FORM 2
THE PATENT ACT 1970 (as amended)
[39 OF 1970]
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
[See Section 10 and Rule 13]
TITLE: “AN INTERCOOLER OF AN AUTOMOBILE AND METHOD
THEREOF”
Name and address of the Applicant:
TATA MOTORS LIMITED, an Indian company having its registered office at
Bombay house, 24 Homi Mody Street, Hutatma Chowk, Mumbai 400 001, Maharashtra,
INDIA.
Nationality: INDIAN
The following specification particularly describes the invention the manner in which it is to be performed.

TECHINCAL FIELD
Embodiments of the present disclosure relates to an intercooler of an automobile, more particularly embodiments relates to the intercooler used in vehicles operating with turbocharged engines.
BACKGROUND OF DISCLOSURE
An internal combustion engine operated with a turbocharger increases the power output as compared to the naturally aspirated engine. Turbocharging however increases the temperature of the boost air. Due to high temperature the boost air has lesser molecules of air as compared to cooler air. Hence the boost air needs to be cooled in order to increase the air molecules entering the combustion chamber to improve the volumetric efficiency. Further, lowering the temperature of the intake air eliminates the danger of pre-detonation (knock) of the fuel air charge prior to ignition timing.
The intercooler or an after cooler is a heat exchanger. An Air-to-Air intercooler uses ambient air flowing over the fins to cool the intake air. Traditionally, air-to-air intercoolers are used for automobile applications because of their lower cost, reduced complexity and packaging-constrained applications.
Hot air from the turbocharger flows through tubes inside the intercooler. The boost air transfers heat to the tubes, warming the tubes and cooling the turbo air. Outside air passes over the tubes and between fins that are attached to the tubes. Heat is transferred from the hot tubes and fins to the atmospheric air. This cools the tubes while heating the outside air. The reduction in air temperature increases the density of the air, which makes for a denser charge entering the combustion chamber. It increases the efficiency of the induction system by reducing intake air heat created by the turbocharger.
When the engine and the inter-cooler of the vehicle are placed at the rear of the vehicle, the cold air available to cool the intercooler is less. The intercooler located in the vicinity of the turbocharger will always draw hot air from the vicinity of the turbocharger. Conventionally, when the intercooler is mounted at the rear of the vehicle forced air cooling is required to increase the cold air to pass over the intercooler for better cooling.

The intercooler fan sucks hot air from the turbocharger deteriorating the efficiency of the intercooler. Further the fan utilizes power from the engine which inturn reduces the efficiency of the engine.
In light of forgoing discussion, it is necessary to provide an intercooler which prevents the flow of hot air on to the fins and improves the flow of cooling fluid on to the fins to cool the intake air circulating in the tubes.
STATEMENT OF THE DISCLOSURE
Accordingly, the present disclosure provides an intercooler of an automobile comprising: an intercooler body consisting an inlet manifold on one end and an outlet manifold on other end; plurality of tubes consisting an internal flow path provided inside the intercooler body for supplying intake air from the inlet manifold to the outlet manifold; plurality of fins arranged on the tubes to facilitate heat exchange between the intake air and cooling fluid; and plurality of shields joined on predetermined peripheral locations of the intercooler body, and also provides for a method of cooling intake air by an intercooler, said method comprising acts of; passing the intake air through an inlet manifold, said inlet manifold is connected to a plurality of tubes having an internal flow path for circulating the intake air; and lifting a cooling air using a shield and guiding the lifted air using shields to increase air mass flow rate on to the fins of the intercooler for cooling the intake air.
SUMMARY OF THE DISCLOSURE
The shortcomings of the prior art are overcome and additional advantages are provided through the provision of system and method as claimed in the present disclosure.
Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
One embodiment of the present disclosure provides an intercooler of an automobile. The intercooler comprises, an intercooler body consisting of an inlet manifold on one end and

an outlet manifold on other end. Plurality of tubes provided inside the intercooler body, said tubes has an internal flow path for supplying intake air from the inlet manifold to the outlet manifold. Heat exchange between the intake air and cooling fluid is facilitated using plurality of fins arranged on the tubes. The intercooler further includes, plurality of shields joined on predetermined peripheral locations of the intercooler body.
In one embodiment of the present disclosure, shields are provided on top edge and vertical edge of the intercooler body respectively to prevent flow of hot air onto the fins.
In one embodiment of the present disclosure, a shield is provided on bottom edge of the intercooler body, said shield configured in the form of scoop to obstruct the cooling air flowing below the intercooler body and supply the same cooling air on to the fins for cooling the tubes.
In one embodiment of the present disclosure, the shield lifts up the cooling air and lifted cool air guided by the shields to enter into intercooler for increasing air mass flow rate onto the fins of the intercooler.
In one embodiment of the present disclosure, pluralities of brackets are joined on the intercooler body, wherein a said bracket comprises at least one hole to facilitate fastening of the intercooler.
In one embodiment of the present disclosure, the shields are joined to the intercooler body by a process selected from at least one of fastening, welding, brazing and fusing.
Another embodiment of the present disclosure provides a method of cooling intake air by an intercooler, said method comprising acts of; passing the intake air through an inlet manifold, said inlet manifold is connected to a plurality of tubes having an internal flow path for circulating the intake air; and lifting a cooling air using a shield and guiding the lifted air using shields to increase air mass flow rate on to the fins of the intercooler for cooling the intake air.

In one embodiment of the present disclosure, flow of hot air onto the fins is prevented using the shields.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
OBJECTIVES OF THE DISCLOSURE
One object of the present disclosure is to provide an intercooler which prevents the flow of hot air onto fins.
One object of the present disclosure is to provide an intercooler which improves the flow of cooling fluid onto the fins.
One object of the present disclosure is to provide an intercooler which improves overall efficiency of the engine.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
FIG. 1 illustrates a perspective view of an intercooler of the present disclosure.
FIG. 2 illustrates a block diagram which shows cooling air flow from front of the intercooler.

FIG. 3 illustrates a block diagram of engine compartment and air flow through an air duct and a scoop.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
To overcome the drawbacks mentioned in the background an intercooler which prevents the flow of hot air on to the fins and improves the flow of cooling fluid on to the fins to cool the intake air circulating in the tubes is provided.
FIG.1 is an exemplary embodiment which illustrates a perspective view of an intercooler (100). The intercooler (100) has some of the components like an intercooler body (101),

plurality of tubes provided in the intercooler body (101) and plurality of shields mounted on predetermined peripheral locations of the intercooler body (101).
The intercooler (100) comprises the intercooler body (101) of predetermined shape. The intercooler body (101) includes an inlet manifold (101a) in its one end and an outlet manifold (101b) at its other end. The inlet manifold (101a) is connected to an outlet of the turbocharger for supplying the intake air from turbo charger (107) to an intercooler (100). The intake air from the inlet manifold (101a) enters plurality of tubes connected to the inlet manifold (101a) to reduce the temperature of the intake air. The tubes are arranged with plurality of fins (105) on its surface to increase effective area of cooling. The tubes are connected to the outlet manifold (101b) for supplying cooled intake air to an engine cylinder. In one embodiment, heat from the intake air is conducted to the tubes and same is radiated to the atmosphere by passing air on the fins (105). The fins (105) increases effective area of heating thereby it facilitates greater amount of heat removal from the tubes.
The intercooler (100) further comprises plurality of shields mounted on predetermined peripheral locations of the intercooler body (101). A shield (102) is mounted on top edge of the intercooler body (101) and a shield (103) is mounted on vertical edge of the intercooler body (101) to prevent flow of hot air onto the fins (105). The shield (102) prevents the flow hot air coming from the vicinity of turbocharger (107) and shield (103) prevents the flow of hot air coming from the engine side, thereby improving the efficiency of the intercooler (100). Further, the shield (103) converge the cooling air flowing in the engine side on to the fins (105) for cooling the intake air. The shield (103) act as an air duct which obstructs the cooling air flowing in the engine side and circulates the same cooling fluid onto the fins (105), which result in cooling of intake air.
Further, a shield (104) is mounted on bottom edge of the intercooler body (101) to obstruct the cooling fluid flowing below the vehicle chassis and circulate the same cooling fluid onto the fins (105) for cooling the intake air. The shield (104) lifts up the cooling air and the lifted air is guided by the shields (102 and 103) for circulating the same on to the fins (105). This improves air mass flow rate on to the fins (105) results in

effective cooling of the intake air passed in the tubes. In one embodiment, the shields (102, 103 and 104) are joined to the intercooler body (101) by the process selected from a group comprising but not limited to fastening, welding, brazing and fusing.
In one embodiment of the present disclosure, one of vertical edge in the intercooler body (101) is configured to form a passage for outward flow of cooling fluid circulated on to the fins (105); thereby it avoids the recirculation cooling fluid. In one embodiment, plurality of brackets (106) are joined to the intercooler body (101), said brackets comprises atleast one hole on their surface to facilitate fastening of the intercooler (100) to the vehicle chassis.
In one embodiment, the shields (102, 103 and 104) are made of material selected from group but not limited to sheet metal, Polyurethane plastic and the said shields withstands temperature up to 250 degree Celsius. However, temperature withstandability can be varied based on requirement.
FIG. 2 is an exemplary block diagram which illustrates air flow from front of the intercooler. The cooling air flowing from the bottom of the intercooler body (101) is obstructed by the shield (104). The shield (104) is inclined at angle of 60 degrees. This inclination helps in lifting of the cooling air and circulates the same air through the intercooler (100). The lifted air is guided by the shields (102 and 103) to circulate onto the fins (105) of the intercooler (100). The shield (102) is inclined at 60 degrees in its end to increase air mass flow rate flowing on to the fins which results in effective cooling of intake air passed through the tubes. In one embodiment, the shields (102 and 103) also prevent the flow hot air from the vicinity of turbocharger (107) and from the sides of engine on to the fins (105), thereby improve the performance of the intercooler (100).
FIG. 3 is an exemplary embodiment illustrates a block diagram of engine compartment and air flow through an air duct (103) and a scoop (104). The cooling air flowing from the side of the engine and the wheels is converged by the shield (103) on to the fins (105) for cooling the intake air. The shield (103) is configured as an air duct which obstructs the cooling air flowing from the side of the engine and the wheels and circulates the same

through the intercooler (100). The cold air circulated by shields (103 and 104) is passed out from the intercooler (100) through the passage formed on vertical edge of the intercooler body (101), this avoids the recirculation of same cooling fluid on to the intercooler (100).
Advantages:
The present disclosure provides an intercooler which prevents a flow of hot air on to fins.
The present disclosure provides an intercooler which improves the flow of cooling fluid onto the fins, hence improves overall performance of the intercooler.
The present disclosure provides an intercooler which operates without the aid of engine, hence improves overall efficiency of the engine.
The present disclosure provides an intercooler which is compact and less weight when compared to the conventional intercoolers.
Equivalents
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory

phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and

embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
Referral Numerals;

Reference Number Description
100 Inter cooler
101 Inter cooler body
101a Inlet manifold
101b Outlet manifold
102 Shield provided on top edge
103 Shield provided on vertical edge
104 Shield provided on bottom edge
105 Fins
106 Brackets
107 Turbo charger

We claim
1. An intercooler (100) of an automobile comprising:
an intercooler body (101) consisting an inlet manifold (101a) on one end and an outlet manifold (101b) on other end;
plurality of tubes comprising an internal flow path provided inside the intercooler body (101) for supplying intake air from the inlet manifold (101a) to the outlet manifold (101b);
plurality of fins (105) arranged on the tubes to facilitate heat exchange between the intake air and cooling fluid; and
plurality of shields joined on predetermined peripheral locations of the intercooler body (101).
2. The intercooler as claimed in claim 1, wherein shield (102) and shield (103) are provided on top edge and vertical edge of the intercooler body (101) respectively to prevent flow of hot air onto the fins (105).
3. The intercooler as claimed in claim 1, wherein a shield (104) is provided on bottom edge of the intercooler body (101), said shield (103) configured in the form of scoop to obstruct the cooling air flowing below the intercooler body (101) and supply the same cooling air on to the fins (105) for cooling the tubes.
4. The intercooler as claimed in claim 1, wherein the shield (104) lifts up the cooling air and is guided by the shields (102 and 103) to enter into intercooler (100) for increasing air mass flow rate onto the fins (105) of the intercooler (100).
5. The intercooler as claimed in claim 1, wherein plurality of brackets (106) are joined on the intercooler body (101), wherein said brackets (106) comprises at least one hole to facilitate fastening of the intercooler (100).
6. The intercooler as claimed in claim 1, wherein the shields (101, 102 and 103) are joined to the intercooler body (101) by a process selected from at least one of fastening, welding, brazing and fusing.

7. A method of cooling intake air by an intercooler (100), said method comprising
acts of;
passing the intake air through an inlet manifold (101a), said inlet manifold (101a) is connected to a plurality of tubes having an internal flow path for circulating the intake air; and
lifting a cooling air using a shield (104) and guiding the lifted air using shields (102 and 103) to increase air mass flow rate on to the fins (105) of the intercooler (100) for cooling the intake air.
8. The method as claimed in claim 7, wherein flow of hot air onto the fins (105) is prevented using the shields (102 and 103).
9. A vehicle comprising an intercooler (100) as claimed in the claim 1.
10. An intercooler (100) of an automobile and a method of cooling intake air by an intercooler (100) are substantially as herein above described and as illustrated in accompanying drawings.