Integrated Charge Air Cooler in Engine Plenum
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Solution Overview
Problem
Existing intake systems with charge air coolers positioned downstream of compressors and upstream of throttles increase the volume of the induction system, compromising compactness, torque response, and EGR control, leading to reduced combustion efficiency and impaired fuel economy and emission reduction.
Innovation Solution
An intake assembly with an integrated charge air cooler within the plenum, featuring water-cooled cooling plates and a throttle body positioned downstream, reduces throttled volume and enhances compactness, allowing for improved combustion efficiency and better control of both low and high pressure EGR systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the charge air cooler is positioned in a separate enclosure downstream of the compressor and upstream of the throttle, then the charge air can be cooled effectively, but the volume of the induction system increases, compromising compactness and increasing losses
Solution Approach 1:
The charge air cooler is integrated directly into the plenum chamber, merging two previously separate components (cooler and plenum) into a single unified structure. This eliminates the need for a separate cooler enclosure and reduces the overall induction system volume while maintaining effective charge air cooling functionality
Solution Approach 2:
The charge air cooler is nested within the plenum chamber space, utilizing the existing volume of the plenum for dual purposes: as an air mixing chamber and as a cooling system housing. This nested arrangement allows the cooler to occupy space that would otherwise be unused, reducing the need for additional external volume
2Temperature
If the charge air cooler is positioned in a separate enclosure, then charge air cooling is provided, but the compactness of the induction system decreases and packaging is negatively impacted
Solution Approach 1:
The charge air cooler is merged with the plenum chamber into a single integrated component, eliminating the need for separate mounting space and reducing the number of discrete parts. This integration simplifies the overall induction system architecture and improves packaging efficiency
3Temperature
If the charge air cooler is positioned in a separate enclosure, then charge air cooling is achieved, but losses within the induction system increase
Solution Approach 1:
By integrating the charge air cooler into the plenum chamber, the patent eliminates additional flow paths and connections that would be required for a separate cooler installation. This reduces flow resistance, minimizes pressure losses, and improves overall induction system efficiency
4Temperature
If the charge air cooler is positioned in a separate enclosure, then charge air cooling is provided, but EGR control is negatively impacted due to large throttled volume
Solution Approach 1:
The integration of the charge air cooler into the plenum chamber reduces the total throttled volume in the induction system. This smaller volume improves the responsiveness and control precision of the EGR system by reducing transport delays and improving the dynamic response of the air-EGR mixture to throttle position changes
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
The integration of the charge air cooler into the plenum reduces throttled volume, increases combustion efficiency, and improves throttle response and EGR control, while maintaining compactness and reducing energy losses in the intake system.
Implementation Method 1
cooling plates extending into a plenum enclosure and coupled to the coolant passage
Implementation Method 2
coolant inlet and a coolant outlet in fluidic communication with a coolant passage
Data Source
AI summary
An intake assembly in an engine is provided. The intake assembly includes a compressor and a plenum in fluidic communication with the compressor, the plenum having an integrated charge air cooler including a coolant inlet and a coolant outlet in fluidic communication with a coolant passage and cooling plates extending into a plenum enclosure and coupled to the coolant passage. The intake assembly further includes a throttle body coupled to the plenum.