Heat exchanger pit structure

Abstract

A heat exchanger dimple configuration having alternating first and second heat exchanger plates (26, 28) coupled to a base heat exchanger plate (24), the first heat exchanger plate (26) including an upstanding indentation (68, 70) extending upwardly from a generally planar surface (66) away from the base heat exchanger plate (24) by a first distance (96), the upstanding indentation (68, 70) extending upwardly from a generally planar surface (66) away from the base heat exchanger plate (24) by a second distance (96) away from the base heat exchanger plate (24). The second heat exchanger plate (28) includes a descending indentation (88, 90) extending downwardly from the second substantially planar surface (66) towards the base heat exchanger plate (24) by a second distance (98), the planar portions of the first and second plates (26, 28) being spaced apart by a third distance (100), the first distance (96) being less than the third distance (100), and the second distance (98) being less than the third distance (100), the upstanding indentation (68, 70) extending along a first length (72), the upstanding indentation (68, 70) extending along a second length (72). The first length (72) extends along the first length (72), and the descending indentations (88, 90) extend along the second length (92), a third length of each upright indentation (68, 70) adjoins a fourth length of the respective descending indentation (88, 90), the third length being less than the first length (72), and the fourth length being less than the second length (92).

Description

Technical Field

[0001] The present disclosure relates to heat exchangers. The heat exchanger includes a plurality of alternating plates to allow heat exchange between two different fluids. In an oil cooler, oil and coolant flow between adjacent plates. To enhance heat exchange between adjacent plates, the alternating plates typically include one or more protrusions and / or turbulator inserts. However, protrusions and turbulators increase the pressure drop across the heat exchanger, which is undesirable. Background Art

[0002] CA 2 29 118 C discloses a self-enclosed heat exchanger. The self-enclosed heat exchanger is made of stacked plates with raised peripheral flanges on one side of the plates and continuous peripheral ridges on the other side of the plates so that when the plates are put together, completely enclosed alternating flow channels are provided between the plates. The plates have raised bosses that define fluid ports that are arranged in the stacked plates to form a manifold for allowing heat exchange fluid to flow through alternating plates. In the plates, rib and groove barriers are formed within the peripheral flanges and ridges. These barriers prevent short-circuiting flow on one side of the plates and promote flow to distant areas on the other side of the plates to improve the overall efficiency of the heat exchanger.

[0003] EP 0 867 679 A2 discloses a deep-drawn guide. The deep-drawn guide comprises two parallel ribs in the form of crossing shares, the height of which corresponds to half the spacing of the opposite sides of the base of the grooves. The bases of these grooves have parallel ribs. The parallel ribs of directly adjacent heat exchanger plates are arranged on the facing sides of the heat exchanger plates, or on the sides facing away from each other, and extend exclusively into the flow path for one of the two media.

[0004] DE 195 19 312 A1 discloses a plate heat exchanger. The plates are assembled together in a stack to form individual channels for the medium being processed. The main faces by which the plates are connected together are horizontal and extend in the circumferential direction, wherein each upper plate rests on a horizontal step formed in the lower edge of the plate. The edges of all the plates can have the same shape, and the vertical forces acting on the stack are transmitted only via the steps and the vertical plate edges. The steps can be cold-formed, so that a sharp inner edge and a rounded outer edge are formed.

[0005] US 6 209 629 B1 discloses a beaded plate for a heat exchanger and a method for manufacturing the same, the heat exchanger comprising a plate having a substantially planar surface and a plurality of beads extending substantially perpendicular to the surface of the plate. The beads are formed in a non-aligned pattern of non-aligned beads within a plurality of rows of beads.

[0006] US 2020 / 072556 A1 discloses a multi-plate oil cooler. The multi-plate oil cooler has high bonding strength with inner fins while suppressing the amount of nickel brazing filler used, even when ferrite-based stainless steel having low wettability to the nickel brazing filler is provided for the plates. A plate made of ferrite-based stainless steel and an inner fin made of a pure iron plate or a carbon steel plate are joined with a nickel brazing filler to form a multi-plate oil cooler. Generally, a structure is provided in which ferrite-based stainless steel and pure iron or carbon steel are joined with a nickel brazing filler.

[0007] It is an object of the present invention to provide a heat exchanger protrusion configuration which enhances heat exchange compared to other protrusion configurations while maintaining a low pressure drop. Summary of the invention

[0008] In some embodiments, an oil cooler is connected to a vehicle. The oil cooler includes a flange plate having fastener holes and fluid flow holes. Each fastener hole is sized to receive a fastener to connect the flange plate to the vehicle. The fluid flow holes allow oil and coolant to flow through the flange plate.

[0009] In some embodiments, the base heat exchanger plate has a first surface connected to the flange plate and a second surface spaced apart from the flange plate. The base heat exchanger plate includes fluid flow holes to allow oil and coolant to flow through the base heat exchanger plate.

[0010] In some embodiments, a first heat exchanger plate is coupled to a base heat exchanger plate. The first heat exchanger plate has a first peripheral portion and a first central portion. The first peripheral portion surrounds the first central portion and includes a first upwardly extending flange. The first central portion includes a first generally planar surface and an upstanding indentation extending upwardly from the generally planar surface away from the base heat exchanger plate. An upper distal portion of the upstanding indentation is spaced a first distance from the first generally planar surface. The upper distal portion extends along a first length.

[0011] In some embodiments, a second heat exchanger plate is connected to the first heat exchanger plate. The second heat exchanger plate has a second peripheral portion and a second central portion. The second peripheral portion surrounds the second central portion and includes a second upwardly extending flange. The second upwardly extending flange can contact the inner surface of the first upwardly extending flange, thereby connecting the second heat exchanger plate to the first heat exchanger plate. The second central portion includes a second generally planar surface and a plurality of descending indentations extending downward from the second generally planar surface toward the base heat exchanger plate. The lower distal portion of the descending indentation is spaced a second distance from the second generally planar surface. When the second heat exchanger plate is connected to the first heat exchanger plate, the second generally planar surface is spaced a third distance from the first generally planar surface. The lower distal portion extends along a second length.

[0012] In some embodiments, the turbulators are positioned on an upper surface of the second heat exchanger plate.

[0013] In some embodiments, the first distance is less than the third distance, and the second distance is less than the third distance.

[0014] In some embodiments, a third length of an upper distal portion of one of the upstanding indentations is configured to abut a fourth length of a lower distal portion of a corresponding descending indentation.

[0015] In some embodiments, the third length is less than the first length, and the fourth length is less than the second length.

[0016] In some embodiments, a third heat exchanger plate is positioned above the turbulators and a fourth heat exchanger plate is positioned above the third heat exchanger plate. The third heat exchanger plate is substantially identical to the first heat exchanger plate and the fourth heat exchanger plate is substantially identical to the second heat exchanger plate. An oil cooler directs coolant between the first heat exchanger plate and the second heat exchanger plate and directs oil between the second heat exchanger plate and the third heat exchanger plate through the turbulators.

[0017] In some embodiments, the upper distal portion extends along a first width measured perpendicular to the first length, the lower distal portion extends along a second width measured perpendicular to the second length, the first length is greater than the first width, and the second length is greater than the second width.

[0018] In some embodiments, the first length is at least twice the first width and the second length is at least twice the second width.

[0019] In some embodiments, the first upwardly extending flange is generally rectangular with opposing short sides and opposing long sides.The upstanding indentations extend diagonally relative to the opposing short sides and the opposing long sides of the first upwardly extending flange.

[0020] In some embodiments, the second upwardly extending flange has a generally rectangular shape with opposing short sides and opposing long sides, wherein the descending indentation extends diagonally relative to the opposing short sides and the opposing long sides of the first upwardly extending flange.

[0021] In some embodiments, each upstanding indentation extends in a non-parallel direction relative to a corresponding downgoing indentation such that each upstanding indentation abuts a corresponding downgoing indentation along a portion of the first length and a portion of the second length.

[0022] In some embodiments, the upright indentations extend at an angle between about 60 and 120 degrees relative to the descending indentations to allow coolant to flow around the connected first and second length portions above the upright indentations and below the descending indentations.

[0023] In some embodiments, the first distance plus the second distance is substantially equal to the third distance.

[0024] In some embodiments, the first distance is substantially equal to the second distance.

[0025] In some embodiments, the upstanding indentation is elongated and includes a tapered perimeter and a flat upper surface, and wherein the second descending indentation is elongated and includes a tapered perimeter and a flat lower surface.

[0026] In some embodiments, a first portion of each upright indentation is adjacent to a first portion of a corresponding descending indentation, a second portion of the upright indentation is spaced apart from the corresponding descending indentation, and a second portion of the descending indentation is spaced apart from the corresponding upright indentation, such that coolant is allowed to flow over the second portion of the upright indentation and coolant is allowed to flow under the second portion of the descending indentation.

[0027] In some embodiments, the first portion of each of the upstanding indentations is positioned approximately centrally along a first length of the respective upstanding indentation, and wherein the first portion of each of the descending indentations is positioned approximately centrally along a second length of the respective descending indentation.

[0028] In some embodiments, the present application is directed to a vehicle including an oil cooler as shown and described herein.

[0029] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a perspective view of an oil cooler according to some embodiments of the present invention.

[0031] Figure 2 yes Figure 1 Exploded view of the oil cooler.

[0032] Figure 3 is a top view of the first heat exchanger plate.

[0033] Figure 3A yes Figure 3 Close-up view of a portion of the first heat exchanger plate.

[0034] Figure 4 is a top view of the second heat exchanger plate.

[0035] Figure 4A yes Figure 4 Close-up view of a portion of the second heat exchanger plate.

[0036] Figure 5 is along Figure 1 A cross-sectional view taken along line 5-5.

[0037] Figure 6 is a close-up cross-sectional view of two adjacent heat exchanger plates.

[0038] Figure 7 It is shown Figure 6 Schematic diagram of the flow paths between the heat exchanger plates.

[0039] Figure 8 is a graph comparing the pressure drop and heat exchanger performance of this configuration to a standard dimple configuration.

[0040] Fig. 9 A schematic diagram is shown of a possible alternative embodiment.

[0041] Fig.10 is based on Fig. 9 Top view of the first plate of an embodiment.

[0042] Fig.11 is based on Fig. 9 Top view of the second plate of the embodiment. DETAILED DESCRIPTION

[0043] Before explaining any embodiments of the present disclosure in detail, it should be understood that the application of the present disclosure is not limited to the details of construction and arrangement of components set forth in the following description or shown in the following drawings. The present disclosure is capable of other embodiments and can be practiced or carried out in various ways.

[0044] Figure 1An oil cooler 10 is shown that includes a flange plate 12 and a stack of heat exchanger plates 14. The flange plate 12 includes a plurality of fastener holes 16, coolant flow holes 18, and oil flow holes 20. The fastener holes 16 are each configured to receive a fastener to couple the flange plate 12 to a vehicle. The coolant flow holes 18 are configured to allow coolant to flow through the flange plate 12, and the oil flow holes 20 are configured to allow oil to flow through the flange plate 12.

[0045] Figure 2 The stack of heat exchanger plates 14 is shown in more detail. The stack of heat exchanger plates 14 shown comprises a base heat exchanger plate 24, a plurality of first heat exchanger plates 26, a plurality of second heat exchanger plates 28, a plurality of turbulators 30, end heat exchanger plates 32 and end plates 34.

[0046] The base heat exchanger plate 24 is generally planar and includes an upwardly extending flange 40 around the perimeter of the base heat exchanger plate 24. The generally planar portion of the base heat exchanger plate 24 includes a first surface configured to be coupled to the flange plate 12 and a second surface 44 spaced apart from the flange plate 12. The base heat exchanger plate 24 includes coolant flow holes that are substantially aligned with the coolant flow holes 18 when the base heat exchanger plate 24 is coupled to the flange plate 12. Similarly, the base heat exchanger plate 24 includes oil flow holes that are substantially aligned with the oil flow holes 20 when the base heat exchanger plate 24 is coupled to the flange plate 12.

[0047] A first heat exchanger plate of the plurality of first heat exchanger plates 26 is positioned above and coupled to the base heat exchanger plate 24. In some embodiments, a turbulator is positioned between the base heat exchanger plate 24 and the first heat exchanger plate 26. A second heat exchanger plate of the plurality of second heat exchanger plates 28 is positioned above and coupled to the first heat exchanger plate 26 opposite the base heat exchanger plate 24. A turbulator of the plurality of turbulators 30 is positioned above the second heat exchanger plate 28 opposite the first heat exchanger plate 26. The first heat exchanger plates 26 alternate with the second heat exchanger plates 28, and the turbulator 30 is positioned above each second heat exchanger plate 28. The first heat exchanger plates 26 and the second heat exchanger plates 28 will be discussed in more detail below.

[0048] The illustrated end heat exchanger plate 32 is positioned on top of the upper second heat exchanger plate 28 and the upper turbulator 30. The end heat exchanger plate 32 includes a generally planar portion and includes a flange 50 extending upwardly around the perimeter of the end heat exchanger plate 32. The generally planar portion of the end heat exchanger plate 32 includes a first surface configured to contact the upper turbulator 30 and a second surface 54 spaced apart from the upper turbulator 30. The illustrated end heat exchanger plate 32 includes a recess 56 positioned above the coolant flow holes 18.

[0049] The illustrated end plate 34 is generally planar and is configured to be coupled to the second surface of the end heat exchanger plate 32. The end plate 34 is configured to increase the rigidity of the oil cooler 10. In some embodiments, the end plate 34 is omitted.

[0050] The illustrated flange plates 12, base heat exchanger plates 24, end heat exchanger plates 32, and end plates 34 are provided as one possible configuration. Other configurations of flange plates, base heat exchanger plates, end heat exchanger plates, and end plates are possible and are considered within the scope of the present disclosure.

[0051] Figure 3 One of the first heat exchanger plates 26 is shown in more detail. Each of the first heat exchanger plates 26 is substantially identical, so only one of the first heat exchanger plates 26 will be described in detail herein. The first heat exchanger plate 26 has a first peripheral portion 60 and a first central portion 62. The first peripheral portion 60 surrounds the first central portion 62 and includes a first upwardly extending flange 64 (see Figure 2 ).

[0052] The first central portion 62 includes a first generally planar surface 66 and a plurality of upstanding indentations 68, 70 extending upwardly from the generally planar surface away from the base heat exchanger plate 24. The first upwardly extending flange 64 is generally rectangular and has opposite short sides and opposite long sides. All of the upstanding indentations 68, 70 extend diagonally relative to the opposite short sides and the opposite long sides of the first upwardly extending flange 64.

[0053] Figure 3A Upright indentations 68, 70 are shown in more detail. Upright indentations 68, 70 are shown to have similar shapes and sizes, but upright indentation 68 is oriented at a non-parallel angle relative to upright indentation 70. In the illustrated embodiment, the angle between upright indentations 68 and 70 is about 80 degrees. In other embodiments, other angles or other ranges of angles may be used. Applicants have found that angles in the range of 60 to 120 degrees are most beneficial for improving heat exchanger performance.

[0054] The upstanding indentations 68, 70 are elongated and have an upper distal portion having a first length 72 measured parallel to the first generally planar surface 66 and a first width 74 measured perpendicular to the first length 72. The first length 72 is longer than the first width 74. In the illustrated embodiment, the first length 72 is greater than twice the first width 74.

[0055] Optionally, upstanding indentations 68a are included near the long sides of the first upwardly extending flange 64. These optional upstanding indentations 68a are shorter in length than the remaining upstanding indentations 68, 70. The optional upstanding indentations 68a are spaced inwardly from the first upwardly extending flange 64 and can be sized to accommodate different size requirements of the integral oil cooler 10. The illustrated optional upstanding indentations 68a are parallel to the upstanding indentations 68. In some embodiments, some of the optional upstanding indentations are oriented parallel to the upstanding indentations 70.

[0056] Figure 4 The second heat exchanger plates 28 are shown in more detail. Each second heat exchanger plate 28 is substantially identical, so only one second heat exchanger plate 28 will be described in detail herein. The second heat exchanger plate 28 has a second peripheral portion 80 and a second central portion 82. The second peripheral portion 80 surrounds the second central portion 82 and includes a second upwardly extending flange 84 (see Figure 2 ). An outer surface of the second upwardly extending flange 84 is configured to contact an inner surface of the first upwardly extending flange 64 , thereby coupling the second heat exchanger plate 28 to the first heat exchanger plate 26 .

[0057] The second central portion 82 includes a second generally planar surface 86 and a plurality of descending indentations 88 , 90 extending downwardly from the second generally planar surface 86 toward the base heat exchanger plate 24 .

[0058] The second upwardly extending flange 84 is generally rectangular and has opposite short sides and opposite long sides. All of the descending indentations 88, 90 extend diagonally relative to the opposite short sides and the opposite long sides of the second upwardly extending flange 84.

[0059] Figure 4A The descending indentations 88, 90 are shown in more detail. The descending indentations 88, 90 shown have similar shapes and sizes, but the descending indentation 88 is oriented at a non-parallel angle relative to the descending indentation 90. In the embodiment shown, the angle between the descending indentations 88 and 90 is about 80 degrees. In other embodiments, other angles or other angle ranges may be used. Applicants have found that angles in the range of 60 to 120 degrees are most conducive to improving heat exchanger performance.

[0060] The depressions 88, 90 are elongated and have a lower distal portion having a second length 92 measured parallel to the second generally planar surface 86 and a second width 94 measured perpendicular to the second length 92. Although the upper surface of the second heat exchanger plate 28 is shown, it should be understood that the second length 92 and the second width 94 are measured on the lower surface of the second heat exchanger plate. The second length 92 is longer than the second width 94. In the embodiment shown, the second length 92 is greater than twice the second width 94.

[0061] Optionally, a descending indentation 88a is included near the long side of the second upwardly extending flange 84. These optional descending indentations 88a are shorter in length than the remaining descending indentations 88, 90. The optional descending indentations 88a are spaced inwardly from the second upwardly extending flange 84 and can be sized to accommodate different size requirements of the integral oil cooler 10. The optional upright indentations 88a shown are parallel to the upright indentations 88. In some embodiments, some of the optional upright indentations are oriented parallel to the upright indentations 90.

[0062] like Figure 5 and Figure 6 As shown, the perimeters of the upright indentations 68, 70 taper between the generally planar surface 66 and the upper distal portion. The perimeters of the descending indentations 88, 90 taper between the generally planar surface 86 and the lower distal portion.

[0063] The upper distal portion of the upright indentations 68, 70 is a flat upper surface. The lower distal portion of the descending indentations 88, 90 is a flat lower surface. A portion of the flat upper surface abuts against a portion of the flat lower surface. The upper distal portion of each upright indentation 68, 70 is spaced a first distance 96 above the first generally planar surface 66. The lower distal portion of each descending indentation 88, 90 is spaced a second distance 98 from the second generally planar surface 86.

[0064] When the first heat exchanger plate 26 is joined to the second heat exchanger plate 28, the first substantially planar surface 66 of the first heat exchanger plate 26 is spaced a third distance 100 from the second substantially planar surface 86 of the second heat exchanger plate 28. The first distance 96 is less than the third distance 100 and the second distance 98 is less than the third distance 100.

[0065] The first distance 96 plus the second distance 98 is substantially equal to the third distance 100 to allow for joining of the adjoining portions of the first heat exchanger plate 26 and the adjoining portions of the second heat exchanger plate 28 (e.g., by brazing or other suitable joining techniques). In the illustrated embodiment, the first distance 96 is approximately equal to the second distance 98. In other embodiments, the first distance 96 is different from the second distance 98.

[0066] When the first heat exchanger plate 26 is joined to the second heat exchanger plate 28, each upright indentation 68 is positioned adjacent to a corresponding one of the descending indentations 88, and each upright indentation 70 is positioned adjacent to a corresponding one of the descending indentations 90. The coolant is configured to flow over the upright indentations 68, 70 and under the descending indentations 88, 90, and the oil is configured to flow through the turbulator 30. The contact between adjacent indentations 68, 88 and indentations 70, 90 enhances heat exchange between the coolant and the oil, and maintains a consistent spacing between adjacent first and second plates 26, 28. In some embodiments, the adjacent indentations are brazed to further increase the strength of the oil cooler 10.

[0067] like Figure 6 As shown, the upright indentations 68, 70 extend in non-parallel directions relative to the corresponding descending indentations 88, 90. In the illustrated embodiment, the upright indentations 68, 70 intersect the corresponding descending indentations 88, 90 at an angle of about 80 degrees. However, other angles, such as angles between 60 degrees and 120 degrees, are also suitable. Because the upright indentations 68, 70 and the descending indentations 88, 90 are elongated, only a portion of each upright indentation 68, 70 abuts a portion of the corresponding descending indentation 88, 90.

[0068] refer to Figure 7 , the figure schematically shows the upper surface of the upper distal portion of the upright indentations 68, 70 and the lower surface of the lower distal portion of the descending indentations 88, 90. The upper surface of the upper distal portion of each upright indentation 68, 70 extends a first length 72 and a first width 74. The lower surface of the lower distal portion of each illustrated descending indentation 88, 90 extends a second length 92 and a second width 94. Only a portion of the upper surface of the upper distal portion of each upright indentation 68, 70 abuts a portion of the lower surface of the lower distal portion of the corresponding descending indentation 88, 90. Since the upper distal portions of the illustrated upright indentations 68, 70 extend generally perpendicularly to the lower distal portions of the descending indentations 88, 90, the length of the portion of the upper distal portion of each upright indentation 68, 70 abutting the lower distal portion of the corresponding descending indentation 88, 90 is substantially equal to the width of the lower distal portion of the corresponding descending indentation 88, 90. Likewise, in the illustrated embodiment, the length of the portion of the lower distal portion of each descending indentation 88 , 90 that abuts the upper distal portion of the corresponding upright indentation 68 , 70 is substantially equal to the width of the corresponding upright indentation 68 , 70 .

[0069] Figure 7An angle of approximately 90 degrees between the upright indentations 68, 70 and the descending indentations 88, 90 is shown. The upright indentations 68, 70 can be oriented at an angle of between approximately 60 and 120 degrees relative to the descending indentations 88, 90 while still maintaining the desired performance indicators. In embodiments with a non-perpendicular angle between the upright indentations 68, 70 and the descending indentations 88, 90, the abutment length will be greater than the width 74 of the upper distal portion or the width 94 of the lower distal portion of the opposing indentation. However, the abutment length of the upper distal portion of the upright indentations 68, 70 and the lower distal portion of the corresponding descending indentations 88, 90 will always be less than the total length 72 of the upper distal portion of the corresponding upright indentations 68, 70, and less than the total length 92 of the lower distal portion of the descending indentations 88, 90.

[0070] The direction of fluid flow is shown by arrow 104. A first angle 106 is measured between the upright indentation 70 and the descending indentation 90. A second angle 108 is the supplementary angle of the first angle 106. A third angle 110 is measured between the descending indentation 90 and the direction of fluid flow 104. The third angle 110 is half of the first angle 106. The third angle 110 is between about 30 degrees and 60 degrees.

[0071] The remaining portion of the upper distal portion of the upright indentations 68, 70 that is not adjacent to the lower distal portion of the corresponding descending indentations 88, 90 is spaced apart from the remaining portion of the lower distal portion of the corresponding descending indentations 88, 90 to allow coolant to flow through the portion of the upper distal portion of the upright indentations 68, 70. The coolant flow is Figure 7 The remaining portion of the lower distal portion of the descending indentations 88, 90 that is not adjacent to the upper distal portion of the corresponding upright indentations 68, 70 is spaced apart from the remaining portion of the upper distal portion of the corresponding upright indentations 68, 70 to allow coolant to flow under the portion of the upper distal portion of the descending indentations 88, 90.

[0072] The illustrated upright indentations 68, 70 are generally centered over the corresponding descending indentations 88, 90. The center portion of the upright indentations 68, 70 abuts the center portion of the descending indentations 88, 90. In other embodiments not shown, the upright indentations 68, 70 are slightly offset from the corresponding descending indentations 88, 90. In some of these embodiments, the non-center portion of the upright indentations 68, 70 abuts the center portion of the descending indentations 88, 90. In some of these embodiments, the center portion of the upright indentations 68, 70 abuts the non-center portion of the descending indentations 88, 90. In some of these embodiments, the non-center portion of the upright indentations 68, 70 abuts the non-center portion of the descending indentations 88, 90.

[0073] Figure 8Simulation results for several different types of heat exchanger configurations are shown. A standard dimple configuration (DIMPLE) with a channel height of 0.9 mm is used as a control. The remaining configurations are compared to the standard dimple configuration for changes in pressure drop across the coolant channel (X-axis) and changes in heat exchanger performance (Y-axis). The legend indicates that the dimple height is D and the channel height is P.

[0074] HD dimple configuration is sold by a competitor and includes dimples with a high density. P dimple configuration is disclosed in DE 10 2018 007 010 A1. O dimple configuration includes dimples from DE 10 2018 007 010 A1 on two sets of tube sheets. Chevron design such as Figures 9 to 11 As shown, it will be discussed in more detail below.

[0075] This paper newly discloses the ANGLE dimple structure. Different geometric values, such as the third angle 110, the indentation height and the fluid channel height, are changed to obtain five different simulation results. Figure 8 As shown, each of these results outperforms prior art configurations. ANGLE dimple configurations, such as those described above, demonstrate improvements in heat exchanger performance while maintaining an acceptable pressure drop across the coolant passages. Figure 8 As shown, some configurations have reduced pressure drop and improved heat exchanger performance. As described in the technical field section, it is desirable to maintain a relatively low pressure drop across the heat exchanger without compromising heat exchanger performance. The present configuration achieves the desired results of improved heat exchanger performance and reduced pressure drop across the coolant channels.

[0076] The TURBULATOR configuration shows a configuration in which turbulators are included in both the coolant passage and the oil passage between each heat exchanger plate.

[0077] Figures 9 to 11 An alternative embodiment is shown which includes upstanding indentations 268, 270 extending in a V-shape on opposite halves of the first heat exchanger plate 226. Data for this design is included in Figure 8 In the graph of FIG. 2 , it is shown as V-shaped data. Essentially, the upright indentation 268 extends diagonally relative to the first heat exchanger plate 226 and intersects the upright indentation 270 at an angle of approximately 90 degrees in the middle of the first heat exchanger plate 226. Similarly, the descending indentations 288, 290 extend in a V-shape on opposite halves of the second heat exchanger plate 228. The descending indentation 288 extends diagonally relative to the second heat exchanger plate 228 and intersects the descending indentation 290 at an angle of approximately 90 degrees in the middle of the second heat exchanger plate 228. As shown in FIG. Fig. 9As schematically shown in FIG. 1 , each upright indentation 268, 270 abuts portions of several descending indentations 288, 290. Likewise, each descending indentation 288, 290 abuts portions of several upright indentations 268, 270. Each abutment is connected (e.g., joined, brazed, etc.), and coolant is allowed to flow around each abutment, over the upright indentations 268, 270 and under the descending indentations 288, 290.

[0078] In other embodiments, Figures 9 to 11 The configuration of the embodiment can orient the upright indentation 268 at an angle between 60 and 120 degrees relative to the upright indentation 270. Similarly, such an embodiment can orient the descending indentation 288 at an angle between 60 and 120 degrees relative to the descending indentation 290.

[0079] The present application proposes various embodiments of heat exchanger protrusion configurations that enhance the performance of the heat exchanger while maintaining a low pressure drop relative to other protrusion configurations.

Claims

1. An oil cooler (10) configured to be coupled to a vehicle, the oil cooler (10) comprising: a flange plate (12) comprising fastener holes (16) and fluid flow holes, each of the fastener holes (16) being configured to receive a fastener to couple the flange plate (12) to the vehicle, the fluid flow holes (18, 20) being configured to allow oil and coolant to flow through the flange plate (12); a base heat exchanger plate (24) having a first surface coupled to the flange plate (12) and a second surface (44) spaced apart from the flange plate (12), the base heat exchanger plate (24) including fluid flow holes extending through the base heat exchanger plate to allow oil and coolant to flow through the base heat exchanger plate (24); a first heat exchanger plate (26) coupled to the base heat exchanger plate (24), the first heat exchanger plate (26) having a first peripheral portion (60) and a first central portion (62), the first peripheral portion (60) surrounding the first central portion (62) and including a first upwardly extending flange (40), the first central portion (62) including a first generally planar surface (66) and a plurality of upstanding indentations (68, 70) extending upwardly from the generally planar surface (60) away from the base heat exchanger plate (24), upper distal portions of the upstanding indentations (68, 70) being spaced a first distance (96) from the first generally planar surface (66), the upper distal portions extending along a first length (72); a second heat exchanger plate (28) coupled to the first heat exchanger plate (26), the second heat exchanger plate (28) having a second peripheral portion (80) and a second central portion (82), the second peripheral portion (80) surrounding the second central portion (82) and including a second upwardly extending flange (40), the second upwardly extending flange (40) being configured to contact an inner surface of the first upwardly extending flange (40) to couple the second heat exchanger plate (28) to the first heat exchanger plate (26), the second central portion (82) comprising a second generally planar surface (66) and a plurality of descending indentations (88, 90) extending downwardly from the second generally planar surface (66) toward the base heat exchanger plate (24), lower distal portions of the descending indentations (88, 90) being spaced a second distance (98) from the second generally planar surface (66), the second generally planar surface (66) being spaced a third distance (100) from the first generally planar surface (66) when the second heat exchanger plate (28) is coupled to the first heat exchanger plate (26), the lower distal portions extending along a second length (92); as well as a turbulator (30) positioned on an upper surface of the second heat exchanger plate (28), wherein the first distance (96) is smaller than the third distance (100), and the second distance (98) is smaller than the third distance (100), wherein a third length of the upper distal portion of one of the upright indentations (68, 70) is configured to abut a fourth length of the lower distal portion of the corresponding descending indentation (88, 90), and wherein the third length is smaller than the first length (72), and the fourth length is smaller than the second length (92), wherein the upstanding indentation (68) is oriented at a non-parallel angle relative to the upstanding indentation (70), and Wherein, the angle between the upright indentation (68) and the upright indentation (70) is in the range of 60 to 120 degrees.

2. The oil cooler (10) of claim 1, further comprising a third heat exchanger plate and a fourth heat exchanger plate, wherein the third heat exchanger plate is positioned above the turbulator (30), the fourth heat exchanger plate is positioned above the third heat exchanger plate, the third heat exchanger plate is substantially identical to the first heat exchanger plate (26), and the fourth heat exchanger plate is substantially identical to the second heat exchanger plate (28), wherein the oil cooler (10) is configured to direct coolant between the first heat exchanger plate (26) and the second heat exchanger plate (28), and is configured to direct oil between the second heat exchanger plate (28) and the third heat exchanger plate through the turbulator (30).

3. The oil cooler (10) according to claim 1 or 2, wherein: The upper distal portion extends along a first width (74) measured perpendicular to the first length (72), and the lower distal portion extends along a second width (94) measured perpendicular to a second length (92), the first length (72) being greater than the first width (74), and the second length (92) being greater than the second width (94).

4. The oil cooler (10) according to claim 3, wherein: The first length (72) is at least twice the first width (74), and wherein the second length (92) is at least twice the second width (94).

5. The oil cooler (10) according to any one of claims 1 to 4, wherein: The first upwardly extending flange (40) is generally rectangular having opposing short sides and opposing long sides, wherein the upstanding indentations (68, 70) extend diagonally relative to the opposing short sides and the opposing long sides of the first upwardly extending flange (40).

6. The oil cooler (10) according to any one of claims 1 to 5, wherein: The second upwardly extending flange (40) is generally rectangular having opposing short sides and opposing long sides, wherein the descending indentations (88, 90) extend diagonally relative to the opposing short sides and the opposing long sides of the first upwardly extending flange (40).

7. The oil cooler (10) according to any one of claims 1 to 6, wherein: Each upright indentation (68, 70) extends in a non-parallel direction relative to the corresponding descending indentation (88, 90) such that each upright indentation (68, 70) abuts the corresponding descending indentation (88, 90) along a portion of the first length (72) and a portion of the second length (92).

8. The oil cooler (10) according to any one of claims 1 to 7, wherein: The upright indentations (68, 70) extend at an angle of between about 60 and 120 degrees relative to the descending indentations (88, 90) so as to allow coolant to flow around the connected portions of the first length (72) and the second length (92) above the upright indentations (68, 70) and below the descending indentations (88, 90).

9. The oil cooler (10) according to any one of claims 1 to 8, wherein: The first distance (96) plus the second distance (98) is substantially equal to the third distance (100).

10. The oil cooler (10) according to any one of claims 1 to 9, wherein: The first distance (96) is substantially equal to the second distance (98).

11. The oil cooler (10) according to any one of claims 1 to 10, wherein: The upright indentations (68, 70) are elongated and include a tapered perimeter and a flat upper surface, and wherein the second descending indentations (88, 90) are elongated and include a tapered perimeter and a flat lower surface.

12. The oil cooler (10) according to any one of claims 1 to 11, wherein: A first portion of each of the upright indentations (68, 70) is adjacent to a first portion of the corresponding descending indentation (88, 90), a second portion of the upright indentation (68, 70) is spaced apart from the corresponding descending indentation (88, 90), and a second portion of the descending indentation (88, 90) is spaced apart from the corresponding upright indentation (68, 70) so that coolant is allowed to flow over the second portion of the upright indentation (68, 70) and coolant is allowed to flow under the second portion of the descending indentation (88, 90).

13. The oil cooler (10) according to claim 12, wherein: The first portion of each of the upright indentations (68, 70) is approximately centrally located along the first length (72) of the respective upright indentation (68, 70), and wherein the first portion of each of the descending indentations (88, 90) is approximately centrally located along the second length (92) of the respective descending indentation (88, 90).

14. The oil cooler (10) according to any one of the preceding claims, wherein The descending indentation (88) is oriented at a non-parallel angle relative to the descending indentation (90), and wherein the angle between the descending indentation (88) and the descending indentation (90) is in the range of 60 to 120 degrees.

15. A vehicle comprising an oil cooler (10) according to any one of claims 1 to 14.

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