U.S. patent application number 12/882210 was filed with the patent office on 2011-03-17 for multi-layer coolant reservoir.
This patent application is currently assigned to MANN+HUMMEL GMBH. Invention is credited to David Hewkin.
Application Number | 20110062163 12/882210 |
Document ID | / |
Family ID | 43607792 |
Filed Date | 2011-03-17 |
United States Patent
Application |
20110062163 |
Kind Code |
A1 |
Hewkin; David |
March 17, 2011 |
MULTI-LAYER COOLANT RESERVOIR
Abstract
In various aspects of the invention a multi-layer pressurizable
coolant reservoir includes an inner shell member shaped and
configured to define at least one liquid storage chamber. An outer
shell member is layered onto the inner shell member. The outer
shell member is particularly adapted to provide structural
stability and resist pressure deformation of the inner shell. The
outer shell is isolated from the coolant by the inner layer. The
material of the inner shell is selected for compatibility with the
coolant.
Inventors: |
Hewkin; David; (Battle
Creek, MI) |
Assignee: |
MANN+HUMMEL GMBH
Ludwigsburg
DE
|
Family ID: |
43607792 |
Appl. No.: |
12/882210 |
Filed: |
September 15, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61242883 |
Sep 16, 2009 |
|
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Current U.S.
Class: |
220/562 |
Current CPC
Class: |
F01P 11/029
20130101 |
Class at
Publication: |
220/562 |
International
Class: |
B65D 88/12 20060101
B65D088/12 |
Claims
1. A multi-layer pressurizable coolant reservoir providing surge
and overflow capacity to an engine cooling system, comprising: an
inner shell member shaped and configured to define at least one
liquid storage chamber for storing coolant therein, said chamber
having at least one outer surface; and an outer shell member
layered onto at least a portion of said at least one outer surface,
said outer shell member adapted to provide structural stability and
resist pressure deformation of said inner layer; wherein said outer
shell comprises a higher strength material relative to said inner
layer; wherein said outer shell is isolated from said coolant by
said inner layer; and wherein material of said inner shell is
selected for compatibility with said coolant.
2. The coolant reservoir of claim 1, wherein said material of said
inner shell is selected to be compatible with operating temperature
and chemical compatibility with the coolant; wherein said outer
shell material is selected for strength and low cost to provide
structural stability to said reservoir; and wherein said coolant
reservoir formed of said inner and outer shells is lower in weight
or uses less material than a single layer reservoir.
3. The coolant reservoir of claim 1, wherein said inner shell
member comprises molded plastic material; and wherein said outer
shell member comprises a material different than said inner shell
material.
4. The coolant reservoir of claim 3, wherein said material of said
outer shell comprises formed metal.
5. The coolant reservoir of claim 3, wherein said inner shell
member includes a molded plastic upper shell portion and a molded
plastic lower shell portion, said upper and lower shell portions
welded along mateable edge portions to form a one-piece inner shell
member.
6. The coolant reservoir of claim 5, wherein said outer shell
member includes an upper shell portion and a lower shell portion,
said outer shell upper and lower shell portions shaped and
configured to substantially match the shape of and overlay onto
respective ones of said inner shell portions.
7. The coolant reservoir of claim 6, wherein said upper portions of
said shells are molded as a unit using a two shot injection molding
process; and said lower portions of said shells are molded as a
unit using a two shot injection molding process.
8. The coolant reservoir of claim 7, further comprising: a
substantially rigid skeletal shell member secured onto portions of
the outer surface of the outer shell member, said skeletal shell
member operative to provide further structural stability to said
inner and outer shell members.
9. The coolant reservoir of claim 7, wherein said material of said
outer shell member comprises nylon or glass fibers, said fibers
strengthening said outer shell member.
10. The coolant reservoir of claim 7, wherein said inner layer
material selected from the group including: polypropylene and
polyethylene.
11. The coolant reservoir of claim 7, wherein said outer shell
material selected from the set consisting of: nylon, glass fiber
filled polypropylene and metal.
12. The coolant reservoir of claim 7, wherein said outer shell
member forms ribs extending within said liquid storage chamber,
said ribs encapsulated by rib encapsulating members of said inner
shell member, said encapsulating members covering and isolating
ribs of said outer shell member from said coolant.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application claims priority from U.S.
provisional patent application No. 61/242,883 "MULTI-LAYER COOLANT
RESERVOIR" filed Sep. 16, 2009 and all of the contents U.S.
provisional patent application No. 61/242,883 are incorporated
herein by reference and to the fullest extent of the law.
TECHNICAL FIELD
[0002] This disclosure relates generally to internal combustion
engine cooling systems and, more particularly, to engine coolant
reservoirs or surge bottles for such cooling systems.
BACKGROUND OF THE INVENTION
[0003] Most internal combustion engines require a cooling system to
remove the heat generated during fuel combustion from the engine
components. Typically such systems circulate a liquid heat
conducting coolant around a closed fluid loop to conductively
remove heat from a heat source such as an internal combustion
engine and release the heat into a heat sink such as an air cooled
radiator.
[0004] Such closed loop cooling systems typically include a coolant
reservoir or surge bottle to provide additional on-demand coolant
fluid capacity to compensate for small coolant losses as well as to
provide surge capacity to allow for the volumetric thermal
expansion of the coolant.
[0005] Although coolant reservoirs may be directly vented to the
atmosphere, it is more common to operate coolant systems at a
positive pressure. A higher operating pressure raises the
temperature at which the coolant may boil, thereby allowing for
higher engine operating temperatures without the danger of boiling
or vaporizing the coolant fluid. Coolant reservoirs may also
include means for extracting or venting gases from the coolant.
[0006] Additionally, coolants may be formulated to include chemical
components intended to extend coolant life or to reduce corrosion
as well as the formation of deposits in the cooling system. These
chemical components may not be chemically compatible with or may
adversely react with some materials used in some coolant
reservoirs.
[0007] Coolant reservoirs, as OEM components, are now very much
commodity items, which means that component price is a critical
factor to the award of business. There remains a need in the art
for a coolant reservoir that permits the use of a wider variety of
materials and results in a reduction in material usage, weight and
cost in keeping with commodity business trends.
SUMMARY OF THE INVENTION
[0008] In aspects of the invention a multi-layer pressurizable
coolant reservoir for providing surge and overflow capacity to an
engine cooling system, includes an inner shell member shaped and
configured to define at least one liquid storage chamber for
storing coolant therein. An outer shell member is layered onto at
least a portion of the outer surface of the inner shell member. The
outer shell member is particularly adapted to provide structural
stability and to resist pressure deformation of what may be a less
robust inner layer. The outer shell may be formed of a higher
strength material relative to the inner layer. The outer shell is
isolated from the coolant by the inner layer. The material of the
inner shell is selected for compatibility with the coolant and for
lower cost or material savings.
[0009] In another aspect of the invention, the material of the
inner shell is selected to be compatible with the temperature and
for chemical compatibility with the stored coolant. The outer shell
material is selected for strength and low cost to provide
structural stability to the reservoir. The resulting coolant
reservoir formed of the inner and outer shells is lower in weight
or uses less material than a single layer reservoir.
[0010] In another aspect of the invention, the inner shell member
includes molded plastic material and the outer shell member
comprises a material different than the inner shell material.
[0011] In another aspect of the invention, the material of the
outer shell includes metal.
[0012] In another aspect of the invention, the inner shell member
includes a molded plastic upper shell portion and a molded plastic
lower shell portion. The upper and lower shell portions are
compatibly sized and configured to be weldable along mateable edge
portions to form the inner shell member.
[0013] In another aspect of the invention, the outer shell member
includes an upper shell portion and a lower shell portion. The
outer shell upper and lower shell portions are shaped and
configured to substantially match the shape of and overlay onto the
respective ones of the inner shell portions.
[0014] In another aspect of the invention, the upper portions of
the shells are molded as a unit using a two shot injection molding
process and the lower portions of the shells are molded as a unit
using a two shot injection molding process.
[0015] In another aspect of the invention, a substantially rigid
skeletal shell member is provided and secured onto portions of the
outer surface of the outer shell member. The skeletal shell member
is operative to provide further structural stability to the inner
and outer shell members.
[0016] In another aspect of the invention, the material of the
outer shell member comprises nylon or glass fibers to strengthen
the outer shell member.
[0017] In another aspect of the invention, the inner layer material
is selected from the group including: polypropylene and
polyethylene.
[0018] In another aspect of the invention, the outer shell material
is selected from the set consisting of: nylon, glass fiber filled
polypropylene and metal.
[0019] In another aspect of the invention, the outer shell member
forms ribs extending within the liquid storage chamber. The ribs
are encapsulated by rib encapsulating members of the inner shell
member. The encapsulating members are configured to cover and
protect the ribs of the outer shell member.
[0020] The above features and advantages and other features and
advantages of the present invention are readily apparent from the
following detailed description of the best modes for carrying out
the invention when taken in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying Figures, where like reference numerals
refer to identical or functionally similar elements throughout the
separate views and which together with the detailed description
below are incorporated in and form part of the specification, serve
to further illustrate various embodiments and to explain various
principles and advantages all in accordance with the present
invention.
[0022] Features of the present invention, which are believed to be
novel, are set forth in the drawings and more particularly in the
appended claims. The invention, together with the further objects
and advantages thereof, may be best understood with reference to
the following description, taken in conjunction with the
accompanying drawings. The drawings show a form of the invention
that is presently preferred; however, the invention is not limited
to the precise arrangement shown in the drawings.
[0023] FIG. 1 is a cut away perspective view of a multi-layer
coolant reservoir, consistent with the present invention; and
[0024] FIG. 2 is a partial side sectional view of a multi-layer
coolant reservoir, consistent with the present invention.
[0025] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions of
some of the elements in the figures may be exaggerated relative to
other elements to help to improve understanding of embodiments of
the present invention.
DETAILED DESCRIPTION
[0026] Before describing in detail embodiments that are in
accordance with the present invention, it should be observed that
the embodiments reside primarily in combinations of apparatus
components related to an improved coolant reservoir. Accordingly,
the apparatus components have been represented where appropriate by
conventional symbols in the drawings, showing only those specific
details that are pertinent to understanding the embodiments of the
present invention so as not to obscure the disclosure with details
that will be readily apparent to those of ordinary skill in the art
having the benefit of the description herein.
[0027] In this document, relational terms such as first and second,
top and bottom, and the like may be used solely to distinguish one
entity or action from another entity or action without necessarily
requiring or implying any actual such relationship or order between
such entities or actions. The terms "comprises," "comprising," or
any other variation thereof, are intended to cover a non-exclusive
inclusion, such that a process, method, article, or apparatus that
comprises a list of elements does not include only those elements
but may include other elements not expressly listed or inherent to
such process, method, article, or apparatus. An element preceded by
"comprises . . . a" does not, without more constraints, preclude
the existence of additional identical elements in the process,
method, article, or apparatus that comprises the element.
[0028] FIG. 1 is a cut away perspective view of a multi-layer
coolant reservoir, consistent with the present invention. FIG. 2 is
a partial side sectional view of a multi-layer coolant reservoir,
consistent with the present invention.
[0029] The multi-layer coolant reservoir 100 is configured to
provide coolant storage, coolant surge or overflow capacity to an
engine cooling system. The coolant reservoir includes an inner
shell member 102 that is shaped and configured to define a closed
liquid storage chamber 104 adapted for storing overflow or surplus
engine coolant fluid therein. The liquid storage chamber 104 may be
separated into sub chambers by one or more strengthening ribs or
baffles 120. Ribs 120 generally extend through the liquid storage
chamber 104 and may secure to opposing walls of the coolant
reservoir 100. At least some of the ribs typically include fluid
passages 122 or holes through the ribs that permit fluid to flow
between the sub chambers defined by the ribs. In some variants of
the invention, the coolant reservoir 100 may be pressurized and the
ribs 120 provide additional structural support to the coolant
reservoir to resist deformation due to the pressurization.
[0030] The coolant reservoir 100 may include a fitting 128
configured to receive a pressure relief device such as a pressure
cap (not shown). The coolant reservoir 100 may include one or more
overflow connections 130 and one or more outlet connections
132.
[0031] In coolant reservoirs, including prior art coolant
reservoirs, the ribs are positioned and sized to provide structural
support to the coolant reservoir to resist stresses induced by
pressurization of the coolant as well as mechanical stresses and
loads expected during use. The ribs 120 also act to break up the
interior of the coolant reservoir into sub chambers that act to
reduce "sloshing" or movement of the coolant and resulting foaming
within the coolant reservoir.
[0032] Referring again to FIGS. 1 and 2, surrounding and positioned
supportively against the outside surface 106 of the inner shell
member is an outer shell member 118. The outer shell member 118 is
layered over at least a portion of the outer surface of inner shell
member 102, and preferably is layered over a major portion if not
the entirety of the outer surface of the inner shell member
102.
[0033] As the inner shell member is in contact with the coolant,
the material of the inner shell member is selected to be compatible
with the chemistry of the coolant and suitable for the expected
coolant temperature. Advantageously, a wider variety of materials
are available and may be utilized for the inner shell than would be
the case in a conventional single layer coolant reservoir. In the
multi-layer coolant reservoir 100 the inner shell member 102 can
rely upon outer shell members such as outer shell member 118 to
provide required structural stability and support. The inner shell
member may therefore utilize materials that in and of themselves do
not provide sufficient structural stability to meet design
requirements on their own. Advantageously, the material of the
inner shell member 102 may be chosen to utilize less structurally
robust but chemically and thermally suitable materials that are
lower in cost than would otherwise be possible with prior art
coolant reservoirs.
[0034] Advantageously, the inner shell member 102 and the outer
shell member 118 may utilize different materials, each having
properties selected to meet different requirements. For example,
the inner shell member may utilize lower strength materials, such
as (for example) a polypropylene or even a polyethylene or other
low cost materials.
[0035] The outer shell member 118 utilizes higher strength
materials which are structurally stable and able to resist the
maximum expected pressurization of the coolant reservoir and other
expected mechanical and thermal stresses. Some examples of more
structurally stable outer shell member 118 materials include nylon,
glass fiber filled polypropylene, or varieties of formed metal
substrates.
[0036] As shown particularly in FIG. 2, in some variants of the
invention, the ribs 120 may be formed as part of the outer shell
member 118, even though the outer shell member 118 is covered in
its interior by the inner shell member 102. This is advantageous as
the outer shell 118 in many variations will be formed of more
structurally stable and rigid materials than the inner shell 102.
In these variations the outer shell member material forming the
ribs may be encapsulated or covered by rib encapsulating members
124 formed with the inner shell member 102 and overlaying the ribs
formed by the outer shell member. In this way the outer shell
member may form ribs in the interior of the reservoir that are
covered and protected by the inner shell member.
[0037] In some variants of the invention, the upper shell portion
108 of the inner shell 102 and upper shell portion 112 of the outer
shell 118 may be formed or molded as a unitary member by a two shot
plastic injection molding process. Similarly, the lower shell
portion 110 of the inner shell 102 and the lower shell portion 114
of the outer shell 118 may be formed as a unitary member by a
similar two shot plastic injection molding process.
[0038] In another variant of the invention, the inner shell member
102 and structurally stable outer shell member 118 may be further
strengthened by the addition of an overlaying outer skeletal shell
126. The skeletal shell 126, for example, may comprise a formed
metal shell including steel or aluminum or other substantially
rigid and structurally stable material. The skeletal shell may be
adhesively or thermally welded onto the outer shell member and
further operate to resist deformation of the inner and outer shell
members due to stress loading, such as due to pressurization of the
coolant in the coolant reservoir.
[0039] In the current art, coolant reservoir bottles are typically
designed with a minimum wall thickness of 3.5 mm to 4 mm to meet
the design and validation testing requirements of the application.
Advantageously, use of a multi-layer coolant reservoir according to
the present inventive disclosure permits the use of a wider range
of structurally stable materials which are expected to result in
the option to have reduced overall coolant reservoir wall thickness
as well as a reduction in weight and materials usage. It is
anticipated that a multi-layer coolant reservoir with an overall
wall thickness of 3 mm can result in about a 9% reduction in
material relative to prior art coolant reservoirs. It is further
expected that in a multi-layer coolant reservoir according to the
present inventive disclosure the amount of internal ribbing 120 may
be reduced, or the spacing between the ribs increased due to the
additional structural strength provided by multi-layer design. It
is anticipated that removing or re-spacing ribs 120 in the liquid
storage chamber 104 of the coolant reservoir 100 can result in an
overall weight reduction of about 19%.
[0040] Multi-layer coolant reservoirs are particularly useful as
pressurized coolant reservoirs in heavy truck and
off-road/construction equipment applications. In these applications
coolant reservoirs may utilize upwards of 3.8 Kg of material in
order to provide the necessary structural strength and to meet
durability requirements. Material and cost savings in such
applications are expected to be quite considerable.
[0041] In the foregoing specification, specific embodiments of the
present invention have been described. However, one of ordinary
skill in the art appreciates that various modifications and changes
can be made without departing from the scope of the present
invention as set forth in the claims below. Accordingly, the
specification and figures are to be regarded in an illustrative
rather than a restrictive sense, and all such modifications are
intended to be included within the scope of the present invention.
The benefits, advantages, solutions to problems, and any element(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential features or elements of any or all the
claims. The invention is defined solely by the appended claims
including any amendments made during the pendency of this
application and all equivalents of those claims as issued.
* * * * *