Charge Air Cooler Condensate Evacuation via Intake Manifold Pressure
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Solution Overview
Problem
Internal combustion engines face issues with condensate buildup in charge air coolers, leading to engine misfires, premature wear, and potential damage due to condensation entering the combustion chambers and freezing, which existing solutions fail to adequately address.
Innovation Solution
A condensate extractor assembly that includes a sump member integrated with the charge air cooler to collect condensate and a hose member to evacuate it directly to the intake manifold, preventing condensate from entering the engine and minimizing pooling, using a pressure gradient for continuous removal and eliminating the need for a condensate container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a condensate container is used to collect and store condensate from the charge air cooler, then condensate accumulation is prevented, but the system complexity increases and additional components (container, mounting hardware) are required
Solution Approach 1:
The patent extracts the condensate collection function from a separate container system and integrates it directly into the charge air cooler structure. The sump member is formed as an integral part of the CAC housing, eliminating the need for external condensate containers and their associated mounting hardware, thereby reducing system complexity while maintaining reliable condensate removal
Solution Approach 2:
The patent combines multiple functions into a single integrated structure. The sump member simultaneously serves as part of the CAC housing structure and as the condensate collection mechanism. This merging of structural and functional elements eliminates separate condensate containers while ensuring reliable condensate accumulation and removal
2Device complexity
If condensate is allowed to accumulate in the charge air cooler, then the system remains simple, but the condensate can freeze and crack the CAC when ambient temperatures reach below freezing
Solution Approach 1:
The patent implements preliminary action by continuously removing condensate through the evacuated port and hose assembly before it can accumulate to dangerous levels. This proactive condensate removal prevents the formation of large ice masses that could crack the CAC structure during freezing conditions
Solution Approach 2:
The patent introduces an intermediary evacuation system (hose member connected to engine intake) that mediates between the condensate collection need and the structural protection requirement. This intermediary pathway allows condensate to be continuously removed and diverted to a safe location, preventing both accumulation and freezing damage
3Reliability
If condensate is continuously evacuated from the charge air cooler, then engine misfires are prevented, but additional components (sump member, hose member, evacuated port) are required
Solution Approach 1:
The sump member is merged with the CAC housing structure, serving dual purposes as both structural support and condensate collection chamber. This integration reduces the number of separate components while maintaining continuous condensate evacuation capability for reliable engine operation
Solution Approach 2:
The evacuated port serves multiple functions: it acts as an evacuation outlet for condensate, maintains pressure balance in the CAC system, and provides a sealed connection point for the hose member. This multi-functionality reduces the need for additional dedicated components while ensuring reliable condensate removal
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
Prevents engine misfires by continuously evacuating condensate, reducing engine wear, and preventing damage to the charge air cooler by ensuring condensate does not accumulate and freeze, while maintaining proper engine speed control and avoiding issues associated with condensate containers.
Implementation Method 1
A CAC is a heat exchange device used to cool the air charge and, thus, further improve volumetric efficiency of the ICE by increasing intake air charge density through isochoric cooling
Implementation Method 2
The heat exchange process can cause moisture to condense and, thus, form inside of the CAC system
Implementation Method 3
The sump volume is vertically lower than the charge air cooler when the sump member and charge air cooler are operatively attached to the ICE assembly
Implementation Method 4
The hose member continuously evacuates condensate from the sump member and distributes it directly to the intake manifold in response to the pressure gradient generated by the ICE assembly
Data Source
AI summary
A condensate extractor assembly is provided for collecting and evacuating condensate from inside a charge air cooler in an internal combustion engine assembly. The condensate extractor assembly includes a sump that is attached to or formed in the charge air cooler. The sump is adapted to drain and collect condensate from the charge air cooler. A hose is fluidly coupled at one end to the sump, and fluidly coupled at a second end to the intake manifold. The hose is configured to evacuate condensate from the sump and distribute it directly to the intake manifold in response to the pressure gradient generated by the engine assembly when in an on-state. The hose defines an orifice that restricts the flow of air and condensate through the hose. A filter is fluidly coupled to the hose, fluidly intermediate the orifice and the sump member.