A new range of liquid cooled charge air coolers (LCCACs) from Delphi Automotive will help global vehicle manufacturers of both gasoline and diesel engines produce environmentally-friendly vehicles with better engine performance. Compared to existing air-cooled units, the new coolers offer better packaging, improved engine response, faster warm-up and lower losses.
“Our new generation of charge air coolers will help vehicle manufacturers meet future targets for tailpipe emissions and improved fuel economy with cars that are still fun to drive,” said said James Bertrand, president Delphi Thermal Systems.
In order to combine reduced tailpipe emissions, improved fuel economy and maximum driver satisfaction, vehicle manufacturers are turning to downsized engines. Boosted by turbo- or super-charging, these engines give the performance feel of a larger engine with the emissions and fuel savings of a smaller one. However, boosting compresses the air entering the engine, which significantly increases the air temperature greatly reducing combustion efficiency and eroding the performance improvement.
Unlike an air-to-air charge cooler, a LCCAC requires no large diameter elastomeric tubing to route the charge air to and from the cooler, further improving packaging and eliminating large diameter connectors that can lead to warranty problems. Engine response to sudden throttle demand is improved because of the smaller volume of intake air between the boosting device and the engine in a liquid cooled system. Additionally, the intake air stays cooler during acceleration because the liquid cooled charge cooler heats up more slowly. This higher thermal capacity also helps to limit peak NOx emissions during transient driving conditions by maintaining cooler inlet air temperatures.