Patent Publication Number: US-10775114-B2

Title: Heat exchanger with adapter module

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application based on U.S. application Ser. No. 15/906,473 filed Feb. 27, 2018 which is a continuation application based on U.S. application Ser. No. 13/261,976 filed Oct. 24, 2014 which is a national stage entry application based on International Application No. PCT/CA2013/050319, filed on Apr. 26, 2013 under the title HEAT EXCHANGER WITH ADAPTER MODULE, which claims priority to International Application No. PCT/CA2012/050263, filed on Apr. 26, 2012. The content of each one of the above identified patent applications is hereby expressly incorporated by reference into the detailed description hereof. 
    
    
     TECHNICAL FIELD 
     The invention relates to heat exchangers, and in particular, to heat exchangers adapted for direct mounting to the housing of an automobile system component. 
     BACKGROUND 
     Plate-type heat exchangers comprising a plurality of stacked heat exchanger plates are known for a variety of purposes, including heat exchange between oil and a heat exchange fluid. A known way of mounting a stacked plate heat exchanger is to mount a planar, stamped base plate at one end of the stack, for example, the bottom end. The base plate can be brazed to the heat exchanger with or without the use of a shim plate. In order to incorporate the heat exchanger into an automobile heat exchanger system, for example, the heat exchanger with base plate is then, typically, mounted to a cast or moulded adapter structure which in turn is mounted to the transmission or engine housing, for example, using additional fluid lines and/or connectors. The cast or moulded adapter structure includes mounting holes, fluid transfer channels, fluid fittings, filters, etc. to allow the heat exchanger to be incorporated into the overall heat exchange system. In some instances the cast or moulded adapter structure is made of plastic and in other instances it is a more heavy-duty casting that can be quite complex in structure and costly. In both instances, the adapter structure contributes to the overall height and weight of the heat exchanger component as well as to the overall manufacturing costs. 
     In the field of automotive heat exchanger manufacture, weight limitations as well as space limitations are becoming increasingly restrictive. Accordingly, efforts are constantly being made to reduce component weight as well as component height and/or size. Efforts are also being made to reduce the complexity and increase the adaptability and/or flexibility of components to facilitate assembly and mounting of the component within the overall system and in an effort to reduce overall manufacturing and/or assembly costs. For instance, reducing the overall number of components or component interfaces that result from mounting or integrating a component within an overall system reduces the number of potential leakage points thereby reducing testing requirements as well as assembly steps. Reducing the complexity of components and reducing the number of more complex fluid connections between components also serves to reduce costs and is, therefore, desirable. 
     In automobile heat exchange systems, one manner of accommodating or adjusting to space limitations is to consider mounting heat exchangers directly to a related automotive system component without the use of an intervening adapter or mounting structure. For instance, it is not uncommon for an engine oil cooler (EOC) to be mounted directly to the exterior of the automobile engine housing. An example of an EOC mounted directly to the exterior of the engine housing is shown in JP2011149015. 
     The structure of the engine housing is, generally, somewhat conducive to mounting a heat exchanger directly to the exterior of the engine housing. The area of the cylinder head generally provides a flat, machined recess to which the heat exchanger can be bolted while having direct access to the oil inlet and return passages. However, by bolting the heat exchanger to the cylinder head in this area the heat exchanger must bridge or span the machined recess and must therefore be relatively stiff to minimize deflections from the relatively high cyclic pressure loads of the oil system inherent to the engine, which tend to be amplified depending upon the exact distance bridged by the heat exchanger. Accordingly, specific structural requirements need to be addressed when mounting a heat exchanger directly to the engine housing, while still keeping overall height and space limitations in mind. 
     While directly mounting heat exchangers to the exterior of the engine housing requires that a certain degree of structural rigidity be met, the structure of the housings of other automobile system components also present challenges related to the direct mounting of heat exchangers to the component housing. For instance, in the case of transmission housings, the housings are generally curved and are much larger in size which makes it difficult to provide a wide, generally flat area/recess for mounting a heat exchanger without intruding vertically into the internal parts of the transmission. Furthermore, transmission oil supply feed lines and/or oil ports are generally spaced farther away from each other and outside the footprint area of conventional heat exchangers used for this purpose. As well, the exact location/position of the oil ports is often variable. These factors contribute to difficulties associated with direct mounting a heat exchanger, such as a transmission oil cooler (TOC), to the exterior of the transmission housing. 
     Accordingly, there is a need for a heat exchanger with an improved mounting arrangement which allows for the direct mounting of the heat exchanger to the housing of an automobile system component. 
     SUMMARY OF THE PRESENT DISCLOSURE 
     According to one aspect of the present disclosure there is provided a heat exchanger module for mounting directly to the outer surface of a housing of an automobile system component, the heat exchanger module comprising a heat exchanger comprising a plurality of stacked heat exchange plates defining alternating first and second fluid paths through said heat exchanger, the heat exchanger having a footprint corresponding to the area defined by the stack of heat exchange plates; a pair of first fluid manifolds extending through the heat exchanger and coupled to one another by the first fluid paths, the pair of first fluid manifolds comprising an inlet manifold and an outlet manifold for the flow of a first fluid through said heat exchanger; a pair of second fluid manifolds extending through the heat exchanger and coupled to one another by the second fluid paths, the pair of second fluid manifolds comprising an inlet manifold and an outlet manifold for the flow of a second fluid through said heat exchanger; an adapter module having a first surface attached to an end of the heat exchanger and a second surface opposite to said first surface and adapted for face-to-face contact with an interface surface on the outer surface of the housing of the automobile system component, the adapter module comprising at least one fluid transfer channel formed in the adapter module for communicating with one of the inlet and outlet manifolds of one of said pairs of fluid manifolds; a first port communicating with the at least one fluid transfer channel, the first port being located outboard the heat exchanger footprint; and a second port for communicating with the other one of the inlet and outlet manifolds of said pair of fluid manifolds; wherein the first and second fluid ports are formed in the second surface of the adapter module and have mounting surfaces oriented and adapted for fluid communication with corresponding fluid inlet and outlet ports formed in the interface surface on the housing of said automobile component. 
     According to another aspect of the present disclosure, there is provided a heat exchanger module for mounting directly to the outer surface of a housing of an automobile system component, the heat exchanger module comprising a heat exchanger comprising a plurality of stacked heat exchange plates defining alternating first and second fluid paths through said heat exchanger, the heat exchanger having a footprint corresponding to the area defined by the stack of heat exchange plates; a pair of first fluid manifolds extending through the heat exchanger and coupled to one another by the first fluid paths, the pair of first fluid manifolds comprising an inlet manifold and an outlet manifold for the flow of a first fluid through said heat exchanger; a pair of second fluid manifolds extending through the heat exchanger and coupled to one another by the second fluid paths, the pair of second fluid manifolds comprising an inlet manifold and an outlet manifold for the flow of a second fluid through said heat exchanger; an adapter module having a first surface attached to an end of the heat exchanger and a second surface opposite to said first surface and adapted for face-to-face contact with an interface surface on the outer surface of the housing of the automobile system component, the adapter module comprising a first fluid transfer channel formed in the adapter module, the first fluid transfer channel being in direct fluid communication with one of the inlet and outlet manifolds of one of said pairs of fluid manifolds; a first port formed in the second surface of said adapter module, the first port being in fluid communication with the first fluid transfer channel; a second port formed in the second surface of said adapter module, the second port being in fluid communication with the other one of the inlet and outlet manifolds of said pair of fluid manifolds; and a third port formed in the second surface of said adapter module, the third port being in fluid communication with the first fluid transfer channel; wherein the first fluid transfer channel provides fluid communication between inlet and outlet ports formed in the interface surface of the housing of the automobile system component and an inlet manifold of said heat exchanger. 
     According to another aspect of the present disclosure, the heat exchanger module is particularly suited for mounting directly to the transmission housing, the heat exchanger therefore functioning as a transmission oil cooler (TOC). 
     According to another aspect of the present disclosure, the heat exchanger module is particularly suited for mounting directly to the engine housing, the heat exchanger therefore functioning as an engine oil cooler (EOC). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the present disclosure will now be described, by way of example, with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a heat exchanger module according to an exemplary embodiment of the present disclosure; 
         FIG. 2  is an exploded view of the heat exchanger module of  FIG. 1 ; 
         FIG. 3A  is a perspective view of an adapter plate that forms part of an adapter module of the heat exchange module as shown in  FIG. 2 ; 
         FIG. 3B  is a perspective view of an alternate embodiment of the adapter plate of  FIG. 3A ; 
         FIG. 4  is a bottom view of the heat exchanger module of  FIG. 1 ; 
         FIG. 5  is a perspective view of a shim plate that forms part of the adapter module of the heat exchanger module of  FIG. 1 ; 
         FIG. 6  is a view along section line  5 - 5  of  FIG. 4 ; 
         FIG. 7  is a perspective view of the heat exchanger module of  FIG. 1  mounted to the exterior of an, exemplary, transmission housing; 
         FIG. 7A  is an exploded view of an alternate embodiment of the adapter module of the heat exchanger module of  FIG. 1 ; 
         FIG. 8  is a perspective view of a heat exchanger module according to another exemplary embodiment of the present disclosure; 
         FIG. 9  is a bottom view of the structure of  FIG. 8 ; 
         FIG. 10  is a perspective view of a heat exchanger module according to another exemplary embodiment of the present disclosure shown mounted directly on the housing of an automobile system component; 
         FIG. 11  is a bottom perspective view of the heat exchanger module of  FIG. 10 ; 
         FIG. 12  a perspective view of a heat exchanger module according to yet another exemplary embodiment of the present disclosure; 
         FIG. 13  is a perspective view of a portion of the adapter module that forms part of the heat exchanger module shown in  FIG. 12 ; 
         FIG. 14  is a perspective view of a portion of the adapter module of  FIG. 13 ; 
         FIG. 15  is an exploded view of a portion of the adapter module of  FIG. 12 ; 
         FIG. 16  is an exploded, perspective view of the underside of a portion of an alternate embodiment of the adapter module of  FIG. 14 ; 
         FIG. 17  is a perspective view of a heat exchanger module according to yet another exemplary embodiment of the present disclosure; 
         FIG. 18  is an exploded, perspective view of the heat exchanger module shown in  FIG. 17 ; 
         FIG. 19  is a bottom perspective view of the heat exchanger module of  FIG. 17 ; 
         FIG. 20  is an exploded view of a portion of the heat exchanger module of  FIG. 17  illustrating the oil side of the adapter module; and 
         FIG. 21  is an exploded view of a portion of the heat exchanger module of  FIG. 17  illustrating the coolant side of the adapter module. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Referring now to  FIG. 1 , there is shown an exemplary embodiment of a heat exchanger module  10  according to the present disclosure. Heat exchanger module  10  is comprised of a heat exchanger  12  fixedly attached to an adapter module  14 . Heat exchanger  12  is generally in the form of a nested, dished-plate heat exchanger, as is known in the art, and is comprised of a plurality of stamped heat exchanger plates  16 ,  17  disposed in alternatingly stacked, brazed relation to one another to form a heat exchanger core with alternating first and second fluid flow passages  20 ,  22  formed between the stacked plates  16 ,  17 . 
     Referring now to  FIG. 2 , an exploded view of the heat exchanger module  10  is shown. As illustrated, the stamped heat exchange plates  16 ,  17  each comprise a generally planar base portion  24  surrounded on all sides by a sloping edge wall  26 . The heat exchange plates  16 ,  17  are stacked one on top of another with their edge walls  26  in nested, sealed engagement. Each heat exchange plate  16 ,  17  is provided with four holes  28 ,  30 ,  32 ,  34  near its four corners, each of which serves as an inlet hole or an outlet hole for a heat exchange fluid as required by the particular application. Two holes  28 ,  30  are raised with respect to the base portion  24  of the plate  16  while the other two holes  32 ,  34  are formed in and are co-planar with the base portion  24 . The raised holes  28 ,  30  in one plate  16  align with and seal against the flat or co-planar holes  32 ,  34  of the adjacent plate  17  thereby spacing apart the heat exchange plates  16 ,  17  and defining the alternating the first and second fluid passages  20 ,  22 . Turbulizers  35  can be positioned between each of the plates  16 ,  17  in each of the first and second fluid passages  20 ,  22  to improve heat transfer, as is known in the art. Alternatively, rather than having individual turbulizers  35  positioned in each of the fluid passages  20 ,  22 , the plates  16 ,  17  may themselves may be formed with heat transfer augmentation features, such as ribs and/or dimples formed in the planar base portion of the plates  16 ,  17 , as is known in the art. The aligned, sealing holes  28 ,  30 ,  32 ,  34  in the stacked plates  16 ,  17  form a pair of first manifolds  36  (i.e. an inlet manifold and an outlet manifold) coupled to one another by fluid passages  20  for the flow of a first fluid through the heat exchanger and form a pair of second manifolds  38  (i.e. an inlet manifold and an outlet manifold) coupled to one another by fluid passages  22  for the flow of a second fluid through the heat exchanger  12 . If, for example, the heat exchanger module  10  is intended to be used as an oil heat exchanger (i.e. a transmission oil cooler or TOC), one of the first and second fluids can be oil while the other fluid can be a standard, known liquid for cooling (or heating) oil. 
     Top and bottom or end plates  40 ,  42  enclose the stack of heat exchange plates  16 ,  17  to form the heat exchanger  12 . Depending upon the particular application, the end plates  40 ,  42  are designed with a particular number of conduit openings, each in fluid communication with one of the pairs of first and second fluid manifolds  36 ,  38  for the inlet and outlet of the first and the second fluids into and out of the heat exchanger  12 . In the example shown, end plate  40  has two conduit openings  46 ,  48  formed therein, while end plate  42  has four openings  28 ,  30 ,  32 ,  34  (two of which are closed/sealed by adapter module  14 ) and generally has the same form as heat exchanger plates  16 ,  17  except that it may be slightly thicker than plates  16 ,  17 . 
     In the illustrated embodiment, inlet/outlet fittings  54 ,  56  are fixedly attached or brazed to conduit openings  46 ,  48  in the end plate  40  by means of a shim plate  43 . Top or end plate  40  can also be provided with additional fittings or mounting brackets  58 , as required, which fittings or mounting brackets  58  can be brazed to end plate  40  by means of shim plate  43 . 
     Heat exchangers of the type described above are generally known in the art and, for instance, described in U.S. Pat. No. 7,717,164, the teachings of which are incorporated herein by reference. Furthermore, the above-described heat exchanger  12  has been described for illustrative purposes and it will be understood that any suitable heat exchanger, as known in the art, may be used in the heat exchanger module  10  of the present disclosure. 
     Referring now to  FIGS. 1, 3, 4 and 5 , the adapter module  14  according to one exemplary embodiment of the present disclosure will now be described in further detail. In the subject embodiment, adapter module  14  is comprised of an adapter plate  60  and a shim plate  62 . Shim plate  62  is a relatively thin, soft braze clad aluminum sheet which allows the adapter plate  60  to be brazed directly to the end plate or bottom plate  42  of the heat exchanger  12 . The adapter plate  60  is typically machined aluminum and is substantially thicker than shim plate  62  and is also substantially thicker than heat exchange plates  16 ,  17 . Adapter plate  60  has a first surface  64  that, together with shim plate  62 , is brazed to one end, e.g. the bottom, of heat exchanger  12 . As shown in the drawings, heat exchanger  12  has a “footprint” corresponding to the area defined by the base portion  24  of the stacked heat exchange plates  16 ,  17 , the adapter module  14  being fixedly attached to the heat exchanger  12  within the footprint area of the heat exchanger  12 . In the subject embodiment, the adapter module  14  has at least a portion that extends beyond the footprint of the heat exchanger  12 , as will be described in further detail below. 
     Adapter plate  60  further defines a trough portion  66  in the first surface  64  thereof which, in combination with the shim plate  62 , defines a fluid transfer channel  68 . Fluid transfer channel  68  has one end that communicates with one of the fluid manifolds  38  in the heat exchanger via a conduit opening  70  in shim plate  62  positioned within the footprint of heat exchanger  12 , and another end that extends away from the heat exchanger in an extension portion or extension arm  69  of the adapter module  14 . Trough portion  66  has a fluid port  72  formed at the opposite end of the trough portion (i.e. outboard the footprint of the heat exchanger  12  in the extension portion  69  of the adapter module  14 ), the fluid port  72  being adapted to fit and be mounted directly to a corresponding fluid port in the housing of an automobile system component (i.e. an oil port on a transmission housing). Adapter plate  60  has another fluid opening or fluid port  76  formed therein which is aligned with a corresponding opening  78  formed in shim plate  62 . Fluid port  76  provides another direct fluid connection between one of the manifolds  38  in the heat exchanger  12  and a corresponding fluid port in the component housing. Accordingly, one of the fluids flowing through the heat exchanger will ultimately enter and exit the heat exchanger  12  through the adapter module  14 . The adapter plate  60  also has a plurality of bores  80  formed therein, each aligned with a respective bore or mounting hole provided on the component housing for receiving a fastening device (i.e. a bolt), to secure the heat exchanger module  10  to the housing. 
       FIG. 7  shows the heat exchanger module  10  mounted directly to the exterior of an illustrative embodiment of a transmission housing  11 . Therefore, in operation wherein the heat exchanger module  10  is a transmission oil cooler (TOC) mounted directly to the housing of a transmission  11 , the second fluid would be transmission oil that would exit the transmission housing and enter the heat exchanger module  10  through a fluid port on the transmission housing coupled directly to fluid port  76  in adapter plate  60 . The oil would enter the heat exchanger via opening  78  in the shim plate  62  and be distributed via inlet manifold  38  through fluid passages  22  to outlet manifold  38 . The transmission oil would then exit the heat exchanger  12  and enter the adapter module  14  through fluid port  70  in the shim plate  62 , travel through fluid transfer channel  68  in the adapter module  14  (or trough portion  66  in the adapter plate  60 ) and enter the transmission through the outboard fluid port  72  on the adapter module  14 , i.e. the fluid port that is outside the footprint of the heat exchanger  12  and is not in direct connection to one of the inlet/outlet manifold ports of the heat exchanger  12 . A suitable fluid for cooling (or heating) the transmission oil would also flow through the heat exchanger  12  through inlet and outlets  56 ,  58  coupled to the corresponding inlet and outlet manifolds  36  in a direction generally opposite to the flow of the transmission oil. Accordingly, it will be understood that the fluid transfer channel  68  and fluid port  72  provides for an indirect fluid connection between a fluid port located on the second surface of the adapter module  14  and one of the fluid manifolds within the heat exchanger since fluid port is at least partially outside the footprint of the heat exchanger  12 . 
     While a particular example of the fluids circuiting through the heat exchanger  12  has been described, it will be understood that this is not intended to be limiting and that variations depending upon the particular structure of the heat exchanger and/or the associated automobile system component may result in a different fluid pattern/circuit through the heat exchanger module  10  as would be understood by those skilled in the art. 
     While the adapter module  14  is shown as being a relatively flat structure wherein the plurality of bores  80  and the fluid ports are located generally in the same plane, it will be understood that the adapter module  14  can be modified, based on the particular application, to fit the outer surface of the automobile component housing to which it is intended to be fixed. More specifically, the extension portion or extension arm  69  of the adapter plate  60  can be sized and angled as needed to ensure that the adapter module  14  extends to the required location on the component housing to allow for the direct connection between the fluid ports  72 ,  76  (for example) on the adapter module  14  and the corresponding fluid ports on the component housing. Accordingly, the specific shape and/or size of the adapter module  14  is somewhat dependent upon the structure and corresponding mating surface(s) provided on the component housing. For instance, in the case of a transmission housing, the oil ports are typically spaced apart from each other over an area that is generally larger than the “footprint” of conventional heat exchangers or oil coolers traditionally used for this purpose. The exemplary embodiment of the heat exchanger module  10  described above addresses this issue by brazing the heat exchanger directly to the adapter module  14  provided with the extension portion  69  that allows for “outboard” fluid connections. 
     Furthermore, while the adapter module  14  described above is generally a flat structure, it will be understood that the adapter module  14  can also be curved to accommodate a curved outer surface of the housing. As well, the adapter module  14  can be formed with projections and/or protrusions extending from the second surface thereof to provide various contact points between the adapter module  14  and various surfaces on the outer housing. 
     As shown in  FIG. 3B , the adapter plate  60  does not need to cover the entire “footprint” or base area of the heat exchanger  12 , therefore the bottom or end surface of heat exchanger module  10  may be a tiered or multi-level surface. In other embodiments (as shown in  FIG. 3A ), the adapter plate  60  may cover the entire “footprint” or base area of the heat exchanger  12 , the bottom surface thereof being formed as a multi-level surface. 
     Referring now to  FIGS. 2, 4 and 6 , the second surface or mounting interface  65  of the adapter module  14  with fluid ports  72 ,  76  is shown in further detail. A sealing groove  82  is provided around each fluid port  72 ,  76  for receiving a seal or sealing means  83 , such as an o-ring or any other suitable means known in the art. The sealing means  83  provides for a fluid tight connection between the heat exchanger module  10  and the housing of the automobile system component to which it is fixed, such as the transmission housing. In prior art structures wherein a heat exchanger with a stamped base plate or mounting plate is fixed to a plastic cast or moulded structure which, in turn, is mounted to the automobile system component housing, sealing interfaces are required between both the heat exchanger and the plastic structure, and between the plastic structure and the automobile system component. Accordingly, two independent sets of seals are required giving rise to two potential points of failure/leakage, both requiring testing. In the subject embodiment, only one set of seals is required between the heat exchanger module  10  and the housing of the component to which it is fixed. 
     While the adapter module  14  described above and shown in the drawings has only one fluid channel  68  and two fluid ports  72 ,  76 , it will be understood that the adapter module can be modified to include additional fluid channels and/or fluid ports depending upon the particular application. As well, the adapter module can be modified so as to house additional components such as, for example, one or more control valve(s) (i.e. thermal bypass valve(s)) or filters. 
     It will be understood that the heat exchanger module  10  described above offers both a reduction in overall component height and weight as compared to various other heat exchanger mounting structures. More specifically, as mentioned above, the adapter module  14  is brazed directly to the bottom or end plate  42  of heat exchanger  12  without the use of a conventional heat exchanger base plate or mounting plate thereby decreasing the overall package height and weight of the heat exchanger module  10 . Manufacturing costs may also be reduced due to the elimination of the conventional base plate or mounting plate. As well, since the adapter module incorporates fluid transfer channel(s) and fluid ports, seals and attaching holes all formed therein, the use of a secondary plastic or heavy-duty cast or moulded adapter structure typically used for mounting a heat exchanger to an automobile system component is not required which also reduces the overall package height and weight of the component. Furthermore, by having an adapter module  14  that extends beyond the footprint of the heat exchanger imparts a degree of flexibility or adjustability to the heat exchanger module  10  since fluid ports and/or fluid connection points can be positioned outside the footprint of the heat exchanger. 
       FIG. 7A  illustrates an alternate embodiment or variation of the adapter module  14  described above wherein the adapter module  14  is comprised of a series of layered plates. More specifically, rather than being formed of a single adapter plate  60  and a corresponding shim plate  62 , the adapter module  14  in this embodiment is comprised of an adapter plate or channel plate  60  that is sandwiched between shim plate  62  and base plate  63 , the base plate  63  being attached to the second or bottom surface of the adapter or channel plate  60  either directly or by means of an intermediate shim plate  62 ′, and having a cylindrical projection  21  extending from its bottom surface. The intermediate shim plate  62 ′ mimics the shape of the adapter plate  60  and the base plate  63  with all the same corresponding openings formed therein and serves to braze the two together. In this embodiment, the adapter plate  60  is formed with a trough portion  66  in the form of a cut-out, the shim plate  62 , adapter plate  60  and base plate  63  together forming the fluid transfer channel  68 . The layered plate structure of the adapter model  14  shown in  FIG. 7A  may offer manufacturing advantages and/or cost savings over the embodiment shown in  FIGS. 1-7  since the adapter module  14  is comprised of a series of stamped or formed plates rather than a more complex machined singular or unitary adapter plate. 
     Referring now to  FIGS. 8 and 9 , another exemplary embodiment of the heat exchanger module  100  according the present disclosure will now be described, wherein similar reference numerals, increased by a factor of 100, are used to denote similar features. In the subject embodiment, the heat exchanger  112  comprises a base plate  184  fixedly attached to one end thereof, having inlet/outlet fittings  154 ,  156  and mounting bracket  158 . The base plate  184  may be a stamped plate that is substantially thicker than heat exchanger plates  116 ,  117 . The base plate  184  is typically brazed directly to the end of the heat exchanger  112  or is brazed to the heat exchanger  112  by means of an intermediate shim plate (not shown). Adapter module  114  is a fully enclosed module with a fluid transfer channel formed therein. In the subject embodiment, the adapter module  114  has a first set of bores  181  for aligning with corresponding bores provided in the base plate  184  and a second set of bores  180  for aligning with corresponding bores on the housing of the automobile system component. As well, in the subject embodiment, both the first surface and the second surface  164 ,  165  of the adapter module  114  are provided with sealing grooves  182  (first surface grooves no shown) around each of the fluid ports or conduit openings  172 ,  176  to provide seals (i.e. o-rings) between the two separate mounting interfaces. 
     Once again, while the adapter module  114  described above and shown in the related drawings has only one fluid channel  168  and two fluid ports  172 ,  176 , it will be understood that the adapter module  114  can be modified to include additional fluid channels and/or fluid ports depending upon the particular application. 
     Referring now to  FIGS. 10 and 11 , another exemplary embodiment of the heat exchanger module  200  according to the present disclosure will now be described, wherein similar reference numerals, increased by a factor of 200, are used to denote similar features. 
     In particular applications where more complex fluid connections, fluid channels and/or additional features/components (i.e. valves, filters, etc.) are required, the costs associated with a machined or cast aluminum structure for an adapter module  14 ,  114  as described above in connection with  FIGS. 1-9 , may be undesirable. In such instances, the heat exchanger module  200  is comprised of a heat exchanger  212  and an adapter module  214 , wherein the adapter module  214  is comprised of an adapter plate  260  and mounting plate  290 . Adapter plate  260  has a base in the form of a shim plate  292  that, in the illustrated embodiment, generally corresponds in size and shape to the footprint of the heat exchanger  212 , although various other configurations may be used. Individual components and/or adapters  294  for controlling or routing/transferring fluid from the heat exchanger  212  to the automobile system component, such as a transmission, (or vice versa), are individually brazed to one side of shim plate  292 . The shim plate  292  is provided with fluid openings therein (not shown) for allowing fluid communication between the fluid manifolds in the heat exchanger  212  and the various components and/or adapters  294 . The various components and/or adapters  294  that provide fluid connections to the automobile system component are positioned on shim plate  292  and may be oriented to allow for direct connection between the component and/or adapter  294  and the corresponding fluid port on the component housing. For instance, to allow for direct connection to the housing, the adapters  294  would have to be structured and arranged on shim plate  292  to provide fluid openings at their free end that are vertically or axially aligned with the corresponding fluid ports on the component housing. Otherwise, additional connectors and/or tubing would be required to connect the fluid ports on the component housing to the corresponding fluid openings provided at the free ends of the adapters  294 . When the adapters  294  are arranged for direct connection to the fluid ports, by directly brazing the components/adapters  294  to the shim plate  292  and heat exchanger  212 , only one set of seals is required between the adapter plate  260  and automobile system component housing interface(s). 
     While the adapters  294  shown in  FIGS. 10 and 11  only extend slightly beyond the footprint of the heat exchanger  212 , it will be understood that the size and shape of the adapters  294  can be varied based on the particular application to ensure that fluid ports/connections are provided at the appropriate locations. Alternatively, as mentioned above, additional tubing and/or connectors may be used to connect to the fluid ports on the component housing to the corresponding fluid ports/openings of the corresponding component/adapter  294 . 
     In order to secure the adapter module  214  described above to the outer surface of the automobile system component housing, mounting plate  290  is provided. Mounting plate  290  is brazed to shim plate  292  and is configured to fit between the various components/adapters  294  that are also brazed to shim plate. Mounting plate  290  is provided with a plurality of bores  296  for aligning with corresponding mounting holes on the component housing. Mounting plate  290  can be adapted and configured so that the bores  296  are provided in various planes, some of which may have various axial orientations thereby providing a great deal of flexibility to adapt the heat exchanger module  200  to various component housings. 
     The exemplary embodiment described above in connection with  FIGS. 10 and 11  is particularly suited for applications wherein the automobile system component is a transmission and the heat exchanger is a transmission oil cooler (TOC) since the fluid connections/adapters  294  are brazed directly to the base of the heat exchanger  212  by means of shim plate  292  without the use of a conventional, stamped heat exchanger base plate or mounting plate. Since the cyclic loads/pressures associated with the transmission are somewhat less than those associated with other components (i.e. an engine housing) the added structural rigidity provided by a conventional base plate or mounting plate is not necessarily required. This allows for the direct brazing of the various adapters  294  to the heat exchanger  212  and allows for the direct mounting of the heat exchanger module  200  to the automobile system component housing while offering a reduction in overall package height since the base plate and plastic adapter structure are eliminated and since the adapters  294  can be selected to suit/fit the counter surface on the transmission housing. 
     Another exemplary embodiment of the heat exchanger module  300  according to the present disclosure is shown in  FIGS. 12-15  and is described in further detail below wherein similar reference numerals increased by a factor of 300 have been used to identify similar features. 
     As shown in  FIG. 12 , heat exchanger module  300  is comprised of a heat exchanger  312  fixedly attached to an adapter module  314 . In the subject embodiment the heat exchanger module  300  is particularly suited for direct mounting to the exterior of an automobile engine housing (or casing) and, therefore, functions as an engine oil cooler (EOC). However, it will be understood that the heat exchanger module  300  can be adapted for other purposes or applications as discussed above in connection with the other exemplary embodiments disclosed herein. 
     In the subject embodiment, the adapter module  314  is a layered plate structure and is comprised of a first adapter plate  360  that is brazed directly to the base of the heat exchanger  312  by means of a first shim plate  362 . A second adapter plate  360 ′ is brazed directly to the opposite surface of the first adapter plate  360  by means of a second shim plate  362 ′. Accordingly, the first adapter plate  360  is essentially sandwiched between first and second shim plates  362 ,  362 ′. All of the plates  362 ,  360 ,  362 ′,  360 ′ used to form adapter module  314  are relatively simple in structure and relatively easy to manufacture, as compared to some known, conventional complex casting adapter structures. 
     First adapter plate  360  is a relatively thick, machined or formed aluminum plate that offers the required structural rigidity for directly mounting the heat exchanger module  300  to the engine housing, while shim plates  362 ,  362 ′ are substantially thinner than adapter plate  360  and are made of braze clad aluminum. The first adapter plate  360  includes trough portion  366  in the form of a cut-out within the first adapter plate  360 . The cut-out or trough portion  366  extends into the extension arm or extension portion  369  of the adapter module  314 . The cut-out or trough portion  366  in the first adapter plate  360 , together with the first and second shim plates  362 ,  362 ′ form the at least one fluid transfer channel  368  in the adapter module  314  as the shim plates  362 ,  362 ′ essentially enclose the cut-out or trough portion  366  to form the fluid transfer channel  368 . As in the previously described embodiments, one end of fluid transfer channel  368  communicates with one of the fluid manifolds in heat exchanger  312  (i.e. the oil inlet manifold, for example) via a corresponding opening (not shown) formed in the first shim plate  362 . The other end of the fluid transfer channel  368  extends into the extension portion  369  of the adapter module  314  and is adapted for fluid connection to a corresponding fluid port on the automobile system component housing (i.e. the engine oil outlet on the engine housing). The extension portion  369 , therefore providing an indirect fluid connection (i.e. at least partially outside the boundary of or the footprint of the heat exchanger core) to one of the fluid manifolds within the heat exchanger. 
     First adapter plate  360  is also provided with two additional fluid openings  304 ,  306  each of which is in fluid communication with separate ones of the fluid manifolds in heat exchanger  312 . In the specific embodiment illustrated, fluid opening  306  communicates with the oil outlet manifold of heat exchanger  312 , via a corresponding opening (not shown) formed in the first shim plate  362  and is coupled to the corresponding fluid port (i.e. the oil inlet port) on the engine housing via corresponding openings in the both the second shim plate  362 ′ and second adapter plate  360 ′ (see opening  376 ). Fluid opening  304  communicates with the coolant inlet manifold from heat exchanger  312  via a corresponding opening (not shown) formed in the first shim plate  362  and is coupled to a corresponding fluid port (i.e. the coolant inlet port) on the engine housing via corresponding openings in the second shim plate  362 ′ and the second adapter plate  360 ′ (see opening  308 ). 
     While a particular embodiment of the fluid circuiting through heat exchanger module  300  has been described, it will be understood by those skilled in the art that this is not intended to be limiting and that variations to the exact fluid circuits through the heat exchanger module  300  and the number and location of the fluid ports provided on the heat exchanger  312  and/or plates of the adapter module  314  will depend on the particular structure of the heat exchanger  312  and the particular application of the heat exchanger module  300 . 
     As shown in the drawings, the second adapter plate  360 ′ is generally thinner than the first adapter plate  360  and generally corresponds to the shape of the first adapter plate  360 . The second adapter plate  360 ′ includes at least one cylindrical projection  321  that extends from the bottom or second surface  365  of the second adapter plate  360 ′, wherein the open end of the cylindrical projection  321  serves as outboard fluid port  372  of the adapter module  314 . The cylindrical projection  321  is adapted to house a valve component  323 , such as an anti-drain valve or a thermal bypass valve, to control the flow of one of the fluids (i.e. engine oil) to the heat exchanger  312 . The valve component  323  may be threadingly engaged in the cylindrical projection  321  or housed within the cylindrical projection in any suitable manner as known in the art. For instance, the valve component  323  may be press-fit into the cylindrical projection  321  and secured or clamped in place between the extended shim plate  362  and the cylindrical projection  321  by means of indentations that are formed in the lower edge of the cylindrical projection  321  after assembly. 
     In some embodiments, the cylindrical projection  321  is formed directly within the second adapter plate  360 ′ (as shown in  FIG. 14 ) and in other embodiments the cylindrical projection  321  can be formed from a separate component that is brazed (by means of a shim ring  321 ′) or otherwise attached to the outer surface of the second adapter plate  360 ′ in alignment with a corresponding opening  372 ′ formed in the adapter plate  360 ′ to form the outboard fluid port  372  as shown, for example, in  FIG. 16 . 
     The first and second adapter plates  360 ,  360 ′ are also both provided with a plurality of bores  380  around the perimeter thereof, each of which align with corresponding openings in the automobile system component housing (i.e. the engine housing) and are adapted for receiving a fastening device (such as a bolt) for securing the heat exchanger module  300  to the component housing. 
     While the adapter module  314  described above and shown in the related drawings has only one fluid transfer channel  368  and has three fluid ports  372 ,  376 ,  308  formed on its bottom or mounting surface  365 , it will be understood that the adapter module  314  can be modified to include additional fluid channels and/or a different arrangement of fluid ports depending upon the particular application. As well, the adapter module  314  can be further modified so as to house additional components such as, for example, additional valve components and/or filters. 
     Furthermore, it will be understood that while the embodiment described above in connection with  FIGS. 12-16  has been described in the context of an engine oil cooler being mounted directly to the exterior of the engine housing, the adapter module  314  may be modified and/or adapted for use for other applications. For instance, in the embodiment shown, the first adapter plate  360  is a relatively thick plate and provides a certain degree of structural rigidity necessary for mounting heat exchangers to engine housings. However, the thickness and/or material of the plate could be varied in instances where the same degree of structural rigidity is not necessarily required. Additionally, in some instances it may be appropriate to eliminate the second shim plate  362 ′ when the second adapter plate  360 ′ can be formed of braze-clad material. 
     Referring now to  FIGS. 17-21 , there is shown another exemplary embodiment of a heat exchanger module  400  according to the present disclosure Heat exchanger module  400  is similar in structure to the heat exchanger module  300  described above in connection with  FIGS. 12-16  in that it too has a generally layered plate structure and is particularly suited for direct mounting to the exterior of an automobile engine housing (or casing) and, therefore also functions as an engine oil cooler (EOC) in the subject embodiment. However, it will be understood that the heat exchanger module  400  can be adapted for other purposes or applications in accordance with the scope of the present disclosure. 
     As shown in the drawings, heat exchanger module  400  is comprised of heat exchanger  412  that is secured/attached to adapter module  414 . The adapter module  414  is a layered plate structure comprising a first adapter plate or channel plate  460  and a second adapter plate or base plate  460 ′. The first adapter plate or channel plate  460  is brazed to an end of the heat exchanger  412  by means of a first shim plate or extended shim plate  462  (since it extends beyond the footprint of the heat exchanger  412  to enclose the trough portion  466 ). The second adapter plate  460 ′ is brazed to the second or bottom surface of the first adapter plate  460  either directly or by means of a second or intermediate shim plate  462 ′. 
     The first adapter plate or channel plate  460  is a relatively thick machined, stamped or formed aluminum plate. The second adapter plate  460 ′ is a similarly formed plate although the second adapter plate or base plate  460 ′ may not be as thick as the first adapter plate  460 . Together, the first and second adapter plates  460 ,  460 ′ offer the structural rigidity required in order to directly mount the heat exchanger modules  400  to the engine housing. The first and second shim plates  462 ,  462 ′ are substantially thinner than the adapter plates  460 ,  460 ′, as is generally understood in the art and are typically made of braze clad aluminum for brazing the first and second adapter plates  460 ,  460 ′ together in their layered relationship to form the adapter module  414 . 
     The first adapter plate or channel plate  460  is larger than the footprint of the heat exchanger  412  so as to provide an extension arm or extension portion  469  that extends beyond the perimeter of the heat exchanger core. A trough portion  466 , in the form of a cut-out, is formed in the first adapter plate or channel plate  460  and extends into the extension arm or extension portion  469  of the first adapter plate  460 . When the plates are arranged in their stacked or layered arrangement, the first adapter or channel plate  460  together with the second adapter plate or base plate  460 ′ and first shim plate  462  form a first fluid transfer channel  468  as the first shim plate  462  and the second adapter plate  460 ′ essentially enclose the cut-out or trough portion  466  in the first adapter plate  460  to form the first fluid transfer channel  468 . As in the previously described embodiments, one end of the first fluid transfer channel  468  communicates with one of the inlet/outlet manifolds of the heat exchanger  412 . In the subject embodiment where the heat exchanger module  400  is adapted for use as an EOC mounted directly on the engine housing, the first fluid transfer channel  468  communicates with the oil inlet manifold to the heat exchanger  412 . 
     The second adapter plate or base plate  460 ′ generally has the same shape as the first adapter plate  460  and has a primary or main fluid opening  461  formed therein which communicates directly with the portion of the first fluid transfer channel  468  that extends into the extension portion  469  of the adapter module  414 . In the subject embodiment, the main fluid opening  461  is fitted with a separate cylindrical projection  421  that is attached or otherwise fixed to the second adapter plate  460 ′ with the cylindrical projection  421  extending away from the bottom thereof. The free end  472  of the cylindrical projection  421  is adapted to fit directly with or mount directly to the engine oil outlet on the engine housing. A valve component  423  in the form of an anti-drain valve fits within the cylindrical projection  421  which serves as the oil inlet to the adapter module  414  in order to control the flow fluid into/out of the adapter module  414 . More specifically, when the valve component  423  is in the form of an anti-drain valve, the valve component  423  is intended to allow for one-way flow, against gravity, into the adapter module  414  through fluid opening  472 . Accordingly, the anti-drain valve serves to prevent the fluid from flowing out of the adapter module  414  through the same fluid opening  472 , i.e. the oil inlet into the adapter module  414 , with gravity. 
     The first shim plate  462  is positioned on top of the first adapter plate  460  and generally has the same shape as the bottom of the heat exchanger  414  but has a portion  469 ′ that extends beyond the footprint of the heat exchanger core in order to enclose the trough or cut-out portion  466  to form the first fluid transfer channel  468 . Accordingly, the first shim plate  462  can also be referred to as an extended shim plate since it extends beyond the boundary of or the footprint of the heat exchanger. The first shim plate is also provided with a fluid opening  465  for providing direct fluid communication between the oil inlet manifold in heat exchanger  414  and the fluid transfer channel  468 . 
     The first shim plate  462 , the first adapter plate  460 , the intermediate shim plate  462 ′ (if used) and the second adapter plate  460 ′ are all also provided with at least two additional fluid openings  404 ,  406  which all align with each other when the plates are arranged in their stacked or layered arrangement. The aligned fluid openings  404 ,  406  provide for fluid communication between respective inlet/outlet manifolds associated with heat exchanger  414 . In the specific, illustrated embodiment, fluid opening  406  is in direct communication with the oil outlet manifold of heat exchanger  412  while fluid opening  404  is in direct communication with the coolant inlet manifold in the heat exchanger  414 . Therefore, when the heat exchange module  400  is mounted to the engine housing, the fluid openings  461 ,  406 ,  404  on the bottom or interface surface of the adapter module  414  allows for fluid communication between the heat exchanger  412  and the engine to allow for engine oil to enter/exit the heat exchanger module  400  and be returned to the engine housing and also allows for engine coolant to exit the engine housing and enter the heat exchanger module  400  before being directed elsewhere in the system via the coolant outlet located on the top of the heat exchanger  412 . 
     In the illustrated embodiment, the adapter module  414  further provides for both engine oil and coolant bypass channels to allow engine oil that does not enter the heat exchanger  412  to drain back into the engine housing and to allow engine coolant to bypass the heat exchanger  412  and be directed directly to the outlet manifold of the heat exchanger  412 . By providing for both oil and coolant bypass flows within the adapter module  414 , the heat exchanger module  400  can be tuned or adjusted to changes in fluid pressure within the system. 
     In order to allow for engine oil to bypass the heat exchanger  412  and be returned to the engine housing, the adapter module  414  is provided with a first bypass opening  481  in fluid communication with the first fluid transfer channel  468  (as shown more clearly in  FIG. 20 ). The first bypass opening  481  is therefore formed in the second adapter plate or base plate  460 ′ spaced apart from the main fluid opening  461  and in-line with the opening to the oil inlet manifold of heat exchanger  412 . The first bypass opening  481  is therefore in communication with the first fluid transfer channel  468  directly opposite to the oil inlet manifold of the heat exchanger  412 . When the heat exchanger module  400  is mounted in face-to-face contact with the engine housing at the interface surface, the bypass opening  481  is arranged in vertical alignment with the oil inlet opening on the engine housing. 
     In order to provide for coolant bypass flow within the heat exchanger module  400 , the adapter module  414  is provided with a second fluid transfer channel  483  (see  FIG. 21 ) in order to provide fluid communication between the inlet and outlet manifolds for the second fluid flowing through the heat exchanger  412  which, in the illustrated embodiment, is engine coolant. The second fluid transfer channel  483  allows engine coolant to bypass the heat exchanger  412  and instead be directed directly to the outlet manifold of the heat exchanger  412  (without having to flow through the heat transfer fluid passageways formed therein) and out of the heat exchanger  412  through the outlet fitting located at the top of the heat exchanger  412 . Accordingly, the second fluid transfer channel  483  provides a form of bypass channel permitting the coolant to exit the heat exchanger  412  and be directed elsewhere in the system without having to flow through the heat exchanger  412 . The second fluid transfer channel  483  is formed by a second trough portion  485  formed in the first or extended shim plate  462  with the second trough portion  485  extending from the fluid opening  404  to the opposed end of the shim plate  462 , the opposed end of the second trough portion therefore being aligned with the coolant outlet manifold of heat exchanger  412 . When the heat exchanger  412  is attached to the adapter module  414 , the lowermost plate  42  of the heat exchanger  412  essentially encloses the second trough portion formed in the adapter module  414 , thereby forming the second fluid transfer channel  483 . Accordingly, in this embodiment, the adapter module  414  not only provides for fluid communication between the automobile system component housing (i.e. the engine housing) and the heat exchanger  412 , but also provides for fluid communication between a pair of corresponding inlet/outlet manifolds for one of the heat exchange fluids flowing through the heat exchanger  412 . 
     In order to ensure an appropriate seal at the interface between the heat exchanger module  400  and the automobile system component housing (i.e. the engine housing), the adapter module  414  further comprises a gasket plate  487  affixed to the bottom surface of the second adapter plate or base plate  460 ′. The gasket plate  487  is formed with sealing members  488  that essentially encircle or surround the fluid passageways and/or openings provided at the interface surface between the engine housing and the heat exchanger module  400 . 
     Furthermore, as in the previously described embodiments, the adapter module  414  is provided with a plurality of openings  480  formed at spaced apart intervals around the perimeter of the adapter module  414  each for receiving a fastening device for securing the heat exchanger module  400  to the automobile system component housing. Accordingly, it will be understood that the openings  480  are formed by corresponding, axially aligned openings in each of the plates that make up the layered plate structure of the adapter module  414 . 
     In use, when the heat exchanger module  400  is positioned on the outer surface of the engine housing, engine oil exits the engine housing and enters the adapter module  414  via fluid opening  461  through anti-drain valve  423 . The engine oil then travels through the first fluid transfer channel  468  and either enters the heat exchanger  412  oil inlet manifold through the corresponding opening formed in the first shim plate  462  or exits the adapter module  414  through the bypass opening and is returned to the engine housing through the oil inlet opening formed in the engine housing. It will be understood that appropriate fluid communication channels are provided in the interface surface on the engine housing, based on the specific design of the engine housing, to enable the engine oil to flow back into the engine housing and that both the adapter module  414  and the interface surface can be adapted for specific applications. 
     For engine oil that enters heat exchanger  412  through the adapter module  14  (as opposed to the “bypass” oil that is returned to the engine housing), the oil travels through the heat exchanger  412  and exits the heat exchanger  412  through the oil outlet manifold on the bottom of the heat exchanger and is returned to the engine housing through the engine oil inlet opening provided on the housing via the adapter module  414 . As for the second fluid, i.e. engine coolant, flowing through the heat exchanger  412 , this fluid exits the engine housing and enters the adapter module  414  and is directed either to the coolant inlet manifold in the heat exchanger  412  via fluid opening  404 , or travels through the second fluid transfer channel  483  formed in the adapter module  414  to the outlet manifold of the heat exchanger  412  effectively bypassing heat exchanger  412 . Both coolant streams, i.e the coolant that flows through the heat exchanger  412  and the “bypass coolant” exits the heat exchanger  412  through the coolant outlet provided on the top of the heat exchanger  412 . 
     By providing the bypass opening and the second fluid transfer channel within the adapter module  414 , fluid pressure drops within the heat exchanger module  400  can be tuned to appropriate levels based on the particular application or system requirements to ensure that heat transfer performance associated with the heat exchanger module is not adversely affected by changes in fluid pressure. 
     While a particular embodiment of the fluid circuiting through heat exchanger module  400  has been described, it will be understood by those skilled in the art that this is not intended to be limiting and that variations to the exact fluid circuits through the heat exchanger module  400  and the number and location of the fluid ports provided on the adapter module  414  will depend on the particular structure of the heat exchanger  412  and the particular application of the heat exchanger module  400 . 
     Furthermore, while the present invention has been illustrated and described by the various exemplary embodiments referred to in the present disclosure, it will be understood that the present disclosure is not intended to be limited to the exemplary embodiments and details shown herein since it will be understood that various omissions, modifications, substitutions, etc. may be made by those skilled in the particular art without departing from the spirit and scope of the present disclosure.