# US 2021/0276399 A1 · Process for manufacturing a cast metal heat exchanger housing for a vehicle heater > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0276399 A1 - Document ID: US20210276399A1 - Status: Published application - Kind: A1 - Application number: 17/191,353 - Filed: 2021-03-03 - Published: 2021-09-09 - Earliest claimed: 2020-03-05 - Assignees: Eberspächer Climate Control Systems GmbH & Co. KG - Applicants: Eberspächer Climate Control Systems GmbH - Inventors: Andreas COLLMER - Web page: https://patentgrep.com/patent/US20210276399A1 ## CPC - B22C 9/082: {Sprues, pouring cups} - B60H 1/2209: {arrangements of burners for heating an intermediate liquid (B60H1/032 takes precedence)} - B22D 31/00: Cutting-off surplus material, e.g. gates; {Cleaning and working on castings (B22D17/2076 takes precedence)} - B60H 1/2203: {the heat being derived from burners} - B60H 1/2212: {arrangements of burners for heating air} - F23L 15/04: Arrangements of recuperators - F28D 7/10: the conduits being arranged one within the other, e.g. concentrically {(multiple wall tubes for leak detection F28F1/003)} - F28F 1/16: the means being integral with the element, e.g. formed by extrusion (F28F1/22 takes precedence) - B60H 2001/2271: {Heat exchangers, burners, ignition devices} - F23N 2241/14: Vehicle heating, the heat being derived otherwise than from the propulsion plant - F24H 3/0435: {Structures comprising heat spreading elements in the form of fins} - F24H 3/065: {using fluid fuel} - F28D 2021/0096: {for space heating} - F28F 2215/04: Assemblies of fins having different features, e.g. with different fin densities - F28F 2215/10: Secondary fins, e.g. projections or recesses on main fins - Y02E 20/34: Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - B60H: ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - F23L: SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ({air-supply arrangements for fluent fuels F23C;} firebridges with means for feeding air or steam F23M3/04; baffles or shields with air supply passages F23M9/04); VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS {(dampers and throat restrictors for open fire-places F24; air inlet valves for open fire fronts F24)}; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES - F28D: HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT (fluid heaters having heat generating means and heat transferring means F24H; furnaces F27; details of heat-exchange apparatus of general) - F28F: DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION (water and air traps, air venting F16) - F23N: REGULATING OR CONTROLLING COMBUSTION (control devices specially adapted for combustion apparatus in which combustion takes place in a fluidised bed of fuel or other particles F23C10/28; condition responsive controls for regulating combustion in domestic stoves with open fires for solid fuel F24B1/187) - F24H: FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL (steam generation F22) - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract A process for manufacturing a cast metal heat exchanger housing (12) for a vehicle heater having a pot-shape housing wall (14) extending in a direction of a housing longitudinal axis (L) and having a plurality of heat transfer ribs (22) extending on an outer side of the housing wall (14) in the area of a circumferential wall (16) and in the area of a bottom wall (18) of the housing wall (14) in the direction of the housing longitudinal axis (L). The process includes metal casting wherein a sprue cross-sectional area including at least some of the heat transfer ribs (22). The cast metal heat exchanger housing has an axial end face formed upon cutting off metallic material that is essentially at right angles to the housing longitudinal axis and extends into an area of at least some of the heat transfer ribs. ## Claims ### Claim 1 A process for manufacturing a cast metal heat exchanger housing, the process comprising metal casting the metal heat exchanger housing comprising a vehicle heater pot-shape housing wall elongated in a direction of a housing longitudinal axis and comprising a plurality of heat transfer ribs extending in the direction of the housing longitudinal axis on an outer side of the housing wall in an area of a circumferential wall of the housing wall and in an area of a bottom wall of the housing wall, wherein a sprue cross-sectional area, through which molten metallic material is poured during the metal casting, comprises at least some of the heat transfer ribs. ### Claim 2 (depends on 1) The process in accordance with claim 1, wherein the sprue cross-sectional area comprises a central runner and, starting from the central runner, a plurality of diagonal ribs. ### Claim 3 (depends on 2) The process in accordance with claim 2, wherein the plurality of diagonal ribs comprise four diagonal ribs that extend starting from the central runner and wherein: two of the diagonal ribs extend diametrically in relation to one another away from the central runner; or diagonal ribs arranged directly adjacent to one another in a circumferential direction are arranged essentially at right angles to one another; or two of the four diagonal ribs extend diametrically in relation to one another away from the central runner and diagonal ribs arranged directly adjacent to one another in a circumferential direction are arranged essentially at right angles to one another. ### Claim 4 (depends on 2) The process in accordance with claim 2, wherein: at least some of the heat transfer ribs extend starting from the central runner in the area of the sprue cross-sectional area; or at least some of the heat transfer ribs extend starting from the diagonal ribs in the area of the sprue cross-sectional area; or at least some of the heat transfer ribs extend starting from the central runner in the area of the sprue cross-sectional area and at least some of the heat transfer ribs extend starting from the diagonal ribs in the area of the sprue cross-sectional area. ### Claim 5 (depends on 1) The process in accordance with claim 1, wherein: the heat transfer ribs are arranged in a plurality of groups; and the heat transfer ribs of each group of heat transfer ribs are arranged essentially parallel to one another. ### Claim 6 (depends on 1) The process in accordance with claim 1, further comprising: subsequent to the metal casting, cooling of the metallic material; and subsequent to the cooling, cutting off a sprue from the heat exchanger housing to form an axial end face of the heat exchanger housing, which axial end face is essentially at right angles to the housing longitudinal axis and extends into the area of at least some of the heat transfer ribs. ### Claim 7 (depends on 6) The process in accordance with claim 6, wherein: the sprue cross-sectional area comprises a central runner and, starting from the central runner, a plurality of diagonal ribs; and upon cutting off of the sprue, the axial end face is formed extending into the diagonal ribs. ### Claim 8 (depends on 7) The process in accordance with claim 7, wherein: upon cutting off of the sprue, the axial end face is formed with an end face area of a central attachment; upon cutting off of the sprue, the axial end face is formed with end face areas of the diagonal ribs; or upon cutting off of the sprue, the axial end face is formed with an end face area of a central attachment and with an end face areas of the diagonal ribs. ### Claim 9 (depends on 6) The process in accordance with claim 6, wherein: the heat transfer ribs are arranged in a plurality of groups; the heat transfer ribs of each group of heat transfer ribs are arranged essentially parallel to one another; and upon cutting off the sprue, the axial end face is formed with end face portions extending into the groups of the heat transfer ribs. ### Claim 10 A cast metal heat exchanger housing for a vehicle heater, the cast metal heat exchanger housing comprising: a pot-shape housing wall elongated in a direction of a housing longitudinal axis; and a plurality of heat transfer ribs extending in the direction of the housing longitudinal axis on an outer side of the housing wall in an area of a circumferential wall of the housing wall and in an area of a bottom wall of the housing wall, wherein an axial end face of the heat exchanger housing, which axial end face is formed upon cutting off metallic material and is essentially at right angles to the housing longitudinal axis, extends into an area of at least some of the heat transfer ribs. ### Claim 11 (depends on 10) The cast metal heat exchanger housing in accordance with claim 10, wherein the plurality of heat transfer ribs comprise diagonal ribs extend radially outwards from a central attachment extending from the bottom wall essentially coaxially in relation to the housing longitudinal axis. ### Claim 12 A cast metal heat exchanger housing for a vehicle heater, the cast metal heat exchanger housing comprising: a pot-shape housing wall elongated in a direction of a housing longitudinal axis; and a plurality of heat transfer ribs extending in the direction of the housing longitudinal axis on an outer side of the housing wall in an area of a circumferential wall of the housing wall and in an area of a bottom wall of the housing wall, wherein an axial end face of the heat exchanger housing, which axial end face is formed upon cutting off metallic material and is essentially at right angles to the housing longitudinal axis, extends into an area of at least some of the heat transfer ribs, wherein the cast metal heat exchanger housing is formed by a process comprising metal casting the metal heat exchanger housing with a sprue cross-sectional area, through which molten metallic material is poured during the metal casting, comprising at least some of the heat transfer ribs. ### Claim 13 (depends on 12) The cast metal heat exchanger housing in accordance with claim 12, wherein the plurality of heat transfer ribs comprise diagonal ribs extend radially outwards from a central attachment extending from the bottom wall essentially coaxially in relation to the housing longitudinal axis. ### Claim 14 (depends on 12) The cast metal heat exchanger housing in accordance with claim 12, wherein the sprue cross-sectional area comprises a central runner and, starting from the central runner, a plurality of diagonal ribs. ### Claim 15 (depends on 14) The cast metal heat exchanger housing in accordance with claim 14, wherein the plurality of diagonal ribs comprise four diagonal ribs that extend starting from the central runner and wherein: two of the diagonal ribs extend diametrically in relation to one another away from the central runner; or diagonal ribs arranged directly adjacent to one another in a circumferential direction are arranged essentially at right angles to one another; or two of the four diagonal ribs extend diametrically in relation to one another away from the central runner and diagonal ribs arranged directly adjacent to one another in a circumferential direction are arranged essentially at right angles to one another. ### Claim 16 (depends on 14) The cast metal heat exchanger housing in accordance with claim 14, wherein: at least some of the heat transfer ribs extend starting from the central runner in the area of the sprue cross-sectional area; or at least some of the heat transfer ribs extend starting from the diagonal ribs in the area of the sprue cross-sectional area; or at least some of the heat transfer ribs extend starting from the central runner in the area of the sprue cross-sectional area and at least some of the heat transfer ribs extend starting from the diagonal ribs in the area of the sprue cross-sectional area. ### Claim 17 (depends on 12) The cast metal heat exchanger housing in accordance with claim 12, wherein: the heat transfer ribs are arranged in a plurality of groups; and the heat transfer ribs of each group of heat transfer ribs are arranged essentially parallel to one another. ### Claim 18 (depends on 12) The cast metal heat exchanger housing in accordance with claim 12, further comprising: subsequent to the metal casting, cooling of the metallic material; and subsequent to the cooling, cutting off a sprue from the heat exchanger housing to form an axial end face of the heat exchanger housing, which axial end face is essentially at right angles to the housing longitudinal axis and extends into the area of at least some of the heat transfer ribs. ### Claim 19 (depends on 18) The cast metal heat exchanger housing in accordance with claim 18, wherein: the sprue cross-sectional area comprises a central runner and, starting from the central runner, a plurality of diagonal ribs; upon cutting off of the sprue, the axial end face is formed extending into the diagonal ribs. ### Claim 20 (depends on 19) The cast metal heat exchanger housing in accordance with claim 19, wherein: upon cutting off of the sprue, the axial end face is formed with an end face area of a central attachment; upon cutting off of the sprue, the axial end face is formed with end face areas of the diagonal ribs; or upon cutting off of the sprue, the axial end face is formed with an end face area of a central attachment and with an end face areas of the diagonal ribs.