Combined remote first intake air aftercooler and a second fluid from an engine cooler for an engine

• US 6,546,919 B2
• Filed: 04/16/2002
• Issued: 04/15/2003
• Est. Priority Date: 06/14/2001
• Status: Expired due to Fees

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Heston, Donald W., Dupree, Ronald L., Callas, James J.
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): TRIEU, THAI BA
• Application Number:
  US10/123,323
• Publication Number:
  US 20020189255A1
• Time in Patent Office: 364 Days
• Field of Search: 123/563, 123/559.1, 123/41.49, 605/99, 552/69, 165/126, 165/41, 165/132, 165/140
• US Class Current: 123/563
• CPC Class Codes: F02B 29/0456 Air cooled heat exchangers
• CPC Class Codes: F02B 29/0475 the intake air cooler being combined with another device, e.g. heater, valve, compressor, filter or EGR cooler, or being assembled on a special engine location
• CPC Class Codes: F02B 33/44 Passages conducting the charge from the pump to the engine inlet, e.g. reservoirs
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A cooling system has an air-to-air or first heat exchanger and a fluid or second heat exchanger mounted remotely from a main radiator for cooling an internal combustion engine. A filter filters a recipient fluid, such as an ambient air, before the recipient fluid passes through the first heat exchanger and the second heat exchanger. A cooled fluid is conducted to a flow of intake air for the internal combustion engine. A fan causes the recipient fluid to pass through the filter and the first heat exchanger and the second heat exchanger. The spent recipient fluid is discharged to atmosphere.

Claims

1. A cooling system adapted for use with an internal combustion engine, the internal combustion engine having an engine block, an air intake manifold, at least one turbocharger for providing inlet combustion air to the air intake manifold, an exhaust gas manifold, and a main radiator heat exchanger, said cooling system comprising:

a recipient fluid;

a first heat exchanger, separate from the main radiator heat exchanger and disposed upon the engine at a location remote from the main radiator heat exchanger, and having a first passageway defined therein which is fluidically connected to said recipient fluid;

a second passageway defined within said first heat exchanger for receiving turbocharged air from the turbocharger, for conducting said turbocharged air through said first heat exchanger such that said turbocharged air undergoes a heat exchange process with said recipient fluid and can be conducted toward the engine intake manifold;

a second heat exchanger, separate from the main radiator heat exchanger and disposed upon the engine at a location remote from the main radiator heat exchanger, and having a third passageway defined therein which is also fluidically connected for receiving said recipient fluid;

a fourth passageway defined within said second heat exchanger for receiving a fluid from the engine, for conducting said fluid through said second heat exchanger such that said engine fluid undergoes a heat exchange process with said recipient fluid and can be conducted toward the engine intake manifold; and

a fan for causing said recipient fluid to pass through said first and third passageways of said first heat exchanger and said second heat exchanger, and for causing said recipient fluid to be discharged to atmosphere.

2. The cooling system of claim 1 wherein said fan includes a backward-curved centrifugal fan.

3. The cooling system of claim 1 wherein said fan includes a radial centrifugal fan.

4. The cooling system of claim 1 including a filter through which said recipient fluid passes prior to passing through said first heat exchanger and said second heat exchanger.

5. The cooling system of claim 4 wherein said fan is interposed said filter and said first heat exchanger, as well as between said filter and said second heat exchanger, said fan drawing said recipient fluid through said filter and forcing said ambient air through said first heat exchanger and said second heat exchanger.

6. The cooling system of claim 1 wherein said first heat exchanger and said second heat exchanger are disposed in a side by side relationship.

7. The cooling system of claim 1 wherein said first heat exchanger and said second heat exchanger are separate heat exchangers fabricated from separate materials.

8. The cooling system of claim 1 wherein said first heat exchanger and said second heat exchanger includes a single heat exchanger fabricated from the same materials.

9. The cooling system of claim 1 wherein said first heat exchanger and said second heat exchanger are disposed in a serial relationship.

10. The cooling system of claim 1 wherein said first heat exchanger and said second heat exchanger are fabricated from different materials.

11. The cooling system of claim 1 including a motor drive operatively connected to said fan for driving said fan independently of the load and speed of the vehicular engine.

12. The cooling system of claim 1 wherein at least said first heat exchanger and said second heat exchanger include a primary surface-type heat exchangers.

13. The cooling system of claim 12 wherein each one of said primary surface-type heat exchangers has three sheets of corrugated material defining two interdigitated fluid passageways therebetween for said ambient air and either one of said turbocharged air and said fluid from said engine wherein a portion of a first one of said two fluid passageways is interposed portions of a second one of said two fluid passageways, while a portion of said second one of said two fluid passageways is interposed portions of said first one of said two passageways enhancing said heat exchange process between said ambient air and said turbocharged air and said fluid from said engine.

14. The cooling system of claim 13 wherein said corrugated material including said primary surface-type heat exchanger having a material selected from the group including stainless steel, aluminum, and a thermoplastic resin material.

15. The cooling system of claim 1 wherein said internal combustion engine including a first turbocharger and a second turbocharger.

16. The cooling system of claim 15 wherein said first turbocharger and said second turbocharger are positioned in series having said inlet combustion air passing through said first turbocharger and defining a first predetermined compression ratio of said inlet combustion air.

17. The cooling system of claim 16 wherein said first predetermined compression ratio of said inlet combustion air passing through said first heat exchanger and being conducted toward said second turbocharger.

18. The cooling system of claim 16 wherein said first predetermined compression ratio of said inlet combustion air after passing through said second turbocharger defining a second predetermined compression ratio of said inlet combustion air, said second predetermined compression ratio being greater than said first predetermined compression ratio.

19. The cooling system of claim 18 wherein said second predetermined compression ratio of said inlet combustion air being passed through said second heat exchanger.

20. The cooling system of claim 19 wherein said second predetermined compression ratio of said inlet combustion air being said fluid from said engine.

21. The cooling system of claim 1 wherein said recipient fluid being an ambient air.

22. A vehicle cooling system having an internal combustion engine having an engine block, an air intake manifold, at least a turbocharger for providing inlet combustion air to the air intake manifold, an exhaust gas manifold, and a main radiator heat exchanger, said vehicle comprising:

a recipient fluid;

a first heat exchanger, being separate from the main radiator heat exchanger and disposed upon the vehicle at a location remote from the main radiator heat exchanger, and having a first passageway defined therein which is fluidically connected to said recipient fluid;

a second passageway defined within said first heat exchanger for receiving turbocharged air from the turbocharger, for conducting said turbocharged air through said first heat exchanger such that said turbocharged air undergoes a heat exchange process with said recipient fluid and can be conducted toward the engine intake manifold;

a second heat exchanger, being separate from the main radiator heat exchanger and disposed upon the vehicle at a location remote from the main radiator heat exchanger, and having a third passageway defined therein which is also fluidically connected to said recipient fluid;

a fourth passageway defined within said second heat exchanger for receiving a fluid from the engine, for conducting said fluid from the engine through said second heat exchanger such that said fluid from the engine undergo a heat exchange process with said recipient fluid and can be conducted toward the engine intake manifold; and

a fan, causing said recipient fluid to pass through said first and third passageways of said first heat exchanger and said second heat exchanger, and causing said recipient fluid to be discharged to atmosphere.

23. The vehicle cooling system of claim 22 wherein said fan includes a backward-curved centrifugal fan.

24. The vehicle cooling system of claim 22 wherein said fan includes a radial centrifugal fan.

25. The vehicle cooling system of claim 22 including a filter through which said recipient fluid passes prior to passing through said first heat exchanger and said second heat exchanger.

26. The vehicle cooling system of claim 25 wherein said fan is interposed said filter and said first heat exchanger, as well as between said filter and said second heat exchanger, said fan drawing said recipient fluid through said filter and forcing said recipient fluid through said first heat exchanger and said second heat exchanger.

27. The vehicle cooling system of claim 22 wherein said first heat exchanger and said second heat exchanger are disposed in a side-by-side relationship.

28. The vehicle cooling system of claim 22 wherein said first heat exchanger and said second heat exchanger are separate heat exchangers fabricated from separate materials.

29. The vehicle cooling system of claim 22 wherein said first heat exchanger and said second heat exchanger includes a single heat exchanger fabricated from the same materials.

30. The vehicle cooling system of claim 22 wherein said first heat exchanger and said second heat exchanger are disposed in a serial relationship.

31. The vehicle cooling system of claim 22 wherein said first heat exchanger and said second heat exchanger are fabricated from different materials.

32. The vehicle cooling system of claim 22 including a motor drive operatively connected to said fan for driving said fan independently of the load and speed of the vehicular engine.

33. The vehicle cooling system of claim 22 wherein both said first heat exchanger and said second heat exchanger include a primary esurface-type heat exchangers.

34. The vehicle cooling system of claim 22 wherein said internal combustion engine including a first turbocharger and a second turbocharger.

35. The vehicle cooling system of claim 34 wherein said first turbocharger and said second turbocharger are positioned in series having said inlet combustion air passing through said first turbocharger and defining a first predetermined compression ratio of said inlet combustion air.

36. The vehicle cooling system of claim 35 wherein said first predetermined compression ratio of said inlet combustion air passing through said first heat exchanger and being conducted toward said second turbocharger.

37. The vehicle cooling system of claim 36 wherein said first predetermined compression ratio of said inlet combustion air after passing through said second turbocharger defining a second predetermined compression ratio of said inlet combustion air.

38. The vehicle cooling system of claim 37 wherein said second predetermined compression ratio of said inlet combustion air being passed through said second heat exchanger.

39. The vehicle cooling system of claim 38 wherein said second predetermined compression ratio of said inlet combustion air being said fluid from said engine.

40. The vehicle cooling system of claim 22 wherein said recipient fluid being an ambient air.

41. A method of cooling an internal combustion engine, an intake air and at least one of a fluid from said engine directed toward an intake air manifold, said internal combustion engine having a block being liquid cooled, the intake manifold being connected to said block and having said intake air therein, an exhaust manifold being connected to said block and having said exhaust gas therein, said method comprising:

providing a recipient fluid;

providing a flow of recipient fluid;

providing an internal combustion engine heat exchanger, said internal combustion engine heat exchanger cooling said liquid coolant within said internal combustion engine and said recipient fluid acting as a recipient fluid for said internal combustion engine heat exchanger;

providing a first heat exchanger or an intake air heat exchanger, said intake air heat exchanger being remotely mounted from said internal combustion engine heat exchanger and being mounted to said internal combustion engine, and said recipient fluid for said internal combustion engine heat exchanger acting as a recipient fluid for said intake air heat exchanger;

providing a second heat exchanger, said second heat exchanger being remotely mounted from said internal combustion engine heat exchanger and being mounted to said internal combustion engine, and said recipient fluid from said internal combustion engine heat exchanger acting as a recipient fluid for said second heat exchanger; and

providing a connection between said intake air and said fluid from the engine to said intake manifold.

42. The method of cooling of claim 41 wherein said step of providing the flow of said recipient fluid being provided by a fan having a backward-curved centrifugal fan.

43. The method of cooling of claim 42 wherein said step of providing the flow of said ambient air being provided by a radial centrifugal fan.

44. The method of cooling of claim 41 including providing a filter through which said recipient fluid passes prior to passing through said first heat exchanger and said second heat exchanger.

45. The method of cooling of claim 44 wherein said step of providing the flow of said recipient fluid having a fan interposed said first heat exchanger and said filter.

46. The method of cooling of claim 41 wherein said step of providing the flow of said recipient fluid air having said fan interposed said second heat exchanger and said filter.

47. The method of cooling of claim 41 wherein said step of providing the first heat exchanger and said step of providing the second heat exchanger having said first heat exchanger and said second heat exchanger being positioned in a side by side orientation.

48. The method of cooling of claim 41 wherein said step of providing the first heat exchanger and said step of providing the second heat exchanger having said first heat exchanger and said second heat exchanger being separate heat exchangers fabricated from separate materials.

49. The method of cooling of claim 41 wherein said step of providing the first heat exchanger and said step of providing the second heat exchanger having said first heat exchanger and said second heat exchanger being a single heat exchanger fabricated from the same materials.

50. The method of cooling of claim 41 wherein said step of providing the first heat exchanger and said step of providing the second heat exchanger having said first heat exchanger and said second heat exchanger being disposed in a serial relationship.

51. The method of cooling of claim 41 wherein said step of providing the first heat exchanger and said step of providing the second heat exchanger having said first heat exchanger and said second heat exchanger being fabricated from different materials.

52. The method of cooling of claim 42 wherein said step of providing the flow of said recipient fluid includes a fan having a motor drive operatively connected to said fan and driving said fan independently of the load and speed of the vehicular engine.

53. The method of cooling of claim 41 wherein said step of providing the first heat exchanger includes said first heat exchanger being a primary surface type heat exchangers.

54. The method of cooling of claim 41 wherein said step of providing the second heat exchanger includes said second heat exchanger being a primary surface type heat exchanger.

55. The method of cooling of claim 41 wherein said step of providing the first heat exchanger and said step of providing the second heat exchanger includes at least one of said first heat exchanger and said second heat exchanger being a primary surface type heat exchanger.

56. The method of cooling of claim 41 wherein said internal combustion engine includes providing a first turbocharger and a second turbocharger.

57. The method of cooling of claim 56 wherein said first turbocharger and said second turbocharger being positioned in series having said inlet combustion air passing through said first turbocharger and defining a first predetermined compression ratio of said inlet combustion air.

58. The method of cooling of claim 57 wherein said first predetermined compression ratio of said inlet combustion air passing through said first heat exchanger and being conducted toward said second turbocharger.

59. The method of cooling of claim 58 wherein said first predetermined compression ratio of said inlet combustion air after passing through said second turbocharger defining a second predetermined compression ratio of said inlet combustion air, said second predetermined compression ratio being greater than said first predetermined compression ratio.

60. The method of cooling of claim 59 wherein said second predetermined compression ratio of said inlet combustion air being passed through said second heat exchanger.

61. The method of cooling of claim 60 wherein said second predetermined compression ratio of said inlet combustion air being said fluid from said engine.

62. The method of cooling of claim 41 wherein said recipient fluid being an ambient air.