Dual-Stage Turbocharger Intake Air Cooler with Shared Bundle
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Solution Overview
Problem
The existing architecture for turbocharged heat engines with two supercharging stages requires two separate heat exchangers, which increases cost, pressure drop, and bulk, while also complicating aeraulics, especially when mounted at the front of a vehicle.
Innovation Solution
A single heat exchanger housing combines two cooling stages with a shared heat exchanger bundle, allowing intake air to flow in series, and the coolant to circulate in opposite directions through a stack of plates with corrugated spacers, optionally with a movable partition for compressor operation flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two separate heat exchangers are used for dual-stage turbocharging, then cooling efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines two separate heat exchangers into a single integrated heat exchanger with a shared bundle, where the first and second cooling stages are housed in the same casing and share common internal components. This merging reduces the total number of separate devices while maintaining the dual-stage cooling functionality, thereby reducing device complexity and cost without sacrificing cooling efficiency.
Solution Approach 2:
The single heat exchanger is designed to perform multiple functions: it provides both first-stage and second-stage cooling, houses multiple internal ducts and partitions, and accommodates different flow configurations (counter-flow or parallel-flow). This multi-functionality allows one device to replace what would traditionally require two separate heat exchangers.
2Temperature
If two separate heat exchangers are mounted at the front of the vehicle, then cooling capacity is sufficient, but pressure drop increases
Solution Approach 1:
By merging the two cooling stages into a single heat exchanger with integrated internal passages, the patent eliminates the need for air to exit one heat exchanger and enter another, thereby reducing the number of connections and minimizing pressure drops associated with multiple inlets and outlets at the front of the vehicle.
3Reliability
If two separate heat exchangers are used, then cooling protection is improved, but bulk and cost increase
Solution Approach 1:
The patent merges two separate heat exchanger units into a single compact device with shared internal components, significantly reducing the overall bulk and volume required in the engine bay while maintaining the protective cooling function for both compressor stages.
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 reduces costs, minimizes pressure drop, and simplifies the intake air circuit while maintaining efficient heat exchange, supporting both dual and single compressor operations.
Implementation Method 1
The two supercharging stages can comprise a turbocharger associated with a mechanical or electrical compressor... The intake air thus compressed, also called charge air, is heated due to its compression and must be cooled by means of a suitable heat exchanger, called charge air cooler
Implementation Method 2
the beam of heat exchanger comprising a first part and a second part housed respectively in the first conduit and the second conduit... the cooling liquid circulates successively in the first part and the second part of the heat exchanger bundle
Implementation Method 3
the heat exchanger bundle comprises a stack of plates and corrugated spacers defining blades for the circulation of the coolant, alternating with the channels for the circulation of the intake air
Implementation Method 4
The first compressor, or upstream compressor, compresses low pressure intake air, while the second compressor, or downstream compressor, compresses high pressure intake air... The intake air thus compressed, also called charge air, is heated due to its compression
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention concerns an intake air cooler comprising a first cooling stage (24) and a second cooling stage (26) assembled in a single heat exchanger housing (30) and sharing a common heat exchanger bundle (28) accommodated in the housing and traversed by a cooling liquid. The invention is applicable to turbocompressed heat engines for motor vehicles.