AU2018101854A4 - Engine Intercooler System Having A Fluid Loop Integrated With An Interchiller And An Air Conditioning System - Google Patents

Abstract

An interchiller for a vehicle incorporating either a gas turbocharger or crank driven supercharger, a water to air intercooler system and an air conditioning system, the interchiller comprising: a water cooler loop operatively connected to heated water from the turbocharger or superchargers water intercooler system before it enters the vehicles engine combustion phase; and an air conditioning system bypass loop operatively connecting the air conditioning system to the water intercooler loop via its connection into the interchiller. Figure to be published: 1 ,20 FIGi1

Description

Engine Intercooler System Having A Fluid Loop Integrated With An Interchiller And An

Air Conditioning System

Field of the invention [001] The present invention generally pertains to an interchiller incorporated into an water to air intercooler system for intake manifold air. More particularly, the present invention relates to an interchiller arrangement for turbocharged or supercharged engines having a water to air intercooler system with a fluid loop to which additional cooling is provided via a bypass circuit from the engines air conditioning system and directed through an interchiller.

Background of the invention [002] The terms “turbocharging” and “supercharging” both refer to methods of increasing the air or air/fuel mixture density of an engine by increasing the pressure of the intake air stream prior to entering the engines combustion cylinder. Increasing the density of the air in the combustion cylinder is desirable because it is a simple method for increasing power and torque generated by the engine. Turbocharging generally means that the air intake compressor is powered by the engine exhaust stream. Supercharging generally means that the air intake compressor is powered by coupling it to the engine crank via a belt, chain or gear(s), etc. The term “charger” and “charging” is used herein to refer to both turbochargers and superchargers.

[003] Since pressurizing air is directly related to heat, as the charger increases the pressure of the intake air stream it also increases the airs temperature. It is well known that cooling this intake air stream further permits an additional increase in its pressure since cooler air can be more densely packed. This additional cooling of the air is generally accomplished through the use of an intercooler either exchanging heat with ambient air or exchanging heat into fluid generally a water mixture of glycol and water.

[004] The simplest intercooler involves incorporating a heat exchanger into the air stream between the charger and the engines combustion cylinders. Such a heat exchanger can incorporate fins, coils, or a combination thereof to improve the rate at which heat is absorbed and transferred to the ambient air. However, even if the placement and plumbing of the heat exchanger are optimized the ambient air temperature as well as the temperature at the air intake point both represent uncontrollable variables.

This data, for application number 2015224428, is current as of 2018-11-28 21:00 AEST

2018101854 29 Nov 2018 [005] U.S. pat. No. 4,683,725 to Sugiura; U.S. Pat. No. 5,435,289 to Pendlebury, et al; and U.S. P.at No. 6,394,076 B1 to Hudelson; all describe designs that eliminate the problems of a passive intercooler loop. Each of these patents describes an intercooler located in the intake air stream between the charger and the combustion chamber where the intercooler contains a heat exchanger that is cooled by the engines air conditioning system. These designs permit reasonably uniform cooling of the intake air stream. However, the need for maximum cooling of the intake air stream and the passenger cabin of the vehicle are most likely to occur simultaneously. In the best case, this significantly reduces engine efficiency and erases the power gained from charger/engine combination. In the worst case, failure of the air conditioning, charger, and/or engine can result.

[006] Motor vehicles have been increasing in complexity since Henry Ford ushered in the age of manufactured vehicles.

[007] With each successive model year an increasing number of features that contribute to the performance, safety, and operator comfort have been incorporated into vehicles. Features that were once optional are now standard equipment. Probably the only negative aspect of this trend is ever diminishing space in the engine compartment. This, it is most desirable for components that improve engine performance to be compact and retain their functionality no matter where they are mounted in the engine compartment.

[008] Compared to a charger, an interchiller is a simple and relatively inexpensive component. With this fact in mind, it would seem that the use of an interchiller would generally be easy to justify because its contribution to the operating efficiency of the charger is greater than its expense, size and weight. While simple intercoolers are found on many turbocharger or supercharged engines, more advanced interchillers, such as described above, have not been adopted for production engines. It appears that this is because their contribution to the improved engine performance is outweighed by their expense, size, and weight compared to the simplest intercooler or no intercooler at all. Thus, it would be advantageous to provide an improved interchiller that would be inexpensive and small, yet still capable of significantly increasing the efficiency of the charger and intercooler system.

2018101854 29 Nov 2018 [009] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention [010] One object of the present invention is an improved intercooler system arrangement for a vehicle engine that is inexpensive, efficient and relatively small.

[011] Another object of the invention is a dual plate interchiller which has two fluid circuits flowing in opposing directions which can be made of various high heat transfer materials such as but no limited to metals, plastics, nylons in a stack plate design that is adaptable to a variety of engine sizes and configurations and capable of efficiently cooling the intake air stream.

[012] These and other objects are satisfied by an intercooler system for a vehicles engine incorporating an exhaust gas turbocharger or supercharger and an air conditioning system, the interchiller comprising: a intercooler fluid loop which passes through a number of thin plates operatively connected to the heated intercooler fluid which is connected to the pressurized air from the charger before it flows into the vehicle engine; and an air conditioning system bypass loop operatively connecting the air conditioning system to the interchillers second opposing direction fluid loop.

[013] The present invention also provides an interchiller system for an engine incorporating an exhaust gas turbocharger, a water to air intercooler system and an air conditioning system, said interchiller system comprising: at least one interchiller evaporator; an intercooler fluid loop employing a coolant, said intercooler loop being adapted to be operatively connected to said at least one interchiller evaporator to cool heated pressurized air from said turbocharger before it flows into said engine; and at least one respective air conditioning system bypass loop operatively connecting said air conditioning system to said at least one interchiller evaporator; wherein said intercooler fluid loop and said air condition system bypass loop are configurable so that said at least one respective air conditioning system bypass loop is adapted to operate during engine combustion.

[014] The air conditioning bypass loop can be operated manually.

[015] Alternatively, the air conditioning bypass loop can be operated automatically by a control system which senses operating conditions of said engine.

2018101854 29 Nov 2018 [016] The air conditioning system bypass loop can be controlled by a solenoid.

[017] The air conditioning system bypass can be split between the cabin evaporator and said at least one interchiller evaporator; controlled to be variably split between the cabin evaporator and said at least one interchiller evaporator.

[018] The interchiller system and air conditioning system are arranged so as to not allow condensation to leak from the engine and or vehicle.

[019] There can be two or more interchiller evaporators and respective air conditioning system bypass loops.

[020] There are at least one interchiller evaporator can be a sealed device such that water condensation cannot form.

[021] The present invention also provides a land vehicle, a vessel, an aircraft or plant system having an interchiller system as claimed in any one of the preceding paragraphs.

[022] The vehicle can be any one of a car, race car, a truck, 4WD, boat, ship, motorised vessel, hovercraft, aircraft, helicopter.

[023] The plant system can be part of one of: a lifting system, a cooling system, an electricity generation system, a winching system, other motorised system.

[024] The present invention also provides an interchiller system kit, which is adapted to produce an interchiller system, a land vehicle, a vessel, an aircraft or plant system as described above.

[025] The kit can be such that there is included one or more than one of the following: an interchiller evaporator; a suction fitting, a T-piece for a suction hose; an interchiller evaporator mounting bracket; insulating material; thermal insulation for airconditioning connectors; thermal expansion valve; refrigerant solenoid; switch; refrigerant fittings; refrigerant conduit; coolant conduit; clamps; hoses; elbows; Orings; bolts; vacuum T-piece; water bypass solenoid; water bypass valve; vacuum hose.

Brief description of the drawings [026] A detailed description of a preferred embodiment will follow, by way of example only, with reference to the accompanying figures of the drawings, in which:

2018101854 29 Nov 2018 [027] FIG. 1 is a schematic of the embodiment of the present invention.

[028] FIG. 2 is a schematic similar to FIG.1 showing how optional additional interchiller evaporators can be included in the interchiller system.

Detailed description of the embodiment or embodiments [029] The following description of the embodiments will be limited to systems for related to motor vehicle engine systems, but it will be readily understood that the invention can be incorporated into a land vehicle such as a car, race car, a truck, 4WD, a train, a locomotive or a vessel such as a boat, ship, motorised vessel, hovercraft or an aircraft such as an airplane or helicopter or a plant system such as a lifting system, a cooling system, an electricity generation system, a winching system, a pumping system or other motorised system, all of which have an interchiller system as is described below.

[030] The interchiller of the present invention may be used with any water to air intercooler system connected to any variation of turbocharger or supercharger. In the Figurel, like numbers refer to the like parts.

[031] FIG. 1 illustrates a turbocharger or supercharger charge air cooler 1 as a source of heated intercooler fluid 7. This hot liquid fluid 7 is directed through a charge air cooler located in the supercharger or turbocharger 1 or before entry into the turbocharger or supercharger 1 the intercooler fluid 7 is then directed to the intercooler pump 2 where it is pumped into a vacuum controlled bypass valve 3 which is controlled by a vacuum solenoid 4 this vacuum solenoid is controlled by an ON/OFF switch 20 located in the passenger cabin. This bypass valve 3 directs intercooler fluid 7 into the engines water to ambient air intercooler 5 or if bypassed directly into the interchiller 6 when not bypassing the intercooler fluid 7 will first pass through the engines water to ambient air intercooler 5 and then through the interchiller 6 after which point the intercooler fluid 7 will enter the turbocharger or superchargers charge air cooler 1. The bypass valve 3 allows the interchiller 6 to work more effectively in cooling the intercooler fluid 7 it does this by bypassing the intercooler fluid 7 from entering the water to ambient air intercooler 5. The water to ambient air intercooler 5 can become a heat source to the intercooler fluid 7 as the temperature of the intercooler fluid 7 is colder than the ambient air temperature that is being absorbed by the water to ambient air intercooler 5. (The connections between the engine, the charger, and manifold are well known and therefore not illustrated).

2018101854 29 Nov 2018 [032] The engines air conditioning compressor 9 sends the air condition system refrigerant 17 through a series of tubes or hoses 18 before entering the AC condenser 16 during which point the refrigerant 17 condenses from a gas into a liquid state, after exiting the AC condenser 16 a T-piece/solenoid device 12 splits the refrigerant 17 directing half of the refrigerant 17 to the cabin evaporator thermal expansion valve 11 before entering the cabin evaporator 10 for passenger cabin cooling and half to the interchiller thermal expansion valve 11 before entering the interchiller 6 for cooling of the intercooler fluid 7 this T-piece/Solenoid device 12 is controlled by an ON/OFF switch located in the passenger cabin 19. When the switch 19 is powered in the ON position the supply of refrigerant 17 is split between the cabin evaporator 10 and the interchiller 6, when the switch is in the OFF position the supply of refrigerant 17 is dedicated strictly to the interchiller 6 after the refrigerant 17 exits the interchiller 6 it flows to a suction line t-piece 8 before repeating the air conditioning systems refrigerant 17 cycle back into the AC compressor 9. By having the solenoid 12 the interchiller 6 is able to further enhance cooling capacity of the intercooler fluid 7. The solenoid 12 in the OFF position also allows the interchiller 6 to be used in a racing environment e.g. drag racing or circuit track racing since the interchiller 6 is a sealed device water condensation cannot form and drip on to the race track surface. This is unlike normal air conditioning refrigerant 17 systems where by water condensation can form on the cabin evaporator 10 and as such leak and drip on to the race track.

[033] Unlike the prior art (such as discussed in the background of the invention, above) an interchiller of the present invention is a two loop system having a water cooler loop operatively connected to the hot pressurized air from the charger 1 and an air conditioning system 17 that connects the air conditioning system 17 to the interchiller 6. This arrangement results in a simple more cost effective system that uses compact components, that can be mounted in almost any available location in the engine compartment. In addition the described interchiller is readily adaptable to a variety of engine sizes, charger types, desired performance parameters, etc.

[034] Plumbing between the components may be made of plastic, rubber, metal or a combination thereof, and may be rigid or flexible depending on specific vehicle requirements. In order to reduce radiated noise from low stiffness ducts (flexible hoses) and thin wall ducts it is preferable to minimize the extent of such connections by engine mounting the components to the greatest extent possible.

2018101854 29 Nov 2018 [035] The air conditioning system can be any standard air conditioning system. The illustrated air conditioning system 17 is an example. This system comprises an accumulation reservoir 21 connected via a suction line 14 to a compressor 9. The compressor 9 is powered by a connection to the engine (not shown). Gaseous refrigerant 17 is sucked through the suction line 14 by the compressor 9 where it is compressed. This pressurized refrigerant 17 flows from the compressor to the condenser 16 where the heat from the pressurization is dissipated and the refrigerant 17 condenses to a liquid. During normal operation ofthe air conditioning system 17, the thermal expansion Valve 11 (thermal expansion valve) 11 alters the amount of refrigerant allowed into the cabin evaporator 10 as the refrigerant 17 passes through the thermal expansion valve 11 the refrigerant 17 boils and vaporizes resulting in a significant temperature drop. The cold refrigerant 17 is then sucked, by the negative pressure created by the compressor 9, through the cabin evaporator core 10 where the cabin air is cooled.

[036] During operation of the engine, the charger 1 generates hot air, this hot air is absorbed by the internal or external circulation of intercooler fluid 7 which flows through the charger 1 the heat in the compressed air stream is extracted producing the cool air stream that is directed into the combustion cylinder. Increased cooling above that of the standard intercooler is provided by the interchiller 6 connected to the intercooler loop. Preferably this loop is a glycol-water loop comprising of the chargers intercooler 1, an intercooler pump 2, and a water to ambient air intercooler 5. When the engine is in operation the intercooler pump 2 circulates the glycol-water mix then flows through the charger intercooler 1 where the heated air temperature is absorbed into the glycol-water mix and circulated through the water to ambient air intercooler 5 and interchiller 6.

[037] A unique aspect of the present invention is the incorporation of the cooling capacity of the existing engine air conditioning system to provide additional cooling capacity beyond that which can be provided by the standard intercooler loop. When such additional capacity is needed, the thermal expansion valve 11 in the air conditioning system is opened to direct cold refrigerant for the air conditioning system 17 to enter the air conditioning bypass loop, and thus flow through the interchiller 6.

[038] A particular benefit of the present invention is that it permits significant flexibility in size and placement of the system components. In general, sizing a turbocharger or supercharger is based on peak output requirements that are normally reached for only a

2018101854 29 Nov 2018 small fraction of the engine’s overall operating time. With prior art systems, this necessitated the use of relatively large components. For example, a turbocharger designed to function without an intercooler must be relatively large. The use of an intercooler permits a reduction in the size of the turbocharger. By incorporating only an intercooler loop as described above, a slightly smaller turbocharger can be used. By using an intercooler loop combined with an interchiller in conjunction with an air conditioning bypass loop as described herein, all components can be reduced in size, thereby improving the efficiency of cost, sizing, placement, etc with no loss in engine performance.

[039] A desired configuration of the present invention that delivers maximal benefit is the interchiller 6 ability to use bypass solenoids 12 to block of the cabin evaporator 10 and the ability to use a water bypass 3 to block off the water to ambient air intercooler 5 to have the ability to cool the intercooler fluid 7 far beyond what the normal water to ambient air intercooler 5 is capable of achieving. Whilst having the ability to use the interchiller 6 in a car racing environment where racing rules are that no condensation can leak on to a race track surface. Being that if the cabin evaporator 10 was normally in use during this time condensation will form and leak on to the race track surface.

[040] As illustrated in FIG.2, is a system similar to that of FIG.1 where one or more than one additional interchiller evaporator 6’ and or 6” and respective thermal expansion valves 11 ’ and or 11 ”, with respective bypass loops are included in the interchiller system, to get even more effective cooling.

[041] The present invention can be used in a vehicle or automobile having an interchiller system as described above. The vehicle can be any one of a car, race car, a truck, 4WD, boat, ship, motorised vessel, hovercraft, aircraft, helicopter; locomotive and railway vehicles.

[042] While the interchiller system has particular application to vehicles, it will be understood that it can also be used in stationary plant and equipment which utilise engines and air-conditioning systems.

[043] The embodiments of the invention also provide an interchiller system kit, which is adapted to produce an interchiller system, a vehicle or automobile as described above. The kit can be such that there is included one or more than one of the following: an interchiller evaporator; a suction fitting, a T-piece for a suction hose; an interchiller evaporator mounting bracket; insulating material; thermal insulation for air2018101854 29 Nov 2018 conditioning connectors; thermal expansion valve; refrigerant solenoid; switch; refrigerant fittings; refrigerant conduit; coolant conduit; clamps; hoses; elbows; Orings; bolts; vacuum T-piece; water bypass solenoid; water bypass valve; vacuum hose.

[044] While specific embodiments of an interchiller according to the present invention have been disclosed and described herein, alternative embodiments of these and other components of the invention will occur to those skilled in the art. For example, variations on the combinations of the embodiments illustrated in FIG 1 with the size of the different loops, the charger type, etc. Other obvious variations will be suggested through improvements and new developments of appropriate resilient metal and thermoplastics materials, for example that can be readily adapted by one skilled in the art. Accordingly, the scope of this invention is to be considered limited only by the following claims.

[045] Where ever it is used, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[046] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[047] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims (13)

1. Claims

   1. An interchiller system for an engine incorporating a turbocharger or supercharger, a water to air intercooler system and an air conditioning system, said interchiller system comprising:

   at least one interchiller evaporator;

   an intercooler fluid loop employing a coolant, said intercooler loop being adapted to be operatively connected to said at least one interchiller evaporator to cool heated pressurized air from said turbocharger or supercharger before it flows into said engine; and at least one respective air conditioning system bypass loop operatively connecting said air conditioning system to said at least one interchiller evaporator;

   wherein said intercooler fluid loop and said air condition system bypass loop are configurable so that said at least one respective air conditioning system bypass loop is adapted to operate during engine combustion.
2. 2. An interchiller system as claimed in claim 1, wherein said air conditioning bypass loop is operated manually.
3. 3. An interchiller system as claimed in claim 1, wherein said air conditioning bypass loop is operated automatically by a control system which senses operating conditions of said engine.
4. 4. An interchiller system as claimed in any one of the preceding claims wherein said air conditioning system bypass loop is controlled by a solenoid.
5. 5. An interchiller as claimed in any one of the preceding claims wherein said air conditioning system bypass is split between the cabin evaporator and said at least one interchiller evaporator.
6. 6. An interchiller system as claimed in anyone of the preceding claims wherein the interchiller system and air conditioning system do not allow condensation to leak from the engine and or vehicle.
7. 7. An interchiller system as claimed in any one of the preceding claims wherein there are two or more interchiller evaporators and respective air conditioning system bypass loops.

   This data, for application number 2015224428, is current as of 2018-11-28 21:00 AEST

   2018101854 29 Nov 2018
8. 8. An interchiller system as claimed in any one of the preceding claims wherein said at least one interchiller evaporator is a sealed device such that water condensation cannot form.
9. 9. A land vehicle, a vessel, an aircraft or plant system having an interchiller system as claimed in any one of the preceding claims.
10. 10. A vehicle, a vessel or aircraft as claimed in claim 9, wherein said vehicle vessel or aircraft is one of the following: a car, race car, a truck, a 4WD vehicle, a train, a locomotive, a boat, a ship, a motorised vessel, a hovercraft, an aircraft, an airplane, a helicopter.
11. 11. A plant system as claimed in claim 9, wherein said plant system is part of one of: a lifting system, a cooling system, an electricity generation system, a winching system, a pumping system, or other motorised system.
12. 12. An interchiller system kit, which is adapted to produce an interchiller system, land vehicle, a vessel, an aircraft or plant system as claimed in any one of claims 1 to

    11.
13. 13. An interchiller kit as claimed in claim 12, wherein there is included one or more than one of the following: an interchiller evaporator; a suction fitting, a T-piece for a suction hose; an interchiller evaporator mounting bracket; insulating material; thermal insulation for air-conditioning connectors; thermal expansion valve; refrigerant solenoid; switch; refrigerant fittings; refrigerant conduit; coolant conduit; clamps; hoses; elbows; O-rings; bolts; vacuum T-piece; water bypass solenoid; water bypass valve; vacuum hose.