US20080141985A1 — Layered core EGR cooler

Claim 1

Independent Claim 163 words

1 . A combustion engine system comprising: a combustion engine having a combustion gas inlet and an exhaust outlet; a coolant system to supply a coolant flow for heat rejection; an exhaust gas recirculation loop connected to the exhaust outlet to receive a recirculating exhaust gas flow therefrom and to the combustion gas inlet to supply the recirculating exhaust gas flow thereto; and an exhaust gas cooler connected in the loop to transfer heat from the recirculating exhaust gas flow to the coolant flow, the exhaust gas cooler comprising a stack of nested plates, each of the plates including a peripheral flange that is nested with the peripheral flange of any adjacent nested plate, each plate defining a coolant flow passage on one side of the plate with an adjacent nested plate and an exhaust gas flow passage on an opposite side of the plate with another adjacent plate, said flow passages enclosed by the nested flanges of each adjacent pair of plates.

Claim 2

Dependent Claim 163 words

1 . A combustion engine system comprising: a combustion engine having a combustion gas inlet and an exhaust outlet; a coolant system to supply a coolant flow for heat rejection; an exhaust gas recirculation loop connected to the exhaust outlet to receive a recirculating exhaust gas flow therefrom and to the combustion gas inlet to supply the recirculating exhaust gas flow thereto; and an exhaust gas cooler connected in the loop to transfer heat from the recirculating exhaust gas flow to the coolant flow, the exhaust gas cooler comprising a stack of nested plates, each of the plates including a peripheral flange that is nested with the peripheral flange of any adjacent nested plate, each plate defining a coolant flow passage on one side of the plate with an adjacent nested plate and an exhaust gas flow passage on an opposite side of the plate with another adjacent plate, said flow passages enclosed by the nested flanges of each adjacent pair of plates.

Claim 3

Dependent Claim 151 words

2 . The engine system of claim 1 wherein each of the plates comprises: an embossed exhaust gas inlet opening aligned with the exhaust gas inlet openings of the other plates to define an exhaust gas inlet manifold to distribute the recirculating exhaust gas flow to the exhaust gas flow passages; an embossed exhaust gas outlet opening aligned with the exhaust gas outlet openings of the other plates to define an exhaust gas outlet manifold to collect the recirculating exhaust gas flow from the exhaust gas flow passages; an embossed coolant inlet opening aligned with the coolant inlet openings of the other plates to define a coolant inlet manifold to distribute the coolant flow to the coolant flow passages; and an embossed coolant outlet opening aligned with the coolant outlet openings of the other plates to define a coolant outlet manifold to collect the coolant flow from the coolant flow passages.

Claim 4

Dependent Claim 30 words

3 . The engine system of claim 1 wherein every other plate in the stack comprises an embossed, elongate bead to define a pair of passes for the coolant flow.

Claim 5

Dependent Claim 31 words

4 . The engine system of claim 1 wherein every other plate in the stack comprises embossed dimples extending into the coolant passage to enhance the distribution of the coolant flow.

Claim 6

Dependent Claim 34 words

5 . The engine system of claim 1 wherein the cooler further comprises a plurality of fins, each fin located in one of the coolant flow passages or one of the exhaust flow passages.

Claim 7

Dependent Claim 24 words

6 . The engine system of claim 1 further comprising a turbocharger connected to the combustion gas inlet to supply a charge airflow thereto.

Claim 8

Dependent Claim 32 words

7 . The engine system of claim 1 further comprising an exhaust gas bypass valve connected in the exhaust gas recirculation loop to control the flow of the recirculating exhaust gas flow.

Claim 9

Dependent Claim 125 words

8 . A combustion engine system comprising: a combustion engine having a combustion gas inlet and an exhaust outlet; a coolant system to supply a coolant flow for heat rejection; an exhaust gas recirculation loop connected to the exhaust outlet to receive a recirculating exhaust gas flow therefrom and to the combustion gas inlet to supply the recirculating exhaust gas flow thereto; and an exhaust gas cooler connected in the loop, the cooler comprising a plurality of coolant flow passages interleaved with a plurality of recirculating exhaust gas flow passages, the flow passages defined by a stack of nested plates, each of the plates including a peripheral flange that is nested with the peripheral flange of any adjacent nested plate to enclose the flow passages.

Claim 10

Dependent Claim 125 words

8 . A combustion engine system comprising: a combustion engine having a combustion gas inlet and an exhaust outlet; a coolant system to supply a coolant flow for heat rejection; an exhaust gas recirculation loop connected to the exhaust outlet to receive a recirculating exhaust gas flow therefrom and to the combustion gas inlet to supply the recirculating exhaust gas flow thereto; and an exhaust gas cooler connected in the loop, the cooler comprising a plurality of coolant flow passages interleaved with a plurality of recirculating exhaust gas flow passages, the flow passages defined by a stack of nested plates, each of the plates including a peripheral flange that is nested with the peripheral flange of any adjacent nested plate to enclose the flow passages.

Claim 11

Dependent Claim 151 words

9 . The engine system of claim 9 wherein each of the plates comprises: an embossed exhaust gas inlet opening aligned with the exhaust gas inlet openings of the other plates to define an exhaust gas inlet manifold to distribute the recirculating exhaust gas flow to the exhaust gas flow passages; an embossed exhaust gas outlet opening aligned with the exhaust gas outlet openings of the other plates to define an exhaust gas outlet manifold to collect the recirculating exhaust gas flow from the exhaust gas flow passages; an embossed coolant inlet opening aligned with the coolant inlet openings of the other plates to define a coolant inlet manifold to distribute the coolant flow to the coolant flow passages; and an embossed coolant outlet opening aligned with the coolant outlet openings of the other plates to define a coolant outlet manifold to collect the coolant flow from the coolant flow passages.

Claim 12

Dependent Claim 30 words

10 . The engine system of claim 8 wherein every other plate in the stack comprises an embossed, elongate bead to define a pair of passes for the coolant flow.

Claim 13

Dependent Claim 31 words

11 . The engine system of claim 8 wherein every other plate in the stack comprises embossed dimples extending into the coolant passage to enhance the distribution of the coolant flow.

Claim 14

Dependent Claim 34 words

12 . The engine system of claim 8 wherein the cooler further comprises a plurality of fins, each fin located in one of the coolant flow passages or one of the exhaust flow passages.

Claim 15

Dependent Claim 24 words

13 . The engine system of claim 8 further comprising a turbocharger connected to the combustion gas inlet to supply a charge airflow thereto.

Claim 16

Dependent Claim 32 words

14 . The engine system of claim 8 further comprising an exhaust gas bypass valve connected in the exhaust gas recirculation loop to control the flow of the recirculating exhaust gas flow.

Layered core EGR cooler

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