Abstract: A viscous fluid clutch for use as a clutch for a cooling fan for a vehicle, the clutch includes an input shaft, a rotor assembly, a first housing portion, a second housing portion, a coil assembly, and a brush box. The rotor assembly is coupled to the input shaft. The first housing portion is coupled to the second housing portion and the second housing portion is rotatably disposed on the input shaft. The first and second housing portions define a fluid reservoir for receiving the rotor assembly and a viscous fluid, preferably of the magnetorheological type. The coil assembly is coupled to the first housing portion. The brush box is operably coupled to the coil assembly. When the coil assembly is energized by the brush box, a magnetic field is created that acts upon the magnetorheological fluid to vary the torque transfer of the input shaft to the housing and the fan connected thereto.

Abstract: A heat exchanger includes first and second radiator tanks, a radiator core and an oil cooler. The core includes first and second headers associated with the first and second radiator tanks, respectively, and a plurality of radiator tubes extending between therebetween. Each tube provides fluid communication from the first radiator tank to the second radiator tank. The plurality of radiator tubes are generally perpendicular to the headers. Coolant passing through the radiator tubes enters the second radiator tank in a direction perpendicular to the header. The oil cooler includes first and second end tanks and a core having a plurality of convoluted oil cooler plates. The tubes provide fluid communication between the first and second oil cooler tanks. Adjacent plates define coolant paths extending through the core and disposed at an angle relative to the direction the coolant enters the second radiator tank.

Abstract: A system for quick warm-up of a motor vehicle having an engine, an exhaust system and a passenger cabin includes a heat collector disposed in the exhaust system downstream of the catalytic converter. The system additionally includes a heater core in the passenger cabin. The heater core is in fluid communication with the heat collector for receiving a heated fluid from the heat collector. The system further includes an expansion tank for receiving fluid from the heater core. The expansion tank is located below the heat collector such that fluid drains from the heat collector back to the expansion tank solely under gravitational force. The heat collector may be combined with a resonator or with a muffler. The heater core may be a combined heater core that extracts heat from both the exhaust system and the engine.

Abstract: A system for quick warm-up of a motor vehicle includes a housing, a heat collector, and a valve mechanism. The housing includes an input port and an output port, and defines a first exhaust flow path between the input port and the output port. The heat collector is in fluid communication with the housing and defines a second exhaust flow path. The heat collector includes an inlet and an outlet and further defines a fluid path between the inlet and the outlet. The valve mechanism is disposed within the housing and is operable to control the flow of exhaust between the first exhaust flow path and the second exhaust flow path.

Abstract: An apparatus for transferring heat between a first fluid and second fluid in a motor vehicle includes a housing, a first header, a second header, and a plurality of heat exchange tubes. The housing defines a chamber and includes a first inlet, a second inlet, a first outlet, and a second outlet. The first and second headers separate a central portion of the chamber from a first and second header portion of the chamber, respectively. The first inlet and the first outlet are in fluid communication with the central portion. The second inlet is in communication with the first header portion. The second outlet is in fluid communication with the second header portion. Each of the plurality of heat exchange tubes passes through the central portion of the chamber and has a first end in fluid communication with the first header portion and a second end in fluid communication with the second header portion.

Abstract: A heat exchanger includes a first header tank, a second header tank, and a core. The core is positioned between the first header tank and the second header tank. The core includes a plurality of tubes, a set of cooling fins and a plurality of channels. Each tube of the plurality of tubes provides fluid communication between the first header tank and the second header tank. The set of cooling fins are located between the heat exchange tubes of the plurality of tubes to increase a heat exchange area. The plurality of channels is defined by the plurality of tubes and the set of cooling fins. The channels of the plurality of channels are operative for directing a flow of air through the core such that a flow of air enters a front face of the core in a first direction and is generally directed toward a plane.

Abstract: A viscous fluid clutch for use as a clutch for a cooling fan for a vehicle, the clutch includes an input shaft, a rotor assembly, a first housing portion, a second housing portion, a coil assembly, and a brush box. The rotor assembly is coupled to the input shaft. The first housing portion is coupled to the second housing portion and the second housing portion is rotatably disposed on the input shaft. The first and second housing portions define a fluid reservoir for receiving the rotor assembly and a viscous fluid, preferably of the magnetorheological type. The coil assembly is coupled to the first housing portion. The brush box is operably coupled to the coil assembly. When the coil assembly is energized by the brush box, a magnetic field is created that acts upon the magnetorheological fluid to vary the torque transfer of the input shaft to the housing and the fan connected thereto.

Abstract: A viscous fluid clutch for use as a clutch for a cooling fan for a vehicle, the clutch includes an input shaft, a rotor assembly, a first housing portion, a second housing portion, a coil assembly, and a brush box. The rotor assembly is coupled to the input shaft. The first housing portion is coupled to the second housing portion and the second housing portion is rotatably disposed on the input shaft. The first and second housing portions define a fluid reservoir for receiving the rotor assembly and a viscous fluid, preferably of the magnetorheological type. The coil assembly is coupled to the first housing portion. The brush box is operably coupled to the coil assembly. When the coil assembly is energized by the brush box, a magnetic field is created that acts upon the magnetorheological fluid to vary the torque transfer of the input shaft to the housing and the fan connected thereto.

Abstract: A viscous fluid clutch for use as a clutch for a cooling fan for a vehicle , the clutch includes an input shaft, a rotor assembly, a first housing portion, a second housing portion, a coil assembly, and a brush box. The rotor assembly is coupled to the input shaft. The first housing portion is coupled to the second housing portion and the second housing portion is rotatably disposed on the input shaft. The first and second housing portions define a fluid reservoir for receiving the rotor assembly and a viscous fluid, preferably of the magnetorheological type. The coil assembly is coupled to the first housing portion. The brush box is operably coupled to the coil assembly. When the coil assembly is energized by the brush box, a magnetic field is created that acts upon the magnetorheological fluid to vary the torque transfer of the input shaft to the housing and the fan connected thereto.

Abstract: An engine working fluid circuit for a turbocharged internal combustion engine that employs exhaust gas recirculation. The working fluid circuit includes an exhaust gas passage, a charge air passage, and a turbocharger operatively driven by the exhaust gas flowing from the internal combustion engine and acting to provide pressurized air to the charged air passage. An exhaust gas recirculation passage extends between the exhaust gas passage and the charge air passage bypassing the turbo charger and providing a path for recirculating a predetermined amount of exhaust gas into the charge air. A single charge air cooler is also included that has a first manifold assembly, a second manifold assembly, and a plurality of cooling passages disposed therebetween. The cooling passages act to cool the mixed charge air and recirculated exhaust gas prior to induction into the internal combustion engine.

Abstract: The working fluid circuit of the present invention includes an exhaust gas passage through which exhaust gas under pressure flows from the internal combustion engine, a charge air passage, and a turbocharger. An exhaust gas recirculation passage extends between the exhaust gas passage and the charge air passage, but bypasses the turbocharger and provides a path for recirculating a predetermined amount of exhaust gas into the charge air passage in such a way that the exhaust gas and the charge air are mixed together. An intake passage provides intake air to the internal combustion engine. A single charge air cooler is operatively interconnected to and provides fluid communication between the charge air passage and the intake passage and acts to cool the mixed charge air and the recirculated exhaust gas prior to induction into the internal combustion engine through the intake passage.

Abstract: The working fluid circuit of the present invention includes an exhaust gas passage through which exhaust gas under pressure flows from the internal combustion engine, a charge air passage, and a turbocharger. An exhaust gas recirculation passage extends between the exhaust gas passage and the charge air passage, but bypasses the turbocharger and provides a path for recirculating a predetermined amount of exhaust gas into the charge air passage in such a way that the exhaust gas and the charge air are mixed together. An intake passage provides intake air to the internal combustion engine. A single charge air cooler is operatively interconnected to and provides fluid communication between the charge air passage and the intake passage and acts to cool the mixed charge air and the recirculated exhaust gas prior to induction into the internal combustion engine through the intake passage.

Abstract: A thrust and journal bearing assembly is presented that provides for separate thrust and journal segments that are joined together and held in place by interlocking tabs and slots.

Abstract: An internal combustion engine coolant fan assembly including a self contained thermally controlled clutch or externally controlled clutch having a housing and a fan blade assembly which is attached to the housing by a circular hub utilizing an interference fit or threaded connection. Preferably, the housing includes cooling fins, and the blade assembly circular hub is mounted on the outer edges of the cooling fins.

Abstract: An internal combustion engine block having a circumferential channel formed between the cylinder block and a cylinder liner, surrounding and adjacent to the high temperature combustion chamber region of the engine, to which coolant flow is provided to uniformly and effectively cool this critical area of the liner. The flow characteristics of the top liner cooling channel provide a high velocity coolant stream having an aspect ratio of width relative to height within a predetermined range and an equivalent diameter within a predetermined range to assure uniform temperature on both sides of the cylinder liner and about the entire circumference of the liner.

Abstract: An internal combustion engine block having a circumferential channel formed between the cylinder block and a cylinder liner, surrounding and adjacent to the high temperature combustion chamber region of the engine, to which coolant flow is provided to uniformly and effectively cool this critical area of the liner. The flow characteristics of the top liner cooling channel provide a high velocity coolant stream having an aspect ratio of width relative to height within a predetermined range and an equivalent diameter within a predetermined range to assure uniform temperature on both sides of the cylinder liner and about the entire circumference of the liner.

Abstract: A fan clutch includes a housing and a cover cooperating to contain a viscous fluid. A pump plate divides an interior of the fan clutch into a working chamber and a reservoir. A driven clutch plate, disposed in the working chamber, includes hub and disk portions. A wiper is mounted on the pump plate adjacent a discharge orifice so that a first clearance is provided between the wiper and a front surface of the disk portion. An annular blocking wall is formed on the front surface of the disk portion radially inbound of the wiper. The height of the blocking wall is such that a second clearance formed between the blocking wall and the pump plate is less than or substantially equal to the first clearance, thereby forming a dynamic seal.

Abstract: An internal combustion engine block having a circumferential channel formed between the cylinder block and a cylinder liner, surrounding and adjacent to the high temperature combustion chamber region of the engine, to which coolant flow is diverted from the main coolant stream to uniformly and effectively cool this critical area of the liner. The high velocity flow of the main coolant stream, as it passes the end of the cylinder liner adjacent the combustion chamber, provides a reduced pressure head at the port interconnecting the outlet end of the circumferential channel with the main coolant stream. Channel entrance holes, located upstream at relatively stagnant regions in the main coolant flow, are at a higher pressure head than the channel exit port, thus inducing flow through the channel at a high velocity flow.

Abstract: A viscous fluid clutch includes a clutch plate rotatably driven by an input shaft. The clutch plate includes a plurality of concentric, annular lands and grooves in a rear face which are mated with complementary lands and grooves of a clutch body to form a shear zone. A plurality of passages are provided in the clutch plate lands and grooves for directing fluid from a reservoir to the shear zone. A first system of arcuate ramps are provided in a front surface of the clutch plate facing a pump plate of the clutch. The arcuate ramps are radially aligned with pump plate orifices and enhance the pump-out of fluid through the orifices. If desired, a second system of circumferential ramps can be provided about the periphery of the clutch plate to enhance the pump-out of fluid.

Abstract: A viscous fluid clutch having a bimetallic coil includes an insulating retainer. A body of the retainer is mounted between the coil and an outer surface of the clutch housing. A flexible tab on the retainer is placed between a first end of the coil and a slot on the clutch housing to provide an interference fit and eliminate the need for adhesives. The body inhibits the transfer of radiant heat emanating from fluid inside the clutch to the coil. Preferably, the body and tab are integrally formed.