Modified plate and bar type coolant cooled oil cooler assembly

Abstract

The present invention relates to a plate and bar construction for an coolant cooled oil cooler assembly designed to enhance heat transfer efficiency and reduce pressure drop. The assembly includes a tank with first and second inlets / outlets for different mediums, and an oil cooler core with bars, separating members, turbulators, and baffles positioned strategically to optimize heat exchange. The method for constructing the assembly involves specific steps such as providing the tank with inlets / outlets, arranging the oil cooler core components, and positioning baffles to improve heat transfer. This invention offers a more efficient and effective solution for cooling systems in various applications.

Description

[0001] MODIFIED PLATE AND BAR TYPE COOLANT COOLED OIL COOLER ASSEMBLY

[0002] FIELD OF INVENTION:

[0003]

[0001] The invention disclosed herein is cooler assemblies and more particularly is pertained to oil cooler assemblies.

[0004] BACKGROUND:

[0005]

[0002] Heat exchangers play a crucial role in various industries, including aerospace, automotive, and industrial applications, where efficient heat transfer is essential for optimal equipment performance. Traditional heat exchanger designs often involve plate and bar constructions, which consist of stacked plates with fluid passages and fins for heat transfer. These assemblies are widely used due to their effectiveness in transferring heat between fluids while maintaining compactness and structural integrity.

[0006]

[0003] In the field of heat exchangers, plate and bar constructions have been extensively studied and utilized. Prior art includes designs featuring stacked plates with interconnected fluid passages, often combined with fins or turbulators to enhance heat transfer efficiency. These designs have been employed in various applications, such as automotive radiators, industrial cooling systems, and aircraft engine oil coolers.

[0007]

[0004] In surface air cooled oil coolers and other heat exchanger systems across different industries. Overall, plate and bar cooler assemblies represent a well-established and widely adopted technology in heat exchanger design, offering a balance of thermal performance, compactness, and ease of manufacturing and maintenance.

[0008]

[0005] The United States patent application, US20180283813A1 discloses a wet-cooled heat exchanger with associated sensors and data analysis platforms to monitor and adjust operating conditions. Disadvantages compared to a plate and bar cooler assembly without seals include potential complexity, maintenance challenges with seals, and limited adaptability to certain environments due to the wet-cooled design's requirements.

[0006] The Korean patent application, KR20020004518A discloses, oil flow control mechanisms and fixing methods like clinching or brazing, but it may face challenges with local repairs for cracks and increased assembly complexity compared to a plate and bar cooler assembly without seals, which offers simpler maintenance and assembly processes, especially for localized repairs.

[0009]

[0007] The Chinese patent document, CN108869044B discloses, heat exchanger offers a unitary monolithic single body design with enhanced thermal conductivity and reduced manufacturing costs, weight, and assembly complexity. However, it may face limitations in localized repairs or modifications compared to a plate and bar cooler assembly without seals, which typically allows for easier maintenance and component replacement due to its modular design.

[0010]

[0008] There is still a need for a cooler assembly with efficient cooling performance and low pressure drop.

[0011] SUMMARY

[0012]

[0009] In various embodiments, a plate and bar construction for an oil cooler assembly is provided. A first inlet and a first outlet for a first medium and a second inlet and a second outlet for a second medium provided on surface of a tank is provided. An oil cooler core comprising, a plurality of bars placed with a plurality of separating members and a plurality of turbulators for flow of a coolant positioned near a first inlet and a first outlet. A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of an Oil along an opposite direction positioned near a second inlet and a second outlet.

[0013]

[0010] A plurality of baffles positioned within the cooler assembly, wherein said baffles extend alternatively from top and bottom surfaces of tanks to facilitate enhanced heat transfer efficiency,

[0014] [OH] Characterized in that, the oil cooler core includes Rectangular passages to optimize heat exchange efficiency.

[0015]

[0012] In many embodiments, a plurality of baffles extending from sides of the tank facilitating a reduced oil side pressure drop, facilitated by a decreased number of oil flow direction changes within the cooler assembly.

[0016]

[0013] In various embodiments, the first inlet and the first outlet are placed on one side of tank.

[0014] In some embodiments, the second inlet and second outlet are placed on top portion of tank.

[0017]

[0015] In various embodiments, the cooler assembly is provided with metallurgical joints.

[0018]

[0016] In many embodiments, passage of the coolant is perpendicular to the passage of oil.

[0019]

[0017] In various embodiments, a method for constructing an oil cooler assembly is provided.

[0020] A tank with a first inlet and a first outlet for a first medium and a second inlet and a second outlet for a second medium on a surface thereof is provided. An oil cooler core is provided. A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of a coolant positioned near a first inlet and a first outlet. A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of a Oil along an opposite direction positioned near a second inlet and a second outlet. Positioning a plurality of baffles within the cooler assembly, wherein the baffles extend alternatively from upper or lower Tanks to enhance heat transfer efficiency. Oil cooler core in a Rectangular geometry is provided to optimize heat exchange efficiency.

[0021]

[0018] In many embodiments, a plurality of baffles from the sides of the tank to reduce oil side pressure drop by decreasing the number of oil flow direction changes within the cooler assembly.

[0022]

[0019] In various embodiments, designing rectangular water passages with inner fins within the cooler assembly to optimize heat exchange efficiency.

[0023] DRAWINGS

[0024]

[0020] Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

[0025]

[0021] FIGs.lA, represents top view of Oil cooler without top tank.

[0026]

[0022] FIGs.lB, represents side view of Oil cooler without RH tank.

[0027]

[0023] FIG. 2A represents top view of the Oil cooler core

[0028]

[0024] FIG. 2B represents side view of the Oil cooler core

[0029]

[0025] FIG. 3 illustrates sectional inner view of oil cooler tank. DETAILED DESCRIPTION

[0030]

[0026] It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

[0031]

[0027] Throughout the specification and claims, the following terms take the meanings explicitly associated herein unless the context clearly dictates otherwise. The meaning of "a", "an", and "the" include plural references. The meaning of "in" includes "in" and "on." Additionally, a reference to the singular includes a reference to the plural unless otherwise stated or inconsistent with the disclosure herein.

[0032]

[0028] A novel plate and bar construction for an oil cooler assembly 100, designed to achieve superior thermal management performance. The cooler assembly 100, is provided by highlighting the unique features that contribute to exceptional heat transfer efficiency.

[0033]

[0029] The oil cooler assembly 100 is comprised of a primary housing, a tank as shown in FIGs 1A- 2B, which strategically is provided to integrate dedicated inlets and outlets for efficient fluid flow. A first inlet 101 and a first outlet 102 serve as the entry and exit points for the coolant medium. A tank for first medium is represented as 103 and 104. In many embodiments, coolant is typically water or a water-glycol mixture. Their placement on the tank surface allows for easy connection to the engine's cooling system. Counterparts to these are the second inlet 107 and second outlet 108, specifically designated for the engine oil. The specific placement of these oil inlets and outlets, as will be detailed in subsequent claims, plays a crucial role in optimizing the flow path within the assembly. Top and bottom tanks 106 and 108 are provide in FIGs 1 A and IB.

[0034]

[0030] In many embodiments, nestled within the tank lies the heart of the assembly - the oil cooler core. This core is meticulously designed to maximize heat transfer between the engine oil and the coolant. It features an array of bars that constitute the primary heat exchange surfaces. In many embodiments, the bars are short bars 111 and long bars 112. These bars are strategically arranged with separating members to create dedicated flow channels for both the coolant and oil, ensuring distinct and optimized paths for each fluid. Further enhancing the coolant flow path are integrated turbulators positioned near the first inlet 101 and first outlet 102. These turbulators 114 promote controlled turbulence within the coolant, increasing its contact with the bars and significantly improving heat transfer efficiency.

[0031] The oil cooler core is further divided into two distinct sections based on the designated flow direction of the two mediums.

[0035]

[0032] In many embodiments Oil Flow Section is explained in a detailed manner. This section houses an array of bars, separating members, and potentially additional turbulators 114 specifically designed to optimize the flow path for engine oil. Its strategic positioning near the second inlet and second outlet ensures efficient oil circulation within the core.

[0036]

[0033] In various embodiments, Coolant Flow Section is provided. This section, positioned near the first inlet 102a and first outlet 102b for coolant, comprises an array of bars, separating members, and dedicated turbulators 114 specifically designed for the coolant flow path. The meticulous arrangement of these components promotes efficient heat absorption by the coolant as it interacts with the hot engine oil flowing through the neighbouring channels.

[0037]

[0034] In many embodiments as depicted in FIG. 3, Strategic Baffle Placement for Enhanced Heat Transfer are explained in an elaborate manner. The oil cooler assembly 100 incorporates a strategically placed array of baffles positioned within the tank. These baffles are not merely passive dividers, but rather active components that significantly contribute to the assembly's thermal performance. They extend alternatively from the top and bottom surfaces of the tank, effectively directing and guiding the flow paths of both oil and coolant within the core. This strategic placement ensures efficient interaction between the two fluids, maximizing heat transfer by promoting increased contact time and a more even distribution of flow across the entire core area.

[0038]

[0035] In various preferable embodiments, Rectangular Passages for Unparalleled Thermal Management is provided. A key differentiator of this invention from traditional designs lies in the unique configuration of the flow passages within the oil cooler core. Unlike conventional round or oval passages, this design utilizes rectangular passages formed by the bars and separating members. This change is configured to have significant advantages.

[0039]

[0036] In various advantageous embodiments, Increased Surface Area is provided. Compared to traditional passage shapes, rectangular passages provide a substantially larger surface area for heat exchange between the oil and coolant. This translates to enhanced thermal management capabilities, allowing the assembly to absorb and dissipate heat more efficiently.

[0040]

[0037] In many embodiments Improved Flow Dynamics is provided. The rectangular shape of core promotes a more uniform and controlled flow of both fluids within their respective channels. This streamlined flow is configured to minimize turbulence and pressure drops, further optimizing heat transfer efficiency.

[0041]

[0038] In many embodiments, minimized Oil Side Pressure Drop for Optimal Performance is provided. This specific embodiment focuses on addressing a potential challenge within the oil flow path - pressure drop. It achieves this by strategically incorporating baffles extending from the sides of the tank, in addition to those positioned on the top and bottom. These strategically placed baffles play a crucial role in.

[0042]

[0039] In various embodiments, guiding Oil Flow is disclosed. The side baffles effectively guide the oil flow within the core, minimizing the number of times the oil flow direction needs to change. This reduction in directional changes helps to maintain a lower pressure drop on the oil side, ensuring optimal engine oil circulation and preventing potential performance issues.

[0043]

[0040] In many embodiments, Perpendicular Flow Passage Configuration for Peak Efficiency is provided. An additional embodiment focuses on the relative flow directions of oil and coolant within the core. This embodiment ensures that the passage for the coolant flow is oriented perpendicular to the passage for the oil flow. This perpendicular arrangement maximizes the contact surface area between the two fluids, further enhancing heat transfer efficiency for exceptional thermal management.

[0044]

[0041] In various embodiments, the oil cooler assembly is further enhanced by incorporating robust metallurgical joints during its construction. These joints, formed using specialized welding or brazing techniques, create a strong and leak-proof.

[0045]

[0042] In many embodiments, the oil cooler assembly 100 is provided with a unique design that leverages integrated turbulators and a perpendicular flow path configuration to achieve exceptional heat transfer efficiency.

[0046]

[0043] In various embodiments, coolant heat absorption is maximized with turbulators 114. In many embodiments there turbulators 114 are also referred to as fins interchangeably. Within the coolant flow section of the oil cooler core, strategically placed turbulators 114 play a vital role in enhancing heat exchange. These turbulators 114 are small fins or protrusions integrated into the separating members or directly onto the bars. As the coolant flows through the rectangular channels, these turbulators 114 disrupt the laminar flow, creating controlled turbulence. This controlled turbulence increases the mixing within the coolant stream, bringing cooler portions of the coolant into closer contact with the hot bars. This significantly improves the overall heat transfer rate between the engine oil and the coolant. The turbulence also helps to prevent the formation of stagnant zones within the channels, ensuring that all the coolant contributes effectively to the cooling process.

[0047]

[0044] In many embodiments, optimized heat exchange is provided with Perpendicular Flow Paths. A key feature of the oil cooler assembly lies in the configuration of the flow paths for oil and coolant. Unlike traditional designs where these paths might run parallel to each other, this invention employs a perpendicular flow path arrangement. In this configuration, the oil and coolant channels intersect at right angles. This perpendicular arrangement offers several advantages:

[0048]

[0045] In various embodiments, increased Contact Surface Area is obtained. By having the channels intersect at a 90-degree angle, the design maximizes the surface area available for heat transfer between the two fluids. This allows for more efficient heat exchange to occur as the hot oil and the cooler coolant come into direct contact over a larger area.

[0049]

[0046] In many embodiments, improved flow efficiency is provided. The perpendicular flow path minimizes the potential for flow channelling, a phenomenon where the fluid preferentially flows through certain areas within the core. This even distribution of flow across the entire core ensures that all the available heat exchange surfaces are utilized effectively, leading to a more efficient cooling process.

[0050]

[0047] In various embodiments, fluid flow dynamics around baffles is provided. The strategically positioned baffles within the tank play a crucial role in directing and guiding the flow of both oil and coolant within the core. These baffles, extending alternatively from the top and bottom surfaces (or with the addition of side baffles in specific embodiments), create a specific flow pattern.

[0051]

[0048] In many embodiments, guiding coolant flow is provided. The baffles effectively channel the coolant flow as it enters the core from the first inlet. They direct the flow towards the oil flow section, ensuring even distribution across the rectangular coolant channels. This guided flow maximizes the coolant's interaction with the hot bars, promoting efficient heat absorption.

[0052]

[0049] In various advantageous embodiments, enhanced oil flow is achieved. On the oil side, the baffles help to prevent the formation of stagnant zones within the oil passages. They guide the hot oil as it enters from the second inlet, directing it towards the coolant flow section where it can exchange heat effectively. Additionally, the strategic placement of baffles, particularly with the inclusion of side baffles, minimizes the number of directional changes the oil flow needs to make within the core. This reduces pressure drop on the oil side, ensuring optimal oil circulation and preventing potential performance issues.

[0053]

[0050] This detailed description outlines a novel method for constructing an oil cooler assembly designed to achieve superior thermal management performance. This method leverages a unique plate and bar construction with strategic component placement and specific features to optimize heat transfer between engine oil and coolant.

[0054]

[0051] In many embodiments, core construction and baffle placement are provided. In many embodiments, Tank is provided. The construction process begins with a primary housing, the tank. This tank is meticulously designed and manufactured to house the core components of the oil cooler assembly. The tank surface strategically integrates dedicated inlets and outlets for efficient fluid flow. The first inlet and first outlet serve as the entry and exit points for the coolant medium, typically water or a water-glycol mixture. Their placement on the surface allows for easy connection to the engine's cooling system. Counterparts to these are the second inlet and second outlet, specifically designated for the engine oil.

[0055]

[0052] In various embodiments, oil cooler core assembly is provided. The heart of the assembly is the oil cooler core, meticulously constructed to maximize heat transfer. This core features an array of bars that constitute the primary heat exchange surfaces. These bars are strategically arranged with separating members to create dedicated flow channels for both the coolant and oil, ensuring distinct and optimized paths for each fluid. Further enhancing the coolant flow path are integrated turbulators positioned near the first inlet and first outlet. These turbulators promote controlled turbulence within the coolant, increasing its contact with the bars and significantly improving heat transfer efficiency.

[0056]

[0053] In many embodiments, the oil cooler core is further divided into two distinct sections based on the designated flow direction of the two mediums:

[0057]

[0054] In many embodiments, Oil Flow Section is provided. An array of bars, separating members, and potentially additional turbulators are strategically placed near the second inlet and second outlet. This configuration optimizes the flow path for engine oil within the core, ensuring efficient circulation of hot oil throughout the assembly.

[0055] In various embodiments, coolant flow section is provided. This section, positioned near the first inlet 101 and first outlet 102 for coolant, comprises an array of bars, separating members, and dedicated turbulators 114 specifically designed for the coolant flow path. The meticulous arrangement of these components promotes efficient heat absorption by the coolant as it interacts with the hot engine oil flowing through the neighbouring channels.

[0058]

[0056] Following the core construction, a key step involves strategically positioning a plurality of baffles within the tank as depicted in FIG. 3. These baffles are not merely passive dividers, but rather active components that significantly contribute to the thermal performance of the assembly 100. They extend alternatively from the upper or lower surfaces of the tank, effectively directing and guiding the flow paths of both oil and coolant within the core. This strategic placement ensures efficient interaction between the two fluids, maximizing heat transfer by promoting increased contact time and a more even distribution of flow across the entire core area. This even flow distribution is crucial for preventing hot spots within the core, which could lead to localized overheating and reduced cooling efficiency.

[0059]

[0057] In many embodiments, Minimizing Oil Side Pressure Drop is provided. This embodiment addresses a potential challenge within the oil flow path - pressure drop. Pressure drop can occur when the oil encounters resistance as it flows through the core. Excessive pressure drop can hinder oil circulation and ultimately reduce the effectiveness of the cooling system. To achieve minimized pressure drop, the method incorporates an additional step of extending a plurality of baffles from the sides of the tank 103 and 104, in addition to those positioned on the top and bottom. These strategically placed side baffles play a crucial role in pressure drop. The cooler assembly is configured to achieve a pressure drop in the range of 8- 13 psi.

[0060]

[0058] In various embodiments, oil flow is guided. The side baffles effectively guide the oil flow within the core, minimizing the number of times the oil flow direction needs to change. This reduction in directional changes helps to maintain a lower pressure drop on the oil side, ensuring optimal engine oil circulation and preventing potential performance issues such as power loss or increased wear on engine components. By minimizing pressure drop, this embodiment contributes to the overall efficiency of the oil cooler assembly.

[0061]

[0059] In various embodiments, rectangular water passages with inner fins 110 are provided. The Rectangular passages are formed from long bars 112 and short bars 111. This embodiment focuses on further optimizing heat transfer efficiency within the cooler assembly. It involves designing the rectangular water passages within the core to incorporate inner fins or turbulators 110. These inner fins 114 significantly increase the surface area available for heat transfer between the coolant and the bars. A larger surface area allows for more efficient heat exchange, enabling the coolant to absorb more heat from the engine oil at a faster rate. This can be particularly beneficial in applications where high-performance cooling is critical, such as in high-performance engines or vehicles operating in extreme temperatures.

[0062]

[0060] In many embodiments, Inlet / Outlet Placement is provided. These embodiments pertain to the specific placement of the coolant and oil inlets and outlets on the tank surface. The chosen configuration can influence factors like ease of installation and space utilization within the engine compartment.

[0063] EXPERIMENTAL SECTION:

[0064] Table I: Heat transfer performance test results

[0065]

[0061] The efficiency of modified plate and bar type oil cooler assembly is tested for both coolant flow rate and oil flow rate. A coolant flow rate and oil flow rate of 8 and 3 shows a heat load of 15026 and Oil side pressure drop of 8.54.

[0062] The efficiency of modified plate and bar type oil cooler assembly is tested for both coolant flow rate and oil flow rate. A coolant flow rate and oil flow rate of 8 and 6 shows a heat load of 20487 and Oil side pressure drop of 21.09.

[0066]

[0063] Whereas, coolant flow rate and oil flow rate of prior art under same conditions is provided below. A coolant flow rate and oil flow rate of 8 and 3 shows a heat load of 13450 and Oil side pressure drop of 10.68.

[0067]

[0064] The efficiency of modified plate and bar type oil cooler assembly is tested for both coolant flow rate and oil flow rate. A coolant flow rate and oil flow rate of 8 and 6 shows a heat load of 17925 and Oil side pressure drop of 22.31.

[0068]

[0065] A coolant flow rate and oil flow rate of 8 and 3 shows a heat load of 15026 and Oil side pressure drop of 8.54, shows a very low pressure drop achieved proving the efficiency of modified plate and bar type oil cooler assembly.

[0069]

[0066] Various additional modifications of this invention may occur to those skilled in the art. All deviations from the specific teachings of the several embodiments of this specification that basically rely on the principles and their equivalents through which the art has been advanced are properly considered within the scope and ambit of the invention as described and claimed.

Claims

CLAIMSWe Claim:

1. A plate and bar construction for an oil cooler assembly, comprising: a first inlet and a first outlet for a first medium and a second inlet and a second outlet for a second medium provided on surface of a tank; and an oil cooler core comprising:A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of a coolant positioned near a first inlet and a first outlet;A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of an Oil along an opposite direction positioned near a second inlet and a second outlet; andA plurality of baffles positioned within the cooler assembly, wherein said baffles extend alternatively from top and bottom surfaces of tanks to facilitate enhanced heat transfer efficiency,Characterized in that, the oil cooler core includes Rectangular passages to optimize heat exchange efficiency.

2. The cooler assembly as claimed in claim 1, wherein a plurality of baffles extending from sides of the tank facilitating a reduced oil side pressure drop, facilitated by a decreased number of oil flow direction changes within the cooler assembly.

3. The cooler assembly as claimed in claim 1, wherein the first inlet and the first outlet are placed on one side of tank.

4. The cooler assembly as claimed in claim 1, wherein the second inlet and second outlet are placed on top portion of tank.

5. The cooler assembly as claimed in claim 1, wherein the cooler assembly is provided with metallurgical joints.

6. The cooler assembly as claimed in claimed in claim 1, wherein passage of the coolant is perpendicular to the passage of oil.

7. A method for constructing an oil cooler assembly, comprising the steps of: a. Providing a tank with a first inlet and a first outlet for a first medium and a second inlet and a second outlet for a second medium on a surface thereof; b. Providing an oil cooler core comprising: c. A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of a coolant positioned near a first inlet and a first outlet; d. A plurality of bars Placed with a plurality of separating members and a plurality of turbulators for flow of a Oil along an opposite direction positioned near a second inlet and a second outlet; and e. Positioning a plurality of baffles within the cooler assembly, wherein the baffles extend alternatively from upper or lower Tanks to enhance heat transfer efficiency; characterized in providing oil cooler core in a Rectangular geometry to optimize heat exchange efficiency8. The method as claimed in claim 7, further comprising extending a plurality of baffles from the sides of the tank to reduce oil side pressure drop by decreasing the number of oil flow direction changes within the cooler assembly.

9. The method as claimed in claim 7, further comprising placing the first inlet and the first outlet on one side of the tank.

10. The method as claimed in claim 7, further comprising placing the second inlet and the second outlet on the top portion of the tank.

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