U.S. patent application number 14/527943 was filed with the patent office on 2016-05-05 for inlet air turbulent grid mixer and dimpled surface resonant charge air cooler core.
The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Meisam Mehravaran.
Application Number | 20160123683 14/527943 |
Document ID | / |
Family ID | 54768407 |
Filed Date | 2016-05-05 |
United States Patent
Application |
20160123683 |
Kind Code |
A1 |
Mehravaran; Meisam |
May 5, 2016 |
INLET AIR TURBULENT GRID MIXER AND DIMPLED SURFACE RESONANT CHARGE
AIR COOLER CORE
Abstract
A resonant charge air cooler is provided having internal
structures for producing vortexes in the air flow, thus inducing
turbulence and increasing heat transfer efficiency. The air cooler
includes an inlet tank, an outlet tank and a plurality of tubes
fluidly connecting the inlet and outlet tanks. The tubes include
vortex-inducing structures such as dimples or grooves formed on
their interior surfaces. A vortex-inducing structure such as wire
mesh formed from a long wire, a wire grid or parallel wires on a
frame is included in the inlet tank. By changing the geometry of
the internal structures, turbulent eddies are created at very small
length scales. Adjustment of the geometries results in vortexes
that have almost the same size as those produced by the surface
dimples or grooves formed on the walls of the tubes connecting the
inlet and outlet tanks, whereby a resonance behavior occurs and
heat transfer increases.
Inventors: |
Mehravaran; Meisam; (Oak
Park, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
54768407 |
Appl. No.: |
14/527943 |
Filed: |
October 30, 2014 |
Current U.S.
Class: |
165/109.1 |
Current CPC
Class: |
F28D 1/05383 20130101;
F28D 2021/0082 20130101; F28F 13/12 20130101; Y02T 10/12 20130101;
F28F 9/028 20130101; Y02T 10/146 20130101; F28F 1/40 20130101; F02B
29/0462 20130101; F28F 21/067 20130101 |
International
Class: |
F28F 13/12 20060101
F28F013/12 |
Claims
1. A heat exchanger comprising: an inlet tank having an inlet; a
vortex-inducing structure fitted within said inlet tank; an outlet
tank having an outlet; a tube fluidly connecting said inlet tank
and said outlet tank, said tube including an interior surface; and
a vortex-inducing structure formed on said interior surface of said
tube.
2. The heat exchanger of claim 1 wherein said vortex-inducing
structure fitted within said inlet tank is a wire.
3. The heat exchanger of claim 2 wherein said wire comprises a
plurality of randomly-arranged wires.
4. The heat exchanger of claim 2 wherein said wire comprises a wire
grid.
5. The heat exchanger of claim 4 wherein said wire grid is formed
by a plurality of intersecting wires.
6. The heat exchanger of claim 1 wherein said wire comprises
parallel wires positioned on a frame.
7. The heat exchanger of claim 1 wherein said vortex-inducing
structure formed on said interior surface of said tube is a
plurality of raised dimples.
8. The heat exchanger of claim 1 wherein said vortex-inducing
structure formed on said interior surface of said tube is a
plurality of grooves.
9. The heat exchanger of claim 1 wherein said vortex-inducing
structure formed on said interior surface of said tube is a
combination of a plurality of raised dimples and a plurality of
grooves.
10. A heat exchanger comprising: an inlet tank; an inlet
vortex-inducing structure fitted within said tank, said inlet
vortex-inducing structure being selected from the group consisting
of randomly-arranged wires, intersecting wires, and parallel wires;
an outlet tank; a tube fluidly connecting said inlet and outlet
tanks, said tube including an interior surface; and a tube
vortex-inducing structure formed on said interior surface, said
tube vortex-inducing structure being selected from the group
consisting of dimples and grooves.
11. The heat exchanger of claim 10 wherein said wire grid is formed
by a plurality of intersecting wires.
12. The heat exchanger of claim 10 wherein said vortex-inducing
structure formed on said interior surface of said tube is a
combination of said randomly-arranged wires and said wire grid.
13. The heat exchanger of claim 10 wherein said vortex-inducing
structure formed on said interior surface of said tube is a
combination of said dimples and a said grooves.
14. A method for cooling fluid in an internal combustion engine
comprising: forming a heat exchanger having an inlet tank, a
vortex-inducing structure fitted within said tank, an outlet tank,
a tube fluidly connecting said inlet and outlet tanks, said tube
including an interior surface, said interior surface having a
vortex-inducing structure formed thereon; and adjusting the
geometries of said vortex-inducing structures to obtain a preferred
resonance within said heat exchanger when coolant flows
therethrough.
15. The method for cooling fluid of claim 14 wherein said
vortex-inducing structure fitted within said inlet tank is a
wire.
16. The method for cooling fluid of claim 15 wherein said wherein
said wire comprises a plurality of randomly-arranged wires.
17. The method for cooling fluid of claim 15 wherein said wire
comprises a wire grid defined by a plurality of intersecting
wires.
18. The method for cooling fluid of claim 15 wherein said wire
comprises parallel wires positioned on a frame.
19. The method for cooling fluid of claim 14 wherein said
vortex-inducing structure formed on said interior surface of said
tube is a plurality of raised dimples.
20. The method for cooling fluid of claim 14 wherein said
vortex-inducing structure formed on said interior surface of said
tube is a plurality of grooves.
Description
TECHNICAL FIELD
[0001] The disclosed inventive concept relates generally to charge
air coolers for automotive vehicles. More particularly, the
disclosed inventive concept relates to a resonant charge air cooler
core having internal structures to create turbulence and thereby
enhance heat transfer.
BACKGROUND OF THE INVENTION
[0002] It is increasingly common for internal combustion engines to
be fitted with turbochargers or superchargers to force more air
mass into the engine's intake manifold and combustion chamber. The
increased amount of air mass is the result of the air being
compressed by an air compressor driven by a turbine which is itself
driven by an impeller associated with the exhaust system. While
improving engine horsepower, the input of compressed air heats the
intake manifold, thus causing a reduction in the density of the
charge air.
[0003] To offset the increased temperature of the incoming air,
charge air coolers have been provided upstream of the airflow. The
typical charge air cooler (CAC) includes an air inlet tank, an air
outlet tank, and a series of elongated and parallel cooling tubes
fluidly connecting the air inlet tank to the air outlet tank.
[0004] While the technology for efficient charge air coolers
continues to advance, the designers of these coolers are challenged
by constraints on packaging. It is known that to achieve a high
charge air cooler efficiency, charge air coolers should have a
surface area that is large enough to provide sufficient surface
area that proper cooling of the air flowing from the inlet tank to
the outlet tank can take place. However, the size of the charge air
cooler is very often restricted by the available space.
[0005] Restriction of available space is created by a number of
factors. First, for maximum cooling efficiency, charge air coolers
should receive "first air," that is, they should be positioned in
front of the radiator and other heat exchangers. Second, known
components such as the active radar adjustment screw and the active
grill shutter housing result in a very confined space for the
charge air cooler. The minimal space available for the charge air
cooler is in conflict with the need to provide a charge air cooler
that is as large as possible.
[0006] Accordingly, as in so many areas of vehicle technology,
there is room for improvement in the design of charge air coolers
whereby maximum cooling can be achieved using a cooler that is of a
smaller size, thereby being suitably sized for the confined areas
known in today's vehicle.
SUMMARY OF THE INVENTION
[0007] The disclosed inventive concept overcomes the problems
associated with known charge air coolers by providing maximum air
cooling in a cooler being of a relatively small size. This result
is generally achieved by providing structures internal to the
charge air cooler that produce vortexes in the air flow, thus
inducing turbulence and increasing heat transfer efficiency.
[0008] Recognizing that during different working conditions of the
vehicle the flow may be laminar, transitional or turbulent, the
flow is confirmed as being turbulent in most working conditions by
providing a selected internal structure. The structures may be one
of (or a combination of) a wire mesh, a wire grid or a frame having
parallel wires provided in the inlet tank. By changing the geometry
of the internal structure, turbulent eddies are created at very
small length scales. The size of the eddies and the quality of the
turbulence may be determined by the geometry of the internal
structure.
[0009] By adjusting the geometry of the turbulence-inducing
internal structure, turbulent eddies can be formed at very small
length scales. The size of the eddies and quality of the turbulence
may thus be determined by the geometry of the turbulence-inducing
internal structure. Furthermore, by adding grooves or dimples on an
interior surface of the charge air cooler, heat transfer is
increased as a result of the vortexes produced and the intensified
mixing. When the time scale of the fluid unsteadiness (that is, the
turbulence eddies) and the time scale of grooves or dimples (the
time required for the flow to pass the groove surface) coincide,
the heat transfer conductance coefficient increases significantly.
This behavior is similar to a resonance in structural or
vibrational mechanics.
[0010] In order to make use of this resonant effect in the
disclosed inventive concept, the resonant charge air cooler
disclosed herein includes either a long wire squeezed into the
inlet tank or, alternatively, a wire mesh screen provided at the
inlet window of the tube. The geometry of such structures may be
adjusted to impose vortexes that have almost the same size as those
produced by the surface dimples or grooves formed on the walls of
the tubes that connect the inlet and outlet tanks, whereby a
resonance behavior occurs and heat transfer increases considerably.
An increase in heat transfer allows for the reduction of the size
of the charge air cooler without compromising cooling
efficiency.
[0011] The above advantages and other advantages and features will
be readily apparent from the following detailed description of the
preferred embodiments when taken in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more complete understanding of this invention,
reference should now be made to the embodiments illustrated in
greater detail in the accompanying drawings and described below by
way of examples of the invention wherein:
[0013] FIG. 1 is a plan view of a resonant charge air cooler
illustrating an internal turbulence-generating structure according
to a first embodiment of the disclosed inventive concept;
[0014] FIG. 1A is a sectional view of the interior of a tube
illustrating a dimpled surface taken from line 1A of FIG. 1;
[0015] FIG. 1B is a sectional view of the interior of a tube
illustrating a grooved surface taken from line 1B of FIG. 1;
[0016] FIG. 2 is a plan view of a resonant charge air cooler
illustrating an internal turbulence-generating structure according
to a second embodiment of the disclosed inventive concept;
[0017] FIG. 3 is a plan view of the wired mesh fitted to the second
embodiment of the resonant charge air cooler according to the
disclosed inventive concept;
[0018] FIG. 4 is a plan view of a frame having parallel wires
positioned longitudinally relative to the long axis of the frame
that may alternatively be fitted to the second embodiment of the
resonant charge air cooler according to the disclosed inventive
concept; and
[0019] FIG. 5 is a plan view of a frame having parallel wires
positioned diagonally relative to the long axis of the frame that
may alternatively be fitted to the second embodiment of the
resonant charge air cooler according to the disclosed inventive
concept.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] In the following figures, the same reference numerals will
be used to refer to the same components. In the following
description, various operating parameters and components are
described for different constructed embodiments. These specific
parameters and components are included as examples and are not
meant to be limiting.
[0021] The resonant charge air cooler of the disclosed inventive
concept is illustrated in its various embodiments in FIGS. 1
through 5. However, it is to be understood that the illustrated
embodiments are suggestive and are not intended as being
limiting.
[0022] Referring to FIG. 1, a plan view of a resonant charge air
cooler, generally illustrated as 10, is shown. The resonant charge
air cooler 10 includes an inlet tank 12 having an inlet 14 and an
inlet tank body 16. The inlet tank 12 may be made from any one of
several materials, including a polymerized material (such as
polypropylene or polyamide) or a metal or a combination of the
two.
[0023] Perpendicular to and extending from the inlet tank body 16
and fluidly connected thereto are a plurality of coolant tubes 18.
The number, shape and placement of the tubes 18 may be other than
as illustrated.
[0024] The resonant charge air cooler 10 further includes an outlet
tank 20 having an outlet 22 and an outlet tank body 24. Like the
inlet tank 12, the outlet tank 20 may be made from any one of
several materials, including a polymerized material or a metal or a
combination of the two.
[0025] Brackets are preferably attached to the resonant charge air
cooler 10 for fixing the resonant charge air cooler 10 to the heat
exchanger (not shown), to a structure in the vehicle's engine
compartment, or to both. A first set of brackets 26 and 26' and a
second set of brackets 28 and 28' are preferably provided. The
shape, placement and number of brackets may be varied beyond the
illustrated brackets 26, 26', 28 and 28'.
[0026] To create the appropriate vortex in the coolant tubes 18,
the inner surfaces of the tubes 18 have structures formed thereon.
The inner surfaces may be dimpled or grooved or may have another
vortex-inducing structure formed thereon. FIGS. 1A and 1B
illustrate two non-limiting examples of such structures.
[0027] Referring to FIG. 1A, a tube 18 is shown in partial
cross-section. The tube 18 includes an interior surface 30. Formed
on the interior surface 30 of the tube 18 are raised dimples 32.
The shape, number and placement of the raised dimples 32 may each
be varied other than as illustrated.
[0028] Vortex-initiating alternatives for the interior surface 30
of the tube 18 other than the raised dimples 32 shown in FIG. 1A
are available. Instead of raised dimples 32, a series of grooves 34
may be formed in the interior surface 30. The grooves 34 may be
perpendicular to the long axis of the tube 18 as illustrated or may
be axially formed.
[0029] While the raised dimples 32 and the grooves 34 are provided
to create vortices within the tube 18, an additional
vortex-initiating structure is provided in relation to the
inflowing air. Particularly, and referring to FIG. 1, one or more
randomly-arranged wires 36 are "squeezed" into the inlet tank 12,
thereby creating turbulence in the incoming air as it passes
between the inlet 14 and the tubes 18. The randomly-arranged wires
36 may be made from a variety of materials and may be made in a
variety of lengths and thicknesses.
[0030] The geometries of the raised dimples 32 and/or grooves 34 as
well as the geometries of the randomly-arranged wires 36 may be
modified in the resonant charge air cooler 10 to achieve maximum
cooling within a minimal space. For example, the size, number and
spacing of the raised dimples 32 and the number, depth and
placement of the grooves 34 may be modified. In addition, the
thickness, number, length and spacing of the randomly-arranged
wires 36 may be modified. By adjusting these geometries, an optimum
resonance behavior may be generated within the resonant charge air
cooler 10 to thereby maximize heat transfer.
[0031] While FIG. 1 illustrates the use of the randomly-arranged
wires 36 as a method for inducing vortices within the stream of
incoming air as it passes through the inlet tank 12, other
structures for inducing vortices within the incoming air are
possible. A non-limiting example of such a structure is illustrated
in FIGS. 2 and 3.
[0032] Referring to FIG. 2, a plan view of a resonant charge air
cooler according to an alternate embodiment, generally illustrated
as 40, is shown. The resonant charge air cooler 40 includes an
inlet tank 42 having an inlet 44 and an inlet tank body 46. The
inlet tank 12 may be made from any one of several materials,
including a polymerized material or a metal or a combination of the
two.
[0033] Perpendicular to and extending from the inlet tank body 46
and fluidly connected thereto are a plurality of coolant tubes 48.
The number, shape and placement of the tubes 18 may be other than
as illustrated. Like the coolant tubes 18 shown in FIGS. 1A and 1B,
the interior surfaces of the coolant tubes 48 have vortex-inducing
structures such as raised dimples, grooves, or both formed
thereon.
[0034] The resonant charge air cooler 40 further includes an outlet
tank 50 having an outlet tank body 52 and an outlet 54. Like the
inlet tank 42, the outlet tank 50 may be made from any one of
several materials, including a polymerized material or a metal or a
combination of the two.
[0035] Brackets are preferably attached to the resonant charge air
cooler 40 for fixing the resonant charge air cooler 40 to the heat
exchanger (not shown), to a structure in the vehicle's engine
compartment, or to both. A first set of brackets 56 and 56' and a
second set of brackets 58 and 58' are preferably provided. The
shape, placement and number of brackets may be varied beyond the
illustrated brackets 56, 56', 58 and 58'.
[0036] To induce the appropriate vortex within the inlet tank 42, a
wire grid 60 is fitted to an inner wall 62 of the inlet tank 42 to
which the tubes 48 are fluidly connected. An exemplary version of
the wire grid 60 is shown in FIG. 3. The wire grid 60 includes a
plurality of individual wires 64 positioned in a first direction
and a plurality of individual wires 66 positioned in a second
direction such that the wires 64 and 66 are interwoven and thus
interconnect.
[0037] As with the first embodiment of the resonant charge air
cooler of the disclosed inventive concept illustrated in FIG. 1 and
discussed in relation thereto, the geometries of the raised dimples
32 and/or grooves 34 as well as the geometries of the wire grid 60
may be modified in the resonant charge air cooler 40 to achieve
maximum cooling within a minimal space. Again, as noted above, the
size, number and spacing of the raised dimples 32 and the number,
depth and placement of the grooves 34 may be modified. In addition,
the thickness, number, length and spacing of the individual wires
64 and 66 may be modified. By adjusting these geometries, an
optimum resonance behavior may be generated within the resonant
charge air cooler 40 to thereby maximize heat transfer.
[0038] Structures alternative to the wire grid 60 may be used in
conjunction with the resonant charge air cooler of the disclosed
inventive concept illustrated in FIG. 2. One such alternative
structure is illustrated in FIG. 4 in which a turbulence-inducing
structure 70 is illustrated in plan view. The turbulence-inducing
structure 70 includes a frame 72 having a series of parallel wires
74 attached thereto. It is to be understood that while the parallel
wires 74 are illustrated as being positioned parallel to the long
axis of the frame 72, the parallel wires 74 may be positioned
perpendicular to the long axis of the frame 72.
[0039] As a variation of the turbulence-inducing structure 70 shown
in FIG. 4, a turbulence-inducing structure 80 is illustrated in
FIG. 5. The turbulence-inducing structure 80 has a frame 82 with
wires 84 positioned diagonally with respect to the long axis of the
frame 82 may be used.
[0040] The thicknesses of the wires 74 and 84 and the spacing
between the wires 74 and 84 may be varied from the illustrations of
FIGS. 4 and 5 respectively. Adjustment of such variables may again
be made to generate optimum resonance behavior, thereby maximizing
heat transfer.
[0041] The resonant charge air cooler of the disclosed inventive
concept in its various embodiment overcomes the problems of known
systems by providing maximum heat exchange in a minimum amount of
space. It is to be understood that the resonant system disclosed
herein has been discussed in relation to charge air coolers, the
use of vortex-inducing structures in relation to the inlet tank and
the tubes may be applied as well to other heat exchangers,
including without limitation condensors, transmission coolers, and
radiators.
[0042] While the preferred embodiments of the disclosed inventive
concept have been discussed are shown in the accompanying drawings
and are set forth in the associated description, one skilled in the
art will readily recognize from such discussion, and from the
accompanying drawings and claims that various changes,
modifications and variations can be made therein without departing
from the true spirit and fair scope of the invention as defined by
the following claims.
* * * * *