Air cooler with water separator

Abstract

The air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end to the air inlet manifold and at a second end to the air outlet manifold. The water separator includes a chamber having a first end and an opposite second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end. A water outlet is formed in a bottom surface of the chamber, and a channel is disposed below the water outlet. A condensate outlet is disposed at the bottom surface of the channel. The helical blade has a first end and a second end and is disposed within the chamber between the air inlet and the air outlet.

Description

Technical Field

[0001] Data of Related Applications This application claims priority to U.S. Patent Application No. 16 / 937,650, filed July 24, 2020, the content of which is hereby incorporated by reference in its entirety.

[0002] Aspects of the present invention generally relate to an air cooler (air conditioner) equipped with a water separator, and more specifically, to an air cooler equipped with a water separator including a helical blade.

Background Art

[0003] An air cooler, such as a charge air cooler, which can also be called an intercooler or an aftercooler, can be used on an engine such as a diesel engine to cool the engine air passing through a compressor (e.g., a turbocharger or a supercharger) before it enters the engine's intake manifold and cylinders.

[0004] A turbocharger compresses air to increase power and efficiency. To further increase power to meet emission standards, this air needs to be cooled. This hot air may contain a large amount of water vapor, and when this condenses, it can cause problems such as corrosion, accumulation of scale (boiler scale), leakage of lubricating oil, and freezing.

[0005] It is desirable to provide an air cooler that reduces or overcomes some or all of the problems inherent in conventional known devices. Certain advantages will be apparent to those skilled in the art, i.e., those having knowledge or experience in the relevant technical field, in view of the following disclosure of the present invention and the detailed description of specific embodiments.

[0006] Specific objects and advantages of the present invention will be apparent to those skilled in the art, i.e., those having knowledge or experience in the relevant technical field, in view of the following disclosure of the present invention and the detailed description of specific preferred embodiments.

Summary of the Invention

[0007] By means of an aspect of the present invention, an air cooler equipped with a water separator that improves the separation of water from the airflow before the airflow flows into the engine's intake manifold and cylinders can be advantageously provided. The separation of water from the airflow may also be beneficial in other compressed air applications.

[0008] According to a first embodiment, the air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected to the air inlet manifold at a first end and connected to the air outlet manifold at a second end. The water separator includes a chamber having a first end and a second end on the opposite side, an air inlet adjacent to the first end and connected to the air outlet manifold, and an air outlet adjacent to the second end. The water outlet is formed in the bottom surface of the chamber, and a channel is located below the water outlet. A condensate outlet is located in the bottom surface of the channel. The helical blade has a first end and a second end and is located in the chamber between the air inlet and the air outlet.

[0009] In another embodiment, the air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected to the air inlet manifold at a first end and connected to the air outlet manifold at a second end. The water separator assembly includes a chamber having a first end and a second end on the opposite side, an air inlet adjacent to the first end and connected to the air outlet manifold, extending substantially vertically, and an air outlet adjacent to the second end. The air outlet extends downward and outward from the chamber and is formed from a first portion having a first end and a second end on the opposite side located within the chamber. The second portion is connected to the first end of the first portion and extends substantially horizontally. A water outlet having a plurality of slots is formed at the bottom of the chamber. A channel is located below the water outlet, and a condensate outlet extends downward and outward from the bottom surface of the channel. A helical blade has a first end and a second end and is located between the air inlet and the air outlet within the chamber. The first end face of the helical blade defines a first surface extending nearly perpendicularly within the chamber, and the second end face defines a second surface extending nearly perpendicularly within the chamber. The inner edge of the helical blade defines a central opening extending along the longitudinal axis of the chamber, and the outer edge of the helical blade extends along the inner surface of the chamber.

[0010] Those skilled in the art, i.e., those with knowledge or experience in the art, will readily see from the foregoing disclosure that preferred embodiments of air coolers disclosed herein represent a significant technological advance in terms of improved condensate removal. These features and advantages, as well as further features and advantages, will be further understood from the following detailed disclosures of specific preferred embodiments. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic perspective view showing the air cooler and the water separator connected to the air cooler in a partially assembled state. [Figure 2] This is a schematic perspective view showing a portion of the water separator connected to the air chamber outlet of the air cooler in Figure 1, with a section cut away. [Figure 3] Figure 1 is a partial cross-sectional side view of the water separator and the air chamber outlet. [Figure 4] Figure 1 is a partial cross-sectional end view of the water separator and the air chamber outlet. [Figure 5] Figure 1 is a partial cross-sectional rear perspective view of the water separator and air chamber outlet. [Figure 6] Figure 1 is a schematic rear view of the water separator and air chamber outlet. [Modes for carrying out the invention]

[0012] The drawings described above should be understood not necessarily to exact scale, but to provide an illustrative representation of the present invention illustrating the relevant principles. Some features of the air cooler shown in the drawings are enlarged or distorted relative to others for ease of explanation and understanding. Similar or identical components and features shown in various alternative embodiments are given the same reference numerals in the drawings. The air coolers disclosed herein have configurations and components that are determined to some extent by the intended application and the environment in which they are used.

[0013] The present invention can be implemented in various forms. Figure 1 shows an embodiment of the air cooler 10 connected to a water separator 12. The air cooler 10 can be, for example, a charge air cooler. The air cooler 10 can be used to cool, for example, the hot compressed air discharged from the turbocharger of an engine before it enters the intake manifold and cylinders of the engine. However, it should be understood that the air cooler is not limited to use for cooling hot air in an engine and can be easily used with fluids or gases in other fields.

[0014] For convenience, the terms “upper” and “lower,” as well as “top” and “bottom,” are used herein to distinguish the upper and lower ends of an air cooler from certain elements. It should be understood that “upper” and “lower,” as well as “top” and “bottom,” are used solely for the purpose of facilitating explanation and understanding, and are not intended to limit the possible spatial orientation of the air cooler or its components during assembly or use.

[0015] The air cooler 10 may include an air chamber inlet 14 into which heated air can be introduced into an inlet manifold 16. The heated air can then pass from the inlet manifold 16 through a heat exchanger core 17. In the illustrated embodiment, the heat exchanger core 17 includes a plurality of flow tubes 18 having fins 19 on their outer surfaces. For clarity, only two finned flow tubes 18 are shown in Figure 1. It should be understood that other types of heat exchanger cores may be used to cool the heated air entering the inlet manifold 16 through the air inlet 14. For example, in certain embodiments, the flow tubes 18 may be provided without fins. Other exemplary heat exchanger cores include U-tube, one-pass and two-pass, and bar-plate heat exchanger cores. Other suitable heat exchanger cores will be readily apparent to those skilled in the art in consideration of the interests of this disclosure.

[0016] Cooling air can be supplied in the direction of the flow indicated by arrow F, which crosses the outside of the multiple finned flow tubes 18. It should be understood that the airflow across the flow tubes can be created by a fan (not shown) or by natural convection. It should also be understood that the direction of the flow indicated by arrow F may extend in any direction. The air that flows through the finned flow tubes 18, cooled by the air passing over the outer surface of the finned flow tubes 18, then proceeds to the outlet manifold 21, and from the outlet manifold 21, it can proceed to the water separator 12 through the air inlet 58 described later.

[0017] The cooling air that exits the air cooler 10 via the air outlet manifold 21 and enters the water separator 12 may contain water, which can be harmful to the engine, as mentioned above. As the air and water flow passes through the water separator 12, the water is removed, thus preventing water from entering the engine.

[0018] The water separator 12 and its components can be formed from non-corrosive materials. The water separator can be formed from resin or plastic, or from metal. Exemplary metals include aluminum and stainless steel. Other suitable materials for the water separator 12 will be readily apparent to those skilled in the art in consideration of the interests of this disclosure.

[0019] As shown in Figures 2 to 6, the water separator 12 may include a chamber 50 having a first end 52, a second end 54 on the opposite side, and a side wall 56 extending between the first end 52 and the second end 54. In certain embodiments, the cross-section of the chamber 50 can be substantially cylindrical.

[0020] As used herein, the term “approximately” is intended to mean roughly or nearly the same, within the constraints of common commercial engineering objectives, costs, manufacturing tolerances, and capabilities in the field of water separator manufacture and use. Similarly, as used herein, the term “about” is intended to mean close to or near a specific value, within the constraints of common commercial engineering objectives, costs, manufacturing tolerances, and capabilities in the field of water separator manufacture and use.

[0021] The air inlet 58 can be arranged close to the first end 52 of the chamber 50 so that the chamber 50 is in fluid communication with the heat exchanger core 17 of the air cooler 10, and can be connected to the outlet manifold 21 of the air cooler 10. The cooling air exiting the heat exchanger core 17 through the outlet manifold 21 can enter the chamber 50 of the moisture separator 12 through the air inlet 58. The air inlet 58 can have a substantially cylindrical cross-section and can extend substantially vertically. It should be understood that the air inlet 58 can have any cross-sectional shape and can be oriented in any desired direction. In a particular embodiment, as shown in FIG. 4, the lower surface 60 of the air inlet 58 can define a plane that is at an angle α with respect to the longitudinal axis M of the air inlet 58, which is oriented vertically in this embodiment. In a particular embodiment, the angle α can be about 45°, but it should be understood that the angle α can have any value.

[0022] The chamber 50 can also include an air outlet 62 arranged close to the second end 54, and air can exit the chamber 50 through the air outlet 62. In a particular embodiment, the cross-section of the air outlet 62 can be substantially cylindrical. It should be understood that the air outlet 62 can have any cross-sectional shape.

[0023] As seen in FIG. 5, the air outlet 62 can be formed from a first portion 64 having a first end 65 and an opposite second end 67. The first portion 64 can extend downwardly and outwardly from the interior of the chamber 50 through the side wall 56. As seen in FIG. 6, the longitudinal axis D of the first portion 64 can extend downwardly and outwardly at an angle β with respect to the horizontal. In a particular embodiment, the angle β can be about 45°. The first end 65 of the first portion 64 can be disposed within the chamber 50, and the first end 65 can define a plane that extends substantially vertically. A second portion 66 can be connected to the second end 67 of the first portion 64, and the second portion 66 can extend substantially horizontally. In other embodiments, it should be understood that the air outlet 62 can be formed from a single portion and can be oriented at any desired angle.

[0024] The helical blade 66 can be disposed within the chamber 50 and can have a first end 68 and an opposite second end 70. In certain embodiments, the first end 68 of the helical blade 66 can be disposed downstream of the air inlet 58. In other embodiments, the first end 68 can be disposed upstream of the air inlet 58, and in other elements, the first end 68 can be disposed at the air inlet 58. In certain embodiments, the second end 70 of the helical blade 66 can be disposed upstream of the air outlet 62. In other embodiments, the second end 70 can be disposed downstream of the air outlet 62, and in other elements, the second end 70 can be disposed at the air outlet 62.

[0025] In certain embodiments, the first end 68 of the helical blade 66 can have a first end face 72 that extends substantially horizontally and defines a first face that extends substantially vertically within the chamber 50. It should be understood that in other embodiments, the first end 68 can have any desired orientation. Similarly, the second end 70 of the helical blade 66 can have a second end face 74 that extends substantially horizontally and defines a second face that extends substantially vertically within the chamber 50. It should be understood that in other embodiments, the second end 70 can have any desired orientation.

[0026] The helical blade 60 may have a first surface 76, an opposite second surface 78, an outer edge 80 extending between the first surface 76 and the second surface 78 from the first end 68 to the second end 70, and an opposite inner edge 82 extending between the first surface 76 and the second surface 78 from the first end 68 to the second end 70. In certain embodiments, the outer edge 80 may be in contact with the inner surface 84 of the chamber 50. For example, the outer edge 80 can be directly fixed to the inner surface 84 of the chamber 50 by welding. In certain embodiments, the outer edge 80 may be spot-welded or stitched at multiple points along its length, and in other embodiments, the outer edge 80 may be welded along its entire length. As shown in Figure 5, the inner edge 82 of the helical blade 60 may define a substantially cylindrical central channel 85 extending along the entire length of the helical blade 60, coaxial with the longitudinal axis L of the helical blade 60.

[0027] In the exemplary embodiment, the first surface 76 and the opposite second surface 78 of the helical blade can be wound clockwise from the first end 68 to the second end 70. In other embodiments, the first surface 76 and the opposite second surface 78 of the helical blade can be wound counterclockwise from the first end 68 to the second end 70. In certain embodiments, each of the outer edge 80 and inner edge 82 of the helical blade 60 can make one full turn between the first end 68 and the second end 70 of the helical blade 60. In other embodiments, it should be understood that the outer edge 80 and inner edge 82 may make more or fewer turns between the first end 68 and the second end 70 of the helical blade 60.

[0028] The water outlet 86 can be located at the bottom of the chamber 50, close to the second end 74 of the helical blade 66 and close to the air outlet 62, and functions to discharge water from the chamber 50. In certain embodiments, the water outlet 86 can be in the form of a plurality of openings or slots 88 that extend through the side wall 56 and allow water to be discharged from the chamber 50. In certain embodiments, the slots 88 can be in the form of a racetrack. The slots 88 can be collinear and may have a common longitudinal axis S that extends substantially parallel to the longitudinal axis L of the chamber 50. It should be understood that the water outlet 86 can take any desired shape, including, for example, a screen or a perforated plate.

[0029] The gutter or channel 90 can be fixed to the bottom of the chamber 50 below the grid 86. In certain embodiments, the channel 90 may have a substantially cylindrical cross-section having a longitudinal axis A that extends substantially parallel to the longitudinal axis L of the chamber 50. It should be understood that the channel 90 may have any desired cross-sectional shape.

[0030] The condensate outlet 92 can be connected to the outlet opening 94 at the bottom of the channel 90, allowing water to be discharged from the channel 90. In certain embodiments, the condensate outlet 92 may have a substantially cylindrical cross-section. It should be understood that the condensate outlet 92 may have any desired cross-sectional shape.

[0031] As shown in Figure 3, in certain embodiments, the air outlet 62 can be positioned along the longitudinal axis L of the chamber 50, close to the midpoint of the grid 86 and the channel 90.

[0032] As the heated air moves through the chamber 50, it is redirected by the helical blade 66, which facilitates the removal of moisture from the air. As the air moves along the surface of the helical blade 66 and through the central opening 85, heavier water droplets fall from the inner edge 82 of the helical blade 66 and enter the channel 90 through the water outlet 86.

[0033] As shown in Figures 4 and 6, the air inlet 58 can be positioned with the chamber 50 such that its longitudinal axis M is spaced apart from the longitudinal axis L of the chamber 50 and close to the side wall 56. This helps to introduce spin (rotation) into the air flowing into the chamber 50 and direct the air along the side wall 56 and the helical blade 66.

[0034] As shown in Figure 4, the first end 65 of the first portion 64 of the air outlet 62 can be positioned in the central part of the chamber 50 close to the longitudinal axis L, which can help prevent moisture from the chamber 50 from entering the air outlet 62 as the air leaves the chamber 50.

[0035] Therefore, although various embodiments have been shown, described, and pointed out, it will be understood that various omissions, substitutions, and modifications in the forms and details of the illustrated devices, as well as in their operation, can be made by those skilled in the art without departing from the spirit and scope of the invention. For example, it is explicitly intended that all combinations of those elements and / or steps that perform substantially identical functions in substantially identical ways to achieve the same result are within the scope of the invention. Substitution of elements from one embodiment described to another is also fully intended and considered. Accordingly, it is intended to be limited only to those shown in the claims appended herein.

Claims

1. This is an air cooler assembly, An air cooler comprising an air inlet manifold, an air outlet manifold, and a heat exchanger core connected to the air inlet manifold at a first end and connected to the air outlet manifold at a second end, A water separator assembly, A chamber having a first end and a second end on the opposite side, an air inlet adjacent to the first end and connected to the air outlet manifold, and an air outlet adjacent to the second end, A water outlet formed on the bottom surface of the chamber, A helical blade having a first end and a second end, positioned between the air inlet and the air outlet within the chamber, A channel located below the water outlet, The condensate outlet on the bottom surface of the channel and A water separator assembly including, Equipped with, The air outlet is positioned close to the midpoint of the channel's length along the longitudinal axis of the chamber. Air cooler assembly.

2. The air cooler assembly according to claim 1, wherein the first end of the helical blade is located downstream of the air inlet, and the second end of the helical blade is located upstream of the air outlet.

3. The air cooler assembly according to claim 1, wherein the condensate outlet extends downward and outward from the channel.

4. The air cooler assembly according to claim 1, wherein the air inlet extends almost vertically.

5. The air cooler assembly according to claim 4, wherein the longitudinal axis of the air inlet is spaced apart from the longitudinal axis of the chamber and is close to the side wall of the chamber.

6. The air cooler assembly according to claim 1, wherein the air inlet comprises a cylinder extending substantially vertically, and the bottom surface of the cylinder defines a surface at an angle of approximately 45° with respect to the vertical.

7. The aforementioned air outlet is A first portion having a first end positioned within the chamber and a second end extending downward and outward from the chamber, A second portion extending horizontally from the second end of the first portion, The air cooler assembly according to claim 1, comprising:

8. The air cooler assembly according to claim 7, wherein the first end is positioned in the central portion of the chamber, close to the longitudinal axis of the chamber.

9. The air cooler assembly according to claim 1, wherein each of the first edge and the opposite second edge of the helical blade makes a full turn between the first end and the second end of the helical blade.

10. The air cooler assembly according to claim 1, wherein the surface of the helical blade is wound clockwise from the first end of the helical blade to the second end of the helical blade.

11. The air cooler assembly according to claim 1, wherein the outer edge of the helical blade is in contact with the inner surface of the chamber.

12. The air cooler assembly according to claim 11, wherein the outer edge of the helical blade is fixed to the inner surface of the chamber.

13. The air cooler assembly according to claim 1, wherein the inner edge of the helical blade defines a central channel extending longitudinally along the chamber.

14. The air cooler assembly according to claim 1, wherein the water outlet comprises a plurality of slots formed in the bottom of the chamber.

15. The air cooler assembly according to claim 14, wherein each of the plurality of slots has a longitudinal axis, and the longitudinal axes of each of the slots are collinear with each other and collinear with the longitudinal axis of the chamber.

16. The air cooler assembly according to claim 1, wherein the chamber has a cylindrical cross-section.

17. The air cooler assembly according to claim 1, wherein the helical blade comprises a first end face extending substantially horizontally and defining a first surface extending substantially vertically within the chamber, and a second end face extending substantially horizontally and defining a second surface extending substantially vertically within the chamber.

18. Air cooler water separator assembly, An air cooler comprising an air inlet manifold, an air outlet manifold, and a heat exchanger core connected to the air inlet manifold at a first end and connected to the air outlet manifold at a second end, A water separator assembly, A chamber having a first end and a second end on the opposite side, an air inlet adjacent to the first end and connected to the air outlet manifold and extending substantially vertically, and an air outlet adjacent to the second end, wherein the air outlet is formed from a first portion extending downward and outward from the chamber and having a first end and a second end on the opposite side disposed within the chamber, and a second portion connected to the first end of the first portion and extending substantially horizontally, A water outlet including a plurality of slots formed on the bottom surface of the chamber, A channel located below the water outlet, A condensate outlet extending downward and outward from the bottom surface of the channel, A helical blade having a first end and a second end, positioned between the air inlet and the air outlet in a chamber, wherein the first end face of the helical blade defines a first surface extending substantially vertically within the chamber, the second end face defines a second surface extending substantially vertically within the chamber, the inner edge of the helical blade defines a central opening extending along the longitudinal axis of the chamber, and the outer edge of the helical blade extends along the inner surface of the chamber. A water separator assembly including, Air cooler water separator assembly equipped with...

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