Charge Air Cooler Bypass with Thermal Insulation
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Solution Overview
Problem
Internal combustion engines face issues with condensate formation in charge air coolers during low-load operation in humid and cooler climates, leading to engine misfires due to ingestion of excess water, which reduces engine efficiency and performance.
Innovation Solution
A charge air cooler system with a thermally isolated bypass and a pivotable valve that adjusts airflow between the air cooler and bypass, allowing for diversion of intake air through the bypass during high humidity and low ambient temperatures to mitigate condensate formation, thereby maintaining engine efficiency and preventing misfires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the charge air cooler is used to cool compressed intake air, then the air temperature is reduced and density is improved, but water vapor condenses and stores in the CAC during low-load operation in humid and cooler climates
Solution Approach 1:
The charge air cooler system is divided into two separate parallel paths: a first path through the air cooler and a second path through the bypass. This segmentation allows selective routing of intake air to either cool it through the CAC or bypass the CAC to avoid condensate formation, resolving the contradiction between cooling effectiveness and condensate accumulation.
Solution Approach 2:
A valve is provided that can dynamically adjust between different positions to control airflow distribution. The valve can be actuated based on operating conditions (engine load, ambient temperature, humidity) to route air through the air cooler when cooling is needed or through the bypass when condensate formation is a risk, making the system adaptive to varying conditions.
2Reliability
If the valve routes air through the air cooler during high humidity and low ambient temperature conditions, then condensate formation occurs, but engine efficiency is maintained through proper cooling
Solution Approach 1:
The system performs preliminary routing decisions based on predicted or current operating conditions. By using sensors to detect ambient temperature, humidity, and engine load before air enters the CAC, the valve can pre-adjust to route air through the bypass when conditions indicate high condensate risk, preventing the harmful effect before it occurs.
Solution Approach 2:
The system incorporates sensors that continuously monitor operating conditions (ambient temperature, humidity, engine load) and provide feedback to the control mechanism. This feedback loop enables the valve to adjust airflow routing in real-time, maintaining engine reliability by avoiding condensate ingestion while preserving cooling benefits when appropriate.
3Temperature
If the bypass is thermally connected to the air cooler, then heat transfer between paths occurs, but thermal isolation is needed to prevent heat transfer and maintain bypass effectiveness
Solution Approach 1:
A shared wall with thermal insulation acts as an intermediary element between the first path (air cooler) and the second path (bypass). This insulated wall prevents unwanted heat transfer between the two parallel airflow paths, maintaining the thermal independence of each path while allowing the valve to switch between them based on operating conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces condensate formation in the charge air cooler, preventing engine misfires and maintaining efficiency by controlling airflow through the air cooler and bypass, ensuring optimal engine performance across varying conditions.
Implementation Method 1
A shared wall may be located between the first and second paths, where the shared wall is thermally insulated to prevent heat transfer between the two paths
Implementation Method 2
the valve may route air to the bypass during high humidity and low ambient temperature conditions to mitigate condensate formation in the CAC
Data Source
AI summary
The present disclosure concerns a charge cooler with an air cooler in a first air path and with a bypass in a second air path which is connected in parallel to the first air path, wherein a thermal insulation is assigned to the bypass which thermally isolates the bypass from the air cooler, wherein the air cooler has a double-walled base body with an outer wall and with an inner wall, wherein the thermal insulation is arranged on the inner wall. The present disclosure also concerns a valve for such a charge cooler, and a turbo-charged internal combustion engine with such a charge cooler, and a motor vehicle with such an internal combustion engine.