U.S. patent application number 11/604526 was filed with the patent office on 2007-06-14 for multi-storage isolator with non-perpendicular rib.
This patent application is currently assigned to Valeo, Inc.. Invention is credited to Mohammed Ansari, Peter Jing-Lug Chen, Daniel R. Domen.
Application Number | 20070131384 11/604526 |
Document ID | / |
Family ID | 38138108 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070131384 |
Kind Code |
A1 |
Domen; Daniel R. ; et
al. |
June 14, 2007 |
Multi-storage isolator with non-perpendicular rib
Abstract
Isolator assemblies and isolators between separate parts or
components, and, particularly, multi stage isolators, especially,
isolators useful in automotive applications are described. The
isolators have non perpendicular ribs, made of the same material as
the isolator body, which can flex when in a deflection phase or
stage, or can compress in a compression phase or stage, thus
allowing for reduced wear and/or longer life for both the isolator
and the parts and components separated thereby.
Inventors: |
Domen; Daniel R.; (Rochester
Hills, MI) ; Chen; Peter Jing-Lug; (Rochester,
MI) ; Ansari; Mohammed; (Rochester Hills,
MI) |
Correspondence
Address: |
Valeo, Inc.;Intellectual Property Department
4100 North Atlantic Boulevard
Auburn Hills
MI
48326
US
|
Assignee: |
Valeo, Inc.
Auburn Hills
MI
|
Family ID: |
38138108 |
Appl. No.: |
11/604526 |
Filed: |
November 27, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60740983 |
Nov 30, 2005 |
|
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|
Current U.S.
Class: |
165/67 |
Current CPC
Class: |
F28F 9/002 20130101;
F28F 2265/30 20130101 |
Class at
Publication: |
165/067 |
International
Class: |
F28F 9/00 20060101
F28F009/00 |
Claims
1. An isolator of a generally uniform stiffness for use between
parts or components wherein the isolator is made of a single
durometer material and has at least one non-perpendicular rib.
2. An isolator as in claim 1, wherein the isolator comprises at
least two portions, at least one portion having the at least one
non-perpendicular rib.
3. An isolator, as in claim 2, wherein at least one portion is a
compression portion and wherein at least one portion is a
deflection portion.
4. An isolator as in claim 2, wherein at least one portion is a
deflection portion, and wherein the at least one portion having the
at least one non-perpendicular rib is found on the deflection
portion.
5. An isolator as in claim 4, having at least two non-perpendicular
ribs on the deflection portion, and wherein the at least one other
portion is a compression portion.
6. An isolator as in claim 5, wherein the isolator form part of an
isolation system of at least two other components, each adjacent to
one another, and at least one non-perpendicular, rib is at least
partially deflected at low inertial load conditions at the time of
contact with the adjacent component in the isolation system.
7. An isolator as in claim 5, further comprising a hollow.
8. An isolator as in claim 7, wherein at least one rib, in
compression, nests in the hollow.
9. An isolator, as in claim 8, having at least two hollows and
wherein at least one of the at least two non-perpendicular ribs
nests completely in the at least one hollow.
10. An isolator, as in claim 7, having at least two hollows and
wherein each of the at least two non-perpendicular ribs rests in a
hollow.
11. An isolator, as in claim 8, wherein at least one of the at
least two ribs is a curved rib.
12. An isolator, as in claim 5, wherein the at least two non
perpendicular ribs slow the initial acceleration of the adjacent
component as it moves closer towards the contact surface.
13. An isolator, as in claim 7, wherein at least one of the
non-perpendicular ribs is deflected upon low inertia contact, and
wherein the at least one non-perpendicular rib deflects, at least
partially, into the hollow, and, thereafter, nests in the hollow
when fully deflected under high inertia contact conditions.
14. An isolator and heat exchanger assembly, having an isolator as
in claim 5, wherein at least one first part or component is a heat
exchanger or portion of a heat exchanger and at least one second
part or component is a part or component of, or a portion of a part
or component of, a motor vehicle.
15. An isolator and heat exchanger assembly, as in claim 14,
wherein the at least one first part is a heat exchanger or a
portion of a heat exchanger and wherein the at least one second
part is a mounting frame or portion of a mounting frame of an
automotive vehicle.
16. An isolator and component assembly comprising: an isolator
having at least one wall; at least one non-perpendicular wiper rib
forming part of the at least one wall; a component having a
component contact surface facing an isolator wall; wherein the
isolator is made of a single durometer material of generally
uniform stiffness and wherein the isolator has at least one wall in
alignment with an adjacent component contact surface.
17. An isolator and component assembly, as in claim 16, wherein the
component contact surface is adjacent to the at least one wall.
18. An isolator and component assembly, as in claim 18, wherein the
at least one non-perpendicular wiper rib has length of at least two
time its average thickness.
19. An isolator and component assembly, as in claim 18, wherein the
isolator wall aligned to the adjacent component contact surface is
in contact with the at least one rib, and wherein the at least one
wiper rib is non-perpendicular to the tangential adjacent component
contact surface or the isolator wall.
20. An isolator and component assembly, as in claim 18, wherein the
isolator wall aligned to the adjacent component contact surface is
in contact with at least one wiper rib , and wherein the at least
one wiper rib is non-perpendicular to the adjacent component
contact surface and the isolator wall.
21. An isolator and component assembly, as in claim 16, having at
least one hollow in a portion of the isolator, and having two or
more wiper ribs, wherein the wiper ribs are oriented such that a
load applied to the contact surface causes the at least one or more
ribs to be deflected into the hollow.
22. An isolator and component assembly as in claim 20, wherein the
depth of the hollow is approximately equivalent to the depth of the
at least one wiper rib.
23. An isolator and component assembly, as in claim 22, wherein the
at least one wiper rib, when completely deflected, nests in the
hollow.
24. An isolator and component assembly, as in claim 23, wherein the
wiper rib and adjacent isolator surface outside of the hollow, form
an approximate uniform contact surface such that a plane can be
drawn that is approximately flat when nested in the hollow.
25. An isolator and component assembly, as in claim 22, wherein the
at least two wiper ribs, when deflected into the hollow, are, at
the compression phase at a much slower rate such that the
displacement occurs more slowly with decreasing load.
26. An isolator and component assembly, as in claim 25, wherein the
two wiper ribs are adjacent to one another, and the length of each
wiper rib is such that the free end of each wiper rib has
approximately the same thickness as its adjacent wiper rib.
27. An isolator and component assembly, as in claim 26, wherein the
two wiper ribs, when fully deflected, are of a thickness such that
the two wiper ribs and the adjacent isolator surfaces, form an
approximate uniform planer contact surface.
28. A heat exchanger assembly comprising: a heat exchanger; an
isolator and component assembly; and at least one isolator mount,
wherein the isolator and component assembly comprises at least one
isolator having a wiper rib and a hollow, and wherein the wiper rib
is a non-perpendicular wiper rib.
29. A heat exchanger assembly, as in claim 28, having at least two
wiper ribs.
30. A heat exchanger assembly as in claim 28, having at least two
isolators.
31. A heat exchanger assembly as in claim 30, having at least two
isolator mounts.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to isolators, and, in
particular, isolators useful in automotive applications, to reduce
undesirable contact or impact, and/or its associated noise, between
various parts or components of the automotive vehicle.
BACKGROUND OF THE INVENTION
[0002] Isolators are useful in a number of applications, especially
where vibration or other movement might occur between two devices,
parts or portions of devices, components or parts. Such vibration
or movement can cause contact issues, as well as noise issues
related to undesired contact or impact. Particularly in assemblies
where devices, components or parts must be mounted together or in
close proximity to one another, undesirable contact may occur, and
isolators have, as one of their functions, the function of
preventing or modulating undesirable contact in such a manner that
it either becomes a non-harmful contact, or even an advantageous
one.
[0003] Isolation can occur in numerous stages or steps. Multi-stage
isolation is traditionally achieved in the same isolator or
isolator pad by over-molding different density materials or by
thinning specific elastics areas called `thinning webs` between
larger elastic areas.
[0004] Isolators can be made from elastic material, and, thus, can
have different levels of stiffness. An isolator, for example, may
be of a single stiffness. Isolators may also be made via various
processes. An isolator, for example, may be made from a single
molded process.
[0005] Isolators have been found to be particularly useful in
automotive applications. One such application is that of heat
exchanger assemblies, particularly where such assemblies are
mounted to vehicles, and, in particular, automotive vehicles. In
such automotive applications, heat exchanger assemblies are often
mounted either as a single unit or as a group in, for example,
parts or components of cooling module assembly.
[0006] In general automotive applications, vibration and other
movements are felt throughout various areas of the automobile,
particularly when the automobile is moving in the lateral or
vertical sense. Otherwise stated, a motor vehicle, when either
moving forward or backward, or when being transported in numerous
directions, or even when idling with the motor operation, is
subject to movement that may cause various parts or features of the
automobile to contact one another. A heat exchanger assembly,
and/or its component/parts, may contact or collide with other
parts, components or portions of other assemblies or the frame of
the automobile, and lead to potential damage to either the heat
exchanger, the heat exchanger assembly, or other parts of the
vehicle itself. This can be particularly disturbing due to the
current trend of reducing the amount of materials and the type of
materials used in component parts both of the automobile itself and
the heat exchanger in particular. In the case of heat exchangers,
for example, materials can account for more than half of the total
cost of the exchanger. Such exchangers are, therefore, being made
of materials that are of the minimal thickness possible--however,
such thin metal and plastic materials often cannot withstand the
impact stress which can be transmitted through a motorized vehicle
frame that occurs while driving on rough roads or making sudden
stops or sharp turns. Isolators, correctly designed, reduce
potential damage to the heat exchanger assembly under impact or
contact stress conditions.
[0007] In any system where movement may cause undesired impact or
contact between parts or devices, three elements are often
considered. For example, in heat exchanger mounting and isolation
systems, vibration issues, such as Noise, Vibration & Harshness
(NVH), occur. In such systems, one of the isolator's purposes is to
allow for an attachment that is not too rigid, or even what might
be called a `loose` attachment of a heat exchanger assembly to a
vehicle mounting frame. The isolator can assist in dampening the
differential movement between the heat exchangers and the vehicle,
and thereby, help avoid undesired impact or contact between the
heat exchanger assembly and the rest of the vehicle and/or its
mounting or mounting frame.
[0008] Solutions to noise and vibration issues in various
applications exist in the prior art. For example, soft isolators
composed of lower durometer material (e.g. less than 30 durometer
materials) have been used to eliminate noise transmission. They
present the problem, however, that they can fail over time, and,
more often than not, are unable to absorb high impact energy such
as that experienced while driving an automotive vehicle on unpaved
or otherwise rough roads. Other solutions to noise issues, such as
the use of vertical standing ribs, are described in U.S. Pat. No.
5,960,673, issued Oct. 5, 1999, to Eaton et al., that can absorb
initial noise transmission. However, these solutions also have the
disadvantage that the individual ribs can wear away prematurely
because the high energy present is not adequately distributed over
the full area of the isolator surface.
[0009] Stiff isolators such, as those described in U.S. Pat. Nos.
6,540,216 B2, issued Apr. 1, 2003, to Tousi et al. or U.S. Pat. No.
4,858,866, issued Aug. 22, 1989, to Werner, can absorb impact shock
between components by keeping the components separated, but, both
noise and vibration are more easily transmitted through the stiff
rubber members. Webbed isolators such as those describe in U.S.
Pat. No. 6,722,641, issued Apr. 20, 2004, to Yamada et al., are
described as having various thicknesses of rubber webs and/or
plastic or metal insert members, and rigidly support the mount in
or on each side of the isolator mounting face. The isolator uses a
different thickness of rubber web to vary its stiffness. With this
solution, when parts move closer together relative to each other,
resistance increases. However, this sort of assembly also generally
costs more than other isolators or isolator systems.
[0010] Loosely fitting isolators with, for example, an air gap at
the mounting face, are show in U.S. Pat. No. 6,540,216 B2 issued
Apr. 1, 2003 to Tousi et al., wherein such isolators can be seen as
useful in absorbing some misalignment of parts and/or undesirable
vibration. However, such a gap can cause damaging impact from
unrestricted acceleration across the gap when used between a heat
exchanger and some adjacent components.
[0011] So called `dual density` isolators, have been described but
it is more expensive to manufacture when using a two different
density materials for manufacture. Dual stage webbed isolators, for
example, those using metal or plastic inserts, would normally
require separate placement of the inserts and lead to increased
piece cost and mold cycle time. Webbed isolators themselves can be
too stiff and transmit too much vibration to be useful in many
automotive applications. For example, when the isolator is softened
to reduce vibration transmission, the isolators can fail
prematurely, especially when the isolators have a thinned area of a
web which can be stretched or compressed beyond their normal
elastic limits (usually during harsh movements with high
acceleration).
[0012] Prior art isolators with ribs or contact ribs have been
designed such that the ribs, and particular, perpendicular ribs, go
into immediate compression upon load. Such isolators, therefore,
are limited in their use as they cannot be made of higher elastic
compressible (durometer) elastic materials.
[0013] Isolators of various types are illustrated by two
provisional applications filed Nov. 30, 2005, U.S. Patent
Application Ser. Nos. 60/740,784 and 60/740,767, Daniel Domen,
Peter Chen and Mohammed Ansari, which are hereby incorporated by
reference in their entireties.
SUMMARY OF THE INVENTION
[0014] In the automotive industry, heat exchange modules such as
cooling modules (modules assembled with the intention of using for
heat transfer applications) may be assembled to the vehicle body,
and, often, to the vehicle frame. The cooling modules are not able
to be assembled to the vehicle frame on any consistent basis, to
have `perfect` alignment. Each component or parts of the module and
its fit varies relative to the component or part next to it. The
fit can loose in many cases, or the components themselves can be
grounded or snugly fit to each other through an isolator. This sort
of attachment scenario, however, severely reduces the isolator's
ability to absorb energy. Grounding transmits the vibration energy
more or less in a direct manner to other components in the vehicle.
Loose fitting assemblies can accelerate transfer of inappropriate
energy, and, in particular, movement and later noise energy, during
harsh driving conditions. Higher energy levels can damage both not
only the cooling module, but also any adjacent components to either
the module or the other parts of the automobile, or to the
isolators between the cooling module and the adjacent components of
the automobile.
[0015] The present invention, in its various aspects, avoids the
problems of the prior art, especially due related to undesired
contact or impact scenarios found in assembly of parts in
automotive applications. In various aspects of the present
invention, airborne noise, generated by contact or acoustic
harmonic oscillations and/or movement, impact, is greatly reduced.
By initially softly holding with isolator ribs to slow movement of
the oscillating component with the non-perpendicular (wiper) rib,
an initial "soft contact" is made to slow the resonant movement and
alter movement towards a non-acoustic resonant frequency. A soft or
low stiffness isolator reduces the generation of noise.
[0016] Preferred aspects of the present invention provide for
isolators of a less expensive design that absorbs high frequency
noise vibration, medium vibration and low frequency/high inertia
harsh vibration, without sacrificing overall endurance of the
isolator.
[0017] The present invention, in its various aspects, reduces the
occurrence of the above vibration problems, especially as they
pertain to automotive vehicles.
[0018] For example, a mounting frame or a mounting frame vehicle
component, an engine drive train component, a heat exchanger drive
train component, or other components of an automobile vehicle are
adjacent to one another, or otherwise contact one another, can be
separated by use of isolators, in accordance with an aspect of the
present invention.
[0019] The present invention relates to isolator assemblies and
isolators between separate parts or components, and, particularly,
multi stage isolators, especially isolators useful in automotive
applications. By dampening, or reducing the acceleration of a body
as it travel from its initial point at rest towards its peak
excursion at impact with a second body, isolator and isolator
assemblies, in various aspects of the present invention, reduce
wear and tear or all associated parts or components isolated by
such isolators.
[0020] The isolators have non perpendicular ribs, made of the same
material as the isolator body, which can flex when in a deflection
phase or stage, or can compress in a compression phase or stage,
thus allowing for reduced wear and/or longer life for both the
isolator and the parts and components separated thereby.
[0021] As used in the present application, by perpendicular rib it
is meant a rib that is perpendicular to the contact surface and
aligned against the direction of inertia so that an inertia load
generally compresses the rib. By non-perpendicular rib it is meant
a rib placed at an angle to the normal direction of inertia from
the opposing contact surface so that when an inertia load is
applied to the rib, it deflects with sliding contact that `wipes`
across the opposing surface until it is fully laid lateral and flat
across the rib thickness.
[0022] Aspects of the present invention provide for a wiper ribbed,
preferably multi-stage isolator, useful in vehicle or automotive
vehicle systems or other fixed position systems, such as those used
in or air or space craft applications, for dampening noise
isolation and/or to eliminate undesired results of contact or
impact due to component mismatch at the isolation joints.
[0023] By isolation joint it is meant a location at which two or
more components have a separator or isolator loosely held in
position in relation to each other. By isolation mount it is meant
that one component or assembly is held in approximate position to
another through an elastic member that allows for either or both
differential movements between each other or excentric positioning
relative to each other.
[0024] By reducing vibration by absorbing the energy into the
non-perpendicular contact ribs, the present invention provides for
applications that do not allow undesirable movement due to
vibrations to be passed through an isolator or isolator portion,
and, in particular, a solid compression isolator portion,
preventing undesired movement from being passed on through other
adjacent components. A rib can be straight rib, following a two
point plane, or a curved rib relative to a plane. Vibration
suppression, in various aspects of the present invention, is
controlled by both the angle and thickness of ribs trough a bending
or deflecting action. The angle of non-perpendicular rib, in
various aspects of the invention, is greater than or equal to
45.degree. or greater from normal (or perpendicular) to the
opposing contact surfaces. The length of the rib is, preferably,
greater than two times its width to allow deflection, rather than
compression. The ribs used against or on curved or flat contact
surfaces, may also be curved ribs, thereby enhancing sliding
contact.
[0025] The present invention, in its various aspects, allows for
the production of "low cost", and, in particular, multi stage
isolators that can be made from single durometer material. The
present invention, under conditions of load, provides for an
isolator that can flex under light load and/or flatten, and, in
aspects of the invention, flatten to a uniform thickness, under
heavier loading. The present invention, in various aspects,
therefore, provides for an isolator of a single durometer material,
and, more preferably, an elastic or elastomeric or rubber or rubber
like material, having a rib or ribs that are also made of same
material or stiffness, that can go through at least two load
resisting phases, depending on the loading due to contact (initial
or light contact or impact `low inertia`), or later heavy contact
or impact (`heavy inertia`) that the isolator and part or component
endure.
[0026] In various aspects of the present invention, partial contact
surface ribs are spaced uniformly so that when the ribs are fully
deflected, the rib thicknesses lay flat against the remainder of
the isolator wall to form an approximately uniform contact surface,
and to optimize distribution of higher inertia loads.
[0027] In preferred aspects of the present invention, high impact
energy is dissipated evenly over a uniform surface by the
deflected, non-perpendicular, wiper ribs as they collapse and form
an approximately uniform surface by nesting the lengths one next to
another so that the width forms an approximate uniform thickness.
As one of the parts or components separated by an isolator moves
closer to the adjacent part or component, the acceleration of the
initial movement is slowed by the non-perpendicular separating ribs
on the isolator. The decreasing acceleration of the one part or
component towards an adjacent part or component separated by the
deflecting ribs, absorbs energy and remaining isolator thickness to
a level that is safe, i.e., avoids undesirable or excessive damage
to either of the parts.
[0028] The isolators of various aspects of the present invention,
therefore, absorb lighter vibrations and also resist heavier impact
load, depending on the type or intensity of contact of part with
isolator. At the same time, the ribs and, at least one of the other
elastic, elastomeric or rubber or rubber like portions, are made
from an identical durometer rubber material compound.
[0029] The present invention, therefore, allows for an isolator of
a generally uniforn stiffness that allows for position fits that
may or may not be mis or mal aligned, while still providing for
adequate dampening of noise and contact between parts. By providing
for an isolator with at least one, and, preferably, two or more
non-perpendicular ribs, a "soft contact" or loose positioning
between parts, such as, for example, between a heat exchanger to
another exchanger or an assembly module and a mounting frame of an
automotive vehicle, is provided. Such an isolator with
non-perpendicular ribs slows the initial acceleration of the loose
fit, providing a non-perpendicular low inertia deflecting contact
rib(s) (FIG. 1) that nest into a pocket or depression ("hollow")of
the same approximate length and thickness to allow the rib to nest
therein when fully deflected (FIG. 6) under high inertia
conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic view of an isolator with internal ribs
in free state in accordance with an aspect of the present
invention.
[0031] FIG. 2 is a schematic view of an isolator with ribs in
deflection phase, in accordance with an aspect of the present
invention.
[0032] FIG. 3 is a schematic view of an isolator wiper ribs prior
to insertion of center post, in accordance with an aspect of the
present invention.
[0033] FIG. 4 is a schematic view of an isolator wiper ribs post
insertion of center post in accordance with an aspect of the
present invention.
[0034] FIG. 5 is a schematic view of an isolator and component
assembly, such as those useful in heat exchanger isolators in
housing assembly, in accordance with an aspect of the present
invention.
[0035] FIG. 6 is an exploded view of isolator wiper rib and nesting
pocket for rib, in accordance with an aspect of the present
invention, in deflection phase.
[0036] FIG. 7 is an exploded view of isolator wiper rib and nesting
pocket for rib, in accordance with an aspect of the present
invention, in compression phase.
[0037] FIG. 8 is a cross sectional view of an isolator with wiper
ribs in plate slot without center bolt mount or post, in accordance
with an aspect of the present invention.
[0038] FIG. 9 is a schematic view of a solid block rubber isolator
cross section, in accordance with an aspect of the present
invention.
[0039] FIG. 10 is a schematic view of a wiper rib block elastic
isolator cross section, in accordance with an aspect of the present
invention.
[0040] FIG. 11 is a schematic view/FEA analysis model of a wiper
rib block elastic isolator finite element (FE) model in accordance
with an aspect of the present invention.
[0041] FIG. 12 is a schematic view of a prior art round pin
isolator.
[0042] FIG. 13 is a schematic view of a round pin isolator with
wiper ribs around pin in accordance with an aspect of the present
invention.
[0043] FIG. 14 is a graphic comparison of an isolator wiper rib to
isolator to a solid flat isolator, with cross section comparison
chart, showing relative to applied load, in accordance with an
aspect of the present invention.
[0044] FIG. 15 is a schematic view of a heat exchanger assembly
with isolator mounts, in accordance with an aspect of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] In various aspects of the present invention, an isolator of
a generally uniform stiffness for use between parts or components
is described. The isolator is, preferably made of a single
durometer material, and has at least one non-perpendicular rib. In
various aspects, an isolator of the present invention comprises at
least two portions, at least one portion having the at least one
non-perpendicular rib, more preferably at least one portion is a
compression portion and at least one portion is a deflection
portion.
[0046] Preferred isolators of the present invention having at least
one portion a deflection portion, the at least one portion having
the at least one non-perpendicular rib is found on the deflection
portion.
[0047] In the various aspects of the present invention having at
least one rib, the isolator preferable also has at least one or
more hollows. At least one rib, in compression, nests in a hollow.
An isolator having at least one or two hollows preferably has at
least one non-perpendicular rib that nests in the at least one
hollow. An isolator, for example, having two hollows and two ribs
may have at least two non-perpendicular ribs, each resting in one
or more hollows.
[0048] In various aspects of the present invention, the isolator
forms part of an isolation system of at least two other components,
each adjacent to one another, and at least one non-perpendicular
rib is at least partially deflected at low inertial load conditions
at the time of contact with the adjacent component in the isolation
system.
[0049] In various aspect of the present invention, an isolator
having at least one rib, can have a straight rib or a curved rib.
In various embodiments, at least one of the ribs is a curved
rib.
[0050] Non perpendicular ribs, in general, slow the initial
acceleration of the adjacent component as it moves closer towards
the contact surface. Non-perpendicular ribs that are deflected upon
low inertia contact, and, at least partially, into a hollow or
hollows, can nest in the hollow or hollows when fully deflected
under high inertia contact conditions.
[0051] Also in aspects of the present invention, a isolator and
component assembly comprising: an isolator having at least one
wall; at least one non-perpendicular wiper rib forming part of the
at least one wall; and a component having a component contact
surface facing an isolator wall, is provided. For example, an
isolator made of a single durometer material of generally uniform
stiffness wherein the isolator has at least one wall in alignment
with an adjacent component contact surface, exists.
[0052] In various aspects, an isolator and heat exchanger assembly,
exists having at least one first part or component that is a heat
exchanger or portion of a heat exchanger and at least one second
part or component that is a part or component of, or a portion of a
part or component of, a motor vehicle, such as a mounting frame or
portion of a mounting frame of an automotive vehicle.
[0053] Preferably, in an isolator and component assembly, the
component contact surface is adjacent to the at least one wall.
Also, in various embodiments, the at least one non-perpendicular
wiper rib has length of at least two time its average thickness. In
other embodiments of the present invention, the isolator wall is
aligned to the adjacent component contact surface and is in contact
with the at least one rib, and wherein the at least one wiper rib
is non-perpendicular to the tangential adjacent component contact
surface or the isolator wall. In such examples in an isolator and
component assembly, the isolator wall is aligned to the adjacent
component contact surface and is in contact with at least one wiper
rib, and the at least one wiper rib is non-perpendicular to the
adjacent component contact surface and the isolator wall.
[0054] The depth of the hollow and the thickness of the
non-perpendicular ribs can vary. In various aspects of the present
invention, the depth of the hollow is approximately equivalent to
the depth (or thickness) of the at least one wiper rib.
[0055] Also in various aspects the wiper rib and adjacent isolator
surface outside of the hollow form an approximate uniform contact
surface such that a plane can be drawn that is approximately flat
when nested in the hollow.
[0056] In various examples in accordance with the present
invention, two or more wiper ribs are adjacent to one another, and
the length of each wiper rib is such that the free end of each
wiper rib has approximately the same thickness as its adjacent
wiper rib. In other aspects having at least two wiper ribs, the two
wiper ribs, when fully deflected, are of a thickness such that the
two wiper ribs and the adjacent isolator surfaces form an
approximate uniform planer contact surface.
[0057] Aspects of the present invention include a heat exchanger
assembly comprising: a heat exchanger; an isolator and component
assembly; and at least one isolator mount. The isolator and
component assembly comprise at least one isolator having a wiper
rib and a hollow. The wiper rib is a non-perpendicular wiper rib.
Various embodiments have at least two wiper ribs. Other embodiments
have least two isolators and/or at least two isolator mounts.
[0058] In various aspects of the present invention, an isolator is
provided having a non-perpendicular "wiper" rib such that the rib
`slides` or `wipes` across the contact surface as the rib deflects
to flat. At the adjacent component contact surface, the ribbed
portion of the isolator is able to flex to absorb light inertia
loading. In various embodiments, for example, in heat exchanger to
automotive mountings application, the isolator has a wall that has
a surface extending outward from that wall, for example, as a
non-perpendicular `wiper` rib. The rib wall is longer that its
thickness, preferably at least two times its thickness, in
automotive heat exchanger part to automotive mounting part
applications. The ribs, when fully deflected, lay flat against the
remaining isolator wall (`flattened`), nest against one another
such that an end of one rib rests near and/or next to the base of
the next adjacent rib or to the end of the "nesting pocket" in the
remainder of the wall. The end of the ribs forms an approximate
uniform surface of rib and wall thickness when compressed which
allows heavier impact loads to be uniformly dissipated at full
deflection.
[0059] In embodiments of the present invention, an isolator made of
an elastic or elastomeric material, or rubber or rubber like
material (in this case) rubber, is molded as a single durometer
material. A rib, and, in particular a wiper rib, of the approximate
same durometer (performs a similar function as that of a prior art
design utilizing a second material portion of a lower stiffness or
lower durometer). The lower durometer material would tend to absorb
the lower inertial/higher frequency vibrations and the higher
durometer would tend to absorb the higher inertia/lower frequency
vibration.
[0060] The use of non-perpendicular ribs on the isolator allows for
changes in the rate of loading resistance when the ribs are
initially bent or deflected (`deflecting or deflection stage`) to
when the ribs are compressed together as load is increased
"compressing stage". The deflecting stage provides for high
frequency/short excursion noise and vibration dampening during the
deflection portion of rib movement at initial or low inertia
loading contact. By excursion it is meant the distance traveled
from the initial, at rest position, to the farthest movement from
that location relative to the adjacent component. The compressing
stage, due to the ability of the non-perpendicular ribs to nest
upon one another, provides a low frequency/high inertia dampening
during harsh conditions. The present invention also provides for
aspects that allow for non-perpendicular wiper ribs to be
positioned with a loose fit of adjacent components in the case
where two parts or components are not aligned or are in
misalignment from their normal orientation. In these aspects, the
ribs are designed such that they give way or bend to the off set
adjacent contact surface, and still provide a soft contact that can
slow initial acceleration between the parts or components during
periods of light or short excursion accelerations. In various
aspects, the ribs nest, and, particularly, under high inertial
impact conditions. The ribs, in various aspects deflect to nest in
pockets or depressions ("hollows")to form a uniform isolator wall
thickness during periods of high inertial impact experienced under
rough road conditions.
[0061] The non-perpendicular ribs and the remainder of the isolator
are, in various aspects of the present invention, made of a single
stiffness material of an equivalent durometer stiffness. The
non-perpendicular ribs, and, in particular, the non-perpendicular
wiper ribs, are generally formed in a geometric shape that is of a
constant rib wall thickness that allows the ribs to be initially
deflected at one load rate and then to form an approximately flat
surface configuration (where the total of the individual wall nest
against the remainder of the isolator wall form an approximate
uniform wall thickness) to allow uniform distribution of increasing
inertia loads. As the adjacent components move in closer contact,
there is a second compression rate as the elastic or elastomeric
material of the isolator and rib is compressed. By designing for
ribs that can nest in various embodiments, the ribs form a uniform
surface to distribute load during the compressive stage and are
compressed at a uniform rate using the identical elastic or
elastomeric materials. The rib(s) may also be formed of a variable
wall sickness. Preferably, the thickness generally increases toward
the rib base, as long as the nesting pocket shape match the rib
shape, thus allowing formation of a uniform wall thickness with the
remainder of the isolator wall away from the pocket wall.
[0062] As described above, by providing for ribs of a geometric
shape that allows for at least two (2) separate load phases, noise,
and vibration and harshness conditions are ameliorated such that
the isolator plus the remainder rib wall configuration increases
the load distribution area. The inertia load energy may be
uniformly distributed across the full area at high inertia
harshness conditions. The present invention, in various aspects,
also allows parts or components to contact through the isolator at
different alignment angles. This latter is accomplished, in various
aspects by nesting the rib geometric shapes to form a uniform
isolator wall thickness, thereby minimizing the local stress on the
thin rib wall areas to increase durability.
[0063] The present invention, therefore, in various aspects,
relates to a multiple stage dampening isolator having
non-perpendicular wiper rib shapes, between a contact wall of an
adjacent component and an isolator surface. The isolator has ribs
arranged so they can deflect to flat, i.e. transition from a
flexing stage to and from a compression stage to isolate two or
more parts. The rib deflection during the deflecting stage will
cause the rib to bend or flex in such a way that, in specifics
aspects of the present invention, it can flex to fill a depression,
a space, void or hollow area between components, for example,
between the heat exchanger part and the automobile mounting frame.
The suspension of the heat exchanger component relative to the
mounting frame component is therefore initially maintained within a
certain ribbed area, and contact within this area by the two
components is minimalized and/or reduced to an acceptable level,
due to the bending or deflection resistance of the isolator rib.
The absorption of generated vibration is reduced using the isolator
ribs between the heat exchanger assembly and the mounting
frame.
[0064] Deflection occurs when the ribs that are non vertical with
respect to the adjacent component contact surface move closer or
are non-perpendicular with respect to the adjacent contact surface.
In other words, in various aspects of the present invention, the
ribs are positioned at angles of less than 90.degree. to the
contact surface (FIG. 6) and have tangencies so that they tend to
deflect rather than compress. Compression generally occurs when a
force applied to isolator is vertical to the wall of the isolator,
or to a vertical rib column. When there is no non-perpendicular
rib, for example, contact or impact leads to a compressive force
which resists movement, with compression requiring a greater load
to compress the isolator and allow vibrations to be increasingly
passed through stiff isolators.
[0065] As described above, in various embodiments of the present
invention, isolators with ribs have either nesting pockets at their
base to allow the ribs to deflect flat with the normal contact
surfaces, or the ribs lay end to end when flattened to form an
approximate uniform thickness at the surface of the ribs wall and
the remainder of the isolator wall for better distribution of
heavier inertia loads.
[0066] The aspects of the present invention that allow the isolator
to have both a deflection stage and a compression stage are
accomplished with an isolator of one basic material. After the
deflection phase (and as the contact continues or intensifies), the
isolator with deflecting portion, fully collapsed or goes `flat`,
so that it forms a shape of relatively common uniform thickness in
relation to the rest of the thickness of the isolator (thickness of
the remainder of the isolator wall. When it reaches the flat phase,
if inertia increases to contact or impact force levels continues,
the isolator enters into the compression phase. Energy distribution
under severe or harsh loading is, thereby, uniformly distributed
and inertia energies more easily dissipated over larger areas,
leading to longer durability for both the isolator and the
parts.
[0067] The isolators of the present invention are preferably of
elastic or elastomeric material, such as elastomeric polymers or
resins or rubber, or such types of materials with elastic
properties that are capable of being, preferably is molded of a
single durometer stiffness material. The isolator is formed in such
a shape as to allow for a ribbed portion which, when placed between
at least two parts or components that are normally separated from
one another, lies between a contact surface of the isolator and a
contact surface of, for example, a part or component, such as a
heat exchanger or a vehicle mounting frame (the heat exchanger and
the opposing mounting frame). The rib walls are of a thickness that
vary with the mass size being isolated and the desired dampening
and are arranged in a non-perpendicular manner to the contact
surface of the adjacent part, such that when the ribs are deflected
to a flat position they lay approximately parallel to the contact
surfaces of the heat exchanger and mounting frame walls, and form
an approximately uniform thickness with the remainder of the
isolator wall portions. By laying flat, and having an approximately
uniform thickness, the entire flattened isolator can become an
approximate uniform load bearing member. The isolator walls at the
area of a hollow portions or portions of the isolators accept the
initial inertia load during higher frequency lighter load
inertias.
[0068] The isolator is formed in such a shape that allows a ribbed
portion between the normal contact surfaces of the isolator and the
ribs contact surfaces of the adjacent component such as heat
exchanger. The hollow portion or space ("hollow")between and/or
adjacent to, the ribs and the remainder of walls receives the wall
thickness of the deflecting ribs, such that when the ribs walls are
deflected to a flat position approximately parallel to the isolator
contact surfaces, and/or closely aligned between the heat exchanger
and mounting frame contact walls, they form an approximately
uniform thickness with the remainder of the isolator wall portions
so that the entire flattened isolator demonstrates an approximate
uniform load capability.
[0069] Referring to FIG. 1, is shown an isolator (10) with wiper
ribs (12) in free standing state or condition, and hollows (11)
adjacent to wiper ribs (12). Referring to FIG. 2, isolator (20),
has wiper ribs (21) with post inserted (23) that have been
deflected and now, under increased load, approach a partially
deflected stage, with hollows (22) partially filled in by wiper
ribs (12) when a post (23) is inserted amongst the ribs.
[0070] Referring to FIG. 3 is shown a round post (33) around which
partially deflected wiper ribs (32) are shown under load and
therefore deflected from the free standing state during deflection.
Inertia load direction A is illustrated, as well as contact point
on the wiper contact surface of the post (33), and deflection angle
of greater than or equal to 45 degrees. The contact point (34) on
the wiper surface of the isolator rib (32) and at the post (33) is
shown. Hollows (31) for ribs (32) are also illustrated.
[0071] FIG. 4 represents the same ribs (42) in free standing state
(under non-load) conditions with hollows (41) shown. Dotted or
phantom line representation of ribs under load (44) is shown with
inertia load direction A illustrated, leading to ribs post
deflection (44) with an angled of greater than or equal to 45
degrees. Rib wiping surface B is also illustrated.
[0072] Referring to FIG. 5 is shown an isolator and component
assembly having an isolator (50) with ribs (52) and pockets or
hollows (51) arranged in free standing state. Attachment means or
fastener is shown as a screw (53) which is inserted into aperture
(56) which interacts with fastener sleeve support (54) and with
fastener mount (55) with fastener mounting hole (59) which is a
part or component of an automotive vehicle (not shown) to form an
isolator mount arrangement prior to insertion of the slotted
mounting plate portion (57), the mounting surface of the plate
usually on the part or component, such as a heat exchanger/isolator
part or component (not illustrated) adjacent to the isolator around
the center portion that has the fastener pass through it and
between the wiper rib contact areas and fastener (53). Lateral
movement slot ribs (58) provide for a controlled loose or light fit
along the fastener axis.
[0073] Referring to FIGS. 6 and 7 are shown "plate type" isolator
portions (60a) (60b) (70a) (70b) having intermittent ribs (62) (72)
and pockets (61) (71) and plane A of interior walls (68b, 78b) of
isolator. In FIG. 6, wiper ribs (62) previously in free standing
state and isolator is shown inserted onto a slotted flat plate
(67). Ribs deflect in deflection phase to more or less 45% from the
plane of the internal wall of the isolator with initial load
direction B illustrated. The rib thickness and length are such that
the length L is greater than or equal to 2.times. the width W of
the rib.
[0074] FIG. 7 shows wiper ribs (72a) previously in free standing
state and wiper ribs (72b) under load conditions with isolator
inserted onto a slotted flat plate (77) and plane A of interior
wall of isolator (78b) and fully deflected wiper rib (72b)
deflected into hollow (equivalent to hollow 71, but not shown due
to presence of rib (72b)). In compression phase, inertia load C and
uniform wall for inertia load distribution D, are illustrated by
arrows C, D.
[0075] Referring to FIG. 8 is shown isolator (80) with wiper ribs
(82) previously in free standing state in plate (87) slot (88).
Lateral ribs (82) are shown in deflection (under lighter inertia
load) with dotted line (83) representing position of ribs (82) at
compression stage (under heavier inertia load).
[0076] Referring to FIG. 9 is shown a schematic cross sectional
view of a prior art isolator cross section with no ribs
present.
[0077] Referring to FIG. 10 is shown an elastic isolator (120) in
cross sectional view having ribs (122) and hollows (121) with plane
A across the interior walls (123) of the isolator demonstrated.
Ribs (122) rest in hollows (121) post initial with rib relief on
front pockets (hollows) (for greater flexibility at the rib base)
deflection under lighter loads and further during compression
during heavier loads in this model.
[0078] FIG. 11 is a cross section of elastic isolator (100)
following finite element model wherein the triangles represent
loading points, and the wiper ribs (132) secondary compression rib
flex relief areas (137) and hollows (131) are demonstrated. Initial
compression wall (133) of isolator (130) is also illustrated.
[0079] Referring to FIG. 12 is shown a prior art isolator and
component assembly (140) having an internal wall (148) and
essentially smooth or flat contact surfaces perpendicular to
inertial load so that the compression phase starts at initial
contact.
[0080] Referring to FIG. 13 is illustrated an isolator with ribs
and components assembly mounting (150) having an isolator pin (157)
and isolator with wiper ribs (152) and hollows (151).
[0081] FIG. 14 compares isolator compression in millimeters versus
inertia load force (compression relative to applied load) for the
flat isolator of the prior art FIG. 12 and the nested rib isolator
of FIG. 13. The difference in loads between the ribbed and flat
surfaces allows lighter movements of short excursions from the rest
position shows clear the effect of the use of ribs to allow
misalignment and an initial high frequency vibration isolation
versus the prior art.
[0082] FIG. 15 illustrates a heat exchanger assembly with an
arrangement of dampen isolation mounts to various inertia load
effects and directions with respect to an elastic isolators with
ribs (170) (176). The housing as shown has an isolator slotted
plate (173) and post mount (176) (not shown). The are two types, an
upper slotted plate type (173) and a lower pin type (176). Arrows
A-K (177) lateral, for example, show inertia with various
movements: A-slotted plate movement with during "jounce" and
gravity; B-slotted plate movement during sudden "starts"; C-slotted
plate movement during sudden "stops"; D-lateral load during right
turns; E-slotted plate movement during "rebound"; F-pin movement
during sharp right turns; G-pin movements during jounce and
gravity; H-pin movements during "sudden starts"; I-pin movements
during "sudden stops" I-rearward movement relative vehicle motion
or tendency to stay in same position in virtual space; J-pin
movements during sharp left turns; K-pin movement during
rebound.
[0083] L represents load of slotted plate against isolator and M
represents the direction to the front of the vehicle or normal
forward direction in a vehicle.
[0084] Further embodiments of the present invention comprise an
isolator which maintains its position in space between components
and the mounting frame and the heat exchanger. This is accomplished
by wiper ribs that touch the contact surfaces of both components
and that deflect to absorb reasonable tolerance differences.
[0085] Unless stated otherwise, dimensions and geometries of the
various structures depicted herein are not intended to be
restrictive of the invention, and other dimensions or geometries
are possible. Plural structural components can be provided by a
single integrated structure. Alternatively, a single integrated
structure might be divided into separate plural components. In
addition, while a feature of the present invention may have been
described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other
features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the
unique structures herein and the operation thereof also constitute
methods in accordance with the present invention.
[0086] The preferred embodiment of the present invention has been
disclosed. A person of ordinary skill in the art would realize
however, that certain modifications would come within the teachings
of this invention. Therefore, the following claims should be
studied to determine the true scope and content of the
invention.
* * * * *