Cooling modules for internal combustion engines contain one or more heat exchangers and an air mover such as a fan, and are commonly used to reject heat from fluids and/or gases for the internal combustion engine to a flow of ambient air directed through the cooling module by the air mover. As the size and power of the internal combustion associated with the cooling module increases, the size and complexity of the cooling module likewise increases. In some cases, such as with combustion engines for power generation (sometimes referred to as gen-sets), the structure required to adequately support the heat exchangers, air mover, and other associated equipment can become complex and expensive.
The heat exchangers 30, 31 are mounted into a frame 150 of the cooling module (as best seen in
The frame 150, while capable of providing adequate structural support, is a complex structure that requires many parts to be assembled in a time-intensive and costly manner.
In order to secure the heat exchangers 30, 31 within the frame 150, the U-channels 151 have to be assembled around the heat exchangers, as there is no way to locate the heat exchangers within the channels once the frame 150 is assembled. This makes servicing and replacement of the heat exchangers within the cooling module 101 difficult, since the frame 150 needs to be at least partially disassembled in order to replace and service any one of the heat exchangers.
According to an embodiment of the invention, a frameless cooling module is constructed using a first and a second shroud panel arranged at opposing side of the cooling module. The first and second shroud panels each extend entirely from a front of the cooling module to the back of the cooling module in the front-to-back direction of the cooling module. The first and second shroud panels also extend entirely from the top of the cooling module to the bottom of the cooling module in the top-to-bottom direction of the cooling module. The front-to-back direction thereby defines a first direction of the cooling module and the top-to-bottom direction thereby defines a second direction of the cooling module, with the first and second directions being perpendicular to one another. A third direction of the cooling module perpendicular to both the first and the second directions extends perpendicular to the planes of both the first and the second shroud panels, such that the cooling module is bounded in the third direction by the opposing first and second shroud panels.
An L-shaped stiffener bracket extends between the first and second shroud panels in that third direction. In some embodiments the frameless cooling module includes only a single L-shaped stiffener bracket, whereas in other embodiments the cooling module includes two or more such L-shaped stiffener brackets. The L-shaped stiffener bracket is located, along the first direction, at an intermediate location between the front of the module and the back of the module. In other words, the location of the L-shaped stiffener bracket is offset from both the front of the cooling module and from the back of the cooling module in the first direction. The L-shaped stiffener bracket is also located, along the second direction, at an intermediate location between the top of the cooling module and the bottom of the cooling module. In other words, the L-shaped stiffener bracket is offset from both the top of the cooling module and from the bottom of the cooling module in the second direction.
The L-shaped stiffener bracket includes a first planar wall, a second planar wall, and a right angle bend joining the first and second planar walls. The first planar wall is arranged to be parallel to the front and the back of the cooling module, while the second planar wall is arranged to be parallel to the top and the bottom of the cooling module. The L-shaped bracket can, for example, be formed by bending a flat sheet of metal ninety degrees to form the right angle bend.
The L-shaped stiffener bracket is joined to the first shroud panel by a first formed corner bracket and is joined to the second shroud panel by a second formed corner bracket. Each one of the first and second formed corner brackets is provided with a planar surface, and each one of the formed corner brackets is joined to the corresponding shroud panel by way of the planar surface. The formed corner brackets are additionally provided with formed flanges that extend perpendicularly from the planar surface. A first one of the formed flanges of each of the first and second formed corner brackets is used to join the formed corner bracket to the first planar wall of the L-shaped stiffener bracket. A second one of the formed flanges of each of the first and second formed corner brackets is used to join the formed corner bracket to the second planar wall of the L-shaped stiffener bracket.
In at least some embodiments, the planar surface of the formed corner brackets is in the shape of a right triangle. In other embodiments, the planar surface is in the shape of a square, a rectangle, a rhomboid, or some other shape.
In at least some embodiments, the formed corner brackets are joined to the corresponding shroud panels by mechanical fasteners such as screws, bolts, rivets, or the like. The planar surface of the formed corner bracket is disposed against a surface of the shroud panel, and apertures extending through the planar surface of the formed corner bracket to receive the fasteners are aligned with corresponding apertures of the shroud panel so that the mechanical fasteners can be inserted through the aligned apertures in order to mechanically fasten the formed corner bracket to the shroud panel.
In at least some embodiments, the formed corner brackets are joined to the L-shaped stiffener bracket by mechanical fasteners such as screws, bolts, rivets, or the like. The first and second formed flanges of the formed corner bracket are disposed against the first and second walls, respectively, of the L-shaped stiffener bracket, and apertures extending through the formed flanges of the formed corner bracket to receive the fasteners are aligned with corresponding apertures of the L-shaped stiffener bracket so that the mechanical fasteners can be inserted through the aligned apertures in order to mechanically fasten the formed corner bracket to the stiffener bracket.
Heat exchangers are arranged within the cooling module between the first planar wall of the L-shaped stiffener bracket and the front of the cooling module in the first direction. In at least some embodiments, the intermediate location of the L-shaped stiffener bracket along the first direction is selected such that the distance between the front of the cooling module and the first wall of the L-shaped stiffener bracket is approximately equal to the depth of the heat exchangers. One or more of the heat exchangers are arranged to be between the second planar wall of the L-shaped stiffener bracket and either the top or the bottom of the cooling module in the second direction. In at least some embodiments, the intermediate location of the L-shaped stiffener bracket along the second direction is selected such that the distance between the top or the bottom of the cooling module and the second wall of the L-shaped stiffener bracket is approximately equal to the height of one or more of the heat exchangers.
At least some of the heat exchangers arranged within the module can be structurally mounted to the first planar wall of the L-shaped stiffener bracket in order to at least partially secure those heat exchangers within the cooling module.
In some embodiments, the L-shaped stiffener bracket is one of several (i.e. two or more) L-shaped stiffener brackets. Another one of the L-shaped stiffener brackets also extends between the first and second shroud panels at an intermediate location between the front of the cooling module and the back of the cooling module in the first direction, and at an intermediate location between the top of the cooling module and the bottom of the cooling module in the second direction. That L-shaped stiffener bracket is joined to the shroud panels by additional ones of the formed corner brackets. One or more heat exchangers are arranged within the cooling module between the first planar wall of that L-shaped stiffener bracket and the front of the cooling module, and are structurally mounted to the first planar wall of that L-shaped stiffener bracket to at least partially secure those heat exchanger within the cooling module.
In at least some such embodiments, the first planar wall of one of the L-shaped stiffener brackets is aligned in a common plane with the first planar wall of another of the L-shaped stiffener brackets.
In at least some such embodiments, the first planar wall of one of the L-shaped stiffener brackets extends from the second planar wall of that L-shaped stiffener bracket towards the top of the cooling module, and the first planar wall of another of the first and second L-shaped stiffener brackets extends from the second planar wall of that L-shaped stiffener bracket towards the bottom of the cooling module.
In at least some such embodiments, the second planar wall of one of the L-shaped stiffener brackets abuts against, and is joined to, the second planar wall of another of the L-shaped stiffener brackets. In some such embodiments the two L-shaped stiffener brackets are joined together at least in part by one or more fasteners that extend through aligned apertures in the second planar walls of the L-shaped stiffener brackets and in formed flanges of the formed corner brackets that join those L-shaped stiffener brackets to the shroud panels.
In some embodiments, the cooling module includes a top panel arranged at the top end of the cooling module, and a bottom panel arranged at the bottom end of the cooling module. The top and bottom panels each extend between, and are joined to, the first and second shroud panels. At least one of the top and bottom panels extends from the back of the cooling module to an intermediate location between the front of the cooling module and the back of the cooling module in the first direction.
In at least some such embodiments, that one of the top and bottom panels includes a flange aligned in a common plane with the first planar wall of the L-shaped stiffener bracket. The heat exchanger or heat exchangers that are structurally mounted to that first planar wall are also structurally mounted to the flange of the top or bottom panel in order to at least partially secure the heat exchanger or heat exchangers within the cooling module.
In at least some such embodiments, both of the top and the bottom panels include a flange, with the flange of one of the panels aligned in a common plane with the first planar wall of one of the L-shaped stiffener brackets and the flange of the other one of the panels aligned in a common plane with the first planar wall of another one of the L-shaped stiffener brackets. In at least some embodiments, those flanges and planar walls are all aligned within one common plane. At least some heat exchangers are structurally mounted to the first planar wall of one of the L-shaped stiffener brackets and the flange of the top panel in order to secure those heat exchangers within the cooling module, and at least some of the heat exchangers are structurally mounted to the first planar wall of the other one of the L-shaped stiffener brackets and the flange of the bottom panel in order to secure those heat exchanger within the cooling module.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
A cooling module 1 according to an embodiment of the invention is depicted in
The exemplary cooling module 1 includes a set of heat exchangers 30 arranged at a front end 20 of the cooling module, along with another set of heat exchangers 31 also arranged at the front end 20. In some cases, the heat exchangers 30 can cool one type of fluid (for example, engine coolant) while the heat exchangers 31 cool another type of fluid (for example, lubricating oil). In other cases the cooling module might contain only heat exchangers for a single fluid. In certain cases a fluid is cooled in multiple heat exchangers, such as when the size of a single heat exchanger for cooling the fluid makes it more desirable—for reasons of cost, manufacturability, or other reasons—to divide the total heat transfer duty amongst multiple heat exchangers arranged in parallel. In other cases it might be desirable to have multiple heat exchangers arranged in parallel because the heat sources are similarly distributed. By way of example, a single cooling module 1 can be used to simultaneously cool the fluids for multiple diesel engines, each of which has one or more dedicated heat exchangers within the cooling module.
A fan (not shown) can be arranged at a back end 21 of the cooling module opposite the front end 20. The fan can be mounted to a back panel 16 of the cooling module 1, which is provided with a circular aperture 17 that generally conforms to the swept area of the fan. In this way, cooling air to which the heat from the fluids traveling through the heat exchangers 30, 31 can be rejected is directed from the front 20 to the back 21 in a depth direction 24 of the cooling module.
In contrast to the cooling module 101 of
As best seen in
The L-shaped stiffener bracket 4 is arranged within the cooling module in such a way that the planar wall 6 is perpendicular to the depth direction 24, e.g. parallel to the front 20 and the back 21, and the planar wall 7 is perpendicular to the height direction 25, e.g. parallel to the top 22 and the bottom 23. Furthermore, the L-shaped stiffener bracket 4 is located within the cooling module 1 such that the planar wall 6 is at an intermediate location along the depth direction 24 between the front 20 and the back 21 of the cooling module 1. In addition, the L-shaped stiffener bracket 4 is located within the cooling module 1 such that the planar wall 7 is at an intermediate location along the height direction 25 between the top 22 and the bottom 23 of the cooling module 1.
The L-shaped stiffener bracket 4 is structurally joined to the shroud panel 3 by a formed corner bracket 9, as depicted in
In the exemplary embodiment, the structural connections between the formed corner bracket 9 and both the L-shaped stiffener bracket 4 and the shroud panels are achieved by way of fasteners 12 that extend through aligned apertures in the components to be joined. The fasteners 12 can take the form of threaded bolt and nut fasteners, as shown in the exemplary embodiment, or can take other known forms of mechanical fastening such as, for example, thread-cutting screws, rivets, threaded studs, threaded inserts, self-clinching fasteners, captive fasteners, and the like. In still other embodiments the parts can be joined without the use of fasteners, such as by welding.
A second L-shaped stiffener bracket 5 is also provided in the exemplary embodiment, and is joined to the shroud panels 2, 3 by formed corner brackets 9 in a similar fashion to the first L-shaped stiffener bracket 4. As best seen in
As best shown in
It should be observed that the heights of the first planar walls 6 of the first and second L-shaped stiffener brackets need not be the same. As best seen in
The L-shaped stiffener brackets 4, 5 are used to at least partially support and secure the heat exchangers 30, 31 within the cooling module 1. The heat exchangers 30, 31 are preferably of a style wherein the fluid to be cooled is directed through flow channels between an inlet tank and an outlet tank in a direction generally corresponding to the height direction 25 of the cooling module, with air being directed over the outer surfaces of the flow channels in a direction generally corresponding to the depth direction 24 of the cooling module. Such heat exchangers can be, for example, of a tube and fin or a bar-plate construction, as is known in the art. The tanks of the heat exchangers are preferably equipped with mounting features that align with mounting locations 19 provided on the planar walls 6 of the brackets 4, 5 so that the heat exchangers can be affixed thereto, e.g. by mechanical fasteners.
The cooling module 1 is further provided with a top shroud panel 13 and with a bottom shroud panel 14. As can be seen in
As at least one benefit of the described cooling module construction over that of the prior art cooling module 101, the heat exchangers 30, 31 can be readily removed from the cooling module 1 for service, cleaning, repair, replacement, and the like. After removal of the fasteners used to retain the heat exchangers to the L-shaped stiffener brackets 4, 5 and the top and bottom shroud panels 13, 14, the heat exchangers can be easily removed from the front end 20 of the cooling module 1. In contrast, the heat exchangers as depicted in
It should be understood that, while the exemplary embodiment shown in the figures and described above includes a second L-shaped stiffener bracket 5, such a second L-shaped stiffener bracket is optional and need not be included. In certain embodiments it may be preferable for the flange 6 of the L-shaped stiffener bracket 4 to be of a suitable length for the mounting of both the heat exchangers 30 and the heat exchangers 31, thereby avoiding the expense of the second bracket 5.
The cooling module 1 can additionally be provided with one or more front brackets 26 that are joined to the shroud panels 2, 3 and extend therebetween at the front 20 of the cooling module 1. In the exemplary embodiment of
Various alternatives to the certain features and elements of the present invention are described with reference to specific embodiments of the present invention. With the exception of features, elements, and manners of operation that are mutually exclusive of or are inconsistent with each embodiment described above, it should be noted that the alternative features, elements, and manners of operation described with reference to one particular embodiment are applicable to the other embodiments.
The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention.
This application claims priority to U.S. provisional patent application No. 62/632,697, filed on Feb. 20, 2018, the entire contents of which are hereby incorporated by reference in their entirety.
Number | Name | Date | Kind |
---|---|---|---|
2207147 | Gilbertson | Jul 1940 | A |
3627035 | Astrup | Dec 1971 | A |
5360059 | Olson | Nov 1994 | A |
5971062 | Sadr et al. | Oct 1999 | A |
6189492 | Brown | Feb 2001 | B1 |
6386273 | Hateley | May 2002 | B1 |
6427766 | Zobel et al. | Aug 2002 | B2 |
6474727 | Guyomard | Nov 2002 | B1 |
6817404 | Frana-Guthrie et al. | Nov 2004 | B2 |
6907916 | Koyama | Jun 2005 | B2 |
6908283 | Soofer et al. | Jun 2005 | B2 |
9751394 | Speichinger | Sep 2017 | B1 |
20030079858 | Frana-Guthrie | May 2003 | A1 |
20040200598 | Hitt et al. | Oct 2004 | A1 |
20050217907 | Madson | Oct 2005 | A1 |
20070062671 | Sugimoto et al. | Mar 2007 | A1 |
20090145577 | Shuttleworth | Jun 2009 | A1 |
20110011661 | Takahashi | Jan 2011 | A1 |
20110284301 | Bui | Nov 2011 | A1 |
20150210156 | Manubolu | Jul 2015 | A1 |
20150283895 | Takahashi | Oct 2015 | A1 |
20160091261 | Gopireddy et al. | Mar 2016 | A1 |
20170292789 | Hjorth | Oct 2017 | A1 |
Number | Date | Country |
---|---|---|
1936485 | Mar 2007 | CN |
106812587 | Jun 2017 | CN |
210141172 | Mar 2020 | CN |
4305928 | Sep 1994 | DE |
1284406 | Feb 2003 | EP |
2067952 | Jun 2009 | EP |
0194706 | Dec 2001 | WO |
Entry |
---|
Extended European Search Report for Application No. 18211117.9 dated Apr. 2, 2019, European Patent Office (7 pages). |
First Office Action issued from the Chinese Patent Office for related Application No. 201910125900.1 dated Nov. 20, 2020 (15 Pages). |
Number | Date | Country | |
---|---|---|---|
20190257244 A1 | Aug 2019 | US |
Number | Date | Country | |
---|---|---|---|
62632697 | Feb 2018 | US |