MODULAR FLUID COOLING ASSEMBLY

Abstract

It is described herein a modular fluid cooling assembly. The modular fluid cooling assembly may be assembled from a number of fluid cooling modules and a number of fitting connectors. Each fluid cooling module may comprise a hollow cylinder, an inlet fitting, and an outlet fitting. The hollow cylinder may have an inlet end to which the inlet fitting is connected, an outlet end to which the outlet fitting is connected, a central axis, and a cylinder wall having a cylinder wall thickness in a range of between 0.025 inches and 0.25 inches. Each fitting connector may fluidly connect the inlet fitting of one cooling module to the outlet fitting of another cooling module. The number of fluid cooling modules may be an integer greater than or equal to 1 while the number of fitting connects may equal the number of fluid cooling modules minus 1.

Description

BACKGROUND

Fluid cooling systems are well known in the art and are used across a variety of applications and industries. The general concept of a fluid cooling system involves a heat exchanger in which the transfer of heat between a solid object and a fluid (gas or liquid) occurs. Conventional heat exchangers are of a tube design in which the hot fluid passes through the tube which is made of a solid material and the hot fluid transfers heat to the solid tube, thereby cooling the hot fluid.

Often a cooling mechanism such as cooled air, cold water, refrigerants, and the like are passed over and/or around the outer surface of the tube to continuously cool the solid material. These cooling mechanisms may be aided by surface modifications to the outer and/or inner surface of the tube to increase the surface area that is in contact with the cooling mechanism, thereby providing greater cooling of the solid material and hence more cooling of the hot fluid.

Many applications exist for fluid cooling systems—particularly within automobiles. Specific non-limiting examples include radiators for cooling the engine's water and/or antifreeze, intercoolers for cooling compressed gasses in a forced air induction system such as a turbocharger, oil coolers for cooling engine oil, and transmission coolers for cooling transmission fluid.

Conventional systems utilize a cooling system of a standard size and configuration. For example, a standard automotive core radiator may have 0.5 inch diameter tubes on 0.5625 centers made to fit the particular make and model of vehicle. These standard sizes and configurations limit the ability to adjust the cooling profile for various fluids as cooling needs change due to performance enhancements, engine wear, or other factors.

The need exists, therefore, for a fluid cooling system which can be adapted for changing cooling needs.

SUMMARY

A modular fluid cooling assembly is disclosed. The modular fluid cooling assembly may be assembled from a plurality (n) of cooling modules. The cooling modules may comprise a hollow cylinder, an inlet fitting, and an outlet fitting.

The hollow cylinder may have an inlet end, an outlet end opposite the inlet end, a central axis, and a cylinder wall. The cylinder wall may comprise an outer surface and an inner surface wherein the outer surface and the inner surface define a cylinder wall thickness having a value in a range of between 0.025 inches and 0.25 inches.

The inlet fitting may be connected to the inlet end of the hollow cylinder. Similarly, the outlet fitting may be connected to the outlet end of the hollow cylinder. The inlet fitting of one cooling module may be fluidly connected to the outlet fitting of another cooling module or to a hot fluid source. Similarly, the outlet fitting of one cooling module may be fluidly connected to the inlet fitting of another cooling module or to the hot fluid source. i as set forth in n_i may be an integer greater than or equal to 1. The total number of cooling modules may be less than or equal to 100.

In some embodiments, the modular fluid cooling assembly may further comprise n_i−1 fitting connectors. Each fitting connector may fluidly connect the inlet fitting of one cooling module to the outlet fitting of another cooling module.

In some embodiments, the outer surface of the cylinder wall may comprise at least one outer surface modification. The at least one outer surface modification may be selected from the group consisting of at least one outer surface longitudinal protrusion, at least one outer surface helical protrusion, at least one outer surface radial protrusion, at least one outer surface longitudinal recess, at least one outer surface helical recess, at least one outer surface radial recess, and combinations thereof.

In some embodiments, the outer surface modification may comprise a plurality of outer surface longitudinal protrusions where each outer surface longitudinal protrusion may have a first trapezoidal crossectional profile (187) which may have a first trapezoidal cross-sectional profile height dimension (188), a first trapezoidal cross-sectional profile major width dimension (189A), and a first trapezoidal cross-sectional profile minor width dimension (189B). A first ratio between an outer diameter of the hollow cylinder without protrusions (155A) and an outer diameter of the hollow cylinder with protrusions (155B) may be in a range of between 0.5:1 and 1:1. A second ratio between the first trapezoidal crossectional profile height dimension and the first trapezoidal cross-sectional profile major width dimension may be in a range of between 0.25:1 and 5:1. A third ratio between the first trapezoidal cross-sectional profile minor width dimension and the first trapezoidal cross-sectional profile major width dimension may be in a range of between and 0.5:1 and 1:1.

In some embodiments, the inner surface of the cylinder wall may comprise at least one inner surface modification. The at least one inner surface modification may be selected from the group consisting of at least one inner surface longitudinal protrusion, at least one inner surface helical protrusion, at least one inner surface radial protrusion, at least one inner surface longitudinal recess, at least one inner surface helical recess, at least one inner surface radial recess, and combinations thereof.

In some embodiments, the inner surface modification may comprise a plurality of inner surface longitudinal protrusions where each inner surface modification may have a second trapezoidal cross-sectional profile which may have a second trapezoidal cross. sectional profile height dimension, a second trapezoidal cross-sectional profile major width dimension, and a second trapezoidal cross-sectional profile minor width dimension. A fourth ratio between an inner diameter of the hollow cylinder without protrusions and an inner diameter of the hollow cylinder with protrusions may be in a range of between 0.5:1 and 1:1. A fifth ratio between the second trapezoidal cross-sectional profile height dimension and the second trapezoidal cross-sectional profile major width dimension may be in a range of between 0.25:1 and 5:1. A sixth ratio between the second trapezoidal cross-sectional profile major width dimension and the second trapezoidal cross-sectional profile minor width dimension may be in a range of between 0.5:1 and 1:1.

In some embodiments, the modular fluid cooling assembly may comprise a mounting bracket connected to at least one of the fluid cooling modules in a first plane perpendicular to the central axis at a point on the outer surface and/or an optional outer surface modification. The mounting bracket may comprise at least one mounting hole (405) passing through the mounting bracket in a second plane perpendicular to the first plane.

In some embodiments, the mounting bracket may be integrally connected to at least one hollow cylinder of the fluid cooling modules. In other embodiments, the mounting bracket may be integrally connected to each hollow cylinder of the fluid cooling modules.

In some embodiments, the mounting bracket may comprise a mounting bracket base, at least one clamp, and at least one fastener. The mounting bracket base may comprise the at least one mounting hole and at least one base clamp hole. The at least one clamp may comprise a first clamp section and a second clamp section. The first clamp section may comprise at least one first clamp section hole and a plurality (FCR) of first curvilinear recesses. The second clamp section may comprise at least one second clamp section hole and a plurality (SCR) of second curvilinear recesses. The at least one fastener may pass through the first clamp section hole, the second clamp section hole, and may attach to the base clamp hole. Each of the first curvilinear recesses may be mated to one of the second curvilinear recesses to form an aperture having an inside diameter which is between 0.01% and 0.1% smaller than the greater of an outer diameter of the hollow cylinder with protrusions or an outer diameter of the hollow cylinder without protrusions.

As used in FCR_x and SCR_x, x may be a positive integer less than or equal to i. In some embodiments, x may be a positive integer greater than i.

In some embodiments, the modular fluid cooling assembly may further comprise a heat sink extending from a mounting bracket outer surface. In some embodiments, the modular fluid cooling assembly may comprise a heat sink extending from a mounting bracket base outer surface.

In some embodiments, each hollow cylinder may independently comprise a material selected from the group consisting of aluminum, brass, copper, and steel.

The modular fluid cooling assembly may comprise at least two fluid cooling modules wherein the fluid cooling modules are arranged in a side-by-side linear arrangement. In alternative embodiments, the fluid cooling modules may be arranged in a stacked column arrangement comprising at least two columns and at least two rows wherein each column comprises at least two fluid cooling modules and each row comprises at least two fluid cooling modules.

In some embodiments, at least a portion of at least one of the fluid cooling modules may be fluidly sealed within a chiller box. The chiller box may be fluidly connected to a secondary fluid source. The secondary fluid source may be selected from the group consisting of an engine radiator and a cold water reservoir.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 depicts an exploded perspective view of an embodiment of a fluid cooling module as described herein.

FIG. 2 depicts an assembled perspective view of the embodiment of a fluid cooling module of FIG. 1.

FIG. 3 depicts an exploded perspective view of an embodiment of a modular fluid cooling assembly as described herein.

FIG. 4 depicts an assembled perspective view of the embodiment of a modular fluid cooling assembly of FIG. 3.

FIG. 5 depicts an assembled perspective view of an alternative embodiment of a modular fluid cooling assembly as described herein.

FIG. 6 depicts an assembled perspective view of an alternative embodiment of a modular fluid cooling assembly as described herein.

FIG. 7A depicts a perspective view of an embodiment of a hollow cylinder as described herein.

FIG. 7B depicts a perspective view of an alternative embodiment of a hollow cylinder as described herein.

FIG. 7C depicts a perspective view of another alternative embodiment of a hollow cylinder as described herein.

FIG. 7D depicts a perspective view of another embodiment of a hollow cylinder as described herein.

FIG. 7E depicts a perspective view of another alternative embodiment of a hollow cylinder as described herein.

FIG. 7F depicts a perspective view of another alternative embodiment of a hollow cylinder as described herein.

FIG. 8A depicts a cut-away perspective view of an embodiment of a hollow cylinder as described herein.

FIG. 8B depicts a cut-away perspective view of an alternative embodiment of a hollow cylinder as described herein.

FIG. 8C depicts a cut-away perspective view of another alternative embodiment of a hollow cylinder as described herein.

FIG. 8D depicts a cut-away perspective view of another embodiment of a hollow cylinder as described herein.

FIG. 8E depicts a cut-away perspective view of another alternative embodiment of a hollow cylinder as described herein.

FIG. 8F depicts a cut-away perspective view of another alternative embodiment of a hollow cylinder as described herein.

FIG. 9 depicts an end-cap view of one embodiment of a hollow cylinder as described herein.

FIG. 10 depicts a cross-section view of one embodiment of a modular fluid cooling assembly as described herein.

FIG. 11 depicts a cross-section view of an alternative embodiment of a modular fluid cooling assembly as described herein.

FIG. 12 depicts a cross-section view of another alternative embodiment of a modular fluid cooling assembly as described herein.

FIG. 13 depicts a cut-away perspective view of an embodiment of a modular fluid cooling assembly with a chiller box as described herein.

FIG. 14 depicts a perspective view of the embodiment of a modular fluid cooling assembly with a chiller box of FIG. 13.

DETAILED DESCRIPTION

Disclosed herein is a modular fluid cooling assembly. The modular fluid cooling assembly is described below with reference to the Figures. As described herein and in the claims, the following numbers refer to the following structures as noted in the Figures.

• • 5 refers to a modular fluid cooling assembly.
  • 10 refers to a fluid cooling module.
  • 20 refers to a fitting connector.
  • 100 refers to a hollow cylinder.
  • 110 refers to an inlet end (of a hollow cylinder).
  • 120 refers to an outlet end (of a hollow cylinder).
  • 130 refers to a central axis (of a hollow cylinder).
  • 140 refers to a cylinder wall (of a hollow cylinder).
  • 150 refers to an outer surface (of a hollow cylinder).
  • 155A refers to an outer diameter of the hollow cylinder without protrusions.
  • 155B refers to an outer diameter of the hollow cylinder with protrusions.
  • 160 refers to an inner surface (of a hollow cylinder).
  • 165A refers to an inner diameter of the hollow cylinder without protrusions.
  • 165B refers to an inner diameter of the hollow cylinder with protrusions.
  • 170 refers to a cylinder wall thickness.
  • 180 refers to an outer surface modification.
  • 181 refers to an outer surface longitudinal protrusion.
  • 182 refers to an outer surface helical protrusion.
  • 183 refers to an outer surface radial protrusion.
  • 184 refers to an outer surface longitudinal recess.
  • 185 refers to an outer surface helical recess.
  • 186 refers to an outer surface radial recess.
  • 187 refers to a first trapezoidal cross-sectional profile.
  • 188 refers to a first trapezoidal cross-sectional profile height dimension.
  • 189A refers to a first trapezoidal cross-sectional profile major width dimension.
  • 189B refers to a first trapezoidal cross-sectional profile minor width dimension.
  • 190 refers to an inner surface modification.
  • 191 refers to an inner surface longitudinal protrusion.
  • 192 refers to an inner surface helical protrusion.
  • 193 refers to an inner surface radial protrusion.
  • 194 refers to an inner surface longitudinal recess.
  • 195 refers to an inner surface helical recess.
  • 196 refers to an inner surface radial recess.
  • 197 refers to a second trapezoidal cross-sectional profile.
  • 198 refers to a second trapezoidal cross-sectional profile height dimension.
  • 199A refers to a second trapezoidal crossectional profile major width dimension.
  • 199B refers to a second trapezoidal cross-sectional profile minor width dimension.
  • 200 refers to an inlet fitting.
  • 300 refers to an outlet fitting.
  • 400 refers to a mounting bracket.
  • 405 refers to a mounting hole.
  • 410 refers to a mounting bracket base.
  • 412 refers to a base clamp hole.
  • 414 refers to a mounting bracket base outer surface.
  • 420 refers to a clamp.
  • 421 refers to a first clamp section.
  • 422 refers to a first clamp section hole.
  • 423 refers to a first curvilinear recess.
  • 424 refers to a second clamp section.
  • 425 refers to a second clamp section hole.
  • 426 refers to a second curvilinear recess.
  • 430 refers to a heat sink.
  • 440 refers to a mounting bracket outer surface.
  • 500 refers to a chiller box.
  • 510 refers to a coolant port.

FIG. 1 depicts an exploded perspective view of a fluid cooling module (10) for a modular fluid cooling assembly. As shown in FIG. 1, the fluid cooling module may comprise a hollow cylinder (100), an inlet fitting (200), and an outlet fitting (300). The hollow cylinder (100) has an inlet end (110), an outlet end (120) opposite the inlet end, and a central axis (130).

It is understood that the terms “inlet end” and “outlet end” as used herein and in the claims refer to the flow direction of a fluid flowing through the cooling module. The term “inlet end” meaning the end of the hollow cylinder through which the hot fluid (i.e.—the fluid to be cooled) is introduced into the hollow cylinder, and the term “outlet end” meaning the end of the hollow cylinder through which the fluid exits the hollow cylinder. As used herein and in the claims the term “hot fluid” refers to a fluid such as water, antifreeze, oil, transmission fluid, combustion gases, and the like having a temperature upon entering the modular fluid cooling assembly (5) which is in a range of between 20° C. and 350° C., more preferably between 35° C. and 300° C., with between 50° C. and 250° C. being most preferable. It will be understood that, upon exiting the modular fluid cooling assembly (5), the fluid will have a temperature which is below (i.e.—cooler than) the temperature of the fluid upon entering the modular fluid cooling assembly. Depending upon the configuration of the individual cooling module relative to the hot fluid source and/or the other individual cooling modules, either end of the individual cooling module may be the inlet end or the outlet end.

Similarly, it is understood that the terms “inlet fitting” and “outlet fitting” as used herein and in the claims also refers to the flow direction of a fluid flowing through the cooling module. The term “inlet fitting” meaning the fitting connected to the hollow cylinder at the end of the hollow cylinder through which the hot fluid is introduced into the fluid cooling module, and the term “outlet fitting” meaning the fitting connected to the hollow cylinder at the end of the hollow cylinder through which the fluid exits the fluid cooling module. Depending upon the configuration of the individual cooling module relative to the hot fluid source and/or the other individual cooling modules, either fitting of the individual cooling module may be the inlet fitting or the outlet fitting.

Each hollow cylinder (100) also has a cylinder wall (140 as shown in FIG. 9) comprising an outer surface (150 as shown in FIG. 9) and an inner surface (160 as shown in FIG. 9) which define a cylinder wall thickness (170 as shown in FIG. 9). In preferred embodiments, the cylinder wall thickness will have a value in a range of between 0.025 inches and 0.25 inches.

FIG. 2 depicts an assembled perspective view of the fluid cooling module (10) shown in FIG. 1. As shown in FIG. 2, the inlet fitting (200) may be connected to the inlet end (110 as shown in FIG. 1) of the hollow cylinder (100). Similarly, the outlet fitting (300) may be connected to the outlet end (120 as shown in FIG. 1) of the hollow cylinder (100).

The connection between the inlet fitting (200) and the inlet end (110) of the hollow cylinder (100), and/or the outlet fitting (300) and the outlet end (120) of the hollow cylinder (100) respectively may take many forms. In some embodiments, these connections may be integral connections such as manufacturing the hollow cylinder (100) and the inlet fitting (200) and/or the outlet fitting (300) of a single unitary piece of material. Another example of an integral connection involves welding one or both of the inlet fitting (200) and/or the outlet fitting (300) to the respective inlet end (110) or outlet end (120) of the hollow cylinder (100).

In some embodiments, the connection between the inlet fitting (200) and the inlet end (110) of the hollow cylinder (100), and/or the outlet fitting (300) and the outlet end (120) of the hollow cylinder (100) respectively may be a removable connection. A preferred removable connection is a threaded connection in which threads on an inner surface of one component are mated to corresponding threads on an outer surface of a second component. For example, the inner surface (160 as shown in FIG. 9) of the hollow cylinder (100) may be threaded at either or both of the inlet end (110) and/or the outlet end (120) while an outer surface of the respective inlet fitting (200) and/or outlet fitting (300) may be threaded to mate with the threads of the inlet end (110) and/or the outlet end (120). This type of threaded connection may be assisted by an adhesive and/or a thread sealing tape such as Teflon® tape applied to the threads to reduce or prevent the respective fittings from loosening and becoming disconnected from the hollow cylinder during use.

FIG. 3 depicts an exploded perspective view of one embodiment of a modular fluid cooling assembly (5) assembled from two fluid cooling modules (10) and a fitting connector (20). While the embodiments shown in FIG. 3 include fitting connectors—the fitting connector is not considered a required limitation. Any type of device for fluidly connecting two fluid cooling modules may be utilized. Alternative—non-limiting examples of such devices may include one or more valves, one or more hoses, one or more conduits, and combinations thereof.

As shown in FIG. 3, the fitting connector (20)—when used—is configured to provide a 180° bend angle so that the fluid cooling modules (10) are in a side by side configuration. However, other configurations of fitting connectors may exist. For example, any one individual fitting connector (20) may be configured to provide a 90° bend angle so that the fluid cooling modules (10) are in an “L” shaped configuration. In another example, any one individual fitting connector (20) may be configured to provide a 0° bend angle so that the fluid cooling modules (10) are in a linear configuration.

The configuration of fitting connectors may also be expressed as providing a bend angle within a specific range. In other words, any one individual fitting connector may be configured to individually provide a bend angle in a range selected from the group consisting of between 0° and 180°, between 30° and 180°, between 60° and 180, between 90° and 180°, between 90° and 150°, or between 90° and 120°.

FIG. 4 depicts an assembled perspective view of the modular fluid cooling assembly (5) assembled from two fluid cooling modules (10) and a fitting connector (20) shown in FIG. 3. As shown in FIG. 4, the fitting connector (20) fluidly connects the inlet fitting (200) of one fluid cooling module to the outlet fitting (300) of another fluid cooling module.

The modular fluid cooling assembly (5) may be adapted to add, remove, replace, or reposition individual fluid cooling modules (10) as needed or desired for the specific application. In this regard, the modular fluid cooling assembly (5) can be thought of as being assembled from a number (n) of fluid cooling modules (10) with i being an integer greater than or equal to 1.

In embodiments utilizing fitting connectors (20), there may be n_i−1 fitting connectors. In other words, in any specific modular fluid cooling assembly (5) which utilizes fitting connectors there will be one less fitting connector (20) than there are fluid cooling modules (10). This allows one of the fluid cooling modules (10) to be fluidly connected at its inlet end (110) via its inlet fitting (200) to a hot fluid source in order to receive the hot fluid from the hot fluid source while another fluid cooling module is fluidly connected at its outlet end (120) via its outlet fitting (300) back to the hot fluid source to return the cooled fluid which has passed through the modular fluid cooling assembly back to the hot fluid source. Non-limiting examples of a hot fluid source may include an engine water jacket, a turbocharger, an engine oil pump, and a transmission. One of ordinary skill will recognize that, in embodiments where there is a single fluid cooling module (i.e.—i equals 1) there may be no fitting connectors. As used herein and in the claims—the term “hot fluid” as used in the phrase “hot fluid source” refers to a fluid having a temperature as it passes into the modular fluid cooling assembly which is in a range of between 20° C. and 350° C., more preferably between 35° C. and 300° C., with between 50° C. and 250° C. being most preferable.

As one example, FIG. 5 depicts an assembled perspective view of a modular fluid cooling assembly (5) comprising four fluid cooling modules (10) arranged in a side-by-side arrangement and connected to one another by three fitting connectors (20A, 20B, and 20C). In this arrangement, each of the fitting connectors provides a 180° bend angle allowing for the side-by-side arrangement.

In the FIG. 5 modular fluid cooling assembly (5), a hot fluid from a hot fluid source such as an engine or transmission is introduced into the modular fluid cooling assembly (5) through the first inlet fitting (200A) of the first fluid cooling module. The hot fluid then flows through the first hollow cylinder (100A) from the first inlet end to the first outlet end where it exits the first cooling module through the first outlet fitting (300A). As the hot fluid is passing through the first cooling module it transfers heat to the first hollow cylinder (100A), thereby cooling the fluid.

In the FIG. 5 modular fluid cooling assembly (5), after exiting the first cooling module through the first outlet fitting (300A) the hot fluid passes through a first fitting connector (20A) to the second inlet fitting (200B) of the second fluid cooling module. The hot fluid then flows through the second hollow cylinder (100B) from the second inlet end to the second outlet end where it exits the second cooling module through the second outlet fitting (300B). As the hot fluid is passing through the second cooling module it transfers additional heat to the second hollow cylinder (100B), thereby providing additional cooling of the fluid.

Next, in the FIG. 5 modular fluid cooling assembly (5), after exiting the second cooling module through the second outlet fitting (300B) the hot fluid passes through a second fitting connector (20B) to the third inlet fitting (200C) of the third fluid cooling module. The hot fluid then flows through the third hollow cylinder (100C) from the third inlet end to the third outlet end where it exits the third cooling module through the third outlet fitting (300C). As the hot fluid is passing through the third cooling module it transfers additional heat to the third hollow cylinder (100C), thereby providing additional cooling of the fluid.

Finally, in the FIG. 5 modular fluid cooling assembly (5) after exiting the third cooling module through the third outlet fitting (300C) the hot fluid passes through a third fitting connector (20C) to the fourth inlet fitting (200D) of the fourth fluid cooling module. The hot fluid then flows through the fourth hollow cylinder (100D) from the fourth inlet end to the fourth outlet end where it exits the fourth fluid cooling module through the fourth outlet fitting (300D) to be reintroduced to the hot fluid source. As the hot fluid is passing through the fourth cooling module it transfers additional heat to the fourth hollow cylinder (100D), thereby providing additional cooling of the fluid.

Another example is depicted in FIG. 6 which shows an assembled perspective view of a modular fluid cooling assembly (5) comprising four fluid cooling modules arranged in a 2×2 stacked arrangement and connected to one another by three fitting connectors. In this configuration, each of the fitting connectors (20) provides a 180° bend angle allowing for the side-by-side stacked arrangement.

The flow of the hot fluid through the various fluid cooling modules in the FIG. 6 embodiment is similar to that of the flow of hot fluid through the various fluid cooling modules in the FIG. 5 embodiment. The only difference being that, in the FIG. 6 embodiment the various fluid cooling modules are arranged in a 2×2 stacked arrangement whereas in the FIG. 5 embodiment the various fluid cooling modules are arranged in a side-by-side arrangement.

While examples are shown having two (FIG. 3 and FIG. 4) and four (FIG. 5 and FIG. 6) fluid cooling modules (10) respectively, the number of fluid cooling modules may not be so limited. The number of fluid cooling modules in any specific modular fluid cooling assembly will depend upon a number of factors including the type of fluid being cooled and the desired temperature to which the fluid should be cooled. Without limitation, the total number of fluid cooling modules (10) may be in a range selected from the group consisting of between 1 and 100, between 1 and 75, between 1 and 50, between 1 and 25, between 1 and 10, between 1 and 8, between 1 and 6, and between 1 and 4.

The arrangement of the individual fluid cooling modules may also vary. While side-by-side (FIG. 3, FIG. 4, and FIG. 5) and stacked (FIG. 6) arrangements are shown, many other arrangements may exist by varying the number of fluid cooing modules and the bend angle of the individual fitting connectors. Specific non-limiting examples of different arrangements may include a side-by-side arrangement of two or more fluid cooling modules, a 1×2 stacked arrangement of three fluid cooling modules, a 2×2 stacked arrangement of four fluid cooling modules, a 4×2 stacked arrangement of six fluid cooling modules, a 3×3 stacked arrangement of nine fluid cooling modules, an “L” shaped arrangement of two fluid cooling modules, a “U” shaped arrangement of three fluid cooling modules, and a square shaped arrangement of four fluid cooling modules.

Non-limiting examples of preferred arrangements for the individual fluid cooling modules include a side-by-side linear arrangement or a stacked column arrangement. In a side-by-side linear arrangement there will be at least two fluid cooling modules wherein a substantially straight line can be drawn between the central axis of each fluid cooling module. Examples of such arrangements are shown in FIG. 4 and FIG. 5. While FIG. 4 and FIG. 5 show side-by-side linear arrangements having 2 and 4 fluid cooling modules respectively, the number of fluid cooling modules may not be so limited. Depending upon the application, the number of fluid cooling modules in a side-by-side linear arrangement may be in the range of between 2 and 100.

In a stacked column arrangement there may be at least two columns and at least two rows. Each column may comprise at least two fluid cooling modules while each row may comprise at least two fluid cooling modules. An example of such an arrangement is shown in FIG. 6—which is a modular fluid cooling assembly having two columns each having two fluid cooling modules, and two rows each having two fluid cooling modules. In FIG. 6, the first column may be considered to comprise the second fluid cooling module (100B) and the third fluid cooling module (100C) while the second column may be considered to comprise the first fluid cooling module (100A) and the fourth fluid cooling module (100D). The first row may be considered to comprise the second fluid cooling module (100B) and the first fluid cooling module (100A) while the second row may be considered to comprise the third fluid cooling module (100C) and the fourth fluid cooling module (100D).

While FIG. 6 shows two columns of two fluid cooling modules and two rows of two fluid cooling modules, the configurations may not be so limited. Depending upon the application, the number of columns may be in the range of between 2 and 100, the number of rows may be in the range of between 2 and 100, the number of fluid cooling modules in each column may be between 2 and 100, and the number of fluid cooling modules in each row may be between 2 and 100. While each column may have the same number of fluid cooling modules, and each row may have the same number of fluid cooling modules, it is not considered important for each column and/or each row to have the same number of fluid cooling modules. For example, embodiments may exist having four columns and four rows with the first and second column having two fluid cooling modules, the third and fourth column having two fluid cooling modules, the first and second row having two fluid cooling modules, and the third and fourth row having four fluid cooling modules.

The outer surface of the cylinder wall of each hollow cylinder may individually comprise at least one outer surface modification (180 as shown in FIG. 9). The outer surface modification may be selected from the group consisting of protrusions and recesses. As used herein and in the claims with reference to an outer surface modification a protrusion refers to an outer surface modification formed by material which extends from the outer surface of the cylinder wall while a recess refers an outer surface modification formed by removing material from the outer surface of the cylinder wall.

The protrusions and/or recesses may each be arranged in a pattern which is longitudinal, helical or radial. As used herein and in the claims with reference to an outer surface modification (180 as shown in FIG. 9), the term longitudinal means that the protrusion or recess originates at a first point along the outer surface (150 as shown in FIG. 9) of the cylinder wall (140 as shown in FIG. 9) and extends along a length of the cylinder wall towards a second point along the outer surface of the cylinder wall in a plane parallel to the central axis (130 as shown in FIG. 1) of the hollow cylinder (100). As used herein and in the claims with reference to an outer surface modification, the term helical means that the protrusion or recess originates at a first point along the outer surface of the cylinder wall and extends along a length of the cylinder wall towards a second point along the outer surface of the cylinder wall while also wrapping around the diameter of the outer surface of the cylinder wall as it extends from the first point to the second point. As used herein and in the claims with reference to an outer surface modification, the term radial means that the protrusion or recess wraps around the diameter of the outer surface of the cylinder wall in a plane substantially perpendicular with or perpendicular with the central axis of the hollow cylinder.

Various examples of an outer surface modification are shown in FIG. 7A through FIG. 7F. For example, FIG. 7A depicts a hollow cylinder having at least one outer surface longitudinal protrusion (181). FIG. 7B depicts a hollow cylinder having at least one outer surface helical protrusion (182), FIG. 7C depicts a hollow cylinder having at least one outer surface radial protrusion (183). FIG. 7D depicts a hollow cylinder having at least one outer surface longitudinal recess (184). FIG. 7E depicts a hollow cylinder having at least one outer surface helical recess (185). FIG. 7F depicts a hollow cylinder having at least one outer surface radial recess (186). While FIG. 7A through FIG. 7F show hollow cylinders having only one type of outer surface modification, embodiments may exist in which any individual hollow cylinder comprises a combination of different types of outer surface modifications, for example, a hollow cylinder having at least one outer surface longitudinal protrusion and at least one outer surface helical recess.

Similarly, the inner surface of the cylinder wall of each hollow cylinder may individually comprise at least one inner surface modification (190 as shown in FIG. 9). The inner surface modification may be selected from the group consisting of protrusions and recesses. As used herein and in the claims with reference to an inner surface modification a protrusion refers to an inner surface modification formed by material which extends from the inner surface of the cylinder wall while a recess refers an inner surface modification formed by removing material from the inner surface of the cylinder wall.

The protrusions and/or recesses may each be arranged in a pattern which is longitudinal, helical or radial. As used herein and in the claims with reference to an inner surface modification (190 as shown in FIG. 9), the term longitudinal means that the protrusion or recess originates at a first point along the inner surface (160 as shown in FIG. 9) of the cylinder wall (140 as shown in FIG. 9) and extends long a length of the cylinder wall towards a second point along the inner surface of the cylinder wall in a plane parallel to the central axis (130 as shown in FIG. 1) of the hollow cylinder (100). As used herein and in the claims with reference to an inner surface modification, the term helical means that the protrusion or recess originates at a first point along the inner surface of the cylinder wall and extends along a length of the cylinder wall towards a second point along the inner surface of the cylinder wall while also wrapping around the diameter of the inner surface of the cylinder wall as it extends from the first point to the second point. As used herein and in the claims with reference to an inner surface modification, the term radial means that the protrusion or recess wraps around the diameter of the inner surface of the cylinder wall in a plane substantially perpendicular with or perpendicular with the central axis of the hollow cylinder.

Various examples of an inner surface modification are shown in FIG. 8A through FIG. 8F which are cross-sectional top views of hollow cylinders having different inner surface modifications. For example, FIG. 8A depicts a hollow cylinder having at least one inner surface longitudinal protrusion (191). FIG. 8B depicts a hollow cylinder having at least one inner surface helical protrusion (192), FIG. 8C depicts a hollow cylinder having at least one inner surface radial protrusion (193). FIG. 8D depicts a hollow cylinder having at least one inner surface longitudinal recess (194). FIG. 8E depicts a hollow cylinder having at least one inner surface helical recess (195). FIG. 8F depicts a hollow cylinder having at least one inner surface radial recess (196). While FIG. 8A through FIG. 8F show hollow cylinders having only one type of inner surface modification, embodiments may exist in which any individual hollow cylinder comprises a combination of different types of inner surface modifications such as at least one inner surface radial protrusion and at least one inner surface longitudinal recess.

FIG. 9 depicts an end-cap view of a preferred embodiment of a hollow cylinder (100). As shown in FIG. 9, the preferred embodiment of a hollow cylinder comprises a plurality of outer surface longitudinal protrusions. Each outer surface longitudinal protrusion in the embodiment depicted in FIG. 9 has a first trapezoidal cross sectional profile (187) having a first trapezoidal cross-sectional profile height dimension (188), a first trapezoidal cross-sectional profile major width dimension (189A) and a first trapezoidal cross-sectional profile minor width dimension (189B).

When the hollow cylinder has outer surface protrusions the hollow cylinder will have two outer diameters. The first outer diameter will be the outer diameter of the hollow cylinder without protrusions (155A) while the second diameter will be the outer diameter of the hollow cylinder with protrusions (155B). These two outer diameters result in a ratio between the outer diameter of the hollow cylinder without protrusions (155A) and the outer diameter of the hollow cylinder with protrusions (155B) which is in a range of between 0.5:1 and 1:1, between 0.6:1 and 1:1, between 0.7:1 and 1:1, between 0.8:1 and 1:1, and between 0.9:1 and 1:1.

In the preferred outer surface longitudinal protrusions as shown in FIG. 9 there will also be a ratio between the first trapezoidal cross-sectional profile height dimension (188) and the first trapezoidal cross-sectional profile major width dimension (189A) which is in a range selected from the group consisting of between 0.25:1 and 5:1, between 0.25:1 and 4:1, between 0.25:1 and 3:1, between 0.25:1 and 2:1, between 0.25:1 and 1:1, between 0.5:1 and 5:1, between 0.5:1 and 4:1, between 0.5:1 and 3:1, between 0.5:1 and 2:1, between 0.5:1 and 1:1, between 1:1 and 5:1, between 1:1 and 4:1, between 1:1 and 3:1, and between 1:1 and 2:1. Additionally, there will be a ratio between the first trapezoidal cross-sectional profile minor width dimension (189B) and the first trapezoidal cross-sectional profile major width dimension (189A) which is in a range selected from the group consisting of between 0.5:1 and 1:1, between 0.6:1 and 1:1, between 0.7:1 and 1:1, between 0.8:1 and 1:1, and between 0.9:1 and 1:1.

FIG. 9 also shows the preferred embodiment of a hollow cylinder comprises a plurality of inner surface longitudinal protrusions. Each inner surface longitudinal protrusion in the embodiment depicted in FIG. 9 has a second trapezoidal cross-sectional profile (197) having a second trapezoidal cross-sectional profile height dimension (198), a second trapezoidal cross-sectional profile major width dimension (199A) and a second trapezoidal cross-sectional profile minor width dimension (199B).

When the hollow cylinder has inner surface protrusions the hollow cylinder will have two inner diameters. The first inner diameter will be the inner diameter of the hollow cylinder without protrusions (165A) while the second diameter will be the inner diameter of the hollow cylinder with protrusions (165B). These two inner diameters result in a ratio between the inner diameter of the hollow cylinder without protrusions (165A) and the inner diameter of the hollow cylinder with protrusions (165B) which is in a range of between 1:0.5 and 1:1, between 1:0.6 and 1:1, between 1:0.7 and 1:1, between 1:0.8 and 1:1, and between 1:0.9 and 1:1.

In the preferred inner surface longitudinal protrusions (191) as shown in FIG. 9 there will also be a ratio between the second trapezoidal cross-sectional profile height dimension (198) and the second trapezoidal cross-sectional profile major width dimension (199A) which is in a range selected from the group consisting of between 0.25:1 and 5:1, between 0.25:1 and 4:1, between 0.25:1 and 3:1, between 0.25:1 and 2:1, between 0.25:1 and 1:1, between 0.5:1 and 5:1, between 0.5:1 and 4:1, between 0.5:1 and 3:1, between 0.5:1 and 2:1, between 0.5:1 and 1:1, between 1:1 and 5:1, between 1:1 and 4:1, between 1:1 and 3:1, and between 1:1 and 2:1. Additionally, there will be a ratio between the second trapezoidal cross-sectional profile minor width dimension (199B) and the second trapezoidal cross-sectional profile major width dimension (199A) which is in a range selected from the group consisting of between 0.5:1 and 1:1, between 0.6:1 and 1:1, between 0.7:1 and 1:1, between 0.8:1 and 1:1, and between 0.9:1 and 1:1.

The result of the preferred hollow cylinder (100) having the preferred outer surface longitudinal protrusions and the preferred inner surface longitudinal protrusions as shown in FIG. 9 is a hollow cylinder having an increased surface area for exchanging heat with the hot fluid as it flows through the hollow cylinder. For example, the most preferred hollow cylinder will have an inner diameter of the hollow cylinder without protrusions (165A)—also known as a cylinder bore—of 0.590 inches and an outer diameter of the hollow cylinder without protrusions (155A) of 0.750 inches resulting in a cylinder wall thickness (170) of 0.160 inches. In this FIG. 9 configuration, the outer surface of the hollow cylinder will have a surface area per unit length of 6.713 in² per inch while the inner surface of the hollow cylinder will have a surface area per unit length of 5.0 in² per inch. When the hollow cylinder has a length dimension parallel to the central axis (130) of 11.5 inches, this will result in a total exterior surface area of 77.2 in² and a total interior surface area of 57.5 in².

Due to its modular nature, the modular fluid cooling assembly may be used to increase the surface area available for exchanging heat with the hot fluid as it passes through the assembly. For instance, a modular fluid cooling assembly comprised of a single fluid cooling module of the type and dimensions described in the preceding paragraph would have a total surface area available for exchanging heat with the hot fluid of 134.7 in² (not including the surface area of the inlet fitting, the outlet fitting, or any fitting connectors). By adding a second fluid cooling module (also of the type and dimensions described in the preceding paragraph), the total surface area available for exchanging heat with the hot fluid can be doubled to 269.4 in² (not including the surface area of the inlet fittings, the outlet fittings, or any fitting connectors). The total surface area available for exchanging heat with the hot fluid can be further increased by adding additional fluid cooling modules as desired by the user based on the specific end-use application.

FIG. 10 depicts a cross-sectional view of one embodiment of a modular fluid cooling assembly (5) comprising two fluid cooling modules. As shown in FIG. 10, the fluid cooling modules may be connected to one another by a mounting bracket (400).

The mounting bracket (400) depicted in FIG. 10 may be considered a detachable mounting bracket. As shown in FIG. 10, the detachable mounting bracket may comprise a mounting bracket base (410) comprising at least one mounting hole (405) passing through the mounting bracket base (410) in a plane substantially perpendicular to or perpendicular to the central axis (130 as shown in FIG. 1) of the hollow cylinder (100 as shown in FIG. 1). The mounting bracket base (410) may also comprise at least one base clamp hole (412) which passes at least partially through the mounting bracket base (410) in a plane substantially perpendicular to or perpendicular to the central axis of the hollow cylinder. The mounting bracket (400) shown in FIG. 10 may also comprise at least one clamp (420) comprising a first clamp section (421) and a second clamp section (424). The detachable mounting bracket as shown in FIG. 10 may also comprise at least one fastener.

The first clamp section (421) of the detachable mounting bracket as shown in FIG. 10 may comprise at least one first clamp section hole (422) and a plurality (FCR) of first curvilinear recesses (423). Similarly, the second clamp section (424) of the detachable mounting bracket as shown in FIG. 10 may comprise at least one second clamp section hole (425) and a plurality (SCR) of second curvilinear recesses (426). When assembled, the at least one fastener passes through the first clamp section hole (422), the second clamp section hole (425), and attaches to the base clamp hole (412). Preferably the at least one fastener is a threaded fastener which attaches to a threaded base clamp hole.

The plurality (FCR_x) of first curvilinear recesses (423) and the plurality (SCR) of second curvilinear recesses (426) are preferably equal to one another with each individual first curvilinear recess mated to a corresponding second curvilinear recess when the detachable mounting bracket is assembled to form an aperture. Said aperture preferably has an inside diameter which is between 0.01% and 0.1% smaller than the greater of the outside diameter of the hollow cylinder with protrusions (155B) or the outside diameter of the hollow cylinder without protrusions (155A). This allows the clamp to apply a clamping force radially around one or more of the hollow cylinders when the detachable mounting bracket is assembled onto the fluid cooling modules (10).

The number of clamps, as well as the number of first curvilinear recesses and the number of second curvilinear recesses is not considered important and will largely be a product of the number and configuration of fluid cooling modules used for the desired application. While not necessary, the number of first curvilinear recesses and the number of second curvilinear recesses should be less than or equal to the number of fluid cooling modules. That is to say that x in FCR_x and SCR_x is generally a positive integer less than or equal to i in n_i. However, embodiments may exist where the number of first curvilinear recesses and the number of second curvilinear recesses is greater than the number of fluid cooling modules to allow the user to add additional fluid cooling modules to adjust the fluid cooling. In such embodiments x may be a positive integer greater than i.

In embodiments having a single clamp, the number of first curvilinear recesses and second curvilinear recesses preferably will equal the number of fluid cooling modules. For example, in a modular fluid cooling assembly (5) having two fluid cooling modules as shown in FIG. 10, the clamp (420) will have two separate first curvilinear recesses corresponding to two separate second curvilinear recesses to form two separate apertures. The two separate apertures will each independently provide a radial clamping force to one of the two fluid cooling modules. Additional embodiments may exist in which the first clamp has any number of first curvilinear recesses and second curvilinear recesses in the range of between 2 and 100.

Examples may exist having multiple clamps. For example, the modular fluid cooling assembly (5) may comprise four fluid cooling modules (10) arranged in a stacked 2×2 configuration as shown in FIG. 6. In such a configuration, the mounting bracket may comprise a first clamp and a second clamp. The first clamp may comprise two first curvilinear recesses corresponding to two second curvilinear recesses to form two separate apertures while the second clamp may comprise two first curvilinear recesses corresponding to two second curvilinear recesses to form two additional separate apertures. Again, the number of clamps and the number of first curvilinear surfaces and second curvilinear surfaces within each clamp is not considered important and will largely be a factor of the number and configuration of fluid cooling modules.

FIG. 11 depicts cross-sectional view of an alternative embodiment of a modular fluid cooling assembly comprising two fluid cooling modules (10A and 10B). As shown in FIG. 11, the fluid cooling modules may be connected to one another by a mounting bracket (400). The mounting bracket (400) shown in FIG. 11 is an integral mounting bracket in that a surface of the mounting bracket is integrally connected to one or more of the hollow cylinders (100) along the outer surface (150) of the hollow cylinder(s) and/or the outer surface protrusions. One example of such an integral connection may include welding the mounting bracket (400) to the outer surface (150) of the hollow cylinder and/or the outer surface protrusion. Another example of an integral connection may include manufacturing the hollow cylinder (100) and the mounting bracket (400) from a single contiguous piece of material.

FIG. 12 depicts a cross-sectional view of an alternative embodiment of a modular fluid cooling assembly comprising two fluid cooling modules (10A and 10B). As shown in FIG. 12, the modular fluid cooling assembly may further comprise a heat sink (430) connected to the mounting bracket (400) at the mounting bracket outer surface (440). The heat sink (430) may comprise a number of ribs or protrusions arranged in a pattern along the mounting bracket outer surface. When utilized, the heat sink (430) provides additional surface area to further improve the cooling effect of the modular fluid cooling assembly (5). While FIG. 12 depicts the heat sink (430) connected to the mounting bracket (400) which is integrally connected to the two fluid cooling modules (10A and 10B), the heat sink (430) may also be connected to a mounting bracket which is detachable such as that shown in FIG. 10.

FIG. 13 shows an additional feature of certain embodiments of the modular fluid cooling assembly (5). Specifically, FIG. 13 shows the modular fluid cooling assembly (5) comprising a chiller box (500). The chiller box provides a sealed containment unit which can both encompass all or a portion of the fluid cooling modules (10) as well as surround the fluid cooling modules (10) with a coolant such as water, ice, cooled air, or the like. The chiller box (500) may also include a coolant port (510 as shown in FIG. 14) which allows the coolant to be introduced and removed from the chiller box before, during, or after operation.

FIG. 14 shows the embodiment of FIG. 13 without the chiller box (500) being partially cut away. In the FIG. 14 view, the hollow cylinders are not visible as they are fully encompassed by the chiller box (500). The only portion of the fluid cooling modules visible in the FIG. 14 embodiment are the respective inlet fitting (200) and outlet fitting (300) of the two fluid cooling modules as they pass through a wall of the chiller box. However, it is not considered necessary for the inlet and/or outlet fitting to pass through the wall of the chiller box. In some embodiments, the entirety of all fluid cooling modules may be encompassed by the chiller box (500) while an inlet conduit—such as a line or hose—and an outlet conduit—such as a line or hose—passes through the sidewall of the chiller box to attach to the respective inlet fitting or outlet fitting.

In some embodiments, the chiller box may be fluidly connected to a secondary fluid source. Fluid from the secondary fluid source may enter the chiller box in a continuous or pulsed flow, where it will surround at least a portion of the exterior of the modular fluid cooling assembly to assist in cooling and/or heating the fluid that is within the modular fluid cooling assembly.

For example, in some instances it may be beneficial to heat a fuel—such as diesel fuel—before introducing it into an internal combustion engine. Heating the fuel assists in atomization and improves engine performance. In such a scenario, the modular fluid cooling assembly may be contained—at least partially—within the chiller box and may be fluidly connected to the engine's fuel system while the chiller box may be fluidly connected to a secondary fluid source which is the engine's radiator. As fuel flows through the modular fluid cooling assembly to be introduced into the combustion chambers of the engine it is heated by the coolant which flows into the chiller box from the engine's radiator and surrounds at least a portion of the exterior surfaces of the modular fluid cooling assembly.

In another example, it may be beneficial to cool a fluid—such as engine oil—during engine operation. In such a scenario, the modular fluid cooling assembly may be contained—at least partially—within the chiller box and may be fluidly connected to the engine's oil pump (either the inlet or outlet side) while the chiller box may be fluidly connected to a secondary fluid source which is a cold water reservoir. As oil flows through the modular fluid cooling assembly to be introduced into the engine it is cooled by cold water which flows into the chiller box from the cold water reservoir and surrounds at least a portion of the exterior surface of the modular fluid cooling assembly.

While the chiller box has been described above with reference to heating fuel using hot engine coolant, and cooling oil using cold water, applications for the chiller box may not be so limited. The chiller box may be used to assist with heating or cooling any number of fluids passing through the modular fluid cooling assembly including fuel, oil, transmission fluid, water, anti-freeze, and compressed gases (such as those from a supercharger). The secondary fluid source may be any number of fluid sources including an engine radiator and a cold water reservoir. When used, the cold water reservoir may contain ice water. It is preferable that—when the chiller box is fluidly connected to a secondary fluid source—the fluid connection allows for a first portion of fluid to be introduced into the chiller box while simultaneously a second portion of fluid is removed from the chiller box to maintain circulation of the fluid around the exterior surface of the modular fluid cooling assembly.

While the FIG. 13 and FIG. 14 embodiments show a chiller box having a rectangular cube configuration many different configurations may exist. Non-limiting examples of different chiller box configurations include a square cube configuration, a rectangular cube configuration, and a cylindrical configuration.

The hollow cylinders (100) described herein may be manufactured of a variety of materials using a variety of manufacturing techniques. Examples of preferred materials include aluminum, copper, brass, and steel. One preferred manufacturing technique is metal tube extrusion in which a blank piece of metal is forced through a die having the desired cross-sectional profile in order to apply the desired surface modifications. Following the extrusion process the hollow cylinder may be subjected to additional machining—such as on a mill or lathe—to include additional surface features and/or to add threads to the inlet and/or outlet end of the hollow cylinder for connecting the inlet and/or outlet fitting.

Examples

Cooling data was obtained on various embodiments of the modular fluid cooling assembly disclosed herein. The specific modular fluid cooling assembly comprised four fluid cooling modules arranged in a side-by-side linear arrangement and connected by three fitting connectors each providing a 180° bend angle.

The hollow cylinder of each fluid cooling module comprised both outer surface longitudinal protrusions and inner surface longitudinal protrusions. The outer surface longitudinal protrusions had a first trapezoidal cross-sectional profile having a first trapezoidal cross-sectional profile height dimension of 0.25 inches. The inner surface longitudinal protrusions had a second trapezoidal cross-sectional profile having a second trapezoidal cross-sectional profile height dimension of 0.20 inches.

The hollow cylinder of each fluid cooling module had a cylinder wall thickness (without outer surface protrusions or inner surface protrusions) of 0.16 inches. Each hollow cylinder had a length dimension measured along the outer surface of 6.1215 inches.

The modular fluid cooling assembly was submerged in an ice bath to provide an ambient temperature surrounding the modular fluid cooling assembly. The inlet fitting of the first fluid cooling module was connected to a source of hot water while the outlet fitting of the fourth fluid cooling module was connected to an outlet flow line containing a temperature sensor. The hot water was allowed to flow through the modular fluid cooling assembly at a controlled flow rate and exit through the outlet flow line to simulate water flow through an engine. Temperature of the hot water was measured prior to entering the modular fluid cooling assembly and after exiting the modular fluid cooling assembly. The results of each run are reported below in Table 1 showing that in each example the modular fluid cooling assembly cooled the fluid by at least 20° F.

	TABLE 1
	Run 1	Run 2	Run 3	Run 4
Flow Rate (GPM)	3	5	3	3
Ambient Temperature (° F.)	40	42	64	61
Inlet Water Temperature (° F.)	107	104	103	103
Outlet Water Temperature (° F.)	72	77	83	75
Δ Temperature (° F.)	35	27	20	28

Additional tests were conducted on a modular fluid cooling assembly comprised of two cooling modules arranged in a side-by-side linear arrangement connected by a fitting connector providing a 180° bend angle. Each of the two cooling modules comprised a hollow cylinder of the type described above with reference to Runs 1 through 4.

The modular fluid cooling assembly was submerged in an ice bath to provide an ambient temperature of 36.2° F. surrounding the modular fluid cooling assembly. The inlet fitting of the first fluid cooling module was connected to a source of hot water while the outlet fitting of the second fluid cooling module was connected to an outlet flow line containing a temperature sensor. The hot water was allowed to flow through the modular fluid cooling assembly at a controlled flow rate of 1 GPM and exit through the outlet flow line to simulate water flow through an engine. Temperature of the hot water was measured prior to entering the modular fluid cooling assembly at a temperature of 102° F. and after exiting the modular fluid cooling assembly at a temperature of 75° F. In other words, the modular fluid cooling assembly cooled the fluid by 27° F. (Δ Temperature−27° F.).

Claims

1. A modular fluid cooling assembly (5) assembled from a number (n) of cooling modules (10), each of said fluid cooling modules comprising: a hollow cylinder (100) having: an inlet end (110),an outlet end (120) opposite the inlet end,a central axis (130), anda cylinder wall (140) comprising: an outer surface (150),an inner surface (160), andwherein the outer surface and the inner surface define acylinder wall thickness (170) having a value in a range ofbetween 0.025 inches and 0.25 inches;an inlet fitting (200) connected to the inlet end; andan outlet fitting (300) connected to the outlet end; and

2. The modular fluid cooling assembly of claim 1, further comprising ni−1 fitting connectors (20) wherein each fitting connector fluidly connects the inlet fitting of one fluid cooling module to the outlet fitting of another fluid cooling module.

3. The modular fluid cooling assembly of claim 1, wherein the outer surface of the cylinder wall comprises at least one outer surface modification (180).

4. The modular fluid cooling assembly of claim 3, wherein the at least one outer surface modification is selected from the group consisting of at least one outer surface longitudinal protrusion (181), at least one outer surface helical protrusion (182), at least one outer surface radial protrusion (183), at least one outer surface longitudinal recess (184), at least one outer surface helical recess (185), at least one outer surface radial recess (186), and combinations thereof.

5. The modular fluid cooling assembly of claim 3, wherein the outer surface modification comprises a plurality of outer surface longitudinal protrusions each having a first trapezoidal cross-sectional profile (187) having a first trapezoidal crossectional profile height dimension (188), a first trapezoidal cross-sectional profile major width dimension (189A), and a first trapezoidal cross-sectional profile minor width dimension (189B); wherein a first ratio between an outer diameter of the hollow cylinder without protrusions (155A) and an outer diameter of the hollow cylinder with protrusions (155B) is in a range of between 0.5:1 and 1:1, a second ratio between the first trapezoidal cross-sectional profile height dimension and the first trapezoidal cross-sectional profile major width dimension is in a range of between 0.25:1 and 5:1, and a third ratio between the first trapezoidal cross-sectional profile minor width dimension and the first trapezoidal cross-sectional profile major width dimension is in a range of between and 0.5:1 and 1:1.

6. The modular fluid cooling assembly of claim 1, wherein the inner surface of the cylinder wall comprises at least one inner surface modification (190).

7. The modular fluid cooling assembly of claim 6, wherein the at least one inner surface modification is selected from the group consisting of at least one inner surface longitudinal protrusion (191), at least one inner surface helical protrusion (192), at least one inner surface radial protrusion (193), at least one inner surface longitudinal recess (194), at least one inner surface helical recess (195), at least one inner surface radial recess (196), and combinations thereof.

8. The modular fluid cooling assembly of claim 6, wherein the inner surface modification comprises a plurality of inner surface longitudinal protrusions each having a second trapezoidal cross-sectional profile (197) having a second trapezoidal cross-sectional profile height dimension (198), a second trapezoidal cross-sectional profile major width dimension (199A), and a second trapezoidal cross-sectional profile minor width dimension (199B); wherein a fourth ratio between an inner diameter of the hollow cylinder without protrusions (165A) and an inner diameter of the hollow cylinder with protrusions (165B) is in a range of between 0.5:1 and 1:1, a fifth ratio between the second trapezoidal cross-sectional profile height dimension and the second trapezoidal cross-sectional profile major width dimension is in a range of between 0.25:1 and 5:1, and a sixth ratio between the second trapezoidal cross-sectional profile major width dimension and the second trapezoidal cross-sectional profile minor width dimension is in a range of between 0.5:1 and 1:1.

9. The modular fluid cooling assembly of claim 1, further comprising a mounting bracket (400) connected to at least one of the fluid cooling modules in a first plane perpendicular to the central axis at a point on the outer surface and/or an optional outer surface modification, said mounting bracket comprising at least one mounting hole (405) passing through the mounting bracket in a second plane perpendicular to the first plane.

10. The modular fluid cooling assembly of claim 9, wherein the mounting bracket is integrally connected to at least one hollow cylinder of the fluid cooling modules.

11. The modular fluid cooling assembly of claim 9, further comprising a heat sink (430) extending from a mounting bracket outer surface (440).

12. The modular fluid cooling assembly of claim 9, wherein the mounting bracket comprises: a mounting bracket base (410) comprising the at least one mounting hole and at least one base clamp hole (412);at least one clamp (420) comprising: a first clamp section (421) comprising at least one first clamp section hole (422) and a plurality (FCR) of first curvilinear recesses (423); anda second clamp section (424) comprising at least one second clamp section hole (425) and a plurality (SCRx) of second curvilinear recesses (426); andat least one fastener; and

13. The modular fluid cooling assembly of claim 12, wherein x is a positive integer less than or equal to i.

14. The modular fluid cooling assembly of claim 12, wherein x is a positive integer greater than i.

15. The modular fluid cooling assembly of claim 12, further comprising a heat sink (430) extending from a mounting bracket base outer surface (414).

16. The modular fluid cooling assembly of claim 1, wherein each hollow cylinder independently comprises a material selected from the group consisting of aluminum, brass, copper, and steel.

17. The modular fluid cooling assembly of claim 1, comprising at least two fluid cooling modules wherein the fluid cooling modules are arranged in a side-by-side linear arrangement.

18. The modular fluid cooling assembly of claim 1, wherein the fluid cooling modules are arranged in a stacked column arrangement comprising at least two columns and at least two rows wherein each column comprises at least two fluid cooling modules and each row comprises at least two fluid cooling modules.

19. The modular fluid cooling assembly of claim 1, wherein at least a portion of at least one of the fluid cooling modules is fluidly sealed within a chiller box (500).

20. The modular fluid cooling assembly of claim 19, wherein the chiller box is fluidly connected to a secondary fluid source.