Integrated Multi-Stage Charge Air Cooler Plate Assembly
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Solution Overview
Problem
Existing water-cooled charge air coolers face limitations in performance and efficiency due to the separate low temperature (LT) and high temperature (HT) coolant circuits, leading to increased complexity, cost, and size issues, especially at high turbocharger or supercharger boost levels.
Innovation Solution
A charge air cooler with integrated multi-stage cooling using a unitary plate assembly that forms separate flow channels for both LT and HT coolants, with fins interposed between plate assemblies for enhanced heat transfer, minimizing complexity and cost while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate LT coolant circuit with a secondary radiator is used to cool compressed air, then the charge air cooler can provide dedicated cooling capacity, but the system complexity and package space requirements increase
Solution Approach 1:
The patent combines the LT and HT coolant circuits into a single integrated charge air cooler system. The plate assembly includes flow channels for both LT coolant and HT coolant, allowing both coolant sources to work together in one unified heat exchange structure, thereby reducing system complexity while maintaining cooling performance
Solution Approach 2:
The charge air cooler is designed to accept multiple coolant sources (both LT and HT circuits) and perform multiple cooling functions simultaneously. The plate assembly can handle different coolant flows through separate flow channels, providing versatile cooling capability for various operating conditions
2Power
If the size of the secondary radiator of the LT coolant circuit is increased to improve cooling capacity, then maximum performance can be achieved at high boost levels, but package space requirements and manufacturing costs increase
Solution Approach 1:
The patent merges the cooling functions of both LT and HT coolant circuits into a single charge air cooler unit. By combining the cooling capacities of both circuits in one integrated plate assembly, the system achieves maximum cooling performance without requiring a larger secondary radiator, thus reducing package space requirements
3Reliability
If multiple cooler units or tube-style heat exchange cores are used for multi-stage cooling, then desired cooling performance can be achieved, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent consolidates multiple cooling functions into a single plate assembly structure. The plate includes integrated flow channels for both LT and HT coolants, eliminating the need for multiple separate cooler units or complex tube-style heat exchange cores, thereby reducing manufacturing costs and assembly complexity while maintaining multi-stage cooling performance
Solution Approach 2:
The plate assembly is segmented into distinct flow channels for LT coolant and HT coolant, allowing independent flow paths within a unified structure. This segmentation enables multi-stage cooling functionality while maintaining manufacturing simplicity through a single integrated component
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 effectively cools compressed air, maximizing engine performance and efficiency while reducing manufacturing costs and maintaining package size, ensuring durability and optimal thermal management.
Implementation Method 1
As the compressed air flows through the WCAC, heat is transferred between air compressed by the turbocharger or the supercharger and the coolant from the LT coolant circuit
Implementation Method 2
A plurality of fins are interposed between the plate assemblies
Data Source
AI summary
A charge air cooler includes a plurality of plate assemblies. Each of the plate assemblies includes a unitary first plate and a unitary second plate. The first plate and the second plate each have a channel forming surface. The channel forming surface of the first plate cooperating with the channel forming surface of the second plate to form a first flow channel for receiving a first coolant and a second flow channel for receiving a second coolant. A plurality of fins is interposed between the plate assemblies.