Fresh air supply device of an international combustion engine

Patent metadata

Field	Value
Publication number	US-10422273-B2
Application number	US-201414174829-A
Country	US
Kind code	B2
Filing date	Feb 6, 2014
Priority date	Feb 7, 2013
Publication date	Sep 24, 2019
Grant date	Sep 24, 2019

Abstract

A fresh air supply device for an internal combustion engine may include a suction module for conducting supercharged fresh air and a charge air cooler arranged in the suction module for cooling the supercharged fresh air. The suction module includes a housing with a charge air inlet for uncooled charge air and a charge air outlet for cooled charge air. The housing has a cooler shell, which may include the charge air inlet containing the charge air cooler and an assembly opening. With respect to a flow direction of the charge air the assembly opening may be arranged downstream of the charge air cooler and through which the charge air cooler is inserted into the cooler shell. The housing has a connecting shell, which includes the charge air outlet and which in the region of the assembly opening is attached to the cooler shell in an air-tight manner.

First claim

The invention claimed is:

1. A fresh air supply device for an internal combustion engine, comprising:
a suction module for conducting supercharged fresh air,
a charge air cooler arranged in the suction module for cooling the supercharged fresh air,
wherein the suction module includes a housing with a charge air inlet for uncooled charge air and a charge air outlet for cooled charge air,
the housing includes a cooler shell, which includes the charge air inlet containing the charge air cooler and an assembly opening, which with respect to a flow direction of the charge air the assembly opening is arranged downstream of the charge air cooler and through which the charge air cooler is inserted into the cooler shell, and
the housing has a connecting shell, which includes the charge air outlet and which in the region of the assembly opening is attached to the cooler shell in an air-tight manner,
wherein the cooler shell in a region that is distal from the assembly opening includes at least one receiving contour that is open towards the assembly opening, into which a leading plug contour of the charge air cooler dips in the assembly direction when inserting the charge air cooler;
wherein at least one tensile anchor is integrally formed on an onflow side of the cooler shell, which with respect to the flow direction of the charge air is arranged on an onflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the onflow side of the charge air cooler;
wherein the at least one tensile anchor is configured as a guide blade for the charge air, which extends curved in an inlet region having the charge air inlet and redirects charge air coming from the charge air inlet in the direction of the charge air cooler;
wherein the connecting shell contacts the cooler shell via a tongue and groove connection;
wherein the cooler shell encloses the charge air cooler in a circumferential direction on three sides, while a fourth side is arranged in the region of the assembly opening; and
wherein in the region of the charge air outlet a flap device is attached to the connecting shell via a closed circumferential tongue and groove connection.

2. The device according to claim 1 , wherein the charge air cooler includes a plurality of tubes which in their longitudinal direction run parallel to one another and a plurality of cooling fins which are connected to the tubes in a heat-transferring manner, wherein an assembly direction, in which the charge air cooler is inserted into the cooler shell through the assembly opening, runs perpendicularly to the longitudinal direction of the tubes.

3. The device according to claim 2 , wherein at least one tensile anchor is integrally formed on an outflow side of the connecting shell, which with respect to the flow direction of the charge air is arranged on an outflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the outflow side of the charge air cooler.

4. The device according to claim 2 , wherein the main flow direction of the charge air in the charge air cooler runs parallel to and is oriented opposite of the assembly direction.

5. The device according to claim 4 , wherein the cooler shell includes at least one fixing rib in a region that is distal from the assembly opening which extends parallel to the longitudinal direction of the tubes, the at least one fixing rib projecting opposite to the assembly direction and into the charge air cooler between adjacent tubes.

6. The device according to claim 2 , wherein at least one of the charge air cooler includes an inlet connection for feeding in a coolant, the inlet connection formed by an inlet connector that is separate with respect to the charge air cooler and the suction module, the inlet connection projecting into an inlet opening formed on the charge air cooler through an inlet passage opening formed in the housing of the suction module, and the charge air cooler includes an outlet connection for discharging a coolant, the outlet connection formed by an outlet connector that is separate with respect to the charge air cooler and the suction module, the outlet connector projecting into an outlet opening formed on the charge air cooler through an outlet passage opening formed in the housing.

7. The device according to claim 1 , wherein the connecting shell includes at least one stop contour facing the assembly opening, against which a support contour of the charge air cooler comes to bear opposite to the assembly direction.

8. The device according to claim 1 , wherein on the connecting shell at least one tensile anchor is integrally formed on an outflow side, which with respect to the flow direction of the charge air is arranged on an outflow side of the charge air cooler, the at least one tensile anchor connecting two wall portions located opposite one another on the outflow side of the charge air cooler.

9. The device according to claim 1 , wherein at least one of:
(1) the charge air cooler includes an inlet connection for feeding in a coolant, the inlet connection formed by an inlet connector that is separate with respect to the charge air cooler and with respect to the suction module, the inlet connector projecting into an inlet opening formed on the charge air cooler through an inlet passage opening formed in the housing of the suction module; and
(2) the charge air cooler includes an outlet connection for discharging a coolant, the outlet connection formed by an outlet connector that is separate with respect to the charge air cooler and with respect to the suction module, the outlet connector projecting into an outlet opening formed on the charge air cooler through an outlet passage opening formed in the housing.

10. The device according to claim 1 , wherein at least one of the suction module is plastic and the charge air cooler is metal.

11. The device according to claim 1 , wherein the main flow direction of the charge air in the charge air cooler runs parallel to the assembly direction, and is orientated opposite the assembly direction.

12. The device according to claim 1 , wherein the cooler shell in a region that is distal from the assembly opening includes at least one fixing rib, which extends parallel to the longitudinal direction of the tubes and projects opposite to the assembly direction, the at least one fixing rib projects into the charge air cooler between adjacent tubes.

13. A fresh air supply device for an internal combustion engine, comprising:
a suction module for conducting supercharged fresh air, the suction module including a housing with a charge air inlet for uncooled charge air and a charge air outlet for cooled charge air, and
a charge air cooler arranged in the suction module for cooling the supercharged fresh air,
wherein the housing includes a cooler shell, which includes the charge air inlet containing the charge air cooler and an assembly opening, which with respect to a flow direction of the charge air the assembly opening is arranged downstream of the charge air cooler and through which the charge air cooler is inserted into the cooler shell, and the housing has a connecting shell, which includes the charge air outlet and which in the region of the assembly opening is attached to the cooler shell in an air-tight manner,
wherein the connecting shell contacts the cooler shell via a tongue and groove connection,
wherein at least one tensile anchor is integrally formed on an outflow side of the connecting shell, which with respect to the flow direction of the charge air is arranged on an outflow side of the charge

Assignees

• Mahle Int Gmbh

Inventors

• Bruggesser Veit
• Morgillo Ivano
• Stehlig Juergen
• Fischer Oliver

Classifications

• F28F21/06

  of plastics material · CPC title

• F02B29/0475

  the intake air cooler being combined with another device, e.g. heater, valve, compressor, filter or EGR cooler, or being assembled on a special engine location · CPC title

• F28F2275/14

  by using form fitting connection, e.g. with tongue and groove · CPC title

• F28F2225/02

  for casings · CPC title

• F28F1/126

  consisting of zig-zag shaped fins (F28F1/105 takes precedence) · CPC title