Integral baffle and lubricant cooler

Abstract

A baffle for use in a lubricant pan of an engine that uses a lubricant having a viscosity. The baffle includes a first sheet and a second sheet substantially aligned with the first sheet, the sheets are sized and shaped to reduce turbulence of the lubricant in the lubricant pan. The baffle also includes a tube having a first end and a second end, whereby at least part of the tube is sandwiched between the first and second sheets. A first tube connector is connected to the first end of the tube. A second tube connector is connected to the second end of the tube. A plurality of draining apertures are formed in the first and second sheets, whereby the size of the draining apertures are based on the viscosity of the lubricant.

What is claimed is:  
     
         1 . A baffle for use in a lubricant pan of an engine that uses a lubricant, the lubricant having a viscosity, the baffle comprising: 
 a first sheet;    a second sheet substantially aligned with the first sheet, the first and second sheets sized and shaped so as to reduce turbulence of the lubricant in the lubricant pan;    a tube including a first end and a second end, at least part of the tube being sandwiched between the first and second sheets;    a first tube connector connected to the first end of the tube;    a second tube connector connected to the second end of the tube;    an aperture formed in the first and second sheets, the aperture sized and shaped for accepting a lubricant pickup; and    a plurality of draining apertures formed in the first and second sheets, the size of the draining apertures being based on the viscosity of the lubricant.    
     
     
         2 . The baffle as claimed in  claim 1 , further comprising a plurality of bosses configured to support the baffle in the lubricant pan.  
     
     
         3 . The baffle as claimed in  claim 1 , wherein the tube is configured in a serpentine path.  
     
     
         4 . The baffle as claimed in  claim 3 , wherein the first and second sheets have a common longitudinal axis and the serpentine path is generally oriented along the longitudinal axis.  
     
     
         5 . The baffle as claimed in  claim 1 , wherein the tube is configured as a main load bearing member of the baffle.  
     
     
         6 . The baffle as claimed in  claim 1 , further comprising a plurality of clinch joints, wherein each clinch joint connects the first sheet and second sheet to one another.  
     
     
         7 . The baffle as claimed in  claim 1 , wherein the first and second sheets are made from aluminum.  
     
     
         8 . The baffle as claimed in  claim 1 , wherein the tube is a seamless tube.  
     
     
         9 . The baffle as claimed in  claim 1 , wherein the first tube connector couples the first end of the tube to the lubricant pan, and wherein the second tube connector couples the second end of the tube to the lubricant pan.  
     
     
         10 . The baffle as claimed in  claim 9 , wherein the first tube connector is configured to threadably engage a first threaded aperture in the lubricant pan, and wherein the second tube connector is configured to threadably engage a second threaded aperture in the lubricant pan.  
     
     
         11 . The baffle as claimed in  claim 10 , wherein coolant enters the tube via one of the first and second threaded apertures, and wherein the coolant exits the tube via the other of the first and second threaded apertures.  
     
     
         12 . The baffle as claimed in  claim 1 , wherein the first and second sheets are curved to define a forward baffle portion and a rear baffle portion, and wherein the rear baffle portion is not coplanar with the forward baffle portion.  
     
     
         13 . The baffle as claimed in  claim 12 , wherein the rear baffle portion is parallel to and offset from the forward baffle portion.  
     
     
         14 . The baffle as claimed in  claim 1 , further comprising louvers formed in the first and second sheets, the size of the louvers being based on the viscosity of the lubricant.  
     
     
         15 . A baffle for use in a lubricant pan of an engine that uses a lubricant, the lubricant having a viscosity, the baffle comprising: 
 a first sheet having a size and shape;    a second sheet substantially the same size and shape as the first sheet, the first and second sheets configured to reduce turbulence of the lubricant in the lubricant pan;    a tube including a first end and a second end, at least part of the tube sandwiched between the first and second sheets;    an aperture formed in the first and second sheets, the aperture sized and shaped for accepting a lubricant pickup; and    a plurality of draining apertures formed in the first and second sheets, the size of the draining apertures based on the viscosity of the lubricant.    
     
     
         16 . The baffle as claimed in  claim 15 , further comprising: 
 a first tube connector connected to the first end of the tube; and    a second tube connector connected to the second end of the tube.    
     
     
         17 . The baffle as claimed in  claim 16 , wherein the first tube connector is configured to couple the first end of the tube to the lubricant pan, and wherein the second tube connector is configured to couple the second end of the tube to the lubricant pan.  
     
     
         18 . The baffle as claimed in  claim 15 , wherein the first and second sheets are made from aluminum.  
     
     
         19 . The baffle as claimed in  claim 15 , wherein the first and second sheets are curved to define a forward baffle portion and a rear baffle portion, and wherein the rear baffle portion is not coplanar with the forward baffle portion.  
     
     
         20 . The baffle as claimed in  claim 19 , wherein the rear baffle portion is parallel to and offset from the forward baffle portion.  
     
     
         21 . The baffle as claimed in  claim 15 , wherein the tube is a seamless tube.  
     
     
         22 . The baffle as claimed in  claim 15 , wherein the tube is configured in a serpentine path.  
     
     
         23 . The baffle as claimed in  claim 22 , wherein the first and second sheets define at least one plane, and at least a portion of the serpentine path is generally oriented along the at least one plane.  
     
     
         24 . The baffle as claimed in  claim 15 , wherein the tube provides structural rigidity to the baffle.  
     
     
         25 . The baffle as claimed in  claim 15 , further comprising at least one boss for supporting the baffle in the lubricant pan.  
     
     
         26 . The baffle as claimed in  claim 15 , further comprising a plurality of clinch joints interconnecting the first and second metal sheets.  
     
     
         27 . The baffle as claimed in  claim 15 , further comprising louvers formed in the first and second sheets, the size of the louvers being based on the viscosity of the lubricant.  
     
     
         28 . The baffle as claimed in  claim 15 , wherein the baffle includes a third sheet coupled to at least one of the first and second sheets, the third sheet extending downwardly from the baffle in a plane that is substantially normal to a horizontal plane in which the baffle is generally positioned.  
     
     
         29 . The baffle as claimed in  claim 28 , wherein the third sheet includes a groove formed therein, the groove configured to route lubricant from at least one of the first and second sheets to the lubricant pan.  
     
     
         30 . The baffle as claimed in  claim 29 , wherein the groove has a serpentine configuration.  
     
     
         31 . A combination of a baffle and a lubricant pan for an engine that uses a lubricant, the lubricant having a viscosity, the combination comprising: 
 a baffle including 
 a first sheet;  
 a second sheet substantially aligned with the first sheet, the first and second sheets sized and shaped so as to reduce turbulence of the lubricant in the lubricant pan;  
 a tube including a first end and a second end, at least part of the tube being sandwiched between the first and second sheets;  
 a first tube connector connected to the first end of the tube;  
 a second tube connector connected to the second end of the tube;  
 an aperture formed in the first and second sheets, the aperture sized and shaped for accepting a lubricant pickup; and  
 a plurality of draining apertures formed in the first and second sheets, the size of the draining apertures being based on the viscosity of the lubricant; and  
   a lubricant pan housing the baffle therein, the first tube connector coupling the first end of the tube to the lubricant pan and the second tube connector coupling the second end of the tube to the lubricant pan.    
     
     
         32 . The combination as claimed in  claim 31 , wherein the first and second sheets are made from aluminum.  
     
     
         33 . The combination as claimed in  claim 31 , wherein the first and second sheets are curved to define a forward baffle portion and a rear baffle portion, and wherein the rear baffle portion is not coplanar with the forward baffle portion.  
     
     
         34 . The combination as claimed in  claim 33 , wherein the rear baffle portion is parallel to and offset from the forward baffle portion.  
     
     
         35 . The combination as claimed in  claim 31 , wherein the lubricant pan includes a first threaded aperture and a second threaded aperture, wherein the first tube connector threadably engages one end of the first threaded aperture, and wherein the second tube connector threadably engages one end of the second threaded aperture.  
     
     
         36 . The combination as claimed in  claim 35 , wherein coolant enters the tube via one of the first and second threaded apertures, and wherein the coolant exits the tube via the other of the first and second threaded apertures.  
     
     
         37 . The combination as claimed in  claim 31 , wherein the tube is a seamless tube.  
     
     
         38 . The combination as claimed in  claim 31 , wherein the tube is configured in a serpentine path.  
     
     
         39 . The combination as claimed in  claim 38 , wherein the first and second sheets define at least one plane, and at least a portion of the serpentine path is generally oriented along the at least one plane.  
     
     
         40 . The combination as claimed in  claim 31 , wherein the tube provides structural rigidity to the baffle.  
     
     
         41 . The combination as claimed in  claim 31 , further comprising at least one boss for supporting the baffle in the lubricant pan.  
     
     
         42 . The combination as claimed in  claim 31 , further comprising a plurality of clinch joints interconnecting the first and second metal sheets.  
     
     
         43 . The combination as claimed in  claim 31 , wherein the lubricant pan includes at least one bottom wall and at least one side wall upstanding from the bottom wall, and wherein the baffle includes a third metal sheet coupled to at least one of the first and second metal sheets, the third metal sheet extending downwardly from the baffle in a plane that is substantially normal to a horizontal plane in which the baffle is generally positioned, the third metal sheet positioned adjacent and generally parallel to the at least one side wall.  
     
     
         44 . The combination as claimed in  claim 43 , wherein the third metal sheet includes a groove formed therein, the groove configured to route lubricant from at least one of the first and second metal sheets to the lubricant pan.  
     
     
         45 . The combination as claimed in  claim 44 , wherein the groove has a serpentine configuration.  
     
     
         46 . The combination as claimed in  claim 43 , wherein the lubricant pan includes cooling fins extending from the at least one side wall of the lubricant pan.  
     
     
         47 . The combination as claimed in  claim 31 , wherein the lubricant pan includes a second tube coupled to the lubricant pan and positioned toward a bottom end of the lubricant pan.  
     
     
         48 . The combination as claimed in  claim 47 , wherein coolant passes through the second tube to cool lubricant lying near the bottom end of the lubricant pan.  
     
     
         49 . A method of making a baffle for use in a lubricant pan, the method comprising: 
 providing a tube including a first end and a second end;    bending the tube into a serpentine pattern;    positioning the tube between a first metal sheet and a second metal sheet; and    stamping the first and second metal sheets to at least partially sandwich the tube therebetween.    
     
     
         50 . The method as claimed in  claim 49 , further comprising interconnecting the first and second metal sheets via multiple clinch joints.  
     
     
         51 . The method as claimed in  claim 49 , further comprising forming apertures through the first and second metal sheets.  
     
     
         52 . A method of cooling and controlling turbulence of a lubricant in a lubricant pan of an engine, the method comprising: 
 providing a baffle including a tube sandwiched by interconnected metal sheets;    positioning the baffle over the lubricant in the lubricant pan, such that at least some of the lubricant drains onto the baffle before draining into the lubricant pan;    coupling the baffle to the lubricant pan; and    passing coolant through the tube to cool the lubricant in contact with the baffle.    
     
     
         53 . The method as claimed in  claim 52 , wherein positioning the baffle over the lubricant includes positioning the baffle near the lubricant to decrease splashing of the lubricant.  
     
     
         54 . The method as claimed in  claim 52 , wherein coupling the baffle to the lubricant pan includes coupling opposite ends of the tube with the lubricant pan such that lubricant is not allowed to enter the tube.  
     
     
         55 . A baffle for use in a lubricant pan of an engine that uses a lubricant, the baffle comprising: 
 a first sheet positioned above the lubricant in the lubricant pan, the first sheet configured to receive lubricant from the engine and reduce turbulence of the lubricant in the lubricant pan; and    a second sheet positioned adjacent the first sheet at an angle relative to the first sheet, the second sheet including a groove configured to route lubricant received from the first sheet along an interior surface of the lubricant pan.    
     
     
         56 . The baffle as claimed in  claim 55 , further comprising an aperture formed through the first sheet, the aperture sized and shaped for accepting a lubricant pickup.  
     
     
         57 . The baffle as claimed in  claim 55 , wherein the groove has a serpentine configuration.  
     
     
         58 . The baffle as claimed in  claim 55 , wherein the second sheet substantially abuts the interior surface of the lubricant pan, such that a combination of the groove and the interior surface of the lubricant pan defines a passageway for routing the lubricant therethrough.