Charge Air Cooler Adapter for Non-Metal Housing Stability
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Solution Overview
Problem
Existing air-conveying components, such as intake manifolds in turbocharged internal combustion engines, face challenges in stabilizing and securely positioning charge air coolers, which affects the overall performance and reliability of the cooling process.
Innovation Solution
The integration of an adapter device that securely fastens the charge air cooler to the housing part using a combination of cohesive and non-positive/positive engagement methods, allowing for connection of different materials and forms, and enabling stable fixation through various fastening techniques like welding, soldering, or adhesive joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charge air cooler is integrated into the air-conveying component by welding the shells, then the cooling function is achieved, but the stability and positioning of the charge air cooler in the component deteriorates
Solution Approach 1:
An adapter device is introduced as an intermediary component between the charge air cooler and the air-conveying component. The adapter device includes adapter elements that connect to wall portions of the housing part, providing a stable intermediary connection that improves both the reliability and positioning stability of the charge air cooler integration
Solution Approach 2:
The adapter device combines different connection methods (cohesive connections and non-positive/positive engagements) to create a composite fastening system. This allows the charge air cooler to be securely positioned while maintaining flexibility in material selection and connection types
2Adaptability or versatility
If different materials and forms are used for the air-conveying component and charge air cooler, then design flexibility is improved, but the connection stability deteriorates
Solution Approach 1:
The adapter device serves as a mediator that can connect different materials and forms. The adapter elements can be made from materials suitable for cohesive connection to the housing part wall portions, while the charge air cooler may be made from different materials, thus enabling connection of dissimilar materials without compromising stability
Solution Approach 2:
The adapter device allows for parameter changes in material selection and connection methods. Different adapter elements can be designed with different materials, connection geometries, and fastening methods to optimize the connection between components made of different materials while maintaining connection stability
Data Source
AI summary
An intake manifold of an internal combustion engine includes a non-metal housing and at least one charge air cooler. The non-metal housing has at least one inlet and at least one outlet for charge air. The at least one charge air cooler disposed in the housing between the at least one inlet and at least one outlet. A metal housing frame is carried by the at least one charge air cooler. A metal adapter holding plate is secured to the metal housing frame and holds at least one non-metal mounting adapter to the at least one charge air cooler. The at least one non-metal mounting adapter may be secured to a top interior side wall and a bottom interior side wall the non-metal housing. The metal adapter holding plate is elongated in a direction extending from the inlet to the outlet and has a U-shape profile.