Passive Variable Charge Enabler for Dual Loop Charge Air Cooling
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Solution Overview
Problem
Conventional charge air cooler systems overwork and reduce performance by continuously drawing cooling from additional components, necessitating increased size and inefficient operation.
Innovation Solution
A dual coolant loop system with a passive variable charge enabler (PVCE) assembly, where a first coolant loop provides initial cooling and a second vapor compression loop provides further cooling, sharing a condenser and using a PVCE to adjust refrigerant flow based on compressor operation, eliminating the need for additional valves or controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional CAC continuously draws cooling from an additional component, then cooling function is provided, but the system overworks and performance is reduced
Solution Approach 1:
The patent implements periodic action by controlling the secondary cooling loop to operate only when needed, rather than continuously. The controller activates the secondary loop based on charge air temperature conditions, allowing the system to alternate between single-loop and dual-loop operation modes, thereby preventing continuous overworking while maintaining cooling effectiveness.
Solution Approach 2:
The patent applies dynamics by making the cooling system adaptable and variable. The secondary cooling loop is dynamically engaged or disengaged based on real-time temperature conditions, and the PVCE assembly dynamically adjusts refrigerant charge in response to compressor operation, creating a flexible system that optimizes performance rather than operating in a fixed continuous state.
2Temperature
If an additional component is increased in size to support secondary cooling, then cooling capacity is improved, but device complexity and size increase
Solution Approach 1:
The patent implements universality by designing the second coolant loop to serve multiple functions. The same loop and components are used both for charge air cooling and for HVAC system operation, eliminating the need for separate dedicated systems. The PVCE assembly also serves dual purposes in managing refrigerant charge for both cooling modes.
Solution Approach 2:
The patent applies merging by combining the charge air cooling function with the HVAC system. The second coolant loop is shared between these two functions, and the common condenser serves both purposes. This integration reduces overall system complexity by consolidating functions rather than adding separate independent systems.
3Temperature
If a dual coolant loop system is implemented, then cooling efficiency is enhanced, but refrigerant charge management becomes more complex
Solution Approach 1:
The patent implements self-service through the PVCE assembly, which automatically manages refrigerant charge between the two coolant loops without requiring external control intervention. The PVCE responds to compressor operation status and pressure differentials to autonomously transfer refrigerant, eliminating the need for complex active control systems while maintaining proper charge distribution.
Solution Approach 2:
The patent applies mechanics substitution by replacing complex electronic control systems with a passive mechanical PVCE assembly. The PVCE uses pressure differentials and mechanical movement to automatically regulate refrigerant charge, substituting sophisticated electronic management with a simpler mechanical self-regulating mechanism.
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
This configuration enhances cooling efficiency, reduces the need for a dedicated low-temperature cooling circuit, and optimizes refrigerant charge for improved engine power and fuel economy by dynamically adjusting coolant flow based on engine load conditions.
Implementation Method 1
a first coolant loop thermally coupled to the air intake to provide cooling to the intake air
Implementation Method 2
a second coolant loop is thermally coupled to the air intake to provide further cooling to the intake air, and undergoes a vapor compression cycle
Implementation Method 3
A compressor circulates coolant through the second coolant loop
Implementation Method 4
a passive variable charge enabler (PVCE) assembly is configured to remove coolant circulating in the system when the compressor is on
Data Source
AI summary
An air cooling system for a vehicle engine includes an air intake configured to receive intake air for delivery to the engine, a first coolant loop thermally coupled to the air intake to provide cooling to the intake air, and a pump for circulating coolant through the first coolant loop. A second coolant loop is thermally coupled to the air intake to provide further cooling to the intake air, and undergoes a vapor compression cycle. A compressor circulates coolant through the second coolant loop. The first and second coolant loops are separate loops using a common condenser. A passive variable charge enabler assembly is configured to remove coolant circulating in the system when the compressor is on.