Modular Intercooler Block With Undulating Tubes for Larger Cores
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Solution Overview
Problem
Existing intercooler construction methods are labor-intensive, costly, and limited in size, requiring multiple cores due to manufacturing difficulties, and do not offer optimal heat transfer efficiency.
Innovation Solution
A modular intercooler block fabricated using direct metal printing (DMP) with undulating core tubes and strategically arranged cooling fins and countersunk holes, allowing for larger intercooler assemblies with enhanced heat transfer surface area and flexibility in configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional copper/brass soldered construction or CAB aluminum core construction is used, then manufacturing consistency and material durability are improved, but core size is limited to about 48 inches square and labor requirements increase
Solution Approach 1:
The intercooler core is divided into multiple modular blocks, each block being a manageable size that can be manufactured with consistent precision using traditional methods. These blocks are then assembled together to form larger intercoolers, eliminating the need to manufacture entire large cores in one piece while maintaining manufacturing consistency.
Solution Approach 2:
Multiple modular core blocks are combined through assembly to create larger intercooler units. This merging approach allows the system to achieve large core sizes without requiring large-scale manufacturing equipment or excessive labor, as each block is manufactured independently and then joined together.
2Area of stationary object
If traditional manufacturing methods are used to create large intercoolers, then core size can be increased, but manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The large intercooler core area is achieved by segmenting the core into multiple standardized modular blocks. Each block has a manageable manufacturing complexity, and the overall large area is obtained by assembling these segments together, avoiding the complexity of manufacturing a single large core.
Solution Approach 2:
The modular block design creates universal components that can be used in various intercooler configurations. The same basic block design can be assembled in different arrangements to create intercoolers of various sizes and shapes, reducing manufacturing complexity through standardization.
3Reliability
If traditional manufacturing methods are used, then material costs (copper/brass) provide durability, but material costs and weight increase
Solution Approach 1:
The intercooler employs composite construction combining aluminum core blocks with copper/brass fittings and connectors. The aluminum provides lightweight structure while the copper/brass components provide durable connection points, achieving both weight reduction and maintained reliability through material composition rather than pure material selection.
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 while providing improved heat transfer efficiency and consistency, enabling the assembly of intercoolers of various sizes without the limitations of traditional manufacturing methods.
Implementation Method 1
the core tubes each comprises a spiraled inner passage configured to increase the available surface area whereby heat is transferred to the airstream passing through the multiplicity of cooling fins
Implementation Method 2
an airstream passing through the multiplicity of cooling fins
Data Source
Figure 1
Figure 1A
Figure 2~3
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.