Phase Change Material Bypass for Intake Air Thermal Management
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Solution Overview
Problem
Existing air intake systems for supercharged thermal engines face challenges in quickly reaching optimal operating temperature in cold conditions, leading to combustion issues and increased emissions, and existing heating solutions require time to activate and consume additional electrical energy.
Innovation Solution
An air intake system incorporating a bypass branch with phase change material, such as organic, inorganic, or vegetable phase change material beads, integrated into the wall or contained within the branch, which heats intake air by releasing heat energy as it changes state, and a regulation and redirection device to manage airflow between the charge air cooler and bypass branch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a charge air cooler is connected to a heat source (air conditioning circuit or engine cooling circuit) to heat intake air, then intake air heating is achieved, but the system complexity increases and additional control mechanisms are required
Solution Approach 1:
The patent combines the charge air cooler and bypass branch into a single integrated thermal management system. The phase change material is integrated directly into the bypass branch wall, merging the heating function with the existing charge air cooler structure, thereby reducing overall system complexity while achieving intake air heating.
Solution Approach 2:
The charge air cooler is designed to serve dual functions: cooling intake air during normal operation and heating intake air during cold starts. By incorporating a bypass branch with phase change material into the same structural unit, the system achieves multi-functionality without requiring separate heating and cooling systems.
2Temperature
If an electric heating device is used to heat intake air, then intake air heating is achieved, but electrical consumption increases leading to additional fuel consumption
Solution Approach 1:
The phase change material serves itself by automatically absorbing heat during engine operation (when intake air is hot) and releasing that stored heat during cold starts (when intake air is cold). This self-regulating thermal energy storage system eliminates the need for external electric heating devices, thereby reducing electrical consumption and associated fuel usage.
Solution Approach 2:
The system recovers thermal energy that would otherwise be wasted during normal engine operation. The phase change material captures excess heat from the intake air during hot conditions and stores it, then recovers this stored thermal energy during cold starts to heat the intake air, eliminating the need for additional energy input.
3Temperature
If existing heating solutions are used, then intake air heating is achieved, but the heating effect is delayed and does not provide immediate warming during cold starts
Solution Approach 1:
The phase change material is pre-charged with thermal energy during normal engine operation before cold start conditions occur. This preliminary heat absorption during hot conditions prepares the system in advance, so that when cold start occurs, the stored thermal energy is immediately available for release, providing instant heating without delay.
Solution Approach 2:
The system exploits the phase transition properties of the phase change material, which transitions between solid and liquid states at specific temperatures. During cold starts, the phase change material undergoes phase transition from solid to liquid, releasing latent heat instantly and providing immediate thermal energy to the intake air, eliminating heating delays.
4Productivity
If the phase change material fills a large portion of the bypass branch cross section, then heating efficiency increases, but pressure drop increases
Solution Approach 1:
The phase change material is strategically positioned within the bypass branch to optimize local heat exchange quality. By integrating the phase change material into the bypass branch wall structure rather than filling the entire cross-section, the design maintains adequate flow passages while maximizing thermal contact area, thereby achieving high heating efficiency without excessive pressure drop.
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
Enables immediate heating of intake air during cold starts, reducing the time to reach optimal engine temperature, lowering emissions, and decreasing fuel consumption by utilizing stored heat energy during regeneration modes.
Implementation Method 1
The phase change material makes it possible to heat the intake air passing through the bypass branch when it passes from a liquid state to a solid state by yielding heat energy.
Implementation Method 2
The phase change material makes it possible to heat the intake air passing through the bypass branch when it passes from a liquid state to a solid state by yielding heat energy.
Implementation Method 3
a compressor (7) delivering compressed air to the intake air manifold (11)
Implementation Method 4
a charge air cooler (9) placed downstream of said compressor (7)
Data Source
Figure 1~3
AI summary
The present invention relates to an air intake system (1) for a supercharged combustion engine (3), said air intake system (1) comprising an external-air inlet (2) and a charge air cooler (9), said air intake system (1) further comprising a bypass leg (13) bypassing the charge air cooler (9) between a tapping (101) situated upstream of said charge air cooler (9) and a charge air outlet (103) connected to the combustion engine (3), said bypass leg (13) comprising within it a phase-change material (15), said air intake system (1) also comprising a device (17) for regulating and redirecting the charge air at the tapping (101).