Charge Air Cooler Bypass for Coolant Boiling Prevention
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Solution Overview
Problem
Existing intercoolers for internal combustion engines face challenges in preventing coolant boiling, especially when compressing warm air, which can exceed the boiling temperature of the coolant, potentially damaging engine components.
Innovation Solution
The design incorporates a bypass in the coolant flow path within the charge air cooler, where coolant flows from a point upstream of the effective heat exchange section to a point downstream, allowing for a lower temperature coolant to be introduced at the inlet, thereby reducing heat absorption and preventing boiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coolant flows through the entire operating section for maximum heat exchange, then cooling efficiency is improved, but coolant temperature increases causing boiling risk
Solution Approach 1:
The coolant flow path is segmented into multiple sections: an operating section for heat exchange and a bypass section for temperature control. The bypass connects a first point upstream of the operating section to a second point downstream, allowing coolant to be divided into two paths - one through the heat exchange area and another bypassing it, thus preventing excessive temperature rise while maintaining cooling efficiency
Solution Approach 2:
The bypass acts as an intermediary pathway that mediates between the need for heat exchange and the need to prevent overheating. By introducing a bypass connection, the system creates a temperature regulation mechanism where cooler coolant from downstream can mix with or replace heated coolant, preventing boiling while preserving the heat exchange function
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 design effectively prevents coolant boiling by maintaining a lower temperature at the charge air inlet, enhancing heat absorption capacity and ensuring efficient cooling without overheating the coolant.
Implementation Method 1
The charge air path is in heat exchange contact with the coolant flow path along an effective section of the coolant flow path within the intercooler
Data Source
Figure 1~2
AI summary
A charge air cooler (10) of an internal combustion engine (44) is disclosed, comprising a coolant flow path extending from a coolant inlet (20) to a coolant outlet (28) and a charge air path extending from a charge air inlet (14) to a charge air outlet (18). Along an effective section (26), the charge air path is in heat exchange communication with the coolant flow path, wherein the coolant flow path has a bypass (32) from a first point (36) located upstream of the effective section (26) at the charge air outlet (18) to a second point (38) located downstream of the first point and downstream of the effective section (26) at the charge air inlet (14). The bypass has a diversion flow path (34) that differs from a partial path (24) of the coolant flow path extending between the first (36) and the second point (38). Furthermore, a corresponding method for charge air cooling is described.