Plate for radiator integrated in engine block / collector

Abstract

Primary plate (12) for a cooling plate (10) comprising: a plate having a first surface (12a), a second surface (12b), a recess (24) formed therein, a plurality of first openings (17) formed therethrough, a plurality of second openings (17) formed therethrough, and a plurality of recesses (13) formed through the plate adjacent a periphery thereof and configured to receive a plurality of coupling means (14) therein, each of the plurality of first openings (17) and the plurality of second openings (17) being configured to receive opposite ends of a plurality of tubes (20), wherein the plate has an outer edge (22) extending outwardly from the first surface (12a) perpendicular to a location defined by the plate at a periphery of the plate, and wherein the plate has stiffening features (27) extending from the edge (22) to the first surface (12a) of the primary plate (12).

Description

Technical area

[0001] The present invention relates to an exhaust gas recirculation (EGR) system of a vehicle with an internal combustion engine and, more particularly, to a plate designed to integrate the EGR system onto an engine block of a vehicle with an internal combustion engine. State of the art

[0002] As is well known, exhaust gas recirculation (EGR) systems are used in diesel and gasoline vehicles to reduce emissions and fuel consumption. The EGR system recirculates a portion of the exhaust gases from an internal combustion engine vehicle back to the engine block.

[0003] However, EGR cooling systems can have coolers that take up too much space, are unstable, have undesirable seals, are inefficient, and / or lack sufficient rigidity. For example, an EGR cooling system cooler, which carries coolant, is typically separated from the engine block, requiring a separate housing to contain the cooler. The housing includes a cooler core or gas-handling elements, such as a bundle of straight tubes, U-shaped tubes, or flat tubes.

[0004] Therefore, an EGR cooling system is desirable in which the cooler core is mounted directly to the engine block through a plate connected to the cooler core. The cooler core uses the engine cooling device to cool the exhaust gases that flow through the cooler core. The cooler core and plate are typically arranged at a location within a space formed by the engine block or cylinder head and mounted on the engine block. When mounting the cooler core to the engine block, it is desirable to efficiently seal a gap formed between the plate and the engine block. One solution for sealing is to connect the plate to the engine block with bolts and arrange a metal bead gasket between the engine block and the plate. However, each bolt and associated drilled hole formed in the plate and the engine block increases the cost.Additionally, packing requirements often prevent bolts from being arranged in optimized areas. To reduce costs, it is desirable to minimize the number of bolts required. Minimizing the number of bolts increases the spacing between adjacent bolts, which negatively impacts the uniform loading acting on the metal bead seal. Without this uniform loading, the metal bead seal provides an inadequate seal.

[0005] To ensure a uniform load acting on the bead seals, some applications further increase the thickness of the plate to increase its rigidity. However, increasing the plate thickness results in at least two problems. One is that the increased thickness minimizes the precision of forming holes for the tubes during the stamping process. The tubes are soldered to the plate, and precision in forming the holes for the tubes is important. The other is that increasing the thickness increases the cost and weight of the plate because additional material is required.

[0006] Additionally, it would be desirable to provide a plate assembly for connecting the engine block of the vehicle to an internal combustion engine that is rigid, provides maximum sealing, and minimizes a thickness of the plate assembly.

[0007] Previously known designs of primary plates are known from DE 11 2016 004 891 T5, DE 11 2016 000 323 T5, FR 2 948 755 A1 and DE 10 2007 059 127 A1. Summary of the invention

[0008] In accordance with the present invention, a plate assembly for connecting to the engine block of the internal combustion engine vehicle that is rigid, seals maximally, and minimizes a thickness of the plate assembly has surprisingly been discovered.

[0009] According to one embodiment of the disclosure, a primary plate for a cooler plate assembly includes the features of claim 1.

[0010] According to another embodiment of the disclosure, a cooler plate is disclosed. The cooler plate includes the features of claim 3.

[0011] According to another embodiment of the disclosure, a cooler plate is disclosed. The cooler plate includes the features of claim 15. Brief description of the drawings

[0012] The above-mentioned advantages of the invention will be readily apparent to those skilled in the art by reading the following detailed description of an embodiment of the invention in light of the accompanying drawings, in which Fig. 1A is a bottom perspective view of a primary plate and a gasket of a cooler plate according to an embodiment of the disclosure; Fig. 1B is a perspective top view of the primary plate and seal of Fig. 1A is; Fig. 1C a cross-sectional view of the primary plate and seal of Fig. 1B is along a lateral axis extending between adjacent recesses formed in the primary plate and through a depression formed in the primary plate; Fig. 2A is a top perspective view of a cooler plate according to another embodiment of the disclosure; Fig. 2B is an enlarged partial cross-sectional view taken along a side axis through a stiffening feature of the radiator plate of Fig. 2A extends; Fig. 3A is a top perspective view of the cooler plate according to another embodiment of the disclosure; Fig. 3B a cross-sectional view of the cooler plate of Fig. 3A along a central longitudinal axis of the radiator plate of Fig. 3A is; Fig. 3C is an enlarged partial cross-sectional view of the radiator plate of Fig. 3B along a central longitudinal axis of the radiator plate of Fig. 3B is; Fig. 4A is a top perspective view of the cooler plate according to another embodiment of the disclosure; and Fig. 4B a cross-sectional view of the cooler plate of Fig. 4A is taken along a lateral axis extending between adjacent recesses formed in the primary plate and through a depression formed in the primary plate; Detailed description of the preferred embodiment

[0013] The following detailed description and the accompanying drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings are intended to enable one skilled in the art to make and use the invention and are not intended to limit the scope of the invention in any way.

[0014] The Fig. 1A-2B show a cooler plate 10 for an exhaust gas recirculation (EGR) system of a motor vehicle, in particular a vehicle with an internal combustion engine, according to the present disclosure. The EGR system is configured to receive a gas exhausted from an engine (not shown) of the vehicle. The EGR system may include other components commonly associated with EGR systems, such as an EGR valve. The cooler plate 10 includes a primary plate 12 having a first surface 12a and a second surface 12b. A plurality of recesses 13 are formed through the primary plate 12 adjacent a periphery of the primary plate 12. The recesses 13 are configured to receive a coupling means 14 formed proximate the longitudinal edges of the primary plate 12. The coupling means 14 is configured to attach the cooler plate 10 to the engine block (not shown) of the vehicle.As shown in the exemplary embodiment, the primary plate 12 has a substantially rectangular shape. However, the primary plate 12 may have other shapes as desired.

[0015] A pair of gas boxes 16 having outer peripheral flanges 15 are connected to the first surface 12a of the primary plate 12 adjacent the opposite ends of the primary plate 12. However, it should be understood that the gas boxes 16 may, if desired, be formed integrally with the primary plate 12. The gas boxes 16 extend outwardly from the first surface 12a of the primary plate 12. Each of the gas boxes 16 is configured as a chamber, the chamber having an inlet and an outlet providing fluid communication with a plurality of openings 17 formed in the primary plate 12. In other embodiments, the plurality of openings 17 may each be a single opening relative to each of the gas boxes 16, if desired. Each of the gas boxes 16 includes a coupling flange 18.The coupling flanges 18 provide a connection of the gas boxes 16 to an exhaust system (not shown) of the engine block and an intake system (not shown) of the engine block.

[0016] A plurality of tubes 20 extend longitudinally with respect to the primary plate 12 between each of the openings 17 formed in the primary plate 12 to transport the gas between the gas boxes 16. The plurality of tubes 20 each extend between the openings 17 from the second surface 12b of the primary plate 12. The openings 17 encompassed by the gas boxes 16 provide fluid communication between the gas boxes 16 and the tubes 20. The tubes 20 may be any desired type of tube. For example, the tubes 20 may be U-shaped tubes, flat tubes, C-shaped tubes, or any other tubes now known or later developed.

[0017] The cooler plate 10 is configured to be disposed within an opening in the engine block or a header, with coolant from a cooling system of the vehicle's engine being received within the opening. The tubes 20 are disposed within a flow path of the coolant flowing through the opening. The coolant then circulates around an exterior of the tubes 20 to cool the gas flowing through the tubes 20 from the EGR system. The primary plate 12 facilitates closing and covering the opening to prevent coolant from leaking from the engine block.

[0018] Fig. 1A-1C depict a primary plate 12 of the cooler plate 10 according to one embodiment of the disclosure. As illustrated, the primary plate 12 includes an outer edge 22 extending, with respect to the first surface 12a of the primary plate 12, substantially perpendicular to a plane defined by the primary plate 12 at a perimeter of the primary plate 12. The primary plate 12 further includes the plurality of openings 17 formed therein for fluidly communicating between the gas boxes 16 and the tubes 20. The plurality of openings 17 are configured to receive one end of the tubes 20. A recess 24 is formed in a central portion of the first surface 12a of the primary plate 12. The recess 24 is also configured as a coolant guide member for directing coolant flow to the tubes 20.The recess 24 minimizes the volume of space between the second surface 12b of the plate 12 and the tubes 20, concentrating the flow of coolant along the tubes 20. A plurality of ribs 25 are formed within the recess 24, with the ribs 25 recessed relative to the first surface 12a and projecting relative to the second surface 12b. The rim 22, the recess 24, and the ribs 25 provide increased rigidity and sealing between the primary plate 12 and the engine block.

[0019] As shown, the second surface 12b of the primary plate 12 that engages the engine block is substantially perpendicular to the rim 22 and a wall defining the recess 24. In certain embodiments, a seal 26 contacts the second surface 12b of the primary plate 12. The seal 26 defines the recess 24 and is disposed adjacent the perimeter of the primary plate 12 to provide an improved seal between the primary plate 12 and the engine block at the contact surface between the primary plate 12 and the engine block.

[0020] The Fig. 2A-2B show an alternative embodiment of the cooler plate 10. The cooler plate 10 of the Fig. 2A-2B is comparable to the cooler plate 10 of the Fig. 1A-1C. However, the cooler plate 10 of the Fig. 2A-2B stiffening features 27 to further improve the rigidity and sealing and to further minimize deformation of the cooler plate 10. Comparable features of the cooler plate 10 of Fig. 1A-1C are designated by the same reference numeral for clarity. As shown, the stiffening features 27 are integrally formed with the edge 22 and extend from the edge 22 of the primary plate 12 to the first surface 12a of the primary plate 12. The stiffening features 27 extend from the edge to the primary plate 12, with a first portion of the stiffening feature 27 extending from the edge 22 in a direction substantially parallel to the first surface 12a, a second portion of the stiffening feature 27 extending from the first portion of the stiffening feature 27 in a direction substantially parallel to the edge 22, and a third portion of the stiffening feature 27 extending from the second portion substantially parallel to the first surface 12 and engaging the first surface 12a.The stiffening features 27 are configured to facilitate stiffening of the primary plate 12 by adding additional material to the primary plate 12 at critical points on the primary plate 12 that align with a bead 28 of the seal 26. The stiffening features 27 are disposed between adjacent recesses 13 formed in the primary plate 12. The stiffening features 27 may, for example, be connected to the first surface 12a by a welding or brazing process. However, the stiffening features 27 may be connected to the first surface 12a by other coupling means, if desired. In the embodiment shown, four stiffening features 27 are illustrated. However, any number of stiffening features 27 may be included to maximize stiffening.Additionally, the stiffening features 27 may be formed separately from the second surface 12b and clamped around the edge 22, if desired.

[0021] The Fig. 3A-3C show an alternative embodiment of the cooler plate 10. The cooler plate 10 of the Fig. 3A-3C is comparable to the cooler plate 10 of the Fig. 1A-2B. Similar features of the cooler plate 10 of the Fig. 1A-2B are designated by the same reference numeral for clarity. As shown, the outer peripheral flange 15 of each of the gas boxes 16 in contact with the first surface 12a of the primary plate 12 is arranged in alignment with at least a portion of the bead 28 of the seal 26. Thus, the outer peripheral flange 15 provides concentrated stiffening of the plate 12 in a region of the seal 26 at the bead 28 to maximize the seal.

[0022] The Fig. 4A-4B show an alternative embodiment of the cooler plate 10. The cooler plate 10 of the Fig. 4A-4B is comparable to the cooler plate 10 of the Fig. 1A-3C with the exception that the cooler plate 10 of the Fig. 4A-4B has a support plate 30 arranged on the primary plate 12. Features similar to the cooler plate 10 of Fig. 1A-3C are provided with the same reference numerals for clarity. The support plate 30 is disposed on and enclosed by the first surface 12a of the primary plate 12 and within the rim 22. The gas boxes 16 are formed integrally with the support plate 30 and extend outwardly from the support plate 30 and the primary plate 12. The support plate 30 is connected to the primary plate 12 by any coupling means, such as a welding or brazing process.

[0023] A central recess 32 is formed within the support plate 30. In the illustrated embodiment, the central recess 32 conforms to and is flush with the shape of the depression 24 of the primary plate 12. However, the depression 24 may have any desired shape depending on the application. The support plate 30 further includes an edge 33 extending perpendicularly from a plane defined by a surface thereof. The edge 33 of the support plate 30 is spaced from the edge 22 of the primary plate 12. Although it should be understood that the edge 33 of the support plate 30 may be brought into contact with the edge 22 of the primary plate 12 depending on the position of the bead 28 of the seal 26. The edge 33 of the support plate 30 is substantially perpendicular to a plane defined by the first surface 12a of the primary plate 12 and is aligned with at least a portion of the bead 28 of the seal 26 to maximize sealing.

[0024] It is understood that the support plate 30 may have the gas boxes 16 formed integrally therewith, as shown in the Fig. 4A-4B. However, in an alternative embodiment (not shown), the support plate 30 may be separate from the gas boxes 16, with the gas boxes 16 being connected to the primary plate 12. In such an embodiment, the support plate 30 has holes formed therein to receive the gas boxes 16 connected to the primary plate 12.

[0025] In use, the cooler plate 10 of the embodiments of the Fig.1A-4B are connected to the engine block or the manifold of the internal combustion engine by means of coupling means 14. The gas expelled from the exhaust system of the engine block flows through a first of the gas boxes 16, which is connected to the engine's exhaust system, through the pipes 20 extending between the gas boxes 16, and through a second of the gas boxes 16, which is connected to the intake system of the internal combustion engine. Coolant from the engine cooling system circulates around the pipes 20, thereby cooling the exhaust gas flowing through the pipes 20.

[0026] The primary plate 12 may be preformed by a stamping process or otherwise preformed by other methods, such as casting, rolling, or a similar process. Advantageously, the cooler plate 10 according to the present disclosure provides an improved seal between the cooler plate 10 and the engine block.

[0027] The primary plate 12 is robust and rigid, particularly in the sealing areas where the cooler plate 10 engages the engine block. Furthermore, the concentrated rigidity of the primary plate 12 and the structural arrangement of the primary plate 12 and the gasket 26 result in an increased amount of stiffness and forces applied to the gasket 26, and specifically to the bead 28 of the gasket 26 between the engine block and the primary plate 12. As such, a homogeneous load can be applied to the gasket 26, rather than increasing the amount of coupling means 14 required to ensure a more homogeneous load.In the absence of the additional coupling means 14, which apply the forces required to create a desired seal, the recess 24, the rim 22, the stiffening features 27 and / or the backing plate 30 result in increased forces in critical areas of the primary plate 12 that aligns with the bead 28 of the seal 26, such as adjacent the perimeter of the primary plate 12. As a result, the primary plate 12 can have a minimized thickness and coupling means to minimize deformation and manufacturing cost and complexity.

[0028] From the foregoing description, a person skilled in the art can easily determine the essential features of this invention and, without departing from the spirit and scope of the invention, make various changes and modifications to the invention to adapt it to different applications and conditions. In particular, the features of all embodiments and all claims can be combined with one another, as long as they do not contradict each other.

Claims

[1] Primary plate (12) for a cooling plate (10) comprising: a plate having a first surface (12a), a second surface (12b), a recess (24) formed therein, a plurality of first openings (17) formed therethrough, a plurality of second openings (17) formed therethrough, and a plurality of recesses (13) formed through the plate adjacent a periphery thereof and configured to receive a plurality of coupling means (14) therein, each of the plurality of first openings (17) and the plurality of second openings (17) being configured to receive opposite ends of a plurality of tubes (20), wherein the plate has an outer edge (22) extending outwardly from the first surface (12a) perpendicular to a location defined by the plate at a periphery of the plate, and wherein the plate has stiffening features (27) extending from the edge (22) to the first surface (12a) of the primary plate (12). [2] The primary plate (12) of claim 1, wherein a plurality of ribs (25) are formed in the recess (24). [3] Cooling plate (10) comprising: a primary plate (12) having a first surface (12a), a second surface (12b), a recess (24) therein, a first opening formed therethrough, a second opening formed therethrough, and a plurality of recesses (13) formed therethrough, the plurality of recesses (13) being configured to receive a plurality of coupling means (14), the primary plate (12) being configured to be connected to an engine block of a vehicle having an internal combustion engine; a seal (26) arranged on the second surface (12b) of the primary plate (12); a pair of gas boxes (16) disposed on the first surface (12a) of the primary plate (12), a first of the pair of gas boxes (16) providing fluid communication to the first opening and a second of the pair of gas boxes (16) providing fluid communication to the second opening; and a plurality of tubes (20) extending between the first opening and second opening, wherein the primary plate (12) has an outer edge (22) extending outwardly from the first surface (12a) of the primary plate (12) substantially perpendicular to a plane defined by the plate at a periphery of the primary plate (12), wherein the primary plate (12) has a plurality of stiffening features (27) extending from the edge (22) to the first surface (12a) thereof. [4] Cooling plate (10) according to claim 3, wherein the recess (24) is formed in a central part of the first surface (12a) of the primary plate (12). [5] Cooling plate (10) according to claim 3, wherein a plurality of ribs (25) are formed in the recess (24). [6] Cooling plate (10) according to claim 3, wherein the first opening is divided into a plurality of first openings (17) and the second opening is divided into a plurality of second openings (17). [7] Cooling plate (10) according to claim 3, wherein the pair of gas boxes (16) are arranged adjacent to opposite ends of the primary plate (12). [8] The cooling plate (10) of claim 3, wherein each of the plurality of stiffening features (27) is disposed between adjacent ones of the plurality of recesses (13) formed in the primary plate (12). [9] The cooling plate (10) of claim 3, wherein each of the pair of gas boxes (16) has an outer peripheral flange (15) engaging the first surface (12a) of the primary plate (12). [10] Cooling plate (10) according to claim 9, wherein the outer peripheral flange (15) is arranged in alignment with a part of a bead (28) of the seal (26). [11] The cooling plate (10) according to claim 3, further comprising a support plate (30) disposed on the first surface (12a) of the primary plate (12), wherein the pair of gas boxes (16) is formed integrally with the support plate (30). [12] The cooling plate (10) of claim 3, further comprising a support plate (30) having a pair of holes, the support plate (30) being disposed on the first surface (12a) of the primary plate (12) and receiving the pair of gas boxes (16) through the pair of holes. [13] Cooling plate (10) according to claim 3, wherein the primary plate (12) is formed by a stamping process. [14] Cooling plate (10) according to claim 3, wherein the plurality of recesses (13) are formed adjacent to a periphery of the primary plate (12). [15] Cooling plate (10) comprising: A primary plate (12) having a first surface (12a), a second surface (12b), a plurality of first openings (17) formed therethrough, a plurality of second openings (17) formed therethrough, a plurality of recesses (13) formed therethrough, and a depression (24) formed in the primary plate (12), the plurality of recesses (13) receiving a plurality of coupling means (14), and the primary plate (12) being configured to be connected to an engine block of a vehicle having an internal combustion engine; a support plate (30) arranged on the first surface (12a) of the primary plate (12); a seal (26) having a bead (28) and disposed on the second surface (12b) of the primary plate (12); a pair of gas boxes (16) formed on the support plate (30), a first of the pair of gas boxes (16) providing fluid communication to the plurality of first openings (17) and a second of the pair of gas boxes (16) providing fluid communication to the plurality of second openings (17); and a plurality of tubes (20) extending longitudinally with respect to the primary plate (12) between the pair of gas boxes (16), wherein the primary plate (12) has an outer edge (22) extending outwardly from the first surface (12a) of the primary plate (12) substantially perpendicular to a plane defined by the plate at a periphery of the primary plate (12), wherein the primary plate (12) has a plurality of stiffening features (27) extending from the edge (22) to the first surface (12a) thereof. [16] Cooling plate (10) according to claim 15, wherein the support plate (30) has an edge (22) which is aligned with the bead (28) of the seal (26) and is substantially perpendicular thereto.

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