Modular composite intercooler

Abstract

A modular heat exchanger assembly comprising: a plurality of interlocking housings each having a heat-exchanging element, a first and second side each having a mating connector and a first end and a second end, wherein the interlocking housings interlock to each other by the second side having a mating connector interlocking with the first side having a mating connector to provide a heat exchanger core, the first end has a plurality of first end mating connector openings and the second end has a plurality of second end mating connector openings; there may be at least one first-type end cap, at least one second-type end cap and/or at least one third-type end cap for connection to either one of the first end mating connector openings or one of the second end mating connector openings and there is at least one access opening.

We claim: 
     
         1 . A modular heat exchanger assembly comprising:
 a plurality of interlocking housings each having a heat-exchanging element, a first side having a mating connector and a second side having a mating connector and a first end and a second end, wherein the plurality of interlocking housings interlock to each other by the second side having a mating connector interlocking with the first side having a mating connector to provide a heat exchanger core and wherein the first end has a plurality of first end mating connector openings and the second end has a plurality of second end mating connector openings;   at least one first-type end cap with a plurality of end cap mating connectors for connection to either one of the first end mating connector openings or one of the second end mating connector openings and having one first-type end cap open connector;   at least one second-type end cap with a plurality of end cap mating connectors for connection to either a first end mating connector opening or a second end mating connector opening and having at least one second-type end cap open connector;   wherein at least one first-type end cap open connector is attached to at least one second-type end cap open connector; and   wherein at least one of the at least one first-type end caps and the at least one second type end cap has an access opening.   
     
     
         2 . A modular heat exchanger as in  claim 1 , wherein each of the at least one second-type end caps has two second-type end cap open connectors that provide a parallel coolant flow path. 
     
     
         3 . A modular heat exchanger as in  claim 1 , wherein the plurality of interlocking housings each having a heat-exchanging element are connected to provide a parallel coolant flow path. 
     
     
         4 . A modular heat exchanger as in  claim 1 , wherein the plurality of interlocking housings each having a heat-exchanging element are connected to provide a series coolant flow path. 
     
     
         5 . A modular heat exchanger as in  claim 1 , wherein each of the at least one second-type end caps has two second-type end cap open connectors that provide a series coolant flow path. 
     
     
         6 . A modular heat exchanger as in  claim 1 , wherein the plurality of interlocking housings each having a heat-exchanging element are connected to provide a mixed parallel and series coolant flow path. 
     
     
         7 . A modular heat exchanger as in  claim 1 , further comprising an o-ring seal interposed between the plurality of end cap mating connectors and at least one of the first end mating connector openings and the second end mating connector openings. 
     
     
         8 . A modular heat exchanger as in  claim 1 , further comprising an o-ring seal interposed between a portion of the first-type end cap open connector and the second-type end cap open connectors. 
     
     
         9 . A modular heat exchanger as in  claim 1 , wherein at least one of the first-type end cap open connectors is a female connector. 
     
     
         10 . A modular heat exchanger as in  claim 1 , wherein at least one of the first-type end cap open connectors is a male connector. 
     
     
         11 . A modular heat exchanger as in  claim 1 , wherein the at least one two second-type end cap open connectors are one male connector and one female connector. 
     
     
         12 . A modular heat exchanger as in  claim 1 , wherein the plurality of interlocking housings have outer squared off corners to form a planar seal surface for mating parts. 
     
     
         13 . A modular heat exchanger as in  claim 1 , wherein the plurality of interlocking housings, the at least one first-type end caps and the at least one second-type end cap are formed by injection molding. 
     
     
         14 . A modular heat exchanger as in  claim 1 , wherein at least one of the plurality of interlocking housings, the at least one first-type end caps and the at least one second-type end cap are formed in multiple pieces. 
     
     
         15 . A modular heat exchanger as in  claim 1 , wherein at least one of the plurality of interlocking housings, the at least one first-type end caps and the at least one second-type end cap are formed in a single piece. 
     
     
         16 . A modular heat exchanger as in  claim 1 , further comprising at least one third-type end cap with a plurality of end cap mating connectors for connection to either a first end mating connector opening or a second end mating connector opening. 
     
     
         17 . A modular heat exchanger assembly comprising:
 a plurality of interlocking housings each having a heat-exchanging element, a first side having a mating connector and a second side having a mating connector and a first end and a second end, wherein the plurality of interlocking housings interlock to each other by the second side having a mating connector interlocking with the first side having a mating connector to provide a heat exchanger core and wherein the first end has a plurality of first end mating connector openings and the second end has a plurality of second end mating connector openings;   at least one third-type end cap with a plurality of end cap mating connectors for connection to either a first end mating connector opening or a second end mating connector opening;   at least one first-type end cap with a plurality of end cap mating connectors for connection to either a first end mating connector opening or a second end mating connector opening and having one first-type end cap open connector, wherein at least two of the at least one first-type end cap and the at least one third-type end caps have an access opening.   
     
     
         18 . A modular heat exchanger as in  claim 17 , wherein the plurality of interlocking housings each having a heat-exchanging element are connected to provide at least one of a parallel coolant flow path, a series coolant flow path and a mixed parallel and series coolant flow path. 
     
     
         19 . A modular heat exchanger as in  claim 17 , further comprising an o-ring seal interposed between the plurality of end cap mating connectors and at least one of the first end mating connector openings and the second end mating connector openings. 
     
     
         20 . A modular heat exchanger as in  claim 17 , wherein at least one of the first-type end cap open connectors is either a female connector or a male connector. 
     
     
         21 . A modular heat exchanger as in  claim 17 , wherein the plurality of interlocking housings have outer squared off corners to form a planar seal surface for mating parts. 
     
     
         22 . A modular heat exchanger as in  claim 17 , further comprising at least one second-type end cap with a plurality of end cap mating connectors for connection to either a first end mating connector opening or a second end mating connector opening and having at least one second-type end cap open connector, wherein at least one first-type end cap open connector is attached to at least one second-type end cap open connectors. 
     
     
         23 . A modular heat exchanger as in  claim 22 , further comprising an o-ring seal interposed between a portion of the first-type end cap open connector and the second-type end cap open connectors.