FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13) INTERCOOLER ASSEMBLY
APPLICANT: MAHlNDRA & MAHlNDRA LIMITED
an Indian Company of R&D Centre, Automotive Division, 89, M.I.D.C, Satpur, Nashik -422007,
Maharashtra, India.
Inventors: (a) PATADE VISHNU KEDARI and (b) RAMASAMY VELUSAMY
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
The present invention relates to cooling systems. Particularly, the present invention relates to intercoolers, aftercoolers or charge air coolers for cooling charging air compressed by a turbocharger or a supercharger.
BACKGROUND OF THE INVENTION
An intercooler, an aftercooler or a charge air cooler (hereinafter referred to
as "intercooler") is a heat exchanger device. The intercooler is used
on turbocharged and supercharged internal combustion engines to
improve volumetric efficiency of the engine by increasing intake air charge density through nearly constant pressure cooling. A decrease in intake air charge temperature facilitates use of a denser intake charge into the engine, as a result of supercharging. The lowering of the intake charge air temperature also eliminates the danger of pre-detonation (knock) of the fuel air charge prior to timed spark ignition. Additionally, the intercooler facilitates induction of more air mass into the engine cylinder.
Conventionally, intercoolers are mounted in front of the radiator. Accordingly, such placement of the intercoolers mounted in front of the radiator necessitates very long hoses. Generally, a temperature sensor is used for measuring the temperature of the cooled compressed air leaving the intercooler. The measured temperature of the cooled compressed air leaving the intercooler may be used by an Engine Control Unit (ECU) for managing various parameters of an engine.

Some of the prior art intercoolers are as follows:
For example, US4911135 patent having priority date of January 18, 1988 discloses an intake air cooling arrangement for a turbocharged internal combustion engine. The intake air cooling arrangement includes an intercooler for cooling the air which is conveyed from a turbocharger to an intake manifold of the engine; a first structure for mounting the intercooler just above the intake manifold; and a second structure for defining an air flowing way through which the outside air is forced to flow under running of the vehicle. The intercooler and the intake manifold are arranged in the air flowing way so that the outside air which has passed through the intercooler is directed toward the intake manifold to cool the same. Additionally, the intake air cooling arrangement includes two shorter brackets and two longer brackets for tightly holding the intercooler above the intake manifold. However, the intake air cooling arrangement of the US4911135 patent does not disclose a temperature sensor disposed on an outlet of an intercooler.
US6026775 patent having priority date of January 31, 1997 discloses an intake system for an engine. The intake system includes an intake manifold attached to an engine. A surge tank is attached to the engine and is located rearwardly of the engine. An air cleaner is attached to the engine and is located on one side of the engine. A resonator or intercooler is attached to the engine and is located adjacent the surge tank and the air cleaner. The resonator or intercooler is located above the engine. However, the intake system of the US6026775 patent does not disclose a temperature sensor disposed on an outlet of an intercooler.

US5910099 patent having priority date of Feb. 28, 1997 discloses a turbocharged engine cooling system. The turbocharged engine cooling system has separate, complete engine and aftercooler coolant loops connected by a linking conduit with a link valve and a fan apparatus providing air flow through both engine and aftercooler radiators. An engine cooling control is responsive to a coolant temperature in the engine coolant loop to control the fan apparatus and to derive and output a signal indicative of a desired level of cooling between the selected one and an adjacent one of the discrete cooling levels. An aftercooler cooling control is responsive to a coolant temperature in the aftercooler coolant loop and the signal output by the engine cooling control to control the link valve so as to vary the temperature of coolant in the engine cooling loop, by controlled mixing of coolant of lower temperature from the aftercooler cooling loop. The turbocharged engine cooling system includes three temperature sensors for providing temperature signals to the cooling system. However, the turbocharged engine cooling system of US5910099 patent does not disclose a temperature sensor disposed on an outlet of an intercooler. Additionally, the turbocharged engine cooling system of US5910099 patent does not disclose an intercooler mounted above an engine.
US6314950 patent having priority date of December 1, 2000 discloses a vehicle stated to be operating under various ambient conditions and various operating parameters. To compensate for the ambient conditions and the operating parameters of an engine, a donor intake air temperature is controlled. An ambient air flow restriction system is used to vary the flow of a recipient ambient air through an air to air aftercooler. A plurality of louvers is operatively moved between a closed position and an open position. A

controller interprets respective signals from a plurality of sensors to define the position of the plurality of louvers. The plurality of sensors is attached to the engine in predetermined locations. A plurality of wires is interposed the plurality of sensors and the controller and a signal is transmitted therethrough between the respective one of the plurality of sensors and the controller. However, the vehicle of the US6314950 patent does not discloses an intercooler mounted above an engine. Additionally, the vehicle of the US6314950 patent does not disclose a temperature sensor disposed on an outlet of an intercooler.
US7389759 patent having priority date of June 2, 2003 discloses an internal-combustion engine. The internal combustion engine includes cylinders arranged preferably in a V-formation with corresponding cylinder heads including connectors for the supply and discharge of fluids. The cylinders are mounted in a crankcase and are supplied with air for combustion by a cast air manifold running the length of the engine, the air manifold being located adjacent to the row of cylinders, preferably in the V. To reduce the amount of pipework the manifold has shaped connectors for at least one of the fluids, in particular the air intake and the water coolant, these connectors connecting directly to the relevant connectors on the cylinder head and being pressed against them by the pressure in the manifold. The internal-combustion engine includes an intercooler for a turbocharger arrangement, mounted directly on top of the air manifold. However, the internal combustion engine of the US7389759 patent does not disclose a temperature sensor disposed on an outlet of an intercooler.

US7051786 patent having priority date of July 11, 2003 discloses a non-rail off-road vehicle. The non-rail off-road vehicle includes a cooling system. The cooling system includes an engine cooling radiator positioned above an engine and between the engine and a hood and a fan unit with electric motor-driven fans blowing air upwardly through the radiator. An engine charge air cooler is also positioned above the engine and between the engine and the hood, and a charge air cooler fan unit has electric motor-driven fans which blow air upwardly through the cooler. The hood has openings in its upper surface through which passes air blown by the radiator fan unit and the charge air cooler fan unit. This cooling system blows heated cooling air vertically upwardly, thus preventing the heated cooling air from being drawn back into the intakes of the cooling system and preventing heated air from being blown onto the exterior of the tractor cab. Additionally, the vehicle includes a temperature control unit connected to bus and to an engine thermostat. However, the non-rail off-road vehicle of the US7051786 patent does not disclose a temperature sensor disposed on an outlet of an intercooler.
US7669417 patent having priority date of July 25, 2007 discloses an engine after-cooling system. The engine after-cooling system includes an after-cooler for cooling compressed air which is output from a compressor for combustion by an internal-combustion engine, a heat exchanger for cooling a coolant which is output from the after-cooler, a pump for continuously pumping the coolant through the system, an outlet air temperature sensor for sensing the temperature of the compressed air after being cooled by the after-cooler, a coolant temperature sensor for sensing the temperature of the coolant output from the after-cooler, and a controller for controlling the

flow-rate of coolant through the system in response to the sensed air and coolant temperatures. However, the outlet air temperature sensor for sensing the temperature of the compressed air after being cooled by the after-cooler is comparatively ineffective in providing vibration resistance.
US20080098998 publication having priority date of October 30, 2006 discloses a combustion air cooling system. The combustion air cooling system includes an aftercooler or intercooler operable to supply cooled air to the intake manifold of an engine. The aftercooler is mounted on top of the engine. A fan is operable to force ambient air through the aftercooler. A variable speed fan drive is operable to control the speed of the fan. The combustion air cooling system also includes an inlet manifold temperature sensor operable to detect the inlet manifold air temperature entering into the engine. However, the combustion air cooling system of the US20080098998 publication does not disclose a temperature sensor disposed on an outlet of an intercooler.
Accordingly, there is a need for an intercooler assembly that has a comparatively robust structure. Also, there is a need for an intercooler assembly that is adapted to preclude weakening of the hose pipe by preventing formation of holes thereon. Further, there is a need for an intercooler assembly that is comparatively more vibration resistant. Furthermore, there is a need for an intercooler that is comparatively cheap. Additionally, there is a need for an intercooler assembly that is relatively compact.

OBJECTS OF THE INVENTION
An object of the present invention is to provide an intercooler assembly that has a comparatively robust structure.
Another object of the present invention is to provide an intercooler assembly that is adapted to preclude weakening of the hose pipe by preventing formation of holes thereon.
Yet another object of the present invention is to provide an intercooler assembly that is comparatively more vibration resistant.
Still another object of the present invention is to provide an intercooler assembly that is comparatively cheap.
One more object of the present invention is to provide an intercooler assembly that is relatively compact.
An additional object of the present invention is to provide an intercooler assembly that improves air dynamics.
Also, an object of the present invention is to provide an intercooler assembly that reduces turbo lag.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention there is provided an intercooler assembly. The intercooler assembly includes an intercooler, a sensor housing, a sensor, and fitting means. The intercooler has an outlet spout. The sensor housing is disposed on the outlet spout. The sensor is

adapted to be fitted on the sensor housing. The fitting means are adapted to fit the sensor on the sensor housing.
Preferably, the intercooler is adapted to be mounted above an engine of a vehicle.
Typically, at least one support bracket is adapted to mount said intercooler above an engine of a vehicle.
Preferably, at least one support bracket is of sheet metal.
Furthermore, the intercooler is of aluminum material.
Typically, the sensor housing is disposed on the outlet spout of the intercooler by means of brazing.
In one embodiment of the present invention, the sensor is a temperature sensor.
Additionally, an inlet hose is adapted to connect a turbocharger assembly to the intercooler.
Also, an outlet hose is adapted to connect the outlet spout of the intercooler to an intake throttle of an engine of a vehicle.
Typically, the fitting means are complementary threads configured on the sensor housing and the sensor.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The invention will now be described in relation to the accompanying drawings in which,
Figure 1 illustrates a perspective view of an intercooler assembly connected to a turbocharger assembly, in accordance with one embodiment of the present invention;
Figure 2 illustrates a perspective view of the intercooler assembly of Figure 1 depicting air draft from a bonnet scoop;
Figures 3 illustrates perspective view of the intercooler assembly of Figure 1 mounted above an engine of a vehicle by means of support brackets;
Figure 4 illustrates enlarged perspective view of a sensor housing disposed on an outlet spout of the intercooler assembly of Figure 1;
Figure 5 illustrates a cross-sectional view of the sensor housing of Figure 4; and
Figure 6 and 7 illustrate perspective views of a sensor disposed on said sensor housing of Figure 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Preferred embodiments will now be described in detail with reference to the accompanying drawings. The preferred embodiments do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration.
The present invention provides an intercooler assembly for improving volumetric efficiency of the engine by increasing intake air charge density through nearly constant pressure cooling. The intercooler assembly of the present invention includes a sensor housing disposed on an outlet spout of the intercooler assembly for accommodating a sensor. As the sensor housing is disposed on an outlet spout of the intercooler assembly, there is no need of making holes on an outlet hose pipe of the intercooler assembly and thereby preventing weakening of the outlet hose pipe. Accordingly, the intercooler assembly of the present invention is more vibration resistant and has robust structure.
Referring to Figures 1 to 7, an intercooler assembly 100 is described. The intercooler assembly 100 includes an intercooler 102, a sensor housing 104, a sensor 106 (shown in Figures 6 and 7), and fitting means 108 (shown in Figures 4 and 5).
The intercooler 102 has an outlet spout 110. The intercooler 102 is adapted to be mounted above an engine of a vehicle. The intercooler 102 may be mounted above an engine of a vehicle by means of a pair of support brackets 112a and 112b (shown in Figure 3). The pair of support brackets 112a and

112b may be connected to intercooler brackets, such as intercooler brackets 114a and 114b by means of bolts. However, the present invention is not limited to any particular type of fastener used. Although, in the present embodiment of the present invention, the pair of support brackets 112a and 112b are used, the present invention is not limited to any number of support brackets used. In another embodiment of the present invention, the intercooler 102 may be mounted above an engine of a vehicle by means of one support bracket. Further, in one embodiment of the present invention, the pair of support brackets 112a and 112b may be of sheet metal. However, the present invention is not limited to any particular material used for manufacturing the pair of support brackets 112a and 112b.
Air draft (shown in Figure 2 by downward arrows) required for the intercooler 102 is provided through a scoop configured in the bonnet. The air draft is adapted to be directed above fin arrangement configured on an external surface of the intercooler 102 from the bonnet scoop for cooling of the hot air coming from a turbocharger assembly 116. The turbocharger assembly 116 receives air from an air filter. The direction of the flow of the air from the scoop is from top to bottom. Sides of the intercooler 102 get sealed when the bonnet is shut. The intercooler 102 is adapted to cool the hot air coming from the turbocharger assembly 116 before entry into the engine. Cooling of the air increases its density and more air mass can be inducted into the engine cylinder. The intercooler 102 includes an inlet hose 118 and an outlet hose 120. The inlet hose 118 is adapted to connect compressor of the turbocharger assembly 116 to an intercooler inlet. The air filter is connected to the compressor of the turbocharger assembly 116 with the help of a molded hose (not shown).

The outlet hose 120 is adapted to connect the outlet of the intercooler to the intake throttle of engine. In one embodiment of the present invention, the outlet hose 120 is adapted to connect the outlet of the intercooler to the intake throttle of engine through EGR mixer. In one embodiment of the present invention, the inlet hose 118 and the outlet hose 120 are clamped on intercooler spouts with the help of patented Waveseal clamps by M/s Ideal. The intake hose 116 and the outlet hose 120 of the present invention are adapted to have shorter length as the intercooler 102 is mounted on top of the engine. Due to shortening of the length of the intake hose 116 and the outlet hose 120, the material cost is saved and accordingly there is significant cost saving in construction of the intercooler assembly 100. Further, shortening of the length of the intake hose 116 and the outlet hose 120 facilitate in having more compact design of the intercooler assembly 100. Additionally, short air passages improve air dynamics and reduces turbo lag. Accordingly, mounting of the intercooler assembly 100 above the engine is a more compact and less expensive.
Although, in the present embodiment of the present invention, the intercooler 102 is described as an air to air heat exchanger. However, the present invention is not limited to any particular heat exchange means used. Alternatively, in another embodiment of the present invention, the intercooler 102 may be a liquid to an air heat exchanger. In one embodiment of the present invention, the intercooler 102 is of aluminum material. However, the present invention is not limited to any particular material used for manufacturing the intercooler 102. In one embodiment of the present invention, the inlet hose 118 and the outlet hose 120 are of silicon material.

However, the present invention is not limited to any particular material used for manufacturing the inlet hose 118 and the outlet hose 120. Additionally, in one embodiment of the present invention, an inlet spout and the outlet spout 110 of the intercooler 102 are of Ethylene Propylene Diene Monomer (EPDM). However, the present invention is not limited to any particular material used for manufacturing the inlet spout and the outlet spout 110 of the intercooler 102.
The sensor housing 104 is disposed on the outlet spout 110 of the intercooler 102. In one embodiment of the present invention, the sensor housing 104 is disposed on the outlet spout 110 of the intercooler 102 by means of brazing. However, the present invention is not limited to any particular manufacturing process used for disposing the sensor housing 104 to the outlet spout 110. In other embodiments of the present invention, the sensor housing 104 may be disposed on the outlet spout 110 of the intercooler 102 by means of other manufacturing processes such as soldering, welding, and the like.
Referring to Figures 6 and 7, the sensor 106 fitted on the sensor housing 104 is illustrated. The fitting means 108 (shown in Figures 4 and 5) are adapted to dispose the sensor 106 on the sensor housing 104. In one embodiment of the present invention, the fitting means 108 are complementary threads configured on the sensor housing and the sensor. For example, in one embodiment of the present invention, the fitting means 108 configured on the sensor housing is internal threading. Accordingly, the sensor 106 may be adapted to have external threading for disposing the sensor 106 on the sensor housing 104. Alternatively, in another embodiment of the present invention,

the fitting means 108 configured on the sensor housing 104 is external threading. Accordingly, the sensor 106 may be adapted to have internal threading for disposing the sensor 106 on the sensor housing 104. Therefore, the fitting means 108 are mutually complementary to each other. Although, in the present embodiment of the present invention, the fitting means 108 are complementary threads configured on the sensor housing and the sensor, the present invention is not limited to any particular fitting means described. Accordingly, in other embodiments of the present invention, the fitting means may be various other fitment devices known in the art.
The sensor 106 may be temperature sensor for measuring the temperature of the cooled air existing from the intercooler 102. In another embodiment of the present invention, the sensor 106 may be a pressure sensor adapted to measure the pressure of the cooled air existing from the intercooler 102.
Although, the present embodiment of the present invention depicts use of the intercooler assembly 100 in conjunction with a vehicle, the present invention is not limited to a particular application of the intercooler assembly 100 with respect to a vehicle. The intercooler assembly 100 of the present invention may also be used in stationary engines, tractor engines, lawn movers, heavy duty applications for charge cooling and the like.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The intercooler assembly of the present invention has a comparatively robust structure. Further, the intercooler assembly is adapted to preclude weakening of the hose pipe by preventing formation of holes thereon. Moreover, the

intercooler assembly is comparatively more vibration resistant. Also, the intercooler assembly is comparatively cheap. Additionally, the intercooler assembly is relatively compact. In addition, the intercooler assembly improves air dynamics. Also, the intercooler assembly reduces turbo lag.
The numeral values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention and the claims unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the components and
component parts of the preferred embodiments, it will be appreciated that
many embodiments can be made and that many changes can be made in the
preferred embodiments without departing from the principles of the
invention. These and other changes in the preferred embodiment as well as
other embodiments of the invention will be apparent to those skilled in the
art from the disclosure herein, whereby it is to be distinctly understood that
the foregoing descriptive matter is to be interpreted merely as illustrative of
the invention and not as a limitation.

We Claim:
1. An intercooler assembly comprising:
• an intercooler having an outlet spout;
• a sensor housing disposed on said outlet spout;
• a sensor adapted to be fitted on said sensor housing; and
• fitting means adapted to fit said sensor on said sensor housing.

2. The intercooler assembly as claimed in claim 1, wherein said intercooler is adapted to be mounted above an engine of a vehicle.
3. The intercooler assembly as claimed in claim 1, further comprising at least one support bracket adapted to mount said intercooler above an engine of a vehicle.
4. The intercooler assembly as claimed in claim 3, wherein said at least one support bracket is of sheet metal.
5. The intercooler assembly as claimed in claim 1, wherein said intercooler is of aluminum material.
6. The intercooler assembly as claimed in claim 1, wherein said sensor housing is disposed on said outlet spout of the intercooler by means of brazing.

7. The intercooler assembly as claimed in claim 1, wherein said sensor is a temperature sensor.
8. The intercooler assembly as claimed in claim 1, further comprising an inlet hose adapted to connect a turbocharger assembly to said intercooler.
9. The intercooler assembly as claimed in claim 1, further comprising an outlet hose adapted to connect said outlet spout of said intercooler to an intake throttle of an engine of a vehicle.
lO.The intercooler assembly as claimed in claim 1, wherein said fitting means are complementary threads configured on said sensor housing and said sensor.