Modular Intercooler Block Assembly for Larger High-Transfer Cores

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Solution Overview

Problem

Existing intercooler construction methods are labor-intensive, inconsistent, and costly, with limitations on core size due to manufacturing difficulties and material constraints, while also compromising heat transfer efficiency.

Innovation Solution

A modular intercooler block fabricated using direct metal printing (DMP), comprising a multiplicity of cooling fins, core headers with countersunk holes, and undulating core tubes to enhance heat transfer, allowing for assembly into larger intercoolers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional copper/brass soldered construction is used, then manufacturing consistency and labor efficiency are improved, but material cost increases and heat transfer efficiency decreases

Engineering Contradiction:

Improvemanufacturing consistencyVSAvoidmaterial cost

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent changes the material parameter from traditional copper/brass to aluminum, and changes the joining method parameter from soldering to controlled atmosphere brazing (CAB). This allows achieving manufacturing consistency with aluminum while reducing material cost and improving heat transfer efficiency through the different thermal and mechanical properties of aluminum compared to copper/brass

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical soldering process with controlled atmosphere brazing (CAB), substituting a mechanical/chemical joining method with a controlled thermal process that occurs in a specific atmospheric environment. This substitution improves manufacturing consistency and enables automated production while reducing labor requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If controlled atmosphere brazing (CAB) aluminum core construction is used, then labor requirements are reduced and product strength is improved, but core size is limited to about 48 inches square

Engineering Contradiction:

Improvelabor efficiencyVSAvoidcore size

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent divides the large intercooler core into multiple smaller core modules, each within the 48-inch CAB furnace limitation. These modular cores are then assembled together to form the complete large-scale intercooler, enabling production of cores larger than 48 inches square while maintaining the labor efficiency and automation benefits of CAB construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent nests multiple core modules within a larger intercooler assembly structure. Each modular core unit is independently manufactured using CAB process, then these nested modules are combined to create the final large-scale intercooler product, effectively overcoming the furnace size limitation

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If copper/brass construction is used, then material durability is improved, but heat transfer efficiency decreases and material cost increases

Engineering Contradiction:

Improvematerial durabilityVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent changes the material parameter from copper/brass to aluminum, utilizing aluminum's superior thermal conductivity to improve heat transfer efficiency. The controlled atmosphere brazing process is employed to achieve joint strengths that maintain or exceed the durability of traditional copper/brass constructions, thus improving heat transfer while maintaining reliability

Inventive Principle:

Principle #35Parameter 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 modular intercooler block design reduces labor and material costs, enhances consistency, and improves heat transfer efficiency by enabling larger core sizes and optimized geometric configurations.

Implementation Method 1

The core tubes comprise relatively thin copper walls configured to enhance heat transfer to the airstream passing through the multiplicity of cooling fins

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

heat transfer to the airstream passing through the multiplicity of cooling fins

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

The core tubes may comprise spiraled inner passages configured to increase the available surface area whereby heat may be transferred to the airstream

Methodology Applied

Scientific EffectSurface area enhancement:

Data Source

PatentUS20250172349A1Modular Intercooler Block

Publication Date: 2025.05.29 K&N ENGINEERING INC

AI summary

An apparatus and a method are provided for a modular intercooler block that may be fabricated by way of direct metal printing and assembled to form larger intercoolers. The modular intercooler block comprises cooling fins that are spaced between first and second core headers to allow passage of an airstream. Countersunk holes are arranged on the first and second core headers and configured to receive grommets when the first or second core header is fastened to another core header comprising similarly arranged countersunk holes. A core tube extends along an undulating path from each countersunk hole in the first core header, through the multiplicity of cooling fins, to a similar countersunk hole in the second core header. The core tubes may include thin copper walls and spiraled inner passages to enhance heat transfer to the airstream passing through the multiplicity of cooling fins.