INTAKE HOUSING COMPRISING A HEAT EXCHANGER

An intake housing of a feed gas stream of an internal combustion engine and an intake module of feed gas stream, provided with said housing. By gas, can be understood to mean air or a mixture of air and exhaust gas.

The invention will find particularly its applications as part of a gas intake device, for introducing said gas into the cylinder head of an internal combustion engine of a motor vehicle.

An internal combustion engine for a motor vehicle has a plurality of combustion chambers each defined by a piston, a cylinder and a portion of a cylinder head. These combustion chambers receive a mixture of oxidizer and fuel dedicated to be burned to generate the engine work. The oxidizer contains air, which can be compressed or not, depending on whether the engine has a turbocharger or not. The air can also be mixed with said exhaust gas recirculated exhaust gas. The gas taken into the combustion chamber will be hereinafter referred to as feed gas.

It is known to increase the density of these feed gas provided by conducting cooling them, for example by promoting heat exchange between the feed gas and a flow of air external to the vehicle via an air/air heat exchanger.

It is also known to make cooling by exchange between the feed gas and said cooling fluid, for example in the form of circulating liquid in a heat exchanger through which the feed gas.

In the former case, the heat exchanger is installed within a housing which defines the intake circuit facing of the air surrounding the internal combustion engine. The housing may, for example, be constructed from a plastic material and the heat exchanger is then housed in this case fabricated from a plastic material. It spring however that this type of housing being non-resistant plastic at high temperatures which may be encountered such as when the internal combustion engine with a turbocharger and/or when the internal combustion engine uses the diesel as a fuel.

This situation has been overcome by the use of metal cases made from a casting process. The heat exchanger then has thick walls and cap thereto an inlet box and an outlet box for the intake gas from the foundry. The intake housing is then sealed by welding the inlet manifold and the outlet manifold on thick walls of the heat exchanger. Such a solution, although satisfactory for supporting thermal stresses, is heavy to carry out, mainly due to the use of casting. Further, assembly steps are many, which cramp the cost of that component.

The aim of the present invention is thus to solve the drawbacks described above mainly by performing an intake housing whose wall which encloses or surrounds the heat exchanger is extended to crimp a volume input and/or output volume where the feed gas stream flows, [...] to say a volume where the gas flow enters and leaves the heat exchanger.

The invention has for its object to an inflow housing of an internal combustion engine adapted to receive a heat exchanger between the flow of feed gas flows into the housing and cooling said fluid, said inlet housing comprising a flow volume of feed gas and a receiving volume of the heat exchanger, said heat exchanger receiving volume being defined by at least a first metal member that includes an extension coming from material with the first metallic member, said extension defining at least in part circulating volume of feed gas. It is understood that the receiving volume is a volume in which is inscribed the heat exchanger, but strictly limited to the latter. It also includes the flow volume is the region of the housing between an end face of the heat exchanger and the port through which the feed gas stream flows, that this is in and out of the housing.

According to a first feature of the invention, the metallic member is a plate composed at least partially of aluminum.

Alternatively separate or complementary, the shape of the metal element is made by pressing.

According to a second feature of the invention, the extension extends in a plane coincident with a plane of extension of the metal member. Such a solution facilitates the manufacture of the metal element and the extension.

According to another feature of the invention, the receiving volume is delimited by a second metallic element that includes an extension coming from material with the second metallic member, said extension bounding the volume of gas flow supply oppositely to the first member with respect to the heat exchanger. It is understood herein that the heat exchanger is interposed between two metal members that are each extended by an extension defining a circulation volume flow.

In a still further feature of the invention, the inflow housing has a cover which extends between the first metal member and the second metallic member to delimit the volume of circulating gas supply. This volume is thus bordered exclusively by the extensions from metal elements and by a cover wall to isolate circulating volume from the environment the intake housing.

According to yet another feature of the invention, the extension includes at least one mechanical reinforcement. In an exemplary embodiment, this mechanical reinforcement takes the form of one or more ridges provided across the extension. Such an arrangement limits the deformation of the extension following the supply gas pressure within the circulating volume.

Advantageously, the first metallic member is integral with the heat exchanger. Such an arrangement provides for a piece integral intermediate that includes the heat exchanger and at least partially delimits the flow volume of feed gas to and/or from the heat exchanger. In when assembled, the heat exchanger thus includes walls that border at least in part the inlet chamber and/or the outlet chamber of the housing inlet.

Advantageously still, the first metal member is an end plate forming part of the heat exchanger. The end plate thus becomes part of the assembly of constituent parts of the exchanger which are contiguous with one another prior to brazing step, particularly by passing through a furnace.

Especially noteworthy is the flow volume of feed gas has an intake port of said gas, said extension being predominantly formed on the side of the intake port.

Finally, the invention aims at an air intake module for an internal combustion engine comprising an intake housing as shown above and a heat exchanger, provided in or inside the intake housing at the receiving area.

A very first advantage of the invention resides in the provision of an inflow housing simple and economic production, and able to withstand high inlet temperatures.

A further advantage is the possibility of making the walls of the inlet housing is formed together with the heat exchanger, so as to form a unitary member on which is added a cover to ultimately form a finished product that is an air intake module.

Other features, details and advantages of the invention shall become apparent upon reading the description given below as an indicator in connection with the accompanying drawings in which:

figure 1 - is a perspective view of an example embodiment of an inflow housing according to the invention,

figure 2 - is a perspective view of an example embodiment of an intake module according to the invention.

Figure 1 shows an example embodiment of the inflow housing 1 of the invention. Such a housing receives a heat exchanger (visible on Figure 2), otherwise known as heat exchanger, through which passes a stream of feed gas flows into the housing. This heat exchanger serves mainly to cool the feed gas prior to their entry into the combustion chambers of an internal combustion engine mounted on a motor vehicle. The cooling of the gas stream is operated by thermal transfer between the stream and a cooling fluid flowing from the heat exchanger core. This fluid is, for example, a cooling fluid that flows in a cooling loop provided on the vehicle. Such a loop or circuit of the engine assists in the thermal conditioning of the internal combustion engine provided on the vehicle.

The inflow housing 1 includes or defines a reception volume 2 of the heat exchanger and a flow volume 3 of the feed gas.

The receiving volume 2 is the area of the inflow housing 1 in which extends the entire heat exchanger. In other words, the receiving volume 2 is identical or substantially similar to the volume occupied by the heat exchanger.

More precisely, this receiving volume 2 is bounded by at least a first metal member 4. a second metallic member 5 also defines the receiving volume 2 and the second metallic member 5 is installed opposite to the first metal member 4 with respect to the reception volume 2, i.e. with respect to the heat exchanger. The first metal member 4 and/or the second metallic member 5 are each a plate at least partially formed with aluminum. This will advantageously an aluminum alloy suitable for soldering to the interior of a furnace.

The first metal member 4 and the second metallic member 5 extend in planes parallel and separate. One of dotted lines are referenced 6 to 9 join the angles of the two metal members 4 and 5. these dotted lines illustrate the angles that border the receiving area 2.

A first lateral plane 10 passes through the first stroke and the second stroke 7.6 this first side plane defines one side of the receiving area and provision is made for installing a first flange 11 in the first lateral plane 10 to close the side of the reception volume 2.

In contrast first lateral plane 10 relative to the receiving area 2, there is a second lateral plane 12, in particular 10 side parallel to the first plane. This second side plane 12 passes through the third and the fourth provides 8 provides 9, and thus defines the receiving volume of the heat exchanger 2. This second side plane 12 receives a second flange 13 which closes the receiving volume 2 of the heat exchanger on the side opposite to the side receiving the first cheek 11.

10 side perpendicular to the first plane and the second plane side 12, there is a front plane 14 and a rear plane 15.

The frontal plane 14 is passed through the second and the third provides 7 8 provides and defines a gas inlet into the interior of the heat exchanger. This input is especially parallel and/or coincident to a front face of the exchanger which is apparent in Figure 2.

The rear plane 15 passes through the first stroke 6 and by the fourth backplane provides 9 . 15 is for example parallel to a rear side of the heat exchanger through which the feed gas stream is discharged or leaves the heat exchanger.

It is understood as well as the feed gas stream flowing between the front plane and the back plane 14 15 circulates through the heat exchanger and is cooled by the circulation of liquid fluid within a beam of which the exchanger.

The receiving volume of the heat exchanger 2 is thus defined entirely by:

- the first and the second metallic member 4 and 5,

- the first and second side plane 10 and 12, and

14 - the front plane and the rear plane 15.

In and out of the receiving volume, it is necessary to accommodate areas or portions of input and/or output. The flow volume of the present invention forms such area or portion.

According to the example of Figure 1, circulating volume 3 feed gas is at least partially enclosed by an extension 16 of the first metal element 4. this extension 16 is coming from material with the first metallic member 4 in the sense that the extension 16 extends the first metal element, with the same constituent material metallic element without the presence of a weld or any filler metal. In other words, the metal member and the extension are formed in one piece from a single plate or strip.

The metal element and its extension are advantageously formed by cutting and embossing operation. Such a forming process is made possible by the fact that the metal element is from a strip rather than from a foundry process.

The example describes circulating volume 3 in a case where this volume provides an area or inlet chamber of the feed gas stream in the exchanger. It is obvious that the invention is not limited to such a situation and it will be appreciated that this circulating volume, defined by the extension, can also be a gas outlet chamber feed, [...] to say after passage of the heat exchanger.

The extension 16 of the first metallic member defines at least in part circulating volume 3 in the sense that this extension channels the feed gas stream in the heat exchanger. In an alternative embodiment of the invention, the circulating volume 3 is also delimited or bordered by an extension 17 which is part of the second metallic element 5.

This circulating volume 3 is further defined by a first sector 18 plane which passes through the second stroke 7 and by a fifth dotted line, referenced 19. The boundary of this volume circulation 3 continues with a first sector curve 20 which passes through the fifth 19 provides a sixth and dotted line referenced 21. The latter is located at a point of inflection which delimits the first 20 bending sector to a second sector curve 22 which extends to a seventh dotted line 23. Circulating volume 3 is further defined by a second sector 24 plane which passes through the seventh line 23 and by the third provides 8. this circulating volume 3 is also delimited by the frontal plane 14. In the description made to this paragraph, it should be noted that the traffic volume 3 is free of the heat exchanger, which is camped at receiving volume 2.

Circulating volume 3 of the feed gas stream is thus delimited in its entirety by:

16 - the extension of the first member 4 and the extension 17 of the second member 5,

- the first and second sector plane 18 and 24,

- the first and second bending sector 20 and 22, and

the front plane - 14.

The section of the circulating volume 3 evolves the first sector to the second sector 18 plane plane 24, but must retain that this circulating volume 25 has a first portion wider than a second portion 26, the width corresponding to the distance between the frontal plane 14 of the edge 27 of the extension 16 or 17. 3 circulating volume of feed gas has a gas inlet opening which extends parallel to the first sector 18. plane is the opening through which the feed gas stream enters the circulation volume 3, and hence in the intake housing according to the invention. The inlet port thus has a length defined by the distance between the extension 16 of the first metal member of the extension 17 of the second metallic element 5. the width of the orifice is defined by the distance between the second and the fifth relates 7 provides 19. It is understood as well as the extension is predominantly formed on the side of the intake port, its width being greater at the first portion 25 than at the second portion 26.

The extension 16 of the first metal element 4 and/or the extension 17 of the second metallic element 5 comprises at least one mechanical reinforcement 28. In an example embodiment shown in this fig., the mechanical reinforcement 28 takes the form of one or more ribs or deformations 29 formed by deformation of the plate constituting the extension. This mechanical reinforcement is limited to the extension and does not extend onto the metal. The device provides a structural reinforcement at extensions to prevent said buckle under the effect of the pressure in the intake housing, especially in the case of an internal combustion engine having a compressor or turbocharger.

Figure 2 shows the intake module 30 of the invention. This intake module is comprised of an intake housing 1 as shown in Figure 1 and a heat exchanger 31. Advantageously, this intake module 30 is supplemented by installing a cover 32. Further, a flange 33 can be added.

The lid 32 is a member which closes the flow volume 3 so as to insulate the flow of intake gas flowing in the housing to the outside of the housing. The cover extends in at least one plane perpendicular to the plane in which extends the extension 16. The lid 32 starts at the extension 16 of the first metal element 4 and ends at the extension 17 of the second metallic element 5, in limits circulating volume 3 together with the extension 16 of the first metallic member 4 and with the extension 17 of the second metallic element 5.

The lid 32 is fabricated from sheet or strip metal, in particular aluminum or an aluminum alloy. This cover is shaped by a drawing process. The cover 32 has a central web portion 34 of substantially parallelepiped shape and two sidewalls 35 and 36 referenced extending in the length of the central band 34. These flanks 35 and 36 extend in a plane perpendicular to the plane of extension of the central strip. They are for example formed by a bending operation, or during the stamping operation.

The cover 32 has a first sector beginning at one longitudinal end of the cover. The first segment extends in a first plane and a second sector continues by extending in a second plane angled relative to the first plane at an angle of, for example, between 40 and 90 degrees, according to a folding in the anticlockwise direction. The cover 1 then has the general shape of an "I".

The inlet port 37, through which the feed gas stream enters the circulation volume 3, is formed through the second sector of the cover 32. The flange 33 includes a central opening 38 of substantially equal dimensions to the dimensions of the inlet port 37. this flange 33 is attached to the second sector of the cover 32 and has an attachment means for securing a conduit 39 through the intake system of the engine of the vehicle.

An exemplary embodiment of the heat exchanger will now be described.

The heat exchanger comprises a bundle 31 40 41 and a distribution area of the cooling medium in the beam. The beam 40 is the portion destined to the heat exchange between the feed gas stream and the coolant fluid. The heat exchanger includes a plurality of tubes 42, each formed by a pair of mated plates against each other. A shift between these plates defines the circulation of the fluid coolant in the beam 40. The plane which passes through the edge of each tube defines a front face of the heat exchanger 43 31, this surface being the first traversed by the feed gas stream along the flow direction of the latter in the intake module 30. The plane which passes through the end face 43 is here parallel and/or coincident with the frontal plane 14 which separates the receiving volume 2 relative to the circulating volume 3.

The heat exchanger 31 also includes the distribution area 41 of the coolant where the coolant is channeled to be distributed to each tube 42 of the beam 40. Between each tube 42, there is a wave-shaped spacer 44, whose function is to promote heat transfer between the cooling fluid and the flow of feed gas flowing in the inlet module 30.

The first metal member 4, equipped with its extension 16, is integral with the heat exchanger 31. In an exemplary embodiment, the first metal member is welded to the heat exchanger after formation thereof. In another alternative embodiment, the first metallic member 4 is an end plate 31 of the heat exchanger included within its scope. An end plate is a component adjoined to the heat exchanger and integral with the latter at the same time as the other components of the heat exchanger, in particular the plates and the partitions. This end plate may be coupled to the last intermediate the heat exchanger whereby it is mechanical protection. The plate can also participate in the formation of a tube 42 into which fluid flows liquid.

The paragraph above fact mentions the first metal element 4 but of course that the exchanger can be fabricated by integrating the first metal element and second metal element 4 5, each of which includes an extension defining a chamber inlet and/or outlet of the housing inlet.

The fig. 2 also shows the presence of a first hole and a second hole 45 46 formed through at least one of the metallic members 4 or 5. here, the two holes 45 and 46 are formed through the second metal member 5 substantially opposite the distribution area 41 through which fluid is dispensed into the tubes 42. These two holes to allow the coolant fluid from entering the heat exchanger 31 and form seats to receiving tubes fitted onto the metal, e.g. simultaneously solder the inflow housing 1 or of the intake module 30.

The description hereinabove mention of extension or protuberance by metal element but the invention also covers the case where at least one of the two metallic elements comprises a plurality of extensions or projections which extend on either side of that portion of the metal member which covers or overlaps the receiving area of the heat exchanger 2. Such an arrangement provides for an intake housing incorporating:

- a receiving volume of a heat exchanger defined by a metallic member,

- an intake chamber located upstream of the receiving volume with the travel direction of the airflow in the housing,

- a discharge chamber located downstream of the receiving volume with the travel direction of the airflow in the housing,

- each chamber being at least delimited by an extension coming from material with the metal element.

An air intake module according to the invention is carried out according to the following process:

- pre-assembly of at least one heat exchanger, a metal member adjoined to the exchanger 4 and comprising an extension 16 and a cover 32,

- passing through an oven in order to solder the preassembled components simultaneously.

As an improvement to this method, the first flange and the second flange 11 13 are pre-assembled to be brazed simultaneously with the preassembled components.