Charge air cooler arrangement

Abstract

Intercooler arrangement, comprising: a radiator main body (20) having a heat exchange unit (21); an upper tank (30) having a suction receiving portion (31) connected to the heat exchange unit (21) and coupled to an upper portion of the radiator main body (20); a lower tank (40) having a suction discharge portion (41) connected to the heat exchange unit (21) and coupled to a lower portion of the radiator main body (20); a bypass receiving portion (51) connected to a valve mounting portion (53) and configured to form a passage separate from the suction receiving portion (31); a bypass passage portion (61) having an inlet (63) and an outlet (65) and provided on an outer side of the radiator main body (20), the inlet (63) being connected to the bypass receiving portion (51), and the outlet (65) being connected to the intake discharge portion (41); a valve unit (70) connected to the intake receiving portion (31) and the bypass receiving portion (51) and configured to selectively transmit intake air supplied from a turbocharger (8) to the intake receiving portion (31) and the bypass receiving portion (51); and a condensate collecting section (69) formed on a lowermost side of the bypass passage section (61) and configured to communicate with the suction discharge section (41).

Description

[0001] The invention relates to a charge air cooler arrangement for a vehicle.

[0002] Generally, a vehicle's internal combustion engine system is equipped with an exhaust gas recirculation (EGR) device to return part of the exhaust gas to the intake manifold of the internal combustion engine system.

[0003] The exhaust gas recirculation device may include a high-pressure EGR (HP-EGR) unit that recirculates the exhaust gas at an upstream side of a catalyst and a low-pressure EGR (LP-EGR) unit that recirculates the exhaust gas at a downstream side of the catalyst.

[0004] A turbocharged internal combustion engine system typically includes an intercooler, which cools intake air compressed by a turbocharger, and the low-pressure EGR unit to recirculate the exhaust gas.

[0005] It has been found that in such an intercooler, while cooling the intake air, condensation may be generated due to the cooling of saturated water vapor contained in the low-pressure EGR gas. This condensation may accumulate in the intake flow path and block the flow of intake air, thereby deteriorating the intake efficiency of the intercooler and also the cooling efficiency of the intercooler by reducing a cooling area of ​​the intercooler. Furthermore, the condensation accumulated in the intake flow path may freeze in the winter season and cause breakage or damage to the intake path.

[0006] FR 3 048 027 A1 describes an intercooler assembly comprising a cooler main body having a heat exchange unit, an upper tank having an intake receiving portion connected to the heat exchange unit and coupled to an upper portion of the cooler main body, a lower tank having an intake discharge portion connected to the heat exchange unit and coupled to a lower portion of the cooler main body, a bypass receiving portion connected to a valve mounting portion and configured to form a passage separate from the intake receiving portion, a bypass conduit portion having an inlet and an outlet and provided on an outer side of the cooler main body, the inlet being connected to the bypass receiving portion and the outlet being connected to the intake discharge portion, and a valve unit,which is connected to the intake receiving portion and the bypass receiving portion and is configured to selectively transmit intake air supplied from a turbocharger to the intake receiving portion and the bypass receiving portion.,

[0007] Further charge air cooler arrangements are known from DE 10 2011 056 617 A1, DE 10 2015 208 475 A1, DE 10 2017 214 724 A1 and WO 2009 / 130 083 A1.

[0008] The invention provides an intercooler arrangement which can suppress or prevent freezing of condensate in the intercooler and can drain the condensate.

[0009] This is achieved according to the invention by a charge air cooler arrangement according to the features of claim 1. Advantageous further developments are described in the subclaims.

[0010] According to the invention, an intercooler assembly comprises: a cooler main body having a heat exchange unit, an upper tank having an intake receiving portion connected to the heat exchange unit and coupled to an upper portion of the cooler main body, a lower tank having an intake discharge portion connected to the heat exchange unit and coupled to a lower portion of the cooler main body, a bypass receiving portion connected to a valve mounting portion and configured to form a passage separately separated from (or connected to) the intake receiving portion.divided), a bypass passage portion having an inlet and an outlet and provided on an outer side of the radiator main body, the inlet being connected to the bypass receiving portion, and the outlet being connected to the intake discharge portion, and a valve unit connected to the intake receiving portion and the bypass receiving portion and configured to selectively transmit intake air supplied from a turbocharger to the intake receiving portion and the bypass receiving portion.

[0011] The exemplary charge air cooler assembly further includes a condensate collection portion formed at a lowermost side of the bypass passage portion and communicating with the intake discharge portion.

[0012] Under high temperature and high load condition, the valve unit can close the bypass intake section and open the suction intake section.

[0013] Under low temperature and low load condition, the valve unit can open the bypass intake section and close the suction intake section.

[0014] The valve unit may include: a valve housing having a main receiving portion and mounted on the valve mounting portion, the main receiving portion communicating with the suction receiving portion and the bypass receiving portion; and a valve body assembly installed on the valve housing and selectively opening and closing the passage of the suction receiving portion and the bypass receiving portion by operation of an actuator.

[0015] The valve housing may further include a first valve passage and a second valve passage each communicating with the main receiving portion.

[0016] The first valve passage may have a predetermined passage cross-section and be connected to the intake receiving portion. The second valve passage may have a passage cross-section smaller than a passage cross-section of the first valve passage and be connected to the bypass receiving portion.

[0017] An imaginary central axis of the first valve passage may be arranged closer to an imaginary central axis of the main receiving portion than to an imaginary central axis of the second valve passage.

[0018] The valve body assembly may include: a valve rotating shaft passing through the first and second valve passages and connected to the actuator, a first valve body fixedly installed on the valve rotating shaft in the first valve passage, and a second valve body fixedly installed on the valve rotating shaft in the second valve passage.

[0019] The first and second valve bodies may be circular flaps and may be fixed to the valve rotating shaft perpendicular to each other.

[0020] In exemplary embodiments, in a low temperature / low load condition at a cold start in winter, the intake air is bypassed at a relatively high temperature, and the block of condensate frozen on the intake outlet side is melted by the intake passage, so that breakage or damage of the intake flow path due to the freezing of the condensate can be prevented.

[0021] Other effects that can be achieved or are expected by an exemplary embodiment are described explicitly or implicitly in a detailed description of the present disclosure. That is, various effects that are expected according to an exemplary embodiment are described in the following detailed description.

[0022] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0023] In order to better understand the invention, various embodiments thereof will now be described by way of example, with reference to the accompanying drawings. In the drawings: Fig. 1 is a block diagram of an exemplary internal combustion engine system usable with a charge air cooler assembly according to the invention; Fig. 2 and Fig. 3 perspective views of an intercooler arrangement according to the invention; Fig. 4 shows an upper tank used in an intercooler arrangement according to the invention; Fig. 5 shows a lower tank used in an intercooler arrangement according to the invention; Fig. 6 and Fig. 7 schematic sectional views of a charge air cooler arrangement according to the invention; Fig. 8 to 10 are views of a valve unit used in a charge air cooler arrangement according to the invention; and Fig. 11 and Fig. 12 views for explaining the operation of a charge air cooler arrangement according to the invention.

[0024] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that corresponding reference characters designate like or corresponding parts and features throughout the drawings.

[0025] The present disclosure will be described more fully below with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. As those skilled in the art would appreciate, the described embodiments could be modified in various other ways without departing from the spirit or scope of the present disclosure.

[0026] In order to explain the present disclosure, parts not related to the description are omitted, and the same elements or equivalents are denoted by the same reference numerals throughout the description.

[0027] Likewise, the size and thickness of each component are shown arbitrarily in the drawings, but the invention is not necessarily limited thereto, and in the drawings, the thicknesses of layers, films, panels, regions, etc. are exaggerated for clarity.

[0028] In addition, in the following description, the division of names of components into first, second, and the like is provided when the names of the components are the same, and an order thereof is not particularly limited.

[0029] Unless explicitly stated otherwise, the term “comprise” and variations such as “comprises” or “comprising” are to be understood as implying the inclusion of the elements mentioned but not the exclusion of any other elements.

[0030] In addition, terms such as "...unit", "...means", "...part" and "...element" described in the specification each mean a unit of a comprehensive element that performs at least one function or operation.

[0031] Fig. 1 is a block diagram of an exemplary internal combustion engine system usable with a charge air cooler assembly according to an exemplary embodiment of the invention.

[0032] With reference to Fig. 1, an intercooler assembly 100 according to an exemplary embodiment may be used in an internal combustion engine system 1 of a diesel engine vehicle.

[0033] For example, the internal combustion engine system 1 comprises an intake line 2, a charge air cooler assembly 100, an internal combustion engine 3, an exhaust line 4, a diesel particulate filter (DPF) 5, a low-pressure EGR (exhaust gas recirculation) line 6, a low-pressure EGR cooler 7, a turbocharger 8, a high-pressure EGR line 9, and a high-pressure EGR cooler 10.

[0034] The internal combustion engine system 1 can recirculate a portion of an exhaust gas discharged from an exhaust manifold of the internal combustion engine 3 via the exhaust pipe 4 to the intake pipe 2. The charge air cooler assembly 100 can be used in a low-pressure EGR (LP-EGR) system that recirculates the exhaust gas to the intake pipe 2 at a downstream side of the DPF 5.

[0035] In the low-pressure EGR system, part of the exhaust gas that has passed through the DPF 5 (low-pressure EGR gas) and fresh air can be led to the intake manifold of the internal combustion engine 3 via the turbocharger 8.

[0036] Here, the intake air expands as it is compressed by the turbocharger 8, and the temperature increases, resulting in a decrease in oxygen density. To improve this, the intercooler assembly 100 is installed in the intake line 2 to cool the intake air.

[0037] The intercooler assembly 100 cools (heat exchanges) the intake air supplied from the turbocharger 8 via the intake pipe 2 and can guide the cooled intake air to the intake manifold of the internal combustion engine 3.

[0038] Hereinafter, with respect to a mounting position of the intercooler assembly 100, a portion facing upward with respect to the drawing is referred to as an upper portion, an upper end, an upper surface, or an upper end portion, and a portion facing downward is referred to as a lower portion, a lower end, a lower surface, or a lower end portion.

[0039] However, the above definition of the directions has a relative meaning, and since the directions may vary according to a reference position of the charge air cooler assembly 100 and the like, the above reference direction does not necessarily limit a reference direction of the present disclosure.

[0040] In addition, hereinafter, an “end (one end, another end, and the like)” may be defined as any end or a portion (one end portion, another end portion, and the like) including the end.

[0041] In the intercooler assembly 100 according to an exemplary embodiment, in a low-temperature / low-load condition at a cold start in winter, intake air having a relatively high temperature is bypassed to an intake outlet side, and thereby a problem of freezing of condensate on the intake outlet side can be solved.

[0042] Furthermore, an exemplary embodiment of the invention provides a charge air cooler assembly 100 capable of easily discharging condensate water accumulated on a lowermost side.

[0043] The Fig. 2 and Fig. 3 are perspective views of a charge air cooler assembly according to an exemplary embodiment of the invention.

[0044] With reference to the Fig. 2 and Fig. 3, the charge air cooler assembly 100 includes a cooler main body 20, an upper tank 30, a lower tank 40, a bypass unit 50, and a valve unit 70.

[0045] In an exemplary embodiment, the radiator main body 20 may include various accessories, such as a bracket, a plate, a ring, a block, a projection, a rib, or the like, for installing various components.

[0046] The radiator main body 20 has a heat exchange unit 21 for cooling the intake air while the intake air flows from an intake inlet side to an intake outlet side.

[0047] The heat exchange unit 21 may be formed in a known scheme of a heat exchanger and is not described in more detail.

[0048] In an exemplary embodiment, the upper container 30 receives the exhaust gases generated by the turbocharger 8 ( Fig. 1) and leads the intake air to the heat exchange unit 21.

[0049] The upper tank 30 is coupled to an upper portion of the radiator main body 20. The upper tank 30 forms an internal space connected to an upper end of the heat exchange unit 21 and has a suction receiving portion 31 connected to the heat exchange unit 21.

[0050] The intake receiving portion 31 transmits the intake air supplied from the turbocharger 8 to the heat exchange unit 21 and may be formed at an upper portion of the upper tank 30. As shown in Fig. 4, the intake receiving portion 31 forms an intake receiving passage 33 having a predetermined passage cross section.

[0051] In an exemplary embodiment, the lower tank 40 is provided to supply the intake air, which is cooled while passing from the upper tank 30 through the heat exchange unit 21, to the intake pipe 2 ( Fig. 2) to be paid.

[0052] The lower tank 40 is coupled to a lower portion of the radiator main body 20. The lower tank 40 forms an internal space connected to a lower end of the heat exchange unit 21 and has a suction and discharge portion 41 connected to the heat exchange unit 21.

[0053] The suction discharge portion 41 may communicate with the interior of the lower tank 40 at a lower portion of the lower tank 40. For example, the suction discharge portion 41 is provided in the shape of a pipe and arranged inclined upward from the lower portion of the lower tank 40.

[0054] In an exemplary embodiment, the bypass unit 50 redirects the intake air supplied from the turbocharger 8 to the upper tank 30 to the internal combustion engine 3 via the intake discharge section 41 without passing through the heat exchange unit 21 from the intake intake section 31.

[0055] The bypass unit 50 has a bypass receiving section 51, a bypass line section 61 and a condensate collecting section 69 ( Fig. 6 and Fig. 7).

[0056] As in Fig. 4, the bypass receiving portion 51 is connected to a valve mounting portion 53 on an outer side of the upper tank 30 and is provided in parallel with the suction receiving portion 31.

[0057] The bypass receiving portion 51 forms a bypass passage 55 separated from the suction receiving passage 33 of the suction receiving portion 31. That is, at the valve mounting portion 53, the suction receiving portion 31 is connected to the interior of the upper tank 30 via the suction receiving passage 33. On the other hand, the bypass receiving portion 51 forms the bypass passage 55, which is connected to the bypass pipe portion 61 provided on the outside of the upper tank 30.

[0058] Here, the bypass passage 55 of the bypass accommodating portion 51 has a predetermined passage cross section which is smaller than the passage cross section of the intake accommodating portion 31.

[0059] The bypass passage portion 61 is provided to allow the intake air flowing into the bypass receiving portion 51 to bypass the heat exchange unit 21, and is provided on an outer side of the radiator main body 20.

[0060] The bypass line section 61 is connected via an upper end to the bypass receiving section 51 and, as shown in Fig. 5, is connected to the lower container 40 via a lower end.

[0061] More detailed is how in Fig. 6, the bypass passage portion 61 is formed with an inlet 63 at the upper end and an outlet 65 at the lower end. The inlet 63 is connected to the bypass receiving portion 51 on one side of the upper tank 30. Furthermore, the outlet 65 is connected to the suction and discharge portion 41 on one side of the lower tank 40.

[0062] In more detail, the outlet 65 of the bypass line section 61 is integrally connected to the lower section (or the lower end) of the intake discharge section 41 ( Fig. 2, Fig. 3 and Fig. 6).

[0063] In an exemplary embodiment, as shown in the Fig. 6 and Fig. 7, the condensate collecting section 69 is formed on a lowermost side of the bypass line section 61 and communicates with the suction discharge section 41.

[0064] The condensate collecting portion 69 may be formed at a connecting portion of the bypass pipe portion 61 connected to the suction discharge portion 41, that is, at a side of the outlet 65 of the bypass pipe portion 61.

[0065] The condensate collection section 69 collects condensate on a lowermost side of the charge air cooler assembly 100 and can discharge the condensate via the intake discharge section 41.

[0066] With reference to the Fig. 2 and Fig. 3, in an exemplary embodiment, the valve unit 70 is provided to selectively transmit the intake air supplied from the turbocharger 8 to the intake receiving portion 31 and the bypass receiving portion 51 of the bypass unit 50.

[0067] Here, under a high-temperature / high-load condition, the valve unit 70 can close the bypass receiving portion 51 and open the suction receiving portion 31. Furthermore, under a low-temperature / low-load condition, the valve unit 70 can open the bypass receiving portion 51 and close the suction receiving portion 31.

[0068] The high-temperature / high-load condition (also called low-flow / low-pressure condition) represents a normal driving condition of a vehicle. Furthermore, the low-temperature / low-load condition (also called high-flow / high-pressure condition) represents a cold-start condition in winter.

[0069] Since the high temperature / high load condition and the low temperature / low load condition can be clearly differentiated according to the condition of the vehicle, in an exemplary embodiment it is not necessary to differentiate the high temperature / high load condition and the low temperature / low load condition by special numerical ranges.

[0070] The configuration of sensors and control devices for determining the high temperature / high load condition and the low temperature / low load condition may be obvious to a technically skilled person and will not be described in detail.

[0071] The valve unit 70 is installed such that it is connected to the suction receiving portion 31 and the bypass receiving portion 51. As shown in the Fig. 8 to 10, the valve unit 70 comprises a valve housing 71 and a valve body assembly 81.

[0072] The valve housing 71 is mounted on the valve mounting portion 53, which forms the intake receiving portion 31 and the bypass receiving portion 51. The valve housing 71 forms a main receiving portion 73 that communicates with the intake receiving portion 31 and the bypass receiving portion 51. The main receiving portion 73 transmits the intake air supplied from the turbocharger 8 toward the intake receiving portion 31 and the bypass receiving portion 51.

[0073] The valve housing 71 has a first valve passage 75 and a second valve passage 77 connected to the main receiving portion 73.

[0074] The first valve passage 75 has a predetermined passage cross-section and is connected to the intake receiving portion 31. The second valve passage 77 has a different passage cross-section from that of the first valve passage 75 and is connected to the bypass receiving portion 51. For example, the second valve passage 77 has a passage cross-section smaller than the passage cross-section of the first valve passage 75.

[0075] Here, an imaginary center axis S1 of the first valve passage 75 is arranged closer to an imaginary center axis S3 of the main receiving portion 73 than to an imaginary center axis S2 of the second valve passage 77.

[0076] The valve body assembly 81 is provided to selectively open and close the suction receiving passage 33 of the suction receiving portion 31 and the bypass passage 55 of the bypass receiving portion 51, and is installed on the valve housing 71.

[0077] The valve body assembly 81 is driven by the operation of an actuator 91. The actuator 91 is installed in the valve housing 71. For example, the actuator 91 may comprise a known servomotor suitable for servo-controlling the speed and direction of rotation by receiving an electrical control signal from a control device (not shown).

[0078] The valve body assembly 81 includes a valve rotary shaft 83, a first valve body 85, and a second valve body 87.

[0079] The valve rotating shaft 83 is a single shaft rotatably installed in the valve housing 71 through the actuator 91. The valve rotating shaft 83 traverses the first and second valve passages 75 and 77 and is installed to be connected to the actuator 91.

[0080] The first valve body 85 is fixedly installed in the first valve passage 75 on the valve rotating shaft 83. In addition, the second valve body 87 is fixedly installed in the second valve passage 77 on the valve rotating shaft 83.

[0081] Here, the first and second valve bodies 85 and 87 may be circular flaps which open and close the first and second valve passages 75 and 77, respectively, and are fixed to the valve rotary shaft 83 perpendicular to each other.

[0082] The operation of the charge air cooler assembly 100 according to an exemplary embodiment will be described in detail below with reference to the accompanying drawings.

[0083] The Fig. 11 and Fig. 12 illustrate the operation of a charge air cooler assembly according to an exemplary embodiment of the invention.

[0084] With reference to Fig. 11, in an exemplary embodiment, under a high temperature / high load condition during normal driving of a vehicle, by rotating the valve rotating shaft 83 according to an operation of the actuator 91, the first valve passage 75 is opened by the first valve body 85 and the second valve passage 77 is closed by the second valve body 87.

[0085] Accordingly, the intake receiving passage 33 of the intake receiving portion 31 communicates with the main receiving portion 73 via the first valve passage 75, and the bypass passage 55 of the bypass receiving portion 51 is closed by the second valve body 87.

[0086] In this state, in an exemplary embodiment, the low-pressure EGR gas and the fresh intake air (high-temperature state) compressed in the turbocharger 8 flow into the main accommodating portion 73 via the intake pipe 2.

[0087] Then, the intake air with the high temperature flows through the first valve passage 75 into the intake intake passage 33 of the intake intake section 31 and through the interior of the upper tank 30 into the heat exchange unit 21.

[0088] The intake air that has flowed into the heat exchange unit 21 flows through a predetermined flow path of the heat exchange unit 21 and is cooled by heat exchange and discharged through the intake discharge section 41 of the interior of the lower tank 40. The intake air discharged through the intake discharge section 41 is guided to the intake manifold of the internal combustion engine 3 via the intake pipe 2.

[0089] In an exemplary embodiment, the second valve passage 77 has a smaller passage cross-section than the first valve passage 75, and the imaginary center axis S1 of the first valve passage 75 is located closer to the imaginary center axis S3 of the main accommodating portion 73 than to the imaginary center axis S2 of the second valve passage 77. Therefore, a load exerted by the intake air on the valve rotating shaft 83 via the second valve body 87 can be reduced.

[0090] Furthermore, in an exemplary embodiment, saturated water vapor contained in the low-pressure EGR gas included in the intake air may generate condensate while being cooled. The condensate is collected in the condensate collection portion 69 of the bypass passage portion 61 and may be drawn into the intake passage 2 by boost pressure via the intake discharge portion 41, thereby flowing into the intake manifold of the engine 3.

[0091] On the other hand, with reference to Fig. 12, in an exemplary embodiment, in a low temperature / low load condition during a cold start in winter, by rotating the valve rotating shaft 83 according to an operation of the actuator 91, the first valve passage 75 is closed by the first valve body 85 and the second valve passage 77 is opened by the second valve body 87.

[0092] Accordingly, the intake receiving passage 33 of the intake receiving portion 31 is closed by the first valve body 85, and the bypass passage 55 of the bypass receiving portion 51 communicates with the main receiving portion 73 via the second valve passage 77.

[0093] In this state, in an exemplary embodiment, the low-pressure EGR gas and the fresh intake air compressed in the turbocharger 8 flow into the main intake portion 73 via the intake pipe 2.

[0094] Then, the intake air with the relatively high temperature flows through the second valve passage 77 into the bypass passage 55 of the bypass receiving portion 51 and along the bypass pipe portion 61 to be discharged through the intake discharge portion 41. The intake air discharged through the intake discharge portion 41 is guided to the intake manifold of the internal combustion engine 3 via the intake pipe 2.

[0095] Therefore, in an exemplary embodiment, in a low temperature / low load condition at a cold start in winter, an ice block of condensate frozen on a discharge side of the intake is melted by the intake air having the relatively high temperature, and breakage or damage of the intake flow path due to the freezing of the condensate can be prevented.

[0096] In an exemplary embodiment, the second valve passage 77 has a smaller passage cross-section than the first valve passage 75, and the imaginary center axis S1 of the first valve passage 75 is located closer to the imaginary center axis S3 of the main accommodating portion 73 than to the imaginary center axis S2 of the second valve passage 77. Therefore, a load exerted by the intake air on the valve rotating shaft 83 via the first valve body 85 can be reduced.

[0097] On the other hand, in an exemplary embodiment, under a low-temperature / low-load condition, while the intake air is bypassed via the bypass unit 50, the intake air including the low-pressure EGR gas may flow finely into the heat exchange unit 21 via a gap between the first valve body 85 and the first valve passage 75, and then via the intake accommodating portion 31. Furthermore, the saturated water vapor contained in the low-pressure EGR gas may generate condensation while being cooled.

[0098] The condensate is collected in the condensate collection section 69 of the bypass line section 61 and can be sucked into the intake line 2 by a boost pressure via the intake discharge section 41 to thereby flow into the intake manifold of the internal combustion engine 3.

[0099] In an exemplary embodiment, even if the condensate collected in the condensate collecting portion 69 is not flowed into the intake manifold of the internal combustion engine 3 and thereby freezes under a low temperature / low load condition, the ice block of the condensate may be melted by the intake air having the relatively high temperature, and the melted condensate may flow into the intake pipe 2 via the intake discharge portion 41.

[0100] With the charge air cooler assembly 100 according to an exemplary embodiment, during a high temperature / high load condition during normal driving of a vehicle, the intake air can be cooled as it flows into the heat exchange unit 21 by the operation of the valve unit 70.

[0101] Furthermore, in an exemplary embodiment, during a low temperature / low load condition during a cold start in winter, the operation of the valve unit 70 may redirect the intake air through the bypass unit 50 to the intake discharge section 41.

[0102] Therefore, in an exemplary embodiment, in a low temperature / low load condition during a cold start in winter, an increase in a differential pressure, deterioration in the charge air cooler performance, damage to the intake flow path, or the like due to the freezing of the condensate can be prevented.

[0103] Furthermore, in an exemplary embodiment, the condensate water generated in a high temperature / high load condition and a low temperature / low load condition is collected by the condensate water collecting portion 69 at a lowermost side of the intercooler assembly 100 and discharged to the intake pipe 2 by a boost pressure via the intake discharge portion 41. List of reference symbols 1 combustion engine system 2 intake line 3 combustion engine 4 exhaust pipe 5 DPF 6 Low-pressure EGR line 7 Low-pressure EGR cooler 8 turbochargers 9 High-pressure EGR line 10 high-pressure EGR coolers 20 Radiator main body 21 Heat exchange unit 30 upper container 31 Intake intake section 33 Intake passage 40 lower container 41 Intake and discharge section 50 bypass unit 51 Bypass receiving section 53 Valve assembly section 55 Bypass passage 61 Bypass line section 63 Entrance 65 outlet 69 Condensate collection section 70 valve unit 71 Valve housing 73 Main recording section 75 first valve passage 77 second valve passage 81 Valve body arrangement 83 Valve shaft 85 first valve body 87 second valve body 91 Actuating device 100 intercooler arrangement

Claims

[1] Charge air cooler arrangement, comprising: a radiator main body (20) having a heat exchange unit (21); an upper tank (30) having a suction receiving portion (31) connected to the heat exchange unit (21) and coupled to an upper portion of the radiator main body (20); a lower tank (40) having a suction discharge portion (41) connected to the heat exchange unit (21) and coupled to a lower portion of the radiator main body (20); a bypass receiving portion (51) connected to a valve mounting portion (53) and configured to form a passage separate from the suction receiving portion (31); a bypass passage portion (61) having an inlet (63) and an outlet (65) and provided on an outer side of the radiator main body (20), the inlet (63) being connected to the bypass receiving portion (51), and the outlet (65) being connected to the intake discharge portion (41); a valve unit (70) connected to the intake receiving portion (31) and the bypass receiving portion (51) and configured to selectively transmit intake air supplied from a turbocharger (8) to the intake receiving portion (31) and the bypass receiving portion (51); and a condensate collecting section (69) formed on a lowermost side of the bypass passage section (61) and configured to communicate with the suction discharge section (41). [2] Charge air cooler arrangement according to claim 1, wherein: under a high temperature and high load condition, the valve unit (70) is configured to close the bypass receiving section (51) and open the suction receiving section (31); and in a low temperature and low load condition, the valve unit (70) is configured to open the bypass receiving section (51) and close the suction receiving section (31). [3] Charge air cooler arrangement according to claim 1 or 2, wherein the valve unit (70) comprises: a valve housing (71) having a main receiving portion (73) and mounted on the valve mounting portion (53), the main receiving portion (73) being configured to communicate with the suction receiving portion (31) and the bypass receiving portion (51); and a valve body assembly (81) installed on the valve housing (71) and configured to selectively open and close the passage of the suction receiving portion (31) and the bypass receiving portion (51) by operation of an actuator (91). [4] The charge air cooler assembly according to claim 3, wherein the valve housing (71) further comprises a first valve passage (75) and a second valve passage (77) configured to communicate with the main receiving portion (73), respectively. [5] Charge air cooler arrangement according to claim 4, wherein: the first valve passage (75) has a predetermined passage cross-section and is connected to the intake receiving portion (31); and the second valve passage (77) has a passage cross-section smaller than a passage cross-section of the first valve passage (75) and is connected to the bypass receiving section (51). [6] The charge air cooler assembly according to claim 4 or 5, wherein an imaginary center axis (S1) of the first valve passage (75) is arranged closer to an imaginary center axis (S3) of the main receiving portion (73) than to an imaginary center axis (S2) of the second valve passage (77). [7] Charge air cooler arrangement according to one of claims 4 to 6, wherein the valve body arrangement (81) comprises: a valve rotating shaft (83) configured to traverse the first and second valve passages (75, 77) and connected to the actuator (91); a first valve body (85) fixedly installed in the first valve passage (75) on the valve rotary shaft (83); and a second valve body (87) fixedly installed in the second valve passage (77) on the valve rotary shaft (83). [8] Charge air cooler arrangement according to claim 7, wherein the first and second valve bodies (85, 87) are circular flaps and are fixed to the valve rotary shaft (83) perpendicular to each other.

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