Intercooler Lid Assembly with Integrated Cores
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Solution Overview
Problem
Existing intercooler supercharger systems require complex and time-consuming installation processes, limiting their adoption by original equipment manufacturers (OEMs) due to designs that necessitate multiple castings and external water distribution systems, which restricts their integration into vehicle engines.
Innovation Solution
A pre-assembled intercooler lid assembly with three single-pass intercooler cores integrated into a single-piece lid, featuring built-in heat exchange medium inlets and outlets, and connection flanges for easy mounting onto the supercharger housing, allowing for simplified installation and improved airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intercooler cores are mounted to supercharger housing with separate lid, then cooling function is provided, but installation complexity increases and OEM integration becomes difficult
Solution Approach 1:
The patent combines the intercooler cores with the supercharger housing lid into a single integrated assembly. The lid serves dual purposes: as the housing cover and as the mounting structure for the intercooler cores. This merging eliminates the need for separate mounting brackets and simplifies the installation process, allowing OEM integration as a single unit while maintaining the cooling function.
2Adaptability or versatility
If multiple separate castings are used for supercharger housing, then mounting flexibility is provided, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent integrates the intercooler core mounting structure directly into the supercharger housing lid, creating a unified component. This eliminates the need for multiple separate castings and reduces the number of assembly steps. The integrated design maintains mounting flexibility through properly positioned bolt holes and connection points while significantly reducing assembly time.
3Ease of operation
If intercooler assembly is pre-assembled with cores mounted in lid, then installation ease is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements preliminary assembly of the intercooler cores within the lid structure during the manufacturing process. The cores are positioned and secured to the lid before the final housing assembly is completed. This preliminary action ensures precise core positioning and mounting while simplifying the final installation process, as the entire assembly can be installed as a single unit with pre-established core-to-lid connections.
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
Facilitates easier installation, reduces complexity, enhances airflow capacity, and increases packaging efficiency by integrating heat exchange components within the lid assembly, making it suitable for OEM integration while maintaining high performance.
Implementation Method 1
the plurality of intercooler cores include a plurality of heat exchange medium inlets and outlets coupled together within the intercooler lid to allow heat exchange fluid to transfer there through to cool the plurality of intercooler cores
Data Source
AI summary
An intercooler lid assembly for an intercooler supercharger system, comprising: an intercooler lid mountable to a supercharger housing; a plurality of intercooler cores coupled together, and mounted to and within the intercooler lid to cool supercharger air prior to receipt by an engine, wherein the intercooler lid assembly is pre-assembled and mounted onto the supercharger housing to install the intercooler lid assembly.