Charge Air Cooler Membrane Condensate Control
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Solution Overview
Problem
Turbocharged and supercharged engines face issues with condensation forming in charge air coolers, leading to engine misfires and power loss due to water droplets being blown into combustion chambers, and existing solutions like liquid traps can cause boost pressure loss and environmental emissions concerns.
Innovation Solution
A method involving a membrane in the charge air cooler with a drying air flow system that selectively removes water vapor by directing compressed gas over the membrane, where water vapor condenses on the inner surface and is evaporated by a drying air flow directed to the outer surface, maintaining condensate levels below a threshold to prevent engine misfires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a liquid trap is used to collect condensation, then condensation entering combustion chambers is reduced, but boost pressure is lost and the system becomes more complex
Solution Approach 1:
The patent extracts the harmful condensation from the charge air stream by using a hydrophobic membrane that selectively removes water vapor through phase change and capillary action, eliminating the need for complex liquid traps and drainage systems while preventing boost pressure loss
Solution Approach 2:
The patent converts the harmful condensation into beneficial liquid water on the membrane surface by controlling the phase change process, where the condensed water forms a liquid layer on the hydrophobic membrane surface that is then removed by capillary wicking, transforming a harmful byproduct into a manageable substance
2Object-affected harmful factors
If a liquid trap with drain valve is used, then condensation is collected, but the drain valve may stick causing loss of boost pressure and power
Solution Approach 1:
The patent removes the unreliable drain valve component entirely by using a membrane-based condensation removal system that passes dried air through the membrane, automatically extracting condensation through the membrane's selective permeability without mechanical moving parts that can fail
Solution Approach 2:
The patent replaces the mechanical drain valve system with a passive membrane-based system that uses phase change and capillary action to remove condensation, eliminating mechanical components that can stick or fail while maintaining reliable condensation control
3Object-affected harmful factors
If collection tank is used to store condensation, then condensation is contained, but draining to surroundings causes environmental emissions
Solution Approach 1:
The patent converts the harmful condensed water into a beneficial liquid layer on the membrane surface that can be safely discharged or reused, eliminating environmental emissions by preventing the release of regulated emissions through the air intake system while maintaining proper condensation management
4Object-affected harmful factors
If drying air flow is increased to reduce condensate level, then engine misfire is prevented, but energy consumption increases
Solution Approach 1:
The patent changes the physical parameters of the membrane system by adjusting the hydrophobicity level and capillary pore structure to optimize the phase change and wicking process, reducing the energy required for drying while maintaining effective condensation removal and preventing engine misfire
Solution Approach 2:
The patent enables the membrane system to self-regulate the drying process by using the temperature and humidity conditions of the passing air stream itself to drive the phase change and capillary action, reducing or eliminating the need for external energy input while maintaining effective condensation control
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
This approach effectively reduces condensate levels in the charge air cooler, preventing engine misfires and maintaining engine performance while avoiding environmental emissions from draining condensate, by using a membrane with capillary pores and a controlled drying air flow.
Implementation Method 1
water vapor condenses on the inner surface
Implementation Method 2
water is evaporated by a drying air flow directed to the outer surface
Implementation Method 3
a membrane with capillary pores
Data Source
AI summary
Methods and systems are provided for controlling a condensate level in a charge air cooler. In one example, a method may include adjusting an air flow to a membrane in response to a condensate level in the charge air cooler.