Cooling module and method for assembling cooling module

Abstract

A cooling module (10) for a vehicle, wherein the cooling module (10) includes: two or more heat exchangers (14; 16; 18), wherein the heat exchangers include a top portion and a bottom portion extending in a width direction (Y) and a side portion (24) extending in a height direction (Z); at least one module carrier (50) configured to carry and secure at least one of the heat exchangers (14); the module carrier (50) includes: a first interface (50.1) having mounting features for securing the cooling module (50) in the vehicle and a second interface configured to engage the side portion (24). The interface (49) is characterized in that the side portion (24) includes a blocking member (24.2) that engages with a third interface (50.2) provided on the module carrier (50) for forming a blocking engagement during the assembly of the respective heat exchanger (14) onto the module carrier (50); wherein the blocking member (24.2) and the third interface (50.2) are configured to engage at multiple locations along the width direction (Y), thereby enabling selective adjustment of the positioning of the heat exchanger (14) relative to the module carrier (50) during the assembly of the cooling module (10).

Description

Technical Field

[0001] This invention relates generally to the field of automotive engine cooling and air conditioning systems, and more particularly to cooling modules and methods for assembling cooling modules. Background Technology

[0002] Engines used in motor vehicles require at least one cooling system to ensure adequate heat dissipation and thus proper cooling during operation. Typically, a cooling system includes at least a fan unit and a radiator for discharging atmospheric heat from the circulating liquid coolant. Additionally, motor vehicles provide air conditioning in the passenger compartment, which also requires atmospheric heat dissipation to operate effectively. This is typically achieved using a condenser unit through which heated refrigerant circulates.

[0003] Typically, condensers and radiators are rectangular in shape with similar dimensions, arranged in the engine compartment of a vehicle with a narrow gap between them, thereby moderating airflow, for example, when the vehicle is running. In this paper, the fan unit is arranged on the front or rear side of the condenser-radiator assembly (depending on the design) to generate airflow through the aforementioned components.

[0004] This assembly, comprising a condenser, radiator, and fan, constitutes what is known as a cooling module. A cooling module is often also called a CRFM, which stands for Condenser Radiator and Fan Module. The components of the CRFM are assembled together and installed in the vehicle via mounting parts called module carriers. A typical module carrier has a first interface designed to engage with the edge region of the heat exchanger, and it is typically threaded onto the heat exchanger. A second interface is constructed for securing to the engine compartment, for example, via a mounting shaft.

[0005] One issue with standard cooling modules involves their dimensions, and therefore their assembly and installation in vehicles. In the mass production of cooling modules, the dimensions (measurements) of the components that form the module typically vary within a few millimeters. In particular, components of the cooling module, such as radiators that typically belong to the same production batch, may differ in size from one another. While these dimensional variations are considered to be within acceptable production tolerances, they can complicate the installation of the cooling module in a vehicle. Summary of the Invention

[0006] The purpose of this invention is to provide a cooling module and a method for assembling the cooling module, which solves the shortcomings mentioned above.

[0007] This objective is achieved by the cooling module as defined in the independent claims and the method for assembling the cooling module.

[0008] According to the present invention, a cooling module for a vehicle includes two or more heat exchangers, wherein each heat exchanger includes a top portion and a bottom portion extending in a width direction and a side portion extending in a height direction. The cooling module also includes at least one module carrier configured to carry and secure the heat exchangers within the vehicle. The module carrier includes a first interface with mounting features for securing the cooling module in the vehicle and a second interface configured to mate / engage with a side portion of at least one of the heat exchangers.

[0009] It should be understood that the side portion includes a blocking element that mates with a third interface provided on the module carrier for blocking engagement during the assembly of the respective heat exchanger onto the module carrier. The blocking element and the third interface are configured to engage at multiple locations along the width direction, thereby allowing selective adjustment of the heat exchanger's positioning relative to the module carrier during the assembly of the cooling module.

[0010] The module carrier used in the cooling module of this invention is therefore designed so that it can be mounted to the heat exchanger, but its position relative to the side portions in the width direction can be adjusted to compensate for manufacturing tolerances. This allows a given (nominal) distance to be maintained between the two lateral ends of the cooling module, as required for mounting a cooling module in a vehicle. This invention differs from conventional methods in which the module carrier is fixed directly against the side portions of the heat exchanger.

[0011] "Heat exchanger" can refer to any form of conventional heat exchanger or heat exchanger assembly. For example, the plurality of heat exchangers may include at least one radiator, at least one condenser, and / or at least one pressurized air cooler. Also, for example, a fan unit may be connected to or form part of the plurality of heat exchangers. The fan unit may include a motor-driven fan and a fan shroud. These components may have a conventional design. Each heat exchanger may include an exchanger core with a plurality of exchanger tubes extending between an inlet and an inlet / outlet box. The fluid to be cooled may enter the heat exchanger via the inlet box and flow through the tubes of the exchanger core to the outlet box, where it is cooled. External fins may be provided on the tubes to increase heat transfer to the ambient air. Furthermore, the radiator, condenser, and cooler may, for example, be a so-called Type I, according to which the tubes of the heat exchanger core are oriented horizontally and the inlet and outlet boxes are arranged at opposite tube ends. However, other heat exchanger designs are also possible.

[0012] It is worth noting that in conventional applications where cooling modules are intended for use in thermally powered vehicles, a cooling module may include a radiator (for engine cooling), a condenser (for the air conditioning circuit), possibly a booster air cooler and / or an oil cooler and a fan assembly. This forms a conventional CRFM. However, a cooling module may include various heat exchangers associated with any coolant circulation within the engine for different purposes.

[0013] In other applications, particularly for all-electric vehicles, one or more types of cooling modules may be included. For example, a cooling module may include a first (high-temperature) radiator and a second (low-temperature) radiator. The first radiator is typically connected to a first coolant loop cycle with a relatively high-temperature coolant. The second radiator is used for a secondary coolant loop cycle that typically operates at a low coolant temperature, for alternative configurations of air conditioning systems, or for electric vehicle applications (e.g., battery cooling, 48V). Because such a cooling module incorporates heat exchange, it is often also referred to in a broad sense as a CRFM (Crane-Cooled Fluid Meter).

[0014] The plurality of heat exchangers, or each of them, may have a substantially rectangular and / or cuboid shape. One of the heat exchangers may have a substantially quadrilateral and / or planar form. The heat exchanger may have a top and bottom portion extending along the width direction and a side portion extending along the height direction. The width direction may also be referred to as the horizontal direction, or the direction along the Y-axis. The height direction may also be referred to as the vertical direction, or the direction along the Z-axis.

[0015] A "module carrier" refers to a structural element of a cooling module, constructed to support and secure heat exchanger assemblies in an engine. The module carrier may be arranged at the edge portions and / or edge regions and / or corner portions of at least one of the plurality of heat exchangers. For example, the module carrier may be arranged on the edge portion of a radiator. It should be noted herein that the term "support and secure" refers to the direct and / or indirect support and / or securement of at least one of the heat exchangers. Since the heat exchangers can be assembled to each other, the module carrier may be arranged on at least one of the heat exchangers to support and secure the plurality of heat exchangers.

[0016] Typically, two modular carriers are used to support the heat exchanger assembly from opposing side portions. The two modular carriers may be designed according to the design of this invention (i.e., with three interfaces), or one of the modular carriers may be a conventional design (i.e., first and second interfaces). The modular carrier may include a first interface with mounting features for securing a cooling module in a vehicle. "Interface" generally refers to a portion of the modular carrier, which may be a port, cross, socket, outlet, connector, insertion unit, male connector, female connector, mounting device, pivot, shaft, or similar structural element for achieving a connection between the modular carrier and at least one other element. For example, the first interface may be configured for mounting a cooling module in a vehicle. Also, for example, the modular carrier may include a second interface configured for mating, i.e., engaging / holding / connecting a side portion of at least one of the plurality of heat exchangers, such as a side portion of a radiator. The term "mounting feature" generally refers to a structural element or plurality of elements for achieving support. For example, a mounting feature may be an opening, hole, protrusion, slot, groove, rod, recess, shaft, pivot, or similar element. In some embodiments, the module carrier is formed as a corner element, wherein the second interface mates with the side and bottom portions of the heat exchanger.

[0017] In practice, the heat exchangers can engage with the second interface of the module carrier in such a way that the heat exchangers are directly fixed to or held thereon. Alternatively, and quite commonly, the first heat exchanger is directly fixed and supported by the heat exchanger, and other heat exchangers are attached to the first heat exchanger or adjacent heat exchangers. Other components, such as, for example, fans or grilles, are directly attached to the heat exchangers. In the latter case, some heat exchangers are thus indirectly attached to the module carrier, but the module carrier still functions to fix and support the heat exchanger assemblies within the engine.

[0018] "Side portion" can refer to a lateral portion / section / section / part of at least one of the plurality of heat exchangers. For example, a second interface can be configured to engage / connect a side portion of the radiator to the module carrier. For example, the side portion of the radiator may typically be part of a housing and / or frame element or part of an assembly of different frame elements of the radiator. Also, for example, the second interface may additionally or alternatively be configured to mate / retain / engage with a side portion of another of the plurality of heat exchangers. Furthermore, the second interface may also be configured to attach to an edge element forming the surrounding frame of the cooling module.

[0019] The side portion includes a blocking element that mates with a third interface of the module carrier to form a blocking engagement during the assembly of the respective heat exchanger onto the module carrier. The blocking element and the third interface are configured to engage at multiple locations along the width direction, thereby allowing selective adjustment of the heat exchanger's positioning relative to the module carrier during the assembly of the cooling module. That is, although the blocking element engages with the third interface along the height direction, the two can be locked together at different locations along the width direction when the heat exchanger is assembled with the module carrier.

[0020] A "blocking element" refers to a connecting element used for adjustment and positioning and for blocking / impeding / preventing relative movement between the side portion and the module carrier. Specifically, the blocking element prevents movement in the width direction. Similar to the interface described, the blocking element can generally be a cross, port, socket, outlet, connector, insertion unit, male connector, female connector, mounting device, pivot, shaft, block structure, or similar structural element for connecting the side portion to the module carrier.

[0021] A "third interface" is a component configured to mate / engage with a blocking element. For example, the third interface may also include one or more mounting features. The third interface is arranged on the lateral side of the module carrier to form a blocking engagement, or connection / joining, with the blocking element during the assembly of the respective heat exchanger onto the module carrier. For example, the blocking element and the third interface may form a force-locking and / or form-locking and / or friction-locking connection during assembly. Also, for example, the blocking element and the third interface may be configured such that when the blocking element is inserted into at least a section of the third interface, an interference fit is obtained, whereby the component is compressed / expanded, thereby further enhancing the form-locking and / or friction-locking connection.

[0022] Furthermore, the third interface provides multiple locations for securing the blocking element. For example, the third interface may have mounting features such as slots, where the slots have a larger dimension (in the width direction) than the blocking element. Such a third interface configuration allows the blocking element to be arranged in one of multiple possible locations, i.e., multiple locations along the width direction. Therefore, the positioning of the heat exchanger relative to the module carrier can be selectively adjusted during assembly. This structure is advantageous for assembling cooling modules and / or a series of cooling modules because the total width of the cooling modules, i.e., the width between two opposing carrier modules, can be adjusted to conform to the expected installation distance (nominal distance) in the engine. In other words, this structure can compensate for a wider range of manufacturing tolerances, or different measurements of heat exchangers in a series of heat exchangers. Furthermore, due to the engagement of the blocking element with the third interface, the module carrier is fixedly attached to at least one of the heat exchangers. Therefore, once the blocking element has been secured to the third interface during assembly, relative movement of the blocking element along the width direction of the third interface is restricted / prevented.

[0023] In some embodiments, the third interface includes a slot extending in the width direction. The slot, or notch / groove, allows a corresponding stop of the side element to lock into the third interface of the module carrier. Furthermore, the slot mitigates the elastic expansion of the third interface when the stop is engaged with the module carrier during assembly.

[0024] In some embodiments, the stop has a tapered profile for securing the stop within a slot in the third interface. "Profile" may refer to a cross-sectional profile. For example, the stop may have a tapered profile in a plane perpendicular to the width direction of the slot, wherein the profile tapers vertically. The tapering / narrowing / thinning / tapering profile may become thinner and / or narrower toward one end. For example, the profile may be substantially conical or rectangular. A stop with a tapered profile facilitates the connection of the stop to the third interface. This can result in significant time savings during assembly.

[0025] In some embodiments, the module carrier further includes a guide section with a guide slot for guiding a retaining rod of the side element. The guide slot may extend along the height direction, or in a direction perpendicular to the width of the third interface. The guide slot may be configured to guide the retaining rod of the side element. The retaining rod may be an element configured to be disposed within the guide slot. The guide slot and the retaining rod may also be configured to form a tolerance fit. For example, the guide slot and the retaining rod may form a tolerance fit in a plane perpendicular to the vertical / height direction. In this document, "tolerance" refers to the allowable variation in a measurement from the original measurement. "Tolerance fit" may refer to the connection of two elements, wherein at least one of the two elements has dimensions configured to compensate for variations / tolerances in the measurement of the other element. In other words, the guide slot and the retaining rod may form a connection with clearance. This allows cooling modules in a series of cooling modules, which may vary slightly in their total length, to be connected to the module carrier regardless of their differences in an industrial environment. Furthermore, during the assembly of the module carrier and the side element, the retaining rod has already confined / held the side element in the guide slot of the module carrier. The assembly of the module carrier and side elements may include several steps. In one step, a retaining rod may be inserted into a guide slot, where the side elements can still be adjusted on the module carrier. In another step, the module carrier and side elements may be securely attached to each other via a third interface engaging with a stop / blocking element.

[0026] In one embodiment, the fixing rod has a T-shaped profile. For example, the fixing rod may have a T-shaped profile, or a T-shaped cross-sectional profile. The T-shaped profile may be positioned in a plane perpendicular to the height direction.

[0027] In addition to guiding the heat exchanger during assembly, the combination of the retaining rod and the guide slot locks the heat exchanger to the module carrier to prevent movement in a direction perpendicular to the width of the heat exchanger. This assembly also allows for the distribution of mechanical stresses present at the first and second interfaces of the module carrier.

[0028] In one embodiment, the blocking member further includes at least one wall portion provided with a gripping structure. The gripping structure may refer to surface structures and / or elements arranged on at least one wall portion / surface of the blocking member. The gripping structure reduces or prevents relative movement of the blocking member along its width direction.

[0029] In some embodiments, the gripping structure includes a plurality of ridges. Additionally, each of the plurality of ridges may have a triangular profile. The gripping structure including a plurality of ridges may have teeth / engaging portions / interlocking portions. In particular, the gripping structure may engage with a third interface, for example, having ribs provided on at least one wall segment of a slot in the third interface. The teeth formed by the ridges and the third interface of the module carrier are particularly effective in preventing lateral movement of the blocking element.

[0030] In some embodiments, the groove further includes a first wall segment and a second wall segment, wherein the first wall segment and the second wall segment at least partially form the tapered profile of the groove. Additionally or alternatively, the first wall segment and the second wall segment may at least partially form the V-shaped profile of the groove and / or at least partially form the U-shaped profile of the groove. The profile formed by the first wall segment / first wall portion and the second wall segment / second wall portion may correspond to the tapered profile of the stop.

[0031] In some embodiments, the first wall segment and / or the second wall segment have ribs. Additionally or alternatively, a plurality of guide elements abut the first wall segment and / or the second wall segment. The ribs may restrict relative movement of the stop member along its width. Furthermore, the ribs may interlock with a plurality of ridges of the stop member.

[0032] In some embodiments, the module carrier further includes a platform having an elongated opening. The platform may extend in a plane perpendicular to the vertical / height direction. The length of the elongated opening may extend in the width direction. The elongated opening is configured to provide tolerances for fasteners such as screws. Fasteners may extend vertically through the elongated opening for securing the module carrier to side elements.

[0033] The fastener connection is preferably designed such that once the fastener is in place, the support surface of the heat exchanger side portion contacts the platform. In this document, the two contacting surfaces, namely the platform surface and the support surface, may each be provided with ribs to restrict relative movement. Furthermore, the platform may be provided on each side by opposing walls extending in the width direction (and thus spaced apart in the thickness direction) to surround the side portion.

[0034] In some embodiments, the first interface includes a mounting feature configured to support the buttonhole. For example, the mounting feature, or support element, may be a shaft or pivot for supporting the buttonhole. Alternatively, the mounting feature may extend through an opening in the buttonhole. The buttonhole enhances the secure attachment of the module carrier within the vehicle's engine compartment or assembly frame.

[0035] The present invention also relates to a method for assembling a cooling module. The method for assembling a cooling module according to the invention includes: providing two or more heat exchangers, wherein the heat exchangers include a top portion and a bottom portion extending in a width direction and a side portion extending in a height direction; providing a first module carrier and a second module carrier configured to carry and fix at least one of the heat exchangers, wherein at least one of the module carriers includes a first interface with mounting features for fixing the cooling module in a vehicle, a second interface configured to engage the side portion, and a third interface provided on the module carrier for forming a blocking engagement with a blocking element; wherein the method further includes providing an assembly frame having at least two retaining elements for fixing the first module carrier and the second module carrier; and positioning the first module carrier and the second module carrier relative to each other at a predetermined distance on the retaining elements. The method further includes selectively adjusting the positioning of the heat exchangers relative to the module carriers in the width direction during the assembly of the cooling module. The improvements and embodiments of the cooling module mentioned above are also applicable to the method for assembling the cooling module.

[0036] An "assembly frame" refers to a support structure used to bring together the different components of a cooling module. For example, an assembly frame may include at least two support arms, each of which, or retaining elements, is configured to hold the module's load-bearing components. The assembly of the cooling module may include the following steps:

[0037] In the first step of the method, the first module carrier and the second module carrier may be positioned on the assembly frame at a predetermined distance from each other, or positioned on / within the retaining elements of the assembly frame. The assembly frame may have at least two retaining elements for securing the module carriers. During or before positioning, the first module carrier and the second module carrier may be secured simultaneously or sequentially.

[0038] In the next step, a heat exchanger, such as a radiator, may be attached to the first and second module carriers. During this step, the positioning of the heat exchanger relative to the stationary module carriers is selectively adjusted along its width. Once the positioning has been determined, the heat exchanger is attached to the first and second module carriers. In subsequent steps, other components may be attached to the heat exchanger and / or the first and second module carriers.

[0039] In one embodiment, a blocking element is formed on at least one side portion of a heat exchanger. For example, the blocking element may be formed of plastic and / or composite materials and / or resins and / or similar materials. The blocking element may be molded integrally, for example, by injection molding.

[0040] In one embodiment, a groove is formed within the third interface. Similar to a blocking element, the groove of the third interface, or the third interface itself, may be formed of plastic and / or composite materials and / or resins and / or similar materials. The third interface and the groove of the third interface can be formed by injection molding.

[0041] In one embodiment, the gripping structure is formed on at least one wall portion of the blocking element. The gripping structure can also be formed by injection molding. Alternatively or additionally, the gripping structure can be formed by surface treatment of the blocking element.

[0042] Other aspects and features of the invention are derived from the dependent claims, the drawings and the following description of embodiments. Attached Figure Description

[0043] Embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, wherein

[0044] Figure 1 This is an exploded perspective view of the cooling module;

[0045] Figure 2 This is a perspective view of an embodiment of the module carrier;

[0046] Figure 3 This is a perspective view of a section of an embodiment of the side elements of a heat exchanger;

[0047] Figure 4 This is a perspective view of an embodiment of a side element partially assembled to a module carrier;

[0048] Figure 5 This is a cross-sectional view of an embodiment of the side elements and module carrier;

[0049] Figure 6 This is a perspective view of an embodiment of an assembly frame with fixed modular carriers;

[0050] Figure 7 yes Figure 6 A perspective view of the assembly frame, in which the heat exchanger has been assembled to the module carrier;

[0051] Figure 8 yes Figure 7 A perspective view of the assembly frame, in which the cooling module is fully assembled. Detailed Implementation

[0052] Figure 1An exploded perspective view of the cooling module 10 is shown. The cooling module 10 typically includes several cooling components, such as heat exchangers 1 and 2 surrounded by multiple edge elements 5, 6, 7, and 8. The cooling module 10 is typically mounted in the engine compartment of a vehicle.

[0053] exist Figure 1 In the illustrated embodiment, the cooling unit 10 includes two heat exchangers: a first radiator 1 and a second radiator 2 (which may be referred to as a low-temperature radiator), and a fan unit 4. Reference numeral 3 indicates a protective grid. These components can be of a conventional design. In an alternative embodiment, component 2 can be a condenser.

[0054] Each of the heat exchangers 2 and 3 includes a top portion and a bottom portion extending in the width direction Y, and a side portion extending in the height direction Z. For example, radiator 1 includes two side portions 12 extending in the height direction Z and a top portion 13 and a bottom portion 13' extending in the width direction Y. The side portion 12 of radiator 1 is formed as an inlet box and an outlet box. Each of the heat exchangers includes a plurality of exchanger tubes 11, 21 extending between the inlet box and the outlet box. The low-temperature radiator 2 also has a similar box, which forms side portions 22, 22 and a top portion 23 and a bottom portion 23.

[0055] The fluid to be cooled (not shown) enters heat exchangers 2 and 3 through the inlet box and flows through the tubes of the exchanger core to the outlet box, where it is cooled by ambient air. Figure 1 In the illustrated embodiment, radiator 1 and low-temperature radiator 2 are so-called Type I heat exchangers, meaning the tubes of the heat exchanger core run horizontally, and the inlet and outlet boxes are arranged at opposite tube ends. Both heat exchangers 1 and 2 are provided with inlet and outlet ports arranged in the inlet and outlet boxes to allow fluid communication with the corresponding coolant fluid circuits (not shown). However, other heat exchanger designs or configurations are also possible.

[0056] Radiators 1 and 2 are surrounded by baffle elements 5, 6, 7, and 8. The baffle elements 5, 6, 7, and 8 form the external frame of the cooling module, allowing the cooling module 10 to be hermetically installed in the vehicle. The cooling module 10 also includes two module carriers 50 configured to support and secure the radiators. Alternatively, the module carriers 50 may be configured to support and secure only the radiators 1 and / or a portion thereof.

[0057] Each module carrier 50 has a first interface 51 with mounting features for securing the cooling module 10. The first interface 51 is arranged on the lateral side of the module carrier 50. The first interface 51 extends in the width / horizontal direction Y. The mounting features of the first interface 51 have an axis for supporting a notch 52, or for extending through the notch 52.

[0058] The module carrier 50 is also provided with a second interface 53 for engaging / receiving the side portion 12 of the heat sink 1. In addition, the end portion of the baffle element 7, or baffle element 6, may also engage with the second interface 53.

[0059] Figure 1 In one embodiment, one of the cooling modules 50 is provided with a third interface 54 disposed on the upper portion of the module carrier 50. However, in an alternative embodiment, both cooling modules 50 may be provided with a third interface 54. The term "upper" refers to... Figure 1 The diagram shows the upper portion of the cooling module. The upper portion of the cooling module 50 is positioned along the vertical / height direction Z. The height direction Z is the direction along which the side portion 12 of the heat sink 1 extends.

[0060] The third interface 54 is configured to connect with the blocking member 14 (located on the side portion 12 of the radiator 1, i.e., the radiator housing). Figure 3 (More visible in the middle) The blocking member 14 is laterally arranged on the side portion 12 and extends along the height direction Z. The blocking member 14 is configured to engage / interlock with the third interface. During the assembly of the heat sink 1 and the module carrier 50, the third interface 54 allows the positioning of the blocking member 14 of the heat sink 1 with the heat sink 1 and the engagement of the module carrier 50 with the heat sink 1. In addition, the blocking member 14 and the third interface 54 are configured to prevent any further lateral movement, i.e., movement along the width direction Y, after the blocking member 14 has been connected to the third interface 54. In other words, the blocking member 14 and the third interface 54 are formed / constructed to allow engagement at multiple locations along the width direction Y, thereby allowing selective adjustment of the positioning of the heat exchanger 1 relative to the module carrier 50 during the assembly of the cooling module 10.

[0061] Figure 2 A perspective view of one embodiment of the module carrier 50 is shown. Figure 3 A perspective view of one embodiment of a side element 12 of a heat exchanger 1 is shown. Figure 2 and Figure 3 The module carrier 50 and side element 12 shown are configured to cooperate with each other.

[0062] The module carrier 50 is typically formed as a single piece through injection molding. For example, from... Figure 2 It can be deduced that the second interface 53 defines the inner side of the module carrier 50, wherein, as shown... Figure 3 As shown, the inner side is a side configured to mate with at least the housing forming the side element 12 of the heat sink 1. The side element 2 of the second heat sink 2 may also mate / engage with the second interface 53.

[0063] The module carrier 50 has a first outer wall 50.1 extending in a plane parallel to (Y, Z). The module carrier 50 also has a second outer wall 50.5 disposed at a distance from and opposite the first outer wall 50.1. A middle wall 50.4 is disposed between the second outer wall 50.5 and the first outer wall 50.1, and the middle wall 50.4 also extends in a plane (Y, Z). A third interface 54 is disposed on the module carrier 50 at the upper end of the first outer wall 50.1.

[0064] In a plane perpendicular to the thickness direction X, two spaced-apart wall segments 50.2 and 50.3 form a first receiving segment 50.6 extending in the height direction Z. The first receiving segment 50.6 has a vertical groove. Wall segment 50.3, together with the middle wall 50.4, forms a second receiving segment 50.7 extending in the height direction Z. A third receiving segment 50.8 extends in the vertical direction Z between the middle wall 50.4 and the outer wall 50.5. The first, second, and third receiving segments form a vertical groove that at least partially engages / encloses the corresponding box / side portion of the heat exchanger.

[0065] A guide channel 56 extending vertically is formed adjacent to the third receiving section 50.8. The guide channel 56 is separated from the receiving section 50.8 by four pairs of spacers 56.1, each of which extends in a plane transverse to the width direction Y. Vertical slots 56.2 extend between each pair of these spaced-apart spacers 56.1.

[0066] Multiple horizontal columns 50.10 extend between walls 50.1, 50.4, 50.5 and wall segments 50.2, 50.3. The multiple columns 50.10 provide structural reinforcement to the module support 50. A protruding element 50.9 is arranged on the lower rear side of the module support 50, wherein the protruding element 50.9 extends at an angle from the outer wall 50.1.

[0067] As from Figure 2 It can be deduced that the third interface 54 includes an upwardly open slot 55 extending along the width direction Y. Figure 3 and Figure 4 A side element 12 with a blocking member 14 is shown, the blocking member 14 having a downwardly tapering profile 15 for securing the blocking member 14 in a slot 55 of a third interface 54. The length of the slot 55 in the width direction Y may be greater than the length of the blocking member 14.

[0068] The blocking member 14 actually includes a V-shaped bar 17 that extends in the Y direction and has a gripping structure 18 on at least one side thereon. Figure 3 and Figure 4In the illustrated embodiment, the gripping structure 18 includes a plurality of parallel ridges in a vertical plane. When viewed from a plane perpendicular to the height direction Z (not shown), each of the plurality of ridges has a generally triangular profile. However, other gripping structures and / or ridge forms are also possible.

[0069] like Figure 2 As illustrated, a groove 55 is formed between opposing first and second wall segments 57 and 58. The first wall segment 57 and the second wall segment 58 at least partially form the tapered profile of the groove 55. The profile of the groove 55 tapers Z-shapedly along the height direction. It should be noted that, alternatively, the first wall segment 57 and the second wall segment 58 may at least partially form a V-shaped profile of the groove 55 and / or at least partially form a U-shaped profile of the groove 55.

[0070] Figure 2 The profile of the groove 55 shown corresponds to the tapered / tapered profile of the stop 14. In this respect, the first wall segment 57 has ribs, or multiple ribs arranged parallel to each other, in a direction perpendicular to the width direction Y. During assembly, the ribs engage with the gripping structure 18 of the stop 14. In other embodiments, the second wall segment may also have ribs. Figure 2 As shown, a plurality of guide elements 59 are abutted against the second wall segment 58. The plurality of guide elements 59 arranged on the second wall segment 58 facilitate the insertion of the fastener 14 during assembly. Figure 2 , Figure 4 and Figure 5 In the illustrated embodiment, the plurality of guide elements 59 are integrally formed with the wall segment 58. Each of the plurality of guide elements 59 is spaced apart from the adjacent guide element 59. The plurality of guide elements 59 extend in a direction perpendicular to the width direction Y.

[0071] Reference numeral 16 indicates a guide rod 16 protruding from the side element 12 in the Y direction. The guide rod 16 extends in the lower region of the side element 12 in the Z direction. There is a break in the length of the guide rod 16 here, but the guide rod 16 can be continuous. Figure 4 As illustrated, during assembly, the guide rod 16 is inserted into the guide channel 56 in the Z direction. The retaining rod 16 has a T-shaped profile, wherein the web portion extends in the Y direction and passes through the slot 56.2, and the head of the rod is transverse to this and is thus blocked within the guide channel 56.

[0072] As from Figure 5Understandably, the guide channel 56 and guide rod 16 are constructed / sized to guide the heat sink during assembly to the module carrier by allowing some adjustment in the Y direction. This guidance works in conjunction with the stop and the third interface to adjust the module carrier to a desired distance relative to the side portion 12. The module carrier can be positioned close to the side portion 12, or slightly spaced from the side portion 12 within the limitations allowed by the guide rod / guide channel and the stop / third interface. In other words, this design allows for compensation of manufacturing tolerances of the heat exchanger, thereby enabling the module carrier to be arranged at selected intervals. In particular, this design allows for compensation of tolerances within + / -3 mm in the width direction Y.

[0073] Further as Figure 2 As shown, the module carrier 50 also includes a platform 60 extending in the (X, Y) plane and having an elongated opening 61. The elongated opening 61 extends in the width direction Y. The elongated opening 61 allows a fastening element (not shown) such as a screw to extend through it. The fastening element is capable of securely fixing the module carrier 50 to the corresponding side element 12. Figure 3 As illustrated, the side element 12 includes a corresponding hole 20 on the bottom portion 19 for receiving a fixing element. Due to its elongated shape, the opening 61 allows a screw to be inserted into the hole 20 at a given distance along the width direction Y.

[0074] As will be understood, when assembled, i.e. when the fixing element is in the hole 20, the bottom surface 19 and the platform 60 are rigidly connected and in contact with each other. Advantageously, the bottom surface 19 and the platform 60 are provided with ribs, particularly in the form of parallel ribs extending transversely to the Y direction on both surfaces, to achieve a certain degree of interlocking connection, so as to eliminate the sliding effect in the Y direction under mechanical constraint (thus forming an anti-slip concept).

[0075] It is also worth noting that when the guide rod 16 is in the guide channel 56, the heat sink 1 is still obstructed in the X direction. This, together with the connection between the obstruction and the third interface 54, allows some of the stress to be transferred to the side portion 12 of the heat sink, where the stress would otherwise be concentrated at the fixed connection between the bottom 19 and the platform 60.

[0076] It should also be noted that only radiator 1 is fixed to module carrier 50. Second radiator 2 is fixed to first radiator 1, and grille 3 is attached to second radiator 2. In other embodiments, module carrier may include a mechanism configured to engage / rigidly interlock with second radiator 2, or more generally with one or more other heat exchangers.

[0077] As from Figure 2Understandably, although the radiator 2 is fixed to the radiator 1, the module carrier 50 still engages with the radiator in a manner that surrounds its housing, which allows for the formation of a so-called airtight frame around the cooling module in conjunction with the baffle.

[0078] Figure 6 A perspective view of one embodiment of an assembly frame 70 designed for assembling a cooling module is shown. Figure 7 It shows Figure 6 A perspective view of the assembly frame 70, in which the heat exchanger 1 is assembled to the corresponding module carriers 50, 50. Figure 8 This is a perspective view of the assembly frame 70, in which the cooling module is fully assembled onto the assembly frame 70.

[0079] like Figure 6 As illustrated, assembly begins with positioning two module carriers 50 onto the assembly frame 70. The first and second module carriers 50 are spaced apart by a predetermined (nominal) distance, with second interfaces 53, 53 facing each other. A first interface 51 (not visible) with a buttonhole 52 on each module carrier 50 is attached to a corresponding retaining element 71 on the frame 70. The distance separating the two module carriers corresponds to the nominal distance of the cooling module, i.e., the distance separating corresponding mounting features in the engine compartment.

[0080] For example Figure 7 As shown in the diagram, in the next step, the heat sink 1 is assembled to the module carrier 50. (See diagram for reference.) Figures 6 to 8 In the illustrated embodiment, one (right-hand side) of the module carrier 50 is provided with a third interface 54 as disclosed above. When the heat sink is engaged into the module carrier, the guide rod 16 engages into the guide channel, and simultaneously, the bottom portion of the heat sink approaches the carrier module platform, and the third interface 54 on the module carrier 50 engages with the blocking member 14. In the final stage of heat sink 1 assembly, the positioning of the heat sink 1 relative to the module carrier 50 is selectively adjusted along the width direction Y, as permitted by the guide rod / channel and the blocking member / third interface. Once the desired adjustment is completed, screws are inserted into the opening 61 to securely attach the module carrier to the side portion 12 of the heat sink. This is Figure 7 The structure of.

[0081] Next, as Figure 8 As illustrated, other components of the cooling module 10 can then be assembled to the module carrier. The order of component installation can be changed.

[0082] The examples discussed are embodiments of the invention. In the context of these embodiments, each element of the various embodiments described represents a separate feature of the invention, and these features should be considered independently of each other and also independently contribute to other advancements of the invention. Therefore, these features, individually or in combinations different from those shown, are also considered integral parts of the invention. Furthermore, the described embodiments may be supplemented by other features of the invention already described.

[0083] Other features and embodiments of the invention will become apparent to those skilled in the art within the context of this disclosure and claims.

[0084] List of reference numerals

[0085] 20 orifices

[0086] 1 Heat exchanger 21 Exchanger tubes

[0087] 2. Heat exchanger 22 Side section

[0088] 3 Heat exchanger 23 Top / bottom section

[0089] 4 Fan Units 31 Switch Tubes

[0090] 5 Edge element 32 Side portion

[0091] 6 Edge elements 33 Top / bottom portion

[0092] 7 Edge Components 50 Module Carrier

[0093] 8 Edge element 50.1 First outer wall

[0094] 10 Cooling Module 50.2 Wall Section

[0095] 11. Exchanger tube 50.3 wall section

[0096] 12 Side section 50.4 Middle wall

[0097] 13 Top / Bottom Section 50.5 Second Outer Wall

[0098] 14. Blocking component 50.6. First receiving section

[0099] 15. Conical profile 50.7 Second receiving section

[0100] 16 Fixed rod 50.8 Third receiving section

[0101] 17 Wall section 50.9 Protruding element

[0102] 18. Holding structure with more than 50.10 columns.

[0103] 19 Bottom section 51 First interface

[0104] 52 Buttonhole 57 First wall section

[0105] 53 Second Interface 58 Second Wall Section

[0106] 54 Third Interface 59 Guiding Element

[0107] 55 slots 60 platform

[0108] 56 Guide slot 61 Elongated opening

[0109] 56.1 Separator 70 Assembly Frame

[0110] 56.2 Guide rail 71 Retaining element

Claims

1. A cooling module (10) for a vehicle, wherein the cooling module (10) comprises: Two or more heat exchangers (1; 2); The heat exchanger (1; 2) includes a top portion and a bottom portion (13; 23) extending in the width direction (Y) and a side portion (12; 22) extending in the height direction (Z). At least one module carrier (50) configured to carry and secure the heat exchanger (1; 2) within a vehicle, the module carrier (50) comprising: A first interface (51) with mounting features for securing the cooling module (10) in a vehicle; and Construct a second interface (53) for engaging with at least one of the side portions (12) of the heat exchanger. The side portion (12) includes a blocking member (14) that engages with a third interface (54) provided on the module carrier (50) to form a blocking engagement during the assembly of the corresponding heat exchanger (1) onto the module carrier (50). The blocking member (14) and the third interface (54) are configured to engage at multiple locations along the width direction (Y), thereby enabling selective adjustment of the positioning of the heat exchanger (1) relative to the module carrier (50) during the assembly of the cooling module (10).

2. The cooling module according to claim 1, wherein, The third interface (54) includes a slot (55) that extends along the width direction (Y).

3. The cooling module according to claim 2, wherein, The groove (55) opens toward the height direction.

4. The cooling module according to claim 2, wherein, The blocking member (14) has a tapered profile, the dimensions of which are determined to fit into the groove (55) of the third interface (54).

5. The cooling module (10) according to any one of claims 1 to 4, wherein, The side portion (12) includes a guide rod (16) extending along the height direction, which engages in the guide portion of the module carrier with a guide slot (56) extending in the height direction.

6. The cooling module according to claim 5, wherein, The guide rod (16) has a T-shaped profile and is sized to allow the module carrier to shift a predetermined distance relative to the side portion.

7. The cooling module (10) according to any one of claims 1 to 4, wherein, The blocking member (14) also includes at least one wall portion (17) provided with a gripping structure (18).

8. The cooling module (10) according to claim 7, wherein, The gripping structure (18) includes multiple ridges.

9. The cooling module according to claim 8, wherein, Each of the plurality of ridges has a triangular profile.

10. The cooling module (10) according to any one of claims 2 to 4, wherein, The groove (55) is formed by opposing first wall segments and second wall segments (57, 58), wherein the first wall segment (57) and the second wall segment (58) at least partially form a tapered profile of the groove (55), and / or at least partially form a V-shaped profile of the groove (55), and / or at least partially form a U-shaped profile of the groove (55).

11. The cooling module according to claim 10, wherein, The first wall segment (57) and / or the second wall segment (58) have ribs; and / or a plurality of guide elements (59) are adjacent to the first wall segment (57) and / or the second wall segment (58).

12. The cooling module according to any one of claims 1 to 4, wherein, The module carrier includes a support portion extending in the width direction, which is in direct contact with the heat exchanger.

13. The cooling module according to claim 12, wherein, The support portion includes a platform (60) that contacts the fixing feature (19) of the side portion.

14. The cooling module according to claim 13, wherein, The platform (60) has an elongated opening (61) extending in the width direction, and the fixing feature includes a hole (20) through which the fixing element engages with the elongated opening.

15. The cooling module according to claim 13 or 14, wherein, The fixing feature has a rib surface that contacts the rib surface of the platform.

16. The cooling module according to claim 15, wherein, The surface of the rib is formed by parallel ribs extending transversely to the width direction.

17. The cooling module according to any one of claims 1 to 4, wherein, The first interface (51) includes a mounting feature configured to support a buttonhole (52) and engage with a corresponding mounting feature in the vehicle.

18. A method for assembling a cooling module (10) according to any one of claims 1 to 17, comprising: Two or more heat exchangers (1; 2) are provided, wherein the heat exchangers (1; 2) include a top portion and a bottom portion extending in the width direction (Y) and a side portion (12; 22) extending in the height direction (Z); A first module support (50) and a second module support (50) are provided for carrying and fixing at least one of the heat exchangers (1), wherein at least one of the module supports (50; 50) comprises: A first interface (51) with mounting features for securing the cooling module (10); and Construct a second interface (53) for engaging the side portion (12); and A third interface (54) is provided on the module carrier (50) for forming a blocking engagement with the blocking member (14). An assembly frame (70) is provided, the assembly frame (70) having at least two retaining elements (71) for securing the first module carrier (50) and the second module carrier (50). The first module carrier (50) and the second module carrier (50) are positioned relative to each other on the retaining element (71) at a predetermined distance; The method further includes: During the assembly of the cooling module (10), the positioning of the heat exchanger (1) relative to the module carrier (50) is selectively adjusted along the width direction (Y).

19. The method according to claim 18, wherein, The blocking element (14) is formed on the side portion (12) of at least one heat exchanger (1).

20. The method according to claim 18 or 19, wherein the groove (55) is formed within the third interface (54).

21. The method according to claim 19, wherein, The gripping structure (18) is formed on at least one wall portion (17) of the blocking member (14).

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