Tube design for an air-to-air aftercooler

Abstract

An air-to-air aftercooler may include a tube configured to direct a flow of charged air. The tube may include at least one first protrusion located on a first interior surface of the tube, and a first longitudinal plane may extend through the at least one first protrusion. The tube may also include at least one second protrusion located on a second interior surface of the tube, and a second longitudinal plane may extend through the at least one second protrusion. Furthermore, the first longitudinal plane and the second longitudinal plane may intersect.

1 . An air-to-air aftercooler, comprising: 
 a tube configured to direct a flow of charged air, wherein the tube includes:    at least one first protrusion located on a first interior surface of the tube, wherein a first longitudinal plane extends through the at least one first protrusion;    at least one second protrusion located on a second interior surface of the tube, wherein a second longitudinal plane extends through the at least one second protrusion; and    wherein the first longitudinal plane and the second longitudinal plane intersect.    
   
   
       2 . The air-to-air aftercooler of  claim 1 , wherein the at least one first protrusion includes a plurality of first protrusions having first longitudinal planes.  
   
   
       3 . The air-to-air aftercooler of  claim 2 , wherein the first longitudinal planes of the plurality of first protrusions are substantially parallel to one another.  
   
   
       4 . The air-to-air aftercooler of  claim 2 , wherein the at least one second protrusion includes a plurality of second protrusions having second longitudinal planes.  
   
   
       5 . The air-to-air aftercooler of  claim 4 , wherein the second longitudinal planes of the plurality of second protrusions are substantially parallel to one another.  
   
   
       6 . The air-to-air aftercooler of  claim 4 , wherein the first longitudinal planes and the second longitudinal planes intersect to form a plurality of aligned vertices lying on a line extending perpendicular to a longitudinal axis of the tube.  
   
   
       7 . The air-to-air aftercooler of  claim 1 , wherein the at least one first protrusion contacts the at least one second protrusion.  
   
   
       8 . The air-to-air aftercooler of  claim 7 , wherein the contacting protrusions are joined with a weld.  
   
   
       9 . The air-to-air aftercooler of  claim 1 , wherein the at least one first protrusion and the at least one second protrusion are arranged in a substantially chevron-shaped formation.  
   
   
       10 . A method of making an air-to-air aftercooler tube, the method comprising: 
 deforming a metal plate to create at least one first protrusion and at least one second protrusion on a surface of the metal plate, wherein a first longitudinal plane extends through the at least one first protrusion and a second longitudinal plane extends through the at least one second protrusion, the first longitudinal plane intersecting with the second longitudinal plane;    rolling the plate into a tubular shape; and    joining a first and second edges of the plate to form a tube.    
   
   
       11 . The method of  claim 10 , wherein the deforming of the metal plate further includes creating a plurality of first protrusions and a plurality of second protrusions, with first longitudinal planes extending through the plurality of first protrusions and second longitudinal planes extending through the plurality of second protrusions.  
   
   
       12 . The method of  claim 11 , wherein the first longitudinal planes and the second longitudinal planes intersect to form a plurality of aligned vertices.  
   
   
       13 . The method of  claim 10 , wherein the rolling of the plate brings the at least one first protrusion and the at least one second protrusion into substantial contact.  
   
   
       14 . The method of  claim 13 , further including joining the at least one first protrusion and the at least one second protrusion with a weld.  
   
   
       15 . An engine assembly, comprising: 
 a turbocharger configured to compress intake air before it enters an engine air intake manifold; and    an air-to-air aftercooler operatively connected between the turbocharger and the engine air intake manifold, the air-to-air aftercooler comprising: 
 at least one tube configured to direct the compressed intake air, wherein the at least one tube includes: 
 at least one first protrusion located on a first interior surface of the tube, wherein a first longitudinal plane extends through the at least one first protrusion;  
 at least one second protrusion located on a second interior surface of the tube, wherein a second longitudinal plane extends through the at least one second protrusion; and  
 wherein the first longitudinal plane and the second longitudinal plane intersect.  
 
   
   
   
       16 . The engine assembly of  claim 15 , wherein the at least one first protrusion includes a plurality of first protrusions and first longitudinal planes, each first protrusion configured to cause turbulence in a flow of the compressed intake air.  
   
   
       17 . The engine assembly of  claim 15 , wherein the at least one second protrusion includes a plurality of second protrusions and second longitudinal planes, each second protrusion configured to cause turbulence in a flow of the compressed intake air.  
   
   
       18 . The engine assembly of  claim 15 , wherein the at least one first protrusion and the at least one second protrusion are arranged in a substantially chevron-shaped formation  
   
   
       19 . The engine assembly of  claim 15 , wherein the at least one first protrusion and the at least one second protrusion are in abutting contact.  
   
   
       20 . A tube configured to direct a flow of charged air, the tube comprising: 
 at least one first protrusion located on a first interior surface of the tube, wherein a first longitudinal plane extends through the at least one first protrusion;    at least one second protrusion located on a second interior surface of the tube, wherein a second longitudinal plane extends through the at least one second protrusion; and    wherein the first longitudinal plane and the second longitudinal plane intersect and extend at an angle with respect to a longitudinal axis of the tube.    
   
   
       21 . The tube of  claim 20 , wherein the at least one first protrusion includes a plurality of first protrusions and first longitudinal planes.  
   
   
       22 . The tube of  claim 21 , wherein the at least one second protrusion includes a plurality of second protrusions and second longitudinal planes.  
   
   
       23 . The tube of  claim 22 , wherein the first longitudinal planes and the second longitudinal planes intersect to form a plurality of aligned vertices lying on a line extending perpendicular to the longitudinal axis of the tube.  
   
   
       24 . The tube of  claim 20 , wherein the angle is greater than approximately 15 degrees.