In the early 1990's, Vortech performed exhaustive studies on air-to-air charge cooling for use with centrifugal superchargers. The approach seemed attractive given the simplicity and straight-forward application. In each test case study, however, a net loss in boost pressure and horsepower resulted. Since horsepower is strongly dependent on charge-air density, and density in turn is related to both temperature and pressure, Vortech quickly learned that obtaining good thermal performance from a charge cooler is only half of the challenge. Indeed, the problem with air-to-air cooling was found to be the significant pressure losses associated with long duct runs needed to get the charge air to and from the heat exchanger, which is usually placed up-front ahead of the radiator. In addition, the air-to-air heat exchanger design incorporated rather lengthy, restrictive passageways which only compounded the problem. Vortech shelved the idea temporarily and instead focused development efforts on supercharger efficiency, which yields the double benefit of delivering cooler charge air to begin with and a reduction in required drive horsepower, given any specific flow/pressure operating point. As higher compression engines and increased boost levels became more prevalent, Vortech renewed development efforts on high-performance charge cooling systems.

Realizing that boost loss was just as important as thermal performance, Vortech turned to an air-to-water type system. This type of system clearly proved it's worth. Thermal performance was excellent and it exhibited insignificant frictional (boost) losses which means that for any specific manifold pressure, supercharger drive power would be minimized - a win-win situation. Further, the system would, under most conditions, out-perform an air-to-air system.

Today, what Vortech started years ago is becoming the technology of choice within the OE Automotive industry - liquid-air charge cooling can now be seen on some of the most advanced powertrains of Mercedes Benz (Maybach), Ford (SVT/Harley Davidson F150, 2003 Cobra, et al.), and Jaguar for boosted applications.

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