Corrugated Insert for Exhaust Gas Recirculation Cooler

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Solution Overview

Problem

Current exhaust gas recirculation systems for vehicle engines face inefficiencies in heat transfer between engine exhaust and coolant, particularly due to large bypass areas which reduce heat transfer effectiveness and increase the risk of fouling.

Innovation Solution

The implementation of a corrugated insert within the exhaust gas recirculation cooler's tube, with specific dimensions and orientations, to minimize bypass areas and enhance heat transfer efficiency by maximizing surface contact between the exhaust gas and coolant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a corrugated insert is added to the tube, then heat transfer efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The corrugated insert features a curved, wave-like geometry with alternating peaks and valleys that creates turbulence in the exhaust gas flow. This curvature disrupts laminar flow patterns and enhances heat transfer coefficients, resolving the contradiction by using geometric curvature to improve productivity while maintaining a relatively simple insert structure.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The corrugated insert creates a porous-like flow path through its corrugated structure, forcing the exhaust gas to navigate through channels formed by the waves. This increases the effective heat transfer surface area and promotes better thermal exchange between the exhaust gas and coolant, improving heat transfer efficiency without requiring complex multi-component assemblies.

Inventive Principle:

Principle #31Porous materials

2Productivity

If the corrugated insert width is increased to maximize surface contact, then heat transfer efficiency is improved, but the risk of fouling increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidfouling risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The corrugated geometry with its curved surfaces and wave patterns prevents deposits from adhering uniformly to the insert. The alternating peaks and valleys create areas of high and low velocity that disrupt deposit formation, allowing the insert to maintain large surface area for heat transfer while reducing fouling compared to flat surfaces.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The corrugated structure converts the potential harm of large surface area (which could accumulate fouling) into a benefit by using the extended surface geometry to create turbulence and prevent deposit adhesion. The same features that increase heat transfer area also serve to reduce fouling through flow disruption.

Inventive Principle:

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

3Productivity

If the corrugated insert is positioned to minimize bypass areas, then heat transfer efficiency is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidmanufacturing precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The corrugated insert is designed as a self-contained component with defined endpoints that can be independently manufactured and then installed in the tube. This segmentation allows the insert to be manufactured with standard tolerances and positioned to minimize bypass areas without requiring extremely tight overall assembly tolerances, resolving the contradiction between heat transfer efficiency and manufacturing precision.

Inventive Principle:

Principle #1Segmentation

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 significantly improves heat transfer efficiency while minimizing the cross-sectional area of bypasses, reducing fouling, and optimizing space within the vehicle engine, thereby enhancing the overall performance of the exhaust gas recirculation cooler.

Implementation Method 1

exhaust gas recirculation cooler for transferring heat from engine exhaust to coolant

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

tube body extending between the pair of headers and positioned along a flow path for the coolant and at least partially defining a flow path for the engine exhaust

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS8671921B2Exhaust gas recirculation system and method of operating the same

Publication Date: 2014.03.18 MODINE MFG CO

AI summary

The present invention provides an exhaust gas recirculation cooler for transferring heat from engine exhaust to coolant including a pair of spaced apart headers, a tube body extending between the pair of headers and positioned along a flow path for the coolant and at least partially defining a flow path for the engine exhaust along a length of the tube between the pair of headers, and a corrugated insert supported in an interior of the tube and having a height in a direction of a plurality of corrugations and a width between about 8.6 and about 13.5 times the height. The width can be substantially perpendicular to the length of the tube and can be substantially perpendicular to the height of the insert.