Air to Air Heat Exchanger with Reinforced Sections
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Solution Overview
Problem
Conventional air to air heat exchangers for charge air cooling in internal combustion engines are susceptible to thermal fatigue due to high, fluctuating temperatures, leading to increased emission levels and reduced engine efficiency, and face challenges in maintaining a leak-free flow path under mechanical stresses.
Innovation Solution
The air to air heat exchanger design incorporates thermally conductive separators and structurally reinforced sections within the core depth, with a corrugated fin structure and flow channels to enhance structural support and heat transfer, while minimizing pressure drop by optimizing the distribution of reinforced sections and flow passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bar-plate style heat exchangers are used with flat plates and bars for heat transfer, then heat exchange function is achieved, but the structure is susceptible to thermal fatigue due to high fluctuating temperatures
Solution Approach 1:
The patent applies local quality by providing structurally reinforced sections at specific locations (inlet end and outlet end) of the heat exchanger passages. These reinforced sections have increased wall thickness compared to intermediate sections, creating non-uniform structural properties that specifically address high-stress regions where thermal fatigue occurs most frequently, while maintaining adequate heat transfer in less critical areas.
Solution Approach 2:
The patent employs composite material construction by combining materials with different properties in the heat exchanger structure. The use of thermally conductive separator walls made of aluminum or aluminum alloy, combined with structurally reinforced sections, creates a composite structure that optimizes both thermal performance and mechanical strength to resist thermal fatigue.
2Productivity
If the heat exchanger core depth is increased to improve heat transfer, then heat exchange efficiency increases, but the device size and pressure drop increase
Solution Approach 1:
The patent applies dimensionality change by transitioning from a conventional single-dimension heat exchanger design to a multi-dimensional passage arrangement. The heated air passages and cooling air passages are arranged in alternating three-dimensional patterns, allowing heat transfer to occur simultaneously across multiple dimensions, thereby increasing efficiency without proportionally increasing core depth.
Solution Approach 2:
The patent segments the heat exchanger into multiple alternating heated air passages and cooling air passages arranged in a three-dimensional pattern. This segmentation allows the heat transfer function to be distributed across multiple smaller channels, improving overall heat transfer efficiency while maintaining a compact core depth and reducing pressure drop through optimized flow distribution.
3Productivity
If thermally conductive separator walls are used to improve heat transfer, then heat exchange efficiency increases, but the structure becomes more susceptible to thermal fatigue
Solution Approach 1:
The patent applies local quality by making the separator walls thermally conductive in intermediate sections for optimal heat transfer, while providing structurally reinforced sections at the inlet and outlet ends with increased wall thickness. This creates a non-uniform separator structure that is thin and highly conductive where heat transfer is most effective, and thick and strong where thermal fatigue stresses are highest.
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 improves the endurance of the heat exchanger against thermal and pressure cycles, reduces pressure drop, and maintains efficient heat transfer, thereby enhancing engine efficiency and reducing emissions.
Implementation Method 1
Thermally conductive separators are arranged between the heated air flow passage and each of the cooling air flow passages
Implementation Method 2
a corrugated fin structure is provided between the separators in at least a portion of the heated air flow passage
Data Source
AI summary
An air to air heat exchanger includes a first and a second cooling air flow passage extending over a core depth of the heat exchanger. A heated air flow passage is arranged between the cooling air flow passages, and extends over a first percentage of the core depth. Thermally conductive separators are arranged between the heated air flow passage and each of the cooling air flow passages. A first structurally reinforced section is provided between the separators, and extends from a cooling air inlet face in the core depth direction over a second percentage of the core depth. A second structurally reinforced section is provided between the separators, and extends from a cooling air outlet face in the core depth direction over a third percentage of the core depth. The sum of the first, second, and third percentages is greater than 100 percent.