Charge Air Cooler Front-Surface Shielding Against Thermal Fatigue
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Solution Overview
Problem
Existing charge air coolers suffer from thermomechanical fatigue due to extreme temperature differences and rapid temperature changes, leading to potential breakage, particularly at the axial front surface of heat exchange plates, which is exacerbated by the use of materials like aluminum plate coolers with air fins or stainless steel, resulting in inefficiencies and complex constructions.
Innovation Solution
The implementation of protective elements on the axial front surfaces of heat exchange plates, which act as partial heat shields, reducing thermocycle amplitudes and stress by allowing independent thermal expansion and contraction, without direct mechanical fixation, and are positioned in grooves or seams to facilitate movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If aluminum plate coolers with air fins are used, then heat exchange efficiency is improved, but thermomechanical stress and breakage risk increase due to extreme temperature differences
Solution Approach 1:
The patent introduces protective elements (such as protective plates or reinforcement structures) positioned at the axial front surface of the heat exchange plates before thermal stress occurs. These protective elements act as a buffer to absorb and distribute the thermomechanical stress caused by extreme temperature differences between hot air and cold coolant, preventing crack initiation and propagation in the aluminum plate cooler during thermal cycling.
2Reliability
If stainless steel plate coolers are used, then durability is improved, but heat exchange efficiency decreases compared to aluminum plate coolers
Solution Approach 1:
The patent employs a composite structure where the heat exchange plates are made of aluminum (for high heat exchange efficiency) while incorporating protective elements made of more durable materials (such as stainless steel or other corrosion-resistant materials) at the axial front surface. This composite approach allows the aluminum plates to maintain their superior thermal conductivity while the protective elements provide enhanced durability and resistance to thermomechanical fatigue, effectively combining the advantages of both materials.
3Reliability
If air fins are removed to allow expansion, then crack prevention is improved, but heat exchange efficiency decreases and construction becomes complex
Solution Approach 1:
The patent segments the heat exchange plate structure by introducing protective elements that are separately positioned at the axial front surface, distinct from the main heat exchange plate body. This segmentation allows the protective elements to independently accommodate thermal expansion and contraction through designed movement capabilities (such as gaps, springs, or flexible connections), while the main heat exchange plates maintain their structural integrity and heat exchange efficiency without requiring removal of air fins or complex modifications to the core heat exchange structure.
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 protective elements effectively reduce thermomechanical stress and prevent cracks by smoothing temperature changes, enhancing the durability and efficiency of the air cooler, while maintaining heat exchange performance.
Implementation Method 1
The protective element will act like a partial heat shield to protect this sensitive structural part of the heat exchange block from the heat
Implementation Method 2
allowing independent thermal expansion and contraction
Implementation Method 3
a heat exchange block arranged in the casing... coolant channels extending in the heat exchanges plates
Implementation Method 4
exchanging heat coming from the hot air pushed into the air compartment by the turbochargers to the cold water pushed into the water passages by the water pumps
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention provides an air cooler, in particular a charge air cooler, comprising a casing and a heat exchange block arranged in the casing, the casing comprising an air inlet and and air oulet, with an air flow path extending from the inlet to the outlet through the heat exchange block, with the air flow path extending in an axial direction through the heat exchange block, the heat exchange block comprising a plurality of heat exchange plates stacked in a first traverse direction and extending in a plane defined by the axial direction and a second transverse direction, with coolant channels extending in the heat exchanges plates. According to the invention, at least one protective element is provided on an axial front surface of a heat exchange plate.