Integrated Charge Air Cooler Intake Unit Module

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Solution Overview

Problem

Internal combustion engines with integrated charge air coolers face challenges in compact design and efficient heat dissipation due to spatial constraints and the need for a lightweight, effective solution that integrates well with engine housing.

Innovation Solution

The design incorporates an intake unit with an integrated charge air cooler, comprising three container sections combined into a single module made of light alloy, featuring a tubular body that tapers down to the charger, with a cylindrical charge air cooler and strategically positioned exhaust gas turbocharger, allowing for efficient heat transfer and compact installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the charge air cooler is integrated into the intake unit with multiple container sections, then the heat dissipation efficiency is improved, but the device complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidintake unit structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines the first container section (supporting connecting ducts), second container section (accommodating charge air cooler), and third container section (supplying air) into a single integrated intake unit module. This merging of previously separate components into one unified structure improves heat dissipation efficiency while managing the inherent structural complexity through integration rather than separation.

Inventive Principle:

Principle #5Merging (Combining)

2Volume of moving object

If the intake unit is designed as a compact module, then the installation space is reduced, but the manufacturing complexity increases

Engineering Contradiction:

Improveinstallation spaceVSAvoidmanufacturing complexity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The integrated intake unit is designed with distinct functional sections (first container section for connecting ducts, second container section for charge air cooler, third container section for air supply) that are combined into one module. This segmentation within integration allows the compact design to fit restricted spaces while maintaining manufacturability through clear functional zonation within the unified structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The charge air cooler is accommodated within the second container section, which itself is part of the larger integrated intake unit module. This nested arrangement, where components are housed within container sections that form part of the overall module, achieves compact installation while managing manufacturing complexity through hierarchical structuring.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Volume of moving object

If the third container section is designed as a tapered tubular body, then the space utilization is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvespace utilizationVSAvoidtapered geometry

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The third container section is designed as a tapered tubular body with curved surfaces rather than sharp edges or complex angular features. This use of continuous curved geometry improves space utilization by allowing smooth transitions and better fit within the engine compartment, while the simplicity of the curved form relative to complex angular geometries actually reduces manufacturing precision requirements.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 enables a compact, efficient, and strong intake unit that effectively integrates with the engine housing, optimizing space usage and heat dissipation, even in restricted spatial conditions, while maintaining performance and fuel efficiency.

Implementation Method 1

a second container section (17) accommodating a charge air cooler (16)

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

The exhaust gas turbocharger created by a turbine and a charger is disposed on a top front side of the engine housing

Methodology Applied

Scientific EffectTurbine: Turbine

Implementation Method 3

a third container section (18) conducting the air to charge air cooler (16)

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS10060397B2Intake unit comprising integrated charge air cooler

Publication Date: 2018.08.28 NEANDER MOTORS

AI summary

An outboard turbocharged internal combustion engine includes an outboard engine housing. An exhaust gas turbocharger has a turbine and a charger disposed on the outboard engine housing. A charge air cooler is integrated in an intake unit. The intake unit is routed via connecting ducts and includes a unit container having first, second, and third container sections. The first container section is connected to the second container section accommodating the charge air cooler. The second container section is connected to the third container section that carries air to the charge air cooler. The third container section is formed of a tubular body tapering downward from the second container section toward the charger of the exhaust gas turbocharger. The first container section, the second container section, and the third container section are combined as an integral unit forming an intake unit module composed of a light alloy.