US 12,228,349 B2
Modular intercooler block
Matthew Stevens, Riverside, CA (US); and Steve Williams, Cherry Valley, CA (US)
Assigned to K&N Engineering, Inc., Riverside, CA (US)
Filed by K&N Engineering, Inc., Riverside, CA (US)
Filed on Feb. 13, 2019, as Appl. No. 16/275,075.
Claims priority of provisional application 62/632,999, filed on Feb. 20, 2018.
Prior Publication US 2019/0257592 A1, Aug. 22, 2019
Int. Cl. F28F 9/02 (2006.01); B21D 53/08 (2006.01); B33Y 80/00 (2015.01); F28D 1/04 (2006.01); F28F 1/00 (2006.01); F28F 1/12 (2006.01); F28F 1/32 (2006.01)
CPC F28F 1/126 (2013.01) [B21D 53/08 (2013.01); B33Y 80/00 (2014.12); F28D 1/0443 (2013.01); F28F 1/006 (2013.01); F28F 1/32 (2013.01); F28F 9/0246 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A modular intercooler block, comprising:
a fabricated direct metal printed and configured modular intercooler block;
a multiplicity of cooling fins configured to allow passage of an airstream;
a first core header and a second core header disposed on opposite sides of the multiplicity of cooling fins;
a multiplicity of first countersunk holes arranged in an alternating row and column configuration on an outwardly-facing surface of the first core header, and a multiplicity of second countersunk holes arranged in an alternating row and column configuration on an outwardly-facing surface of the second core header, wherein the modular intercooler block has a first distance that extends from the outwardly-facing surface of the first core header to the outwardly-facing surface of the second core header, and wherein each of the first and second core headers have an inwardly-facing surface that is opposite to the outwardly-facing surface;
wherein an inlet of an inlet tank is in fluid communication with the multiplicity of second countersunk holes; and
a plurality of undulating core tubes directly coupled to the first countersunk holes and the second countersunk holes, each of the plurality of undulating core tubes is extended from each of the multiplicity of first countersunk holes in the first core header through the multiplicity of cooling fins and following an undulating path across the core fins to each of the respective multiplicity of second countersunk holes in the second core header, wherein each of the plurality of undulating core tubes has a second distance that extends from one end to another end that is opposite to the one end, and wherein the first distance is greater than the second distance, wherein the undulation path is such that each of the plurality of undulating core tube tubes extends through each cooling fin only once;
wherein a phase-shift between the undulating paths of adjacent undulating core tubes is 90 degrees; and
wherein the second distance is equal to a third distance from the inwardly-facing surface of the first core header to the inwardly-facing surface of the second core header.