HEAT EXCHANGE MODULES, VEHICLE COOLING SYSTEM, VEHICLE COMPRISING THE SAME, AND METHOD OF MANUFACTURING VEHICLE COOLING SYSTEMS

TECHNICAL FIELD

The present disclosure relates to a heat exchange module, a method of manufacturing a plurality of heat exchange modules, a vehicle cooling system, a vehicle comprising such a vehicle cooling system, and a method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other. In particular, but not exclusively, it relates to a heat exchange module suitable for use in cooling a prime mover of a vehicle, as a radiator, suitable for use as a condenser of a vehicle, and suitable for use in thermal management of other systems of a vehicle, for example as an intercooler, evaporator or oil cooler.

Aspects of the invention relate to a heat exchange module for a vehicle cooling system, a method of manufacturing a plurality of heat exchange modules for one or more vehicle cooling systems, a vehicle cooling system comprising a plurality of similar heat exchange modules, a vehicle comprising such a vehicle cooling system , and a method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other, wherein each of the cooling systems is for one of a range of vehicles having respective prime movers of different heat generating capacities from each other.

BACKGROUND

A conventional vehicle cooling system, which usually comprises at least a radiator and a condenser (for example for a heating ventilation and air conditioning, HVAC, system), is usually positioned at the front end of a vehicle, near to or in front of a front axle of the vehicle, for example. Conventional radiators and condensers of such conventional vehicle cooling systems are usually much broader than they are thick, so that an incoming flow of cooling air meeting such a radiator during forward motion of the vehicle strikes a relatively large surface area of the radiator, before passing through the radiator to the condenser. This has several disadvantages, as follows. Firstly, it creates a relatively large aerodynamic drag on the vehicle, leading to a loss of fuel efficiency. Purely by way of example, the total aerodynamic drag factor of a typically medium-sized hatchback car may be 0.335, of which the contribution due to an upper grille

l located in front of the radiator may be 0.006, and due to a lower grille located in front of the condenser may be 0.007, making a combined contribution of 0.013, or about 4%, of the total aerodynamic drag factor. This contribution to the total aerodynamic drag factor of the vehicle may increase significantly for larger vehicles, such as trucks.

Secondly, it restricts design freedom for the front end of the vehicle and increases the size of a front end overhang of the vehicle, in front of the front axle.

Thirdly, it renders the radiator and condenser prone to accidental damage from debris, such as loose chippings, during forward motion of the vehicle, which tends to have a cumulative adverse effect on their performance, also resulting in a loss of fuel efficiency.

Fourthly, because of the relatively large surface areas of the radiator and the condenser, the velocity of the incoming flow of cooling air tends to be non-uniform across their surfaces, resulting in sub-optimal thermal performance of each, with a designed effective temperature differential between the radiator and the condenser on the one hand and the flow of cooling air on the other rarely being achieved.

Fifthly, because the incoming flow of cooling air only encounters the condenser after it has encountered the radiator, it has already been partially warmed by the radiator, which affects the thermal performance of the condenser adversely, thereby also reducing fuel efficiency.

Sixthly, conventional radiators and condensers are usually designed and manufactured individually for each model variant of a vehicle, making them relatively expensive to design and manufacture.

It is an aim of embodiments of the present invention to address at least some of the above disadvantages of the prior art. SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a heat exchange module, a method of manufacturing a plurality of heat exchange modules, a vehicle cooling system, a vehicle comprising such a vehicle cooling system, and a method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other, as claimed in the appended claims. According to a another aspect of the invention, there is provided a heat exchange module for a vehicle cooling system, wherein the heat exchange module comprises a heat exchange fluid pathway for exposure to a flow of cooling air, the pathway having an inlet and an outlet; the inlet comprising one of a plug and socket, and the outlet comprising the other of the plug and socket; wherein the plug is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and the socket is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal.

This provides the advantage that a plurality of such heat exchange modules may be quickly and easily connected together during vehicle manufacture to provide vehicle cooling systems of different cooling capacities according to the number of such heat exchange modules which are connected together, in order to suit the requirements of different vehicles and of different thermal systems within one vehicle. Purely by way of example, three such heat exchange modules could be connected together to provide a radiator of a vehicle and two such heat exchange modules could be connected together to provide a condenser of the same vehicle, obviating the need for differently designed and manufactured radiators and condensers. It also provides the advantage that such a heat exchange module may be quickly and easily removed and replaced during servicing of the vehicle, in the event of any accidental damage to the heat exchange module, without the need to remove and replace an entire vehicle cooling system, or a major component thereof, such as a radiator or a condenser.

The heat exchange module may be a cooling module, but may alternatively or additionally function in certain circumstances, according to requirements, to absorb heat from an external environment of the vehicle, as well as to reject heat to the external environment of the vehicle. For similar reasons, the heat exchange fluid may be a coolant fluid, but may alternatively or additionally function in certain circumstances, according to requirements, to absorb heat from the external environment, as well as to reject heat to the external environment. Heat exchange between the heat exchange fluid and the flow of cooling air may occur by parallel flow or by anti-parallel flow of the two media, for example.

As used herein, the terms "plug" and "socket" mean two mutually interconnectable members, without any limitation as to the form of either one. One of the plug and socket may be male in form and the other female, or vice versa, or both plug and socket may be symmetrical in form, provided that they are interconnectable with each other. In an embodiment, the heat exchange module may comprise a front face configured to receive an incoming flow of cooling air; and a rear face opposite to the front face, configured to eject an outflow of heated air; wherein a length of the heat exchange module between the front face and the rear face thereof is greater than a largest dimension of either the front face or the rear face thereof.

In an alternative embodiment, the length of the heat exchange module between the front face and the rear face thereof is arranged to be greater than the sum of the largest dimension and at least one other dimension of either the front face or the rear face thereof. In this manner, each heat exchange module may adopt an elongate configuration.

This allows a cross-sectional area of the front face which the heat exchange module presents to the incoming flow of cooling air to be reduced during a design phase of the heat exchange module. This provides several advantages, as follows. Firstly, it correspondingly reduces drag on the vehicle during forward movement of the vehicle, thereby helping to increase fuel efficiency. This can provide a significant aerodynamic benefit for larger vehicles, such as trucks. Secondly, it also reduces the cross-sectional area which the heat exchange module presents to loose debris, such as loose stone chippings, thereby helping to reduce accidental damage to the heat exchange module during forward movement of the vehicle, which would otherwise be liable to reduce its heat exchange efficiency. Thirdly, it allows similar such heat exchange modules which are part of different vehicle cooling systems to be arranged in a vehicle with their respective front faces beside each other, in order to receive the same incoming flow of cooling air as each other. Purely by way of example, therefore, a first such heat exchange module belonging to a radiator of a vehicle could by arranged with its front face beside the front face of a second such heat exchange module belonging to a condenser of the vehicle, to receive the same incoming flow of cooling air as each other. This is in contrast to a conventional arrangement, in which a radiator of a vehicle may be positioned in front of a condenser of the vehicle, so that the incoming flow of cooling air is warmed up by the radiator before it reaches the condenser, which is undesirable for optimal operation of the condenser and indirectly reduces fuel efficiency. Fourthly, the reduced cross-sectional area of the front face which the heat exchange module presents also provides increased freedom in designing the shape of a front end of the vehicle. According to a further aspect of the invention, there is provided a method of manufacturing a plurality of heat exchange modules for one or more vehicle cooling systems, the method comprising producing a continuous run of heat exchange apparatus comprising a heat exchange fluid pathway for exposure to a flow of cooling air; cutting the continuous run of heat exchange apparatus into a plurality of portions to provide the heat exchange fluid pathway in each such length with an inlet and an outlet; and fitting the inlet of at least one of the portions with one of a plug and socket, and the outlet of at least another of the portions with the other of the plug and socket, wherein each plug is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and each socket is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal.

Optionally, the method comprises cutting the continuous run of heat exchange apparatus into a plurality of substantially equal portions.

This provides the advantage that it allows the plurality of heat exchange modules to be manufactured from a single continuous run of heat exchange apparatus, but that the length of the heat exchange modules may be quickly and easily varied during the manufacturing process to provide heat exchange modules of different heat exchange capacities according to requirements, after which the plurality of heat exchange modules may still be connected together quickly and easily, in spite of the alteration of their heat exchange capacity during the manufacturing process. Purely by way of example, the heat exchange apparatus may be made of an aluminium alloy.

In an embodiment, the method of manufacturing a plurality of heat exchange modules may comprise providing each of the heat exchange modules with a front face to receive an incoming flow of cooling air and a rear face opposite to the front face, to eject an outflow of heated air; wherein cutting the continuous run of heat exchange apparatus into a plurality of substantially equal portions results in the length of each heat exchange module between the front face and the rear face thereof being greater than a largest dimension of either the front face or the rear face thereof.

Optionally, the method comprises cutting the continuous run of heat exchange apparatus into a plurality of substantially equal portions such that the length of each heat exchange module between the front face and the rear face thereof is greater than the sum of the largest dimension and at least one other dimension of either the front face or the rear face thereof. In this manner, each heat exchange module may adopt an elongate configuration. This has the same advantages as those described above which follow from being able to reduce a cross-sectional area of the front face which the heat exchange modules present to the incoming flow of cooling air, during a design phase of the heat exchange modules. According to yet another aspect of the invention, there is provided a vehicle cooling system comprising a plurality of similar heat exchange modules each having a front face configured to receive an incoming flow of cooling air; and a rear face opposite to the front face, configured to eject an outflow of heated air; wherein a respective length of each of the similar heat exchange modules between the front face and the rear face thereof is greater than a largest dimension of either the front face or the rear face thereof.

In an embodiment, the length of each heat exchange module between the front face and the rear face thereof is greater than the sum of the largest dimension and at least one other dimension of either the front face or the rear face thereof. In this manner, each heat exchange module may adopt an elongate configuration.

This has the same advantages as those described above which follow from being able to reduce a cross-sectional area of the front face which the heat exchange modules present to the incoming flow of cooling air, during a design phase of the heat exchange modules.

In an embodiment of the vehicle cooling system, each of the plurality of similar heat exchange modules may comprise a heat exchange fluid pathway for exposure to the flow of cooling air, the pathway having an inlet and an outlet; the inlet comprising one of a plug and socket, and the outlet comprising the other of the plug and socket; wherein the plug is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and the socket is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal.

This provides the advantages described above that a plurality of such heat exchange modules may be quickly and easily connected together during vehicle manufacture, and that such a heat exchange module may be quickly and easily removed and replaced during servicing of the vehicle, without the need to remove and replace the entire vehicle cooling system, or a major component thereof, such as a radiator or a condenser. In an embodiment, the vehicle cooling system may comprise at least a first cooling circuit having a first operating temperature, and comprising a first one of the similar heat exchange modules; and at least a second cooling circuit having a second operating temperature higher than the first operating temperature, and comprising a second one of the similar heat exchange modules.

This has the advantage that even though different cooling circuits having different operating temperatures may be provided for optimal thermal management of different thermal aspects of the vehicle, similar heat exchange modules may be used in each such cooling circuit, thereby reducing the manufacturing and servicing costs of the vehicle by the use of interchangeable components. The vehicle cooling system may comprise more than just two such cooling circuits, each having different operating temperatures for optimal thermal management of different thermal aspects of the vehicle, but all comprising similar heat exchange modules, with the same cost advantages in manufacturing and servicing of the vehicle.

If the vehicle cooling system does comprise two or more such cooling circuits, each having different operating temperatures, the respective lengths of the first and second ones of the similar heat exchange modules may be substantially equal to each other. This provides the advantage of reducing the manufacturing and servicing costs of the vehicle by the use of interchangeable components still further. Alternatively, the similar heat exchange modules in each of the two or more different cooling circuits may have lengths which are different from each other between the two or more different cooling circuits, but which are the same as each other within one and the same cooling circuit. This has the advantage of providing greater flexibility in the design of each cooling circuit both for thermal management and for packaging the cooling circuits in the vehicle. In an embodiment of the vehicle cooling system, the at least first cooling circuit may be connected to a first thermal system of the vehicle; the at least second cooling circuit may be connected to a second thermal system of the vehicle; and the first and second thermal systems of the vehicle may each comprise at least one of a heating, ventilation and/or air conditioning system of the vehicle, an energy storage means of the vehicle, an engine of the vehicle, an electric machine of the vehicle, an electronic control system of the vehicle and a fuel cell of the vehicle.

As used herein, the term "energy storage means" comprises at least one of a battery and a fuel tank, the term "engine" comprises at least one of a petrol engine and a diesel engine, the term "electric machine" comprises at least one of an electric motor, an electric generator and an electric machine able both to provide motive power when supplied with electricity and to generate electricity when set in motion, and the term "fuel cell" comprises a hydrogen fuel cell.

Thus the first and second cooling circuits may be connected to different thermal systems of the vehicle from each other. Alternatively, however, the first and second cooling circuits may both be connected to the same thermal system of the vehicle as each other, even though they have different operating temperatures, for thermal management of different aspects of the same thermal system. Purely by way of example, the first and second cooling circuits could both be connected to a battery of the vehicle, one cooling circuit being for charging of the battery and the other for discharging thereof. Purely by way of another example, the first and second cooling circuits could both be connected to an electric machine of the vehicle, one for operation of the machine as a motor, and the other for operation of the machine as a generator. In an embodiment, the vehicle cooling system may comprise an inlet duct configured to channel the cooling air to the front face of at least one of the heat exchange modules.

This provides the advantage that it allows the at least one of the heat exchange modules to be positioned in the vehicle at a location other than at a front end of the vehicle, and still to receive the flow of cooling air.

If so, the vehicle cooling system may also comprise a shutter operable to open and close the inlet duct. This provides the advantage that it allows the flow of cooling air to the at least one of the heat exchange modules to be modulated according to the thermal requirements of the heat exchange module, and for the flow of cooling air to be closed off when not required, thereby reducing drag and increasing fuel efficiency. If so, the vehicle cooling system may also comprise a shutter control system operable to actuate the shutter.

This provides the advantage that actuation of the shutter may be optimized by design, rather than being manually actuated during operation of the vehicle cooling system.

If so, the shutter control system may be configured to optimize at least one of a fuel efficiency of the vehicle and a performance of the vehicle. In an embodiment, the vehicle cooling system may comprise an outlet duct configured to channel the heated air away from the rear face of at least one of the heat exchange modules, and a valve located in the outlet duct operable to selectively direct the heated air to at least one of an engine of the vehicle during engine warm-up, a passenger cabin of the vehicle, a heat storage device of the vehicle, and an external environment of the vehicle.

This provides the advantage that the heated air may be re-used as desired for improved thermal management of the vehicle, rather than always being lost to the external environment, with is indirectly advantageous for the fuel efficiency of the vehicle.

If the vehicle cooling system does comprise such an outlet duct, the vehicle cooling system may also comprise a valve control system operable to actuate the valve. This provides the advantage that actuation of the valve may be optimized by design, rather than being manually actuated during operation of the vehicle cooling system.

In an embodiment, the vehicle cooling system may comprise a common frame, to which the plurality of similar heat exchange modules are mounted.

This provides the advantage that individual ones of the plurality of similar heat exchange modules may be quickly and easily removed and replaced with minimal disruption to the vehicle cooling system. If so, the plurality of similar heat exchange modules may be slidable lengthwise into and out of the common frame, for removal and replacement of any one of the heat exchange modules.

As used herein, the term "lengthwise" means substantially parallel to a longest dimension of the respective heat exchange module.

This provides the advantage that even if the vehicle cooling system comprises a plurality of similar heat exchange modules which are arranged in a vehicle with their respective front faces beside each other, in order to receive the same incoming flow of cooling air as each other, individual ones of the plurality of similar heat exchange modules may be quickly and easily removed and replaced with minimal disruption to the vehicle cooling system. If so, the common frame may be modular and comprise a frame element for each of the plurality of similar heat exchange modules.

This provides the advantage that differently sized frames to accommodate differently sized vehicle cooling systems comprising different respective numbers of heat exchange modules may all be manufactured from similar frame elements, thereby reducing the manufacturing and servicing costs of the vehicle cooling systems by the use of interchangeable components. In an embodiment, the vehicle cooling system may comprise at least one pump configured to supply heat exchange fluid to at least one of the cooling circuits.

If so, the at least one pump may be a variable flow pump configured to supply a variable amount of heat exchange fluid to the at least one of the cooling circuits.

This provides the advantage that the amount of heat exchange fluid supplied to the at least one of the cooling circuits may be varied according to requirements, for optimal thermal management. In an embodiment, the at least one pump may comprise a plurality of pumps each respectively configured to supply heat exchange fluid to a respective one of the cooling circuits.

This provides the advantage that it allows each one of the plurality of pumps to supply heat exchange fluid to a respective one of the cooling circuits independently of each other, and therefore for the cooling circuits to be thermally managed independently of each other.

If so, the plurality of pumps may be controllable independently of each other; for example the flow rate or speed of each of the plurality of pumps may be controllable independently.

The plurality of pumps may be switchable on and off independently of each other.

This provides the advantage that it allows each one of the pumps to be switched off when not required, thereby saving energy and contributing to the fuel efficiency of the vehicle. In an embodiment, if the vehicle cooling system comprises at least one pump, the vehicle cooling system may also comprise a pump control system operable to actuate the at least one pump. This provides the advantage that the thermal behavior of the vehicle cooling system may be modelled during a design phase of the vehicle cooling system, and then actuation of the at least one pump may be controlled during operation of the vehicle cooling system according to the modelling. If so, the pump control system may be configured to optimize thermal management of the at least one of the cooling circuits.

This provides the advantage that the behavior of at least one of the cooling circuits may be controlled by the pump control system in such a way as to save energy and contribute to the fuel efficiency of the vehicle.

In an embodiment, the vehicle cooling system may comprise an air filter to filter the incoming flow of cooling air, wherein the air filter is removable and replaceable during servicing of the vehicle.

This provides the advantage of ensuring that the flow of cooling air to the vehicle cooling system is not obstructed, for example by debris, which might otherwise adversely affect the performance of the vehicle cooling system. According to a yet further aspect of the invention, there is provided a vehicle comprising a vehicle cooling system according to the earlier aspect of the invention described above.

In an embodiment, the at least two of the plurality of similar heat exchange modules are distributed at different locations from each other around the vehicle.

This provides several advantages, as follows. Firstly, it allows greater flexibility in packaging the vehicle cooling system into the vehicle. For example, by using one or more inlet ducts configured to channel the cooling air to the front face of the heat exchange modules and/or using one or more outlet ducts configured to channel the heated air away from the rear face of the heat exchange modules, the heat exchange modules may be positioned at a wide variety of different locations in the vehicle. This can be used either to improve the weight distribution of the vehicle or to make use of previously unused spaces within the vehicle, or both. It also gives greater design freedom to the external appearance of the vehicle, and allows the size of an overhang at the front end of the vehicle beyond a front axle of the vehicle, where a conventional radiator and/or condenser might otherwise have been located, to be reduced. This is advantageous because in some jurisdictions, such as India, vehicles may be taxed according to their overall length.

According to another aspect of the invention, there is provided a method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other, each of the cooling systems being for one of a range of vehicles having respective prime movers of different heat generating capacities from each other, the method comprising manufacturing a plurality of heat exchange modules similar to each other; selecting different numbers of the similar heat exchange modules, each such number having a combined cooling capacity matching the heat generating capacity of a different one of the prime movers; and assembling the different numbers of heat exchange modules together to make the vehicle cooling systems of different cooling capacities.

This provides the following advantages. Conventionally, a plurality of vehicle cooling systems of different cooling capacities from each other, intended for a range of vehicles with respective prime movers of different heat generating capacities from each other, had to be independently designed and manufactured from different components in order to suit the different heat generating capacities of the different vehicles in the range. With the above- described new method, however, the plurality of vehicle cooling systems of different cooling capacities from each other can instead be designed together and manufactured from similar components, thereby reducing the design, manufacturing and servicing costs of the vehicle cooling systems by the use of interchangeable components.

Purely by way of example, in order to help explicate the above-described new method, the method could comprise selecting four, five, seven and nine similar heat exchange modules as the different numbers thereof, in order to match the heat generating capacities of the prime movers in a small city car, a hatchback car, a family saloon car and a sports-utility vehicle, and then assembling these different numbers of heat exchange modules together to make four vehicle cooling systems of different cooling capacities from each other, each one of which is suitable for one of these four different vehicles. As used herein, the term "prime mover" comprises at least one of an engine, such as a petrol engine or a diesel engine, an electric machine, such as an electric motor, an electric generator or an electric machine able both to provide motive power when supplied with electricity and to generate electricity when set in motion, a battery and a fuel cell, such as a hydrogen fuel cell.

In an embodiment, the method may comprise fitting the vehicle cooling systems of different cooling capacities to respective ones of the vehicles in the range having respective prime movers with heat generating capacities matching the different cooling capacities of the vehicle cooling systems.

This provides the advantage that the method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other may be integrated into a method of manufacturing a range of vehicles.

In an embodiment, the method may comprise determining a size of the similar heat exchange modules from a highest common factor of the different heat generating capacities of the prime movers of the vehicles in the range.

Purely by way of example, suppose, therefore, that the heat generating capacities of the prime movers of the vehicles in the range were 60, 90, 120 and 150 kilowatts. Then the size of the similar heat exchange modules could be determined each to have a cooling capacity of 30 kilowatts, which is the highest common factor of the heat generating capacities of the prime movers just stated. In an alternative possible embodiment, however, purely by way of example, there may be two or more different sizes of heat exchange modules, each respectively determined to have a different cooling capacity, such as 20 kilowatts and 10 kilowatts, in order to provide a wider range of vehicle cooling systems of different cooling capacities from each other.

In an embodiment, the method may comprise using at least one of the engine capacity and the power output rating of each of the prime movers to represent the heat generating capacity of each of the prime movers.

This provides the advantage that if the heat generating capacity of a prime mover once it has been installed in a vehicle is difficult to measure accurately or at all, at least one of the engine capacity and the power output rating of the prime mover, both of which may be easier to measure, may be used instead.

In an embodiment, the method may comprise determining a cross-sectional area of the similar heat exchange modules during a design phase of the heat exchange modules, and determining a length of the similar heat exchange modules during a manufacturing phase of the heat exchange modules.

This provides the advantage that the cross-sectional area of the heat exchange modules may be determined prior to manufacture, and then the length of the heat exchange modules may be quickly and easily varied during manufacture, for example by cutting them from a continuous run of heat exchange apparatus, in order to vary the heat exchange capacity of the heat exchange modules according to requirements. In an embodiment of the method, manufacturing a plurality of heat exchange modules similar to each other may comprise producing a continuous run of heat exchange apparatus comprising a heat exchange fluid pathway for exposure to a flow of cooling air; cutting the continuous run of heat exchange apparatus into a plurality of substantially equal portions to provide the heat exchange fluid pathway in each such length with an inlet and an outlet; and fitting the inlet of at least one of the portions with one of a plug and socket, and the outlet of at least another of the portions with the other of the plug and socket, wherein each plug is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and each socket is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal.

This provides the advantage that it allows the plurality of heat exchange modules to be manufactured from a single continuous run of heat exchange apparatus, but that the length of the heat exchange modules may be quickly and easily varied during the manufacturing process to provide heat exchange modules of different heat exchange capacities according to requirements, after which the plurality of heat exchange modules may still be connected together quickly and easily, in spite of the alteration of their heat exchange capacity during the manufacturing process.

In an embodiment, the method may comprise mounting each of the vehicle cooling systems of different cooling capacities on a respective frame, wherein each respective frame is modular and comprises a frame element for each of the plurality of similar heat exchange modules in the respective vehicle cooling system.

This provides the advantage that differently sized frames to accommodate differently sized vehicle cooling systems comprising different respective numbers of heat exchange modules may all be manufactured from similar frame elements, thereby reducing the manufacturing and servicing costs of the vehicle cooling systems by the use of interchangeable components.

According to another aspect of the invention, there is provided a computer program product comprising a set of instructions which, when executed on a processor, cause at least one controller or control units to implement at least one of the shutter control system, the valve control system and the pump control system as described hereinbefore.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which :

Fig. 1 is an exploded perspective view of part of a front end of a first vehicle;

Fig. 2 is a cut-away side view of a front end of a second vehicle; Fig. 3 is a schematic perspective view of an embodiment of a heat exchange module; Fig. 4 is a schematic exploded diagram of a first embodiment of a vehicle cooling system ; Fig. 5 is a schematic perspective view of an embodiment of a frame; Fig. 6 is a schematic perspective view of an embodiment of a heat exchange apparatus;

Fig. 7 is a partially cut-away perspective view of a front end of a third vehicle; Fig. 8 is a schematic block diagram of a second embodiment of a vehicle cooling system ;

Fig. 9 is a cut-away top plan view of a front end of a fourth vehicle; Fig. 10 is a schematic flow diagram of a third embodiment of a vehicle cooling system ; and

Fig. 1 1 is a flow diagram schematically representing a method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other. DETAILED DESCRIPTION

Fig. 1 shows part of a front end of a first vehicle 10. The front end of the vehicle 10 comprises a front body panel 12 comprising an upper grille 14 and a lower grille 16 for admitting an incoming flow of cooling air 24. The vehicle 10 comprises a vehicle cooling system 20 of a conventional type. The vehicle cooling system 20 comprises a conventional radiator 22. As may be seen from Fig. 1 , the radiator 22 presents a relatively large surface area to the incoming flow of cooling air 24.

Fig. 2 shows part of a front end of a second vehicle 1 10. The front end of the vehicle 1 10 comprises a front body panel 1 12, an engine block 1 18 and a vehicle cooling system 120 of a conventional type. The engine block 1 18 is mounted within the vehicle 1 10 above and slightly in front of a front axle 102 of the vehicle 1 10. As may be seen from Fig. 2, the vehicle cooling system 120 is mounted substantially vertically within the vehicle 110 in front of the engine block 118. The vehicle cooling system 120 therefore adds considerably to the overall length of the vehicle and increases the size of the overhang of the vehicle in front of the front axle 102.

Fig. 3 schematically shows an embodiment of a heat exchange module 31 according to the present invention. The heat exchange module 31 comprises a heat exchange fluid pathway 38 for exposure to a flow of cooling air 24. The pathway 38 has an inlet 34 and an outlet 36. The inlet 34 comprises a plug 35 and the outlet 36 comprises a socket 37, although in an alternative possible embodiment, the plug and the socket may be the other way round on the inlet 34 and the outlet 36. The plug 35 is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and the socket 37 is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal. The heat exchange module 31 also comprises a front face 39a configured to receive an incoming flow of cooling air 24, and a rear face 39b opposite to the front face, configured to eject an outflow of heated air 26. A length, t, of the heat exchange module 31 between the front face 39a and the rear face 39b is greater than a largest dimension, d, of either the front face or the rear face thereof. In a variation of the above embodiment, the length, t, of the heat exchange module 31 between the front face 39a and the rear face 39b is optionally greater than the sum of the largest dimension, d, of either the front face or the rear face thereof and at least one other dimension of either the front face or the rear face thereof. This confers a substantially elongate form to each heat exchange module in this variation.

Fig. 4 schematically shows a first embodiment of a vehicle cooling system 30. The vehicle cooling system 30 comprises a plurality of heat exchange modules 31 a, 31 b, 31 c; 32a, 32b; 33, each of which is similar to the heat exchange module 31 shown in Fig. 3. Three of these heat exchange modules 31 a, 31 b, 31 c belong to a first cooling circuit of the vehicle cooling system 30, which functions as a condenser. Two of the heat exchange modules 32a, 32b belong to a second cooling circuit of the vehicle cooling system 30, which functions as a radiator for a prime mover of the vehicle, such as its engine. One of the heat exchange modules 33 belongs to a third cooling circuit of the vehicle cooling system 30, which functions as a transmission oil cooling system. During operation, the incoming flow of cooling air 24 encounters each of the first, second and third cooling circuits at the same time, since the front faces of all of the plurality of heat exchange modules 31 a, 31 b, 31 c; 32a, 32b; 33 are substantially coplanar with each other. The cooling air passes parallel to each of the cooling modules 31 a, 31 b, 31 c; 32a, 32b; 33, and is ejected as an outflow of heated air 26 from the rear faces thereof.

Fig. 5 schematically shows an embodiment of a common frame 40, to which the plurality of similar heat exchange modules 31 a, 31 b, 31 c can be mounted. The heat exchange modules 31 a, 31 b, 31 c are slidable lengthwise into and out of the common frame 40, for removal and replacement of any one of these heat exchange modules. The common frame 40 is modular and comprises a frame element 42a, 42b, 42c for each of the plurality of similar heat exchange modules.

Fig. 6 schematically shows an embodiment of a continuous run of a heat exchange apparatus 50. The continuous run of heat exchange apparatus 50 comprises a heat exchange fluid pathway 38 for exposure to a flow of cooling air, in the same manner as the heat exchange module 31 described above in relation to Fig. 3. The continuous run of heat exchange apparatus 50 may, for example, be made of an aluminium alloy. In a method of manufacturing a plurality of heat exchange modules for one or more vehicle cooling systems 30, the continuous run of heat exchange apparatus 50 is cut at locations indicated by the dashed lines in Fig. 6 into a plurality of substantially equal portions 51 , 52, 53, 54 to provide the heat exchange fluid pathway in each such length with an inlet 34 and an outlet 36. The inlet 34 of at least one of the portions 51 , 52, 53, 54 is then fitted with one of a plug 35 and socket 37 and the outlet 36 of at least another of the portions 51 , 52, 53, 54 with the other of the plug and socket. Each plug 35 is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and each socket 37 is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal. Thus two or more of the resulting heat exchange modules may be joined together according to requirements to provide one or more vehicle cooling systems 30.

During the manufacturing process, each of the heat exchange modules is provided with a front face 39a to receive an incoming flow of cooling air 24 and a rear face 39b opposite to the front face, to eject an outflow of heated air 26. Cutting the continuous run of heat exchange apparatus 50 into a plurality of substantially equal portions 51 , 52, 53, 54 results in the length Z of each heat exchange module between the front face and the rear face thereof being greater than a largest dimension d of either the front face or the rear face thereof. Alternatively, the cutting may result in the length, Z, of each heat exchange module between the front face and the rear face thereof being greater than the sum of the largest dimension, d, of either the front face or the rear face thereof and at least one other dimension of either the front face or the rear face thereof. This confers a substantially elongate form to each heat exchange module. A cross-sectional area, X, of the similar heat exchange modules is determined during a design phase of the heat exchange modules, whereas the length, Z, of the similar heat exchange modules is determined during a manufacturing phase of the heat exchange modules.

Fig. 7 shows part of a front end of a third vehicle 210. The front end of the vehicle 210 comprises a front body panel 212, an engine block 218 and a vehicle cooling system 30 of the type shown in Fig. 4 and described above. The engine block 218 is mounted within the vehicle 210 above and slightly in front of a front axle 202 of the vehicle 210. As may be seen from Fig. 7, the vehicle cooling system 30 is mounted in an otherwise unused space within the vehicle 210 beside the engine block 218. Since the vehicle cooling system 30 is not mounted in front of the engine block 218, it does not contribute to the overall length of the vehicle and the size of the overhang at the front end of the vehicle 210 in front of the front axle 202 may therefore be reduced. Fig. 8 schematically shows a second embodiment of a vehicle cooling system 130. The vehicle cooling system 130 comprises a plurality of heat exchange modules 31 similar to those shown in Fig. 3 and described above. However, for simplicity of representation, only a single one of this plurality of heat exchange modules 31 is shown in Fig. 8. Each of the heat exchange modules 31 has a front face 39a configured to receive an incoming flow of cooling air 24 and a rear face 39b opposite to the front face, configured to eject an outflow of heated air 26. Additionally, a respective length, Z, of each of the heat exchange modules between the front face 39a and the rear face 39b thereof is greater than a largest dimension, d, of either the front face or the rear face thereof. Alternatively, a respective length, Z, of each of the heat exchange modules between the front face 39a and the rear face 39b thereof is greater than the sum of the largest dimension, d, of either the front face or the rear face thereof and at least one other dimension of either the front face or the rear face thereof. This confers a substantially elongate form to each heat exchange module. Each of the plurality of heat exchange modules also comprises a heat exchange fluid pathway 38 for exposure to the flow of cooling air 24. The pathway 38 has an inlet 34 and an outlet 36. The inlet 34 comprises one of a plug 35 and socket 37 and the outlet 36 comprises the other of the plug and socket. The plug is insertable into a socket of another similar heat exchange module to form a fluid-tight seal, and the socket is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal. Once again, however, for simplicity of representation, the heat exchange module 31 is shown in Fig. 8 only schematically, so that the inlet 34, plug 35, outlet 36, socket 37 and heat exchange fluid pathway 38 thereof are not explicitly shown in Fig. 8.

As also shown schematically in Fig. 8, the vehicle cooling system 130 comprises an inlet duct 60, a shutter 62, a shutter control system 620, an air filter 64, an outlet duct 70, a valve 72 and a valve control system 720. The inlet duct 60 is configured to channel the cooling air 24 to the front face 39a of at least one of the plurality of heat exchange modules 31 . The shutter 62 is operable to open and close the inlet duct 60. The shutter control system 620 is operable to actuate the shutter 62, and is configured to optimize at least one of a fuel efficiency of the vehicle and a performance of the vehicle, where "performance", means at least one of speed, acceleration and range of the vehicle or a combination thereof. The air filter 64 is configured to filter the incoming flow of cooling air 24 and is removable and replaceable during servicing of the vehicle. The outlet duct 70 is configured to channel the heated air 26 away from the rear face 39b of at least one of the heat exchange modules 31 . The valve 72 is located in the outlet duct and is operable to selectively direct the heated air to at least one of an engine 82 of the vehicle during engine warm-up, a passenger cabin 84 of the vehicle, a heat storage device 86 of the vehicle, and an external environment of the vehicle 88. The valve control system 720 is operable to actuate the valve 72. Fig. 9 shows part of a front end of a fourth vehicle 310. The front end of the vehicle 310 comprises a front body panel 312, an engine block 318 and a vehicle cooling system 30 of the type shown in Fig. 4 and described above. As may be seen from Fig. 9, the vehicle cooling system 30 is mounted in an otherwise unused space within the vehicle 310 behind the engine block 318. Since the vehicle cooling system 30 is not mounted in front of the engine block 318, it does not contribute to the overall length of the vehicle. As may also be seen from Fig. 9, however, the vehicle cooling system 30 is mounted in the vehicle 310 with all of the heat exchange modules 31 thereof in a substantially vertical orientation. This is possible because the vehicle 310 further includes an inlet duct 60 (not shown in Fig. 9) of the type described above in relation to Fig. 8. This inlet duct 60 channels the flow of cooling air 24 which encounters the front body panel 312 during forward movement of the vehicle 310 to the front faces of the plurality of heat exchange modules 31 .

In the embodiment shown in Fig. 9, the plurality of similar heat exchange modules 31 are all located together. However, in an alternative possible embodiment, at least two of the plurality of similar heat exchange modules 31 may instead be distributed at different locations from each other around the vehicle 310 by the use of at least two inlet ducts 60 to channel the flow of cooling air 24 to the front faces of respective ones of the at least two heat exchange modules 31 which are at the different locations. Fig. 10 schematically shows a third embodiment of a vehicle cooling system 230. The vehicle cooling system 230 comprises a plurality of heat exchange modules 31 similar to those shown in Fig. 3 and described above. The vehicle cooling system 230 also comprises a first cooling circuit 90a having a first operating temperature, and comprising a first one of the heat exchange modules 31 , and a second cooling circuit 90b having a second operating temperature higher than the first operating temperature, and comprising a second one the heat exchange modules 31 . The respective lengths, t, of the first and second ones of the similar heat exchange modules 31 are substantially equal to each other. In this embodiment, the first and second cooling circuits 90a, 90b are both connected to the same thermal system of the vehicle, which in this embodiment, is an engine 418 of the vehicle.

In an alternative possible embodiment to that shown in Fig. 10, however, the first cooling circuit 90a could be connected to a first thermal system of the vehicle and the second cooling circuit 90b could be connected to a second thermal system of the vehicle. In such a case, the first and second thermal systems of the vehicle could each comprise at least one of a heating, ventilation and/or air conditioning system of the vehicle, an energy storage means of the vehicle, an engine of the vehicle, an electric machine of the vehicle, an electronic control system of the vehicle and a fuel cell of the vehicle.

Returning to Fig. 10, since the second cooling circuit 90b has a second operating temperature which is higher than the first operating temperature of the first cooling circuit 90a, whereas the first and second cooling circuits 90a, 90b are both connected to the same thermal system of the vehicle, the first and second cooling circuits 90a, 90b can be used for thermal management of different aspects of the same thermal system. Thus the first cooling circuit 90a can be used for recirculating heat to the engine 418 during engine warm-up, whereas the second cooling circuit 90b can be used to extract excess heat from the engine 418 after it has warmed up.

As also shown schematically in Fig. 10, the vehicle cooling system 230 comprises two pumps 92a, 92b, which are respectively configured to supply heat exchange fluid to a respective one of first and second cooling circuits 90a, 90b. The pumps 92a, 92b are variable flow pumps, which are configured to supply a variable amount of heat exchange fluid to the first and second cooling circuits 90a, 90b. Both pumps 92a, 92b are also switchable on and off independently of each other. The vehicle cooling system 230 also comprises a pump control system 920 operable to actuate the pumps 92a, 92b. The pump control system 920 is configured to optimize thermal management of the first and second cooling circuits 90a, 90b.

Finally, Fig. 1 1 schematically shows a method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other. Each of the cooling systems is for one of a range of vehicles having respective prime movers of different heat generating capacities from each other. The method comprises manufacturing, 1001 , a plurality of heat exchange modules which are similar to each other, selecting, 1002, different numbers of the similar heat exchange modules, each such number having a combined cooling capacity matching the heat generating capacity of a different one of the prime movers, and assembling, 1003, the different numbers of heat exchange modules together to make the vehicle cooling systems of different cooling capacities. Each of the vehicle cooling systems of different cooling capacities are then mounted, 1004, on a respective frame. Each respective frame is modular and comprises a frame element for each of the plurality of similar heat exchange modules in the respective vehicle cooling system. The vehicle cooling systems of different cooling capacities are then fitted, 1005, to respective ones of the vehicles in the range having respective prime movers with heat generating capacities matching the different cooling capacities of the vehicle cooling systems. In this embodiment, manufacturing, 1001 , a plurality of heat exchange modules similar to each other comprises producing, 1001 a, a continuous run of heat exchange apparatus comprising a heat exchange fluid pathway for exposure to a flow of cooling air, cutting, 1001 b, the continuous run of heat exchange apparatus into a plurality of substantially equal portions to provide the heat exchange fluid pathway in each such length with an inlet and an outlet, and fitting, 1001 c, the inlet of at least one of the portions with one of a plug and socket, and the outlet of at least another of the portions with the other of the plug and socket. Each plug is insertable into a socket of another similar heat exchange module to form a fluid- tight seal, and each socket is configured to receive a plug of a third similar heat exchange module also to form a fluid-tight seal.

As part of the method of manufacturing a plurality of vehicle cooling systems of different cooling capacities from each other, a size of the similar heat exchange modules is determined, 1000d, from a highest common factor of the different heat generating capacities of the prime movers of the vehicles in the range. At least one of the engine capacity and the power output rating of each of the prime movers is used, 1000a, to represent the heat generating capacity of each of the prime movers. A cross-sectional area, X, of the similar heat exchange modules is determined, 1000b, during a design phase of the heat exchange modules, and a length, I, of the similar heat exchange modules is determined, 1000c, during a manufacturing phase of the heat exchange modules.

For purposes of this disclosure, it is to be understood that the control systems described herein can each comprise a control unit or computational device having one or more electronic processors. A vehicle and/or a system thereof may comprise a single control unit or electronic controller or alternatively different functions of the controllers may be embodied in, or hosted in, different control units or controllers. A set of instructions could be provided which, when executed, cause said controllers or control units to implement the control techniques described herein, including the described methods. The set of instructions may be embedded in one or more electronic processors, or alternatively, the set of instructions could be provided as software to be executed by one or more electronic processors. For example, a first controller may be implemented in software run on one or more electronic processors, and one or more other controllers may also be implemented in software run on or more electronic processors, optionally the same one or more processors as the first controller. It will be appreciated, however, that other arrangements are also useful, and therefore, the present disclosure is not intended to be limited to any particular arrangement. In any event, the set of instructions described above may be embedded in a computer- readable storage medium (e.g., a non-transitory storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors/computational device, including, without limitation: a magnetic storage medium (e.g., floppy diskette); optical storage medium (e.g., CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information/instructions.

As used herein, the term "module" refers to a unit or apparatus that excludes certain parts or components that would be added by a manufacturer or a user. The blocks illustrated in Fig. 1 1 may represent steps in a method and/or sections of code in a computer program. The illustration of a particular order to the blocks does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the block may be varied. Furthermore, it may be possible for some steps to be omitted.

Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed.

Features described in the preceding description may be used in combinations other than the combinations explicitly described.

Although functions have been described with reference to certain features, those functions may be performable by other features, whether described or not.

Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not. Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings, whether or not particular emphasis has been placed thereon.