Integrated Intercooler Outlet Tank Structural Design
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Solution Overview
Problem
There is a need for a heat exchanger mounting solution that allows direct attachment to a motor vehicle engine block while maintaining structural integrity and minimizing manufacturing costs, particularly in applications with space constraints and vibration challenges.
Innovation Solution
A heat exchanger design featuring an inlet tank, a heat exchange assembly with multi-pass flow channels, and an outlet tank with openings to match engine block cylinders, directly coupled to the engine block via a header with support members for structural rigidity and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heat exchanger is directly mounted to the engine block, then manufacturing cost is reduced and assembly is simplified, but structural integrity under vibration and pressure loads may be compromised
Solution Approach 1:
The outlet tank is merged with the engine block to form an integrated assembly, eliminating separate mounting brackets and fasteners. The outlet tank is formed as an integral part of the engine block structure, reducing part count and manufacturing cost while maintaining structural integrity through the unified design.
Solution Approach 2:
The outlet tank is segmented into multiple sections with reinforcing ribs that divide the structure into smaller load-bearing elements. This segmentation allows the structure to better distribute vibration and pressure loads across multiple reinforcement points, maintaining strength while using thinner, more cost-effective materials.
2Productivity
If the outlet tank is designed with multiple openings for cylinder communication, then air flow efficiency is improved, but structural strength of the outlet tank is reduced
Solution Approach 1:
The outlet tank features localized reinforcement around each opening with thickened rim structures and surrounding ribs. The material distribution is non-uniform, with higher concentration around openings where stress concentrates, and thinner sections in areas experiencing lower stress, optimizing both air flow and structural strength.
Solution Approach 2:
The outlet tank utilizes composite construction with varying wall thicknesses and integrated reinforcement ribs formed as part of the tank structure. This composite approach allows thin-walled sections for lightness and cost-effectiveness while incorporating localized thickened sections for strength where openings are present.
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 solution provides effective air cooling, minimizes manufacturing and assembly costs, and maintains structural integrity under vibration and pressure loads, ensuring efficient air flow and heat transfer without significant air pressure drop.
Implementation Method 1
The heat exchange assembly exchanges heat between the air and a coolant
Implementation Method 2
The plate assemblies define a plurality of serpentine multi-pass flow channels receiving a coolant therein
Data Source
AI summary
A heat exchanger for a vehicle includes an inlet tank configured to receive air from an air circuit of the vehicle. The heat exchanger further includes a heat exchange assembly disposed intermediate the inlet tank and an outlet tank. The heat exchange assembly exchanging heat between the air and a coolant. The outlet tank is configured to directly couple to an engine block of the vehicle and convey the air to the engine block. The outlet tank has at least two openings formed therein. The openings are configured to communicate with corresponding cylinders of the engine block of the vehicle.