U.S. patent application number 13/073913 was filed with the patent office on 2011-10-06 for engine-mountable cooling system.
This patent application is currently assigned to Daimler Trucks North America LLC. Invention is credited to Daniel J. Borski, James V. McHorse, Bryan T. Morriss.
Application Number | 20110240252 13/073913 |
Document ID | / |
Family ID | 44708264 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110240252 |
Kind Code |
A1 |
Borski; Daniel J. ; et
al. |
October 6, 2011 |
ENGINE-MOUNTABLE COOLING SYSTEM
Abstract
An engine-mountable cooling system for a vehicle includes a
fluid cooling component, a fan shroud and an elongate
engine-mounting cross member. The fluid cooling component includes
an upper portion, a lower portion and first and second opposed
cooling component side portions. The fan shroud includes an
engine-mounting shroud portion coupled to the lower portion of the
fluid cooling component and a second shroud portion positioned at
least partially above the engine-mounting shroud portion. The
elongate engine-mounting cross member is spaced from and positioned
above the engine-mounting shroud portion and includes a first cross
member end portion coupled to the first cooling component side
portion and a second cross member end portion coupled to the second
cooling component side portion. The cooling system is mountable to
an engine such that the engine-mounting cross member and the
engine-mounting shroud portion support substantially the entire
weight of the cooling system.
Inventors: |
Borski; Daniel J.;
(Fairview, OR) ; Morriss; Bryan T.; (Portland,
OR) ; McHorse; James V.; (Portland, OR) |
Assignee: |
Daimler Trucks North America
LLC
|
Family ID: |
44708264 |
Appl. No.: |
13/073913 |
Filed: |
March 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61319101 |
Mar 30, 2010 |
|
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|
61391013 |
Oct 7, 2010 |
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Current U.S.
Class: |
165/51 ; 165/148;
165/67; 220/562 |
Current CPC
Class: |
F01P 2070/52 20130101;
F28F 9/002 20130101; F01P 2060/02 20130101 |
Class at
Publication: |
165/51 ; 165/67;
165/148; 220/562 |
International
Class: |
F01P 9/00 20060101
F01P009/00; F28F 9/00 20060101 F28F009/00; F28D 1/00 20060101
F28D001/00; B65D 90/00 20060101 B65D090/00 |
Claims
1. An engine-mountable cooling system for a vehicle, the cooling
system comprising: a fluid cooling component comprising an upper
portion, a lower portion and first and second opposed cooling
component side portions; a fan shroud comprising an engine-mounting
shroud portion coupled to the lower portion of the fluid cooling
component and a second shroud portion positioned at least partially
above the engine-mounting shroud portion; and an elongate
engine-mounting cross member spaced from and positioned above the
engine-mounting shroud portion comprising a first cross member end
portion coupled to the first cooling component side portion and a
second cross member end portion coupled to the second cooling
component side portion; wherein the cooling system is mountable to
an engine such that the engine-mounting cross member and the
engine-mounting shroud portion support substantially the entire
weight of the cooling system.
2. An engine-mountable cooling system according to claim 1, wherein
the fluid cooling component further comprises a front portion and a
rear portion and the engine-mounting shroud portion comprises first
and second shroud end portions and an intermediate shroud base
portion extending between the first and second shroud end portions,
the shroud base portion spanning across the rear portion of the
fluid cooling component and being mountable to the engine, the
first shroud end portion extending forwardly from a rear portion of
the fluid cooling component and along the first cooling component
side portion of the cooling system and being attached thereto, the
second shroud end portion extending forwardly from a rear portion
of the fluid cooling component and along the second cooling
component side portion and being attached thereto.
3. An engine-mountable cooling system according to claim 1, wherein
the engine-mounting shroud portion comprises a neck portion
comprising a first rim portion and the second shroud portion
comprises a second rim portion, the first and second rim portions
together comprising an annular rim that defines a central fan
shroud opening.
4. A manifold for an air cooling component of a vehicle cooling
system, the manifold comprising: a body comprising first and second
air flow ports and defining a fluid passageway between said air
flow ports, the body being adapted for coupling to a side portion
of the air cooling component with the second port being in fluid
communication with the air cooling component; the body further
comprising a first mounting portion extending upwardly from the
body to a location above the air cooling component, the first
mounting portion comprising first mounting features positioned for
use in mounting the manifold directly to a radiator and to an upper
mounting cross member of the cooling system; and the body further
comprising a second mounting portion extending downwardly from the
body to a location below the air cooling component, the second
mounting portion comprising second mounting features positioned for
use in mounting the manifold directly to the radiator and to a
lower mounting cross member.
5. A manifold according to claim 4, wherein the first mounting
features comprise a first aperture and a second aperture, the first
aperture being adapted to receive a first fastener therethrough
such that the first fastener is also received by the radiator to
fasten the manifold to the radiator, the second aperture being
adapted to receive a second fastener therethrough such that the
second fastener is also received by the upper mounting cross member
to fasten the manifold to the upper mounting cross member; and
wherein the second mounting features comprise a third aperture and
a fourth aperture, the third aperture being adapted to receive a
third fastener therethrough such that the third fastener is also
received by the radiator to fasten the manifold to the radiator,
the fourth aperture being adapted to receive a fourth fastener
therethrough such that the fourth fastener is also received by the
lower mounting cross member to fasten the manifold to the lower
mounting cross member.
6. A manifold according to claim 4, wherein the manifold is
monolithic.
7. An air cooler assembly for a cooling system for a vehicle, the
air cooler assembly comprising: a radiator portion; an air cooling
portion comprising an uppermost portion, a lowermost portion, and
first and second opposed side portions; and first and second
opposed manifolds, each manifold comprising: a body fluidly coupled
to a respective one of the first and second side portions of the
air cooling portion; an upper mounting portion extending upwardly
from the body and above the uppermost portion of the air cooling
portion; and a lower mounting portion extending downwardly from the
main body and below the lower-most portion of the air cooling
portion; wherein the upper and lower mounting portions of the first
and second manifolds are adapted to together support substantially
the entire combined weight of the air cooling portion and the
radiator.
8. An air cooler assembly according to claim 7 further comprising
an upper engine mounting cross member extending from side to side
of the radiator, wherein the upper mounting portions of the first
and second manifolds each comprise a first upper mounting feature
and a second upper mounting feature, the first upper mounting
features being adapted for use in mounting the radiator to the
upper mounting portions, and the second upper mounting features
being adapted for use in mounting the upper mounting portion to the
upper engine-mounting cross member of the cooling system; and
further comprising a lower engine mounting cross member extending
from side to side of the radiator, wherein the lower mounting
portions of the first and second side manifolds each comprise first
lower mounting features and second lower mounting features, the
first lower mounting features being adapted for use in mounting the
radiator to the lower mounting portions, and the second lower
mounting features being adapted for use in mounting the lower
mounting portions to a lower engine-mounting component of the
cooling system.
9. An air cooler assembly according to claim 8, wherein the lower
engine mounting cross member comprises a portion of a fan shroud
with an interior surface bounding a portion of an air flow
passageway from the radiator.
10. A surge tank for an engine-mountable cooling system for a
vehicle, the surge tank comprising an internal reservoir volume for
containing coolant fluid and a mounting member adapted to mount the
cooling system to an engine of the vehicle such that the surge tank
supports a substantial portion of the weight of the cooling
system.
11. A surge tank according to claim 10, wherein the surge tank is
elongated in a side to side direction when mounted in the vehicle
and comprises a first side end portion, a second side end portion
opposed to the first side end portion, and an intermediate portion
extending between the first and second side end portions, the first
and second side end portions being adapted to mount a fluid cooling
component of the cooling system to the surge tank, the intermediate
portion being adapted to mount the cooling system to the
engine.
12. A surge tank according to claim 10, wherein the surge tank
comprises two primary components, the two primary components being
an upper portion and a lower portion that together define the
internal reservoir volume, one of the upper and lower portions
being comprised primarily of a first material, the other of the
upper and lower portions being comprised primarily of a second
material, the first material being substantially more rigid than
the second material.
13. A surge tank according to claim 12, wherein the mounting member
comprises said one of the upper and lower portions.
14. An engine-mounted cooling system for a vehicle, comprising: a
charge air cooler comprising an upper portion and a lower portion;
a radiator mounted to the charge air cooler; an upper
engine-mounting member attached to an upper portion of the charge
air cooler; and a lower engine-mounting member attached to a lower
portion of the charge air cooler; wherein the upper and lower
engine-mounting members couple the integrated cooling system to an
engine and support at least the majority of the entire weight of
the cooling system.
15. An engine-mounted integrated cooling system according to claim
14, wherein the charge air cooler comprises a first side manifold
and a second side manifold, and the upper engine-mounting member is
attached to both the first and second side manifolds.
16. An engine-mounted integrated cooling system according to claim
15, wherein the charge air cooler comprises a first side manifold
and a second side manifold, and the lower engine-mounting member is
attached to both the first and second side manifolds.
17. An engine-mounted integrated cooling system according to claim
14, wherein the charge air cooler comprises a first side manifold
and a second side manifold, and the lower engine-mounting member is
attached to both the left side manifold and the right side
manifold.
18. An engine-mounted integrated cooling system according to claim
14, wherein the upper engine-mounting member comprises a portion of
a surge tank.
19. An engine-mounted integrated cooling system according to claim
14, wherein the lower engine-mounting member comprises a portion of
a fan shroud.
20. An engine-mounted integrated cooling system according to claim
14, wherein the charge air cooler comprises a first side manifold
and a second side manifold, and the lower engine-mounting member is
attached to both the first and second side manifolds.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Application No. 61/319,101, filed Mar. 30, 2010, and
U.S. Provisional Application No. 61/391,013, filed Oct. 7,
2010.
FIELD
[0002] The present disclosure relates to a cooling system for a
vehicle, and more particularly to an engine-mountable cooling
system for a truck.
BACKGROUND
[0003] Conventional truck cooling systems can include a radiator, a
charge air cooler, a surge tank, a fan and various other
components. A cooling system can additionally include frames,
brackets, braces, strut rods, and other components that mount the
various cooling system components to one another, to the chassis or
to the engine. Typically, each of these components is designed
either for a cooling function or for a mounting function.
SUMMARY
[0004] Described herein are embodiments of a cooling system, and
components thereof, that is intended to be mounted to and
structurally supported by an engine of a vehicle and operable to
regulate temperatures of the engine and other parts of the
vehicle.
[0005] Some exemplary embodiments of an engine-mountable cooling
system for a vehicle include a fluid cooling component, a fan
shroud and an elongate engine-mounting cross member. The fluid
cooling component includes an upper portion, a lower portion and
first and second opposed cooling component side portions. The fan
shroud includes an engine-mounting shroud portion coupled to the
lower portion of the fluid cooling component and a second shroud
portion positioned at least partially above the engine-mounting
shroud portion. The elongate engine-mounting cross member is spaced
from and positioned above the engine-mounting shroud portion and
includes a first cross member end portion coupled to the first
cooling component side portion and a second cross member end
portion coupled to the second cooling component side portion. The
cooling system is mountable to an engine such that the
engine-mounting cross member and the engine-mounting shroud portion
support substantially the entire weight of the cooling system.
[0006] In some of these cooling system embodiments, the fluid
cooling component also includes a front portion and a rear portion
and the engine-mounting shroud portion includes first and second
shroud end portions and an intermediate shroud base portion
extending between the first and second shroud end portions. The
shroud base portion spans across the rear portion of the fluid
cooling component and is mountable to the engine. The first shroud
end portion extends forwardly from a rear portion of the fluid
cooling component and along the first cooling component side
portion of the cooling system and is attached thereto. The second
shroud end portion extends forwardly from a rear portion of the
fluid cooling component and along the second cooling component side
portion and is attached thereto.
[0007] In some embodiments of the engine-mountable cooling system,
the engine-mounting shroud portion includes a neck portion
comprising a first rim portion and the second shroud portion
includes a second rim portion. The first and second rim portions
together form an annular rim that defines a central fan shroud
opening.
[0008] In some embodiments of the engine-mountable cooling system,
the engine-mounting shroud portion is monolithic.
[0009] Some exemplary embodiments of a manifold for an air cooling
component of a vehicle cooling system include a body that includes
first and second air flow ports and defines a fluid passageway
between the air flow ports. The body is adapted for coupling to a
side portion of the air cooling component and the second port is in
fluid communication with the air cooling component. The body also
includes a first mounting portion extending upwardly from the body
to a location above the air cooling component. The first mounting
portion includes first mounting features positioned for use in
mounting the manifold directly to a radiator and to an upper
mounting cross member of the cooling system. The body also includes
a second mounting portion extending downwardly from the body to a
location below the air cooling component. The second mounting
portion includes second mounting features positioned for use in
mounting the manifold directly to the radiator and to a lower
mounting cross member.
[0010] In some of these manifold embodiments, the first mounting
features include a first aperture and a second aperture. The first
aperture is adapted to receive a first fastener therethrough such
that the first fastener is also received by the radiator to fasten
the manifold to the radiator. The second aperture is adapted to
receive a second fastener therethrough such that the second
fastener is also received by the upper mounting cross member to
fasten the manifold to the upper mounting cross member. The second
mounting features comprise a third aperture and a fourth aperture.
The third aperture is adapted to receive a third fastener
therethrough such that the third fastener is also received by the
radiator to fasten the manifold to the radiator. The fourth
aperture is adapted to receive a fourth fastener therethrough such
that the fourth fastener is also received by the lower mounting
cross member to fasten the manifold to the lower mounting cross
member. Some manifold embodiments are monolithic.
[0011] Some exemplary embodiments of an air cooler assembly for a
cooling system for a vehicle include a radiator portion, an air
cooling portion and first and second opposed manifolds. The air
cooling portion includes an uppermost portion, a lowermost portion,
and first and second opposed side portions. The first and second
opposed manifolds each include a body fluidly coupled to a
respective one of the first and second side portions of the air
cooling portion, an upper mounting portion extending upwardly from
the body and above the uppermost portion of the air cooling
portion, and a lower mounting portion extending downwardly from the
main body and below the lower-most portion of the air cooling
portion. The upper and lower mounting portions of the first and
second manifolds are adapted to together support substantially the
entire combined weight of the air cooling portion and the
radiator.
[0012] Some of these air cooler assembly embodiments also include
an upper engine mounting cross member and a lower engine mounting
cross member. The upper engine mounting cross member extends from
side to side of the radiator. The upper mounting portions of the
first and second manifolds each include a first upper mounting
feature and a second upper mounting feature. The first upper
mounting features are adapted for use in mounting the radiator to
the upper mounting portions and the second upper mounting features
are adapted for use in mounting the upper mounting portion to the
upper engine-mounting cross member of the cooling system. The lower
engine mounting cross member extends from side to side of the
radiator. The lower mounting portions of the first and second side
manifolds each include first lower mounting features and second
lower mounting features. The first lower mounting features are
adapted for use in mounting the radiator to the lower mounting
portions and the second lower mounting features are adapted for use
in mounting the lower mounting portions to a lower engine-mounting
component of the cooling system. In some cases, the lower engine
mounting cross member includes a portion of a fan shroud with an
interior surface bounding a portion of an air flow passageway from
the radiator.
[0013] Some exemplary embodiments of a surge tank for an
engine-mountable cooling system for a vehicle include an internal
reservoir volume for containing coolant fluid and a mounting member
adapted to mount the cooling system to an engine of the vehicle
such that the surge tank supports a substantial portion of the
weight of the cooling system.
[0014] In some of these surge tank embodiments, the surge tank is
elongated in a side to side direction when mounted in the vehicle.
The surge tank includes a first side end portion, a second side end
portion opposed to the first side end portion, and an intermediate
portion extending between the first and second side end portions.
The first and second side end portions are adapted to mount a fluid
cooling component of the cooling system to the surge tank and the
intermediate portion is adapted to mount the cooling system to the
engine.
[0015] In some surge tank embodiments, the surge tank includes two
primary components: an upper portion and a lower portion. The upper
and lower portions together define the internal reservoir volume.
One of the upper and lower portions is comprised primarily of a
first material and the other of the upper and lower portions is
comprised primarily of a second material such that the first
material is substantially more rigid than the second material. In
some cases, the mounting member comprises one of the upper and
lower portions.
[0016] Some exemplary embodiments of an engine-mounted cooling
system for a vehicle include a charge air cooler, a radiator, an
upper engine-mounting member and a lower engine-mounting member.
The charge air cooler includes an upper portion and a lower
portion. The radiator is mounted to the charge air cooler. The
upper engine-mounting member is attached to an upper portion of the
charge air cooler. The lower engine-mounting member is attached to
a lower portion of the charge air cooler. The upper and lower
engine-mounting members couple the integrated cooling system to an
engine and support at least the majority of the entire weight of
the cooling system.
[0017] In some of these cooling system embodiments, the charge air
cooler includes a first side manifold and a second side manifold
and the upper engine-mounting member is attached to both the first
and second side manifolds. In some cooling system embodiments, the
charge air cooler includes a first side manifold and a second side
manifold and the lower engine-mounting member is attached to both
the first and second side manifolds. In some cooling system
embodiments, the charge air cooler includes a first side manifold
and a second side manifold and the lower engine-mounting member is
attached to both the left side manifold and the right side
manifold. In some cooling system embodiments, the upper
engine-mounting member comprises a portion of a surge tank. In some
cooling system embodiments, the lower engine-mounting member
comprises a portion of a fan shroud. In some cooling system
embodiments, the charge air cooler includes a first side manifold
and a second side manifold and the lower engine-mounting member is
attached to both the first and second side manifolds.
[0018] The inventive features include all novel and non-obvious
features disclosed herein both alone and in novel and non-obvious
sub-combinations with other elements. In this disclosure, it is to
be understood that the terms "a", "an" and "at least one" encompass
one or more of the specified elements. That is, if two of a
particular element are present, one of these elements is also
present and thus "an" element is present. The phrase "and/or" means
"and", "or" and both "and" and "or".
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a rear perspective view of an integrated cooling
system, according to one embodiment, including a radiator, a charge
air cooler, a fan, a lower fan shroud, a surge tank and engine
mounting brackets.
[0020] FIG. 2 is a front perspective view of one embodiment of the
charge air cooler of FIG. 1.
[0021] FIG. 3 is a rear perspective view of one embodiment of the
lower fan shroud of FIG. 1.
[0022] FIG. 4 is a rear perspective view of an exemplary upper
cross member of another embodiment of an integrated cooling
system.
[0023] FIG. 5 is a rear perspective view of one embodiment of the
surge tank of FIG. 1.
DETAILED DESCRIPTION
[0024] With reference to FIG. 1, an integrated cooling system 2 is
shown. The cooling system 2 can be for a vehicle, such as a truck,
and more specifically for a vehicle engine. The cooling system 2
can be operable to dissipate heat and/or otherwise regulate
temperatures of the engine and other parts of the vehicle. The
cooling system 2 is primarily intended to be mounted to and
structurally supported by an engine.
[0025] The integrated cooling system 2 can comprise a plurality of
individual components integrated into one system. For example, the
cooling system 2 can comprise a radiator 4, a fan 6, an air cooling
sub-system 7 comprising central cooling portion 40 and first and
second side manifolds 8 and 10, a lower fan shroud 50, an upper fan
shroud 14, a surge tank 16, as well as other components. Many of
these components can serve two or more functions, such as
conducting fluids and serving as weight-bearing mounting
members.
[0026] FIG. 2 shows an exemplary embodiment of air cooling
sub-system 7 of the integrated cooling system 2. In one embodiment,
the air cooling sub-system 7 can comprise a charge air cooler for
cooling gas from a supercharger (not shown). First and second side
manifold components, such as left side manifold 8 and right side
manifold 10 (as used herein, left, right, front and rear are from
the perspective of a driver of a vehicle equipped with the cooling
system 2), can be coupled to opposite sides of a central, primary
air cooling component 40 positioned in front of the radiator 4. The
side manifolds 8, 10 can be fluidly coupled to the central
component 40 and can serve as both structural supports for the
central component and as fluid conduits for conducting fluids
through the central component.
[0027] The left side manifold 8 can comprise an at least partially
hollow body 22 having a side portion 24 for coupling the body to a
side portion 18 of the central component 40. An upper mounting
portion 26 is shown extending upwardly from the body 22 and
extending above the top of the central component 40. The upper
mounting portion 26 can comprise mounting features, such as
apertures 28 and 30, for coupling the left side manifold 8 to other
components, such as to the radiator 4 and/or a surge tank 16 (see
FIG. 1). In the embodiment shown, a fastener can pass through the
aperture 30 of the side component 8 and an aperture 120 of the
radiator 4 (see FIG. 1) to fasten the upper portion of the left
side manifold 8 to a corresponding upper left portion of the
radiator.
[0028] As shown in FIG. 2, a lower mounting portion 32 is shown
extending downward from the body 22 and extending below the bottom
of the central component 40. The lower mounting portion 32 can
comprise mounting features, such as apertures 34, 37 and/or 38, for
coupling the lower portion 32 of the left side manifold 8 to other
components of the cooling system 2. In the embodiment shown, a
fastener can pass through aperture 34 and through aperture 122 of
the radiator 4 (see FIG. 1) to fasten the lower mounting portion 32
of the left side manifold 8 to the bottom left portion of the
radiator 4. In other embodiments, apertures 34 and 122 can be
oriented vertically such that a fastener can be inserted upward
into the bottom of the radiator 4. FIG. 1 also shows a fastener
passing through aperture 52 of the lower fan shroud 50 and aperture
38 of the lower portion 32 (hidden) and another fastener passing
through aperture 54 of the lower fan shroud 50 and aperture 37 of
the lower portion 32 (hidden) to fasten the lower mounting portion
of the left side manifold 8 to the lower fan shroud 50. The body 22
of side component 8 can also comprise an opening portion 36 (see
FIG. 2) extending rearwardly from the body 22. The opening portion
36 can be coupled to a conduit (not shown) to conduct fluid into
and/or out of the hollow portion within the body 22.
[0029] The right side component 10 of the sub-system 7 can be
substantially similar to the left side manifold 8, but in a
generally mirrored relation, and can comprise similar features for
connecting the right side component to the central component 40,
the radiator 4, the lower fan shroud 50 and other components of the
cooling system 2. The left and right side manifolds 8, 10 can
cooperate with the central component 40 to conduct fluid into one
side component, through the central component, and out of the
opposite side component. The central component 40 can function like
a radiator to conduct heat from the fluid passing through the
central component 40. In some embodiments, for example, hot gasses
from a turbocharger are conducted through the central component 40,
cooled, and then recirculated back through the engine systems.
[0030] The left side manifold mounting features 30, 34 along with a
similar pair of mounting features of the right side manifold can
together mount the radiator 4 to the manifolds 8, 10. The upper and
lower mounting portions of the manifolds 8, 10 can also mount the
manifolds to upper cross member 16 and lower fan shroud 50 and can
thus be sufficient to support substantially the entire combined
weight of the air cooling sub-system 7 and the radiator 4.
[0031] In some embodiments, the side components 8, 10 each comprise
a one piece monolithic component, while in other embodiments they
can comprise a plurality of subcomponents assembled together.
[0032] With reference to FIG. 3, the lower fan shroud 50 is shown.
The illustrated lower fan shroud 50 can function both as a
structural support member and as a fan shroud. The lower fan shroud
50 can comprise a central portion 60, a left side portion 56 and a
right side portion 62. The central portion 60 can function in
conjunction with other fan shroud components, such as the upper fan
shroud 14, to form a full shroud around the fan 6. The fan shroud
can improve the functionality of the fan 6 in drawing air through
the radiator 4 and/or the central component 40 by restricting the
air flow paths around the periphery of the fan. The fan shroud can
comprise a central annular rim 66 that encircles the outer
perimeter of the fan blades. The central portion 60 of the lower
fan shroud 50 can comprise a neck portion 58 that includes a curved
rim portion 64 that forms a portion of the annular rim 66. The
central portion 60 can also comprise one or more upper flange
portions 66 that can be attached to one or more lower flange
portions 68 of the upper fan shroud 14, such as with fasteners 69.
The left side portion 56 can extend forwardly around the left side
of the radiator 4 and overlap the lower mounting portion 32 of the
left side manifold 8. The left side portion 56 of the lower fan
shroud 50 can comprise mounting features, such as apertures 52 and
54, for attaching the lower fan shroud 50 to other components of
the cooling system 2. In the embodiment shown, a fastener passes
through aperture 52 and aperture 38 and a second fastener passes
through aperture 54 and aperture 37 to fasten the lower fan shroud
50 to the lower mounting portion 32 of the left side manifold 8.
The right side portion 62 of the lower fan shroud 50 can be
substantially similar to the left side portion 56 and can also
include features for fastening the lower fan shroud 50 to the right
side manifold 10. The lower fan shroud 50 can further comprise
features for attaching it to other components, such as the radiator
4. In the embodiment shown, the lower fan shroud 50 comprises
features 70 and 72 for attaching a lower mounting bracket 74 (see
FIG. 1) to the structural shroud. The lower mounting bracket 74 can
be a component of the engine (not shown), a component of the
cooling system, or an intermediate component between the cooling
system and the engine. The lower mounting bracket 74 can, for
example, mount the lower fan shroud 50, and thereby the assembled
cooling system 2, to the engine and/or other vehicle components.
The lower fan shroud 50 can comprise a monolithic one-piece member
or can comprise a plurality of subcomponents assembled
together.
[0033] With reference to FIG. 4, the integrated cooling system 2
can comprise an upper cross support 80 having an intermediate
portion 82, a left end portion 84 and a right end portion 85. The
left end portion 84 can extent forwardly around the left side of
the radiator 4 and comprise mounting features, such as aperture 86,
for fastening the upper cross support 80 to the left side manifold
8. In the embodiment shown, a fastener passes through aperture 86
and aperture 28 to fasten the left side portion 84 of the upper
cross support 80 to the upper mounting portion 26 of the left side
manifold 8. The right side portion 85 can be substantially similar
to the left side portion 84 and can comprise mounting features used
to attaching the upper cross support 80 to the right side manifold
10. The upper cross support 80 can comprise mounting features 88,
such as tabs or flanges, for use in attaching the upper cross
support 80 to the radiator 4 and/or the upper fan shroud 14. The
intermediate portion 82 can be horizontally disposed and can extend
rearwardly away from the upper fan shroud 14 and can comprise
mounting features, such as apertures 90, for use in attaching the
upper cross member 80 to an upper mounting bracket 92 (see FIG. 1).
The upper mounting bracket 92 can, for example, couple the upper
cross support 80, and thereby the assembled cooling system 2, to
the engine (not shown) and/or other vehicle components. The upper
mounting bracket 80 can comprise a one-piece member or can comprise
a plurality of subcomponents assembled together. The upper mounting
bracket 92 can, for example, mount the upper cross support 80, and
thereby the assembled cooling system 2, to the engine and/or other
vehicle components.
[0034] With reference to FIGS. 1 and 5, the upper cross support 80
can be replaced by and/or supplemented by a surge tank 16. The
surge tank 16 can comprise a structural element to rigidify the
upper portion of the integrated cooling system 2. The surge tank 16
can comprise features similar to the upper cross support 80, such
as left and right end portions 108, 110 that extend forwardly
around the radiator 4 and include mounting features, such as an
aperture 112, for attaching the surge tank 16 to the left and right
side manifolds 8, 10 of the charge air cooler 7. The surge tank 16
can further comprise a top portion 102 and a bottom portion 104
that can together form an at least partially hollow inner surge
tank volume. One portion, such as the bottom portion 104, can
comprise a reinforced member of, for example, metal, with the other
portion comprising a polymeric material such as polypropylene
plastic (Hostacom 1850 polypropylene is a more specific example).
In other embodiments, both the top portion 12 and the bottom
portion 104 can comprise a reinforced member. In other embodiments,
the surge tank 16 can be formed from a single component or more
than two subcomponents. The inner volume can act as an overflow
tank for storing of excess coolant fluid from the cooling system 2.
The surge tank 16 can include one or more inflow/outflow conduit
portions, such as a conduit 106 extending from the lower portion
104. Similar to the upper cross support 80, the surge tank 16 can
be horizontally disposed and can extend rearwardly from the
radiator 4 and/or upper fan shroud 14 and comprise mounting
features, such as apertures 114, for attaching an upper mounting
bracket 92 to the surge tank, and thereby coupling the cooling
system 2 to the engine and/or other vehicle components. The upper
mounting bracket 92 can be a component of the engine, a component
of the cooling system, or an intermediate component between the
cooling system and the engine.
[0035] Many of the components of the integrated cooling system 2
can serve more than one function and thus can take the place of
multiple components of a conventional vehicle cooling system. For
example, the left and right side manifolds 8, 10 can replace both
conventional radiator side mounting features, such as brackets,
braces, and channels, and conventional fluid conducting manifolds.
The lower fan shroud 50, for another example, can replace both a
conventional lower fan shroud and a conventional lower structural
support member. Similarly, the surge tank 16 can replace both a
conventional surge tank and conventional upper strut rods with
engine supports. In each example, the parts count is reduced and
the complexity of the cooling system is reduced. The integrated
cooling system 2 can further result in simpler and quicker
assembly, reduced weight and fuel efficiency, reduced space
requirements, and increased integrity and durability.
[0036] It should be noted that any portion or portions of the
cooling systems described herein that can comprise exemplary
attachment features or mounting features, such as apertures with
fasteners passing therethrough, can alternatively or additionally
comprise any other suitable attachment or mounting means known in
the art, such as interlocking or interfitting features, for
example.
[0037] The cooling system components can comprise metal and/or
polymer materials, such as carbon fiber and/or glass fiber
reinforced thermoset plastic or other fiber reinforced composite
materials. These components can be formed in a conventional manner,
such as by stamping, casting, and/or molding. The side manifolds 8,
10 can be comprised of cast aluminum, for example. The lower fan
shroud 50 can be comprised of stamped aluminum and/or steel, for
example. The upper fan shroud 14 can be comprised of polypropylene,
for example. The cross member 80 can be comprised of stamped steel,
for example. The surge tank 16 can be comprised of stamped steel
and/or a plastic tank, for example.
[0038] In view of the many possible embodiments to which the
principles of our invention may be applied, it should be recognized
that illustrated embodiments
[0039] Having illustrated and described the principles of the
invention with reference to a number of embodiments, it should be
apparent to those of ordinary skill in the art that these
embodiments are only examples of the invention and should not be
considered a limitation on the scope of the invention. The
illustrated embodiments may be modified in arrangement and detail
without departing from these inventive principles. We claim all
such modifications that fall within the scope of the following
claims.
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