Multi-pass fluid cooler

Abstract

A cooler for fluids uses multiple internal channels to increase the time a hot fluid is contained in the cooler, thus increasing cooling efficiency, and allowing the length of the cooler to be shorter than an equivalent cooler with fewer passes. The cooler uses external and internal heat-exchanging fins to increase surface area for contact with both the fluid and the external environment. The cooler is designed around a cylindrical vessel, equipped with a set of internal baffles, forming the multiple channels. End caps, one of which contains inlet and outlet ports, are welded to the cooling vessel, increasing ability to contain pressure. The small channel size and fluid flow-path holes cut through the baffles prevent air bubbles, which would reduce cooling efficiency. Coolers with four channels are provided for higher-pressure applications and coolers with six channels are provided for lower-pressure applications. Some coolers have an air flow assembly with a fan, to direct more cooling air around the cooler vessel. An airflow assembly with a fan controlled by a thermostat on the cooler is also disclosed.

1 . A multi-pass cooler, comprising: 
 a heat-conducting vessel provided with an internal cylindrical chamber, having a first end and a second end, comprising:    an internal baffle structure, comprising: 
 a plurality of baffles, forming a multiplicity of channels, the multiplicity comprising a first channel, intermediate channels, and a last channel;  
 a first end cap, fixed to the first end of the heat-conducting vessel; and  
 a second end cap, comprising an inlet port and an outlet port, fixed to the second end of the heat-conducting vessel;  
 wherein, the inlet port is capable of receiving a fluid and directing the fluid into the first channel, and the outlet port is capable of receiving the fluid from the last channel, and directing the fluid out of the cooler.  
   
   
   
       2 . The multi-pass cooler of  claim 1 , wherein the baffle structure comprises six baffles forming six channels.  
   
   
       3 . The multi-pass cooler of  claim 2  wherein the six baffles are spaced at 60 degree angles.  
   
   
       4 . The multi-pass cooler of  claim 2 , wherein two channels are formed by baffles spaced at 72 degrees and four channels are formed by baffles spaced at 54 degrees.  
   
   
       5 . The multi-pass cooler of  claim 1 , wherein the baffle structure comprises three baffles forming four channels.  
   
   
       6 . The multi-pass cooler of  claim 5 , wherein two of the channels are formed by baffles spaced at a 72 degree angle and two of the channels are formed by baffles spaced at a 104 degree angle.  
   
   
       7 . The multi-pass cooler of  claim 6 , wherein slits are provided at a portion of the ends of a portion of the baffles to facilitate fluid flow between channels.  
   
   
       8 . The multi-pass cooler of  claim 7  wherein the vessel further comprises external heat-transfer fins; and internal heat-transfer fins.  
   
   
       9 . The multi-pass cooler of  claim 8 , wherein the conducting vessel is formed by extrusion of aluminum.  
   
   
       10 . A multi-pass fluid cooler, comprising: 
 a vessel, comprising 
 a cylindrical inner volume,  
 a heat-radiating outer surface,  
 a heat-conducting inner surface,  
 a first end opening, and  
 a second end opening;  
   a baffle structure, comprising: 
 a first baffle, comprising an exit hole;  
 a second baffle, comprising an entrance hole and an exit hole;  
 a third baffle, comprising an entrance hole and an exit hole;  
 a fourth baffle, comprising an entrance hole;  
 a fifth baffle, comprising an entrance hole and an exit hole; and  
 a sixth baffle, comprising an entrance hole and an exit hole;  
   wherein, the first baffle, second baffle, third baffle, fourth baffle, fifth baffle, and sixth baffle radiate from a central axis, and extend to substantially fill the cylindrical inner volume of the vessel;    a first end-cap, fastened to the first end opening of the vessel; and    a second end-cap, comprising an inlet port and an outlet port, fastened to the second end opening of the vessel, wherein the inlet port is located between the first baffle and the second baffle of the baffle structure, and the outlet port is located between the fourth baffle and the fifth baffle of the baffle structure.    
   
   
       11 . The multi-pass cooler of  claim 10 , wherein the vessel is extruded of aluminum.  
   
   
       12 . The multi-pass cooler of  claim 11 , wherein the vessel cylindrical inner volume has a diameter between 1 and 3 inches.  
   
   
       13 . A method of making a cooler, comprising the steps of: 
 a. Extruding a vessel blank, comprising a plurality of external cooling fins, and a plurality of internal cooling fins;    b. Creating a vessel by cutting a segment of the vessel blank to a desired length, having a first end and a second end;    c. Inserting a baffle assembly, comprising: 
 a plurality of baffles provided with apertures for fluid flow;  
   d. Forming a first end cap.    e. Welding the first end-cap onto the first end of the vessel;    f. Forming a second end cap, provided with an inlet port and an outlet port; and    g. Welding the second end-cap onto the second end of the vessel.    
   
   
       14 . A four-pass fluid cooler, comprising: 
 a vessel, comprising 
 a cylindrical inner volume,  
 a heat-radiating outer surface,  
 a heat-conducting inner surface,  
 a first end opening, and  
 a second end opening;  
   a baffle structure, positioned in the vessel, comprising: 
 an upper baffle, comprising an exit slit, forming an upper channel;  
 an intermediate baffle, comprising an entrance slit and an exit slit, forming two intermediate channels;  
 a lower baffle, comprising an entrance slit, forming a lower channel;  
   a first end-cap, fastened to the first end opening of the vessel; and    a second end-cap, comprising an inlet port and an outlet port, fastened to the second end opening of the vessel, wherein the inlet port is aligned with the upper channel and the outlet port is aligned with the lower channel.    
   
   
       15 . The four-pass fluid cooler of  claim 14 , wherein the upper baffle and lower baffle are each formed of a horizontal plane segment and two angled plane segments, and wherein the intermediate baffle is a vertical plane segment.  
   
   
       16 . The four-pass fluid cooler of  claim 15 , wherein the two angled plane segments of the upper baffle and of the lower baffle angled at approximately 72 degrees to each other.  
   
   
       17 . The four-pass fluid cooler of  claim 16 , wherein slits are provided at a portion of the ends of a portion of the baffles to facilitate fluid flow between channels.  
   
   
       18 . The four-pass fluid cooler of  claim 17 , wherein the conducting vessel is formed by extrusion of aluminum.  
   
   
       19 . The cooler of any of claims  2 ,  5 ,  14 , or  18 , further comprising an airflow assembly, comprising an air pipe surrounding a portion of the cooling vessel, and having a fan at one end.  
   
   
       20 . The cooler of  claim 19 , further comprising a temperature sensor, in thermal contact with the vessel, capable of turning the fan off and on.