Modular cooler and isolation valve assembly

Abstract

A heat exchange system comprising an inlet manifold, an outlet manifold, and a modular cooler. The modular cooler comprises an inlet end body coupled to the inlet manifold, an outlet end body coupled to the outlet manifold, a heat exchange body fluidly coupled between the inlet end body and the outlet end body, an inlet isolation valve assembly coupled to the inlet end body and movable between an open position and a closed position, and an outlet isolation valve assembly coupled to the outlet end body and movable between an open position and a closed position. The inlet and outlet isolation valve assemblies are configured to control fluid flow between the manifolds and the end bodies.

Description

BACKGROUNDField

[0001] Embodiments disclosed herein generally relate to a modular cooler for a radiator of a heat exchange system. Embodiments disclosed herein also generally relate to an isolation valve assembly of the modular cooler. Description of the Related Art

[0002] Radiators are an essential component of heat exchange systems and designed to maintain optimal temperature levels in various environments. There can be multiple radiator and / or cooling circuits in a heat exchange system with each circuit cooling a separate fluid. A cooler, which is a component of the radiator, works in conjunction with other coolers and fans to dissipate heat and maintain a desired temperature. For certain applications, very large coolers are needed, which increase weight, size, and therefore cost of the heat exchange system. To service the cooler and / or replace the cooler within a radiator circuit, the applicable radiator circuit needs to be drained before removing the cooler, which similarly increases labor and coolant costs as well as downtime.

[0003] Therefore, there is a need for new and / or improved heat exchange systems. SUMMARY

[0004] In one or more embodiments, a heat exchange system comprises an inlet manifold; an outlet manifold; and a modular cooler. The modular cooler comprises an inlet end body coupled to the inlet manifold; an outlet end body coupled to the outlet manifold; a heat exchange body fluidly coupled between the inlet end body and the outlet end body; an inlet isolation valve assembly coupled to the inlet end body and movable between an open position and a closed position, wherein when in the open position, the inlet isolation valve assembly is configured to allow fluid flow between the inlet manifold to the inlet end body, and wherein when in the closed position, the inlet isolation valve assembly is configured to prevent fluid flow between the inlet manifold to the inlet end body; and an outlet isolation valve assembly coupled to the outlet end body and movable between an open position and a closed position, wherein when in the open position, the outlet isolation valve assembly is configured to allow fluid flow between the outlet end body to the outlet manifold, and wherein when in the closed position, the outlet isolation valve assembly is configured to prevent fluid flow between the outlet end body to the outlet manifold.

[0005] In one or more embodiments, a heat exchange system comprises an inlet manifold; an outlet manifold; and a modular cooler. The modular cooler comprises an inlet end body coupled to the inlet manifold; an outlet end body coupled to the outlet manifold; a heat exchange body fluidly coupled between the inlet end body and the outlet end body; and an inlet isolation valve assembly coupled to the inlet end body and at least partially disposed within the inlet manifold. The inlet isolation valve assembly comprises a valve member movable between an open position and a closed position, and a plug comprising a plunger portion that extends through the inlet end body and into the inlet manifold, wherein the plunger portion is configured to move the valve member into the open position, wherein when in the open position, the valve member is configured to allow fluid flow between the inlet manifold to the inlet end body, and wherein when in the closed position, the valve member is configured to prevent fluid flow between the inlet manifold to the inlet end body.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0007] FIG. 1 illustrates an isometric view of a heat exchange system, according to one or more embodiments.

[0008] FIG. 2 illustrates a right side isometric view of a modular cooler of the heat exchange system, according to one or more embodiments.

[0009] FIG. 3 illustrates a left side isometric view of the modular cooler, according to one or more embodiments.

[0010] FIG. 4 illustrates an isometric view of an upper section of the modular cooler, according to one or more embodiments.

[0011] FIG. 5 illustrates a cross-sectional view of the upper section of the modular cooler, according to one or more embodiments.

[0012] FIG. 6 illustrates an isometric view of a lower section of the modular cooler, according to one or more embodiments.

[0013] FIG. 7 illustrates a cross-sectional view of the lower section of the modular cooler, according to one or more embodiments.

[0014] FIG. 8 illustrates a cross-sectional view of the modular cooler, according to one or more embodiments.

[0015] FIG. 9 illustrates a cross-sectional view of an isolation valve assembly, according to one or more embodiments.

[0016] FIG. 10 illustrates a cross-sectional view of an isolation valve assembly, according to one or more embodiments.

[0017] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.DETAILED DESCRIPTION

[0018] The disclosure contemplates that terms such as “couples,”“coupling,”“couple,” and “coupled” may include but are not limited to welding, interference fitting, magnetic coupling, and / or fastening such as by using bolts, threaded connections, pins, clips, and / or screws. The disclosure contemplates that terms such as “couples,”“coupling,”“couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,”“coupling,”“couple,” and “coupled” may include but are not limited to direct coupling and / or indirect coupling, such as indirect coupling through components such as links.

[0019] FIG. 1 illustrates an isometric view of a heat exchange system 1000, according to one or more embodiments. The heat exchange system 1000 comprises a frame 100, a fan assembly 200 coupled to the frame 100, and a radiator 400 coupled to a side of the frame 100. The fan assembly 200 is configured to draw air into the heat exchange system 1000. The heat exchange system 1000 may comprise multiple radiator circuits, such as the radiator 400, coupled to the opposing sides of the frame 100. These radiator circuits may be fluidly isolated from each other, and the fluids flowing through one of the radiator circuits may be the same or different than the fluids flowing through any one of the other radiator circuits.

[0020] The radiator 400 is an air-to-liquid cooler that comprises an inlet manifold 410, an outlet manifold 420, and a plurality of modular coolers 450 (in a side-by-side configuration) each fluidly coupled at opposite ends to the inlet manifold 410 and the outlet manifold 420. The inlet manifold 410 is in fluid communication with at least one inlet 413 through which heated liquid (e.g., a coolant comprising a water glycol mixture or oil) may flow, and the outlet manifold is in fluid communication with at least one outlet 414 through which cooled liquid may flow out, thereby forming a closed fluid circuit. Ambient air may be drawn through the modular coolers 450 by the fan assembly 200 to remove heat from the heated liquid flowing through the closed fluid circuit. In one or more embodiments, fluid flow through the modular coolers 450 may be designed to flow in the opposite direction such that fluid flows into the outlet manifold 420, up through the modular coolers 450, and out through the inlet manifold 420 as illustrated. Although shown at the upper and lower ends of the frame 100 and oriented horizontally, in one or more embodiments, the inlet and outlet manifolds 410, 420 may be positioned on the sides of the frame 100 and oriented vertically with the modular coolers 450 oriented horizontally in a stacked configuration.

[0021] FIGS. 2 and 3 illustrate right and left side isometric views, respectively, of one modular cooler 450 of the radiator 400, according to one or more embodiments. The modular cooler 450 comprises an inlet end body 430, an outlet end body 440, and a heat exchange body 460 disposed between the inlet and outlet end bodies 430, 440. The inlet end body 430 is coupled to and in fluid communication with the inlet manifold 410. The outlet end body 440 is coupled to and in fluid communication with the outlet manifold 420. Fluid, such as a heated liquid (e.g., a coolant comprising a water glycol mixture) may flow from the inlet manifold 410 into the inlet end body 430, then into the heat exchange body 460, then into the outlet end body 440, and then into the outlet manifold 420. The fluid may be cooled when flowing through the heat exchange body 460, which may comprise a plurality of internal fluid channels 418 (illustrated in FIGS. 5, 7, and 8) through which the fluid flows, and a plurality of external fluid channels 419 through which air may flow to remove the heat. For example, the heat exchange body 460 may comprise an aluminum bar and plate or other conventional heat exchange cores, and is not limited to these examples and may include different types of heat exchange core materials and technologies.

[0022] An inlet isolation valve assembly 470 (e.g., a check valve) is coupled to the inlet end body 430 and configured to control fluid flow between the inlet manifold 410 and the inlet end body 430. An outlet isolation valve assembly 480 (e.g., a check valve) is coupled to the outlet end body 440 and configured to control fluid flow between the outlet end body 440 and the outlet manifold 420. As further described below, the isolation valve assemblies 470, 480 can be used to fluidly isolate the modular cooler 450 from other modular coolers 450 of the radiator 400 such that the fluid in the isolated modular cooler 450 can be drained while the other modular coolers 450 remain filled with fluid. The inlet and outlet isolation valve assemblies 470, 480 may comprise different types of valves configured to control fluid flow, such as check valves, gate valves, ball valves, and / or other types of valves.

[0023] FIG. 4 illustrates an isometric view of an upper section of the modular cooler 450, according to one or more embodiments. The inlet end body 430 is coupled to a mounting block 473 of the isolation valve assembly 470 via one or more fasteners 416, such as bolts. The mounting block 473 is coupled to an outer surface of the inlet manifold 410, such as by welding. A plug 471 of the isolation valve assembly 470 is inserted into, seals, and extends through a port 474 formed in the inlet end body 430. When sealed, the plug 471 prevents fluid from flowing out through the port 474. The inlet end body 430 may comprise a rounded section 472 through which the plug 471 extends.

[0024] FIG. 5 illustrates a cross-sectional view of the upper section of the modular cooler 450, according to one or more embodiments. A seal 475, such as an o-ring, may be positioned between an end of the plug 471 and the outer surface (such as a groove) of the inlet end body 430 to help seal the port 474. The port 474 may be threaded such that the plug 471 is threaded into the port 474 to compress the seal 475 therebetween. Alternatively, where the port 471 is not threaded, a threaded fitting may be coupled (such as by welding) to the port 474 and the plug 471 is threaded into the threaded fitting to compress the seal 475 therebetween. The plug 471 has a plunger portion 488 that extends into the inlet manifold 410 through a bore 431 of the inlet end body 430, through a bore 491 of the mounting block 473, and through a bore 492 of a valve housing 481 of the isolation valve assembly 470. The valve housing 481 is disposed in and extends through an opening 412 formed in a sidewall of the inlet manifold 410.

[0025] One end of the valve housing 481 that extends out of the inlet manifold 410 is at least partially disposed in the bore 491 of the mounting block 473 and comprises an outer shoulder 478 that engages a recess in the mounting block 473. The valve housing 481 and the bore 491 of the mounting block 473 may comprise corresponding threads such that the valve housing 481 can be threaded into the bore 491 of the mounting block 473. A seal 477, such as an o-ring may be positioned between the inner surface of the mounting block 473 forming the bore 491 and the outer surface of the valve housing 481. Another seal 476, such as an o-ring may be positioned between the outer surface (e.g., an end face) of the inlet end body 430 and the outer shoulder 478 (e.g., an end face) of the valve housing 481. Fluid flow is therefore sealed between the inlet manifold 410 and the inlet end body 430.

[0026] An opposite end of the valve housing 481 extends into the inlet manifold 410. The plunger portion 488 of the plug 471 extends into the inlet manifold 410 and engages a valve member 484, such as a check disc, of the isolation valve assembly 470. The valve member 484 compresses a biasing member 486, such as a spring, between the valve member 484 and a back cover 483 of the isolation valve assembly 470. The back cover 483 is coupled to the end of the valve housing 481. The valve member 484 comprises a guide portion 485 that extends through back cover 483. One or more openings 482 are disposed through sidewalls of the portion of the valve housing 481 surrounding the valve member 484 and the biasing member 486. Fluid may flow from the inlet manifold 410 into the valve housing 481 through the openings 482 and / or through openings 497 formed in the back cover 483.

[0027] When installed and during operation of the heat exchange system 1000, the plunger portion 488 of the plug 471 contacts and holds the valve member 484 in an open position such that fluid may flow from the inlet manifold 410 through the isolation valve assembly 470 and into the inlet end body 430. Specifically, as illustrated by reference line 490, fluid flows through the inlet 413 and into a bore 411 of the inlet manifold 410, through the openings 482 of the valve housing 481 and / or through the openings 497 of the back cover 483, through the bores of the valve housing 481, mounting block 473, and inlet end body 430, and then out through an open end of the inlet end body 430 that is in fluid communication with the internal fluid channels 418 of the heat exchange body 460. As the fluid flows through the internal fluid channels 418 to the outlet end body 440, air (which may be drawn in by the fan assembly 200 illustrated in FIG. 1) flows through the external fluid channels 419 to remove the heat from the fluid that is transferred to the heat exchange body 460, thereby cooling the fluid.

[0028] When the plug 471 with the plunger portion 488 is removed from the inlet end body 430, the valve member 484 is movable by the biasing member 486 into a closed position in contact with the valve housing 481. Specifically, the valve member 484 comprises a sealing surface 487 (e.g., an outer shoulder) that is moved into contact with a sealing surface 479 (e.g., an inner shoulder) of the valve housing 481 to close fluid flow through the bore 492 of the valve housing 481. The isolation valve assembly 470 therefore can selectively be used to open and close fluid communication between the inlet manifold 410 and the modular cooler 450.

[0029] FIG. 6 illustrates an isometric view of a lower section of the modular cooler 450, according to one or more embodiments. FIG. 7 illustrates a cross-sectional view of the lower section of the modular cooler 450, according to one or more embodiments. The outlet end body 440 and the isolation valve assembly 480 are a mirror image of the inlet end body 430 and the isolation valve assembly 470, and function in a similar manner, a full description of which will not be repeated herein for brevity. The components of the isolation valve assembly 480 that are similar to the isolation valve assembly 470 are identified with the same reference numbers. The outlet end body 440 is coupled to the outlet manifold 420 in a similar manner as the inlet end body 430 is coupled to the inlet manifold 410.

[0030] With reference to FIG. 7, the valve housing 481 is disposed in and extends through an opening 422 formed in a sidewall of the outlet manifold 420. When installed and during operation of the heat exchange system 1000, the plunger portion 488 of the plug 471 holds the valve member 484 in an open position such that fluid may flow from the outlet end body 440 through the isolation valve assembly 480 and into the outlet manifold 420. Specifically, as illustrated by reference line 490, fluid flows from the internal fluid channels 418 of the heat exchange body 460 through an open end of the outlet end body 440, through the bores of the outlet end body 440, mounting block 473, and valve housing 481, through the openings 482 of the valve housing 481 and / or through the openings 497 of the back cover 483, into a bore 421 of the outlet manifold 420. The fluid may flow out of the bore 421 of the outlet manifold 420 through the outlets 414.

[0031] FIG. 8 illustrates a cross-sectional view of the modular cooler 450, according to one or more embodiments. The plugs 471 of the isolation valve assemblies 470, 480 have been removed from the inlet end body 430 and the outlet end body 440. The isolation valve assemblies 470, 480 are moved by the biasing members 486 into the closed positions to close fluid communication with the inlet manifold 410 and the outlet manifold 420. The sealing surfaces 487 of the valve members 484 are moved into contact with the sealing surfaces 479 of the valve housings 481 to close fluid flow through the bores 492 of the valve housings 481.

[0032] The modular cooler 450 is therefore fluidly isolated from the inlet manifold 410, the outlet manifold 420, and the other modular coolers 450 (illustrated in FIG. 1) that are fluidly coupled to the inlet manifold 410 and the outlet manifold 420. Fluid in the modular cooler 450 can now be drained out through the ports 474 of the inlet end body 430 and the outlet end body 440, without draining fluid from the inlet manifold 410, the outlet manifold 420, and / or the other modular coolers 450. Specifically, as illustrated by reference line 495, fluid in the inlet end body 430 may flow out through the port 474 of the inlet end body 430. Fluid may also flow from the inlet end body 430, through the heat exchange body 460, into the outlet end body 440 and out through the port 474 of the outlet end body 440. The modular cooler 450 can also be detached from the inlet manifold 410 and the outlet manifold 420 (such as by removing the fasteners 416 illustrated in FIG. 4) for further servicing, repair, and / or replacement.

[0033] FIG. 9 illustrates a cross-sectional view of an isolation valve assembly 570, according to one or more embodiments. The isolation valve assembly 570 can be used in place of the isolation valve assemblies 470, 480. The isolation valve assembly 570 (e.g., a flapper valve) includes a plug 571 having a plunger portion 588 that engages a valve member 584. The valve member 584 is coupled to a valve housing 581 which is coupled to a mounting block 573. The valve member 584 is coupled to and biased into engagement with the valve housing 581 by a biasing member 586, such as a spring-hinged connection. The valve member 584 is movable between an open position and a closed position to open and close fluid flow through a bore 592 of the valve housing 581. The biasing member 586 moves the valve member 584 into the closed position, and the plug 571 with the plunger portion 588, when installed, moves the valve member 584 into the open position.

[0034] FIG. 10 illustrates a cross-sectional view of an isolation valve assembly 670, according to one or more embodiments. The isolation valve assembly 670 can be used in place of the isolation valve assemblies 470, 480. The isolation valve assembly 670 operates in a similar manner as the isolation valve assembly 570, and the components of the isolation valve assembly 670 that are similar to the isolation valve assembly 570 are identified with the same reference number but have a 600-series designation. One difference of the isolation valve assembly 670 is that the mounting block 673 is disposed about an outer shoulder 697 of the valve housing 681.

[0035] It will be appreciated by those skilled in the art that the preceding embodiments are exemplary and not limiting. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements. The disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted in for one or more of the other aspects described. The scope of the disclosure is determined by the claims that follow.

Claims

1. A heat exchange system, comprising:an inlet manifold;an outlet manifold; anda modular cooler comprising:an inlet end body coupled to the inlet manifold;an outlet end body coupled to the outlet manifold;a heat exchange body fluidly coupled between the inlet end body and the outlet end body;an inlet isolation valve assembly coupled to the inlet end body and movable between an open position and a closed position, wherein when in the open position, the inlet isolation valve assembly is configured to allow fluid flow between the inlet manifold to the inlet end body, and wherein when in the closed position, the inlet isolation valve assembly is configured to prevent fluid flow between the inlet manifold to the inlet end body; andan outlet isolation valve assembly coupled to the outlet end body and movable between an open position and a closed position, wherein when in the open position, the outlet isolation valve assembly is configured to allow fluid flow between the outlet end body to the outlet manifold, and wherein when in the closed position, the outlet isolation valve assembly is configured to prevent fluid flow between the outlet end body to the outlet manifold.

2. The heat exchange system of claim 1, wherein the inlet isolation valve assembly comprises a mounting block that is coupled to an outer surface of the inlet manifold.

3. The heat exchange system of claim 2, wherein the inlet end body is coupled to the mounting block.

4. The heat exchange system of claim 3, wherein the inlet isolation valve assembly comprises a valve housing at least partially disposed in a bore of the mounting block, and wherein a seal is positioned between an end face of the valve housing and an end face of the inlet end body.

5. The heat exchange system of claim 4, wherein a plug of the inlet isolation valve assembly extends through a port formed in the inlet end body, and wherein a seal is disposed between an end of the plug and an outer surface of the inlet end body to seal the port.

6. The heat exchange system of claim 5, wherein the plug has a plunger portion that extends through a bore of the inlet end body, through the bore of the mounting block, through a bore of the valve housing, and through an opening of the inlet manifold.

7. The heat exchange system of claim 6, wherein the valve housing extends through the opening of the inlet manifold and is at least partially disposed within the inlet manifold.

8. The heat exchange system of claim 7, wherein the inlet isolation valve assembly comprises a valve member configured to open and close fluid flow through the bore of the valve housing, which thereby opens and closes fluid flow between the inlet manifold and the inlet end body.

9. The heat exchange system of claim 8, wherein the plunger portion of the plug extends into the inlet manifold and holds the valve member in an open position.

10. The heat exchange system of claim 9, wherein the valve member compresses a biasing member between the valve member and a back cover of the isolation valve assembly, wherein the back cover is coupled to an end of the valve housing, and wherein the biasing member is configured to move the valve member to a closed position.

11. The heat exchange system of claim 10, wherein one or more openings are disposed through sidewalls of a portion of the valve housing surrounding the valve member and the biasing member.

12. The heat exchange system of claim 11, wherein fluid flows from the inlet manifold into the bore of the valve housing through at least one of the openings in the valve housing and openings formed in the back cover.

13. A heat exchange system, comprising:an inlet manifold;an outlet manifold; anda modular cooler comprising:an inlet end body coupled to the inlet manifold;an outlet end body coupled to the outlet manifold;a heat exchange body fluidly coupled between the inlet end body and the outlet end body; andan inlet isolation valve assembly coupled to the inlet end body and at least partially disposed within the inlet manifold, wherein the inlet isolation valve assembly comprises:a valve member movable between an open position and a closed position, anda plug comprising a plunger portion that extends through the inlet end body and into the inlet manifold, wherein the plunger portion is configured to move the valve member into the open position, wherein when in the open position, the valve member is configured to allow fluid flow between the inlet manifold to the inlet end body, and wherein when in the closed position, the valve member is configured to prevent fluid flow between the inlet manifold to the inlet end body.

14. The heat exchange system of claim 13, wherein the plug extends through a port formed in the inlet end body, and wherein a seal is disposed between an end of the plug and an outer surface of the inlet end body to seal the port.

15. The heat exchange system of claim 14, wherein the inlet isolation valve assembly comprises a mounting block that is coupled to an outer surface of the inlet manifold, and wherein the inlet end body is coupled to the mounting block.

16. The heat exchange system of claim 15, wherein the inlet isolation valve assembly comprises a valve housing at least partially disposed in a bore of the mounting block, and wherein a seal is positioned between an end face of the valve housing and an end face of the inlet end body.

17. The heat exchange system of claim 16, wherein the plunger portion extends through a bore of the inlet end body, through the bore of the mounting block, through a bore of the valve housing, through an opening of the inlet manifold and into contact with the valve member.

18. The heat exchange system of claim 17, wherein the valve housing extends through the opening of the inlet manifold and is at least partially disposed within the inlet manifold.

19. The heat exchange system of claim 18, wherein the valve member compresses a biasing member between the valve member and a back cover of the isolation valve assembly, wherein the back cover is coupled to an end of the valve housing, and wherein the biasing member is configured to move the valve member to a closed position.

20. The heat exchange system of claim 13, further comprising an outlet isolation valve assembly coupled to the outlet end body and movable between an open position and a closed position, wherein when in the open position, the outlet isolation valve assembly is configured to allow fluid flow between the outlet end body to the outlet manifold, and wherein when in the closed position, the outlet isolation valve assembly is configured to prevent fluid flow between the outlet end body to the outlet manifold.

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