Methods and systems for an engine

Patent metadata

Field	Value
Publication number	US-11255298-B2
Application number	US-202016856388-A
Country	US
Kind code	B2
Filing date	Apr 23, 2020
Priority date	May 6, 2019
Publication date	Feb 22, 2022
Grant date	Feb 22, 2022

Abstract

Methods and systems for an engine intake system are provided. In one example, a system includes a first charge air cooler arranged upstream of a second charge air cooler. The first charge air cooler is configured to provide thermal transfer between a compressed charge air and a fresh intake air.

First claim

The invention claimed is:

1. A system, comprising:
a first charge air cooler configured to provide thermal communication between a compressed charge air and an uncompressed intake air, wherein the first charge air cooler blocks the compressed charge air from mixing with the uncompressed intake air; and
a second charge air cooler configured to provide thermal communication between the compressed charge air and a liquid coolant.

2. The system of claim 1 , wherein the first charge air cooler is arranged in an intake line upstream of an exhaust gas recirculation line relative to a direction of air flow.

3. The system of claim 1 , wherein the uncompressed intake air flows through the first charge air cooler in a first direction and the compressed charge air flows through the first charge air cooler in a second direction, normal to the first direction.

4. The system of claim 1 , wherein the intake line comprises an intake bypass line and an intake bypass line valve, wherein the intake bypass line is configured to direct a portion of uncompressed intake air away from the first charge air cooler based on a position of the intake bypass line valve.

5. The system of claim 4 , wherein the first charge air cooler, the intake bypass line valve, and an air filter are housed in a housing.

6. The system of claim 1 , wherein a charge air line, which extends from a compressor outlet to an engine, comprises a first charge air cooler bypass line and a first charge air cooler bypass valve, wherein the first charge air cooler bypass line is configured to direct a portion of the compressed charge air away from the first charge air cooler based on a position of the first charge air cooler bypass valve.

7. An engine system with an internal combustion engine, an intake line for intake air arranged upstream of a compressor, an exhaust gas recirculation line opening into the intake line, and a charge air line which is arranged downstream of the compressor, wherein the engine system comprises:
a first charge air cooler configured as a gas-gas heat exchanger and arranged in a portion of the intake line upstream of the exhaust gas recirculation line relative to a direction of fresh air flow, wherein the charge air line is configured to flow compressed charge air from the compressor to the first charge air cooler; and
a second charge air cooler arranged in the charge air line, the second charge air cooler configured as a liquid-gas heat exchanger.

8. The engine system of claim 7 , wherein the exhaust gas recirculation line is a low-pressure exhaust gas recirculation line.

9. The engine system of claim 7 , wherein the first charge air cooler is arranged in a housing, wherein an air filter is arranged in the housing upstream of the first charge air cooler.

10. The engine system of claim 7 , wherein an intake bypass line configured to bypass the first charge air cooler is connected to the intake line upstream of the first charge air cooler at an inlet of the intake bypass line and downstream the first charge air cooler, between the first charge air cooler and the exhaust gas recirculation line at an outlet of the intake bypass line, wherein a volume flow ratio between the intake line and the intake bypass line is adjusted via an intake bypass valve.

11. The engine system of claim 7 , wherein the second charge air cooler is arranged downstream of the first charge air cooler and the compressor.

12. The engine system of claim 7 , wherein compressed charge air flowing through the first charge air cooler is blocked from mixing with fresh air flowing through the first charge air cooler while thermally communicating therewith.

13. The engine system of claim 7 , further comprising a first charge air bypass line and a first charge air bypass valve, wherein the first charge air bypass line is configured to flow compressed charge air from a portion of the charge air line upstream of the first charge air cooler to a portion of the charge air line between the first charge air cooler and the second charge air cooler.

14. An intake system for an engine, comprising:
a first charge air cooler configured to provide thermal communication between a compressed charge air and an uncompressed intake air;
a second charge air cooler configured to provide thermal communication between the compressed charge air and a liquid coolant; and
a controller with computer-readable instructions stored on non-transitory memory thereof that when executed enable the controller to:
adjust a position of at least one of an intake bypass line valve and a position of a first charge air cooler bypass valve in a first direction to flow more of the uncompressed intake air and the compressed charge air, respectively, through the first charge air cooler in response to a cold-start or an engine temperature exceeding a threshold temperature.

15. The intake system for the engine of claim 14 , wherein the instructions further enable the controller to adjust the position of at least one of the intake bypass line valve and the position of the first charge air cooler bypass valve in a second direction to flow less of the uncompressed intake air and the compressed charge air, respectively, through the first charge air cooler in response to an engine temperature being within a desired range and a temperature of the uncompressed intake air being above a dew point.

16. The intake system of claim 14 , wherein the first charge air cooler comprises at least one thermally conductive sheet arranged between a portion of a charge air line passing through the first charge air cooler and a portion of an intake air line passing through the first charge air cooler.

17. The intake system of claim 16 , wherein an exhaust gas recirculation line is fluidly coupled to the intake air line in a region between the first charge air cooler and a compressor.

18. The intake system of claim 14 , wherein the second charge air cooler is configured to thermally communicate with only compressed charge air.

Assignees

• Ford Global Tech Llc

Inventors

• Kuske Andreas
• Quix Hans Guenter
• Turner Paul Nigel

Classifications

• Y02T10/12

  Improving ICE efficiencies · CPC title

• F02M26/06 Primary

  Low pressure loops, i.e. wherein recirculated exhaust gas is taken out from the exhaust downstream of the turbocharger turbine and reintroduced into the intake system upstream of the compressor · CPC title

• F02M26/28

  with liquid-cooled heat exchangers · CPC title

• F02M31/06

  by hot gases, e.g. by mixing cold and hot air · CPC title

• F02M26/10

  having means to increase the pressure difference between the exhaust and intake system, e.g. venturis, variable geometry turbines, check valves using pressure pulsations or throttles in the air intake or exhaust system · CPC title