Integrated Airflow Cooler Module for Turbocharged Engine
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Solution Overview
Problem
Existing combustion air intake systems for internal combustion engines face issues with packaging, noise, vibration, and leakage due to long ducts from turbochargers to charge air coolers, leading to 'turbo lag' caused by delayed pressure build-up of charge air.
Innovation Solution
An integrated airflow cooler module with a lower and upper manifold assembly, a throttle body, and heat exchangers internalized within the manifold volume, where the throttle blade meters combustion air through heat exchangers to the cylinder head, reducing duct length and preventing hot air bypass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If long ducts are used to connect turbochargers to charge air coolers, then the charge air cooler can be mounted in the under hood area near the radiator and condenser, but the duct length causes packaging issues, noise, vibration, and leakage
Solution Approach 1:
The patent merges the charge air cooler with the intake manifold by integrating the cooler cores directly into the manifold structure. This eliminates the need for separate long ducts connecting the cooler to the manifold, thereby reducing noise and vibration while maintaining effective charge air cooling.
Solution Approach 2:
The charge air cooler cores are nested within the intake manifold structure, with the cooler cores positioned inside the manifold housing. This nesting arrangement eliminates external ducting and reduces the harmful effects of long ducts while maintaining the cooling function.
2Temperature
If long ducts are used to connect turbochargers to charge air coolers, then the charge air cooler can be mounted in the under hood area, but the duct length causes packaging issues and leakage opportunities
Solution Approach 1:
By merging the charge air cooler with the intake manifold through direct integration, the patent eliminates multiple seal interfaces that would exist between separate ducts and components. This reduces leakage opportunities while maintaining effective charge air cooling.
Solution Approach 2:
The nested arrangement of cooler cores within the manifold structure eliminates external ducting and its associated seal interfaces, thereby reducing packaging constraints and leakage opportunities while maintaining the cooling function.
3Temperature
If long ducts are used to deliver compressed air, then the charge air cooler can be positioned away from the engine, but the duct length delays pressure build-up and causes turbo lag
Solution Approach 1:
The integration of the charge air cooler with the intake manifold eliminates long ducts that would delay pressure transmission. This merging allows compressed air to be cooled and delivered to the manifold rapidly, reducing turbo lag while maintaining effective cooling.
Solution Approach 2:
The nested configuration of the cooler within the manifold eliminates external ducting delays, allowing compressed air to be cooled and delivered immediately to the intake manifold, thereby reducing turbo lag while maintaining cooling effectiveness.
4Temperature
If the charge air cooler is mounted externally near the radiator and condenser, then the cooling function can be performed, but the external mounting results in long ducts that increase system complexity
Solution Approach 1:
The patent combines the charge air cooler and intake manifold into a single integrated assembly, eliminating the need for separate external mounting and long ducting systems. This merging simplifies the overall system while maintaining effective charge air cooling.
Solution Approach 2:
The nested arrangement of the cooler cores within the manifold structure eliminates external ducting and reduces system complexity. The cooling function is maintained while the integrated design simplifies the overall air intake system architecture.
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 enhances engine performance by minimizing turbo lag, reducing noise and vibration, and ensuring efficient cooling and metering of combustion air, thereby improving transient performance.
Implementation Method 1
A heat exchanger is disposed in the upper manifold volume between a combustion air inlet of the integrated airflow cooler module and the throttle body
Implementation Method 2
A throttle blade disposed in the throttle body meters combustion air through the integrated airflow cooler module from the upper manifold volume to the lower manifold volume
Data Source
AI summary
The intake system includes an integrated airflow cooler module comprising a lower manifold assembly and a throttle body fluidly connected to, and disposed within the lower manifold assembly to meter combustion air into a lower manifold volume of the lower manifold assembly. An upper manifold assembly is configured for assembly to the lower manifold assembly to define a manifold volume therebetween and a heat exchanger is disposed in the manifold volume, between the upper manifold assembly and the lower manifold assembly and between a combustion air inlet in the integrated airflow cooler module and the throttle body.