DE102023108428A1 - HEAT EXCHANGER ASSEMBLY WITH EDDY CURRENT CONDUCTOR - Google Patents

Abstract

A cooling system of an internal combustion engine system includes an engine cooling circuit for defining a flow path and direction for engine coolant fluid flowing 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 structured to transfer heat from the engine coolant fluid to a working fluid and includes a shell defining an internal cavity, a core disposed within the internal cavity and structured to receive the working fluid, and a A main flow path and a bypass flow path of the engine coolant fluid, the core including a baffle in the bypass flow path, the baffle including: a base portion coupled to an end of the core, and a curved portion extending from the base portion extends so that the curved portion prevents bypass flow of engine coolant fluid from continuing along the flow path.

Description

TECHNICAL FIELD

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

STATE OF THE ART

In internal combustion engine systems, cooling systems with heat exchanger assemblies (also called heat exchangers) lower the temperature of the coolant by transferring the coolant's heat to another fluid that flows through a core of the heat exchanger assembly. However, coolant passing through the heat exchanger assembly without coming into contact with the core (e.g., bypass flow) does not contribute to heat transfer.

One solution to minimize or otherwise reduce bypass flow is to attach baffles, e.g. B. rubber, on the core to reduce or close a gap between the core and a wall of the heat exchanger assembly. However, attaching the baffles to the core close enough to the wall to prevent bypass flow requires tight tolerance dimensions, potentially leading to manufacturing and assembly difficulties. Other solutions, such as increasing the size of the core, may result in higher manufacturing costs.

SHORT PRESENTATION

Various embodiments relate to assemblies and methods for controlling bypass flow in a cooling system of an internal combustion engine system. In various embodiments, a heat exchanger assembly includes a baffle that has a curved portion for reducing bypass flow. Various embodiments and implementations of such assemblies and methods can provide reduced bypass flow around a core of the heat exchanger assembly, which can result in improved cooling efficiency.

In at least one embodiment, a cooling system of an internal combustion engine system is provided. The cooling system includes an engine cooling circuit for defining a flow path and direction for engine coolant fluid flowing through the internal combustion engine system; and a heat exchanger assembly positioned along the engine cooling circuit and structured to transfer heat from the engine coolant fluid to a working fluid, the heat exchanger assembly including: a shell defining an internal cavity, a core defined in the internal cavity arranged and structured to receive the working fluid, and a main flow path and a bypass flow path of the engine coolant fluid, the core comprising a baffle in the bypass flow path, the baffle including: a base portion connected to an end of the core and a curved portion extending from the base portion such that the curved portion prevents 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 do not limit the present teachings.

BRIEF DESCRIPTION OF DRAWINGS

• 1 ein Blockdiagramm eines Kühlsystems einschließlich einer Wärmetauscherbaugruppe gemäß einer beispielhaften Ausführungsform ist;
• 2 eine perspektivische Ansicht einer Wärmetauscherbaugruppe mit abgenommener Hülle ist, die gemäß einer beispielhaften Ausführungsform zum Beispiel in dem Kühlsystem von 1 verwendet werden kann;
• 3 eine Seitenansicht der Wärmetauscherbaugruppe von 2 ist, bei der die Hülle entfernt wurde;
• 4 eine perspektivische Ansicht von Detail A der Wärmetauscherbaugruppe ist, wie in 3 zu sehen;
• 5 eine Seitenansicht von Detail A der Wärmetauscherbaugruppe ist;
• 6 eine Veranschaulichung von Detail B der Wärmetauscherbaugruppe in 2 ist, die zeigt, wie ein Motorkühlmittelfluid gemäß einer beispielhaften Ausführungsform durch die Wärmetauscherbaugruppe fließt; und
• 7 eine Querschnittsansicht der Wärmetauscherbaugruppe entlang der Linie 7-7 von 2 ist.

The disclosure will be better understood from the following detailed description taken in conjunction with the accompanying figures, in which like reference numerals refer to like elements unless otherwise indicated, in which:

• 1 is a block diagram of a cooling system including a heat exchanger assembly according to an example embodiment;
• 2 is a perspective view of a heat exchanger assembly with the shell removed, according to an exemplary embodiment, for example, in the cooling system of 1 can be used;
• 3 a side view of the heat exchanger assembly from 2 is where the cover has been removed;
• 4 a perspective view of detail A of the heat exchanger assembly is as shown in 3 to see;
• 5 is a side view of detail A of the heat exchanger assembly;
• 6 an illustration of detail B of the heat exchanger assembly in 2 Fig. 10 showing engine coolant fluid flowing through the heat exchanger assembly in accordance with an example embodiment; and
• 7 a cross-sectional view of the heat exchanger assembly taken along line 7-7 of 2 is.

DETAILED DESCRIPTION

Below are more detailed descriptions of various concepts and implementations mentations of assemblies, devices and methods for providing a cooling system for an internal combustion engine system. The cooling system includes a heat exchanger assembly structured to transfer heat from an engine coolant fluid to a working fluid. The various concepts introduced above and explained in more detail below can be implemented in various ways, as the concepts described are not limited to a particular type of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

I. Overview

Various implementations described herein relate to a cooling system of an internal combustion engine system. The cooling system includes an engine cooling circuit that includes an engine coolant fluid. The cooling system also includes a heat exchanger assembly positioned along the engine cooling circuit. The heat exchanger assembly is structured to transfer heat from the engine coolant fluid to a working fluid. The heat exchanger assembly includes a shell defining an internal cavity, a core disposed within the internal cavity and structured to receive the working fluid, an inlet port fluidly coupled to the internal cavity and structured to providing engine coolant fluid to the internal cavity, an outlet port fluidly coupled to the internal cavity, and a baffle including a base portion coupled to an end of the core and a curved portion extending from the base portion .

II. Cooling system

1 illustrates a block diagram illustrating an engine system 100 according to an example embodiment. The engine system 100 includes a cooling system 101 that includes an engine cooling circuit 102 and a heat exchanger assembly 118. The engine system 100 may also include an engine 104 with an engine block 106 and engine overhead 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 below, the engine coolant circuit 102 defines a flow path and direction for engine coolant fluid flowing through the internal combustion engine system. In some embodiments, the flow path includes channels (e.g., flow path inlets, flow path outlets, conduits, etc.) that fluidly couple the components of the engine system 100. In some embodiments, the engine coolant fluid may include a glycol-based coolant, water, or other coolant fluids. In other embodiments, the engine coolant fluid is a thermal oil or other type of heat transfer fluid. It should also be noted that the terms "upstream" and "downstream" when referring to the engine system 100 refer to a direction of engine coolant fluid flowing through the engine cooling circuit 102.

Referring to 1 , the engine system 100 includes an engine 104. The engine 104 can be any type of internal combustion engine. Thus, the engine 104 may be a gasoline, natural gas, or 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 movement of one or more pistons within the combustion chambers of the cylinders. The engine 104 also includes an engine overhead 108. The engine overhead 108 is positioned above the engine block 106 and may include, for example, an intake valve, an exhaust valve, and one or more camshafts.

The engine system 100 of the 1 includes a turbocharger 110 downstream of the engine block 106. The turbocharger 110 receives the exhaust gases that arise during combustion in the engine block 106. In some embodiments, the turbocharger 110 includes a bypass that allows at least a portion of the exhaust gases from the turbocharger 110 to be selectively redirected to reduce engine boost and torque under certain operating conditions. The turbocharger 110 may be positioned on the engine cooling circuit 102, thereby being configured to receive the engine coolant fluid from the engine. The engine coolant fluid may be used by the turbocharger 110 to lubricate internal components (e.g., bearings, spindles, etc.).

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

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

The engine system 100 from 1 also includes a valve 116 (e.g., a control 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 an amount of engine coolant fluid flowing through the engine cooling circuit. In particular, valve 116 controls the amount of engine coolant fluid flowing through heat exchanger assembly 118, as discussed in more detail below. The valve 116 may control engine coolant fluid by limiting or blocking engine coolant fluid from flowing to the heat exchanger assembly 118.

The heat exchanger assembly 118 from 1 is positioned downstream of the valve 116 and is structured to transfer thermal energy 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. 2 is a perspective view of an example heat exchanger assembly 118 according to an example embodiment. 3 is a side view of the heat exchanger assembly 118 of 2 . 4 is a perspective view of detail A of the heat exchanger assembly 118, as shown in 3 to see. 5 is a side view of detail A of the heat exchanger assembly 118. 6 is an illustration of how an engine coolant fluid flows through the heat exchanger assembly 118 of FIG 2 flows.

The engine system 100 from 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 144 particulate matter (e.g., soot, metal particles, etc.) from the engine coolant fluid, such that the engine coolant fluid exiting the coolant filter 144 contains fewer particles than the engine coolant fluid entering the coolant filter 144 (e.g., B. flows from the heat exchanger assembly 118, etc.). In this manner, the coolant filter 144 also prevents or reduces the entry of particulate matter into the engine 104 downstream of the coolant filter 144, thereby allowing longer operation or less maintenance of the engine 104.

III. Heat exchanger assembly configuration

Like from the 2 , 6 and 7 As shown, the heat exchanger assembly 118 includes a shell 120 (e.g., a housing, a panel, a casing, etc.). The shell 120 encloses the internal components of the heat exchanger assembly 118. In this manner, the shell 120 protects the internal components of the heat exchanger assembly 118 and reduces the exposure of other components of the internal combustion engine system to high temperatures.

By enclosing the internal components of the heat exchanger assembly 118, the shell 120 defines an internal cavity 122. The internal cavity 122 is structured to receive the engine coolant fluid provided by the pump 114 via the engine cooling circuit. In particular, the inner cavity 122 receives the engine coolant fluid via the inlet port 124. The inlet port 124 is in fluid communication with upstream components positioned on the engine cooling circuit, such as the valve 116. In some embodiments, the inlet port 124 is with an end 121 (e.g., a sidewall, etc. - see 7 ) of the shell 120 coupled (e.g. attached, fixed, welded, fastened, riveted, glued, bonded, pinned, etc.). In other embodiments, the inlet port 124 is formed integrally with the end of the sheath 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, glued, bonded, pinned, etc.) to another end 123 of the shell 120 that is opposite the end corresponding to the inlet port 124. In some embodiments, the outlet port 126 is formed integrally with the other end of the sleeve 120.

The heat exchanger assembly 118 includes a core 128. The core 128 is located within the internal cavity 122 and is structured to receive the working fluid. The working fluid is used to cool the engine coolant fluid. For example, the engine coolant fluid passing through the internal cavity 122 is heated by the engine. As the heated engine coolant fluid flows through the interior cavity 122, the heated engine coolant fluid comes with it the core 128 in contact and transfers heat to the working fluid flowing through the core 128. Therefore, the engine coolant fluid is cooled before it reaches the engine. According to various embodiments, the working fluid may include various types of fluids, such as a refrigerant (e.g., R245a or other low global warming potential (“GWP”) substitutes), ethanol, toluene, other hydrocarbon-based working fluids, other fluorocarbon-based working fluids, or water . In some embodiments, core 128 receives the working fluid through a plurality of channels extending through core 128.

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

The main flow 130 of engine coolant fluid flows through a main flow path 132. The main flow path 132 is defined as a space between the core 128 and the shell 120 and extends from the inlet port 124 to the outlet port 126. As the main flow 130 flows through 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 branch off from the main flow path 132. In particular, the main flow 130 can branch off from the main flow path 132 to define a bypass flow 134. The engine coolant fluid bypass flow 134 flows along a flow path 136. In some embodiments, the flow path 136 is a space between the end 125 of the core 128 closest to the inlet port 124 and the shell 120. With reference to 6 The bypass flow path 136 extends upward from the main flow path 132 in a bypass flow direction 127 and around the core 128. In some embodiments, the bypass flow path 136 is perpendicular to the main flow path 132. In this manner, the bypass flow path 136 branches off from the main flow path 132. In particular, since the bypass flow path 136 branches off 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 facilitate.

Like from the 2-6 As shown, the heat exchanger assembly 118 includes a baffle 138 (e.g., a plate, a boss, etc.). In some embodiments, the baffle 138 is formed integrally with the core 128. However, the baffle 138 can also be a separate component that is coupled to the core 128. The baffle 138 includes a base section 140. The base portion 140 is coupled to or integrally formed with one end of the core 128. In particular, the base portion 140 may be coupled to or integrally formed with the end 125 of the core 128 that is closest to the inlet port 124.

In some embodiments, the base portion 140 extends in a direction parallel to a surface of the end of the core 128. The base portion 140 may also be coupled to the core 128 at a predetermined location to reduce a gap between the core 128 and the shell 120 . In this manner, a diameter of the flow path 136 is reduced in a 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 shell 120 to reduce flow interference. In some embodiments, the base portion 140 includes a metal sheet. Accordingly, the base portion 140 can be more securely attached to the core 128 than other systems with rubber baffles, which can cause problems during installation and come loose during operation.

The baffle 138 includes a curved section 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 section 142 is structured to reduce (e.g., obstruct, restrict, etc.) the bypass flow 134 in the bypass flow direction 127 by increasing a size of the bypass flow path 136 (e.g B. a diameter of the bypass flow path, a width of the bypass flow path, etc.) at the downstream section 137 is reduced compared to a section 139 upstream of the baffle 138. For example, when the bypass flow 134 reaches the curved section 142, a portion of the bypass flow 134 is received (e.g., concentrated, captured, collected, etc.) by the curved section 142 and prevented from passing along the bypass flow path 136 to flow on to section 137 downstream. Furthermore, the curved section 142 is structured to create a vortex 131 in the bypass flow 134. Because the curved section 142 creates the vortex in the bypass flow 134, the path of the bypass flow 134 is reduced at the downstream section 137 compared to the upstream section 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 manner, the bypass flow 134 of the engine coolant fluid that does not contribute to heat transfer reduced.

As described above, the heat exchanger assembly 118 is of 2-6 the curved section 142 is concavely curved in the bypass flow direction 127. Due to its concave curvature in the bypass flow direction 127, the curved section 142 is structured such that it returns at least a portion of the bypass flow 134 into the main flow path 132. For example, when the bypass flow 134 is received by the curved section 142, the curved section 142 is structured to create a region in the bypass flow 134 in which the pressure is higher than a pressure of the main flow 130 of engine coolant fluid. Accordingly, since 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 the portion the bypass flow 134 flows in the direction opposite to the bypass flow direction (e.g. in the direction of the main flow path 132, etc.). Furthermore, the baffle 138 is structured so that it reduces the flow velocity of the bypass flow 134 in the bypass flow direction 127. Since the curved section 142 accommodates the bypass flow 134 and obstructs the bypass flow 134 in the bypass flow direction 127, the flow velocity of the bypass flow 134 is reduced and the portion of the bypass flow 134 is returned to the main flow 130.

III. Configuration of the exemplary embodiments

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

As used herein, the terms “substantially,” “generally,” “approximately,” and similar terms have a broad meaning consistent with the common and accepted usage of those in the field of technology to which the subject matter of this disclosure relates related, are expert. Those skilled in the art reviewing this disclosure should understand that these terms are intended to provide a description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges specified. Accordingly, these terms should be interpreted so that insubstantial or inconsistent modifications or changes to the subject matter described and claimed are considered to fall within the scope of the appended claims.

The term “coupled” and the like as used herein means the connection of two components directly or indirectly to one another. Such connections can be stationary (e.g. permanent) or movable (e.g. removable or detachable). Such a connection can be achieved in that the two components or the two components and any additional intermediate components are formed in one piece with one another as a single, unitary body, wherein the two components or the two components and any additional intermediate components are secured together.

The terms "fluidically coupled to" and the like as used herein mean that the two components or objects have a path formed between the two components or objects in which a fluid, such as air, reducing agent, an air reducing agent -Mixture, exhaust gas, hydrocarbon, an air-hydrocarbon mixture, can flow, either with or without intervening components or objects. Examples of fluid couplings or configurations for enabling fluid communication may include pipes, channels, or other suitable components for enabling the flow of fluid from one component or object to another.

It is important to note that the construction and arrangement of the various systems shown in the various exemplary implementations are only illustrative and not restrictive. All changes and modifications that are within the spirit and/or scope of the described implementations are intended to be protected. It is to be understood that some features may not be necessary and that implementations lacking the various features may be considered to fall within the scope of the disclosure, which scope is defined by the following claims.

In addition, the term "or" is used in the context of a list of items in its inclusive sense (and not in its exclusive sense), so that the term "or" when used to connect a list of items means a, some or means all elements in the list. Conjunctive expressions such as "at least one of , X and Y, X and Z, Y and Z or X, Y and Z (i.e. any combination of X, Y and Z). Unless otherwise stated, such conjunctive wording generally does not mean that at least one of X, at least one of Y, and at least one of Z must be present in certain embodiments.

In addition, the use of value ranges herein includes their maximum and minimum values unless otherwise specified. Additionally, a range of values does not necessarily require the inclusion of intermediate values within the range of values unless otherwise specified.

It is important to note that the construction and arrangement of the various systems and operations according to the various techniques shown in the various exemplary implementations are only illustrative and are not limiting in nature. All changes and modifications that are within the spirit and/or scope of the described implementations are intended to be protected. It is to be understood that some features may not be necessary and that implementations lacking the various features may be considered to fall within the scope of the disclosure, which scope is defined by the following claims.

Claims (14)

Cooling system of an internal combustion engine system, the cooling system comprising: an engine cooling circuit for defining a flow path and direction for engine coolant fluid flowing through the internal combustion engine system; and a heat exchanger assembly positioned along the engine cooling circuit and structured to transfer heat from the engine coolant fluid to a working fluid, the heat exchanger assembly including: a shell that defines an internal cavity, a core arranged in the inner cavity and structured so that it can absorb the working fluid, and a main flow path and a bypass flow path for the engine coolant fluid, wherein the core comprises a baffle in the bypass flow path, the baffle including: a base portion coupled to one end of the core, and a curved portion extending from the base portion such that the curved portion prevents bypass flow of engine coolant fluid from continuing along the flow path. cooling system Claim 1 , wherein the curved portion extends into the bypass flow path of the engine coolant fluid and is concavely curved in a bypass flow direction. cooling system Claim 2 , wherein the curved section is structured to create a region in the bypass flow in which the pressure is higher than the pressure of the main flow of engine coolant fluid. cooling system Claim 2 or 3 , where the curved section is structured to create a vortex in the bypass flow. Cooling system according to one of the Claims 2 until 4 , wherein the curved portion is structured to reduce an amount of bypass flow downstream of the baffle. Cooling system according to one of the Claims 2 until 5 , wherein the curved portion is structured to reduce a flow velocity of the bypass flow in the bypass flow direction. Cooling system according to one of the preceding claims, wherein the baffle is formed integrally with the core. A cooling system according to any preceding claim, wherein the base portion extends in a direction parallel to a surface of the end of the core. Cooling system according to one of the preceding claims, further comprising an inlet port fluidly coupled to the internal cavity and structured to provide the engine coolant fluid to the internal cavity and an outlet port fluidly coupled to the internal cavity. Engine system comprising: the cooling system according to one of the preceding claims; and an engine including an engine block and engine overhead positioned along the engine cooling circuit downstream of the heat exchanger assembly. engine system Claim 10 , further comprising a pump structured to circulate the engine coolant fluid through the engine cooling circuit. engine system Claim 10 or 11 , further comprising a turbocharger positioned on the engine cooling circuit downstream of the engine. engine system Claim 12 , further comprising a coolant reservoir positioned on the engine cooling circuit downstream of the turbocharger and structured to receive and store the engine coolant fluid. Engine system according to one of the Claims 10 until 13 , further comprising a valve positioned on the cooling circuit upstream of the heat exchanger assembly and configured to control engine coolant fluid provided to the heat exchanger assembly.

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