Inlet air turbulent grid mixer and dimpled surface resonant charge air cooler core

Abstract

A resonant charge air cooler is provided having internal structures for producing vortexes in the air flow, thus inducing turbulence and increasing heat transfer efficiency. The air cooler includes an inlet tank, an outlet tank and a plurality of tubes fluidly connecting the inlet and outlet tanks. The tubes include vortex-inducing structures such as dimples or grooves formed on their interior surfaces. A vortex-inducing structure such as wire mesh formed from a long wire, a wire grid or parallel wires on a frame is included in the inlet tank. By changing the geometry of the internal structures, turbulent eddies are created at very small length scales. Adjustment of the geometries results in vortexes that have almost the same size as those produced by the surface dimples or grooves formed on the walls of the tubes connecting the inlet and outlet tanks, whereby a resonance behavior occurs and heat transfer increases.

Description

TECHNICAL FIELD[0001]The disclosed inventive concept relates generally to charge air coolers for automotive vehicles. More particularly, the disclosed inventive concept relates to a resonant charge air cooler core having internal structures to create turbulence and thereby enhance heat transfer.BACKGROUND OF THE INVENTION[0002]It is increasingly common for internal combustion engines to be fitted with turbochargers or superchargers to force more air mass into the engine's intake manifold and combustion chamber. The increased amount of air mass is the result of the air being compressed by an air compressor driven by a turbine which is itself driven by an impeller associated with the exhaust system. While improving engine horsepower, the input of compressed air heats the intake manifold, thus causing a reduction in the density of the charge air.[0003]To offset the increased temperature of the incoming air, charge air coolers have been provided upstream of the airflow. The typical char...

AI Technical Summary

Benefits of technology

The patented invention is a charge air cooler that is smaller than existing coolers but still provides maximum cooling efficiency. This is achieved by structures within the cooler that create vortexes, which induce turbulence and increase heat transfer. By using a long wire or a wire mesh screen, the structure's geometry can be adjusted to create the same size vortexes as those produced by the cooler's walls. This results in a resonance behavior that increases heat transfer, allowing for a smaller cooler size without sacrificing cooling efficiency.

Problems solved by technology

While the technology for efficient charge air coolers continues to advance, the designers of these coolers are challenged by constraints on packaging.

However, the size of the charge air cooler is very often restricted by the available space.

Second, known components such as the active radar adjustment screw and the active grill shutter housing result in a very confined space for the charge air cooler.

The minimal space available for the charge air cooler is in conflict with the need to provide a charge air cooler that is as large as possible.

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