Two-Stage Intercooler Layout With Shared Condenser Cooling

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Solution Overview

Problem

Existing heat exchange devices for vehicles, such as those described in Patent Documents 1 and 2, face challenges in downsizing the condenser and radiator components due to high thermal loads, leading to complex configurations and increased vehicle dimensions and ventilation resistance.

Innovation Solution

A two-stage type water-cooled intercooler with first and second cores, where the first core cools supercharge intake air with first cooling water and the second core further cools it with second cooling water, which is then used to cool the air conditioner's coolant in a water-cooled condenser, while a first radiator cools the first cooling water and a second radiator cools the second cooling water, allowing for a compact layout with an air-cooled condenser arranged adjacent to the second radiator, reducing the size of all components and improving airflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a water-cooled condenser is added to cool the air conditioner coolant, then the cooling performance of the air conditioner is improved, but the device complexity increases due to requiring a separated cooling circuit

Engineering Contradiction:

Improvecooling performanceVSAvoidconfiguration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the water-cooled condenser into the existing second cooling water circuit that serves the two-stage intercooler. The second cooling water flows through both the second core of the intercooler and the water-cooled condenser, eliminating the need for a separate cooling circuit while maintaining effective cooling of the air conditioner coolant

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The second cooling water circuit is designed to serve multiple functions: it cools the supercharge intake air in the second core of the intercooler and simultaneously cools the air conditioner coolant in the water-cooled condenser, making the cooling system more versatile and efficient

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Length of stationary object

If the condenser and radiator are arranged adjacently in the vertical direction to downsize the vehicle, then the vehicle dimensions are reduced, but the ventilation resistance increases

Engineering Contradiction:

Improvevehicle dimensionVSAvoidventilation resistance

Core Design Contradiction:

Length of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent transitions from a horizontal arrangement to a vertical stacking arrangement of heat exchangers (first radiator, second radiator, and air-cooled condenser arranged in front of the first radiator). This dimensional change allows compact packaging that reduces vehicle length while managing thermal loads through optimized airflow paths

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If a two-stage water-cooled intercooler is used to cool supercharge intake air, then the cooling efficiency is improved, but the device complexity increases due to requiring first and second cooling water circuits

Engineering Contradiction:

Improvecooling efficiencyVSAvoidcircuit complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines the cooling functions for both stages of intercooling into a single integrated second cooling water circuit. The same cooling water flows through both the second core and the water-cooled condenser, simplifying the circuit architecture while maintaining two-stage cooling capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The second cooling water circuit performs multiple cooling functions: it cools the supercharge intake air in the second core and simultaneously cools the air conditioner coolant in the water-cooled condenser, reducing overall system complexity through functional integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 efficiently cools supercharge intake air and condenses coolant, downsizes the air-cooled condenser and second radiator, and allows for a two-tier layout of heat exchangers, reducing vehicle dimensions and ventilation resistance while maintaining effective heat dissipation and cooling performance.

Implementation Method 1

a first radiator disposed at a position to receive wind due to vehicle traveling, and structured to cool the first cooling water by heat exchange with air

Methodology Applied