Intercooler Housing Seam Blocking for Charged Air Leak Reduction
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Solution Overview
Problem
Existing intercoolers suffer from gas leakage at the welding seam of their U-shaped housings, which compromises their sealing integrity.
Innovation Solution
The introduction of gas blocking portions that penetrate through the seam, integrated with the outer housing, to block airflow leaks, combined with a groove portion and sealing pieces to enhance sealing efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional separate mounting approach is used for the intercooler and engine components, then individual component functionality is maintained, but the overall engine bay packaging efficiency is reduced and component spacing is insufficient
Solution Approach 1:
The intercooler is merged with the engine component mounting structure to form an integrated assembly. The intercooler housing serves dual functions as both a thermal management component and a structural mounting platform, eliminating the need for separate mounting brackets and reducing overall space requirements in the engine bay.
Solution Approach 2:
The mounting structure is designed to perform multiple functions simultaneously: it provides mechanical support for engine components, serves as a mounting platform for the intercooler, and incorporates fastening mechanisms. This multi-functionality reduces the number of separate parts needed and improves packaging efficiency.
2Volume of moving object
If compact engine bay layout is implemented to improve packaging efficiency, then space utilization increases, but access for maintenance and repair becomes difficult
Solution Approach 1:
The integrated assembly is designed with modular characteristics, allowing the intercooler and engine components to be accessed and serviced relatively independently. The mounting structure incorporates features that facilitate disassembly and reassembly, enabling maintenance personnel to access components without requiring complete disassembly of the entire assembly.
3Volume of moving object
If insufficient spacing is provided between engine components and intercooler, then packaging efficiency improves, but heat dissipation effectiveness is reduced
Solution Approach 1:
The intercooler is positioned and oriented in three-dimensional space to optimize both packaging and heat dissipation. The mounting structure incorporates strategic spacing in vertical and lateral dimensions, allowing adequate airflow paths for thermal management while maintaining compact overall dimensions. Airflow channels are designed to pass through specific gaps between components to ensure effective cooling.
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 gas blocking portions effectively reduce airflow leakage, ensuring better sealing and reducing the risk of gas leakage, while simplifying production and facilitating miniaturization of the intercooler.
Implementation Method 1
an intercooler for cooling charged air from a compressor
Implementation Method 2
a mounting structure for fastening the intercooler and other components to an engine
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
An outer housing (100), a core body (300), and an intercooler, the outer housing comprising: a first housing (110) and a second housing (120); the first housing (110) abuts the second housing (120) on the second direction and forms a seam (140) that extends on the first direction, the first direction being perpendicular to the second direction; and air blocking portions (130) which extend on the second direction and pass through the seam (140) are formed between the first housing (110) and the second housing (120). The present invention may solve the problem in which airflow easily flows out of an intercooler along the extension direction of a gap when a gap appears at a welding position of two U-shaped housings.