Integrated Sump Heat Exchanger Module Design
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Solution Overview
Problem
Conventional oil sump and oil cooler modules (OSOC modules) are time-consuming, complex, and costly to produce and assemble, with heat exchangers exposed to adverse environmental conditions leading to corrosion, high coolant pressure drop, and susceptibility to clogging.
Innovation Solution
A sump and heat exchanger module with a plastic housing that integrates a heat exchanger within a corrosion-resistant plastic shell, using a submarine-style heat exchanger to minimize exposure and reduce coolant pressure drop, and incorporates a cover to seal the heat exchanger and sump spaces, eliminating the need for external fixation features and separate aluminum components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat exchanger is mounted outside the housing using external fixation features, then the heat exchanger can be securely mounted, but the production and assembly process becomes time-consuming, complex, and costly
Solution Approach 1:
The heat exchanger is integrated within the housing structure, merging two previously separate components (housing and heat exchanger) into a unified assembly. This eliminates the need for external fixation features and reduces assembly complexity while maintaining mounting security through the integrated design
Solution Approach 2:
The housing structure serves multiple functions: it provides structural enclosure, mounting support, and integration of the heat exchanger. By making the housing multi-functional, the design eliminates the need for separate external fixation components, reducing overall device complexity
2Ease of manufacture
If the heat exchanger is disposed outside the housing, then assembly is simplified, but the heat exchanger is exposed to adverse environmental conditions leading to corrosion
Solution Approach 1:
By integrating the heat exchanger within the housing, the design protects the heat exchanger from environmental exposure while maintaining manufacturing simplicity. The housing acts as a protective enclosure that shields the heat exchanger from corrosion-prone conditions
3Power
If traditional heat exchangers with separate coolant and oil plates are used, then heat exchange function is achieved, but coolant pressure drop is high impacting performance
Solution Approach 1:
The heat exchanger employs a nested plate structure where coolant passages are formed within the housing walls surrounding the oil plates. This nested configuration allows coolant to flow through the housing walls rather than through separate external passages, reducing pressure drop while maintaining effective heat exchange surface area
4Power
If traditional heat exchangers are used, then heat exchange function is provided, but they are susceptible to clogging from coolant contamination
Solution Approach 1:
The design extracts the coolant flow path from the traditional internal passage configuration and relocates it to flow through the housing walls externally around the oil plates. This separation removes the heat exchanger plates from direct contact with contaminated coolant, eliminating clogging susceptibility while preserving heat exchange functionality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The module reduces production and assembly costs, protects the heat exchanger from corrosion, minimizes weight, and enhances coolant flow efficiency while reducing clogging and weight compared to conventional modules.
Implementation Method 1
a first subset of plates that conduct oil and a second subset of plates that conduct coolant
Implementation Method 2
heat exchanger (e.g., an oil cooler)
Data Source
AI summary
A sump and heat exchanger module may include a housing shell and a cover. The housing shell may at least partially define an internal space. The housing shell may include a sump section configured to receive at least a portion of a sump and a heat exchanger section configured to receive at least a portion of a heat exchanger. The cover may be disposed in the housing shell and may divide the internal space into a heat exchanger space and a sump space. The housing shell may further include a recess via which the heat exchanger space opens into the sump space. The cover may be connected to the housing shell and close the recess sealing the heat exchanger space and the sump space from one another.