Patent Publication Number: US-2023137500-A1

Title: Air Cooler with Water Separator

Description:
RELATED APPLICATIONS DATA 
     This application is a continuation application which claims priority to U.S. patent application Ser. No. 16/937,650, filed on Jul. 24, 2020, issuing as U.S. Pat. No. 11,542,859, which is hereby incorporated by reference in its entirety. 
    
    
     FIELD 
     Aspects of this invention relate generally to an air cooler with a water separator, and, in particular, to an air cooler with a water separator that includes a helical blade. 
     BACKGROUND 
     An air cooler, for example a charge air cooler, which may also be referred to as an intercooler or an aftercooler, may be used on engines, such as diesel engines, to cool engine air that has passed through the compressor (e.g., turbocharger or supercharger) before it enters the intake manifold and cylinders of the engine. 
     Turbo chargers compress air to increase power and efficiency. To further increase power and meet emission standards, that air needs to be cooled. This hot air may contain large quantities of moisture vapor which, as it condenses, contributes to corrosion, scale build-up, washing out of lubricant and possible freezing issues. 
     It would be desirable to provide an air cooler that reduces or overcomes some or all of the difficulties inherent in prior known devices. Particular advantages will be apparent to those skilled in the art, that is, those who are knowledgeable or experienced in this field of technology, in view of the following disclosure of the invention and detailed description of certain embodiments. 
     Particular objects and advantages of the invention will be apparent to those skilled in the art, that is, those who are knowledgeable or experienced in this field of technology, in view of the following disclosure of the invention and detailed description of certain preferred embodiments. 
     SUMMARY 
     Aspects of the present invention may be used to advantageously provide an air cooler with a water separator that improves the separation of water from the air stream before it enters the intake manifold and cylinders of an engine. The separation of water from the air stream may also be beneficial in other compressed air applications. 
     In accordance with a first aspect, an air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold. A water separator includes a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end. A water outlet is formed in a bottom surface of the chamber, and a channel is positioned beneath the water outlet. A condensate outlet is positioned on a bottom surface of the channel. A helical blade has a first end and a second end, and is positioned within the chamber between the air inlet and the air outlet. 
     In accordance with another aspect, an air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold. A water separator assembly includes a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold and extending substantially vertically, and an air outlet proximate the second end. The air outlet is formed of a first portion extending downwardly and outwardly from the chamber and has a first end positioned within the chamber and an opposed second end. A second portion is connected to the first end of the first portion and extends substantially horizontally. A water outlet including a plurality of slots is formed in a bottom of the chamber. A channel is positioned beneath the water outlet, and a condensate outlet extends downwardly and outwardly from a bottom surface of the channel. A helical blade has a first end and a second end, and is positioned within the chamber between the air inlet and the air outlet. A first end surface of the helical blade defines a first plane that extends substantially vertically within the chamber, and a second end surface defines a second plane that extends substantially vertically within the chamber. An interior edge of the helical blade defines a central aperture that extends along a longitudinal axis of the chamber, and an exterior edge of the helical blade extends along an interior surface of the chamber. 
     From the foregoing disclosure, it will be readily apparent to those skilled in the art, that is, those who are knowledgeable or experienced in this area of technology, that preferred embodiments of an air cooler as disclosed herein provide a significant technological advance in terms of improved removal of condensed water. These and additional features and advantages will be further understood from the following detailed disclosure of certain preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic perspective view, shown partially assembled, of an air cooler and a water separator connected to the air cooler. 
         FIG.  2    is a schematic perspective view, shown partially broken away, of the water separator connected to an air chamber outlet of the air cooler of  FIG.  1   . 
         FIG.  3    is a side elevation view, partially in section, of the water separator and air chamber outlet of  FIG.  1   . 
         FIG.  4    is an end elevation view, partially in section, of the water separator and air chamber outlet of  FIG.  1   . 
         FIG.  5    is a rear perspective view, partially in section, of the water separator and air chamber outlet of  FIG.  1   . 
         FIG.  6    is a schematic rear perspective view of the water separator and air chamber outlet of  FIG.  1   . 
     
    
    
     The figures referred to above are not drawn necessarily to scale and should be understood to provide a representation of the invention, illustrative of the principles involved. Some features of the air cooler depicted in the drawings have been enlarged or distorted relative to others to facilitate explanation and understanding. The same reference numbers are used in the drawings for similar or identical components and features shown in various alternative embodiments. Air coolers as disclosed herein would have configurations and components determined, in part, by the intended application and environment in which they are used. 
     DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS 
     The present invention may be embodied in various forms. An embodiment of an air cooler  10  with a water separator  12  connected thereto is shown in  FIG.  1   . Air cooler  10  may be a charge air cooler, for example. Air cooler  10  may be used, for example, to cool hot compressed air discharged from an engine turbocharger before it enters the intake manifold and cylinders of the engine. It is to be understood, however, that the air cooler is not limited to use in cooling hot air in engines, and may easily be used with fluids or gases in other fields. 
     For convenience, the terms “upper” and “lower” and “top” and “bottom” are used herein to differentiate between the upper and lower ends of the air cooler and particular elements. It is to be appreciated that “upper” and “lower” and “top” and “bottom” are used only for ease of description and understanding and that they are not intended to limit the possible spatial orientations of the air cooler or its components during assembly or use. 
     Air cooler  10  may include an air chamber inlet  14  that allows heated air to be introduced into an inlet manifold  16 . Heated air may then pass from inlet manifold  16  through a heat exchanger core  17 . In the illustrated embodiment, heat exchanger core  17  includes a plurality of flow tubes  18  with fins  19  on exterior surfaces thereof. For clarity purposes, only two finned flow tubes  18  are shown in  FIG.  1   . It is to be appreciated that other types of heat exchanger cores may be used to cool the heated air entering inlet manifold  16  through air inlet  14 . For example, in certain embodiments, flow tubes  18  could be provided without fins. Other exemplary heat exchanger cores include U-tube, single pass and double pass, and bar and plate heat exchanger cores. Other suitable heat exchanger cores will become readily apparent to those skilled in the art, given the benefit of this disclosure. 
     Cool air may be directed in the direction of flow arrow F across an exterior of the plurality of finned flow tubes  18 . It is to be appreciated that the flow of air across flow tubes may be created by a fan (not shown), or by natural convection. It is also to be appreciated that the direction of flow arrow F can extend in any direction. The air flowing through finned tubes  18 , which has been cooled by the air passing over the exterior surfaces of finned flow tubes  18 , may then pass to an outlet manifold  21 , and then from outlet manifold  21  on to water separator  12  through an air inlet  58  described below. 
     The cooled air leaving air cooler  10  by way of air outlet manifold  21  and entering water separator  12  may include water, which, as noted above, can be harmful to the engine. As the stream of air and water passes through water separator  12 , the water may be removed, thereby preventing water from entering the engine. 
     Water separator  12  and its components may be formed of a non-corrosive material. Water separator may be formed of a resin or plastic, or of metal. Exemplary metals include aluminum and stainless steel. Other suitable materials for water separator  12  will become readily apparent to those skilled in the art, given the benefit of this disclosure. 
     As illustrated in  FIGS.  2 - 6   , water separator  12  may include a chamber  50  having a first end  52 , an opposed second end  54 , and a sidewall  56  extending between first end  52  and second end  54 . In certain embodiments, chamber  50  may be substantially cylindrical in cross-section. 
     The term “substantially”, as used herein, is meant to mean mostly, or almost the same as, within the constraints of sensible commercial engineering objectives, costs, manufacturing tolerances, and capabilities in the field of water separator manufacturing and use. Similarly, the term “approximately” as used herein is meant to mean close to, or about a particular value, within the constraints of sensible commercial engineering objectives, costs, manufacturing tolerances, and capabilities in the field of water separator manufacturing and use. 
     An air inlet  58  may be positioned proximate first end  52  of chamber  50 , and may be connected to outlet manifold  21  of air cooler  10  such that chamber  50  is in fluid communication with heat exchanger core  17  air cooler  10 . The cooled air passing out of heat exchanger core  17  through outlet manifold  21  may enter chamber  50  of water separator  12  through air inlet  58 . Air inlet  58  may be substantially cylindrical in cross-section and may extend substantially vertically. It is to be appreciated that air inlet  58  may have any cross-sectional shape, and may be oriented in any desired direction. In certain embodiments, as illustrated in  FIG.  4   , a lower surface  60  of air inlet  58  may define a plane that is at an angle α with respect to longitudinal axis M of air inlet  58 , which is oriented in a vertical direction in this embodiment. In certain embodiments, angle α may be approximately 45°, however, it is to be appreciated that angle α may have any value. 
     Chamber  50  may also include an air outlet  62  positioned proximate second end  54 , and air may exit chamber  50  through air outlet  62 . In certain embodiments, air outlet  62  may be substantially cylindrical in cross-section. It is to be appreciated that air outlet  62  may have any cross-sectional shape. 
     As seen in  FIG.  5   , air outlet  62  may be formed of a first portion  64  having a first end  65  and an opposed second end  67 . First portion  64  may extend from an interior of chamber  50  downwardly and outwardly through sidewall  56 . A longitudinal axis D of first portion  64  may extend downwardly and outwardly at an angle β with respect to horizontal, as seen in  FIG.  6   . In certain embodiments, angle β may be approximately 45°. First end  65  of first portion  64  may be positioned within chamber  50  and may define a plane that extends substantially vertically. Second portion  66  may be connected to second end  67  of first portion  64  and extend substantially horizontally. It is to be appreciated that in other embodiments, air outlet  62  may be formed of a single portion, and may be oriented at any desired angle. 
     A helical blade  66  may be positioned within chamber  50 , and may have a first end  68  and an opposed second end  70 . First end  68  of helical blade  66  may, in certain embodiments, be positioned downstream of air inlet  58 . In other embodiments, first end  68  may be positioned upstream of air inlet  58 , while in other elements it may be positioned at air inlet  58 . Second end  70  of helical blade  66  may, in certain embodiments, be positioned upstream of air outlet  62 . In other embodiments, second end  70  may be positioned downstream of air outlet  62 , while in other elements it may be positioned at air outlet  62 . 
     In certain embodiments, first end  68  of helical blade  66  may have a first end surface  72  that extends substantially horizontally, and defines a first plane that extends substantially vertically within chamber  50 . It is to be appreciated that in other embodiments first end  68  may have any desired orientation. Similarly, second end  70  of helical blade  66  may have a second end surface  74  that extends substantially horizontally, and defines a second plane that extends substantially vertically within chamber  50 . It is to be appreciated that in other embodiments second end  70  may have any desired orientation. 
     Helical blade  60  may have a first surface  76 , an opposed second surface  78 , an exterior edge  80  extending between first surface  76  and second surface  78  from first end  68  to second end  70 , and an opposed interior edge  82  extending between first surface  76  and second surface  78  from first end  68  to second end  70 . In certain embodiments, exterior edge  80  may be in contact with an interior surface  84  of chamber  50 . Exterior edge  80  may be directly secured to interior surface  84  of chamber  50 , such as by welding, for example. In certain embodiments, exterior edge  80  may be spot or stitched welded at a plurality of points along its length, while in other embodiments, exterior edge  80  may be welded along an entirety of its length. As seen in  FIG.  5   , interior edge  82  of helical blade  60  may define a substantially cylindrical central channel  85  extending along an entire length of helical blade  60  coaxially with longitudinal axis L of helical blade  60 . 
     In the illustrated embodiment, first surface  76  and opposed second surface  78  of helical blade may be wound clockwise from first end  68  toward second end  70 . In other embodiments, first surface  76  and opposed second surface  78  of helical blade may be wound counterclockwise from first end  68  toward second end  70 . In certain embodiments, each of exterior edge  80  and interior edge  82  of helical blade  60  may complete a full revolution between first end  68  and second end  70  of helical blade  60 . It is to be appreciated that in other embodiments, exterior edge  80  and interior edge  82  may complete more or less than a full revolution between first end  68  and second end  70  of helical blade  60 . 
     A water outlet  86  may be positioned at a bottom of chamber  50  proximate second end  74  of helical blade  66  and proximate air outlet  62 , and serves to allow water to drain from chamber  50 . In certain embodiments, water outlet  86  may be in the form of a plurality of apertures or slots  88  extending through sidewall  56 , which allow water to drain out of chamber  50 . In certain embodiments, slots  88  may be racetrack shaped. Slots  88  may be collinear and have a common longitudinal axis S that extends substantially parallel to a longitudinal axis L of chamber  50 . It is to be appreciated that water outlet  86  can take any desired form including, for example, a screen or a perforated plate. 
     A gutter or channel  90  may be secured to a bottom of chamber  50  beneath grate  86 . Channel  90  may have a substantially cylindrical cross-section in certain embodiments, with a longitudinal axis A that extends substantially parallel to longitudinal axis L of chamber  50 . It is to be appreciated that channel  90  may have any desired cross-sectional shape. 
     A condensate outlet  92  may be connected to an outlet opening  94  on a bottom of channel  90 , allowing water to be drained out of channel  90 . In certain embodiments, condensate outlet  92  may have a substantially cylindrical cross-section. It is to be appreciated that condensate outlet  92  may have any desired cross-sectional shape. 
     As illustrated in  FIG.  3   , in certain embodiments, air outlet  62  may be positioned along longitudinal axis L of chamber  50  proximate a midpoint of grate  86 , and channel  90 . 
     As the heated air moves through chamber  50 , it is redirected by helical blade  66 , helping to remove moisture from the air. As the air moves along the surface of helical blade  66  and through central aperture  85 , the heavier drops of moisture fall off the interior edge  82  of helical blade  66 , and pass through water outlet  86  into channel  90 . 
     As seen in  FIGS.  4  and  6   , air inlet  58  may be positioned with chamber  50  such that its longitudinal axis M is spaced from longitudinal axis L of chamber  50  and proximate sidewall  56 , which helps introduce spin to the air flowing into chamber  50 , directing it along sidewall  56  and along helical blade  66 . 
     As seen in  FIG.  4   , first end  65  of first portion  64  of air outlet  62  may be positioned in a central portion of chamber  50  proximate longitudinal axis L, which can help prevent moisture from chamber  50  entering air outlet  62  as the air leaves chamber  50 . 
     Thus, while there have been shown, described, and pointed out fundamental novel features of various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. For example, it is expressly intended that all combinations of those elements and/or steps which perform substantially the same function, in substantially the same way, to achieve the same results are within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.