Dual Coolant Loop Intake Cooling System for Vehicle Engines

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Solution Overview

Problem

Conventional intercooler cooling systems for vehicle engines overwork and reduce the performance of additional cooling components, requiring increased size to support secondary cooling, which is inefficient and less effective.

Innovation Solution

A dual coolant loop system where a first coolant loop provides initial cooling to the intercooler and a second coolant loop, sharing a condenser with the first loop, offers further cooling to the intercooler, utilizing a compressor and expansion valve to achieve two-phase heat transfer and reduce the need for a dedicated low-temperature cooling circuit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional intercooler cooling system uses an additional cooling component (such as vehicle air conditioning circuit) to provide secondary cooling, then the cooling effect is improved, but the additional component is overworked and its performance is reduced

Engineering Contradiction:

Improveintake air temperatureVSAvoidperformance of additional cooling component

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The cooling system is segmented into two separate coolant loops: a first coolant loop for primary cooling and a second coolant loop for secondary cooling. This segmentation allows each loop to operate independently with optimized control, preventing the additional cooling component from being overworked while still achieving effective intake air cooling.

Inventive Principle:

Principle #1Segmentation

2Temperature

If an additional cooling component is used to support secondary cooling, then the cooling capability is improved, but the component size must be increased

Engineering Contradiction:

Improveintake air temperatureVSAvoidsize of cooling component

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The second coolant loop is designed to share the condenser with the first coolant loop, allowing the condenser to serve dual purposes. This multi-functionality approach reduces the need for separate dedicated components, thereby avoiding increased component size while still providing effective secondary cooling capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If a dual coolant loop system is implemented, then the cooling control is improved and component size is reduced, but the system complexity is increased

Engineering Contradiction:

Improvecooling control capabilityVSAvoidcooling system structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The first and second coolant loops share common components including the condenser, reducing the overall number of components needed. This merging approach maintains the adaptability and control capability of a dual-loop system while minimizing the increase in system complexity through component sharing.

Inventive Principle:

Principle #5Merging (Combining)

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 system effectively cools intake air to below ambient temperatures, increasing charge density and engine power, improving fuel economy, and reducing the workload on cooling components, while eliminating the need for a dedicated low-temperature cooling circuit.

Implementation Method 1

a first coolant loop thermally coupled to the air intake to provide cooling to the intake air

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

a second coolant loop thermally coupled to the air intake to provide further cooling to the intake air

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 3

wherein the second coolant loop includes a compressor to circulate the coolant therethrough

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

wherein the second coolant loop includes an expansion valve upstream of the intercooler and downstream of a condenser

Methodology Applied

Scientific EffectThrottling: Valve

Implementation Method 5

wherein the first and second coolant loops share a condenser; wherein the second coolant loop includes an expansion valve upstream of the intercooler and downstream of a condenser

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS10830122B2Intake and charge air cooling system

Publication Date: 2020.11.10 FCA US LLC

AI summary

An air cooling system for a vehicle engine includes an air intake configured to receive intake air for delivery to the engine, a first coolant loop thermally coupled to the air intake to provide cooling to the intake air, and a second coolant loop thermally coupled to the air intake to provide further cooling to the intake air. The first and second coolant loops are separate loops using a common condenser