GB2593684A

GB2593684A - A charge air cooler end diffuser housing and assembly

Info

Publication number: GB2593684A
Application number: GB2004568.8A
Authority: GB
Inventors: Johnson Steve; Nigel Turner Paul; James Thistlethwaite Simon; Hitchings Andrew; Edward Smith Kristian
Original assignee: Ford Global Technologies LLC
Current assignee: Ford Global Technologies LLC
Priority date: 2020-03-30
Filing date: 2020-03-30
Publication date: 2021-10-06
Also published as: GB202004568D0

Abstract

Diffuser end of an intercooler housing 150 with an integrated bypass valve support 132 configured to receive a valve element 134 from the bypass valve. A secondary supercharger arranged in parallel with the bypass valve, the end housing have two inlets, one 151a for the bypass valve and one 151b for the secondary supercharger. The end housing may increase in cross sectional area to diffuse incoming charge air flow from a turbocharger. The valve element may be fixed or moveable relative to the support or may be selectively fixed. The bypass valve support may comprise a hub with spokes and direct the airflow radially outward and may have a housing formed of two parts. Also claimed is a charge air cooler assembly comprising the housing (and bypass valve).

Description

A CHARGE AIR COOLER END DIFFUSER HOUSING AND ASSEMBLY

Technical Field

The present disclosure relates to a charge air cooler end diffuser housing and assembly and particularly although not exclusively relates to a charge air cooler end diffuser housing that forms at least a first part of a bypass valve housing.

Background

With reference to Figure I, an internal combustion engine (not shown) may comprise first and second pressure boosters 10, 20 to pressurize charge air for the engine. The first and second boosters 10, 20 may be arranged in a series configuration, e.g. such that the second pressure booster 20 may enhance the pressure boost provided by the first booster 10. This additional pressure boost may be useful to counteract turbo-lag experienced by the first booster 10.

As best shown in Figure 2, a bypass valve 30 may be provided in parallel with the second pressure booster 20. The bypass valve 30 may open when the pressure delivered by the first booster reaches a certain threshold, e.g. when the second pressure booster 20 is no longer required to supplement the pressure delivered by the first pressure booster 10.

The second pressure booster 20 and bypass valve 30 may both feed charge air into a charge air cooler 40. The charge air cooler 40 may cool the charge air prior to delivery to the engine to increase its density and thus increase the power output of the engine.

This arrangement is particularly beneficial for smaller engines for which power enhancement is desirable. However, the above-described components require a large package space, with such space being limited in an engine bay of a vehicle.

Statements of Invention

According to an aspect of the present disclosure there is provided a charge air cooler end diffuser housing comprising an integrated bypass valve support configured to receive a valve element of a bypass valve.

The charge air cooler end diffuser housing may increase in cross-sectional area so as to diffuse an incoming charge air flow. The charge air cooler end diffuser housing may distribute the flow across an inlet face of a charge air cooler. The charge air cooler end diffuser housing may extend between first and second ends. The first end may have a smaller cross sectional area than the second end. The bypass valve support may be in line with the first end.

The charge air cooler end diffuser housing may further comprise the valve element. The valve element may be movable with respect to the bypass valve support. The valve element may be fixed with respect to the bypass valve support. The bypass valve support may be configured to receive the valve element such that the valve element may be selectively fixed or movable with respect to the bypass valve support. The charge air cooler end diffuser housing may receive a common bypass valve support that may support the valve element in either a fixed or movable mode.

The charge air cooler end diffuser housing may form at least a first part of a bypass valve housing. The first part of the housing may receive the bypass valve support. The charge air cooler end diffuser housing may be configured to mate with a second part of the bypass valve housing. The first and second parts of the bypass valve housing may together form the bypass valve housing. The second part of the bypass valve housing may comprise a valve scat for the valve element to selectively seal against.

The charge air cooler end diffuser housing may comprise a flange to mate with the second part of the bypass valve housing. The flange may comprise a radially inner portion that is set back from a radially outer portion. The inner portion of the flange may receive the bypass valve support. The bypass valve support arid flange outer portion may together mate with a flange of the second part of the bypass valve housing.

The bypass valve support may comprise a hub configured to receive the valve element of the bypass valve. A shaft of the valve element may be supported by the hub. The valve shaft may be fixed or movable relative to hub.

The hub may be supported by at least one spoke. The spoke(s) may connect the hub to an outer ring of the bypass valve support. The outer ring may be received on the flange inner portion. The spoke may be configured to direct a flow of charge air in a lateral direction of the charge air cooler end diffuser housing. For example, the spoke may direct charge air in a direction with a component in a radial direction. The hub may comprise a flared end configured to direct a flow of charge air radially outwardly.

The bypass valve support may comprise at least one guide ring disposed around the hub and in the charge air flow path. The guide ring may be configured to redirect the flow of charge air.

For example, the guide ring may direct the charge air in a lateral direction of the charge air cooler end diffuser housing and/or in a direction with a component in the radial direction.

According to another aspect of the present disclosure there is provided a charge air cooler assembly comprising the above-mentioned charge air cooler end diffuser housing. The charge air cooler assembly may further comprise a charge air cooler. The charge air cooler end diffuser housing may be configured to diffuse charge air across an inlet end of the charge air cooler. The charge air cooler assembly may further comprise the bypass valve.

To avoid unnecessary duplication of effort and repetition of text in the specification, certain features are described in relation to only one or several aspects or embodiments of the invention However, it is to be understood that, where it is technically possible, features described in relation to any aspect or embodiment of the invention may also be used with any other aspect or embodiment of the invention.

Brief Description of the Drawings

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Figure 1 is a perspective view of a previously-proposed pressure booster and charge air cooler arrangement; Figure 2 is a partially cutaway perspective view of the previously-proposed pressure booster and charge air cooler arrangement of Figure 1 with the cutaway showing inside the bypass valve; Figure 3 is a perspective view of a charge air cooler assembly comprising a charge air cooler, a charge air cooler end diffuser housing and a bypass valve according to an arrangement of the

present disclosure;

Figures 4a and 4b (collectively Figure 4) are perspective cutaway views of the charge air cooler assembly of Figure 3 with Figures 4a and 4b showing the bypass valve in closed and open positions respectively; Figure 5 is a perspective view of a bypass valve support and valve element of the bypass valve according to an arrangement of the present disclosure; Figure 6 is a perspective view of a bypass valve support according to another arrangement of the present disclosure; and Figure 7 is a perspective view of a charge air cooler end diffuser housing according to an alternative arrangement of the present disclosure.

Detailed Description

With reference to Figures 3, 4 and 5, the present disclosure relates to a charge air cooler end diffuser housing 150, which may form part of a charge air cooler 140. The charge air cooler 140 may condition, e.g. cool, charge air for an engine, such as an internal combustion engine (not shown).

The charge air cooler end diffuser housing 150 may receive incoming charge air and may diffuse, e.g. distribute, the flow of air across the width of a heat exchanger (not shown). As such, the charge air cooler end diffuser housing 150 may be provided upstream of the heat exchanger. The heat exchanger may be provided within a central housing 142 of the charge air cooler 140. The charge air cooler end diffuser housing 150 may connect with the central housing 142.

The charge air cooler end diffuser housing 150 may comprise a first inlet 151a to receive incoming charge air from a first pressure booster 10 (such as a turbocharger, supercharger or other pressure booster) via a bypass valve 130. The charge air cooler end diffuser housing 150 may comprise a second inlet 151b, which may receive charge air from a second pressure booster 20 (such as a turbocharger, supercharger or other pressure booster). The bypass valve 130 may be in a parallel arrangement with the second pressure booster 20. The first inlet 151a may be approximately central with respect to the charge air cooler end diffuser housing 150. The second inlet 15 lb may be provided at one side of the charge air cooler end diffuser housing 150.

A flow path defined by the charge air cooler end diffuser housing 150 (and in particular from the first inlet 151a) may increase in cross-sectional area in the direction of flow so as to diffuse an incoming charge air flow. Accordingly, a first upstream end 150a of the charge air cooler end diffuser housing 150 may have a smaller flow cross sectional area than a second downstream end 150b of the charge air cooler end diffuser housing 150.

The charge air cooler end diffuser housing 150 and the charge air cooler 140 may together form a charge air cooler assembly 100. The charge air cooler assembly 100 may thither comprise the bypass valve 130.

With reference to Figure 4, the charge air cooler end diffuser housing 150 may comprise or directly couple to a bypass valve support 132. The bypass valve support 132 may be configured to receive a valve element 134 of the bypass valve 130. The valve element 134 may be movable with respect to the bypass valve support 132. Figure 4a shows the valve element 134 in a closed position in which the valve element 134 seals against a valve seat (not shown) and prevents the flow of charge air through the bypass valve 130. Figure 4b shows the valve dement 134 in an open position in which the valve element 134 is spaced apart from the valve seat and thereby permits flow through the bypass valve 130.

The bypass valve support 132 and the charge air cooler end diffuser housing 150 may be integrated together. The bypass valve support 132 and the charge air cooler end diffuser housing 150 may be separate components that may be closely-coupled to one another or they may be unitarv. The bypass valve support 132 may be in line with the first end 150a of the charge air cooler end diffuser housing 150.

The charge air cooler end diffuser housing 150 may form at least a first part 136a of a bypass valve housing 136. The first part 136a of the housing may receive the bypass valve support 132. The charge air cooler end diffuser housing 150 may be configured to mate with a second part 136b of the bypass valve housing 136. The first and second parts 136a, 136b may together form the bypass valve housing 136. The second part 1361) of the bypass valve housing 136 may comprise the valve scat on an inner surface of the housing for the valve element 134 to selectively seal against.

In the particular arrangement shown, the charge air cooler end diffuser housing 150 may comprise a flange 152 to mate with the second part 136b of the bypass valve housing 136. The flange 152 may comprise a radially inner portion that is axially set back from a radially outer portion 152a so as to define an annular recess for receiving the bypass valve support 132. The bypass valve support 132 and flange outer portion 152a may together mate with a flange 137 of the second part 136b of the bypass valve housing 136.

With reference to Figure 5, the bypass valve support 132 may comprise a hub 138 configured to receive the valve element 134 of the bypass valve. The hub 138 may be supported by at least one spoke 139. The spoke(s) 139 may connect the hub 138 to an outer ring 131 of the bypass valve support. The outer ring 13 I may be received in the annular recess of the flange 152. In addition to extending in a radial direction, the spoke(s) 139 may extend in an axial direction, e.g. so that the spoke(s) connect to the hub 138 at a location upstream of the outer ring 131.

Such an arrangement limits the effect of the bypass valve support 132 on the cross-sectional flow area at a particular axial location.

Referring still to Figure 5, the valve element 134 comprises a shaft 135a and a valve head 135b.

The shaft 135a is supported by the hub 138. The valve shaft 135a is movable, e.g. slidably movable, relative to the hub 138. The valve head 135b comprise a seal 135c or surface that may seal against the valve seat provided by the second part I36b of the bypass valve housing 136. The valve head I35b may be curved, e.g. dome shaped, and such curvature may assist flow through the bypass valve 130. A resilient element, such as a spring 135d, may urge the valve head 135b into sealing engagement with the valve seat.

The bypass valve support 132 may assist in diffusing the charge air flow across the inlet face of the charge air cooler heat exchanger to avoid the charge air flow being concentrated in a particular region of the heat exchanger. For example, the hub 138 may comprise a flared end 138a that flares radially outwards and is configured to direct a flow of charge air radially outwardly. This may assist in directing the flow away from the charge air cooler inlet. Additionally or alternatively, one or more of the spokes 139 may be configured, e.g. shaped or angled, to direct a flow of charge air in a lateral direction of the charge air cooler end diffuser housing 150. For example, the spoke may direct charge air in a direction perpendicular to an axial direction of the bypass valve support 132. Different spokes may direct the flow in different directions so that the charge air is more distributed across the width of the charge air cooler heat exchanger.

With reference to Figure 6, in another arrangement according to the present disclosure, the bypass valve support 132 may comprise at least one guide ring 133 disposed around the hub 138 and in the charge air flow path. The guide ring 133 may be concentrically disposed around the hub 138. The guide ring 133 may be configured (e.g. flared, angled or otherwise shaped) to redirect the flow of charge air. For example, the guide ring 133 may direct the charge air radially outwards and/or in a lateral direction of the charge air cooler end diffuser housing. The configuration of the guide ring 133 may vary about the circumference of the guide ring, e.g. so that the flow redirection varies about the circumference.

In addition to supporting the valve element 134, the bypass valve support 132 helps to redistribute the charge air flow towards the radial outer edges. This increases the flow away from the centre of the bypass valve support 132 and better distributes flow across the width of the heat exchanger (and thereby increases the effectiveness of the heat exchange or permits a smaller heat exchanger). Furthermore, the redirection of the incoming flow by the bypass valve support 132 provides increased flow velocities at the periphery of the inlet to the charge air cooler end diffuser housing 150. Having higher velocities at the edges provides a fuller boundary layer that is more resistant to flow separation. This allows the flow to remain attached to the walls of the charge air cooler end diffuser housing as it fans out. This in turn permits a more compact charge air cooler end diffuser housing 150 and a wider (and hence shorter) charge air cooler. The bypass valve 130 is also closer to the charge air cooler 140, which further reduces package space Due to limited package space, it is desirable for the charge air cooler to have a shorter length.

To maintain the same heat exchange surface area, this requires a larger cross-sectional area for the charge air cooler. The arrangements of the present disclosure are thus well suited to this scenario as they better distribute the charge air flow across the width of the heat exchanger and thus permit shorter charge air coolers.

With reference to Figure 7, in an alternative arrangement, the valve element 134 may be omitted, e.g. for an engine configuration without the second pressure booster 20. This may be desirable, for example, in an arrangement without the second pressure booster 20 as it may allow a common charge air cooler end diffuser housing 150 and bypass valve support 132 arrangement to be used across a range of engine configurations. The valve element 134 may be added if needed. However, in another arrangement, the valve clement 134 may be fixed with respect to the bypass valve support 132, in particular the valve element may be fixed into the open position shown in Figure 4b. The bypass valve support 132 may be configured to receive the valve dement 134 such that the valve element may be selectively fixed (e.g. locked) or movable with respect to the bypass valve support depending on the engine configuration. In particular, the charge air cooler end diffuser housing 150 may receive a common bypass valve support 132 that can support the valve element in either a fixed or movable mode, which can be selected depending on the desired configuration (e.g. if a second pressure booster is present or not). Retaining the bypass valve support 132 and optionally the valve element 134 in an engine configuration without a second pressure booster may still be desirable, because the bypass valve support 132 (and optional valve element 134) may assist in better distributing the charge air across the width of the charge air cooler heat exchanger. It also simplifies product inventory and assembly.

It will be appreciated by those skilled in the art that although the invention has been described by way of example, with reference to one or more examples, it is not limited to the disclosed examples and alternative examples may be constructed without departing from the scope of the invention as defined by the appended claims.

Claims

Claims A charge air cooler end diffuser housing comprising an integrated bypass valve support configured to receive a valve element of a bypass valve.
2 The charge air cooler end diffuser housing of claim 1, wherein the charge air cooler end diffuser housing increases in cross-sectional area so as to diffuse an incoming charge air flow and the charge air cooler end diffuser housing extends between first and second ends, the first end having a smaller cross sectional area than the second end, and wherein the bypass valve support is in line with the first end.
3. The charge air cooler end diffuser housing of claim I or 2 further comprising the valve element.
4. The charge air cooler end diffuser housing of claim 3 wherein the valve element is movable with respect to the bypass valve support.
The charge air cooler end diffuser housing of claim 3, wherein the valve element is fixed with respect to the bypass valve support.
6. The charge air cooler end diffuser housing of any of the preceding claims, wherein the bypass valve support is configured to receive the valve element such that the valve element is selectively fixed or movable with respect to the bypass valve support.
7. The charge air cooler end diffuser housing of any of the preceding claims, wherein the charge air cooler end diffuser housing forms a first part of a bypass valve housing.
S. The charge air cooler end diffuser housing of claim 7, wherein the charge air cooler end diffuser housing is configured to mate with a second part of the bypass valve housing, the first and second parts of the bypass valve housing together forming the bypass valve housing.
9. The charge air cooler end diffuser housing of claim 8, wherein the second part of the bypass valve housing comprises a valve seat for the valve element to selectively seal against.
10. The charge air cooler end diffuser housing of claim 8 or 9, wherein the charge air cooler end diffuser housing comprises a flange to mate with the second part of the bypass valve housing.
11. The charge air cooler end diffuser housing of claim 10, wherein the flange comprises a radially inner portion that is set back from a radially outer portion, and wherein the inner portion of the flange receives the bypass valve support.
12. The charge air cooler end diffuser housing of claim 11, wherein the bypass valve support and flange outer portion together mate with a flange of the second part of the bypass valve housing.
13. The charge air cooler end diffuser housing of any of the preceding claims, wherein the bypass valve support comprises a hub configured to receive the valve element of the bypass valve.
14. The charge air cooler end diffuser housing of claim 13, wherein the hub is supported by at least one spoke.
15. The charge air cooler end diffuser housing of claim 14, wherein the spoke is configured to direct a flow of charge air in a lateral direction of the charge air cooler end diffuser housing.
16. The charge air cooler end diffuser housing of any of claims 13 to 15, wherein the hub comprises a flared end configured to direct a flow of charge air radially outwardly.
17. The charge air cooler end diffuser housing of any of claims 13 to 16, wherein the bypass valve support comprises at least one guide ring disposed around the hub and in the charge air flow path, the guide ring being configured to redirect the flow of charge air.
18. A charge air cooler assembly comprising the charge air cooler end diffuser housing of any of the preceding claims.
19. The charge air cooler assembly of claim 18 further comprising a charge air cooler, the charge air cooler end diffuser housing being configured to diffuse charge air across an inlet end of the charge air cooler.
20. The charge air cooler assembly of claim 18 or 19 further comprising the bypass valve.