Intercooler tank with integrated protective structure

Abstract

Charge air cooler tank (130), which includes the following: a first section (25), a second section (27) attached to the first section (25), wherein the second section (27) is essentially elbow-shaped, wherein a structure (23) comprising a first surface (23A) facing the first section (25) and a second surface facing opposite the first surface (23A), wherein the structure (23) is integrally attached with at least one of its sides to an inner wall of the charge air cooler tank (130) and the structure (23) extends over the interior of the elbow-shaped second section (27) such that a space (29) is created between the second surface of the structure and an inner wall of the second section (27) corresponding to the delimited part of the second section (27), characterized by an assembly unit (21) for a vehicle component, wherein the assembly unit (21) is integrally provided on an outer wall of the second section (27) and delimits a part of the second section (27), the structure (23) is relatively curved in the first section (25).

Description

Technical area

[0001] The present invention relates, at a general level, to an intercooler tank with an integrated protective structure that improves thermal management in vehicles with an internal combustion engine. background

[0002] The purpose of an intercooler, historically often referred to as an intercooler, is to increase the efficiency of a turbodiesel engine. This task is achieved by lowering the temperature of the charge air coming from a turbocharger before it enters the engine. Consequently, the intercooler is positioned between the turbocharger and the engine.

[0003] The achieved reduction in air temperature will increase the density of the charge air, resulting in improved scavenging—the process of removing the burned fuel / air mixture from the engine cylinder and then drawing fresh fuel / air mixture into the cylinder. A further benefit of increasing air density is that a larger mass of air can be compressed inside the cylinder, allowing more fuel to be burned inside the combustion chamber, resulting in more energy.

[0004] The intercooler operates on the principle of heat exchange. Coolers used in automotive applications are typically air-to-air heat exchangers and are often conveniently located at the very front of the vehicle, directly behind the radiator grille. Structurally, this type of cooler typically includes an intercooler tank on the inlet side. The tank comprises a first segment, which is fluidly coupled to a fluid line leading from the turbocharger, and a second segment, which is fluidly coupled to the intercooler itself. A corresponding tank is also located on the outlet side of the intercooler.

[0005] In addition, several pipes, possibly equipped with external fins, extend between these peripherally positioned tanks and are exposed to external ambient air. The pressure difference between the turbocharger and the engine inlet forces the hot air from the inlet tank to flow through the fluid lines and reach the outlet tank. In this process, the heat from the hot air is transferred to the pipes, which are usually made of metal with a high thermal conductivity, such as aluminum. Thus, heated pipes are cooled by the freely flowing ambient air. At the same time, the temperature of the hot air is reduced. Typically, the process described above reduces the air temperature from 200°C at the radiator's inlet tank to near ambient temperature (40-50°C) at its outlet tank.

[0006] The intercooler can be used as a cooling module carrier. The cooling module comprises several different components, such as an air conditioning condenser, an oil cooler, or a cooling unit. The intercooler is also used to mount other components. Accordingly, the car radiator and the air conditioning condenser are typically attached to the intercooler. In commercial vehicles, such as trucks, which are state-of-the-art, the intercooler is suspended from the chassis or base bracket as a cooling module carrier using a suitable mounting device.

[0007] More specifically, it is suspended so that the mounting fixture is located near the intercooler's inlet / outlet tank. The mounting fixture typically comprises a rubber grommet housed in a metal housing that is in direct contact with the exterior of the intercooler. As discussed above, temperatures of up to 200°C occur at the cooler inlet. Thus, both the metal housing and the rubber grommet reach elevated temperatures, ranging between 130 and 180°C. Most traditionally used rubber materials are unsuitable for these high temperatures and will degrade due to thermal degradation. One method to prevent the rubber material from becoming excessively hot would be to install an external cooling duct in close proximity to the mounting fixture. However, this solution is not feasible due to space constraints.

[0008] JP 2011-52555 A discloses a flow control device for the intake manifold of a motor vehicle, designed to control the mixing point between EGR gas (EGR = exhaust gas recirculation) at a temperature of 200°C and ambient air. The device is structurally complex and comprises shielding plates anchored in a heat-insulating gasket made of a polymer material. A metal gasket is sandwiched between the insulating gasket and a pipe conveying EGR gas. Accordingly, and given its structural complexity, the device is relatively difficult to assemble. Insertion of the device creates an air pocket that thermally insulates an inner wall of the intake manifold. The chosen design, combined with the complexity discussed above, creates an unstable structure that could begin to flutter upon exposure to typical gas flow velocities, leading to material fatigue.In addition, wear on the structure is further increased due to the fact that the two gases flowing through the device flow in essentially opposite directions.

[0009] DE 10 2013 206 089 A1 discloses a charge air cooler assembly including a charge air cooler with an operative thermal transfer area configured to transfer heat from inside the charge air cooler to outside the charge air cooler. The charge air cooler assembly may further include a valve configured to change the operative thermal transfer area from a relatively large area to a relatively small area.

[0010] DE 10 2006 017 610 A1 discloses a heat exchanger for charge air cooling for motor vehicles with at least one tube for the flow through of at least one medium to be cooled, with at least one tube sheet for receiving tubes, with at least one side part for stiffening the heat exchanger, wherein the heat exchanger has at least one stiffening element for reducing the stresses between the tube sheet and the tubes.

[0011] According to JP 2003-14393 A, a collision wall is provided to allow cooling water to collide with a part near an inlet port to change the flow direction of the cooling water substantially by 90 degrees. Thus, the high-temperature cooling water entering a header tank collides with the collision wall to change its flow direction without directly colliding with the inner wall surface of a tank main body.

[0012] Although described in connection with an intercooler and components suspended from it, it is understood that the presented technical problem may also occur in connection with other parts of the vehicle where thermal protection is of interest, e.g. the vehicle's exhaust system.

[0013] In view of the above background, it is an object of the present invention to provide a structure that enables a reduction in the thermal load of the mounting device used for suspending the vehicle component while enhancing the structural stability. Brief description

[0014] The above-mentioned object is achieved by means of an intercooler tank according to the independent claim.

[0015] Accordingly, the intercooler tank comprises a first portion and a second portion attached to the first portion, the second portion being substantially elbow-shaped. The intercooler tank further comprises a mounting unit for a vehicle component, the mounting unit being integrally provided on an outer wall of the second portion and defining a portion of the second portion. A structure comprising a first surface facing the first portion and a second surface opposite the first surface is also included. The structure is integrally attached with at least one of its sides to an inner wall of the intercooler inlet tank, and the structure extends over the interior of the elbow-shaped second portion such that a space is created between the second surface of the structure and an inner wall of the second portion corresponding to the defined portion of the second portion.The structure arches relatively in the first section.

[0016] As a result, the inner wall of the second section, which corresponds to the demarcated part of the second section, is not directly exposed to the flow of hot EGR gas flowing through the intercooler tank. This results in less heat being transferred from the gas to this region of the inner wall. This, in turn, results in less heat being conductively transferred through the intercooler material to the integral mounting unit. Thus, the temperature rise to which the mounting unit is exposed is considerably reduced. Accordingly, the temperature of the intercooler tank in the mounting unit region is well below 130°C. This also means that the rubber grommet, which is arranged to be in thermal contact with the tank in the mounting unit region, is never exposed to unacceptably high temperatures.As a result, and knowing that the rubber material used doesn't need to withstand particularly high temperatures, a grommet made of a less advanced, more affordable rubber material can be advantageously selected. Furthermore, the elbow-shaped section is structurally reinforced by the transversely extending structure. This improves the wear resistance of the section and the intercooler as a whole.

[0017] A second aspect of the present invention relates to a vehicle comprising the claimed charge air cooler tank.

[0018] Different embodiments of the invention are disclosed in the dependent claims and in the detailed description. Brief description of the drawings Fig. 1 is a schematic view of a vehicle from above. Fig. 2 is a perspective exploded view of an intercooler with two peripheral mounting fixtures. Fig. 3 is a perspective view of a mounting fixture suitable for an intercooler and / or a cooling module. Fig. Figure 4 is a detailed view of a segment of an intercooler inlet tank showing mounting units. Fig. 5 is a sectional view showing an interior of a segment of an intercooler inlet tank including a protective structure according to a first embodiment of the present invention.

[0019] Further advantages and features of embodiments will become apparent upon reading the following detailed description in conjunction with the drawings. Detailed description

[0020] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments shown herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like reference numerals refer to like elements.

[0021] Fig. Figure 1 is a schematic view from above of a vehicle 1 suitable for implementing the present invention. The vehicle 1 shown is a truck or a tractor pulling a trailer, with a body 9 and a front pair of wheels 10A and a rear pair of wheels 10B. The vehicle 1 shown is only an example of why the vehicle of the present invention can also be implemented as a bus or a similar vehicle. A driver's compartment 7 is positioned far forward on the vehicle 1. An internal combustion engine 4 is located below the driver's compartment 7. The vehicle 1 has an intercooler 8, which is carried by the body 9 and is located at the very front of the vehicle, i.e., behind the radiator grille (not shown). The operation of the intercooler 8 is normally controlled by a control unit 19 located in Fig. 1 is shown schematically.

[0022] Fig. Figure 2 is a perspective exploded view of a charge air cooler 8 with two peripheral mounting devices 11. The devices 11 are connected by engagement with mounting units (in Fig. 4) is fixedly attached to the intercooler 8. The intercooler 8 has an inlet section 13 and an outlet section 33, respectively, which comprise an intercooler inlet tank / intercooler outlet tank. In particular, the inlet tank is connected to the Fig. 4 and Fig. 5. The two mounting devices 11 are arranged in connection with the inlet section 13 and the outlet section 33, respectively. The mounting devices 11 are typically used for suspending a cooling module, which includes, among other things, a cooling unit of the vehicle. An air conditioning condenser 59 and an oil cooler 57, both of which are to be mounted on the charge air cooler 8, are also shown.

[0023] Fig. Figure 3 is a perspective view of a mounting device 11 which is designed for use in conjunction with an intercooler (in Fig. 3 not shown) that functions as a cooling module carrier. The mounting device 11 shown is substantially elongated and has a complex shape. The device 11 is typically made of a light metal, such as aluminum. It has a series of through-holes 12 and is also provided with several shaped pieces 14. The through-holes 12 are used to mount the charge air cooler, which here is the cooling module carrier, to the chassis or the base brackets.

[0024] In this context, the upper portion of the mounting device 11 is provided with a large through-hole 15 which allows engagement with a mounting unit (in Fig. 4 and discussed in more detail). For this purpose, the mounting device 11 comprises a grommet 18, i.e., a cylindrical lining made of rubber. The grommet 18 is thermally connected to the rest of the mounting device 11. The mounting device 11 is in turn in direct contact with the material of an inlet section (in Fig. 3 not shown) or an outlet section (in Fig. 3 not shown) of the intercooler, the material usually being a metal and preferably aluminum.

[0025] Fig. Figure 4 is a detailed view of a segment of an intercooler inlet tank 130, showing a mounting unit 21. The inlet tank 130 may be integrally molded to maximize its structural stability. In this embodiment, the mounting unit 21 includes a proximal blind bore 22A and a distal disc-shaped element 22B with an axial through-bore. Such a construction is suitable for inserting a Fig. 2 described mounting device 11. In this context, the term distal is defined as being separated from a protective structure (in Fig. 5) is to be understood as being away, whereas the term proximal is to be understood as being next to or closest to the structure.

[0026] In a variant, the engagement of the mounting device 11 and the mounting unit 21 is implemented by providing the blind hole 22A of the mounting unit 21 with an internal thread. The mounting device 11 is then secured by means of a suitable screw, which is secured by the Fig. 3 discussed large through-hole, secured to the mounting unit 21.

[0027] Fig. 5 is a sectional view showing an interior of a segment of a charge air cooler inlet tank 130 including a protective structure 23 according to a first embodiment of the present invention. The inlet tank 130 has a first portion 25. The first portion 25 is substantially straight in this embodiment. The inlet tank 130 further includes a second portion 27 attached to the first portion 25. The second portion 27 is substantially elbow-shaped. A mounting unit 21 for a vehicle component, such as a cooling module, is integrally provided on an outer wall of the second portion 27. The mounting unit 21 defines a part of the second portion 27. A protective structure 23 is integrally attached with one of its sides to an inner wall of the charge air cooler inlet tank 130. The structure 23 has a first surface 23A facing the first portion 25 and a second surface (in Fig. 5 not visible), which is opposite to the first surface 23A. The protective structure 23 extends over the interior of the elbow-shaped second section 27, so that a space is created between the second surface of the structure 23 and an inner wall of the second section 27, which corresponds to the delimited part of the second section 27. The second section 27 of Fig. 5 expands, but other forms are also conceivable.

[0028] As a result, the inner wall of the second section 27 is not directly exposed to the flow of hot EGR gas to be cooled, which flows through the intercooler inlet tank 130. This results in less heat being transferred from the gas to this region of the inner wall. This, in turn, results in less heat being conductively transferred through the material of the intercooler inlet tank 130 to the defined part of the second section 27. Here, the integral provision of the unit 21 means that the unit 21 and the section of an intercooler inlet tank 130 are manufactured as one piece, usually by molding. Thus, the temperature rise to which the assembly unit 21 is exposed is considerably reduced. This also means that the rubber grommet (in Fig. 5 not shown), which is arranged so that it can be used as in connection with Fig. 3, is never exposed to unacceptably high temperatures. Consequently, and knowing that the rubber material used does not need to withstand particularly high temperatures, a grommet made of a less developed, more affordable rubber material can advantageously be selected.

[0029] In one embodiment, the defined portion of the second portion 27 is proportional to the cylindrical projection of the disc-shaped element 22B on the inner wall of the second portion 27.

[0030] In the Fig. In the embodiment shown in Figure 4, the protective structure 23 tapers toward the side with which it is attached to an inner wall of the charge air cooler inlet tank 130. In a further embodiment (not shown), the structure 23 curves relatively within the first pipe section. This keeps the internal pressure loss to a minimum.

[0031] In the drawings and description, typical preferred embodiments of the invention have been disclosed, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.

Claims

[1] Intercooler tank (130) comprising: a first section (25), a second portion (27) attached to the first portion (25), the second portion (27) being substantially elbow-shaped, wherein a structure (23) comprising a first surface (23A) facing the first portion (25) and a second surface opposite the first surface (23A), wherein the structure (23) is integrally attached with at least one of its sides to an inner wall of the intercooler tank (130), and the structure (23) extends over the interior of the elbow-shaped second portion (27) so as to create a space (29) between the second surface of the structure and an inner wall of the second portion (27) corresponding to the delimited part of the second portion (27), characterized by a mounting unit (21) for a vehicle component, the mounting unit (21) being provided integrally on an outer wall of the second section (27) and defining a part of the second section (27), wherein the structure (23) curves relatively in the first portion (25). [2] The charge air cooler tank (130) of claim 1, wherein the charge air cooler tank (130) is integrally formed. [3] Charge air cooler tank (130) according to one of the preceding claims, wherein the charge air cooler tank (130) is made of aluminum. [4] Charge air cooler tank (130) according to one of the preceding claims, wherein the mounting unit (21) comprises a proximal blind hole (22A) and a distal disc-shaped element (22B) with an axial through-hole. [5] Charge air cooler tank (130) according to claim 4, wherein the blind hole is provided with a thread. [6] Charge air cooler tank (130) according to one of the preceding claims, wherein the vehicle component is a cooling module. [7] Charge air cooler (8) comprising a charge air cooler tank (130) according to one of the preceding claims. [8] Vehicle (1) comprising an intercooler tank (130) according to any one of claims 1-6.

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