US20180156104A1 - Intercooler having a condensate collector - Google Patents

Intercooler having a condensate collector Download PDF

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Publication number
US20180156104A1
US20180156104A1 US15/575,381 US201615575381A US2018156104A1 US 20180156104 A1 US20180156104 A1 US 20180156104A1 US 201615575381 A US201615575381 A US 201615575381A US 2018156104 A1 US2018156104 A1 US 2018156104A1
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US
United States
Prior art keywords
condensate collector
intercooler
condensate
expansion chamber
collector
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/575,381
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English (en)
Inventor
Stefan Dieterle
Thomas Strauss
Christian Buerck
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mahle International GmbH
Original Assignee
Mahle International GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mahle International GmbH filed Critical Mahle International GmbH
Publication of US20180156104A1 publication Critical patent/US20180156104A1/en
Assigned to MAHLE INTERNATIONAL GMBH reassignment MAHLE INTERNATIONAL GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DIETERLE, STEFAN, STRAUSS, THOMAS, BUERCK, CHRISTIAN
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B29/00—Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
    • F02B29/04—Cooling of air intake supply
    • F02B29/045—Constructional details of the heat exchangers, e.g. pipes, plates, ribs, insulation, materials, or manufacturing and assembly
    • F02B29/0468—Water separation or drainage means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B29/00—Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
    • F02B29/04—Cooling of air intake supply
    • F02B29/045—Constructional details of the heat exchangers, e.g. pipes, plates, ribs, insulation, materials, or manufacturing and assembly
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
    • F02M25/022—Adding fuel and water emulsion, water or steam
    • F02M25/0221—Details of the water supply system, e.g. pumps or arrangement of valves
    • F02M25/0222—Water recovery or storage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
    • F02M25/022—Adding fuel and water emulsion, water or steam
    • F02M25/0221—Details of the water supply system, e.g. pumps or arrangement of valves
    • F02M25/0225—Water atomisers or mixers, e.g. using ultrasonic waves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M25/00—Engine-pertinent apparatus for adding non-fuel substances or small quantities of secondary fuel to combustion-air, main fuel or fuel-air mixture
    • F02M25/022—Adding fuel and water emulsion, water or steam
    • F02M25/025—Adding water
    • F02M25/028—Adding water into the charge intakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F17/00—Removing ice or water from heat-exchange apparatus
    • F28F17/005—Means for draining condensates from heat exchangers, e.g. from evaporators
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
    • F28D2021/0082—Charged air coolers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2230/00—Sealing means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2275/00—Fastening; Joining
    • F28F2275/08—Fastening; Joining by clamping or clipping
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/06—Arrangements for sealing elements into header boxes or end plates by dismountable joints
    • F28F9/14—Arrangements for sealing elements into header boxes or end plates by dismountable joints by force-joining
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to an intercooler comprising a condensate collector for collecting, in particular, condensate precipitated in the intercooler according to the preamble of claim 1 .
  • the invention further relates to an internal combustion engine comprising such an intercooler as well as a to a condensate collector.
  • a generic intercooler which comprises a condensate collector for collecting condensate precipitated in the intercooler.
  • the condensate collector is connected to the internal combustion engine, that is, the manifold thereof, via a hose element so as to be able to optionally supply precipitated condensate to the combustion process.
  • a combustion engine arrangement which comprises an internal combustion engine, a charge-air compressor, an intercooler as well as a charge-air line. It is provided here that, at the lowest point of the intercooler's air channel, the intercooler has a closable condensate discharge opening which is connected to the charge-air line via a condensate discharge line. In this case, the condensate collector represents an integral part of the intercooler.
  • a device for exhausting condensate oil precipitated in an air collecting tank of an intercooler is known.
  • the known device is composed of a suction pipe which extends into an air collecting tank and into a container and from which the condensate oil can be admixed again to the charge air in form of droplets and finely dispersed.
  • a generic intercooler for an internal combustion engine comprising a plurality of substantially parallel pipes and at least one collector on the output side, each of the pipes opening into the output-side collector and a gas flow flowing into the collector and out of the collector into an outlet of the collector.
  • a structure for interacting with the gas flow is formed either on the pipes or the collector, wherein transport of a condensate to the outlet is carried out by means of the structure.
  • condensate occurs in the intercooler: on the one hand, preferably at low load and low charge pressure and, on the other hand, in the case of low-pressure exhaust-gas recirculation.
  • This may result in the charge-air-cooling operation being adversely affected, in particular at an ambient temperature below the freezing point at which the condensate can freeze.
  • the passage of the charge air through the intercooler can be blocked partially or entirely.
  • the volume expansion of the water as it freezes which may result in burst pipes of the intercooler.
  • a sudden input of the entire amount of collected condensate into the internal combustion engine may in some cases cause irreparable damage to the internal combustion engine.
  • the present invention therefore deals with the problem of specifying, for an intercooler of the generic type, an improved or at least an alternative embodiment, which overcomes in particular the disadvantages which are known from the prior art.
  • the present invention is based on the general idea of equipping an intercooler with a specially designed condensate collector for collecting, in particular, condensate precipitated in the intercooler, wherein this specially designed condensate collector has an equalizing volume which can be utilized in the case of a freezing process of the condensate, and as a result of which damage from freezing, in particular destroying a wall of the condensate collector or of condensate collector lines, can be reliably prevented.
  • the condensate collector is formed separately from the intercooler and arranged below the same and has at least one expansion chamber which, during the operation of the intercooler, is arranged above an inlet and above an outlet of the condensate collector and for this reason only contains air and absorbs no condensate in the liquid state.
  • the at least one expansion chamber is attached on the condensate collector in a bump-like manner and due to this position, together with being arranged above the inlet and the outlet of the condensate collector, cannot be filled with liquid condensate during the normal operating state of the intercooler.
  • the at least one expansion chamber always provides a sufficient air volume which is sufficient to provide enough space in the event of unexpected freezing of the condensate in the condensate collector so that the condensate freezing therein can expand and therefore cannot cause a bursting effect in the condensate collector affecting the functional reliability thereof.
  • the condensate collector designed according to the invention it is possible for the first time to design the latter in a freezeproof manner thereby reliably avoiding damages which, up to now, were caused, for example, by freezing condensate.
  • the volume of the at least one expansion chamber comprises at least 10% of the volume of the condensate collector. While the water is freezing, the volume thereof increases by approx. 9%, that means that an expansion chamber which is provided in the condensate collector according to the invention and the volume of which comprises at least 10%, in particular 10-15% of the volume of the condensate collector, is sufficient to absorb the volume increase of the frozen condensate without any problems, even if the condensate collector is completely filled with condensate.
  • the at least one expansion chamber it is possible here for the at least one expansion chamber to be distributed over a plurality of separate expansion chambers or to be combined within a single common expansion chamber.
  • At least one expansion chamber forms an integral part of the condensate collector. This offers the great advantage that the at least one expansion chamber can be produced together with the condensate collector, for example in a common plastic injection molding process. Such a production not only ensures a high-quality production but at the same time also a cost-effective production.
  • At least one wall of the expansion chamber is formed elastically and the expansion chamber can thus be expanded.
  • Such an elastic formation of the wall can be achieved, for example, by means of a reduction in wall thickness so that the additional volume occurring during the freezing of the condensate can be compensated for by bulging or pressing-back of the wall.
  • the expansion space and/or the condensate collector are/is made from plastics or from aluminum, wherein, in particular in the region of the expansion chamber, no stiffening ribs are provided, which would impede expansion and thus an elastic backward movement of the wall during the freezing of the condensate.
  • a wall of the condensate collector can, of course, also be formed elastically.
  • At least one expansion chamber is arranged externally with respect to the condensate collector.
  • An expansion chamber arranged externally in such a manner can be connected to the condensate collector via a hose connection, for example.
  • the expansion chamber can also have a balloon-like structure and thus react particularly elastically to volume changes of condensate freezing in the condensate collector.
  • the hose connection can also be implemented, for example, by means of an elastic hose, in particular a rubber hose, which also allows elastic expansion under pressure caused by freezing.
  • the present invention is further based on the general idea of specifying a condensate collector for a previously described intercooler which has a condensate inlet and a condensate outlet as well as at least one expansion chamber which, in operation, is arranged above the inlet and the outlet and thus is not accessible for liquid condensate.
  • this at least one expansion chamber there is therefore always a compressible air cushion which, while the condensate accumulated in the condensate collector is freezing, can be utilized to provide an equalizing volume for the volume increase of the frozen condensate.
  • Such a condensate collector according to the invention can also be easily installed as a retrofit part in previously used intercoolers.
  • the condensate collector is attached, in particular welded, soldered, glued, screwed or clipped onto the air-outlet tank.
  • This non-exhaustive list already reveals the various possibilities available for attaching the condensate collector to the air-outlet tank, namely by means of detachable connections as well as by means of non-detachable connections.
  • screwing or clipping also makes it possible to increase the ease of maintenance and repair, since the condensate collector can be easily detached from the air-outlet tank and, for example, a condensate drain in the air-outlet tank can be cleaned.
  • the air-outlet tank can be designed as a diffuser.
  • the condensate collector is integrated into the air-outlet tank and forms an integral part of the condensate collector. This can in particular be carried out in the manner of a double bottom below the air-outlet tank or the charge air cooler.
  • the size of the condensate collector depends primarily on the expected amount of condensate. Due to the integration of the condensate collector into the air-outlet tank, assembly of the condensate collector on the air-outlet tank can be completely dispensed with, which eliminates these assembly costs, and the intercooler can be produced overall in a more cost-effective manner.
  • FIG. 1 shows a sectional view through an intercooler according to the invention in the region of an air-outlet tank and a condensate collector
  • FIGS. 2-6 show different possible embodiments of a condensate collector according to the invention.
  • an intercooler 1 according to the invention of an internal combustion engine 2 , which is otherwise merely indicated, has a heat-exchanger block 3 , an air-inlet tank, which is not shown but is located upstream of the heat-exchanger block as viewed in the flow direction 4 , and an air-outlet tank 5 . Also provided is a condensate collector 6 for collecting condensate 7 precipitated in the intercooler 1 .
  • the condensate 7 here runs via a discharge opening 8 , which is arranged in the bottom of the air-outlet tank 5 , into the condensate collector 6 , which is arranged therebelow.
  • a condensate line 9 is provided, said condensate line being connected to the condensate collector 6 via an entrance 10 .
  • the condensate line 9 opens out into the air-outlet tank 5 via an exit, which is not shown, wherein a pressure difference p 1 >p 2 prevails between the entrance 10 and the exit of the condensate line 9 during operation of the intercooler 1 , which pressure difference effects a differential-pressure-induced discharge of condensate from the condensate collector 6 via the condensate line 9 into the air-outlet tank 5 .
  • the condensate collector 6 now has an expansion chamber 11 which, in operation of the intercooler 1 , is arranged above an inlet 12 and an outlet 13 of the condensate collector 6 . Due to the at least one expansion chamber 11 and the position thereof above the inlet 12 for condensate as well as the outlet 13 , this at least one expansion chamber 11 is not accessible for liquid condensate 7 during operation of the intercooler 1 , but rather represents an air volume which, in the frozen state, i.e., with the condensate 7 being frozen, is capable of equalizing the accompanying volume increase thereof.
  • a volume of the at least one expansion chamber 11 comprises here at least 10% of the volume of the condensate collector 6 , so that the volume increase during the freezing of the condensate 7 can be absorbed without any problems. If, for example, the condensate 7 is water, the volume increase thereof during freezing is only 9%, so that with an additional volume of the at least one expansion chamber 11 of at least 10% of the volume of the entire condensate collector 6 , a sufficient expansion volume is available.
  • the at least one expansion chamber 11 can form an integral part of the condensate collector 6 , as illustrated according to FIGS. 1 to 4 , for example.
  • the at least one expansion chamber 11 is arranged externally with respect to the condensate collector 6 , as is illustrated, for example, in the case of the embodiments of the condensate collector 6 according to FIGS. 5 and 6 .
  • the expansion chamber 11 is usually connected to the condensate collector 6 via a hose connection 14 .
  • the expansion chamber 11 and/or the condensate collector 6 can be made here from plastics or aluminum, wherein it can additionally be provided that at least one wall of the expansion chamber 11 and/or the condensate collector 6 is formed elastically thereby additionally allowing for a volume increase during freezing of the condensate 7 .
  • expansion chamber 11 Looking at the expansion chamber 11 according to FIG. 2 , it can be seen that there is only one additional expansion chamber 11 on this condensate collector 6 , while overall a plurality of expansion chambers 11 is provided in the case of the condensate collector 6 according to FIG. 1 as well as 3 and 4 .
  • the condensate collector 6 is attached on the air-outlet tank 5 of the intercooler 1 , for example welded, soldered, glued, screwed or clipped.
  • the condensate collector 6 forms an integral part of the air-outlet tank 5 of the intercooler 1 .
  • the latter creates for the first time a possibility to provide a sufficient expansion volume when the condensate freezes, which makes it possible to reliably prevent damages caused by freezing.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Water Supply & Treatment (AREA)
  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
US15/575,381 2015-05-20 2016-05-18 Intercooler having a condensate collector Abandoned US20180156104A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102015209209.7 2015-05-20
DE102015209209.7A DE102015209209A1 (de) 2015-05-20 2015-05-20 Ladeluftkühler
PCT/EP2016/061146 WO2016184917A1 (fr) 2015-05-20 2016-05-18 Refroidisseur d'air de suralimentation comprenant un collecteur de condensat

Publications (1)

Publication Number Publication Date
US20180156104A1 true US20180156104A1 (en) 2018-06-07

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ID=55970868

Family Applications (2)

Application Number Title Priority Date Filing Date
US15/575,381 Abandoned US20180156104A1 (en) 2015-05-20 2016-05-18 Intercooler having a condensate collector
US15/159,472 Expired - Fee Related US10100715B2 (en) 2015-05-20 2016-05-19 Inter cooler

Family Applications After (1)

Application Number Title Priority Date Filing Date
US15/159,472 Expired - Fee Related US10100715B2 (en) 2015-05-20 2016-05-19 Inter cooler

Country Status (4)

Country Link
US (2) US20180156104A1 (fr)
EP (2) EP3095995B1 (fr)
DE (1) DE102015209209A1 (fr)
WO (1) WO2016184917A1 (fr)

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KR102463703B1 (ko) * 2016-12-15 2022-11-07 현대자동차주식회사 배기유체 중의 물 배출장치 및 연료전지 차량용 소음기
EP3564613A1 (fr) * 2018-05-03 2019-11-06 Mann+Hummel GmbH Échangeur de chaleur, système d'admission d'air avec échangeur de chaleur et procédé de montage d'un échangeur de chaleur
JP2020127293A (ja) * 2019-02-05 2020-08-20 ファナック株式会社 ロータコアの製造装置及びロータコアの製造方法、並びにロータ構造
KR20210001022A (ko) * 2019-06-26 2021-01-06 현대자동차주식회사 인터쿨러 드레인장치
JP7287292B2 (ja) * 2020-01-20 2023-06-06 マツダ株式会社 エンジンの吸気装置
KR20220150083A (ko) * 2021-05-03 2022-11-10 현대자동차주식회사 인터쿨러의 응축수 제거장치 및 방법
CN116025491A (zh) * 2021-10-26 2023-04-28 本田技研工业株式会社 内燃机的进气装置
KR20230061842A (ko) * 2021-10-29 2023-05-09 현대자동차주식회사 엔진 시스템
CN115479482B (zh) * 2022-09-21 2023-05-02 浙江银钛制冷设备有限公司 一种空气冷却器
DE102022133931A1 (de) 2022-12-19 2024-06-20 Paul Hartmann Ag Verbindungseinrichtung zur unterdruckdichten fluidischen Verbindung eines Unterdruck-Wundverbands mit einer Unterdruckquelle, Unterdruck-Wundtherapiekit und Unterdruck-Wundtherapiesystem

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Also Published As

Publication number Publication date
EP3298256A1 (fr) 2018-03-28
WO2016184917A1 (fr) 2016-11-24
DE102015209209A1 (de) 2016-11-24
US20170022886A1 (en) 2017-01-26
EP3095995A1 (fr) 2016-11-23
EP3095995B1 (fr) 2018-09-19
US10100715B2 (en) 2018-10-16

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