EGR Heat Exchanger Deflection Baffles Coolant Overheating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current EGR heat exchangers face challenges in preventing coolant overheating and boiling, especially when the coolant inlet is positioned at a distance greater than the safety distance from the gas inlet, which is not flexible and poses a risk of rupture due to high exhaust gas temperatures.

Innovation Solution

The heat exchanger incorporates deflection means, such as longitudinal and transverse baffles with strategically arranged through-openings, to precisely direct the cooling fluid jet towards the gas inlet end, ensuring accurate and efficient cooling of critical areas while maintaining a safe distance from the gas inlet.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the coolant inlet is positioned at a distance greater than the safety distance from the gas inlet, then the flexibility of the heat exchanger design is improved, but the risk of coolant overheating and boiling increases

Engineering Contradiction:

Improvedesign flexibilityVSAvoidcoolant overheating risk

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by positioning deflection means (baffles) upstream of the coolant flow path, closer to the gas inlet end. These baffles pre-direct the coolant jet towards the gas inlet area before the coolant would naturally travel, ensuring the coolant reaches the critical cooling zone promptly even when the inlet is positioned far from the gas inlet, thus maintaining reliability while enabling design flexibility

Inventive Principle:

Principle #10Preliminary action

2Productivity

If fins are added to improve heat exchange, then the heat exchange performance is improved, but the local temperature of the coolant increases

Engineering Contradiction:

Improveheat exchange performanceVSAvoidcoolant local temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent applies local quality by implementing deflection means (baffles) specifically at the coolant inlet area and directing coolant flow precisely to the gas inlet end where heat exchange is most critical. This localized flow direction control ensures that coolant is delivered exactly where needed, preventing local overheating while maintaining the heat exchange performance provided by fins

Inventive Principle:

Principle #3Local quality

3Productivity

If the coolant flow distribution is improved to prevent stagnation, then the cooling efficiency is improved, but the complexity of the internal structure increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidinternal structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the internal flow path into distinct zones using multiple baffles (first baffle, second baffle, third baffle) positioned at different locations. These segmented structures guide coolant flow through specific pathways, preventing stagnation and improving cooling efficiency while maintaining manageable structural complexity through modular baffle design

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 solution effectively prevents coolant overheating and boiling by directing the cooling fluid with precision and increased speed towards the most critical areas, enhancing cooling performance and reducing stagnation risks, even when the coolant inlet is positioned farther than the safety distance from the gas inlet.

Implementation Method 1

The main function of EGR heat exchangers is the exchange of heat between the exhaust gases and the cooling fluid, in order to cool the gases.

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a bundle of tubes intended for the circulation of the exhaust gases; a casing that houses therein said bundle of tubes... for heat exchange with the exhaust gases circulating through same

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

means for preventing the overheating of said cooling fluid inside the casing, which comprise some deflection means arranged inside the casing and suitable for directing the flow of cooling fluid entering via said inlet orifice towards said gas inlet end

Methodology Applied

Scientific EffectFluid flow direction control:

Data Source

PatentEP3430340B1Heat exchanger for gases, in particular the exhaust gases of an engine

Publication Date: 2023.03.08 VALEO TERMICO SA

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

The exchanger comprises: - a bundle of tubes for the circulation of the exhaust gases; - a casing that houses therein the bundle of tubes, which comprises: - a gas inlet end and a gas outlet end; and - a cooling fluid inlet orifice and an outlet orifice; and - means for preventing the overheating of the cooling fluid, which comprise some deflection means that include a longitudinal baffle (6) with a through-opening (A1) for access to an area inside the casing adjacent to the gas inlet end, and which is arranged and dimensioned for directing a jet of cooling fluid towards a sub- area of said area.