Clip-Type Charge Air Cooler Pipe Connector
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Solution Overview
Problem
Existing charge-air coolers for supercharged internal combustion engines face challenges in the design of pipe connectors for efficient coolant introduction and discharge, which can lead to complex installations and potential mechanical stresses due to temperature fluctuations.
Innovation Solution
The charge-air cooler features a clip-type connection between a pipe element and an adapter element, allowing for easy detachment and attachment, with components made from materials like aluminum and plastic to ensure cohesive connections and matching thermal expansion coefficients, reducing mechanical stresses and facilitating installation in fresh-air systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional pipe connectors are used for coolant introduction and discharge, then the charge-air cooler can be installed in the fresh-air system, but the installation becomes complex and mechanical stresses occur due to temperature fluctuations
Solution Approach 1:
The pipe connector is divided into two separate elements: a pipe element and an adapter element. The adapter element is permanently attached to the cooler box, while the pipe element can be detachably connected. This segmentation simplifies installation and maintenance operations while reducing overall connector complexity.
Solution Approach 2:
The clip-type connection between the pipe element and adapter element provides a dynamic, adjustable fastening mechanism that can accommodate thermal expansion and contraction. This dynamic connection reduces mechanical stresses during temperature fluctuations compared to rigid traditional connectors.
2Reliability
If traditional pipe connectors are used for coolant introduction and discharge, then the charge-air cooler can function, but mechanical stresses occur due to temperature fluctuations
Solution Approach 1:
The clip-type connection provides a dynamic fastening mechanism that can flex and adjust during thermal cycles, reducing mechanical stresses while maintaining reliable connection. The complementary geometric shaping ensures consistent engagement under varying thermal conditions.
Solution Approach 2:
The material selection (aluminum and plastic with matching thermal expansion coefficients) changes the thermal parameters of the connector components. This parameter matching reduces differential thermal expansion and associated mechanical stresses during temperature fluctuations.
3Stress or pressure
If components are made from aluminum and plastic, then mechanical stresses are reduced due to matching thermal expansion coefficients, but manufacturing complexity increases
Solution Approach 1:
The adapter element combines aluminum and plastic materials to achieve matching thermal expansion coefficients. This composite construction reduces mechanical stresses during thermal cycles while the modular design keeps manufacturing processes manageable through specialized fabrication techniques.
4Ease of operation
If a clip-type connection is used for the pipe element and adapter element, then detachment and attachment become easy, but connection security may be compromised
Solution Approach 1:
The clip-type connection features complementary geometric shaping at the connection interface, creating localized engagement points that provide secure fastening. This geometric interlocking ensures reliable connection strength while maintaining ease of attachment and detachment through the clip mechanism.
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 enables simple and secure mounting of the charge-air cooler, reduces mechanical stresses, and maintains fluid sealing, enhancing the reliability and efficiency of coolant circulation within the system.
Implementation Method 1
The two first end sections 10a, 9a of pipe element 9 and adapter element 10, respectively, have a substantially complementary geometric shaping
Implementation Method 2
The cooling of the charge air is realized by heat transfer from the charge air to the surroundings
Implementation Method 3
at least two heat exchangers are used, typically a coolant cooler which dissipates the heat from the coolant to the surroundings, and a charge-air cooler which transfers the heat from the charge air to the coolant
Implementation Method 4
a coolant cooler which dissipates the heat from the coolant to the surroundings
Implementation Method 5
on the gas side, in order to improve the heat transfer, are connected to a rib structure, which rib structure serves firstly for the support of the flat pipes but is secondly also, in the charge-air cooler, integrated into the fluid path of the charge air to be cooled
Data Source
AI summary
A charge-air cooler for a fresh-air system of an internal combustion engine may include a cooler box and an upper shell such as a flange plate. The cooler box may include a cooler box passage opening, and the flange plate may include a flange plate passage opening arranged complementary with the cooler box passage opening. An adapter element may have a first end section and a second end section. The adapter element may be connected to a rim of the cooler box that borders the cooler box passage opening. A pipe element may be detachably secured to the adapter element and have a first end section and a second end section. The first end section of the adapter element and the first end section of the pipe element may define a clip-type connection when the adapter element and the pipe element are secured to one another.