Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
  • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
  • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
  • F28D1/0408—Multi-circuit heat exchangers, e.g. integrating different heat exchange sections in the same unit or heat exchangers for more than two fluids
  • F28D1/0426—Multi-circuit heat exchangers, e.g. integrating different heat exchange sections in the same unit or heat exchangers for more than two fluids with units having particular arrangement relative to the large body of fluid, e.g. with interleaved units or with adjacent heat exchange units in common air flow or with units extending at an angle to each other or with units arranged around a central element
  • F28D1/0435—Combination of units extending one behind the other
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
  • F02B29/00—Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
  • F02B29/04—Cooling of air intake supply
  • F02B29/0406—Layout of the intake air cooling or coolant circuit
  • F02B29/0425—Air cooled heat exchangers
  • F02B29/0431—Details or means to guide the ambient air to the heat exchanger, e.g. having a fan, flaps, a bypass or a special location in the engine compartment
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
  • F02B29/00—Engines characterised by provision for charging or scavenging not provided for in groups F02B25/00, F02B27/00 or F02B33/00 - F02B39/00; Details thereof
  • F02B29/04—Cooling of air intake supply
  • F02B29/045—Constructional details of the heat exchangers, e.g. pipes, plates, ribs, insulation, materials, or manufacturing and assembly
  • F02B29/0456—Air cooled heat exchangers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/02—Header boxes; End plates
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/26—Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
  • F01P3/00—Liquid cooling
  • F01P3/18—Arrangements or mounting of liquid-to-air heat-exchangers
  • F01P2003/182—Arrangements or mounting of liquid-to-air heat-exchangers with multiple heat-exchangers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0082—Charged air coolers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0084—Condensers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0091—Radiators
  • F28D2021/0094—Radiators for recooling the engine coolant
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/10—Internal combustion engine [ICE] based vehicles
  • Y02T10/12—Improving ICE efficiencies

Definitions

• the invention relates to heat exchanger devices for cooling fluids used in an internal combustion engine, and more particularly, to a heat exchanger package including a coupled radiator and charge air cooler for an engine of a motor vehicle such as a heavy-duty highway truck or bus.
• Heat exchanger packages comprising a radiator and a charge air cooler (CAC), also known as an intercooler, have been used for years in over the road highway trucks and buses and other heavy-duty motor vehicles.
• the radiator provides cooling for the engine coolant, usually a 50-50 solution of water and anti-freeze.
• the charge air cooler also known as an intercooler
• radiator and charge air cooler heat exchanger package depicted in Fig. 1, the charge air cooler is split between an upper unit 101 and a lower unit 103, disposed respectively behind and in front of radiator 107 with respect to the direction of cooling air flow 127.
• Radiator 107 has a conventional downflow-type tube and fin core 117 between upper tank 109a and lower tank 109b. Radiator 107 receives coolant 131 from the engine into upper tank 109a and the cooled engine coolant exits as 133 from the lower portion of lower tank 109b, to be transferred back to the engine.
• Both charge air cooler units 101 , 103 are cross-flow type charge air coolers wherein the compressed charge air is flowed horizontally through the respective tube and fin cores 11 1 , 113.
• Compressed, heated charge air 121 is first flowed into vertically oriented tank 105a of upper charge air cooler 101 , through core 111 in direction 129a, and into vertical tank 105b.
• the charge air is cooled by air 127 as it exits the upper portion of radiator core 117.
• the partially cooled compressed charge air 123 is then transferred into vertical tank 105d of lower charge air cooler 103, where it is then flowed in horizontal direction 129b through core 113 and into vertical tank 105c, and thereafter exits 125 and flows to the engine intake manifold.
• the charge air is cooled by air 127 before it flows through the lower portion of radiator core 117.
• the heat exchanger package of Fig. 1 did not achieve good performance and did not go into normal production, to the inventor's knowledge. It has now been determined that the performance of the heat exchanger package of Fig. 1 suffered in large part due to excessive charge air pressure drop through the two charge air cooler units. There is urgent need for greater engine cooling capacity in the highway trucks of the near future. One factor is the enactment of more stringent emission regulations which will become effective in 2007.
• Many engine manufacturers plan to meet the new requirements by means of exhaust gas recirculation (EGR), in which a portion of the engine exhaust gas is recirculated to the intake manifold for reburning.
• EGR exhaust gas recirculation
• exhaust gas coolers are used to lower the temperature of the exhaust gas before it enters the intake manifold.
• the heat load from these coolers is added to the normal engine cooling heat load, requiring increased cooling capacity from the engine cooli ng system.
• the second factor is the demand by truck owners and operators for
• the heat exchanger apparatus also includes a second heat exchanger having two portions for cooling a second fluid, with each second heat exchanger portion having opposite front and rear faces through which cooling air flows, opposite first and second ends adjacent the faces, and sides adjacent the faces between the first and second ends, and including tubes through which the second fluid may flow while being cooled.
• One of the second heat exchanger portions is disposed in overlapping relationship and adjacent to one of the first heat exchanger portions, such that one face of the one of the first heat exchanger portions is disposed adjacent one face of the one of the second heat exchanger portions, such that the ambient cooling air may flow in series through the one of the first heat exchanger portions and the one of the second heat exchanger portions.
• the other of the second heat exchanger portions is disposed in overlapping relationship and adjacent to the other of the first heat exchanger portions, such that the other face of the other of the first heat exchanger portions is disposed adjacent one face of the other of the second heat exchanger portions. In this manner, the cooling air may flow in series through the other of the second heat exchanger portions and the other of the first heat exchanger portions.
• the first and second heat exchanger portions have heights between the first and second ends thereof, and the heights of the ones of the first and second heat exchanger portions may be greater than the heights of the others of the first and second heat exchanger portions, or may be substantially the same. The heights of the first and second heat exchanger portions also may all be different.
• the first and second heat exchanger portions have widths between the sides thereof, and the widths of the first heat exchanger portion may be greater than the widths of the second heat exchanger portion, or may be substantially the same.
• the present invention provides a method for cooling fluids used in an internal combustion engine comprising providing a heat exchanger assembly
• the method then includes flowing the first fluid in series or parallel through the first heat exchanger portions and flowing the second fluid in series between the one and the other of the second heat exchanger portions.
• the method also includes flowing ambient cooling air through the heat exchanger assembly such that ambient cooling air flows in series through the one of the first heat exchanger portions and the one of the second heat exchanger portions, and ambient cooling air flows in series through the other of the second heat exchanger portions and the other of the first heat exchanger portions.
• ambient air includes all of the cooling air as it passes through the heat exchanger package, even though it is heated as it passes through the fins of the radiator and CAC units.
• the first fluid may flow in parallel through the first heat exchanger portions, with one portion of the first fluid flowing through the one of the first heat exchanger portions and another portion of the first fluid flowing through
• the first fluid may flow in series through both of the first heat exchanger portions, with all of the first fluid flowing through both first heat exchanger portions.
• the first heat exchanger portions include a manifold along each of the sides with the first heat exchanger portion tubes connecting the manifolds, and the first fluid flows from one side of the first heat exchanger portions to the other side of the first heat exchanger portions through the tubes.
• the first heat exchanger portions may be operatively connected such that the first fluid flows between the one of the first heat exchanger portions and the other of the first heat exchanger portions adjacent at least one side of the first heat exchanger portions.
• the second heat exchanger portions are operatively connected such that the second fluid may flow in series between the one and the other of the second heat exchanger portions.
• the second heat exchanger portions may include a manifold between each of the sides at upper and lower ends of each of the portions with the second heat exchanger portion tubes connecting the manifolds, such that the second fluid flows between one end of the second heat exchanger portions and the other end of the second heat exchanger portions through the tubes.
• a down flow system may be employed wherein the second fluid flows from the lower manifold of the one of the second heat exchanger portions to the upper manifold of the other of the second heat
• an upflow system is employed wherein the second fluid flows from the upper manifold of the other of the second heat exchanger portions to the lower manifold of the one of the second heat exchanger portions.
• the second heat exchanger portions may be operatively connected such that the second fluid flows therebetween through a conduit extending substantially across the widths of the second heat exchanger portions.
• the one of the second heat exchanger portions has greater thickness between faces than the other of the second heat exchanger portions.
• the other of the second heat exchanger portions has greater thickness between faces than the one of the second heat exchanger portions.
• the one of the first heat exchanger portions and the other of the second heat exchanger portions are disposed in a substantially same first plane, and the other of the first heat exchanger portions and the one of the second heat exchanger portions are disposed in a substantially same second plane.
• the ambient cooling air then flows simultaneously through the one of the first heat exchanger portions and the other of the second heat exchanger portions, and simultaneously through the one of the second heat exchanger portions and the other of the first heat exchanger portions.
• the first heat exchanger is a radiator and the first fluid is engine coolant
• the second heat exchanger is a charge air cooler and the second fluid is charge air, with each of the radiator and the charge air cooler portions being cooled by ambient air.
• the present invention is directed to a combined radiator and charge air cooler package comprising a radiator having upper and lower portions for cooling engine coolant, and a charge air cooler having upper and lower portions for cooling charge air.
• Each radiator portion has opposite front and rear faces through which ambient cooling air flows, opposite upper and lower ends adjacent the faces, and sides adjacent the faces between the upper and lower ends, and include manifolds between the sides at upper and lower ends of each of the radiator portions and tubes through which the engine coolant may flow connecting the radiator manifolds.
• Each charge air cooler portion has opposite front and rear faces through which cooling air flows, opposite upper and lower ends adjacent the faces, and sides adjacent the faces between the upper and lower ends, and includes manifolds along the upper and lower ends and tubes through which the charge air may flow connecting the
• the upper charge air cooler portion is disposed in overlapping relationship and adjacent to the upper radiator portion, with one face of the upper radiator portion being disposed adjacent one face of the upper charge air cooler portion, such that the ambient cooling air may flow in series through the upper radiator portion and the upper charge air cooler portion.
• the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower radiator portion, with the other face
• the radiator portions are operatively connected such that the engine coolant may flow in series or parallel through the radiator portions.
• the charge air cooler portions are operatively connected such that the charge air may flow in series between the upper charge air cooler portion and the lower charge air cooler portion.
• the radiator portions may be operatively connected such that the engine coolant flows in parallel through the radiator portions, with one portion of the coolant flowing through the upper radiator portion and another portion of the coolant flowing through the lower radiator portion.
• radiator portions are operatively connected such that the engine coolant may flow in series through both of the radiator portions, with all of the coolant flowing through both radiator portions.
• the upper charge air cooler portion may have a greater or lesser thickness between faces than the lower charge air cooler portion.
• the present invention is directed to a heat exchanger apparatus comprising a first heat exchanger having two portions for cooling a first fluid.
• Each first heat exchanger portion has opposite front and rear faces through which ambient cooling air flows, opposite first and second ends adjacent the faces, and sides adjacent the faces between the first and second ends.
• the heat exchanger package further includes a second heat exchanger having two portions for cooling a second fluid.
• Each second heat exchanger portion has opposite front and rear faces through which air flows, opposite first and second ends adjacent the faces, and sides adjacent the faces between the first and second ends, and includes manifolds at the first and second ends and fluid-carrying tu es extending substantially directly therebetween.
• One of the second heat exchanger portions is disposed in overlapping relationship and adjacent to one of the first heat exchanger portions, with the first and second ends of the one of the second heat exchanger portions being oriented in the same direction as the first and second ends of the one of the first heat exchanger portions.
• One face of the one of the first heat exchanger portions is disposed adjacent one face of the one of the second heat exchanger portions, such that the ambient cooling air may flow in series through the one of the first heat exchanger portions and the one of the second heat exchan ger portions.
• the other of the second heat exchanger portions is disposed in overlapping relationship and adjacent to the other of the first
• first and second ends of the other of the second heat exchanger portions being oriented in the same direction as the first and second ends of the other of the first heat exchanger portions.
• the other face of the other of the first heat exchanger portions is disposed adjacent one face of the other of the second heat exchanger portions, such that the ambient cooling air may flow in series through the other of the second heat exchanger portions and the other of the first heat exchanger portions.
• the first heat exchanger portions are operatively connected such that the first fluid may flow between the second manifold of the one of the first heat exchanger portions and the first manifold of the other of the first heat exchanger portions.
• the second heat exchanger portions are operatively connected such that the second fluid may flow between the second manifold of the one of the second heat exchanger portions and the first manifold of the other of the second heat exchanger portions.
• the one of the first heat exchanger portions and the other of the second heat exchanger portions are disposed in substantially the same plane, and the other of the first heat exchanger portions and the one of the second heat exchanger portions are disposed in substantially the same plane.
• the first heat exchanger portions may be operatively connected such that the first fluid may flow between the second manifold of the one of the first heat exchanger portions and the first manifold of the other of the first heat exchanger portions adjacent at least one side of the first heat exchanger portions, or around at least one side of the second heat exchanger portions.
• the second heat exchanger portions may be operatively connected such that the second fluid may flow therebetween through a conduit extending from and along the second manifold of the one of the second heat exchanger portions to and along the first manifold of the other of the second heat exchanger portions.
• the first heat exchanger portions typically include fluid-carrying tubes, with the fluid-carrying tubes of each of the first heat exchanger portions extending in the same direction as the fluid-carrying tubes of each of the second heat exchanger portions.
• the dimension between the first and second ends of the second heat exchanger portions is less than the dimension from one side of the second heat exchanger portions to the other side of the second heat exchanger portions, such that the fluid-carrying tubes extend across the shorter dimension of the faces of the second heat exchanger portions.
• the sides of the first heat exchanger portions are aligned with the sides of the second heat exchanger portions, the first end of the one of the first heat exchanger portions is adjacent the first end of the one of the second heat exchanger portions, and the second end of the other of the first heat exchanger portions is adjacent the second end of the other of the second heat exchanger portions.
• the second end of the one of the first heat exchanger portions may be adjacent the first end of the other of the first heat exchanger portions, and the second end of the one of the second heat exchanger portions may be adjacent the first end of the other of the second heat exchanger portions.
• the manifolds of the first and second heat exchanger portions may extend
• At least one of the sides or ends of one of the first heat exchanger portions extends outward of a side or end of one of the second heat exchanger portions.
• the first end of the one of the first heat exchanger portions may extend outward of the first end of the one of the second heat exchanger portions, and the second end of the other of the first heat exchanger portions extends outward of the second end of the other of the second heat exchanger portions.
• the present invention is directed to a method for cooling fluids used in an engine of a motor vehicle comprising providing a heat exchanger assembly as described above. The method then includes flowing the first fluid through the first heat exchanger portions, and flowing the second fluid through the substantially directly extending tubes of the second heat exchanger portions and between the second manifold of the one of the second heat exchanger portions and the first manifold of the other of the second heat exchanger portions.
• the method also includes flowing cooling air through the heat exchanger assembly such that ambient cooling air flows in series through the one of the first heat exchanger portions and the one of the second heat exchanger portions, and ambient cooling air flows in series through the other of the second heat exchanger portions and the other of the first heat exchanger portions.
• the second fluid flows in sequence through the first manifold of the one of the second heat exchanger portions, the substantially
• the second fluid may alternatively flow in sequence through the second manifold of the other of the second heat exchanger portions, the substantially directly extending tubes of the other of the second heat exchanger portions, the first manifold of the other of the second heat exchanger portions, the second manifold of the one of the second heat exchanger portions, the substantially directly extending tubes of the one of the second heat exchanger portions, and the first manifold of the one of the second heat exchanger portions.
• the first heat exchanger is a radiator and the first fluid is engine coolant
• the second heat exchanger is a charge air cooler and the second fluid is charge air, each of the radiator and the charge air cooler portions being cooled by ambient air.
• the present invention is directed to a combined radiator and charge air cooler package including a radiator having upper and lower portions for cooling engine coolant. Each radiator portion has opposite front and
• the more preferred package also includes a charge air cooler having upper and lower portions for cooling charge air.
• Each charge air cooler portion has opposite front and rear faces through which cooling air flows, opposite upper and lower ends adjacent the faces, and sides adjacent the faces between the upper and lower ends, and includes manifolds at the upper and lower ends and charge air-carrying tubes extending substantially directly therebetween.
• the upper charge air cooler portion is disposed in overlapping relationship and
• the upper radiator portion is disposed adjacent to the upper radiator portion, with the upper and lower ends of the upper charge air cooler portion being oriented in the same direction as the upper and lower ends of the upper radiator portion.
• One face of the upper radiator portion is disposed adjacent one face of the upper charge air cooler portion, such that the ambient cooling air may flow in series through the upper radiator portion and the upper charge air cooler portion.
• the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower radiator portion, with the upper and lower ends of the lower charge air cooler portion being oriented in the same direction as the upper and lower ends of the lower radiator portion.
• the other face of the lower radiator portion is disposed adjacent one face of the lower charge air cooler portion, such that the ambient cooling air may flow in series through the lower charge air cooler portion and the lower radiator portion.
• the radiator portions are operatively connected such that the engine coolant may flow between the lower manifold of the upper radiator portion and the upper manifold of the lower radiator portion.
• the charge air cooler portions are operatively connected such that the charge air may flow between the lower manifold of the upper charge air cooler portion and the upper manifold of the lower charge air cooler portion.
• the present invention is directed to a heat exchanger apparatus comprising a first heat exchanger having two portions for cooling a first fluid.
• Each first heat exchanger portion has opposite front and rear faces through which ambient cooling air flows, a pair of manifolds, and fluid-carrying tubes extending substantially directly therebetween.
• One of the first heat exchanger portions is disposed in a first plane, and the other of the first heat exchanger portions is disposed in a second plane, with the first and second planes being substantially parallel.
• the heat exchanger apparatus also includes a second heat exchanger having two portions for cooling a second fluid.
• Each second heat exchanger portion has opposite front and rear faces through which ambient cooling air flows, a pair of manifolds, and fluid-carrying tubes extending substantially directly therebetween.
• One of the second heat exchanger portions is disposed in the second plane in overlapping relationship and adjacent to the one of the first heat exchanger portions, wherein one face of the one of the first heat exchanger portions is disposed adjacent one face of the one of the second heat exchanger portions.
• the ambient cooling air may flow in series through the one of the first heat exchanger portions and the one of the second heat exchanger portions.
• the other of the second heat exchanger portions is disposed in the first plane in overlapping relationship and adjacent to the
• the first heat exchanger portions are operatively connected such that the first fluid may flow between a manifold of the one of the first heat exchanger portions and a manifold of the other of the first heat exchanger portions.
• the second heat exchanger portions are operatively connected such that the second fluid may flow between a manifold of the one of the second heat exchanger portions and a manifold of the other of the second heat exchanger portions.
• the second heat exchanger portions may be operatively connected such that the second fluid may flow therebetween through a conduit extending from and along the manifold of the one of the second heat exchanger portions to and along the manifold of the other of the second heat exchanger portions.
• the conduit may contain at least one stiffening member.
• the first heat exchanger portions may be operatively connected such that the first fluid may flow between a manifold of the one of the first heat exchanger portions
• a further related aspect of the invention provides a method for cooling fluids used in an engine of a motor vehicle, comprising providing a heat exchanger assembly as described above, flowing the first fluid sequentially or in parallel through the one and the other of the first heat exchanger portions, and flowing the second fluid sequentially through the one and the other of the second heat exchanger portions.
• method also includes flowing cooling air through the heat exchanger assembly such that ambient cooling air flows in series through the one of the first heat exchanger portions and the one of the second heat exchanger portion s, and ambient cooling air flows in series through the other of the second heat exchanger portions and the other of the first heat exchanger portions.
• Fig. 1 is a perspective view of a prior art radiator/charge air cooler heat exchanger package.
• Fig. 2 is a side elevational view of one embodiment of the radiator/charge air cooler heat exchanger package of the present invention.
• Fig. 3 is a top plan view of the radiator of the radiator/charge air cooler package of Fig. 2.
• Fig. 4 is a front elevational view of the split charge air cooler portions of the heat exchanger package of Fig. 2, without the radiator portions, and showing cooling fins over only a portion of the tubes of the core.
• Fig. 5 is a front elevational view of the split radiator portions of the heat exchanger package of Fig. 2, without the charge air cooler portions, and showing cooling fins over only a portion of the tubes of the core.
• Fig. 6 is a perspective view of the radiator/charge air cooler package of Fig. 2.
• Fig. 7 is a perspective view of an alternate heat exchanger package.
• Fig. 8 is a plan or side elevational view of the radiator/charge air cooler heat exchanger package of the present invention in relation to a cooling fan.
• FIG. 9 is a side cross-sectional view of a portion of the heat exchanger package of the present invention showing one embodiment of the connecti ng manifold between the two charge air cooler units.
• Fig. 10 depicts a cross-section of a perspective view of another embodiment of the connecting manifold between the two charge air cooler units, which is cast in a single unit.
• Fig. 1 1 depicts a cross-section of a perspective view of the same connecting manifold as shown in Fig. 11 , except that it is welded of several sections.
• Fig. 12 is perspective view of a portion of the heat exchanger package of the present invention showing one embodiment of a connection between the two radiator units, with the charge air cooler (CAC) units removed.
• CAC charge air cooler
• FIG. 13 is a perspective view of fluid connections between the radiator units and CAC units, with the CAC units removed, wherein the connections are contained within the overall width of the radiator and CAC units in the heat exchanger package.
• Fig. 14 is a perspective view of an alternate embodiment of the two-core-deep heat exchanger package of the present invention, in which both the radiator and CAC units are up- or downflow units, arranged side-by-side.
• Fig. 15 is a top plan view of the alternate heat exchanger package of Fig. 14, showing the crossover manifold configuration of the charge air cooler units.
• Fig. 16 is a elevational view of the back side of the alternate heat exchanger package of Fig. 14. Fig.
• FIG. 17 is a rear perspective view of a preferred embodiment of the CAC portion of the radiator/charge air cooler heat exchanger package of the present invention, to be used in conjunction with the radiator units of Fig. 18, in which both the CAC units are downflow units.
• Fig. 18 is a rear perspective view of a preferred embodiment of the radiator
• Fig. 19 is a side elevational view of the combined radiator/charge air cooler heat exchanger package employing the CAC units of Fig. 17 and the radi tor units of Fig. 18.
• Fig. 20 is a rear perspective view of a first alternate embodi ment of the radiator units of Fig. 18, connected in series.
• Fig. 21 is a rear perspective view of a second alternate embodiment of the radiator units of Fig. 18, connected in series.
• FIG. 22 is a side elevational view, partially cut away, showing the combined radiator/charge air cooler heat exchanger combination of the present invention mounted under the hood of a highway truck.
• Fig. 23 shows alternate locations of the combination radiator/charge air cooler heat exchanger package of the present invention mounted in the rear of a highway bus.
• the preferred embodiment of the present invention is a cooling package utilizing a radiator in two portions and a charge air cooler (CAC) in two portions.
• the charge air cooler is arranged so that the entering hot charge air is directed into the first portion of the charge air cooler, which is located downstream in the direction of cooling air flow from the first portion of the radiator.
• the partially cooled charge air exiting the first portion of the charge air cooler is then directed into the second portion
• the charge air cooler portions are designed in a downflow configuration such that they have the greatest number of short tubes, as opposed to being in a crossflow configuration with a smaller number of longer tubes.
• the radiator portions in the invention cooling package are connected so that the engine coolant flows through the two portions in parallel, thereby providing low coolant pressure drop and improving the filling and de-aeration characteristics of the radiator.
• the preferred cooling package becomes only two units deep, as opposed to having the radiator in one piece and the charge air cooler in two portions, placing one charge air cooler portion in back of the upper part of the radiator and the other in front of the lower part of the radiator. Further, since the charge air which becomes partially cooled in the first portion of the charge air cooler has reduced volume, the second portion of the charge air cooler can be made with a thinner core. This reduction in core depth provides room for an air conditioning condenser to be added to the cooling package. In conventional cooling packages, the heat transfer performance is normally a tradeoff between the radiator and the charge air cooler. When the performance of one
• a first embodiment of the heat exchanger package of the present invention is depicted in Figs. 2-6.
• a combined, integrated heat exchanger package 20 preferably comprises a first heat exchanger having at least two vertically split and separated units or portions 21 , 22 for cooling a first fluid, preferably a radiator for use in cooling liquid
• engine coolant from an engine of a motor vehicle or other internal combustion engine, and another heat exchanger having at least two split units or portions 30, 32 for cooling a second fluid, preferably charge air coolers for cooling compressed charge air from a turbo or supercharger of an internal combustion engine.
• engine coolant will be used to exemplify the first fluid
• compressed charge air will be used to exemplify the second fluid
• any other fluids may be substituted.
• Both heat exchangers are normally in an upstanding, essentially vertical position, and are preferably rectangular in shape, and the width and length of the combined heat exchanger package is consistent with the requirements of the truck or bus engine compartments.
• Radiator units 21, 22 of the present invention may be down flow type radiators, wherein engine coolant 40 enters the first radiator unit 21 through an upper manifold or tank 24a extending substantially the entire width of the radiator. The coolant is then distributed from manifold 24a into attached core 26a having an otherwise conventional
• the charge air cooler (CAC) of the present invention preferably comprises a pair
• Upper CAC unit 30 is disposed in an overlapping fashion with radiator upper unit 21 , so that the
• CAC unit 30 contains an upper tank or manifold 34a and a lower tank or manifold 34b and a core 37a attached therebetween, each extending substantially the full width of the charge air cooler unit.
• CAC unit 32 is positioned in front of radiator lower unit 22, with respect to air flow direction 46, and the lower end 39d and sides 33a, 33b of unit 32 are essentially coincident with the lower end 25d and lower sides 27a, 27b of radiator unit 22.
• Rear face 35d of CAC unit 32 is abutted to or slightly spaced from front face 28c of radiator unit 22.
• CAC unit 32 contains an upper tank or manifold 34c and a lower tank or manifold 34d and a core 37b attached therebetween, each extending substantially the full width of the charge air cooler unit. Both CAC cores 37a, 37b are conventional tube and fin construction.
• Lower manifold 34b of CAC unit 30 is operatively connected to upper manifold 34c of CAC unit 32, so that charge air may flow therebetween.
• the charge air cooler units of Figs. 2-6 are preferably either up or down flow units, and not cross flow units. Thus, as shown in Fig. 6, the entering heated
• each of the cores 37a, 37b for the CAC units 30, 32 comprise spaced, vertically extending tubes 36, between which are disposed serpentine cooling fins 38, oriented to permit cooling air flow through the unit.
• both charge air cooler units 30 and 32 have a horizontal width, measured in the direction of the manifolds, which is greater than the vertical height of each of the units, measured between the manifolds.
• Improved heat exchanger package performance, and in particular, improved performance of the charge air cooler units as a result of reduced charge air pressure drop, has been obtained by utilizing tubes 36 which are as short as possible and as numerous as possible, given the configuration of the charge air cooler unit.
• charge air cooler units 30 and 32 employ tubes 36 which are oriented with the shorter vertical height of each of the units so that there are a larger number of shorter tubes, as contrasted to the smaller number of longer tubes as used in the cross flow CAC unit of Fig. 1.
• Cores 26a, 26b for radiator units 21 , 22 are shown in Fig. 5 as down flow units having cooling fins 29 extending between spaced, vertically extending tubes 33 to permit cooling air flow through the unit. Such fins should extend between all of the tubes in the core.
• These tubes 23 may be two (2) rows deep, as shown in Fig. 2, or any other configuration.
• the radiator units 21 , 22 are depicted in Fig. 5 as down flow units, with the tubes extending in the direction of the shorter dimension of the unit, the height, so that a large number of tubes are employed.
• the radiator units can be cross-flow units, where the tubes extend in the direction of the length of the longer, width dimension of the unit, with a fewer number of tubes being employed).
• Heat exchanger cores 26a, 26b, 37a, 37b can be co nstructed of typical materials, for example aluminum, brass or copper tubes and fins.
• Manifolds 24a, 24b, 24c, 24d, 34a, 34b, 34c, 34d may be any conventional materials such as plastic, aluminum, brass or copper.
• Fig. 7 depicts another embodiment 20' of the present invention which is structurally identical to the previous embodiment, with the difference being that the
• radiator and charge air cooling units are rotated 90°, so that the radiator and CAC units are horizontally separated.
• manifolds 24a, 24b, 24c, 24 d of radiator units 21 and 22 may be oriented in the same direction as manifolds 34a, 3 ⁇ 1b, 34c, 34d of CAC units 30 and 32.
• all of the manifolds of the radiator and charge air cooler units are vertically oriented and horizontally spaced and, consequently, the fluid flow through the now horizontal tubes within the cores of the respective radiator and charge air cooler units is now horizontal.
• Fig. 7 depicts the heat exchanger package 20, 20' of the previous embodiments in relation to a cooling suction fan having fan blades 62 powered by a fan motor 60.
• the heat exchanger package 20, 20' is in line with the area swept by the fan blades to move the outside ambient cooling air 46 through each of the CAC units 30, 32 and radiator units 21 , 22.
• Radiator manifolds 24b, 24c and CAC manifolds 34b, 34c may be positioned in line with the center of the fan blades 62 and fan motor 60, where airflow is low or nearly zero.
• a fan shroud (not shown) may be positioned circumferential ly around the fan blades and the heat exchanger package top and side edges to contain and direct the airflow.
• the heat exchanger package is configured so that one radiator unit, 21, is aligned with one CAC unit, 32, in the same plane normal to the direction of cooling air flow 46, so that the cooling air flows in parallel through these radiator and CAC units.
• the other radiator unit, 22, is aligned with the other CAC unit, 30, also in the same plane normal to the direction of cooling air flow 46, so that the cooling air flows in parallel through these radiator and CAC units.
• Radiator/CAC units 22, 32 are in an abutted or closely spaced relationship with and connected in series to the radiator/CAC units 21, 30 and are aligned so that ambient cooling air 46 passes through both radiator and CAC units 21 and 30, and radiator and CAC units 32 and 22, in a serial or sequential manner.
• the front and back faces of radiator/CAC units 21 and 32 and the front and back faces of radiator/CAC units 22 and 30 are also preferably in the same respective planes, as shown in Fig. 8. In operation, ambient cooling air 46 presented to approximately half of the heat
• the term ambient air includes all of the cooling air as it passes through the heat exchanger package.
• the operational flow of fluid to be cooled is such that the initially hot engine coolant 40 is received in manifold 24a of radiator unit 21 and cooled as it passes 42 through radiator core 26a, given that ambient air 46 is at a lower temperature than the incoming engine coolant 40.
• Incoming compressed charge air 50 is normally at a
• CAC unit 32 is in front of radiator lower unit 22 with respect to the cooling air flow, and as the charge
• air 56 passes downward through core 37b, it is cooled by the fresh ambient air before it passes out through manifold 34d of CAC unit 32 as cooled compressed air 58, which is then routed to the air intake manifold of the engine.
• the flow of ambient cooling air may be reversed for the embodiments described herein, so that it flows in direction 46' (Figs. 6 and 7).
• a blower fan may be used in place of the suction fan to blow air first through the fan and then through the heat exchanger package.
• the flow of fluids to be cooled may be reversed from that described above.
• the cooling performance of the heat exchanger package including the CAC units, will be the same when reversing the flow of the ambient cooling air, so that it flows in direction 46', and reversing the flow of the charge air, so that the charge air enters through manifold 34d and exits through manifold 34a.
• the sides and upper and lower ends of the CAC and radiator units are preferably aligned, so that there are no non-overlapping regions between the top, bottom or sides of the radiator and the corresponding top, bottom and sides of the CAC units.
• the heat exchanger package of the present invention may include such non-overlapping regions. For example, as shown in Fig.
• radiator ends 25a' or 25d' adjacent manifolds 24a, 24d, respectively may extend above and below the corresponding charge air cooler unit ends 39a, 39d, adjacent manifolds 34a, 34d, respectively.
• ends 39a', 39d' of the charge air cooler units may extend above and below the upper and lower ends 25a, 25d of the radiator
• any of the charge air cooler sides 33a', 33b' may extend beyond the sides 27a, 27b of the radiator units.
• the radiator and CAC units may have different widths. If any such non-overlapping regions are used, the portions of either of the charge air cooler units or radiator extending beyond and behind the other will then receive fresh ambient air.
• Additional heat exchangers typically employed in motor vehicles may be used in the heat exchanger package of the present invention, such as engine oil and transmission oil coolers, and air conditioning condenser units may also be used, either in front of or behind upper or lower portions of the package.
• One embodiment of the manifold connection between the charge air cooler units is depicted in Fig. 9.
• Core 37a of CAC unit 30 has on it a lower end manifold 34b, and CAC unit 32 has on its upper end manifold 34c, both contained within transition conduit 64.
• an air passageway or conduit 66 formed by duct walls 68a, 68b extends between manifolds 34b and 34c, along substantially their full lengths, and directly and operatively connects the CAC units 30, 32 substantially along their full widths and in their different planes to permit airflow therebetween.
• Other preferred embodiments of the connecting manifolds are depicted in cross-section in Figs. 10 and 11 , wherein the transition conduit 64a is as-cast as a single, integral unit 64a (Fig. 10) or is a welded unit 64b made up of four formed sections joined by welds 110 (Fig. 11).
• tube openings 102a, 102b receive CAC tubes in polymeric grommets from cores 37a, 37b, respectively, to create the tube-to-header joints.
• these CAC tubes are one-deep through the thickness of the core, as opposed to the two deep tube arrangement of Fig. 2, for example.
• a central, vertical stiffening rib 106 extends from top to bottom within the manifold conduit, along substantially the full width of the CACs, to resist bursting as a result of the internal charge air pressure (generally about 50-55 psig), and contains multiple openings 104 for charge air passage therethrough. Multiple stiffening ribs, with spaces or openings
• Fig. 12 there is shown an embodiment of the operative coolant connection between radiator units 21 , 22, with the CAC units removed.
• Manifolds 24b, 24c each have extensions 124b, 124c, respectively, that extend outward from a side of the radiator units, and utilize clamps 114 and/or hose 1 12 to provide for coolant flow between the two.
• a similar extension and connection is provided around the opposite side of the radiator units.
• This radiator unit coolant connection may then be used in conjunction with the CAC unit charge air connection of Figs. 9, 10 and 11, which connect along the center of the CAC units.
• Fig. 13 shows another embodiment of a coolant connection between radiator
• radiator manifolds 24b, 24c pairs of coolant inlets/outlets 131 and 132, on radiator manifolds 24b, 24c, respectively, connect on opposite ends to transition coolant connectors 134, to transfer coolant between the radiator units.
• the coolant connection is disposed adjacent a side, but within the width, of radiator units 21 , 22, so as not to widen the overall width of the heat exchanger package, and the width of conduit 64 between the CAC manifolds is shortened accordingly.
• the width of the CAC units would be approximately the same as that of conduit 64, so that the CAC units would have a width less than the radiator units.
• Another embodiment of the present invention is shown in Figs. 14, 15 and 16.
• This heat exchanger package 220 also has the two-core-deep configuration of the split radiator and CAC units as shown in the previous embodiments.
• radiator unit 221 and CAC unit 232 are disposed side-by-side in one plane
• CAC unit 230 and radiator unit 222 are side-by-side in another plane.
• a portion of the cooling ambient air flow 246 is first through fins 229 of core 226a in radiator unit 221 and fins 238 of core 237b in CAC unit 232, and then, in parallel with this, a second portion of the cooling ambient air flow 246 flows sequentially through the respective fins and cores of CAC unit 230 and radiator unit 222.
• this embodiment utilizes up- or downflow cores, wherein the CAC tubes 236 and radiator tubes 233 extending between their respective manifolds are shorter than the width dimension of the manifolds. Where charge air pressure drop may not be of great a concern, the CAC and radiator tubes may be made longer than the width dimension of the manifolds.
• heat exchange package 220 may be rotated 90° so that the CAC and radiator unit cores are side-flow.
• This embodiment of Figs. 14-16 also provides a compact heat exchanger package. Charge air flow is initially into inlet 250, through manifold 234a, tubes 236,
• FIGs. 17-19 depict a preferred embodiment of the heat exchanger package of the present invention.
• the split radiator and CAC units of heat exchanger package 320 are arranged in the manner depicted in Figs. 2-6, but have some significant differences. The identification of the components are consistent with previous numbering, except
• CAC units 330 and 332 again are configured as downflow heat exchangers, with charge air 50 entering upper rear CAC unit 330 through inlet 350, being distributed through horizontal inlet manifold 334a and passing 52 through core 337a and transition manifold 364 (extending substantially across the widths of the CAC units 330 and 332), where it enters lower front CAC unit 332 and passes 56 through core 337b, horizontal outlet manifold 334d, and out 58 through outlet 358.
• Coolant 18 are similar to those shown in the previous figures, except that they are cross flow units having the manifolds along each of the sides, extending vertically along the height of the units, with the tubes in cores 326a and 326b extending horizontally to carry the engine coolant. Instead of flowing in series, i.e., sequentially between the upper an lower radiator units, the coolant flows in parallel through both of the units. Coolant enters 40 into upper radiator unit 321 through radiator inlet 340 and the flow is split so that a first portion flows through vertical manifold 324a, passes 42 through core 326a, through vertical manifold 324b, and out 48a through radiator outlet 348a.
• the second portion of the coolant passes 44 into lower radiator unit 322 through hose 334 or other connection between the radiator units, is distributed through vertical manifold 324c, passes 45 through core 326b, through vertical manifold 324d, and then out 48b through radiator outlet 348b.
• the incoming hot coolant 40 may be split before it enters inlet 340, and the second portion flowed directly into manifold 324c, in which case connector 334 is not necessary.
• the parallel connection between the radiator units 321 , 322 results in a lower pressure drop.
• Other coolant flow arrangements for the radiator units 321, 322 to be employed in heat exchanger package 320 are shown in Figs. 20 and 21, where the flow is in series through the units, rather than in parallel as in Fig. 18. In Fig. 20, coolant flow
• radiator outlet 348 the partially-cooled coolant enters 40 through inlet 340 of upper radiator unit 321, is distributed by vertical manifold 324b so that it passes 42 through core 326a and through vertical manifold 324a, where it passes 44 downward through connector 334.
• lower radiator unit 322 the partially-cooled coolant then is distributed by vertical manifold 324c so that it passes 45 through core 326b and through vertical manifold 324d, where it exits 48 through radiator outlet 348.
• the flow is reversed in Fig. 21 , where coolant flow enters 40 through inlet 340 of lower radiator unit 322, is distributed by vertical manifold 324d so that it passes 42 through core 326b and through vertical manifold 324c, where it passes 44 upward through connector 334.
• the partially- cooled coolant then is distributed by vertical manifold 324a so that it passes 45 through core 326a and through vertical manifold 324b, where it exits 48 through radiator outlet
• a heavy duty highway truck 70 is shown including engine
• the vehicle located in engine compartment 76 at the front portion of the truck.
• the vehicle includes a lower frame 74 having the combined radiator/CAC heat exchanger package 20, 20', 220, 320 mounted vertically at the front end of engine compartment 76.
• the fan is mounted within fan shroud 78 positioned behind the heat exchanger package.
• the radiator units are operatively connected to the cooling system of engine 72 by inlet hose 71 a and outlet hose 71 b which provide for flow of the engine coolant from and to the engine.
• the charge air cooler units are operatively connected between the engine turbo or supercharger and the engine air intake manifold by inlet hose 73a and outlet hose 73b.
• Fig. 23 depicts the heat exchanger package of the invention 20, 20', 220, 320 mounted at the rear of a bus behind grill 82, or at the side near the rear (in
• the conventional cooling package is identified as Production and the cooling package of Figs. 17-19 is identified as Split Series.
• Test type C is performed under conditions designed to check charge air cooler capability and test type R is performed at rated power to check both charge air cooler and radiator capability.
• the engine manufacturer's specifications are given in the top three listed tests, labeled Spec.
• radiator top tank temperature engine outlet coolant temperature
• 32.8°F (18.2°C) improvement increase (increase) in ambient capability (the maximum operating ambient temperature at which the maximum allowable top tank temperature will not be
• the invention cooling package provided a 26.7°F (14.8°C) improvement in the radiator top tank
• the heat exchanger package of the present inventions provides a combination radiator and charge air cooler which achieves high heat transfer performance with a minimal frontal area, while minimizing pressure loss to the fluids.

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• 2004
  • 2004-11-09 EP EP04800894A patent/EP1706609A4/en not_active Withdrawn
  • 2004-11-09 AU AU2004295677A patent/AU2004295677B2/en not_active Ceased
  • 2004-11-09 CA CA2547164A patent/CA2547164C/en not_active Expired - Fee Related
  • 2004-11-09 WO PCT/US2004/037275 patent/WO2005054639A1/en not_active Application Discontinuation
  • 2004-11-19 AR ARP040104278A patent/AR048994A1/es active IP Right Grant

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