U.S. patent application number 09/924440 was filed with the patent office on 2002-02-28 for charge air cooler and method of assembling the same.
Invention is credited to Wagner, William W..
Application Number | 20020023734 09/924440 |
Document ID | / |
Family ID | 26918308 |
Filed Date | 2002-02-28 |
United States Patent
Application |
20020023734 |
Kind Code |
A1 |
Wagner, William W. |
February 28, 2002 |
Charge air cooler and method of assembling the same
Abstract
A charge air cooler includes a tube block having a plurality of
finned tubes and a tank assembly at each end. Each of the tank
assemblies includes a tank body for receiving one of the ends of
the finned tubes in the tube block. A connecting plate, a heat
resistant flexible gasket and a backing plate provide a first
resilient seal with each of the tubes and the connecting plate. A
flexible annular seal extends around the connecting plate for
providing a second resilient seal between the connecting plate and
the tank body. The connecting plate includes a base having a
plurality of spaced tabs extending therefrom, and the tank has a
plurality of spaced raised bosses around the exterior thereof
adjacent the open face of the tank which are so sized and
positioned as to interdigitate when the tank is assembled to the
connecting plate.
Inventors: |
Wagner, William W.;
(Prescott, AZ) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
26918308 |
Appl. No.: |
09/924440 |
Filed: |
August 9, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60223979 |
Aug 9, 2000 |
|
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|
Current U.S.
Class: |
165/81 ; 165/153;
165/173; 165/175 |
Current CPC
Class: |
F28F 9/0226 20130101;
F28D 1/05366 20130101; F28F 9/001 20130101 |
Class at
Publication: |
165/81 ; 165/153;
165/173; 165/175 |
International
Class: |
F28F 007/00; F28D
001/02; F28F 009/02 |
Claims
What is claimed is:
1. A charge air cooler comprising: a plurality of tubes having
first and second ends; a first connecting plate located around said
first ends of said tubes; a first backing plate located around said
first ends of said tubes; a first gasket located between said first
connecting plate and said first backing plate for providing a
resilient seal between each of said tubes and said first connecting
plate; a first tank positioned at said first ends of said tubes;
and a first sealing member extending around said first connecting
plate for providing a resilient seal between said first connecting
plate and said first tank.
2. The charge air cooler according to claim 1, wherein said first
gasket has a plurality of openings for receiving and providing a
seal with each of said tubes.
3. The charge air cooler according to claim 1, wherein said first
connecting plate has a base including a first recess formed therein
for receiving and supporting said first gasket and said first
backing plate.
4. The charge air cooler according to claim 3, wherein said base of
said first connecting plate further comprises a second recess
formed therein for receiving said first sealing member.
5. The charge air cooler according to claim 4, wherein an open face
of said first tank includes a groove formed therein for receiving
said first sealing member.
6. The charge air cooler according to claim 1, further comprising a
weld around a periphery of said first tank for providing a
mechanical connection between said first tank and said first
connecting plate.
7. The charge air cooler according to claim 6, wherein said weld is
intermittent and discontinuous around said periphery of said first
tank.
8. The charge air cooler according to claim 11 wherein said first
tank includes a plurality of raised bosses around an open face
thereof.
9. The charge air cooler according to claim 8, wherein said first
connecting plate includes a base having a plurality of tabs
extending therefrom.
10. The charge air cooler according to claim 9, wherein said tabs
and said bosses are interdigitated with one an other.
11. The charge air cooler according to claim 10, further comprising
a plurality of separate welds between said tabs and said bosses for
providing a mechanical connection between said first tank and said
first connecting plate.
12. The charge air cooler according to claim 1, wherein said tubes
have fins thereon for radiating heat from said tubes.
13. The charge air cooler according to claim 1, wherein said first
gasket is separate from said first sealing member.
14. The charge air cooler according to claim 1, wherein said first
sealing member is a flexible annular seal.
15. The charge air cooler according to claim 1, further comprising:
a second connecting plate located around said second ends of said
tubes; a second backing plate located around said second ends of
said tubes; a second gasket located between said second connecting
plate and said second backing plate for providing a resilient seal
between each of said tubes and said second connecting plate; a
second tank positioned at said second ends of said tubes; and a
second sealing member extending around said second connecting plate
for providing a resilient seal between said second connecting plate
and said second tank.
16. The charge air cooler according to claim 15, further including
a pair of support plates mechanically fastened to said first tank
and said second tank for connecting said first tank to said second
tank.
17. The charge air cooler according to claim 15, wherein said first
gasket has a plurality of openings for receiving and providing a
seal with each of said tubes, and said second gasket has a
plurality of openings for receiving and providing a seal with each
of said tubes.
18. The charge air cooler according to claim 17, wherein said first
connecting plate has a base including a first recess formed therein
for receiving and supporting said first gasket and said first
backing plate, and said second connecting plate has a base
including a second recess formed therein for receiving and
supporting said second gasket and said second backing plate
19. The charge air cooler according to claim 18, wherein said first
and second tanks each include a plurality of raised bosses around
open faces thereof, said first and second connecting plates each
include a base having a plurality of tabs extending therefrom, and
said tabs and said bosses are interdigitated with one another.
20. A method for assembling a charge air cooler comprising the
steps of: providing a tube block having a plurality of finned
tubes; providing a tank assembly at one end of said tube block into
which said finned tubes open, said tank assembly including a tank
body having a plurality of spaced raised bosses around the exterior
thereof adjacent an open face of said tank body; providing a
connecting plate including a base having a plurality of spaced tabs
extending therefrom; providing a heat resistant flexible gasket and
a backing plate; fitting said connecting plate, said heat resistant
flexible gasket and said backing plate over each of the tubes at
said one end of said tube block for providing a first resilient
seal with each of said tubes and said connecting plate; providing a
flexible annular seal extending around said open face of said tank
body for providing a second resilient seal between said connecting
plate and said tank body; positioning said tank body onto said tube
block in such a manner that said tabs and said bosses being fit
together in an interdigitated relationship; and intermittently
welding said tabs and said bosses around the periphery of said tank
body for establishing a mechanical connection between said tank
body and said connecting plate.
Description
[0001] This nonprovisional application claims priority under 35
U.S.C. .sctn. 119(e) on U.S. provisional application No.
60/223,979, filed on Aug. 9, 2000, which is herein incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a charge air cooler for use with
internal combustion engines. More particularly, the invention
relates to an improved charge air cooler assembly which is
particularly well suited for large, high horsepower turbocharged
diesel engines.
[0004] 2. Description of the Background Art
[0005] In recent years, charge air coolers have become rather
common components on diesel engines, and particularly on large
turbocharged diesel engine of the type used in commercial trucks
and heavy equipment. Charge air coolers are used to cool intake air
after it has been compressed by the turbocharger and before it
enters the combustion chambers of the engine.
[0006] Engines which use charge air coolers achieve a significant
power gain through their usage, but repair costs associated with
the charge air coolers tend to be high. This is so because of the
thermal and mechanical demands and stresses placed upon the charge
air cooler when the engine is operated. These units typically
receive incoming air which has been compressed to pressures on the
order of 40 psi (pounds per square inch). Because of the heat of
compression, the air is heated by the compressing of the
turbocharger to temperatures on the order of 400-500.degree. F.
[0007] In order to achieve the power increases afforded by charge
air cooling, it is necessary to cool the compressed air to
temperatures on the order of 120.degree. F. Moreover, because the
heated incoming air is generally at a rather high pressure on the
order of 40 psi, the charge air cooler unit must be well sealed in
order to prevent pressure losses at any seals which might be used
in the units.
[0008] Sealing the charge air coolers has been a particularly
vexing problem in the past. Often, the units were soldered or
brazed together in the same manner as radiators had been sealed.
However, such sealing techniques were quickly found to be
deficient, since the result was a rather rigid structure which
would be quickly damaged by thermal stresses induced by the change
of temperature, and accentuated by vibrational stress from the
operation of the engine. The normal vibrations of diesel engines
tended to quickly cause cracks to develop in the brazed or soldered
joints, and pressures began to drop early in the life of the cooler
units.
[0009] Attempts to overcome this problem have sought to provide
vibration damping mounts for the charge air coolers, to prevent
vibrations from being transmitted to the charge air cooler
units.
[0010] The finned tube units open into chambers at their ends. The
finned tubes are generally made of highly heat conducting material
such as aluminum in order to allow quick removal of heat from the
incoming air, but these finned tubes must be connected to the tanks
into which the tubes open. The tanks are generally made of cast
metal such as aluminum or steel, and are therefor rather heavy
components. The juncture of the finned tubes with the tanks is the
location of many leaks. Because of the heat of the incoming,
compressed air, the tanks are heated to essentially the same
temperature as the incoming air, but the finned tubes quickly
dissipate heat from the same air, and the air begins to cool
immediately upon entering the finned tubes. The result is
differential thermal expansion at the joint between the tank and
the tubes. The thermal gradient from inlet to outlet across the
charge air cooler can be on the order of 200-300.degree. F.
[0011] Unlike other heat exchange units which are mounted in a
shock and vibration damping mounting arrangement, because of their
size and weight, charge air coolers tend to be more rigidly mounted
on and connected with the engines in order to perform their
function, such that vibration damping is not possible in
conventional ways, and the problems caused by vibration continue to
persist in the industry. Because of the relatively high cost of the
charge air cooling units, an improved charge air cooler with
improved service life is greatly needed. This is particularly true
since the engines generally have a long service life before
overhaul is required, and having to pull an engine out of service
prematurely imposes an even greater cost.
[0012] As engines have grown in horsepower output in recent years,
so has the problem of leaks in the charge air coolers increased in
severity. These problems are particularly severe in the case of
high horsepower engines in the 500 to 700 horsepower range.
[0013] One prior technique for overcoming the differential thermal
expansion problems associated with charge air coolers involved the
provision of end strips having supporting fins between plural
layers of coolant ducts as described in U.S. Pat. No. 6,019,169 to
Ruppel, et al. Such a technique, though, increases the number of
parts in the assembly, thus increasing the production cost of the
charge air cooler.
SUMMARY AND OBJECTS OF THE INVENTION
[0014] Accordingly, a primary object of the present invention is to
provide an improved charge air cooler which overcomes the
disadvantages of prior charge air coolers.
[0015] Another object of the present invention is to provide a
charge air cooler system which is provided with improved sealing
between the cooling tubes and the tanks for maintaining a seal
under conditions of high internal pressure.
[0016] Still another object of the present invention is to provide
a charge air cooler system which is less susceptible to vibration
damage.
[0017] Yet another object of the present invention is to provide a
charge air cooler system which provides a combination of mechanical
strength and flexible resilient sealing in order to obtain improved
advantages of extended life and resistance to leakage.
[0018] Still another object of the invention is to provide an
improved construction for a charge air cooler in which a continuous
resilient seal is coupled with a discontinuous mechanical
connection for improving the overall durability of the charge air
cooler.
[0019] Yet a further object of the invention is to provide an
improved construction for a charge air cooler in which multiple
resilient seals are combined with a strong mechanical connection
for improving the durability and service life of the charge air
cooler.
[0020] Another object of the invention is to provide an improved
charge air cooler in which resilient seals are utilized to overcome
the differential thermal expansion, while welds are used to provide
the necessary strength to the assembly.
[0021] Another object of the invention is to provide an improved
method for assembling a charge air cooler which will assist in
providing an improved and lasting seal between the component
parts.
[0022] According to the present invention, a charge air cooler
assembly is provided which utilizes a block of finned heat exchange
tubes opening at opposite ends of the block. The ends of the block
of tubes are connected to end tanks or manifolds in order that the
hot, compressed air will enter one of the tanks, pass through the
tube block where it is cooled, and exit from the tube block into
the other tank before entering the engine combustion air
intake.
[0023] The tube block comprises a plurality of tubes of preferably
rectangular cross section, and the ends of each of the tubes extend
from the block through openings in a connecting plate, through
openings in a flexible resilient gasket, through openings in a
rigid backing plate, and then open into one of tanks at each end.
The openings in the resilient gasket are specially configured with
a pair of spaced, raised ribs projecting from the body of the
gasket into each tube receiving opening for contacting the tubes
and providing a good seal with the tubes. During the assembly
process, the backing plate and connecting plate are pressed
together with the gasket in between in order to slightly compress
the gasket and improve the seal against the walls of the tubes.
[0024] The connecting plate is provided with a plurality of
securing tabs spaced around the periphery of the connecting plate,
and the securing tabs extend from the connecting plate in the
direction of the end tank. Each end tank comprises a housing open
along its connecting face for receiving the ends of the tubes. The
housing is provided with a plurality of raised bosses on the
exterior thereof and spaced around the connecting face. The bosses
are positioned such that when the connecting plate is fitted to the
end tank, the tabs of the connecting plate interdigitate with the
bosses on the tank.
[0025] A groove on the end face of the tank is adapted to receive
an annular seal much like an O-ring between the end face of the
tank and the connecting plate, and a shoulder on the end face of
the tank contacts the backing plate such that as the connecting
plate and the tank are pressed together, the annular seal as well
as the gasket are compressed slightly in order to effectuate the
seal between the tank and the tube block. A pair of mounting plates
may be secured to opposite ends of the connecting plates to protect
the upper and lower sides of the tube blocks.
[0026] After the end tank has been fitted onto the tube block, the
securing tabs of the connecting plate are touch welded or spot
welded to the tank housing around the periphery of the joint. It is
not necessary that a continuous weld be provided between the
connecting plate and the housing, since the fluid seal is not
provided by the weld. The strength of the assembly is secured by
the welds, while the fluid tight seal is provided by the
combination of the gasket and the annular seal.
[0027] Further scope of applicability of the present invention will
become apparent from the detailed description given hereinafter.
However, it should be understood that the detailed description and
specific examples, while indicating preferred embodiments of the
invention, are given by way of illustration only, since various
changes and modifications within the spirit and scope of the
invention will become apparent to those skilled in the art from
this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present invention will become more fully understood from
the detailed description given hereinbelow and the accompanying
drawings which are given by way of illustration only, and thus, are
not limitive of the present invention, and wherein:
[0029] FIG. 1 is an exploded view of a charge air cooler according
to the present invention;
[0030] FIG. 2 is a side view of one connecting plate;
[0031] FIG. 3 is a plan view of the connecting plate of FIG. 2;
[0032] FIG. 4 is a fragmentary cross-sectional view of the
connecting plate taken along line 4-4 of FIG. 3; and
[0033] FIG. 5 is a cross-sectional view of the tank on one end of
an assembled charge air cooler according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] The charge air cooler 10 according to the present invention
is shown in FIG. 1 with one end exploded for purposes of clarity.
It will be understood that both ends of the charge air cooler 10
are constructed in a similar manner. The unit is seen to comprise a
tube block 12 made in a well known manner and comprising a
plurality of tubes 14 of a generally rectangular cross-section and
having fins 16 thereon for dissipating heat. The ends of the tubes
14 extend beyond the fins 16 as shown. A connecting plate 18 is
provided with a plurality of openings 20 passing therethrough and
corresponding to the size and number of tubes 14 in the tube block
12. The connecting plate 18 is shown in greater detail in FIGS.
2-4.
[0035] A flexible heat resistant gasket 22 is provided with
openings 24 passing through the gasket 22, and corresponding in
size and number to the tubes 14 in the tube block 12. The walls of
these openings 24 may be provided with a spaced pair of raised ribs
encircling and engaging the tubes and enhancing the seal. A backing
plate 26 is provided on the opposite side of the gasket 22, and the
backing plate 26 also includes openings 28 which correspond in
size, number and shape to the tubes 14 in the tube block 12. In
this manner, the gasket 22 is sandwiched between the connecting
plate 18 and the backing plate 26.
[0036] The charge air cooler is provided on each end with a
manifold or tank 30, 30(a) having a large air passageway 32, 32a.
The passageway 32 on one tank 30 is deemed the inlet and the
passageway 32a on the other tank 30a is deemed the outlet,
depending upon the direction of flow of the air through the charge
air cooler. The tanks 30, 30a in this example are mirror images of
each other, although other arrangements are contemplated. The tank
30 has one face which is open toward the tubes 14 projecting
through the plates 18 and 26 and the gasket 22, such that the air
flows unobstructedly from the inlet passageway 32, through the
inlet tank and into and through the tubes 14 to the other tank, and
then out through the outlet passageway 32a.
[0037] The gasket 22 serves to provide a seal around each of the
tubes 14, and by virtue of the clamping between the backing plate
26 and the connecting plate 18, the seal is enhanced and
reinforced. To provide a seal between the connecting plate 18 and
the tank 30, a flexible annular seal 34 is provided between the
connecting plate 18 and the tank 30, as will be described in
greater detail below. Both the gasket 22 and the annular seal 34
are preferably made of a high temperature resistant rubber
material, which retains its flexibility at temperatures up to about
500 degrees.
[0038] Finally, a pair of support plates 36, 38 are bolted to each
of the tanks 30, 30a by bolts 37 to protect the tube block 10 and
to provide a mounting surface at the top and bottom of the charge
air cooler. These support plates 36, 38 also secure the ends of the
charge air cooler together as a further safety feature.
[0039] As seen in FIGS. 2-4, the connecting plate 18 comprises a
base 39 having a plurality of finger-like projecting tabs 40
separated by spaces 41. These tabs 40 are located around the
periphery of the connecting plate 18, and are preferably equally
spaced. Additionally, a semicircular recess or groove 44 may be
provided to extend completely around the connecting plate 18,
inside of the tabs 40. The groove 44, if used, serves as a seat on
the connecting plate 18 for the annular seal 34. A semicircular
groove 45 is provided on the open face of the tank for receiving
the annular seal 34. An additional recess 46 is provided in the
base 39 on the inside of the connecting plate 18, and the recess 46
provides a seat for the gasket 22 on the connecting plate 18. In
this manner, the connecting plate 18 functions to support the
entire surface of the gasket 22 on one side, while the backing
plate 26 supports the other side of the gasket 22.
[0040] The tanks 30, 30a are provided around their periphery with a
plurality of raised bosses 48 integrally molded or cast as part of
the tanks 30, 30a. As the tanks 30, 30a are applied against the end
of the tube block 12, the tabs 40 interdigitate with the bosses 48.
The tabs 40 and the bosses 48 thus coact to facilitate the assembly
of the tanks 30, 30a onto the tube block 12 with the seals 22, 34
and the plates 18, 26 therebetween, by positioning the tanks 30,
30a with respect to the connecting plate 18 and the backing plate
26 in order that the seal 34 not be misplaced and possibly damaged
during assembly. The positioning of the components during the
assembly is precisely guided by the coacting tabs 40 and bosses 48
in order to assure the integrity of the seal once the assembly is
completed.
[0041] According to the improved method for assembling the charge
air cooler, the connecting plate 18 having a plurality of tabs 40
spaced around the periphery thereof is first applied over the ends
of the tubes 14 with the tabs 40 facing away from the tubes 14.
Next, the gasket 22 is positioned over the ends of the tubes 14 and
pushed snugly against the connecting plate 18. Then, the rigid
steel backing plate 26 is placed over the ends of the tubes 14 and
positioned against the gasket 22. The annular seal 34 is then
placed in the groove 45 on the tank 30. Finally, the tank 30 and
the tube block 12 are positioned together, with the tabs 40
interdigitating with the bosses 48, and the assembly is slid
together. Next, pressure is applied urging the tank 30 toward the
tube block 12 in order to seat and slightly compress the gasket 22
and the annular seal 34, and the tabs 40 are then touch or spot
welded to the tank 30 at the bosses 48 to secure the tank 30 in
position.
[0042] It is not necessary to continuously weld the entire
periphery between the tank 30 and the connecting plate 18, because
the function of the weld is not to seal the tank 30 as in
conventional welded tanks, but rather to provide a mechanical
securing of the tank 30 to the connecting plate 18. The sealing of
the tank 30 in order to prevent leakage of the pressurized air is
achieved by means of the heat resistant gasket 22 which provides
the seal between the tubes 14 and the connecting plate 18, and by
means of the heat resistant annular seal 34 which provides the seal
between the connecting plate 18 and the tank 30. With this
construction, if a weld should crack or break due to vibration (or
any other reason), as is common in prior charge air coolers, the
pressurized air is not lost through the cracked weld, since the
weld is not providing the seal function. Moreover, since there are
a number of such welds, the strength of the tank remains intact
even with a cracked weld.
[0043] The other tank 30a is assembled in a similar manner, and the
support plates 36, 38 are then bolted to the tanks 30, 30a to
complete the assembly. In addition to providing a supporting
structure for the charge air cooler, the support plates 36, 38 also
serve as a backup safety feature to prevent the tanks from being
blown off because of the high pressure air in the charge air cooler
in the event that several welds crack simultaneously.
[0044] The invention being thus described, it will be obvious that
the same may be varied in many ways. Such variations are not to be
regarded as a departure from the spirit and scope of the invention,
and all such modifications as would be obvious to one skilled in
the art are to be included within the scope of the following
claims.
* * * * *