Rotatable Seal Bypass for Charge Air Cooler Condensate
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Solution Overview
Problem
Integrated charge air coolers in engine intake systems can form condensate, leading to engine misfires and instability due to increased mass air flow during acceleration, and existing bypass solutions often require additional components that compromise the compactness of the system.
Innovation Solution
An engine intake assembly with an integrated charge air cooler and rotatably movable seals that adjust airflow to bypass or flow through the cooler, maintaining sealing and reducing condensate buildup while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If charge air cooler is integrated into the intake system, then system compactness is improved, but condensate buildup occurs leading to engine misfires
Solution Approach 1:
The patent employs movable seals that can dynamically adjust their position to control airflow through the charge air cooler. The seals transition between engaged and disengaged states based on operating conditions, allowing the system to adapt and prevent condensate buildup while maintaining compactness
Solution Approach 2:
The system changes the flow parameter by using movable seals to either allow or restrict airflow through the charge air cooler. By adjusting the seal position, the system can modify the amount of air passing through the cooler, preventing condensate formation while maintaining system integration
2Reliability
If bypass passage is added to prevent condensate, then engine misfires are reduced, but system compactness is compromised
Solution Approach 1:
The bypass passage is merged with the charge air cooler assembly, utilizing the existing integrated structure. The movable seals are positioned within the CAC housing, allowing the bypass function to be incorporated into the compact integrated design without requiring separate external components
Solution Approach 2:
The movable seals serve multiple functions: they control airflow through the charge air cooler, create bypass passages when disengaged, and maintain sealing when engaged. This multi-functionality eliminates the need for separate bypass components while maintaining system compactness
3Reliability
If movable seals are used to control airflow, then condensate buildup is reduced, but device complexity increases
Solution Approach 1:
The movable seals are designed to respond automatically to pressure differentials and temperature conditions without requiring external control systems. The seals self-adjust their position based on the operating environment, reducing the need for complex actuation mechanisms while maintaining effective condensate management
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 adjustable seals effectively manage airflow through the charge air cooler, reducing condensate and maintaining optimal intake air temperature, thereby preventing engine misfires and maintaining system efficiency and compactness.
Implementation Method 1
the first movable seal varying airflow through the bypass passage
Implementation Method 2
charge air coolers may be positioned in the intake system... the charge air cooler may be water cooled and mounted in the engine compartment
Implementation Method 3
compressors in the intake system to provide boost to the engine to increase the pressure in the combustion chamber
Implementation Method 4
condensate may form within the integrated charge air cooler (CAC) when the ambient air temperature decreases, or during humid or rainy weather conditions, where the intake air is cooled below the water dew point temperature
Data Source
AI summary
Methods and systems are provided for regulating airflow through a charge air cooler integrated in an intake assembly. In one example, an engine intake assembly comprises a plenum having an integrated charge air cooler (CAC), a first header seal positioned around a circumference of a first CAC header, and a first rotatably movable seal positioned in a bypass passage of the plenum. The first movable seal interfaces via sliding contact with the first header seal and adjusting a position of the first movable seal may vary the amount of airflow through the bypass passage.