Tube design for an air-to-air aftercooler

• US 20070044939A1
• Filed: 08/30/2005
• Published: 03/01/2007
• Est. Priority Date: 08/30/2005
• Status: Abandoned Application

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Ma, Jiubo, Jin, Peitong, Hummel, Kyle, Heins, Kristen
• Application Number:
  US11/213,792
• Publication Number:
  US 20070044939A1
• Time in Patent Office: Days
• US Class Current: 165/41
• CPC Class Codes: F02B 29/0456 Air cooled heat exchangers
• CPC Class Codes: F28D 1/05366 Assemblies of conduits connected to common headers, e.g. core type radiators
• CPC Class Codes: F28D 2021/0082 Charged air coolers
• CPC Class Codes: F28F 1/40 the means being only inside the tubular element
• CPC Class Codes: F28F 13/12 by creating turbulence, e.g. by stirring, by increasing the force of circulation F28F13/08 takes precedence
• CPC Class Codes: F28F 3/04 the means being integral with the element
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An air-to-air aftercooler may include a tube configured to direct a flow of charged air. The tube may include at least one first protrusion located on a first interior surface of the tube, and a first longitudinal plane may extend through the at least one first protrusion. The tube may also include at least one second protrusion located on a second interior surface of the tube, and a second longitudinal plane may extend through the at least one second protrusion. Furthermore, the first longitudinal plane and the second longitudinal plane may intersect.

Claims

1. An air-to-air aftercooler, comprising:

a tube configured to direct a flow of charged air, wherein the tube includes;

at least one first protrusion located on a first interior surface of the tube, wherein a first longitudinal plane extends through the at least one first protrusion;

at least one second protrusion located on a second interior surface of the tube, wherein a second longitudinal plane extends through the at least one second protrusion; and

wherein the first longitudinal plane and the second longitudinal plane intersect.

2. The air-to-air aftercooler of claim 1, wherein the at least one first protrusion includes a plurality of first protrusions having first longitudinal planes.

3. The air-to-air aftercooler of claim 2, wherein the first longitudinal planes of the plurality of first protrusions are substantially parallel to one another.

4. The air-to-air aftercooler of claim 2, wherein the at least one second protrusion includes a plurality of second protrusions having second longitudinal planes.

5. The air-to-air aftercooler of claim 4, wherein the second longitudinal planes of the plurality of second protrusions are substantially parallel to one another.

6. The air-to-air aftercooler of claim 4, wherein the first longitudinal planes and the second longitudinal planes intersect to form a plurality of aligned vertices lying on a line extending perpendicular to a longitudinal axis of the tube.

7. The air-to-air aftercooler of claim 1, wherein the at least one first protrusion contacts the at least one second protrusion.

8. The air-to-air aftercooler of claim 7, wherein the contacting protrusions are joined with a weld.

9. The air-to-air aftercooler of claim 1, wherein the at least one first protrusion and the at least one second protrusion are arranged in a substantially chevron-shaped formation.

10. A method of making an air-to-air aftercooler tube, the method comprising:

deforming a metal plate to create at least one first protrusion and at least one second protrusion on a surface of the metal plate, wherein a first longitudinal plane extends through the at least one first protrusion and a second longitudinal plane extends through the at least one second protrusion, the first longitudinal plane intersecting with the second longitudinal plane;

rolling the plate into a tubular shape; and

joining a first and second edges of the plate to form a tube.

11. The method of claim 10, wherein the deforming of the metal plate further includes creating a plurality of first protrusions and a plurality of second protrusions, with first longitudinal planes extending through the plurality of first protrusions and second longitudinal planes extending through the plurality of second protrusions.

12. The method of claim 11, wherein the first longitudinal planes and the second longitudinal planes intersect to form a plurality of aligned vertices.

13. The method of claim 10, wherein the rolling of the plate brings the at least one first protrusion and the at least one second protrusion into substantial contact.

14. The method of claim 13, further including joining the at least one first protrusion and the at least one second protrusion with a weld.

15. An engine assembly, comprising:

a turbocharger configured to compress intake air before it enters an engine air intake manifold; and

an air-to-air aftercooler operatively connected between the turbocharger and the engine air intake manifold, the air-to-air aftercooler comprising;

at least one tube configured to direct the compressed intake air, wherein the at least one tube includes;

at least one first protrusion located on a first interior surface of the tube, wherein a first longitudinal plane extends through the at least one first protrusion;

at least one second protrusion located on a second interior surface of the tube, wherein a second longitudinal plane extends through the at least one second protrusion; and

wherein the first longitudinal plane and the second longitudinal plane intersect.

16. The engine assembly of claim 15, wherein the at least one first protrusion includes a plurality of first protrusions and first longitudinal planes, each first protrusion configured to cause turbulence in a flow of the compressed intake air.

17. The engine assembly of claim 15, wherein the at least one second protrusion includes a plurality of second protrusions and second longitudinal planes, each second protrusion configured to cause turbulence in a flow of the compressed intake air.

18. The engine assembly of claim 15, wherein the at least one first protrusion and the at least one second protrusion are arranged in a substantially chevron-shaped formation

19. The engine assembly of claim 15, wherein the at least one first protrusion and the at least one second protrusion are in abutting contact.

20. A tube configured to direct a flow of charged air, the tube comprising:

at least one first protrusion located on a first interior surface of the tube, wherein a first longitudinal plane extends through the at least one first protrusion;

at least one second protrusion located on a second interior surface of the tube, wherein a second longitudinal plane extends through the at least one second protrusion; and

wherein the first longitudinal plane and the second longitudinal plane intersect and extend at an angle with respect to a longitudinal axis of the tube.

21. The tube of claim 20, wherein the at least one first protrusion includes a plurality of first protrusions and first longitudinal planes.

22. The tube of claim 21, wherein the at least one second protrusion includes a plurality of second protrusions and second longitudinal planes.

23. The tube of claim 22, wherein the first longitudinal planes and the second longitudinal planes intersect to form a plurality of aligned vertices lying on a line extending perpendicular to the longitudinal axis of the tube.

24. The tube of claim 20, wherein the angle is greater than approximately 15 degrees.