Corrosion resistant charge air cooler and method of making same
a charge air cooler, corrosion-resistant technology, applied in the direction of machines/engines, laminated elements, lighting and heating apparatus, etc., can solve the problems of increasing the possibility of corrosion within the aftercooler, increasing the temperature of the charged air, etc., to resist corrosion of the core components and lower the melting point
Inactive Publication Date: 2007-03-08
BEHR GMBH & CO KG
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Benefits of technology
[0008] The invention is generally directed to a heat exchanger for a motor vehicle, such as an aftercooler, that includes turbulator components within the heat exchanger cooling tubes. The turbulator components are comprised of a core and cladding, which, when brazed in a brazing oven, create a “brown band” or sacrificial diffusion layer that resists corrosion in a superior manner when compared with pr
Problems solved by technology
The process of charging air through a turbocharger results in an increase in temperature of the charged air.
Diesel engines compress large volumes of air, which when mixed with fuel and ignited combusts to create power.
These corrosive acid condensates, such as sulfuric, acetic and formic acids, increase the possibility of corrosion within the aftercooler.
Method used
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[0021] One possible example for the application of the present invention involves an EGR turbocharged diesel engine system. FIG. 1 schematically illustrates the “plumbing” of such a system. The diesel engine itself is schematically represented by reference numeral 8. In this system, ambient air 1 enters a turbocharger 2, which is powered by exhaust gas 7 exiting the diesel engine 8. Exhaust gas 7, after powering the turbine of the turbocharger 2, is subsequently vented to the atmosphere 9. Charged air 3 exiting from turbocharger 2 is thereafter mixed with a different stream of (low pressure) exhaust gas 5. Although this mixing may occur in a variety of ways, it is illustrated in FIG. 1 as occurring in a mixer element 4, which may be a suitable valve or manifold.
[0022] In this exemplary environment, after the charged air 3 is mixed with exhaust gas 5, the mixture 6 enters an air-to-air aftercooler 10. Air mixture 6 passes through cooling tubes (described below) within the aftercoole...
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Abstract
A corrosion-resistant heat exchanger for use in cooling a mixture of exhaust gas and charged air is provided comprising an air inlet chamber, an air outlet chamber, and a plurality of flat tubes through which the mixture passes and is cooled by ambient air. The flat tubes include turbulators to promote cooling of the exhaust gas / air mixture, and the turbulators are formed from a first aluminum alloy that is cladded by a second aluminum alloy, which combination of alloys create a sacrificial “brown band” layer upon brazing. In a highly preferred embodiment, both the tubes and the turbulators are formed of the same material.
Description
FIELD OF THE INVENTION [0001] The present invention relates to a heat exchanger in general, and turbulator for a charge air cooler in particular, that is resistant to corrosion, and a method for making such a heat exchanger in an efficient manner. A heat exchanger including a turbulator made according to the present invention may be particularly advantageous for use with vehicles in which low-pressure exhaust gas is fed into the charge air cooler. BACKGROUND OF THE INVENTION [0002] Automobile and other motor vehicle manufacturers face a constantly increasing demand to produce cleaner and more fuel-efficient vehicles. These manufacturers must produce internal combustion engines that meet power demands while simultaneously satisfying the growing emissions requirements of various governmental and industry standards. [0003] Engine technologies that address this demand include electronic engine controls and associated sensors, turbochargers and exhaust / engine gas recirculation (“EGR”) me...
Claims
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Patent Timeline
Login to View More IPC IPC(8): F28D1/02
CPCF02B29/0456Y02T10/146F28F19/06F28F3/025Y02T10/12
Inventor GRAJZL, HAROLD A.
Owner BEHR GMBH & CO KG