Charge Air Cooler Core Segmentation for Uniform Flow

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In turbocharged internal combustion engine systems, the cooling of charge air using liquid coolant in charge air coolers can lead to blockages that reduce the distribution of air to individual cylinders, causing inefficiencies due to the compression of charge air, which increases temperature and results in reduced engine output and higher emissions.

Innovation Solution

The charge air cooler is integrated within the air intake manifold with a first and second core section and coolant inlet and outlet manifolds arranged in parallel, blocking the flow through a centrally located section to ensure even distribution of cooled charge air to all runners, reducing pressure drop and bypassing, and utilizing convoluted fin structures for enhanced heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If coolant inlet and outlet manifolds are placed in the charge air cooler to route liquid coolant, then heat transfer efficiency is improved, but charge air flow distribution to individual cylinders deteriorates due to blockages

Engineering Contradiction:

Improvecharge air temperatureVSAvoidcharge air flow distribution

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The charge air cooler core is divided into multiple sections (first core section, second core section, and third core section) with the coolant manifolds positioned in the third section. This segmentation allows the coolant flow path to be separated from the charge air flow path, enabling heat transfer functionality while maintaining charge air flow distribution to all cylinders through the first and second core sections.

Inventive Principle:

Principle #1Segmentation

2Productivity

If charge air is compressed using exhaust gases to increase engine output, then thermal efficiency is improved, but charge air temperature increases causing harmful emissions

Engineering Contradiction:

Improveengine outputVSAvoidoxides of nitrogen emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The exhaust gases, which contain residual thermal energy, are utilized to drive the turbocharger compressor for charge air compression. The same exhaust heat that would otherwise be waste is now harnessed to increase charge air pressure and engine output. Subsequently, the charge air cooler removes excess heat from the compressed charge air, converting the potential harmful effect of high temperature into a controlled cooling process that reduces NOx emissions while maintaining the benefits of compression.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If coolant manifolds block the flow through a centrally located section of the charge air cooler, then charge air flow distribution is improved, but heat transfer area is reduced

Engineering Contradiction:

Improvecharge air flow distributionVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The charge air cooler is designed with different functional zones: the first and second core sections are optimized for charge air flow and heat transfer, while the third core section is dedicated to coolant manifold placement. This local differentiation allows each section to perform its specific function effectively - heat transfer in the first and second sections, and flow distribution control in the third section - without compromising overall system performance.

Inventive Principle:

Principle #3Local quality

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 configuration ensures uniform distribution of cooled charge air to all cylinders, reduces emissions, and enhances heat transfer efficiency while minimizing structural stresses and bypassing issues, leading to improved engine performance and emissions control.

Implementation Method 1

a plurality of coolant circuits extending between the coolant inlet and the coolant outlet. The charge air cooler includes a plurality of charge air flow channels extending from the first end of the heat exchanger core to the second end of the heat exchanger core in heat transfer relationship with the plurality of coolant circuits

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

utilizing convoluted fin structures for enhanced heat transfer

Methodology Applied

Scientific EffectHeat transfer enhancement: Fin

Data Source

PatentUS9038610B2Charge air cooler, and intake manifold including the same

Publication Date: 2015.05.26 MODINE MFG CO

AI summary

A charge air cooler includes a housing and a heat exchanger core positioned within the housing. The heat exchanger core includes a first core section, a second core section, and a centrally located section positioned between the first core section and the second core section. The charge air cooler also includes a plurality of coolant circuits. Each coolant circuit extends through at least one of the first and second core sections. The charge air cooler further includes a coolant inlet extending from the centrally located section to deliver coolant to the plurality of coolant circuits, and a coolant outlet extending from the centrally located section to receive coolant from the plurality of coolant circuits. The charge air cooler also includes a fastener extending through the centrally located section of the core to secure the core to the housing.