Plastic intercooler

Abstract

An intercooler comprises a plurality of plastic cooling tubes extending between a first end plate and a second end plate and a baffle arranged in the intercooler and extending at least partially between the first end plate and the second end plate. The baffle comprises a plurality of first openings for receiving a respective plastic cooling tube, the baffle further comprising a plurality of second openings arranged between the first openings. The second openings permit air to flow through the intercooler whilst creating turbulence in the air flow which increase the thermal transfer between the air and the tubes increasing the efficiency of the intercooler.

1 . An intercooler comprising:
 a plurality of plastic cooling tubes extending between a first end plate and a second end plate; and   a baffle arranged in the intercooler and extending at least partially between the first end plate and the second end plate, the baffle comprising a plurality of first openings for receiving a respective plastic cooling tube and a plurality of second openings arranged between the first openings.   
   
   
       2 . The intercooler according to  claim 1 , wherein the baffle has one or more folds to form a concertina shape. 
   
   
       3 . The intercooler according to  claim 1 , wherein the cross section of the plastic tubes is substantially circular and the first openings in the baffle for receiving the plastic tubes are oval shaped. 
   
   
       4 . The intercooler according to  claim 1 , wherein the plastic tubes have a non-circular cross section. 
   
   
       5 . The intercooler according to  claim 14 , wherein the tubes furthermore have a twisted form along their length. 
   
   
       6 . The intercooler according to  claim 1 , wherein the second openings in the baffle are circular. 
   
   
       7 . The intercooler according to  claim 1 , wherein the baffle is made from plastic, metal or card. 
   
   
       8 . An intercooler comprising:
 a first tank including a first end plate;   a second tank including a second end plate; and   a plurality of plastic tubes extending between the first and second end plates and in communication on distal ends with each of the first tank and the second tank, the plastic tubes including a non-arcuate cross-sectional shape.   
   
   
       9 . The intercooler as recited in  claim 8 , wherein the cross-sectional shape comprises a rectangle. 
   
   
       10 . The intercooler as recited in  claim 8 , wherein the cross-sectional shape comprises a square. 
   
   
       11 . The intercooler as recited in  claim 9 , wherein the cross-sectional shape is twisted at least once between the first end plate and the second end plate. 
   
   
       12 . The intercooler as recited in  claim 11 , wherein the cross-sectional shape is disposed along an axis and is rotated at least once about the axis. 
   
   
       13 . The intercooler as recited in  claim 8 , including a baffle for disrupting fluid flow over the plurality of plastic tubes. 
   
   
       14 . The intercooler as recited in  claim 13 , wherein the baffle includes a first plurality of openings through which extend the first plurality of tubes, and a second plurality of openings through which fluid flows. 
   
   
       15 . The intercooler as recited in  claim 8 , wherein the baffle is disposed at an angle relative to the direction of fluid flow over the plurality of plastic tubes.