches into the air duct when the heat exchanger is fixedly coupled within in the air intake system. Further, at the same time there may still be sufficient space for using a coupling tool, e.g. a crimping tool, to access said at least one coupling element of the heat exchanger and/or said at least one coupling element of the air inlet or air outlet duct. This allows an easier and more stable coupling of the heat exchanger.

In embodiments, the method comprises employing a crimping tool at an outer circumferential section of the air duct, wherein the outer circumferential section is opposite to an inner circumferential section of the air duct surrounding the insertion section.

Bringing the at least one coupling portion of the heat exchanger into contact with the at least one corresponding coupling portion of the air inlet or air outlet duct can be construed as abutting the at least one coupling portion of the heat exchanger and the at least one corresponding coupling portion of the air inlet or air outlet duct.

According to further embodiments, the fixedly coupling includes deforming at least one of the at least one coupling element of the heat exchanger and the at least one corresponding coupling element of the air inlet or air outlet duct.

The embodiments and features described above and below with reference to the heat exchanger also apply mutatis mutandis to the intake pipe with a heat exchanger and the method for arranging a heat exchanger in an intake pipe.

Further possible implementations or alternative solutions of the heat exchanger, the intake pipe and the method for arranging a heat exchanger inside an intake pipe also encompass combinations - that are not explicitly mentioned herein - of features described above or below with regard to the embodiments.

Further embodiments, features and advantages of the present heat exchanger will become apparent from the subsequent description and dependent claims, taken in conjunction with the accompanying drawings, in which:.

<FIG> shows a schematic cross-sectional view of an air intake system <NUM>. The air intake system <NUM> includes a heat exchanger <NUM> according to a first embodiment. The heat exchanger <NUM> is provided for cooling intake air F1 with a coolant F2. The heat exchanger <NUM> comprises a first front face <NUM> (inlet face) as an inlet for the air F1 and a second front face <NUM> (outlet face) as an outlet for the air F1', respectively. The heat exchanger <NUM> further comprises an air-tight shell <NUM> between the inlet face <NUM> and the outlet face <NUM> to guide the air F1 through the interior of the heat exchanger <NUM>. The shell <NUM>, the inlet face <NUM> and the outlet face <NUM> in conjunction have a rectangular block shape. The shell <NUM> has four rectangular shaped shell sides, and the inlet face <NUM> and the outlet face <NUM> each have a rectangular shape.

The heat exchanger <NUM> is connected to an air inlet duct <NUM>. The air inlet duct <NUM> is configured to guide intake air F1 to the inlet face <NUM> of the heat exchanger <NUM>. Furthermore, the heat exchanger <NUM> is connected to an air outlet duct <NUM>. The air outlet duct <NUM> is configured to guide cooled air F1' from the outlet face <NUM> of the heat exchanger <NUM> to the engine of a vehicle (not shown).

The shell <NUM> has a port <NUM> as an inlet for coolant F2 and a port <NUM> as an outlet for the coolant F2', respectively. The coolant runs inside the shell along an interior duct system that can be a tube arrangement <NUM>.

The shell <NUM> hence comprises a tube arrangement <NUM> in its interior. The tube arrangement <NUM> is connected to the inlet port <NUM> and the outlet port <NUM> for the coolant F2, F2' such that the coolant F2, F2' is guided from the inlet port <NUM> through the tubes of the tube arrangement <NUM> to the outlet port <NUM>.

The coolant flow F2, F2' within the tube arrangement <NUM> provides an indirect means to cool the air F1, F1' that flows around (i.e. at the outside of) the tubes of the tube arrangement <NUM>. The direction of the air flow from the inlet face <NUM> to the outlet face <NUM> in the example of <FIG> is substantially transverse to the direction of the coolant flow, whereby an efficient cooling of the air is provided.

The shell <NUM> has at least one coupling element or elements <NUM> along a circumferential line <NUM> of the shell <NUM>. The circumferential line <NUM> is spaced apart from the inlet face <NUM> by a predetermined distance d1. The coupling element <NUM> is adapted to fixedly couple by means of a crimp connection with a corresponding coupling element <NUM> of the air inlet duct <NUM>. The corresponding coupling elements <NUM>, <NUM> of the air ducts <NUM>, <NUM> are shown as solid blocks. , the coupling element <NUM> of the heat exchanger <NUM> is implemented as a deformable element, and the corresponding coupling element <NUM> of the air inlet duct <NUM> is a non-deformable element. The coupling element <NUM> of the heat exchanger <NUM> is configured to engage with the non-deformable coupling element <NUM> of the air inlet duct <NUM> in a crimping process. There can be a plurality of coupling elements arranged along the circumference of the shell <NUM> and/or the respective air duct <NUM>, <NUM>.

Furthermore, the shell <NUM> has a further coupling element or second coupling element <NUM> in the orientation of <FIG> on the left side. The further (left) coupling element or elements <NUM> is/are adapted to fixedly couple by means of a crimp connection with at least one corresponding further coupling element <NUM> of the air outlet duct <NUM>. In the embodiment of <FIG>, the further coupling element <NUM> is arranged at the edge of the shell <NUM> adjacent to the outlet face <NUM>. The further coupling element <NUM> of the heat exchanger <NUM> is a deformable element, and corresponding further coupling element <NUM> of the air outlet duct <NUM> is a non-deformable element. The further coupling element <NUM> of the heat exchanger <NUM> is configured to fixedly couple the non-deformable coupling element <NUM> of the air outlet duct in a crimping process. The coupling elements <NUM>, <NUM>, <NUM>, <NUM> fasten the heat exchanger <NUM> to the air ducts <NUM>, <NUM> by means of a form closure or a form fit.

The inlet port <NUM> and the outlet port <NUM> are arranged between the coupling elements <NUM>, <NUM>. In particular, the inlet port <NUM> is arranged at a distance from the inlet face <NUM> that is larger than the predetermined distance d1.

The shell <NUM> includes an insertion section <NUM> being located between the inlet face <NUM> and the circumferential line <NUM>. The insertion section <NUM> is indicted by the hashed region and comprises portions of the shell <NUM> between the inlet face <NUM> and the circumferential line <NUM> as well as the interior volume between the line <NUM> and the inlet face <NUM>. The insertion section <NUM> accommodates a section of the tube arrangement <NUM> through which the coolant F2, F2' is guided. The air F1, F1' flows around the tube arrangement <NUM> in the interior of the shell <NUM> and transfers heat to the coolant in the tube arrangement <NUM>. In the example of <FIG>, the tube arrangement <NUM> includes a bent section <NUM> that is bent in the direction of the inlet face <NUM>. Thus, the coolant F2, F2' is guided on its way through the tube arrangement <NUM> into the insertion section <NUM> of the shell <NUM> in order to cool air F1, F1' also within the insertion section <NUM>. Hence, active heat exchange between the coolant F2, F2' and the air F1, F1' is taking place also within the insertion section <NUM> of the shell <NUM>.

The arrangement of the at least one coupling element <NUM> of the heat exchanger <NUM> along the circumferential line <NUM> that is spaced apart from the inlet face <NUM> by a predetermined distance d1 allows to couple the air inlet duct <NUM> to the heat exchanger <NUM> such that the air inlet duct <NUM> accommodates a part of the heat exchanger <NUM>, namely the insertion section <NUM>, in its interior. Therefore, a length d3 of the heat exchanger <NUM> from the air inlet face <NUM> to the air outlet face <NUM> is larger than the distance between the coupling element <NUM> of the heat exchanger <NUM> and the outlet face <NUM>. Thus, the heat exchanger <NUM> is configured such that its length d3 in the direction of the air flow can be larger than the available space for mounting the heat exchanger <NUM> in an air intake system of a combustion engine. The space for mounting is sometimes limited by the mounting distance between the openings of the air inlet and outlet ducts <NUM>, <NUM>. Hence, for a given limited space for mounting the heat exchanger <NUM>, a heat exchanger having a matrix larger than the mounting distance can be used. As there is active heat exchange taking place also within the insertion section <NUM> of the heat exchanger <NUM>, as described above, this larger heat exchanger also has a larger area of active heat exchange (matrix). Thus, for a given limited space for mounting the heat exchanger <NUM>, a heat exchanger <NUM> with a more efficient cooling can be provided.

Furthermore, the arrangement of the coupling element <NUM> of the heat exchanger <NUM> being spaced apart from the front face <NUM> provides sufficient space for handling with a coupling tool without reducing the length, and thus the cooling efficiency, of the heat exchanger <NUM>. In particular, there is sufficient space for a crimping tool to access the at least one coupling element <NUM> of the heat exchanger <NUM> and/or the at least one coupling element <NUM> of the air inlet duct <NUM>. As illustrated in <FIG>, the heat exchanger <NUM> provides sufficient space in the region <NUM> left from the coupling arrangement <NUM>, <NUM> for handling with a crimping tool for example between the at least one coupling element <NUM> and the inlet pipe <NUM> as well as between the at least one corresponding coupling element <NUM> of the inlet duct <NUM> and the edge of the shell <NUM> adjacent to the inlet face <NUM>.

<FIG> shows a perspective view of the heat exchanger from <FIG> without the inlet and outlet ducts <NUM>, <NUM>. As can be seen from <FIG>, the coupling portion <NUM> of the shell <NUM> is arranged circumferentially at the outside of the shell <NUM> and is spaced apart from the inlet face <NUM> of the shell <NUM> by a distance d1. Thereby an extension of the shell <NUM> extending beyond the coupling portion <NUM> (in the orientation of <FIG> to the left) by a length d1 can be seen. This extension of the shell <NUM> includes the above described insertion section <NUM>, and it is configured to be inserted into an air inlet or air outlet duct <NUM>, <NUM>. In the embodiment of <FIG>, the insertion section <NUM> is configured to be inserted into the air inlet duct <NUM>.

As shown in <FIG>, another coupling element <NUM> is arranged at the edge of the shell <NUM> adjacent to the outlet face <NUM>. In the embodiment of <FIG>, it corresponds to the further coupling element <NUM> which is adapted to fixedly couple with the corresponding further coupling element <NUM> of the air outlet duct <NUM> (see <FIG>).

<FIG> shows a schematic cross-sectional view of an air intake system <NUM> with a heat exchanger <NUM> according to a second embodiment. The second embodiment is similar to the first embodiment apart from the arrangement of the further coupling element <NUM> of the heat exchanger <NUM>. Hereinafter, only those features of the second embodiment will be described which are different from that of the first embodiment. A description of same features will be omitted.

As shown in <FIG>, in the second embodiment the further coupling element <NUM> of the shell <NUM> is arranged along a further circumferential line <NUM> of the shell <NUM>. The further circumferential line <NUM> is spaced apart from the outlet face <NUM> by a further predetermined distance d2'. The further coupling element <NUM> is adapted to fixedly couple with the corresponding further coupling element <NUM> of the air outlet duct <NUM>. The tube arrangement <NUM> is adapted to guide the coolant F2, F2' into a further insertion section <NUM> of the shell <NUM>. The further insertion section <NUM> is located between the outlet face <NUM> and the further circumferential line <NUM>.

In the second embodiment, the air inlet duct <NUM> is further adapted to accommodate the inlet face <NUM> and the insertion section <NUM> of the shell <NUM>. Similarly, the air outlet duct <NUM> is adapted to accommodate the outlet face <NUM> and the further insertion section <NUM> of the shell <NUM>.

The length d3' of the heat exchanger <NUM> from the inlet face <NUM> to the outlet face <NUM> is larger than the distance d4' between the coupling element <NUM> and further coupling element <NUM> of the heat exchanger <NUM>.

Thus, the length d3' of the heat exchanger <NUM> from the inlet face <NUM> to the outlet face <NUM> can be even larger than the available space for mounting the heat exchanger <NUM> in an air intake system of a combustion engine. The mounting space is often limited by the distance between the openings of the air inlet and outlet ducts <NUM>, <NUM>. Thus, for a given limited space for mounting the heat exchanger <NUM>, an even larger heat exchanger <NUM> with an even larger area of active heat exchange can be provided. Thus, a heat exchanger with an even more efficient cooling can be used.

Furthermore, the specific arrangement of the coupling elements <NUM>, <NUM> of the heat exchanger <NUM> provides sufficient space for a coupling tool, e.g. a crimping tool, to access said coupling elements <NUM>, <NUM> of the heat exchanger <NUM> and the air ducts <NUM>, <NUM> without reducing the length d3' of the heat exchanger <NUM> or extending the mounting distance between the air ducts <NUM>, <NUM>.

<FIG> illustrate steps involved in a method for mounting the heat exchanger <NUM> of <FIG> inside an air intake system <NUM> of a combustion engine.

In a first step, as shown in <FIG>, an air inlet duct <NUM> and an air outlet duct <NUM> similar to the respective air inlet duct <NUM> and the air outlet duct <NUM> shown in <FIG> are provided. <FIG> shows the air intake system <NUM> without a heat exchanger.

The air inlet duct <NUM> of the air intake system <NUM> is connected to a turbocharger <NUM>. The air inlet duct <NUM> receives air F1 compressed by a compressor of the turbocharger <NUM>. The air inlet duct <NUM> guides the compressed air F1 to an inlet face <NUM> of a heat exchanger <NUM> to be mounted between the air ducts <NUM>, <NUM>. <FIG> shows a respective heat exchanger. <FIG> and <FIG> further show the air outlet duct <NUM> of the air intake system <NUM>. The air outlet duct <NUM> is configured to guide air F1' cooled by a heat exchanger <NUM> to be installed from the outlet face <NUM> of the heat exchanger <NUM> (see <FIG>). The air outlet duct <NUM> guides the cooled air F1' from the outlet face <NUM> of the respective heat exchanger <NUM>, for example, to an intake manifold of an engine (not shown) for providing cooled air to the engine.

The air inlet duct <NUM> comprises a coupling element <NUM> corresponding to the at least one coupling element <NUM> of the heat exchanger <NUM> to be mounted. The least one coupling element <NUM> of the air inlet duct <NUM> is configured to fixedly couple by means of a crimp connection with the at least one coupling element <NUM> of the heat exchanger <NUM>.

The air outlet duct <NUM> comprises at least one further coupling element <NUM> corresponding to the at least one further coupling element <NUM> of the heat exchanger <NUM>. The least one coupling element <NUM> of the air outlet duct <NUM> is configured to fixedly couple by means of a crimp connection with the at least one coupling element <NUM> of the heat exchanger <NUM>.

The distance between the coupling element <NUM> of the air inlet duct <NUM> and the coupling element <NUM> of the air outlet duct <NUM> represents the available space for mounting a heat exchanger. In other words, the configuration of the air inlet duct <NUM> and the air outlet duct <NUM> shown in <FIG> allows to mount only such a heat exchanger for which the distance between its two (sets of) coupling elements <NUM>, <NUM> corresponds to the distance between the two (sets of) coupling elements <NUM>, <NUM> of the air inlet and air outlet duct <NUM>, <NUM>.

As shown in <FIG>, in the first step also a heat exchanger <NUM> similar to the heat exchanger <NUM> of <FIG> and <FIG> is provided. For a detailed description of the features of the heat exchanger <NUM>, it is referred to the description of <FIG> and <FIG>. The coupling elements <NUM>, <NUM> can be deformable metal flaps or latches that can be used for a crimp connection with corresponding coupling elements <NUM>, <NUM> of the air ducts <NUM>, <NUM>.

As described with reference to <FIG> and <FIG>, coupling element <NUM> at the shell <NUM> of the heat exchanger <NUM> is advantageously arranged along the circumferential line <NUM> of the shell <NUM> which is spaced apart from the inlet face <NUM> by a predetermined distance d1. In this manner, the insertion section <NUM> is defined which is to be inserted into the air inlet duct <NUM>. Thus, the heat exchanger <NUM> has a length between the inlet face <NUM> and the outlet face <NUM> that is larger than the distance between the coupling element <NUM> and the coupling element <NUM>. Furthermore, the advantageous arrangement of the coupling element <NUM> also provides sufficient space for a coupling tool to access the coupling elements <NUM>, <NUM>, as will be described later.

The further coupling element <NUM> of the shell <NUM> of the heat exchanger <NUM> is in this example arranged at the edge of the shell <NUM> adjacent to the outlet face <NUM>.

The coupling element <NUM> and the coupling element <NUM> of the heat exchanger <NUM> are both deformable elements. The coupling element <NUM> of the air inlet duct <NUM> and the coupling element <NUM> of the air outlet duct <NUM> are both non-deformable elements. The coupling elements <NUM> and <NUM> are both configured to be crimped or coupled with the corresponding coupling element <NUM> of the air inlet duct <NUM> and the coupling element <NUM> of the air outlet duct <NUM>, respectively. <FIG> shows a state in which the deformable coupling elements <NUM> and <NUM> are not yet deformed.

In a second step, as shown in <FIG>, the insertion section <NUM> and the inlet face <NUM> of the heat exchanger <NUM> are inserted in the interior of the air inlet duct <NUM>.

Next, as shown in <FIG> as well, the coupling elements <NUM> of the heat exchanger <NUM> are brought into contact with the corresponding coupling elements <NUM> of the air inlet duct <NUM>. Furthermore, the further coupling element <NUM> of the heat exchanger <NUM> is brought into contact with the corresponding further coupling element <NUM> of the air outlet duct <NUM>. Thereby, the coupling elements <NUM> and <NUM> abut as well as the coupling elements <NUM> and <NUM>. In <FIG> a handling space <NUM> left from the flap <NUM> is indicated that is available for a crimp tool.

In a further step, as shown in <FIG>, the coupling element <NUM> of the heat exchanger <NUM> and the corresponding coupling element <NUM> of the air inlet duct <NUM> are fixedly coupled to each other by deforming the flap <NUM> with a respective tool <NUM>. Hence, a fluid connection between the heat exchanger <NUM> and the air inlet duct <NUM> is achieved. As shown in <FIG>, fixedly coupling is performed by deforming the flap <NUM> with a crimping tool <NUM> such that it form fits with the non-deformable coupling element <NUM> of the air duct <NUM>.

As illustrated in <FIG>, the advantageous arrangement of the at least one coupling element <NUM> spaced apart from the inlet face <NUM> by the distance d1 provides sufficient space <NUM> (see <FIG>) for the crimping tool <NUM> to access the coupling elements <NUM> and <NUM>. This allows an easier and more stable coupling of the heat exchanger <NUM> to the air inlet duct <NUM>.

Furthermore, as shown in <FIG>, the further coupling element <NUM> at the left of the heat exchanger <NUM> and the corresponding further coupling element <NUM> of the air outlet duct <NUM> are fixedly coupled to each other for providing a fluid connection between the heat exchanger <NUM> and the air outlet duct <NUM>. Fixedly coupling of coupling elements <NUM> and <NUM> is performed by deforming the at least one coupling element <NUM> with the crimping tool <NUM> such that it encloses the non-deformable coupling element <NUM>. Other fixed coupling measures can be contemplated, e.g. soldering, welding, press fitting, employing clips or buckles. It is however an advantage that the heat exchanger is partly inserted into the air ducts thereby leaving space for the use of coupling tools.

Claim 1:
Heat exchanger (<NUM>, <NUM>) for cooling intake air (F1) with a coolant (F2), comprising:
a first and a second front face (<NUM>, <NUM>) as an inlet or outlet for the air (F1), respectively, and
a shell (<NUM>) between the first and the second front face (<NUM>, <NUM>), the shell (<NUM>) having at least one coupling element (<NUM>) along a circumferential line (<NUM>) of the shell (<NUM>), the circumferential line (<NUM>) being spaced apart from the first front face (<NUM>) by a predetermined distance (d1), the shell (<NUM>) having at least one port (<NUM>) as an inlet or an outlet for the coolant (F2), the port (<NUM>) being arranged at a distance from the first front face (<NUM>) that is larger than the predetermined distance (d1),
wherein the at least one coupling element (<NUM>) is adapted to fixedly couple with at least one corresponding coupling element (<NUM>) of an air inlet duct (<NUM>) or air outlet duct (<NUM>), and
wherein the shell (<NUM>) comprises a tube arrangement or an internal duct system (<NUM>) connected to the port (<NUM>) for the coolant (F2) and adapted to guide the coolant (F2) into an insertion section (<NUM>) of the shell (<NUM>), the insertion section (<NUM>) being located between the first front face (<NUM>) and the circumferential line (<NUM>), wherein a ratio of the predetermined distance (d1, d1') and a distance (d3, d3') between the first front face (<NUM>, <NUM>) and the second front face (<NUM>, <NUM>) is more than <NUM>%, preferably more than <NUM>%, even more preferably more than <NUM>%.