WO2012061928A1

WO2012061928A1 - Double baseplate oil cooler construction

Info

Publication number: WO2012061928A1
Application number: PCT/CA2011/001242
Authority: WO
Inventors: Herve Palanchon
Original assignee: Dana Canada Corporation
Priority date: 2010-11-08
Filing date: 2011-11-08
Publication date: 2012-05-18
Also published as: DE112011103693T5; CN103270385A; CN103270385B

Abstract

A method for joining aluminum structures to cast or moulded structures is disclosed. In the method a mounting surface is defined on the cast or moulded structure, the surface having defined therein a plurality of threaded sockets. The aluminum structure is brazed to an aluminum face plate via a shim plate. The face plate has bores and is secured to the surface by passing the bolt shafts through the bores and engaging the shafts in the sockets. The cast or moulded structure can be plastic. The shim plate can be braze clad aluminum and the face plate can be unclad aluminum. The method can be used to produce an oil cooler module wherein the aluminum structure is a heat exchanger, the moulded structure is plastic and has a port and the face plate has a port and is secured by the bolts such that the ports are sealingly coupled.

Description

DOUBLE BASEPLATE OIL COOLER CONSTRUCTION

FIELD OF THE INVENTION

The present invention relates to the field of machinery. BACKGROUND OF THE INVENTION

In the field of machine manufacture, and particularly at least in the field of automotive heat exchanger manufacture, efforts are constantly being undertaken to reduce component weight. As a result, aluminum structures are looked upon with increasing interest in comparison to steel. However, the reduced strength of aluminum in comparison to steel and the ubiquitous use of brazing in the construction of aluminum structures can be an impediment to the adoption of lightweight aluminum structures, at least in the automotive industry, wherein structures are commonly secured together with bolts.

SUMMARY OF THE INVENTION

The present invention provides, according to one aspect, a novel method for joining aluminum structures to cast or moulded structures. In the method, a mounting surface is defined on the cast or moulded structure, the mounting surface having defined therein a plurality of threaded sockets. The aluminum structure is brazed to an aluminum face plate via an intermediate shim plate. A bolt is provided for each threaded socket, the bolt having a shaft threaded into the socket for which it is provided and an enlarged head. The face plate is disposed on said mounting surface, has bores through which the bolts pass and is secured to the mounting surface by the bolt heads.

According to another aspect, the mounting surface can be defined on a plastic structure. An oil cooler module forms another aspect of the invention and comprises: a cast or moulded submodule having a mounting surface, the mounting surface having defined therein a plurality of threaded sockets; for each threaded socket, a bolt, the bolt having a shaft threaded into the socket for which it is provided and an enlarged head; and an aluminum submodule including an aluminum face plate and a heat exchange element. The aluminum face plate is disposed on said mounting surface, has bores through which the shafts pass and is secured to the mounting surface by the bolt heads. The heat exchange element is brazed to the face plate.

According to another aspect, the face plate can have stiffening structures defined therein, the structures selected from dimples and ribs and arranged to counter bolt load stresses. According to another aspect, the aluminum submodule can further comprise a shim plate disposed between the face plate and the heat exchange element and brazed thereto.

According to another aspect, the shim plate can be braze clad aluminum and the face plate can be unclad aluminum.

According to another aspect, the shim plate can have bores defined therethrough, each aligned with a respective threaded socket and sized such that the bolts bear on the face plate and are partially received in sockets defined by the bores of the shim plate.

According to another aspect, the heat exchange element can comprise a plurality of stamped aluminum plates disposed in stacked relation and sealed by brazing to form a stack wherein there is defined: · a plurality of oil paths and a plurality of coolant paths, disposed in stacked, spaced, alternating relation; and

• a plurality of manifolds extending through the stack, the plurality including a pair of oil manifolds coupled to one another by the oil paths and a pair of coolant manifolds extending through the stack and coupled to one another by the oil paths. According to another aspect:

• the cast or moulded submodule can define a port;

• the face plate can have a portion which defines: a trough; and a port communicating with the trough;

• the trough-defining portion and the shim plate can define therebetween a channel communicating with one of the manifolds; and

• the face plate can be secured to the mounting surface by the bolts such that the port defined in the trough is coupled in sealed relation to the port defined by the cast or moulded submodule.

According to another aspect, the face plate can be relatively hard aluminum and the shim plate can be relatively soft aluminum.

According to another aspect, the cast or moulded structure can be a plastic structure.

According to another aspect, the face plate can have stiffening structures defined therein, the structures selected from dimples and ribs and arranged to counter bolt load stresses.

Forming yet another aspect of the invention is apparatus comprising: a cast or moulded submodule having a mounting surface, the mounting surface having defined therein a plurality of threaded sockets; for each threaded socket, a bolt, the bolt having a shaft threaded into the socket for which it is provided and an enlarged head; and an aluminum submodule including an aluminum face plate and a body. The aluminum face plate is disposed on said mounting surface, has bores through which the shafts pass and is secured to the mounting surface by the bolt heads. The body is brazed to the face plate.

According to another aspect, the aluminum submodule can further comprise a shim plate disposed between the face plate and the body and brazed thereto. According to another aspect, the shim plate can be braze clad aluminum and the face plate can be unclad aluminum.

According to another aspect, the shim plate can have bores defined therewithin, each aligned with a respective threaded socket and sized such that the bolts bear on the face plate and are partially received in sockets defined by the bores of the shim plate.

According to another aspect: the cast or moulded submodule can define a port; the face plate can have a portion which defines a trough and a port communicating with the trough; the trough-defining portion and the shim plate can define therebetween a channel communicating with one of the manifolds; and the face plate can be secured to the mounting surface by the bolt heads such that the port defined in the trough is coupled in sealed relation to the port defined by the cast or moulded submodule.

According to another aspect, the cast or moulded submodule can be a plastic submodule.

Other advantages, features and characteristics of the present invention will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter being briefly described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an oil cooler module apparatus according to an exemplary embodiment of the invention;

FIG. 2 is a partially exploded view of the structure of FIG. 1;

FIG.3 is a further exploded view of a portion of the structure of FIG. 2;

FIG. 4 is an exploded view of a portion of the structure of FIG. 3;

FIG. 5 is a perspective view of the structure of encircled area 5 of FIG. 3;

FIG. 6 is a side view of the structure of FIG. 5;

FIG. 7 is a top view of the structure of FIG. 5;

FIG. 8 is a bottom view of the structure of FIG. 5;

FIG. 9 is a top plan view of the structure indicated with numeral 46B in FIG. 4;

FIG.10 is a top plan view of the structure indicated with numeral 40 in FIG. 6;

FIG. 11 is a top plan view of the structure indicated with numeral 42 in FIG. 6;

FIG. 12 is a perspective view of the structure visible in FIG. 11;

FIG. 12A is a view of an alternate embodiment of the structure of FIG. 12;

FIG. 13 is a view along section 13-13 of FIG. 7; and

FIG. 14 is a view along section 14-14 of FIG 8. DETAILED DESCRIPTION

A transmission oil cooler module 20 according to an exemplary embodiment of the invention is shown in FIG. 1 and will be seen to comprise a plastic submodule structure 22 and an aluminum submodule 24. With reference to the exploded view in FIG.2, the module 20 will be understood also to comprise a plurality of bolts 26.

As best seen in FIG. 3, the plastic submodule 22 will be seen to define a mounting surface 30 and a notch 32, the mounting surface 30 having defined therein a plurality of threaded sockets 34 and a pair of oil ports 36. Gaskets 37 are disposed in sockets 34 and gaskets 39 are disposed in ports 36. The aluminum submodule 24 includes an oil cooler 38, a shim plate 40, a face plate 42 and a pair of coolant fittings 48A,48B.

As indicated in FIG. 5, the oil cooler 38 is aluminum and includes a heat exchange element 44 and a pair of end plates 46A,46B.

The heat exchange element 44 is shown in FIG. 4 to comprise a plurality of stamped aluminum plates 50 disposed in stacked, brazed relation to one another to form a stack. The heat exchange element 44 is of the general type described in United States Patent No. 7,735,520, the teachings of which are incorporated by reference herein. In the stack there is defined:

• a plurality of oil paths 52 and coolant paths 54, disposed in stacked, spaced, alternating relation · a plurality of manifolds extending through the stack, the plurality including o a pair of oil manifolds 56 coupled to one another by the oil paths 52 and o a pair of coolant manifolds 58 coupled to one another by the coolant paths 54 The end plates 46A,46B are stamped aluminum plates disposed in stacked relation on opposite ends of the stack and brazed thereto in sealing relation.

One of the end plates 46A has a single conduit 60 defined therein communicating with one of the coolant manifolds; the other of the end plates 46B has three conduits 62,64,66 defined therein, each aligned with a respect one of the remaining manifolds 58,56,56.

The shim plate 40, shown best in FIG. 10: is relatively soft braze clad 1.88mm aluminum sheet, with a 3003 alloy core and AA4045 cladding; is brazed to the heat exchange element 44; has a through passage 68A,68B,68C for each conduit 64, 62,66 in the other of the end plates 46B and communicating therewith; and has a plurality of bores 70 defined therein, each aligned with a respective one of the threaded sockets 34.

The face plate 42, best shown in FIGS. 11-12:

• is relatively hard 2.5 mm 5052 aluminum sheet, brazed to the shim plate 40;

• defines a port 72 aligned with one of the oil manifolds 56 and communicating therewith via conduit 68A in shim plate 40 and conduit 64 in end plate 46B, the port 72 further communicating with one of the ports 36 in the plastic structure 22

• has a trough-defining portion 74 which, in combination with the shim plate 40, defines a channel which communicates with the other of the oil manifolds 56 via conduit 66 in the other of the end plates leads and conduit 68C of shim plate 40

• has a port 76 extending from the channel and communicating with the other of the ports 36 of the plastic structure 22

• has a cut-out 78 defined therewithin which is aligned with through passage 68B and of larger diameter; and has a plurality of bores 80 defined therewithin, each aligned with a respective bore 70 in shim plate but of smaller diameter.

One of the coolant fittings 48A is brazed to the one 46A of the end plates to communicate with the one of the coolant manifolds via the single conduit 60; the other of the coolant fittings 48B is brazed to the shim plate 40, to communicate with the other of the coolant manifolds via through passage 68B and conduit 62. From the shim plate 40, coolant fitting 48B extends through cut-out 78 in face plate 42 and notch 32 in plastic structure 22.

With reference to FIGS. 1-3, the bolts 26 are provided one for each threaded socket 34, the bolt 26 having a shaft 78 and an enlarged head 79. The shaft 78 is threaded into the socket 34 for which the bolt is provided and the enlarged head 79 holds the face plate 42 against the plastic structure 22 such that a seal is created between ports 72,76 and ports 36,36 by virtue of gaskets 39.

The bolt heads 79 have a diameter larger diameter than bore 80 but smaller than bore 70, such that bore 70 defines a socket in which bolt head 79 is partially received. Gaskets 37 are relatively hard, and provide for a stable seat between submodule 22 and submodule 24.

The structure is of advantage:

• the module is relatively inexpensive to manufacture

• bolts 26 bear on unclad aluminum, i.e. face plate 42, which is relatively harder and less susceptible to creep than the clad aluminum of shim plate 40; this tends to reduce vibration-induced back-out of the bolts

• it is relatively lightweight

• it is, by virtue of the stiffness provided by the trough, relatively rigid

• it permits coupling to the coolant circuit using conventional hose connections A variation on the above is shown in FIG. 12A. Herein, face plate 42 is provided with a plurality of strengthening ribs 99. These ribs 99, by virtue of their own geometries, and further strengthened by brazing of the face plate 42 to shim plate 40, provide localized stiffening of the face plate 42, so as to address bolt loads that could otherwise cause distortion. The advantage of this structure is compounded by the ease and economy by which these ribs can be formed in the relatively thin face plate.

Whereas but two exemplary embodiments of the present invention are shown and described herein, it will be appreciated that numerous variations are possible.

For example, whereas a nested dish type heat exchanger is illustrated, this is not essential. The invention could be employed with other types of heat exchangers, and indeed, with structures other than heat exchangers.

Additionally, whereas a specific arrangement of stiffening ribs is shown, it will be evident that the number and locations of ports and bolts will vary in other embodiments of the module and this will invite corresponding variation in the ribs in terms of shape and arrangement.

Further, whereas aluminum is specified, the invention could be employed with other brazed metals.

Additionally, whereas a plastic structure is described, the methodology can be employed to secure an aluminum structure to any threadable structure and can be advantageously used with parts which are provided with threads as part of the process by which such parts are produced, including but not limited to parts constructed by injection moulding, casting, thixomolding and semi-solid casting processes. Plastic as well as metal parts can be constructed by these methods, and all are encompassed within the scope of the invention. Thus, in this specification and in the accompanying claims, "cast or moulded" should be understood as encompassing all parts capable of being cast or moulded in any casting or moulding processing, including semisolid casting processes. As well, whereas specific thicknesses and alloys are mentioned, these, of course, are subject to variance. The face plate, for example, could be made of 6061 and 6063 alloy. The clad layers could be AA4343 alloy.

As well, whereas the illustrated cooler includes end plates that have geometries different than that of the plates of the stack, this is not strictly required: indeed, even in the illustrated structure, the end plate that is brazed to the shim plate could be omitted.

Additionally, whereas the oil cooler is specified to be a transmission oil cooler, the invention could be employed with oil coolers for other purposes.

Further, whereas the description mentions that rigidity flows from the trough-defining portion, this is not the only methodology by which rigidity can be provided: dimples or ribs could also be formed on the face plate and/or the shim plate.

Accordingly, the invention should be understood as limited only by the accompanying claims, purposively construed.

Claims

1. An oil cooler module comprising: a cast or moulded submodule having a mounting surface, the mounting surface having defined therein a plurality of threaded sockets; for each threaded socket, a bolt, the bolt having a shaft threaded into the socket for which it is provided and an enlarged head; and an aluminum submodule including an aluminum face plate and a heat exchange element, the aluminum face plate being disposed on said mounting surface, the face plate having bores through which the shafts pass and being secured to the mounting surface by the bolt heads; and the heat exchange element being brazed to the face plate.

2. A module according to claim 1, wherein the aluminum submodule further comprises a shim plate disposed between the face plate and the heat exchange element and brazed thereto.

3. A module according to claim 2, wherein the shim plate is braze clad aluminum and the face plate is unclad aluminum.

4. A module according to claim 2, wherein the face plate has stiffening structures defined therein, the structures selected from dimples and ribs and arranged to counter bolt load stresses.

5. A module according to claim 3, wherein the shim plate has bores defined therewithin, each aligned with a respective threaded socket and sized such that the bolts bear on the face plate and are partially received in sockets defined by the bores of the shim plate.

6. A module according to claim 3, wherein the heat exchange element comprises a

plurality of stamped aluminum plates disposed in stacked relation and sealed by brazing to form a stack wherein there is defined: a plurality of oil paths and a plurality of coolant paths, disposed in stacked, spaced, alternating relation; and a plurality of manifolds extending through the stack, the plurality including a pair of oil manifolds coupled to one another by the oil paths and a pair of coolant manifolds extending through the stack and coupled to one another by the oil paths.

7. A module according to claim 6, wherein: the cast or moulded submodule defines a port; the face plate has a portion which defines: a trough; and a port communicating with the trough; the trough-defining portion and the shim plate define therebetween a channel communicating with one of the manifolds; and the face plate is secured to the mounting surface by the bolts such that the port defined in the trough is coupled in sealed relation to the port defined by the cast or moulded submodule.

8. A module according to claim 5, wherein the face plate is relatively hard aluminum and the shim plate is relatively soft aluminum.

9. Apparatus comprising: a cast or moulded submodule having a mounting surface, the mounting surface having defined therein a plurality of threaded sockets; for each threaded socket, a bolt, the bolt having a shaft threaded into the socket for which it is provided and an enlarged head; and an aluminum submodule including an aluminum face plate and a body, the aluminum face plate being disposed on said mounting surface, the face plate having bores through which the shafts pass and being secured to the mounting surface by the bolt heads; and the body being brazed to the face plate.

10. Apparatus according to claim 9, wherein the aluminum submodule further comprises a shim plate disposed between the face plate and the body and brazed thereto.

11. Apparatus according to claim 10, wherein the shim plate is braze clad aluminum and the face plate is unclad aluminum.

12. Apparatus according to claim 11, wherein the face plate has stiffening structures

defined therein, the structures selected from dimples and ribs and arranged to counter bolt load stresses.

13. Apparatus according to claim 11, wherein the shim plate has bores defined therewithin, each aligned with a respective threaded socket and sized such that the bolts bear on the face plate and are partially received in sockets defined by the bores of the shim plate.

14. Apparatus according to claim 11, wherein: the cast or moulded submodule defines a port; the face plate has a portion which defines: a trough; and a port communicating with the trough; the trough-defining portion and the shim plate define therebetween a channel communicating with one of the manifolds; and the face plate is secured to the mounting surface by the bolt heads such that the port defined in the trough is coupled in sealed relation to the port defined by the cast or moulded submodule.

15. Apparatus according to claim 11, wherein the face plate is relatively hard aluminum and the shim plate is relatively soft aluminum.

16. A method for joining aluminum structures to cast or moulded structures, the method comprising the steps of: defining a mounting surface on the cast or moulded structure, the mounting surface having defined therein a plurality of threaded sockets; brazing the aluminum structure to an aluminum face plate via an intermediate shim plate, the face plate having bores; and securing the face plate to the mounting surface by passing the shafts of the bolts through the bores and engaging the shafts in the threaded sockets.

17. A module according to claim 1, wherein the cast or moulded structure is a plastic

structure. Apparatus according to claim 9, wherein the cast or moulded submodule is a plastic submodule.

A method according to claim 16, wherein the mounting surface is defined on a plastic structure.

A method according to claim 16, wherein the face plate has stiffening structures defined therein, the structures selected from dimples and ribs and arranged to counter bolt load stresses.