Charge air cooler mounting arrangement

A charge air cooler mounting arrangement for mounting a charge air cooler heat exchanger within an engine intake manifold comprising:

• a plate-fin heat exchanger core formed by a plurality of first and second plate-fin heat transfer elements arranged in a generally alternating stack with each adjacent pair thereof separated by one of a plurality of divider plates and said stack sandwiched between a pair of relatively rigid side plates, said first plate-fin elements cooperating with said divider plates and said side plates to define a first flow path for charge air and said second plate-fin elements cooperating with said divider plates to define a second flow path for a coolant in heat transfer relation with the charge air;
• at least one threaded nut associated with one of said side plates and secured within a portion of said first flow path at the inboard side of said associated side plate and isolated from said second flow path, said one side plate having a bolt-receiving hole formed therein in general alignment with said nut;
• an engine intake manifold having a chamber formed therein for relatively close sliding reception of said core, said manifold having a bolt-receiving opening formed therein generally in alignment with said bolt-receiving opening formed in said one side plate;
• and
• a bolt for reception through said bolt-receiving opening in said manifold and further through said bolt-receiving opening in said one side plate for threaded reception into said nut, said bolt having a length insufficient to bear against the one of said divider plates adjacent said one side plate.

A charge air cooler heat exchanger for mounting into an engine intake manifold, comprising:

• a plate-fin heat exchanger core formed by a plurality of first and second plate-fin heat transfer elements arranged in a generally alternating stack with each adjacent pair thereof separated by one of a plurality of divider plates and said stack sandwiched between a pair of relatively rigid side plates, said first plate-fin elements cooperating with said divider plates and said side plates to define a first flow path for charge air and said second plate-fin elements cooperating with said divider plates to define a second flow path for a coolant in heat transfer relation with the charge air;
• and
• first and second pluralities of threaded nuts secured within said core respectively to the inboard sides of said pair of side plates within portions of said first flow path and in isolation from said second flow path, said nuts being positioned generally in individual alignment with bolt-receiving holes formed in said side plates;
• said first plate-fin elements adjacent said side plates having a thickness at least slightly greater than the thickness of said nuts and having clearance apertures formed therein for aligned individual reception of said nuts.

A charge air cooler mounting arrangement for mounting a charge air cooler heat exchanger within an engine intake manifold, comprising:

• a plate-fin heat exchanger core formed by a plurality of first and second plate-fin heat transfer elements arranged in a generally alternating stack with each adjacent pair thereof separated by one of a plurality of divider plates and said stack sandwiched between a pair of relatively rigid side plates, said first plate-fin element cooperating with said divider plates and said side plates to define a first flow path for charge air and said second plate-fin elements cooperating with said divider plates to define a second flow path for a coolant in heat transfer relation with the charge air;
• and
• first and second pluralities of threaded nuts secured within said core respectively to the inboard sides of said pair of side plates within portions of said first flow path and in isolation from said second flow path, said nuts being positioned generally in individual alignment with bolt-receiving holes formed in said side plates;
• said first plate-fin elements adjacent said side plates having a thickness at least slightly greater than the thickness of said nuts and having clearance apertures formed therein for aligned individual reception of said nuts;
• an engine intake manifold having a chamber formed therein for relatively close sliding reception of said core and bounded on opposite sides by a pair of manifold side walls having a plurality of bolt-receiving holes formed therein generally for alignment with the bolt-receiving holes in said side plates;
• and
• bolt means for reception through the bolt-receiving holes in said manifold side walls and further through the bolt-receiving holes in said side plates for threaded reception into said nuts to secure said core within said intake manifold, said bolt means including a plurality of bolts each having having a length insufficient to bear substantially against the outermost divider plates in said stack adjacent said side plates.