CN116892442A

CN116892442A - Heat exchanger assembly with vortex baffles

Info

Publication number: CN116892442A
Application number: CN202310354107.5A
Authority: CN
Inventors: N·J·威尔奇
Original assignee: Cummins Inc
Current assignee: Cummins Inc
Priority date: 2022-04-05
Filing date: 2023-04-04
Publication date: 2023-10-17
Also published as: GB202204982D0; JP2023153766A; GB2619393A; AT526122A2; US20230313728A1; AT526122A3; AU2023202094A1; GB2617353A; GB202304598D0; DE102023108428A1

Abstract

The invention relates to a heat exchanger assembly with vortex baffles. A cooling system of an internal combustion engine system includes an engine cooling circuit for defining a flow path and direction for an engine coolant fluid to flow through the internal combustion engine system. The cooling system also includes a heat exchanger assembly positioned along the engine cooling circuit. The heat exchanger assembly is configured to transfer heat from an engine coolant fluid to a working fluid and includes a housing defining an interior cavity, a core disposed within the interior cavity and configured to receive the working fluid, the core including a baffle in the bypass flow path, and a main flow path and a bypass flow path of the engine coolant fluid, the baffle comprising: a base portion coupled to an end of the core; and a curved portion extending from the base portion such that the curved portion prevents the bypass flow of engine coolant fluid from continuing along the bypass flow path.

Description

Heat exchanger assembly with vortex baffles

Technical Field

The present disclosure relates generally to cooling systems for internal combustion engine systems.

Background

In an internal combustion engine system, a cooling system that utilizes a heat exchanger assembly (also referred to as a heat exchanger) reduces the temperature of the coolant by dissipating heat from the coolant to another fluid flowing through the core of the heat exchanger assembly. However, coolant (e.g., bypass flow) passing through the heat exchanger assembly without contacting the core of the heat exchanger assembly does not contribute to heat transfer.

One solution for minimizing or otherwise reducing bypass flow is to attach a baffle (e.g., a rubber baffle) to the core to reduce or close the gap between the core and the wall of the heat exchanger assembly. However, attaching the baffle sufficiently close to the wall to the core to prevent bypass flow requires tight tolerance dimensions, potentially resulting in manufacturing and assembly difficulties. Other solutions, such as increasing the size of the core, may result in increased manufacturing costs.

Disclosure of Invention

Various embodiments relate to assemblies and methods for managing bypass flow in a cooling system of an internal combustion engine system. In various embodiments, the heat exchanger assembly includes a baffle having a curved portion for reducing bypass flow. Various embodiments and implementations of such assemblies and methods may provide for reduced bypass flow around the core of a heat exchanger assembly, thereby having the potential to increase cooling efficiency.

In at least one embodiment, a cooling system for an internal combustion engine system is provided. The cooling system includes: an engine cooling circuit for defining a flow path and direction for an engine coolant fluid to flow through the internal combustion engine system; and a heat exchanger assembly positioned along the engine cooling circuit and configured to transfer heat from the engine coolant fluid to a working fluid, the heat exchanger assembly comprising: a housing defining an interior cavity; a core disposed within the inner cavity and configured to receive the working fluid; and a main flow path and a bypass flow path for the engine coolant fluid, the core including a baffle (baffle) located in the bypass flow path, the baffle comprising: a base portion coupled to an end of the core; and a curved portion extending from the base portion such that the curved portion prevents a bypass flow of engine coolant fluid from continuing along the bypass flow path.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present teachings.

Drawings

The present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements, unless otherwise specified, and in which:

FIG. 1 is a block diagram of a cooling system including a heat exchanger assembly according to an exemplary embodiment;

FIG. 2 is a perspective view of a heat exchanger assembly, with a housing removed, that may be used in, for example, the cooling system of FIG. 1, according to an exemplary embodiment;

FIG. 3 is a side view of the heat exchanger assembly of FIG. 2 with the housing removed;

FIG. 4 is a perspective view of detail A of the heat exchanger assembly as seen in FIG. 3;

FIG. 5 is a side view of detail A of the heat exchanger assembly;

FIG. 6 is a diagram of detail B of the heat exchanger assembly of FIG. 2, showing engine coolant fluid flowing through the heat exchanger assembly, in accordance with an exemplary embodiment; and

FIG. 7 is a cross-sectional view of the heat exchanger assembly taken along line 7-7 of FIG. 2.

Detailed Description

The following is a more detailed description of various concepts and implementations of components, devices, and methods for providing a cooling system for an internal combustion engine system. The cooling system includes a heat exchanger assembly configured to transfer heat from an engine coolant liquid to a working fluid. The various concepts introduced above and discussed in more detail below may be implemented in any of a variety of ways, as the described concepts are not limited to any particular implementation. Examples of specific embodiments and applications are provided primarily for illustrative purposes.

I. Summary of the invention

Various embodiments described herein relate to cooling systems for internal combustion engine systems. The cooling system includes an engine cooling circuit that contains an engine coolant fluid. The cooling system also includes a heat exchanger assembly positioned along the engine cooling circuit. The heat exchanger assembly is configured to transfer heat from the engine coolant fluid to the working fluid. The heat exchanger assembly includes: a housing defining an interior cavity; a core disposed within the inner cavity and configured to receive the working fluid; an inlet port fluidly coupled to the inner cavity and configured to provide the engine coolant fluid to the inner cavity; an outlet port fluidly coupled to the lumen; and a baffle plate including a base portion coupled to an end of the core and a curved portion extending from the base portion.

II. Cooling System

FIG. 1 depicts a block diagram illustrating an engine system 100 according to an exemplary embodiment. The engine system 100 includes a cooling system 101, the cooling system 101 including an engine cooling circuit 102 and a heat exchanger assembly 118. The engine system 100 may also include an engine 104 having an engine block 106 and an engine top (overlap) 108, a turbocharger 110, a coolant reservoir 112, a pump 114, a valve 116, a heat exchanger assembly 118, and a coolant filter 144. As discussed further below, the engine cooling circuit 102 defines a flow path and direction for an engine coolant fluid to flow through the internal combustion engine system. In some embodiments, the flow path includes a channel (e.g., a flow path inlet, a flow path outlet, a conduit, etc.) fluidly coupling components of the engine system 100. In some embodiments, the engine coolant fluid may include a glycol-based coolant, water, or other coolant fluid. In other embodiments, the engine coolant fluid is hot oil or other type of heat transfer fluid. It should also be noted that when referring to engine system 100, the terms "upstream" and "downstream" refer to the direction of the engine coolant fluid flowing through engine cooling circuit 102.

Referring to FIG. 1, an engine system 100 includes an engine 104. The engine 104 may be any type of internal combustion engine. Thus, the engine 104 may be a gasoline engine, a natural gas engine, or a diesel engine, a hybrid engine (e.g., a combination of an internal combustion engine and an electric motor), and/or any other suitable engine. The engine 104 includes an engine block 106. The engine block 106 may at least partially define one or more cylinders of the engine. The one or more cylinders are configured to allow the one or more pistons to move within the combustion chambers of the cylinders. The engine 104 also includes an engine top 108. The engine top 108 is positioned above the engine block 106 and may include, for example, inlet valves, exhaust valves, and one or more camshafts.

The engine system 100 of fig. 1 includes a turbocharger 110 downstream of the engine block 106. Turbocharger 110 receives exhaust gas generated by combustion in engine block 106. In some embodiments, the turbocharger 110 includes a bypass operable to selectively bypass at least a portion of the exhaust gas from the turbocharger 110 to reduce boost pressure and engine torque under certain operating conditions. The turbocharger 110 may be positioned on the engine cooling circuit 102, configured to receive engine coolant liquid from the engine. Engine coolant fluid may be used by turbocharger 110 to lubricate internal components (e.g., bearings, main shaft, etc.).

The engine system 100 of fig. 1 includes a coolant reservoir 112 (e.g., a disc, oil pan, etc.), the coolant reservoir 112 being positioned on the engine cooling circuit 102 downstream of the engine roof 108 and the turbocharger 110. The coolant reservoir 112 is fluidly coupled to the engine roof 108 and the turbocharger 110 via an engine cooling circuit, and is configured to receive and store engine coolant fluid from the engine roof 108 and the turbocharger 110.

The engine coolant fluid received and stored in the coolant reservoir 112 may be later recirculated within the cooling system. For example, the engine system 100 may include a coolant pump 114. In some embodiments, the coolant pump 114 is disposed downstream of the coolant reservoir 112. The coolant pump 114 is configured to circulate an engine coolant fluid through the engine cooling circuit 102.

The engine system 100 of fig. 1 also includes a valve 116 (e.g., a regulator valve, etc.) positioned on the engine cooling circuit 102. The valve 116 may be positioned downstream of the coolant pump 114. In some embodiments, valve 116 controls the amount of engine coolant fluid flowing through the engine cooling circuit. More specifically, the valve 116 controls the amount of engine coolant fluid flowing through the heat exchanger assembly 118, as discussed in further detail below. The valve 116 may control the engine coolant fluid by restricting or preventing the engine coolant fluid from flowing to the heat exchanger assembly 118.

The heat exchanger assembly 118 of fig. 1 is positioned downstream of the valve 116 and is configured to transfer heat from the engine coolant fluid in the engine cooling circuit 102 to the working fluid to cool the engine coolant fluid and heat the working fluid. FIG. 2 is a perspective view of an example heat exchanger assembly 118, according to an example embodiment. Fig. 3 is a side view of the heat exchanger assembly 118 of fig. 2. Fig. 4 is detail a of the heat exchanger assembly 118 as seen in fig. 3. Fig. 5 is a side view of detail a of heat exchanger assembly 118. FIG. 6 is an illustration of an engine coolant fluid flowing through the heat exchanger assembly 118 of FIG. 2, according to an exemplary embodiment.

The engine system 100 of fig. 1 may also include a coolant filter 144 (e.g., an oil filter, etc.). The coolant filter 144 may be positioned between the heat exchanger assembly 118 and the engine 104. The coolant filter 144 is configured to filter out 144 particulates (e.g., soot, metallic particulates, etc.) from the engine coolant liquid such that the engine coolant liquid exiting the coolant filter 144 contains fewer particulates than the engine coolant liquid entering the engine coolant liquid filter 144 (e.g., flowing from the heat exchanger assembly 118, etc.). In this manner, the coolant filter 144 also inhibits or reduces particulate infiltration into the engine 104 downstream of the coolant filter 144, thereby helping to prolong operation of the engine 104 or reduce maintenance requirements of the engine 104.

Construction of an example heat exchanger assembly

Referring to fig. 2, 6, and 7, the heat exchanger assembly 118 includes a housing 120 (e.g., shell, box, shell, etc.). A housing 120 encloses the internal components of the heat exchanger assembly 118. In this manner, the housing 120 protects the internal components of the heat exchanger assembly 118 and reduces exposure of other components of the internal combustion engine system to high temperatures.

The housing 120 defines an interior cavity 122 by surrounding the internal components of the heat exchanger assembly 118. The interior cavity 122 is configured to receive engine coolant fluid provided through the engine cooling circuit via the pump 114. Specifically, the internal cavity 122 receives engine coolant fluid via an inlet port 124. The inlet port 124 is in fluid communication with an upstream component (such as the valve 116) positioned on the engine cooling circuit. In some embodiments, the inlet port 124 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhered, glued, pinned, etc.) to an end 121 (e.g., a sidewall, etc., as seen in fig. 7) of the housing 120. In other embodiments, the inlet port 124 is integrally formed with the end of the housing 120.

The heat exchanger assembly 118 also includes an outlet port 126. The outlet port 126 is in fluid communication with downstream components positioned on the engine cooling circuit. In some embodiments, the outlet port 126 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhered, glued, pinned, etc.) to the other end 123 of the housing 120, the end 123 being opposite the end corresponding to the inlet port 124. In some embodiments, the outlet port 126 is integrally formed with the other end of the housing 120.

The heat exchanger assembly 118 includes a core 128. A core 128 is disposed within the inner cavity 122 and is configured to receive a working fluid. The working fluid is used to cool the engine coolant fluid. For example, engine coolant fluid passing through the interior cavity 122 is heated by the engine. As the heated engine coolant liquid flows through the inner cavity 122, the heated engine coolant fluid contacts the core 128 and transfers heat to the working fluid flowing through the core 128. Thus, the engine coolant fluid is cooled before reaching the engine. According to various embodiments, the working fluid may include any of a variety of types of fluids, such as, for example, refrigerants (e.g., R245a or other low global warming potential ("GWP") alternatives), ethanol, toluene, other hydrocarbon-based working fluids, other hydrofluorocarbon-based working fluids, or water. In some embodiments, the core 128 receives the working fluid through a plurality of channels extending through the core 128.

As described above, engine coolant fluid passes through the inner cavity 122. A portion of the engine coolant fluid flowing through the interior cavity 122 is defined as the main flow 130. The main flow 130 is configured to flow in a main flow direction 133 from the inlet port 124 to the outlet port 126. In this manner, the outlet port 126 is configured to provide a main flow 130 (e.g., a main flow of coolant, oil, etc.) to downstream components of the cooling system. However, in some embodiments, the primary flow 130 may be configured to flow in a direction opposite the primary flow direction 133 (e.g., from the outlet port 126 to the inlet port 124, etc.).

A main flow 130 of engine coolant fluid flows along a main flow path 132. The primary flow path 132 is defined as the space between the core 128 and the housing 120 and extends from the inlet port 124 to the outlet port 126. As the main flow 130 flows along the main flow path 132, the heated engine coolant fluid contacts the core 128 and transfers heat to the working fluid flowing through the core 128.

Although the main flow 130 flows along the main flow path 132, the main flow 130 may diverge from the main flow path 132. In particular, the main flow 130 may diverge from the main flow path 132 to define a bypass flow 134. A bypass flow 134 of engine coolant fluid flows along a bypass flow path 136. In some embodiments, the bypass flow path 136 is the space between the end 125 of the core 128 closest to the inlet port 124 and the housing 120. Referring to fig. 6, a bypass flow path 136 extends upwardly from the main flow path 132 in a bypass flow direction 127 and surrounds the core 128. In some embodiments, the bypass flow path 136 is perpendicular to the main flow path 132. In this way, the bypass flow path 136 diverges from the main flow path 132. Notably, because the bypass flow path 136 diverges from the main flow path 132 and extends around the core 128 in this manner, the core 128 is unable to facilitate heat transfer from the bypass flow 134 to the core 128.

Referring to fig. 2-6, the heat exchanger assembly 118 includes baffles 138 (e.g., plates, protrusions, etc.). In some embodiments, the baffle 138 is integrally formed with the core 128. However, the baffle 138 may alternatively be a separate component coupled to the core 128. The baffle 138 includes a base portion 140. The base portion 140 is coupled to the end of the core 128 or is integrally formed with the end of the core 128. More specifically, the base portion 140 may be coupled to the end 125 of the core 128 closest to the inlet port 124 or integrally formed with the end 125 of the core 128.

In some embodiments, the base portion 140 extends in a direction parallel to the surface of the end of the core 128. The base portion 140 may also be coupled to the core 128 at a predetermined location so as to reduce the gap between the core 128 and the housing 120. In this way, the diameter of the bypass flow path 136 decreases in the portion 137 downstream of the baffle 138, thereby restricting the bypass flow 134 in the bypass flow direction. However, the baffle 138 may also be positioned such that the baffle 138 is separated from the housing 120 to reduce flow disturbances. In some embodiments, the base portion 140 is constructed from sheet metal or sheet material. Thus, the base portion 140 may be more securely fastened to the core 128 than other systems that use rubber baffles, which may present installation challenges and may fall out during operation.

The baffle 138 includes a curved portion 142. The curved portion 142 extends from the base portion 140. In particular, the curved portion 142 extends into the bypass flow path 136 of the engine coolant fluid and is concavely curved in the bypass flow direction 127. In this manner, the curved portion 142 is configured to reduce (e.g., block, restrict, etc.) the bypass flow 134 in the bypass flow direction 127 by reducing the size (e.g., diameter of the bypass flow path, width of the bypass flow path, etc.) of the bypass flow path 136 at the downstream portion 137 (as compared to the upstream portion 139 of the baffle 138). For example, when the bypass flow 134 reaches the curved portion 142, a portion of the bypass flow 134 is received (e.g., concentrated, captured, collected, etc.) by the curved portion 142 and prevented from continuing along the bypass flow path 136 to the downstream portion 137. Further, the curved portion 142 is configured to create the vortex 131 in the bypass flow 134. Because the curved portion 142 creates a vortex in the bypass flow 134, the bypass flow 134 path is reduced at the downstream portion 137 when compared to the upstream portion 139. By creating the vortex 131 within the curvature of the curved portion 142, the curved portion 142 reduces the bypass flow 134 in the bypass flow direction 127. In this way, the bypass flow 134 of engine coolant fluid that does not contribute to heat transfer is reduced.

As described above, in the heat exchanger assembly 118 of fig. 2-6, the curved portion 142 is concavely curved in the bypass flow direction 127. By concavely curving in the bypass flow direction 127, the curved portion 142 is configured to return at least a portion of the bypass flow 134 to the main flow path 132. For example, when the bypass flow 134 is received by the curved portion 142, the curved portion 142 is configured to create a region in the bypass flow 134 that is higher than the pressure of the main flow 130 of engine coolant fluid. Thus, because the bypass flow 134 generally flows in a direction from a higher pressure region to a lower pressure region, the higher pressure region reduces the bypass flow 134 in the bypass flow direction 127 and causes at least a portion of the bypass flow 134 to flow in a direction opposite the bypass flow direction (e.g., toward the main flow path 132, etc.). Further, the baffle 138 is configured to reduce the flow rate of the bypass flow 134 in the bypass flow direction 127. When the curved portion 142 receives the bypass flow 134 and blocks the bypass flow 134 in the bypass flow direction 127, the flow rate of the bypass flow 134 decreases and a portion of the bypass flow 134 returns to the main flow 130.

Configuration of example embodiments

While this specification contains various implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Furthermore, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

As used herein, the terms "substantially," "approximately," and similar terms are intended to have a broad meaning consistent with the ordinary and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art who review this disclosure will appreciate that these terms are intended to allow the description of certain features described and claimed without limiting the scope of such features to the precise numerical scope provided. Accordingly, these terms should be construed to indicate that non-essential or discontinuous modifications or changes of the described and claimed subject matter are considered to be within the scope of the appended claims.

As used herein, the term "coupled" or the like means that two components are directly or indirectly joined to one another. Such engagement may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved by the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another and the two members or the two members and any additional intermediate members being attached to one another.

As used herein, the term "fluidly coupled to" or the like means that two components or objects have a passageway formed between the two components or objects in which a fluid (such as air, reductant, air-reductant mixture, exhaust gas, hydrocarbon, air-hydrocarbon mixture) may flow with or without intermediate components or objects. Examples of fluid couplings or configurations for effecting fluid communication may include pipes, channels, or any other suitable component for enabling fluid flow from one component or object to another.

It is important to note that the construction and arrangement of the various systems as shown in the various example implementations is illustrative only and not limiting. It is intended to protect all changes and modifications that come within the spirit and/or scope of the described implementations. It should be understood that some features may not be necessary and embodiments lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the appended claims.

Furthermore, the term "or" is used in the context of a list of elements in its inclusive sense (rather than in its exclusive sense) such that when used in conjunction with a list of elements, the term "or" means one, some, or all of the elements in the list. Unless explicitly stated otherwise, connectivity language such as the phrase "at least one of X, Y and Z" is otherwise understood to be commonly used to convey that items, terms, etc. may be X, Y, Z, X and Y, X and Z, Y and Z, or X, Y and Z (i.e., any combination of X, Y and Z) may be X, Y, Z, X and Y. Thus, unless otherwise indicated, such connectivity language is not generally intended to imply that certain embodiments require the presence of at least one X, at least one Y, and at least one Z, all.

In addition, unless otherwise indicated, ranges of values used herein include their maximum and minimum values. Furthermore, unless otherwise indicated, a numerical range does not necessarily include intermediate values within the numerical range.

It is important to note that the arrangement of the various systems and the operation of the various techniques shown in the various example implementations are illustrative only and not limiting. It is intended to protect all changes and modifications that come within the spirit and/or scope of the described implementations. It should be understood that some features may not be necessary and embodiments lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the appended claims.

Claims

1. A cooling system of an internal combustion engine system, the cooling system comprising:

an engine cooling circuit for defining a flow path and direction for an engine coolant fluid to flow through the internal combustion engine system; and

a heat exchanger assembly positioned along the engine cooling circuit and configured to transfer heat from the engine coolant fluid to a working fluid, the heat exchanger assembly comprising:

a housing defining an interior cavity;

a core disposed within the inner cavity and configured to receive the working fluid; and

the core includes a baffle in the bypass flow path, the baffle comprising:

a base portion coupled to an end of the core; and

a curved portion extending from the base portion such that the curved portion prevents a bypass flow of engine coolant fluid from continuing along the bypass flow path.

2. The cooling system of claim 1, wherein the curved portion extends into the bypass flow path of the engine coolant fluid and curves concavely in a bypass flow direction.

3. The cooling system of claim 2, wherein the curved portion is configured to create a region in the bypass flow that is higher than a pressure of a main flow of the engine coolant fluid.

4. A cooling system according to claim 2 or 3, wherein the curved portion is configured to generate a vortex in the bypass flow.

5. The cooling system of any one of claims 2 to 4, wherein the curved portion is configured to reduce the size of the bypass flow downstream of the baffle.

6. The cooling system of any one of claims 2 to 5, wherein the curved portion is configured to reduce a flow velocity of the bypass flow in the bypass flow direction.

7. The cooling system of any one of the preceding claims, wherein the baffle is integrally formed with the core.

8. The cooling system of any one of the preceding claims, wherein the base portion extends in a direction parallel to a surface of the end of the core.

9. The cooling system of any one of the preceding claims, further comprising:

an inlet port fluidly coupled to the inner cavity and configured to provide the engine coolant fluid to the inner cavity; and

an outlet port fluidly coupled to the lumen.

10. An engine system, the engine system comprising:

a cooling system according to any one of the preceding claims; and

an engine including an engine block and an engine roof positioned downstream of the heat exchanger assembly along the engine cooling circuit.

11. The engine system of claim 10, further comprising a pump configured to circulate the engine coolant fluid through the engine cooling circuit.

12. The engine system of claim 10 or 11, further comprising a turbocharger positioned on the engine cooling circuit downstream of the engine.

13. The engine system of claim 12, further comprising a coolant reservoir positioned on the engine cooling circuit downstream of the turbocharger and configured to receive and store the engine coolant fluid.

14. The engine system of any of claims 10-13, further comprising a valve positioned on the engine cooling circuit upstream of the heat exchanger assembly and configured to manage the engine coolant fluid provided to the heat exchanger assembly.