Intercooler System

Abstract

The present invention relates to an apparatus and a system that may be utilized to maximize and utilize greater air flow through an intercooler apparatus. The present invention utilizes unique coil configurations and designs to help promote better air flow through an intercooler apparatus. The present invention utilizes unique profiled passage separators to improve air flow through the passages of the intercooler. Additionally, the present invention utilizes profiled passage separators that improve and significantly cool temperatures of the air flow in much smaller packaging because of the unique passage separators and air flow design of the intercooler.

Claims

1. A heat exchange apparatus for improving fluid flow, the apparatus comprising: a hot fluid inlet end and a cooled fluid discharge end; an internal portion having a cooling fluid path contained within the internal portion of the heat exchange apparatus; a plurality of cooling fluid passageways in the cooling fluid path portion; and a plurality of profiled passageway separators.

2. The apparatus of claim 1, wherein the fluid path is utilized to cool a gaseous fluid.

3. The apparatus of claim 1, wherein the fluid path is utilized to cool a liquid fluid.

4. The apparatus of claim 1, wherein the plurality of profiled passageways are capped by a convex surface to funnel fluid more efficiently through the passageways.

5. The apparatus of claim 4, wherein the convex surface is connected to the passageway on the hot fluid inlet end of the heat exchange apparatus.

6. The apparatus of claim 4, wherein the convex surface is connected to the passageway on the cooled fluid discharge end of the heat exchange apparatus and the hot fluid inlet end of the heat exchange apparatus.

7. The apparatus of claim 1, wherein the apparatus applies basic fluid mechanics to the entry and exit of the cooling fluid passageways to improve air flow through the heat exchanger device.

8. The apparatus of claim 1, wherein the apparatus utilizes unique shaping of the passageways of the apparatus to greatly improve air flow through the apparatus.

9. The apparatus of claim 1, wherein the unique shaping comprises a wave-like coil configuration.

10. The apparatus of claim 1, wherein each cooling fluid passageway is separated from another cooling fluid passageway by a material.

11. The apparatus of claim 10, wherein the material is a metal.

12. The apparatus of claim 1, wherein the internal portion is adjacent to a plurality of end tanks.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIG. 1 is a side perspective view of the apparatus exterior in an exemplary embodiment of the present invention;

[0044] FIG. 2 is a side perspective view of the apparatus interior in an exemplary embodiment of the present invention;

[0045] FIG. 3 is a front cross-sectional view of the apparatus in an exemplary embodiment of the present invention;

[0046] FIG. 4 is a close-up view of the heat exchange apparatus illustrating the profiled passage separators in an exemplary embodiment of the present invention; and

[0047] FIG. 5 is another close-up view of the heat exchange apparatus illustrating the profiled passage separators in an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

[0048] The present invention relates to an apparatus and a system that may be utilized to maximize and utilize greater air flow through an intercooler apparatus. The present invention utilizes unique coil configurations and designs to help promote better air flow through an intercooler apparatus. The present invention utilizes unique profiled passage separators to improve air flow through the passages of the intercooler. Additionally, the present invention utilizes profiled passage separators that improve and significantly cool temperatures of the air flow in much smaller packaging because of the unique passage separators and air flow design of the intercooler.

[0049] FIG. 1 shows a heat exchange apparatus 100 in accordance with an embodiment of the present invention. In an exemplary embodiment of the present invention, an apparatus for cooling air to the engine of a vehicle is provided. Air flow 140, as hot air, enters the heat exchange apparatus through the hot fluid inlet end 110 of the end tanks 125. The specially designed shape of the end tanks 125 increases volumetric efficiency. Heat build-up is reduced, which keeps the intake charge cool. Smooth internal features minimize air turbulence and maximize air flow. By correctly shaping the entry into and out of the heat exchange apparatus 100, air flow is greatly increased. A more efficient intercooler lets the turbo and the motor run far cooler and produce more power.

[0050] In an exemplary embodiment, the apparatus 100 can be uniquely small as compared with the prior art intercooler designs because current intercooler technology is based on size for an application, so the higher the heat rejection requirement the larger the intercooler. With the current state of art in intercoolers, most other heat exchanging devices do not pay attention to the fluid flow entering and exiting the core of the exchanger. The unique design of the present apparatus allows for greater fluid flow through the intercooler to more adequately cool without the need for a larger sized intercooler apparatus.

[0051] FIG. 2 shows the internal portion 150 of the heat exchange apparatus 100 in accordance with an embodiment of the present invention. The coil configuration 120 may be seen in both the side and front view of the apparatus 100. Profiled passage separators 105 on the front and side of the apparatus 100 provide a shaped entry profile into each internal air passageway 135 (also referred to herein as a cooling fluid path) by forming bars of material, preferably being a metal or substantially rigid material, that separate each passage. Each passageway is separated from another passageway by a profiled passage separator 105. This structure serves to reduce the dimensions of the vena contracta in the flow path. Vena contracta is the point in a fluid stream where the diameter of the stream is the least, and fluid velocity is at its maximum.

[0052] FIG. 3 is a front cross-sectional view of the internal portion 150 in an exemplary embodiment of the present invention. The heat exchange apparatus 100 has a plurality of fluid flow passages that allow for cooling of the fluid flow there through and further wherein the passageway 135 has at least a hot fluid side inlet end 110 and a cooled fluid discharged end 115. Air flow 140 is seen entering the end tanks 125 of the heat exchange apparatus 100 at the hot fluid inlet end 110, passing through the cooling fluid passageways 135 by shaped entry due to the convex surfaces, and exiting at the cooled fluid discharge end 115. In an exemplary embodiment, a heat exchange apparatus is provided whereby the same profiles can be applied to the hot side and cold side of the intercooler. The concept is to provide a shaped entry profile into each internal air passageway 135 by forming the bars of material, profiled passage separator 105, that separate each passage. The heat exchange apparatus 100 has a plurality of fluid flow passageway 135 that allow for cooling of the fluid flow there through. The passageways have a distal portion and a proximal portion each ending with a uniquely configured abutment, preferably in the form of a convex surface 130.

[0053] FIG. 4 is a close-up view of the heat exchange apparatus 100 illustrating the profiled passage separators 105 in an internal portion 150. In an exemplary embodiment, the apparatus has a passageway 135 whereby fluid flow is channeled there through and cooling of the fluid flow is affected. The apparatus 100 utilizes convex shaping of the passageways of the intercooler to greatly improve air flow through the apparatus 100. Air flow 140 enters the hot fluid inlet end 110 by being funneled past the convex surface 130 of the profiled passage separators 105.

[0054] FIG. 5 is another close-up view of the heat exchange apparatus 100 illustrating the profiled passage separators 105 in an internal portion 150. The cooling fluid path 135, beginning at the hot fluid inlet end, ends at the cooled fluid discharge end 115. The apparatus applies basic fluid mechanics to the entry and exit of the hot side passages of the heat exchangers to improve air flow through the heat exchangers. The apparatus correctly and uniquely shapes the entry into and out of the passageway 135 of the apparatus 100 to greatly increase air flow.

[0055] Thus, specific embodiments and applications of an intercooler system have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. The terms comprises and comprising should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.