Patent Description:
The disclosure also relates to an assembly of such heat exchange modules, to a catalyst/steam reforming assembly in a vehicle with an internal combustion engine (ICE), and to a vehicle with an internal combustion engine comprising such a catalyst/steam reforming assembly. <CIT> discloses a room heater consisting of a pipe system arranged in a substantially vertical plane for passing through a heat emitting medium and partly in good heat conducting contact with the pipe system, which forms vertical air ducts, and partly a pipe system and the secondary elements facing the room side covering. <CIT> discloses heat exchangers, including exhaust gas coolers for use in vehicles and to a method of making heat exchangers. <CIT> discloses a corrugated fin for dissipating heat of a heat exchange medium in a heat exchanger such as a radiator, an oil cooler or an after-cooler.

Fuel Reforming technology that uses the heat available in the exhaust to upgrade ethanol fuel to a higher energy level hydrogen fuel is applied in the combustion engines with higher thermal efficiency for the ICE as a result.

To manufacture the heat exchanger with different pressures and tightness requirements for the two sides is a challenge.

Another challenge is to stack and assemble the components in the correct position for a rapid and reliable automated process of welding or soldering of the pipes.

A third challenge is to manage the thermal expansion on both sides of the heat exchanger without introducing tension that may lead to cracks.

It is an object to solve these issues and to provide a heat exchange module that enables cheaper automatic production in higher volumes. It is also an object to provide a heat exchanger that can accommodate thermal expansion and contraction that occurs in process involving temperatures above 4000C that are subject to rapid variations, so that it can be used in the high temperature process of steam reforming and that has good tightness properties for H2. The heat exchanger should be compact and sturdy so that it is suitable for automotive applications.

Furthermore, the heat exchanger should be easily adaptable to provide the required capacity. It is again an object to provide a vehicle with an internal combustion engine (ICE) having an ethanol fuel reformer comprising one or more heat exchanger modules according to the invention.

A heat exchange module according to the disclosure comprises tubes extending in a width direction between the top and bottom substrates, in heat exchanging contact with the ridges, the width direction being oriented transversely to the length direction of the channels and the ridges, from an inflow side to an outflow side,.

The tubes can accommodate thermal expansion and contraction while maintaining fluid tightness.

The tubes are maintained clamped between the top and bottom corrugated substrates and can freely mover relative to the substrates so that thermal expansion and contraction of the different components is allowed while maintaining good heat transfer contact.

The tubes maintain secure fluid tightness at high and varying temperatures and pressures. This makes the module suitable for use in an ethanol steam reformer, to operate at temperatures between <NUM><NUM>C and <NUM><NUM>C.

The slits in the casing side walls, which may be formed of sheet metal, receive the tubes in a high-speed automated assembly process, and align the tubes in accurately defined positions. The slits can effectively be sealed by welding or soldering to seal the passage of each tube through the side wall.

The overlapping side walls of the casing members result in gas-tight connection by welding or soldering.

The modules according to the disclosure can be stacked and combined to form a heat transfer unit that is suited for specific applications, such as a combined three-way catalyst and steam reforming unit for ethanol for use in vehicles comprising an internal combustion engine.

substrates may be connected to a casing member along a casing side edge that is situated along a lower part of a respective casing side wall.

By welding or brazing the substrates along their edges to the side walls of the casing, a strong and reliable interconnection is obtained allowing sufficient relative movement between the casing and the substrate for accommodating thermal expansion while maintaining a defined position.

The tubes at the position of the transverse side walls may have a straight section extending in the width direction, transversely to the side walls.

The straight end parts of the tubes allow strong and fluid tight connection of the tube exterior to the slits in the side walls, which is particularly suitable in cases the heat exchange module is used in applications in which hydrogen is present in the module.

The slits in the side walls can comprise at their free end a V-shaped receiving part for guiding of the tubes upon placement of the tubes in the slits.

The V-shaped receiving part centers the tubes on placing in the slits and facilitates automated positioning and welding/brazing at high speeds.

The tubes may extend along an undulating trajectory with undulations in the width direction.

The undulating path of the tubes causes turbulence in the gases flowing over and under the tubes in crossflow, and results in improved heat transfer.

The undulating trajectory comprises bend parts at a distance from a line that is parallel to the width direction, a distance of the two adjacent undulations being between <NUM> and <NUM> times a width of a channel.

The dimensions of the undulations in the pipe allow specific tailoring of the contact area for heat transfer between the pipe and the corrugated substrates. A larger area towards the gases flowing through the channels may balance the inner surface area that is in contact with the contents of the tubes. This ratio can be established using tests or CFD to work at peak efficiency for both sides of the heat exchanger.

The position of the ridges of the upper substrate in the width direction may correspond to the position of the channels of the lower substrate.

The tubes are firmly clamped between the ridges of the upper and lower substrate for obtaining good positioning and heat transfer while allowing sufficient relative movement for accommodating thermally induced movements.

The substrates may be coated with a platinum group metal.

In addition to the substrates, that may act as a three-way catalyst (TWC), the tubes may be coated with a platinum-group metal (PGM) to activate the reforming process. The coating of the tubes may have a different specification of PGM than the TWC substrate.

The modules of the disclosure can be formed into an assembly of at least two modules stacked on top of each other, the bottom surface of the upper casing member being soldered or brazed to the top surface of the lower casing member.

A combined catalyst/steam reforming assembly may be formed, comprising a heat exchange module according to disclosure, exhaust gases being led through the channels and ethanol and steam through the tubes.

A vehicle may be provided comprising an internal combustion engine with cylinders that are connected to a fuel inlet and to an exhaust outlet, the exhaust outlet being in fluid contact with a catalyst/steam reforming assembly, such that exhaust gases flow through the channels, an evaporator that is in heat exchanging contact with the exhaust gases, a water and ethanol supply unit flowing water and ethanol through the evaporator for forming water and ethanol steam, the water and ethanol steam being passed into the tubes, and a reformed fuel duct connected to an outflow side of the tubes and being connected to a fuel inlet of the cylinders.

The heat exchange module according to the disclosure provides a compact and stable combined catalyst/ steam reforming unit for the treatment of exhaust gases and for forming H<NUM> from ethanol, such as from bio-fuel, in automotive applications.

A heat exchange module according to the disclosure will, by way of non-limiting example, be described in detail with reference to the accompanying drawings. In the drawings:.

<FIG> shows a stack <NUM> of interconnected heat exchange modules <NUM>, <NUM>, <NUM>, each module comprising two spaced-apart corrugated heat exchange substrates <NUM>, <NUM> with tubes <NUM> extending in heat exchanging contacting relationship between the substrates. The substrates <NUM>,<NUM> and tubes <NUM> are encased between top and bottom casing members <NUM>, <NUM>, the casing members having overlapping side walls <NUM>, <NUM> that are interconnected by brazing or soldering.

As can be seen in <FIG>, the top and bottom heat exchange substrates <NUM>,<NUM> have ridges <NUM>, <NUM> and channels <NUM>, <NUM> that extend in the length direction Lather tubes <NUM>, <NUM>, <NUM> extend transversely to the ridges <NUM>, <NUM> and channels <NUM>, <NUM> in the width direction W from an inflow side <NUM> to an outflow side <NUM> and are clamped between the opposing ridges and channels <NUM>, <NUM> of the top and bottom heat exchange substrates <NUM>, <NUM>. The tubes <NUM>, <NUM>, <NUM> pass through the slits <NUM>, <NUM>, <NUM> in the overlapping sidewalls <NUM>, <NUM> of the casing members <NUM>, <NUM>. Each slit <NUM>, <NUM>, <NUM> has a V-shaped end part <NUM>, <NUM> in which the tubes <NUM>-<NUM> are received and oriented during automated positioning. The tubes <NUM>, <NUM>, <NUM> are soldered into the slits <NUM>-<NUM> to form a gas-tight enclosure within the casing members <NUM>, <NUM>. The sidewalls <NUM>, <NUM> are joined in a gas-tight manner by soldering in an overlapping position along their perimeter.

The heat exchange substrates <NUM>,<NUM> are brazed against the lower edges of the sidewall <NUM> so that the corrugated parts can slide with respect to the casing members <NUM>, <NUM> while being kept firmly in place.

<FIG> shows a detail of the tubes <NUM>,<NUM>,<NUM> passing through the sidewall <NUM> via slits <NUM>,<NUM>,<NUM> with a V-shaped end part having slanting edges <NUM>, <NUM>. The tubes <NUM>, <NUM>, <NUM> extend along an undulating path in the width direction W in heat conducting contact with the heat exchange substrate <NUM>. At the position of the sidewall <NUM>, the tubes <NUM> extend along a straight line to allow easy handling upon insertion into the slits <NUM>, <NUM>, <NUM> and easy and accurate automated positioning.

<FIG> shows a perspective view of the lower casing member <NUM> and heat exchange substrate <NUM>, with the tubes <NUM> supported by the sidewalls <NUM>, <NUM> and extending from an inflow side <NUM> to an outflow side <NUM>. A number of <NUM>-<NUM> tubes may be accommodated in the arrangement shown. The undulating path of the tubes causes turbulence of the gases flowing in the length direction L, over and under the tubes, through the channels of the heat exchange substrates for improved heat transfer.

<FIG> shows the width C of the channels <NUM>,<NUM> and the amplitude D and period T of the undulating tubes <NUM>. The values of C, D and T are carefully tuned to result in optimal heat transfer of gases flowing through the channels <NUM>,<NUM> in the direction F, and a fluid substance flowing through the tubes <NUM> in a crossflow manner. C:D: T may be about <NUM>:<NUM>:<NUM>.

<FIG> shows the flow of gases flowing through the channels of the upper and lower heat exchange substrates <NUM>, <NUM> while passing over and under the tubes <NUM>. The turbulent flow pattern results in good heat exchange properties.

<FIG> shows an internal combustion engine assembly <NUM> with an internal combustion engine <NUM> having four cylinders <NUM>. A fuel inlet <NUM> supplies a fuel, that may contain bio-ethanol, for instance in the form of an E10, to the cylinders <NUM>.

A turbocharger <NUM> compresses the air that is supplied from an air intake <NUM> and transports the intake air through a cooler <NUM> to the intake manifold <NUM> for supply to the cylinders <NUM>. The exhaust gases of the fuel that has been burned in the cylinders <NUM>, leave the engine <NUM> via an exhaust manifold <NUM> and flow through an exhaust duct <NUM> to drive the turbocharger <NUM>. After passing through the turbocharger <NUM>, the exhaust gases flow via the duct <NUM> into an integrated catalytic converter/fuel reformer unit <NUM> that is formed from stacked heat exchange modules that are described in <FIG>. Via an exhaust duct <NUM>, the exhaust gases pass to an ethanol evaporator <NUM> and from there via exhaust duct <NUM> to a tail pipe to be expelled into the ambient.

A pump <NUM> is connected to a water/ethanol tank <NUM> and supplies water and ethanol from the tank <NUM> to the evaporator <NUM> where the water/ethanol, that is at ambient temperature, is brought in heat exchanging contact with the exhaust gases. The ethanol steam and water steam that is produced in the evaporator <NUM>, is supplied via a duct <NUM> to a pre-heater/cooler unit <NUM>.

The pre-heated water steam and ethanol steam mixture is fed from the unit <NUM> to the integrated catalytic converter/fuel reformer unit <NUM> through duct <NUM>, where the water and steam are flowing through the tubes <NUM> shown in <FIG>, of the reformer unit <NUM>, to be reformed into syngas. The exhaust gases flow through the channels of the heat exchange substrates. The tubes <NUM> may be coated with a PGM to activate the reforming process. The coating of the tubes may have a different specification of PGM than the coating of the heat exchange substrate, that forms a TWC for the removal of NOx and hydrocarbons from the exhaust gases.

The exhaust gases flow from the duct <NUM> in the reformer unit <NUM> through the channels <NUM>,<NUM> of the top and bottom heat exchange substrates <NUM>,<NUM>; <NUM>,<NUM> that are shown in <FIG>.

The syngas that is formed in the integrated catalytic converter/fuel reformer unit <NUM> is transported via a syngas outlet duct <NUM>, through the pre-heater/cooler unit <NUM> and preheats the water and ethanol by being brought in heat exchanging contact with the water/ethanol steam that is supplied at the inlet of the unit <NUM>.

Claim 1:
Heat exchange module (<NUM>, <NUM>, <NUM>) comprising:
a corrugated top heat exchange substrate (<NUM>) and a corrugated bottom heat exchange substrate (<NUM>), the substrates being spaced apart in a transverse direction (T), each substrate having ridges (<NUM>, <NUM>) and channels (<NUM>, <NUM>) that extend in a length direction (L), the channels (<NUM>) and ridges (<NUM>) of the top substrate (<NUM>) extending parallel to the channels (<NUM>) and ridges (<NUM>) of the bottom substrate (<NUM>),
tubes (<NUM>; <NUM>, <NUM>, <NUM>) extending in a width direction (W) between the top and bottom substrates (<NUM>, <NUM>), in heat exchanging contact with the ridges (<NUM>,<NUM>), the width direction (W) being oriented transversely to the length direction (L) of the channels and the ridges, from an inflow side (<NUM>) to an outflow side (<NUM>),
a top and a bottom casing member (<NUM>, <NUM>) comprising casing surfaces adjacent the top and bottom substrates (<NUM>, <NUM>)
characterized in that said top and bottom casing members (<NUM>, <NUM>) having at the inflow and outflow sides (<NUM>, <NUM>) a transverse side wall (<NUM>, <NUM>, <NUM>) with slits (<NUM>, <NUM>, <NUM>) oriented in the transverse direction (T) and accommodating the tubes (<NUM>; <NUM>, <NUM>, <NUM>),
the side walls (<NUM>, <NUM>) of the top and bottom casing members (<NUM>, <NUM>) overlapping and being mutually connected by soldering or brazing.