Integrated Oil Sump Heat Exchanger for Low Pressure Drop Cooling
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Solution Overview
Problem
Conventional oil sump and oil cooler modules are complex, costly, and inefficient to produce, with heat exchangers exposed to adverse environmental conditions leading to corrosion and experiencing high coolant pressure drops, clogging, and performance issues.
Innovation Solution
A sump and heat exchanger module with a plastic housing that integrates the heat exchanger within the sump, using a submarine-style exchanger to minimize coolant flow through the core, reducing weight and susceptibility to corrosion, and incorporating a cover to seal the heat exchanger space from the sump space, enhancing durability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the heat exchanger is mounted outside the sump housing, then the heat exchanger is exposed to adverse environmental conditions leading to corrosion, but this arrangement allows for simpler mounting structures
Solution Approach 1:
The heat exchanger is integrated inside the sump housing, merging two previously separate components (sump housing and heat exchanger) into a single unified structure. This eliminates the need for external mounting brackets and fixation features, while simultaneously protecting the heat exchanger from environmental corrosion.
Solution Approach 2:
The sump housing serves multiple functions: it contains the oil sump cavity and simultaneously houses the heat exchanger. This multi-functional design eliminates the need for separate mounting structures and provides protective enclosure for the heat exchanger.
2Reliability
If traditional heat exchangers with coolant flow through the core are used, then cooling performance is achieved, but coolant pressure drop increases and clogging susceptibility increases
Solution Approach 1:
Instead of allowing coolant to flow through the heat exchanger core (traditional approach), the design inverts the flow path: coolant flows around the exterior of the heat exchanger core. This reversal eliminates high pressure drop through the core while maintaining effective heat transfer.
Solution Approach 2:
The coolant flow path is extracted from the heat exchanger core and redirected to flow externally around the core. This separation removes the harmful effect of high pressure drop and clogging susceptibility from the cooling system.
3Strength
If external fixation features are used to mount the heat exchanger, then the heat exchanger can be securely mounted, but production and assembly time increases and cost increases
Solution Approach 1:
The heat exchanger is merged with the sump housing structure, eliminating the need for separate fixation features. The housing itself provides the mounting function, integrating structural support and heat exchanger mounting into a single component.
Solution Approach 2:
The housing is segmented into distinct functional zones (sump cavity and heat exchanger housing) that are formed as integral parts of the same structure, allowing for simplified manufacturing and assembly without additional fixation components.
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, minimizes corrosion, and improves performance by eliminating the need for external fixation features, reducing weight, and minimizing coolant pressure drop while maintaining efficient fluid separation.
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 section configured to receive at least a portion of a heat exchanger
Data Source
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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.