DUAL RADIATOR ENGINE COOLING MODULE - SINGLE COOLANT LOOP

Abstract

An engine cooling system for a motor vehicle having a dual radiator assembly plumbed in parallel within a single coolant loop to provide improved engine cooling.

Description

FIELD

The present disclosure relates generally to engine cooling systems for motor vehicles and, more particularly, to a single loop dual radiator cooling module for such engine cooling systems.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

As motor vehicles continue to require more towing capacity and engine cooling for optimal performance and to meet stringent emissions regulations, the heat rejection requirements from the engine into the coolant rises. As such, the use of larger radiators is necessary to meet the increased heat rejection requirements. Unfortunately, the packaging space available in front of the engine within the engine compartment is limited and does not always permit the use of larger radiators. In addition, since it is a conventional practice to include the radiator, blower fan, and condenser of the motor vehicle's HVAC system into a pre-assembled condenser, radiator and fan module (CRFM) assembly, it is usually impractical to increase the radiator's thickness.

In an effort to address this situation, it is known to use two radiators in a cooling system that is configured to split the heat rejection requirements between a first cooling circuit for engine cooling and a second cooling circuit for auxiliary component cooling, such as transmission oil and/or EGR cooling. Unfortunately, such dual radiator cooling systems require that a separate water pump be provided in conjunction with each of the independent cooling circuits. Accordingly, there remains a need in the art to overcome the limitations of prior art vehicle cooling systems and provide cost-effective alternatives that meet the packaging and heat rejection requirements of modern motor vehicles.

SUMMARY

This section provides a general summary of the present disclosure, and is not a comprehensive disclosure of its full scope or all of its features and advantages.

It is an aspect of the present disclosure to provide a dual radiator module having first and second radiators that are plumbed in parallel and which is adapted for use with a vehicular cooling system having a single water pump.

It is a related aspect of the present disclosure to provide such a dual radiator module having a larger first radiator located in front of the vehicle's cooling fan and a smaller second radiator disposed between the first radiator and a condenser of the vehicle's HVAC system.

In accordance with these and other aspects of the present disclosure, a dual radiator module is provided which is adapted to fit into available packaging spaces, has lower air restriction values compared to thick single radiator modules, and which is configured for use with a single water pump for common coolant flow to both radiators.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected exemplary embodiments and are not intended to limit the scope of the present disclosure in any way. Similar or identical elements are given consistent reference numerals throughout the various figures.

The present disclosure will become more fully understood from the detailed description and the accompanying drawings wherein:

FIG. 1 is a diagrammatical view of a cooling system for use in a motor vehicle and which is equipped with a dual radiator module constructed in accordance with the present teachings;

FIG. 2 is a rear perspective view of the dual radiator module constructed in accordance with an exemplary embodiment of the present disclosure;

FIG. 3 is a front perspective view of the dual radiator module of the present disclosure:

FIG. 4 is a top perspective view of the dual radiator module of the present disclosure;

FIG. 5 is a cross-sectional view illustrating an arrangement of the components associated with the cooling system equipped with the dual radiator module; and

FIG. 6 is a cross-sectional view illustrating an alternative arrangement of the components of the cooling system having the dual radiator module.

DETAILED DESCRIPTION

Referring to FIG. 1, a cooling system 10 for use in a motor vehicle 12 is schematically shown. Cooling system 10 is operable for thermally managing various components of motor vehicle 12. To this end, cooling system 10 includes a first or primary fluid circuit 14 and a second or auxiliary fluid circuit 16. First fluid circuit 14 is configured to thermally manage an internal combustion engine 18 of motor vehicle 12 while second fluid circuit 16 is configured to thermally manage one or more auxiliary components 20 associated with motor vehicle 12. Cooling system 10 includes a pump 22 integrated into both fluid circuits 14, 16 that is operable to pump a common coolant therethrough. As such, fluid circuits 14, 16 share a common supply of coolant. An expansion tank (not shown) may be included to receive coolant overflow from the radiators associated with each of the fluid circuits 14, 16.

First fluid circuit 14 is configured to thermostatically manage the temperature of engine 18. Coolant is supplied by pump 22 to a first heat exchanging device 24 associated with engine 18. For example, first heat exchanging device 24 can include a coolant jacket of engine 18 that is configured to circulate coolant about and through engine 18 to transfer heat between engine 18 and the coolant for selectively heating or cooling engine 18. Downstream from first heat exchanging device 24 is a first thermostatic valve or thermostat 26 which selectively directs coolant between a first or primary radiator module 28 and a first radiator bypass 30 parallel to first radiator module 28 in response to the coolant temperature. First thermostat 26 includes an inlet 32 in fluid communication with an outlet 34 of first heat exchanging device 24, a first outlet 36 in fluid communication with an inlet 38 to first radiator module 28, and a second outlet 40 in fluid communication with an inlet 42 to first bypass 30.

When the temperature of the coolant is below a first predefined temperature value, first thermostat 26 functions to direct coolant through first bypass 30 back to pump 22 so that the coolant bypasses first radiator module 28 and can be used, for example, in warming-up engine 18 during cold starts. Once the coolant has reached the first predefined coolant temperature value, first thermostat 26 begins to open and allows flow of the coolant to first radiator module 28 for transferring heat out of the coolant and into air flowing past first radiator module 28. The flow of air past first radiator module 28 results from operation of an onboard cooling fan 44 and/or movement of motor vehicle 12. Fan 44 can be driven by engine 18 through an accessory drive system or can, in the alternative, be a motor-driven unit. As the coolant temperature increases, first thermostat 26 continues to open such that all, or a substantial amount of the coolant discharged from first heat exchanging device 24 flows to first radiator module 28 for cooling engine 18 to a desired operating temperature.

A portion of the coolant supplied to pump 22 is delivered to second fluid circuit 16 and flows to an inlet 46 of a second thermostatic valve or thermostat 48. Second thermostat 48 selectively directs the coolant between a second radiator module 50 and a second radiator bypass 52 in parallel thereto in response to the coolant temperature. As such, second thermostat 48 has a first outlet 54 in fluid communication with second radiator module 50 and a second outlet 56 in fluid communication with second radiator bypass 52. Second thermostat 48 is configured to direct the coolant to second bypass 52 when the coolant temperature is below a second predefined temperature value. In such case, all or a substantial amount of the coolant flows through second bypass 52 to one or more second heat exchanging devices 58, thereby bypassing second radiator module 50. This arrangement is also useful during cold-start conditions when the auxiliary components 20 are relatively cold. Thus, use of second bypass 52 enables relatively quick warming of auxiliary components 20 when required to enhance performance of vehicle 12.

Once the coolant reaches the second predefined temperature value, second thermostat 48 starts to open inlet 54 and allows coolant to flow to second heat exchanging devices 58 through second radiator module 50. Coolant flowing through second radiator module 50 is cooled due to heat transferred from the coolant to air flowing past second radiator module 50 which may be located forward or aft of first radiator module 28 to benefit from the air flow resulting from operation of cooling fan 44 and/or movement of vehicle 12. With increasing coolant temperature, second thermostat 48 continues to open inlet 54 allowing more coolant to flow through second radiator module 50 to second heat exchanging devices 58. Second thermostat 48 may be configured such that eventually most, if not all, of the coolant in second fluid circuit 16 flows through second radiator module 50.

Coolant discharged from second radiator module 50 and second bypass 52 flows to one or more of second heat exchanging devices 58. For example, second heat exchanging devices 58 may include, but not be limited to, one or more charged air coolers (CAC) for cooling engine intake air charged by a turbo/supercharger, one or more hydraulic oil coolers such as a power steering oil cooler (PSOC) and/or a transmission oil cooler (TOC). As such, auxiliary components 20 may include, but not be limited to charge air for engine intake air, hydraulic oil for hydraulic functions onboard vehicle 12 and/or transmission oil for a transmission associated with the powertrain of vehicle 12. After passing through second heat exchanging devices 58, the coolant flows back to pump 22.

In second fluid circuit 16, the coolant is always able to flow to second heat exchanging devices 58 during operation of vehicle 12 regardless of temperature, either through second bypass 52, second radiator module 50, or both. This enable second fluid circuit 16 to respond quickly to instantaneous heat loads of auxiliary components 20 at one of more of second heat exchanging devices 58 (i.e., charge air cooler, hydraulic oil cooler, transmission oil cooler) to cool such heat loads relatively quickly.

By fluidly connecting first fluid circuit 14 and second fluid circuit 16 via a common pump 22, the coolant is able to flow therebetween. As a result, first radiator module 28 of first fluid circuit 14 is able to add cooling capacity to second radiator module 50 of second fluid circuit 16, thereby allowing use of a smaller second radiator module 50.

In general, the present disclosure is directed to optimizing the heat transfer characteristics of first radiator module 28 for providing superior engine cooling. To this end, first radiator module 28 is configured as a dual radiator assembly 80 having a first radiator unit 100 and a second radiator unit 102. Each of the first and second radiator units have a reduced core thickness that, when plumbed in parallel, function to provide equal or greater cooling capacity in comparison to conventional single radiator units. In accordance with this aspect, a preferred construction of one exemplary embodiment of dual radiator assembly 80 will now be described in greater detail.

Referring now to FIGS. 2 through 4, an exemplary construction of first radiator module 28 in accordance with the present teachings is shown to include dual radiator assembly 80 having first radiator unit 100, second radiator unit 102, an upper inlet hose assembly 104 and a lower outlet hose assembly 106. In general, first radiator unit 100 and second radiator unit 102 are plumbed in parallel to establish dual radiator assembly 80 that is configured for use with first fluid circuit 14 in cooling system 10, as shown in FIG. 1.

Inlet hose assembly 104 can include a first inlet hose 108, a second inlet hose 110, a Y-joint inlet connector 112, and an inlet supply tube 114. One end of first inlet hose 108 is connected to an inlet port 116 of an inlet tank 117 associated with first radiator unit 100 while its opposite end is connected to one junction 112a of inlet connector 112. Similarly, one end of second inlet hose 110 is connected to an inlet port 118 of an inlet tank 119 associated with second radiator unit 102 while its opposite end is connected to a second junction 112b of inlet connector 112. Supply tube 114 is adapted to provide fluid communication via a hose (not shown) between outlet 36 of first thermostat 26 and a common inlet 112c of inlet connector 112. Accordingly, coolant flowing from first heat exchanger 24 through first thermostat 26 is supplied through inlet hose assembly 104 to the inlet tanks 117,119 of both radiator units 100, 102 associated with dual radiator assembly 80.

Outlet hose assembly 106 can include a first outlet hose or coupling 120, a second outlet hose or coupling 122, a Y-joint outlet connector 124, and an outlet supply tube 126. One end of first outlet hose or coupling 120 is connected to an outlet port 128 of an outlet tank 129 associated with first radiator unit 100 while its opposite end is connected to one junction 124a of outlet connector 124. Similarly, one end of second outlet hose or coupling 122 is connected to an outlet port 130 of an outlet tank 131 associated with second radiator unit 102 while its opposite end is connected to a second junction 124b of outlet connector 124. Outlet supply tube 126 is adapted to provide fluid communication via a hose (not shown) between a common inlet 124c of outlet connector 124 and pump 22. Accordingly, the coolant discharged from the outlets of dual radiator assembly 80 is supplied to pump 22.

In comparison to a conventional single radiator type of first radiator module commonly associated with prior art engine cooling systems, dual radiator assembly 80 utilizes a pair of radiator units 100,102 having reduced core thicknesses yet an increased total cross-sectional area to provide the required heat transfer characteristics. Such thinner radiator units 100,102 also produce less airflow restriction (air-side pressure drop) to cooling system 10. Additionally, the plumbing of dual radiator assembly 80 in such a parallel arrangement with common inlet and outlet hoses permits use of a single water pump 22.

In accordance to one exemplary packaging arrangement, dual radiator assembly 80 is configured to generally locate a larger first larger radiator unit 100 in a conventional position in front of cooling fan 44 while a smaller second radiator unit 102 is located in the available vehicle packaging space either forward or aft of first radiator unit 100. In accordance with a specific exemplary configuration for dual radiator assembly 80, first radiator unit 100 can have a 27 mm core depth and second radiator unit 102 can have a 27 mm core depth and be located in front of first radiator unit 100 right below the hood line of vehicle 12. Such an arrangement is shown in FIG. 5 to further include auxiliary components 20 associated with second fluid circuit 16 which can include charged-air cooler 20A and an oil cooler 20B. A condenser 88 associated with the vehicle's HVAC system is shown located forward of dual radiator assembly 80. An alternative arrangement is shown in FIG. 6 wherein greater spacing is provided between first radiator unit 100 and second radiator unit 102 and charged-air cooler 20A is located out of the radiator airstream. As will be appreciated, first radiator unit 100 and second radiator unit 102 are plumbed in parallel regardless of the package spacing or orientation therebetween.

Claims

1. A radiator assembly for use in an engine cooling system of a motor vehicle, comprising:

a first radiator unit having a first inlet and a first outlet;

a second radiator unit having a second inlet and a second outlet;

an inlet hose assembly having a first inlet hose connected to said first inlet, a second inlet hose connected to said second inlet, an inlet supply hose, and an inlet connector interconnecting said inlet supply hose to both of said first and second inlet hoses; and

an outlet hose assembly having a first outlet hose connected to said first outlet, a second outlet hose connected to said second outlet, an outlet supply hose, and an outlet connector interconnecting said outlet supply hose to both of said first and second outlet hoses.

2. The radiator assembly of claim 1 wherein said first radiator unit is larger than said second radiator unit.

3. The radiator assembly of claim 1 wherein a thickness dimension of a first core for said first radiator unit is equal to a thickness dimension of a second core for said second radiator unit.

4. The radiator assembly of claim 1 wherein said first radiator unit is disposed between a blower fan and said second radiator unit.

5. The radiator assembly of claim 1 wherein said inlet hose assembly is supplied with coolant exiting the engine and said outlet hose assembly supplies coolant to a water pump.

6. A radiator assembly for use in an engine cooling system of a motor vehicle having a water pump and a fluid flow circuit through which coolant is circulated between the engine and the water pump, the radiator assembly comprising:

a first radiator unit having a first inlet and a first outlet;

a second radiator having a second inlet and a second outlet;

an inlet hose assembly having an inlet supply hose in fluid communication with the fluid flow circuit to receive coolant from the engine, a first inlet hose connecting said inlet supply hose to said first inlet, and a second inlet hose connecting said inlet supply hose to said second inlet, and

an outlet hose assembly having an outlet supply hose in fluid communication with the fluid flow circuit to supply coolant to the water pump, a first outlet hose connecting said outlet supply hose to said first outlet, and a second outlet hose connecting said outlet supply hose to said second outlet.

7. The radiator assembly of claim 6 wherein said first radiator unit is larger than said second radiator unit.

8. The radiator assembly of claim 6 wherein a thickness dimension of a first core for said first radiator unit is equal to a thickness dimension of a second core for said second radiator unit.

9. The radiator assembly of claim 6 wherein said first radiator unit is disposed between a blower fan and said second radiator unit.

10. The radiator assembly of claim 6 wherein said inlet hose assembly includes an inlet coupling interconnecting said inlet supply hose to said first and second supply hoses, and wherein said outlet hose assembly includes an outlet coupling interconnecting said outlet supply hose to said first and second outlet hoses.