Charge Air Cooler Deflector for Uniform Airflow
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Solution Overview
Problem
Non-uniform airflow distribution at the inlet of charge air coolers due to angled or non-symmetrical inlet ports and air ducts leads to inefficient heat exchange and potential thermal shock, affecting the performance and longevity of the cooler.
Innovation Solution
A deflector with a base portion and angled flap, featuring protruded portions that direct airflow uniformly across the core of the charge air cooler, ensuring even distribution and optimal heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If an angled inlet port or non-symmetrical air duct is used to strategically position the charge air cooler, then space utilization is improved, but airflow distribution uniformity deteriorates
Solution Approach 1:
A deflector is introduced as an intermediary component in the inlet tank to redirect and redistribute airflow. The deflector intercepts the non-uniform airflow from the angled inlet and redirects it to achieve uniform distribution across the core, resolving the contradiction between space utilization and airflow uniformity
Solution Approach 2:
The deflector is strategically positioned at specific locations within the inlet tank where airflow non-uniformity occurs. By locally modifying the airflow path at the inlet region, the system achieves uniform distribution across the entire core while maintaining the angled inlet configuration for space optimization
2Productivity
If non-uniform airflow distribution occurs at the inlet, then heat exchange efficiency deteriorates, but the system structure remains simple
Solution Approach 1:
The deflector serves as a simple intermediary component that significantly improves heat exchange efficiency by ensuring uniform airflow distribution across the core. This single added element enhances productivity without requiring complex structural modifications to the inlet tank
Solution Approach 2:
The deflector modifies the airflow parameters (velocity distribution, flow direction) at the inlet of the core. By changing these flow parameters rather than the core structure itself, the system achieves improved heat exchange efficiency with minimal increase in device complexity
3Reliability
If non-uniform airflow distribution is present, then thermal shock damage risk increases, but no additional protective components are added
Solution Approach 1:
The deflector acts as a protective intermediary that prevents thermal shock by ensuring uniform airflow distribution before air enters the core. This simple component redistributes the airflow to eliminate localized high-velocity regions that would cause thermal shock, thereby improving reliability without adding complex protective systems
Solution Approach 2:
The deflector performs preliminary airflow redistribution at the inlet stage, before the air reaches the core. By pre-conditioning the airflow to achieve uniform distribution, the system prevents thermal shock damage before it can occur, enhancing reliability with a simple preventive measure
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
The deflector ensures homogeneous airflow distribution, enhancing heat exchange efficiency and preventing thermal shock, thereby improving the performance and reliability of the charge air cooler.
Implementation Method 1
a deflector provided within the inlet tank to enable uniform distribution of a first fluid onto a core of the charge air cooler
Implementation Method 2
both fluid circuits are defined in a heat exchange configuration, so that the hot air exchanges heat with the coolant flowing therein
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An embodiment of the invention herein provides a heat exchanger for a vehicle. The heat exchanger includes a housing with a core and at least one deflector. The housing is connected with an inlet tank and adapted to accommodate a core. The deflector is provided within the inlet tank and the deflector includes at least one flap inclined at an angle towards the core of the heat exchanger.