Note: Descriptions are shown in the official language in which they were submitted.
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`` " INTERCOOLER FOR INTERNAL COMBUSTION ENGINE
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;- This invention relates to an intercooler for a
turbocharged internal combustion engine and more particu-
larly to an intercooler adapted for use with an intake
manifold which can be mounted with or without the inter-
cooler without modification of the manifold or the head on
the internal combustion engine.
An internal combustion engine operated as a
naturally aspirated engine is initially designed to
10 develop a predetermined horsepower, with a given piston
displacement. The engine when turbocharged will increase
horsepower output. Turbocharging, however, increases the
temperature oE the air, and accordingly when~the air i5
cooled an increased weight of air can be supplied to the
;~ 15 engine through the intake manifold. With an increase in
the weight of the air supplled~to the combustion chamber,
a greater amount of fuel can also be burned and the
`~ ~ horsepower output of the engine is increased.
Accordingly, an internal combustion engine can
` 20 be designed to run as a naturally aspirated engine or can
be designed to run as a turbocharged engine and the degree
of turbocharging depends on the horsepower to be delivered
from the engine. This can all be accomplished with a
fixed displacement by the pistons of the~engine. Accord-
ingly, this invention provides an intercooler which is
mounted as a spacer between the cylinder head and the
intake manifold. The intake manifold can be mounted
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directly on the cylindec head to provide a naturally
aspirated engine. Without modification, the intercooler
which operates as a spacer can be sandwiched between the
cylinder head and the intake manifoldO A suitable
fastening means is provided to fasten both the intake
manifold and intercooler on the cylinder head. The core
of the intercooler is integral with the wall structure of
the intercooler forming a passage for conveying the intake
air from the intake manifold to the cylinder head. Cool-
ing condui~s extend rom end to end oE the intercoolerwith suitable cooling fins to reduce the air temperature
as it passes through the intake manifold into the com-
bustion chamber. Accordingly, the intercooler eliminates
the complex manifold requiring special machining for the
`15 headers and sealing to allow for thermal expansion which
varies under normal operating conditions. The conven-
tional intercooler normally used on internal combustion
`engines floats in the intake manifold in the header
sealing arrangement which has been eliminated by this
version. The applicants' invention requires only a simple
finishing operation on planar surfaces of the intercooler
which is positioned between normally machined planar sur-
faces of the cylinder head and the intake manifold.
It is an object of this invention to provide an
intercooler on an internal combustion engine.
It is another object of this invention to pro-
vide an intercooler which operates as a spacer between the
intake manifold and the cylinder head. The engine can
operate as a naturally aspirated engine without the inter-
cooler or by selective positioning of the intercoolerbetween the intake manifold and the cylinder head without
modification to the engine to operate as a turbocharged
engine.
It is a further object of this invention to
provide an intercooler as an integral unit on an internal
combustion engine removably mounted between the intake
manifold and the cylinder head. The core of the inter~
cooler is integral with the support structure and adapted
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for use in an engine. The intercooler is machined so that
~` it can be sandwiched between the intake manifold and the
cylinder head since the complementary surfaces between the
- intercooler, the intake manifold and the cylinder head are
all mating surfaces permitting the interchangeable
~` operation of the engine as a naturally aspirated engine or
` a turbocharged engine.
The objects of this invention are accomplished
by providing an intake manifold which is machined to fit
on a cylinder head through complementary surfaces forming
an interface for mounting of the intake manifold on the
engine to operate the engine as a naturally aspirated
engine. The complementary surfaces are also machined on
an intercooler to allow the sandwiching of the intercooler
between the intake manifold and the cylinder head. Suit-
able gaskets are provided for sealing of the intake mani-
fold, the intercooler and the cylinder head. The inter-
cooler is an integral structure which is replaceably
mounted between the intake manifold and the cylinder head
- 20 with suitable fastening means. The intercooler is pro-
vided with coolant conduits extending between the ends of
the intercooler and cooling fins to provide cooling of air
passing through a cross passage formed in the intercooler.
The cross passage in the intercooler extends between a
turbocharger plenum chamber in the intake manifold and the
air delivery chamber in the cylinder head fo~ supplying
air to the combustion chamber of the internal combustion
engine.
In accordance with the invention, an internal
combustion engine having at least one cylinder comprising,
a cylinder head defining a side mounting surface for an
intake manifold and an air delivery chamber, an intake
;~ manifold defining a plenum chamber for receiving incoming
air, an integral intercooler forming a spacer mounted on
the side of said cylinder head and providing a cantilever
mounting of said intake manifold including, passage walls
forming a cross passage between said intake manifold and
- said cylinder head, peripheral reinforcing structure
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enclosing said passage walls on said intercooler for
rigidly supporting said manifold on said engine head, said
peripheral reinforcing structure defining bolt holes
extending continuously through said structure and aligned
with bolt holes in said head and intake manifold for
receiving common fastening means, coolant conduits extend-
ing the length of said cross passage of said intercooler
for circulating coolant fluid through said conduits, a
plurality of cooling fins interleaved along the cooling
conduits for cooling air passing through the said cross
passage, means defining cooling fluid chambers at the ends
- of said intercooler for circulating coolant fluid through
said intercooler, complementary mounting surfaces
including said side mounting surface on said cylinder head
and a surface on said intake manifold adapted or selec-
tively mounting said intake manifold directly on said
cylinder head to operate the engine as a naturally
aspirated engine, said intercooler defining complementary
mounting surfaces for selectively mounting said inter-
- 20 cooler between said cylinder head and said intake manifold
for supporting said intake manifold and a supercharger
when operating the engine as a supercharged engine.
Referring to the drawings, the preferred embodi-
ment of this invention is illustrated.
Fig. 1 illustrates a side elevation view of a
- turborcharged internal combustion engine.
Fig. 2 illustrates an end view of the turbo-
charged internal combustion engine.
Fig. 3 illustrates a cross section view of the
intake manifold, the intercooler and the cylinder head of
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`` the internal combustion engine taken on line III-III of
`~ Fig. 1.
Fig. 4 is a partially sectioned view of the
intercooler taken on line IV-IV as shown in Fig. 3.
Fig. 5 is a partial cross section view of ~he
intake manifold as viewed on line V-V of Fig. 4.
Referring to the drawings, Fig. 1 illustrates a
side elevation view of an internal combustion engine 1 and
a turbocharger 2 including a compressor 53 receiving air
from pipe 54 and which is delivered through the air pipe 3
- to the intake manifold 4. The intake manifold 4 is
~`~ mounted on the engine by a plurality of capscrews or studs
5 which extend through the intercooler to fasten to the
engine head 6. The intercooler is connected through the
- 15 couplings 7 and 8 to the cooling system. The hose 9 is
~` connected to the thermostat 10 to the coolant conduits 11
- connected through suitable means to a radiator for the
engine. Similarly, the hose 12 is connected to the other
side of the cooling system.
The intake manifold 4 is adapted for mounting
directly on the facing 21 for operation without the
- intercooler of the head 6. The intercooler 15, howeverl
is mounted between the intake manifold 4 and the cylinder
head 6 as shown in Figs. 2 and 3. The bolts 5 extend from
the intake manifold through the intercooler to fas~en to
- the head 6 of the engine.
Figs. 3, 4 and 5 show the intercooler 15 in its
mounting position on the engine. The intake manifold 4 is
connected to the air pipe 3 by means of the bolts 17 with
a gasket 18 providing a seal between the pipe 3 and the
intake manifold 4. The plenum chamber 19 is formed in the
manifold 4 to receive air discharge from the turbocharger
2. The plenum chamber 19 contains air which has been
pressurized by the turbocharger 2 which is to be supplied
to the combustion chamber. The intake manifold 4 is shown
fastened to the engine by means of the bolts 5 which
; extend from the manifold 4 through the intercooler 15 to
fasten to the cyLinder head 6. The gasket 22 is posi-
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tioned between the intake manifold 4 and the intercooler
15. Similarly, the gasket 23 is positioned between the
intercooler 15 and the facing 21 of the cylinder head 6
The facing 24 of the intake manifold is a planar facing
adapted for mounting on the facing 25 of the intercooler
or the facing 21 of the cylinder head 6~ Similarly, the
facing 21 is adapted for fastening to the face 24 of the
intake manifold 4 or the facing 26 of the intercooler 15.
The intercooler 15 is formed with a plurality o
sleeves 27, 28, 29 and 30 positioned between the flanges
31 and 32. Similarly, sleeves are positioned on the
opposite side of the intercooler oE which sleeve 33 is
shown in Fig. 3 between the flanges 34 and 35. The
sleeves reinforce the flanges and operate as spacers
between the flanges to hold the flanges rigidly in place
when the intercooler is fastened on the engine as shown in
Fig. 3. The intercooler 15 operates essentially as a
spacer between the intake manifold and the cylinder head 6
as shown. The plenum chamber 19 is connected by the cross
passage 36 to the air delivery chamber 37 in the cylinder
head 6.
Positioned in the cross passage 36 are a plur-
ality of coolant conduits 38 which extend rom the inlet
chamber 40 which is connected to the inlet port 39 to the
recirculating chamber 41. The coolant conduits 38 also
extend to the outlet chamber ~2 which is connected to the
outlet port 43. The coolant 10w is circulated through
the intercooler 15 by flowing from the inlet port 39 to
the opposite end of the intercooler and returning through
alternate coolant conduits to the outlet port 43 through
which it is discharged and re-enters the cooling system
for the internal combustion engine.
The coolant conduits 38 extend through multiple
interleaved cooling fins 44 which are mounted in the cross
passage 36 to essen-tially fill the cross passage 36. The
plenum chamber 19 receiving air discharged from the turbo-
charger distributes the air across the length of the cross
passage 36. The supply chamber 37 in the cylinder head
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receives the air passing through the cross passage 36 of
the intercooler 15 and distributes the air to a plurality
of cylinders of the internal combustion engine. For the
purpose of illustration, the engine as shown is a
4-cylinder in-line internal combustion engine.
The coolant conduits 38 are sealed at their ends
; in the inlet and outlet chambers 40 and 42 as well as the
recirculating chamber 41. For the purpose of illustra~ -
tion, a double pass of coolant fluid is shown in the
intercooler, although a multiple pass arrangement may be
provided by repositioning of portions in the inlet and
outlet chambers. The intercooler is an integral structure
providing air passage through the cross passage 36 of the
intercooler and circulation through the coolant conduits
for cooling of the air as it passes from the intake mani-
fold 4 to ~he supply chamber 37 shown in the engine
supplying air to the combustion chamber 20.
The operation of the engine and intercooler will
be described in the following paragraphs.
; 20 While the engine is running, exhaust gas is
exhausted through the exhaust manifold 50 and the turbine
51 to the exhaust pipe 520 The turbine 51 drives a com-
pressor 53 which pressurizes air coming from the air pipe
;~ 54 from ~he air cleaner and supplies air to the pipe 3
~ 25 connected to the intake manifold 4. Discharged air from
- the compresso,r 53 is supplied to the plenum chamber 19 of
the intake manifold 4 and the air passes through the cross
passage 36 of the intercooler 15. The air continues to
flow through the air supply chamber 37 in the cylinder
head 6 and the intake passage 55 to the combustion chamber
,' 20. The air compressed in the compressor by the turbo-
charger is heated due to the compression and accordingly,
the intercooler 15 i5 used to cool the air before it is
supplied to the engine. The hoses,9 and 12 supply and
return coolant fluid from the engine cooling system~ The
coolant fluid flows through the inlet port 39 to the inlet
chamber 40 and flows through connected coolan~ conduits 38
of the intercooler 15. All of the coolant fluid conduits
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are connected to the chamber 41, and accordingly the
coolant fluid is returned to the outlet chamber 42 and
flows through the outlet port 43 to return the coolant
fluid to the engine cooling system~ By use of the cooling
system, the heat is dissipated to the atmosphere for
normal operation of the engine. The intercooler in the
process of cooling the air allows a greater weight of air
to be supplied to the intake passage 55 and the combustion
chamber 20 of the engine. By increasing the weight of the
10 air supplied to the combustion chamber, an increased
amount of fuel can also be burned under normal combustion
conditions in the engine. This in turn increases the
power output of the engine for a given piston displacement
of the engine~
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