Fan shroud, mounting bracket and pin mount

Abstract

A shroud assembly mounts a radiator to a vehicle frame, the shroud assembly including a shroud, a first frame bracket for mounting the shroud to the vehicle frame, and a second frame bracket for mounting the shroud to the vehicle frame, the shroud including a first shroud portion having an opening for receiving a fan, and a second shroud portion having an opening for receiving the fan, the second shroud portion has an opening for receiving a fan, the first mounting bracket connects the first shroud portion to the second shroud portion, and the second mounting bracket further connects the first shroud portion to the second shroud portion.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 350,103, filed on June 8, 2022, the entire contents of which are incorporated herein by reference in their entirety. Background Art

[0003] The present disclosure relates to vehicle components, and more particularly to fan shrouds for motor vehicles. The present disclosure relates to vehicle powertrain heat exchanger modules and vehicle heat exchange systems for regulating the temperature of vehicle components, and more particularly to the manner in which such heat exchanger modules are mounted to a vehicle. More particularly, the present disclosure relates to fan shrouds and fan shroud assemblies for motor vehicles. Heat exchanger modules have been mounted to vehicles via a module frame that is attached to the vehicle at a frame or other location, and to which the heat exchanger is attached and supported. Some designs require additional structural supports, such as struts or ties, or additional supports via the structure or construction of the tank of the heat exchanger. Summary of the invention

[0004] In some embodiments, the combination of a heat exchanger module and a structural shield provides advantages to the structure of a vehicle heat exchange system. The structural shield provides structural support for the entire heat exchanger system. Compared to conventional frameless heat exchanger mounting designs, this improved design provides rigid mounting support to the heat exchanger even when the heat exchanger has varying heights. For example, based on other vehicle requirements, the charge air cooler may have a design that is shorter in length than the radiator core. Conventional designs may require extensions from, for example, the bottom of the supercharger air cooler tank to mount to the radiator core. These extensions may be structurally vulnerable.

[0005] Conventional frameless heat exchanger mounting designs are also known to be structurally vulnerable. In conventional designs, stresses from normal use are absorbed by the heat exchanger tubes or headers, channels (e.g., steel channels) that house the radiator, cross braces that connect the radiator corners to the vehicle frame or other mounting location, and / or the radiator itself. As disclosed, the damaging loads applied by the vehicle to the heat exchanger are removed or mitigated by the structural shield. The structural support provided by the structural shield reduces the loads on these components, or in some embodiments, completely replaces these components.

[0006] In one embodiment, a shroud assembly includes a fan, a radiator, and a two-piece fan shroud that directs airflow generated by the fan through the radiator. The components of the two-piece fan shroud are held together by a bracket. The bracket mounts the entire fan shroud assembly to a vehicle. The vehicle may be a motor vehicle. More specifically, the motor vehicle may be a vehicle having an electric motor or a vehicle having an internal combustion engine, or a vehicle having both an electric motor and an internal combustion engine.

[0007] In one aspect, the cooling module includes a shroud assembly, a radiator, and a fan. The shroud assembly includes a shroud, a first mounting bracket, and a second mounting bracket. The shroud includes a first shroud portion and a second shroud portion, wherein the first shroud portion has a first hemispherical opening and the second shroud portion has a second hemispherical opening. The first mounting bracket mechanically engages the first shroud portion and the second shroud portion, and the second mounting bracket mechanically engages the first shroud portion and the second shroud portion. The radiator is mounted between the first shroud portion and the second shroud portion, so that the first mounting bracket and the second mounting bracket also hold the radiator between the first shroud portion and the second shroud portion when mechanically engaging the first shroud portion and the second shroud portion. The fan is mounted in at least one of the first portion and the second portion, and the fan is configured to pass air through the shroud and through the radiator. The first mounting bracket and the second mounting bracket are configured to attach the shroud assembly, the radiator, and the fan to the frame.

[0008] In another aspect, a shield assembly includes a shield, a first mounting bracket, and a second mounting bracket. The shield includes a first shield portion and a second shield portion, wherein the first shield portion has a first hemispherical opening and the second shield portion has a second hemispherical opening. The first mounting bracket mechanically engages the first shield portion and the second shield portion, and the second mounting bracket mechanically engages the first shield portion and the second shield portion.

[0009] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a front isometric view of a cooling module with a shroud assembly.

[0011] Figure 2 yes Figure 1 Front assembly view of the cooling module.

[0012] Figure 3 yes Figure 1 Rear isometric view of the cooling module.

[0013] Figure 4 yes Figure 1 Rear assembly view of the cooling module.

[0014] Figure 5 yes Figure 3 A detailed view of a portion of Figure 3 Part of the cooling module.

[0015] Figure 6 A front isometric view of another embodiment of a cooling module is shown.

[0016] Figure 7 yes Figure 6 Rear isometric view of the cooling module.

[0017] Figure 8 yes Figure 6 Detailed view of the central portion of the cooling module.

[0018] Fig. 9 yes Figure 7 Detailed view of the cooling module.

[0019] Fig.10 A front isometric view of another embodiment of a cooling module is shown.

[0020] Fig.11 yes Fig.10 Front assembly view of the cooling module.

[0021] Fig.12 yes Fig.10 Side view of the cooling module.

[0022] Fig.13 yes Fig.10 Rear isometric view of the cooling module.

[0023] Fig.14 A front isometric view of another embodiment of a cooling module is shown.

[0024] Fig.15 A front isometric view of another embodiment of a cooling module is shown.

[0025] Before any embodiments of the invention are explained in detail, it should be understood that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. DETAILED DESCRIPTION

[0026] Figure 1 A cooling module 1000 having a shroud assembly 1 is shown. The shroud assembly 1 includes a first shroud portion 5 and a second shroud portion 10. The first shroud portion 5 and the second shroud portion 10 cooperate together to direct flow from a fan (e.g., first fan 15) through the heat sink 55, 65, 75 (see Figure 2), so that heat exchange can occur between the air directed by the fan 15 and the heat sink 55, 65, 75. In one embodiment, the first shield portion 5 and the second shield portion 10 are similar or identical, which results in certain advantages over other known heat sink shields in the art. These advantages include ease of manufacture, as only one mold is required to produce both the first shield portion 5 and the second shield portion 10, and ease of assembly, as the assembler does not have to mount the first shield portion 5 and the second shield portion 10 in any particular manner, but rather the two components are interchangeable.

[0027] Each of the first shroud portion 5 and the second shroud portion 10 has a fan opening, shown as a first shroud portion fan opening 7 and a second shroud portion fan opening 12. The first shroud portion fan opening 7 and the second shroud portion fan opening 12 are shown as being hemispherical. The first shroud portion fan opening 7 and the second shroud portion fan opening 12 receive a first fan 15 and a second fan 20 therein, respectively. The first fan 15 and the second fan 20 are mounted directly to the respective first shroud portion 5 and the second shroud portion 10. Figure 2 As best shown, first and second shroud portions 5, 10 direct the air flow generated by first and second fans 15, 20 through heat sinks 55, 65, 75. First and second fans 15, 20 are the main components of cooling module 1000 along with heat sinks 55, 65, 75 and shroud assembly 1.

[0028] The first shield portion 5 and the second shield portion 10 may include a lattice structure 86 formed by a plurality of walls 86A, 86B intersecting at oblique angles to each other. The lattice structure 86 provides additional strength to the first shield portion 5 and the second shield portion 10 without adding significant additional weight. Figure 1 The plurality of walls 86A, 86B intersect at right angles, but the same effect may be achieved by using walls 86A, 86B that intersect at other angles.

[0029] Each of the first shield portion 5 and the second shield portion 10 includes a flow guide portion 6 and a closed portion 8. The flow guide portion 6 is formed in an arched manner from the opposite end where the radiator 55 is installed (for example, Figure 2 Flow is directed from the first fan 15 and the second fan 20 through the heat sinks 55, 65, 75 mounted on the combined first shroud portion 5 and the second shroud portion 10. In other embodiments, more or fewer fans 15, 20 may be provided. For example, Figure 6 The illustrated embodiment of the cooling module 1000 includes a shroud assembly 100 having four fans 115, and Fig.10The illustrated embodiment includes a shroud assembly 200 having only a single fan 215. However, the number of fans 15, 20 is not limited to the illustrated embodiment. Other embodiments are contemplated that may include any number of fans 15, 20. Furthermore, other embodiments are contemplated where the number of fans 15, 20 mounted on the first shroud portion 5 and the second shroud portion 10 is not equal. For example, in some embodiments, the first shroud portion 5 has three fans 15, 20 mounted thereon, while the second shroud portion 10 has two fans 15, 20 mounted thereon. Return to Reference Figure 2 , the closed portion 8 closes the arcuate flow guiding portion 6 so that the air flow does not escape without passing through the heat sink 55, 65, 75. As shown in the figure, the closed portion 8 is flat.

[0030] Return to reference Figure 1 , the first shield portion 5 and the second shield portion 10 are held against each other by the first mounting bracket 25. Figure 1 In the illustrated embodiment, the first shield portion 5 and the second shield portion 10 are additionally held against each other by a second mounting bracket 30. In one embodiment, the first mounting bracket 25 and the second mounting bracket 30 are similar or identical so that they are interchangeable. The first mounting bracket 25 and the second mounting bracket 30 are connected to the first shield portion 5 and the second shield portion 10 via connecting hardware 50. The connecting hardware 50 may be in the form of screws, rivets, bolts, snaps, or other fasteners. Figure 1 The illustrated embodiment also includes a center or "bow tie" mounting bracket 31. This is also referred to as a connecting bracket 31. While the first mounting bracket 25 and the second mounting bracket 30 may be the only structure holding the first shield portion 5 against the second shield portion 10, the center mounting bracket 31 further stabilizes the connection between the first shield portion 5 and the second shield portion 10. In the illustrated embodiment, the center mounting bracket 31 includes four fingers 32. Each finger 32 extends away from a center portion 33 of the connecting bracket 31. Each finger 32 includes a connection to one of the first shield portion 5 and the second shield portion 10, such that two of the fingers 32 are connected to the first shield portion 5 and two of the fingers 32 are connected to the second shield portion 10. The center mounting bracket 31 is attached to the first shield portion 5 and the second shield portion 10 via connecting hardware 50.

[0031] The first mounting bracket 25 and the second mounting bracket 30 are also used to connect the shield assembly 1 and the entire cooling module 1000 to the vehicle frame 4. The vehicle 4' is a motor vehicle. Therefore, the first mounting bracket 25 and the second mounting bracket 30 connect the first shield part 5 and the second shield part 10, the first fan 15 and the second fan 20, and the radiator 55, 65, 75 (see Figure 2) is supported on the vehicle frame 4. In some embodiments, the first mounting bracket 25 and the second mounting bracket 30 serve as the sole structural support for the first shroud portion 5 and the second shroud portion 10, the first fan 15 and the second fan 20, and the radiator 55, 65, 75 within the vehicle 4'. In other words, the first mounting bracket 25 and the second mounting bracket 30 substantially carry the entire structural load of the shroud assembly 1 and the cooling module 1000. While there may be other connections to the vehicle 4' that physically contact other parts of the vehicle 4' (i.e., the radiator 55, 65, 75 may have a coolant line connection, and the first fan 15 and the second fan 20 may have an electrical connection 580, 680), these connections do not substantially carry the entire structural load of the shroud assembly 1 and the cooling module 1000.

[0032] Figure 1 The first mounting bracket 25 and the second mounting bracket 30 shown in FIG. 1 are mounted to the vehicle 4' via isolators 35A, 35B, 35C and 35D. Figure 2 As best seen in FIG. 1 , the isolators 35A-35D include a rigid member 36 (in one embodiment, a metal material or a plastic material) having an internal passage for a fastener 50 to pass therethrough. An elastic member 37 surrounds the rigid member 36. The elastic member 37 may be formed of rubber. When installed, the elastic member 37 passes through the first mounting bracket 25 or the second mounting bracket 30 to interact with the first mounting bracket 25 or the second mounting bracket 30. The rigid member 36 is directly connected to the vehicle frame 4 via the fastener 50 passing through the internal passage of the rigid member 36. As a result, the elastic member 37 is used to dampen vibrations from the vehicle 4' (e.g., these vibrations are caused by road vibrations, engine vibrations, input from vehicle loads, etc.) when the vibrations pass through and enter the rigid member 36. Therefore, these vibrations are limited or eliminated from entering the first mounting bracket 25 and the second mounting bracket 30, thereby also limiting or eliminating the vibrations transmitted from the vehicle 4' to the cooling module 1000. As a result, the service life of the cooling module 1000 is improved. Although two isolators 35A- 35D are shown with respect to each of the first mounting bracket 25 and the second mounting bracket 30 , more or fewer isolators 35A- 35D may be used with each of the first mounting bracket 25 and the second mounting bracket 30 to achieve similar results.

[0033] Advantageously, by providing two spacers in each of the first mounting bracket 25 and the second mounting bracket 30, two connection points are provided between the first mounting bracket 25 and the second mounting bracket 30 and the vehicle frame 4. Having two connection points limits the other components of the cooling module 1000 (such as the radiator 55, 65, 75 (see Figure 2As an example of such a force, the movement of the vehicle 4' can cause the cooling module 1000 to rotate about an axis extending from the first mounting bracket 25 to the second mounting bracket 30. This rotational force is mitigated by providing two connection points in the first frame bracket 25 and the second frame bracket 30. By limiting the torsional and rotational forces on the radiator 55, 65, 75, the cooling module 1000 does not require tie rods or other structures to limit these forces. This reduces cost and simplifies the installation of the cooling module 1000 into the vehicle 4'.

[0034] Reference again Figure 2 , the first mounting bracket 25 includes two halves, a first half 26 and a second half 27. In some embodiments, the first half 26 and the second half 27 are identical mirror images of each other. The first half and the second half are joined together via corresponding joining areas 28, which are surfaces of the first half 26 that contact the second half 27. In some embodiments, the joining areas 28 are bonded or welded together. In other embodiments, the joining areas 28 are fastened against each other using fasteners 50 or via the first and second isolators 35A, 35B.

[0035] The first half 26 and the second half 27 also include respective first and second shield mounting members 29A and 29B. Figure 2 As shown, the first shield mount 29A extends at a right angle away from the joint area 28 of the first half 26. Similarly, the second shield mount 29B extends at a right angle away from the joint area 28 of the second half 27. The first shield mount 29A and the second shield mount 29B are attached to the first shield portion 5 and the second shield portion 10 respectively using connecting hardware 50. Although not described in detail, the second mounting bracket 30 includes the same structure as the first mounting bracket 25. In some embodiments, the first shield portion 5 and the second shield portion 10 have a planar surface on a portion of the guide portion 6, so that the planar portions of the first shield mount 29A and the second shield mount 29B are more easily attached to the first shield portion 5 and the second shield portion 10 respectively.

[0036] like Figure 2 As best shown, the cooling module 1000 includes a first heat sink 55, a second heat sink 65, and a third heat sink 75. The first heat sink 55 includes at least one heat sink pin 45. When the first heat sink 55 is installed in the shroud assembly 1, the heat sink pin 45 extends through the heat sink pin hole 40 in the first shroud portion 5 to hold the first heat sink 55 in place. The heat sink pin 45 extending through the heat sink pin hole 40 is Figure 1In some embodiments, a rubber sleeve 47 is positioned around the radiator pin 45. The rubber sleeve 47 is used to dampen vibrations from the first shroud portion 5 (and ultimately from the vehicle 4' via the first mounting bracket 25 and the second mounting bracket 30) so that the vibrations do not fully enter the first radiator 55. This damping is used to protect and extend the service life of the first radiator 55.

[0037] In the illustrated embodiment, the first radiator 55 includes four radiator pins 45. To mount the first radiator 55 between the first shroud portion 5 and the second shroud portion 10, two radiator pins 45 from the corners of the first radiator 55 extend through the first shroud portion 5, and two radiator pins 45 from the corners of the first radiator 55 extend through the second shroud portion 10. Thus, the first shroud portion 5 and the second shroud portion 10 each have two radiator pin holes 40 that receive the radiator pins 45. Thus, the layout of the radiator pins 45 is thus achieved in the mounting brackets 25, 30 by holding the first shroud portion 5 and the second shroud portion 10 together, thereby also holding the radiator pins 45 in the radiator pin holes 40, and thus locking the radiators 55, 65, 75 in place on the shroud assembly 1.

[0038] The second radiator 65 and the third radiator 75 are mounted in a stacked manner. This layout is different from the first radiator 55, which extends across the entire shield assembly 1 (i.e., from the first shield portion 5 to the second shield portion 10). The second radiator 65 is attached to the third radiator 75 by a radiator bracket 80. Figure 3 and Figure 4 Two radiator brackets 80 are shown for holding the second radiator 65 and the third radiator 75 together. Since the second radiator 65 and the third radiator 75 are mounted together in the shroud assembly 1, only two radiator pins 45 are required on each of the second radiator 65 and the third radiator 75. In the embodiment shown, two radiator pins 45 from the second radiator 65 extend through the first shroud portion 5, and two radiator pins 45 from the third radiator 75 extend through the second shroud portion 10.

[0039] Although the shroud assembly 1 is shown as having three heat sinks 55, 65, 75 mounted thereon, more or fewer heat sinks 55, 65, 75 may be used with the cooling module 1000 as desired by the cooling requirements of the application in which the cooling module 1000 is used. Thus, a different number or configuration of heat sinks 55, 65, 75 will result in a different number or configuration of heat sink pins 45, and therefore a different number or configuration of heat sink pin holes 40 in the first shroud portion 5 and the second shroud portion 10. Those skilled in the art understand that modifications to the heat sinks 55, 65, 75 may result in movement or changes to the heat sink pins 45 and heat sink pin holes 40, but still use the same pins 45 and holes 40 as shown to mount the components.

[0040] The first heat sink 55 includes a first heat sink connector 60, and the second heat sink 65 includes a second heat sink connector 70. The heat sinks 55, 65, 75 may include more or fewer connectors 60, 70 as required by the cooling requirements of the application in which the cooling module 1000 is used.

[0041] Figure 3 and Figure 4 Shows Figure 1 and Figure 2 Different views of the cooling module 1000 and the shield assembly 1 are shown in FIG. It is worth noting that Figure 3 and Figure 4 It is better shown how the second radiator 65 and the third radiator 75 are held together via the radiator bracket 80 , and how the two radiator pins 45 from the second radiator 65 extend through the first shroud portion 5 . Figure 4 It also shows in more detail how the air is moved by the fan 15 (specifically, Figure 4 1 ) is shown in FIG. 1 , and shows how the air passes through the first radiator 55 before passing through the second radiator 65 and the third radiator 75 .

[0042] Figure 5 A detailed view of the heat sink pins 45 of the first heat sink 55 is shown (the first heat sink 55 is obscured by the first shroud portion 5 ), and the second heat sink 65 extends through the aperture 40 in the first shroud portion 5 .

[0043] Figure 6 Another embodiment of a shroud assembly 100 for use in a cooling module 1000 is shown, which includes a Figure 1 Similar features are given reference numerals increased by 100 to facilitate cross-references between embodiments. Figure 1 The embodiment shown, Figure 6The shield assembly 100 shown includes a first shield portion 105 and a second shield portion 110. The first shield portion 105 and the second shield portion 110 are arranged in a Figure 6 The embodiment shown is different, but the first shield portion 105 and the second shield portion 110 are still matched together to form the shield assembly 100 similar to the first embodiment. The cooling module 1000 having the shield assembly 100 includes four fans 115, two mounted on the first shield portion 105 and two mounted on the second shield portion 110. The first shield portion 105 and the second shield portion 110 are held together via the first mounting bracket 125 and the second mounting bracket 130, but the first shield portion 105 and the second shield portion 110 are still matched together to form the shield assembly 100 similar to the first embodiment. Figure 6 1000 . In other embodiments, more or fewer mounting brackets 125, 130 are provided. For example, in some embodiments, only one mounting bracket is provided (e.g., only the first mounting bracket 125), and it is the only structure holding the first shroud portion 105 and the second shroud portion 110 together and the only mounting connection of the cooling module 1000 to the vehicle 4' in which the cooling module 1000 is installed.

[0044] Figure 7 Shows Figure 6 A rear view of the cooling module 10000 and the shroud assembly 100 is shown in FIG. Figure 7 Visible in FIG. 1 is a first mounting bracket 125, which is Figure 6 Not visible in Figures 2 to 4 When compared to the embodiment shown, Figure 7 An alternative embodiment of the first heat sink 155 and the second heat sink 165 is shown. Figure 7 In the illustrated embodiment, both the first heat sink 155 and the second heat sink 165 extend from the first shield portion 105 to the second shield portion 110. Figure 1 shown in and Figure 4 and Figure 5 In the embodiment described in detail in FIG. 1 , the first heat sink 155 and the second heat sink 165 are held between the first shield portion 105 and the second shield portion 110 via the heat sink pins 145. Figure 3 When compared with the embodiments shown in Figure 7 The embodiments in exemplify the fact that different radiator configurations are contemplated for use with the shroud assemblies 1 , 100 , but different radiator pin 45 , 145 and associated radiator pin hole 40 locations are required depending on the embodiment.

[0045] Figure 8 Shows Figure 6A detailed view of the cooling module 1000 and the shroud assembly 100 is shown, and the interface between the first shroud portion 105 and the second shroud portion 110 is shown, which is located in the center between the four fans 115. Although not required, fasteners 185 (e.g., relative to Figure 1 The illustrated embodiment further includes one of the fasteners 50 discussed in more detail in the illustrated embodiment to attach the first shield portion 105 to the second shield portion 110. Similar to the function of the center mounting bracket 31 described with reference to the first embodiment, the fastener 185 further stabilizes the connection between the first shield portion 105 and the second shield portion 110.

[0046] Fig. 9 Another embodiment of fastener 185 is shown and is labeled fastener 190 . Fig. 9 The interface between the first shield portion 105 and the second shield portion 110 is shown, but is more Figure 8 The illustration is closer to the first mounting bracket 125 (see Figure 7 , which details Fig. 9 1000 as shown). Fig. 9 The fastener shown is comprised of a retainer 192 positioned on the first shield portion 105 and an insert portion 193 positioned on the second shield portion 110. To retain the first shield portion 105 against the second shield portion 110, the insert portion 193 is pushed through the retainer 192 such that the insert portion 193 and the retainer 192 are elastically deformed and a lip 194 of the insert portion 193 passes through and abuts the retainer 192. In other embodiments, the fasteners 185, 190 may be positioned at other locations along the interface between the first shield portion 105 and the second shield portion 110 to strengthen the connection between the first shield portion 105 and the second shield portion 110.

[0047] Fig.10 Another embodiment of a cooling module 1000 having a shroud assembly 200 is shown, which includes a Figure 1 The embodiments shown and Figure 6 Similar features are given reference numerals increased by 200 (with Figure 1 to facilitate cross-references between embodiments. Figure 1 and Figure 6 The embodiment shown, Fig.10 The shield assembly 100 shown includes a first shield portion 205 and a second shield portion 210. The first shield portion 205 and the second shield portion 210 are arranged in a Fig.10 The illustrated embodiments are identical such that they are interchangeable, which allows for easier assembly of the shroud assembly 200 . Fig.10The most significant difference between the illustrated embodiment and other embodiments is that Figures 10 to 13 The embodiment includes only a single fan 215. Because the first shroud portion 205 and the second shroud portion 210 are identical, the fan 215 is centrally located on the shroud assembly 200, but other embodiments are contemplated in which the fan 215 is located at a non-central or asymmetrical position on the shroud assembly 200.

[0048] and Figure 6 Unlike the illustrated embodiment, first mounting bracket 225 and second mounting bracket 230 are the only structures holding first shield portion 205 against second shield portion 210. Although other structures connecting first shield portion 205 and second shield portion 210 may be added, no other connection between first shield portion 205 and second shield portion 210 is required.

[0049] and Figure 1 Unlike the illustrated embodiment, the first mounting bracket 225 and the second mounting bracket 230 include only a single "half" (see FIG. Figure 2 25). In other words, Fig.10 The bracket 225 shown is "L" shaped, and Figure 1 The embodiment shown is a "T" shape. Fig.11 As better shown in FIG. 1 , the different shapes of the first mounting bracket 225 and the second mounting bracket 230 result in the four pieces of connecting hardware 50 being positioned in one leg of the “L” shaped bracket. This is different from Figure 1 In the illustrated embodiment, each half 26, 27 of the mounting bracket 25 (where each half 26, 27 is equivalent to the entire mounting bracket 225) includes only two pieces of connection hardware. The mounting bracket 25 and the mounting bracket 225 both have a total of four pieces of connection hardware 50, two of which are anchored in the first shield portion 5, 205 and the second shield portion 10, 210, respectively.

[0050] The first bracket 225 and the second bracket 230 each include a frame flange 237 and a shield mount 239. The frame flange 237 and the shield mount 239 form two legs of the "L" shape of the first mounting bracket 225 and the second mounting bracket 230. The frame flange 237 and the shield mount 239 can be planar flanges extending perpendicularly away from each other. The frame flange 237 and the shield mount 239 can be formed by a planar sheet (e.g., a steel sheet) bent into an "L" shape. The frame flange 237 is connected to the frame 4. The spacer 237 can form a connection between the frame flange 237 and the frame 4. The shield mount 239 is connected to the first shield portion 205 and the second shield portion 210. The shield mount 239 holds the first shield portion 205 against the second shield portion 210.

[0051] As in Fig.11 As best seen in FIG. 4 , the first mounting bracket 225 and the second mounting bracket 230 are connected to the first shield portion and the second shield portion by connecting hardware 50. Similar to the other embodiments shown, the first mounting bracket 225 and the second mounting bracket 230 are connected to the vehicle 4 ′ via an isolator 235. Figure 1 The illustrated embodiment describes the structure of the isolator 235 in more detail. Fig.10 and Fig.11 In the illustrated embodiment, the first mounting bracket 225 and the second mounting bracket 230 each have two spacers 235 , although more or fewer spacers 235 are contemplated.

[0052] Figure 11 to Figure 13 A first heat sink 255, a second heat sink 265, and a third heat sink 275 are shown. Figure 1 In the illustrated embodiment, the heat sink 255, 265, 275 is mounted between the first shield portion 205 and the second shield portion 210 and is provided by extending through the heat sink pin hole 40 (see Figure 1 ) is held in place by heat sink pins 245. Figures 10 to 13 The embodiment shown in includes three heat sinks 255, 265, 275, but embodiments with more or fewer heat sinks 255, 265, 275 or different heat sink 255, 265, 275 configurations are contemplated depending on the amount of cooling required for a particular application.

[0053] Fig.14 Another embodiment of a cooling module 1000 is shown, which includes aspects that can be combined with the other embodiments shown. Similar features are given reference numerals increased by 500 (with Figure 1 to facilitate cross-references between the embodiments. Fig.14 The illustrated embodiment includes a Figure 1 The embodiment shown has two fans 515, 520. However, Fig.14 The embodiment shown is Figure 1 The embodiment shown differs in that Fig.14 The illustrated embodiment includes a first shroud portion 505 and a second shroud portion 510 formed of metal. In some embodiments, the metal is steel. This material difference results in the fan shroud assembly 1 and Fig.14 The structural changes between the shield assembly 500 shown. Due to the increased structural strength of metal, the first shield portion 505 and the second shield portion 510 do not include Figure 1 The grid structure 86 is shown. In contrast, the first shield portion 505 and the second shield portion 510 may each be formed from a single sheet of metal that is stamped and otherwise formed into the shape of the first shield portion 505 and the second shield portion 510.

[0054] The shield assembly 500 includes a first shield portion fan opening 507 and a second shield portion fan opening 512, which are hemispherical and have a first fan 515 and a second fan 520 mounted therein, respectively. A power supply 580 provides power and controls operation to the first fan 515 and the second fan 520. A first mounting bracket 525 and a second mounting bracket 530 hold the first shield portion 505 and the second shield portion 510 against each other. The first mounting bracket 525 and the second mounting bracket 530 are similar to Fig.10 The embodiment shown is "L" shaped, but other mounting bracket configurations are contemplated. The first mounting bracket 525 and the second mounting bracket 530 each include two spacers 535 to facilitate mounting the first mounting bracket 525 and the second mounting bracket 530 to the vehicle frame 4. Connecting hardware 550 secures the first mounting bracket 525 and the second mounting bracket 530 to the first shield portion 505 and the second shield portion 510.

[0055] The bow-tie mounting bracket or connecting bracket 531 is positioned between the first shroud portion fan opening 507 and the second shroud portion fan opening 512, and therefore also between the first fan 515 and the second fan 520. The connecting bracket 531 includes a central portion 533 having fingers 532 extending therefrom, wherein each finger is connected to one of the first shroud portion 505 and the second shroud portion 510 via connecting hardware 550. The connecting bracket 531 and the first mounting bracket 525 and the second mounting bracket 530 hold the first shroud portion 505 and the second shroud portion 510 against each other. The connecting bracket 531 also serves to provide additional structural support to the first shroud portion 505 and the second shroud portion 510.

[0056] Fig.14 Also shown is a second heat sink 565 mounted between the first shield portion 505 and the second shield portion 510. The first heat sink 565 is also included, but is shielded by the first and second shield portions 505, 510. The heat sink 565 is mounted via a pin 545 that extends through a pin hole 540 positioned near the edge of the first shield portion 505 and the second shield portion 510. The first mounting bracket 525 and the second mounting bracket 530, together with the connecting bracket 531, retain the pin 545 within the pin hole 540 by retaining the first shield portion 505 against the second shield portion 510. By holding the first shield portion 505 against the second shield portion 510, the pin holes 540 are fixed relative to each other and the pin 540 cannot escape from the pin hole 540. This allows for a floating connection between the shroud assembly 500 and the heat sink 565 , as the pins 545 are free to move within the pin holes 540 , but the movement is restricted so that the heat sink 565 remains attached to the shroud assembly 500 .

[0057] Fig.15 Another embodiment of a cooling module 1000 is shown, which includes aspects that can be combined with other disclosed embodiments. Similar features are given reference numerals increased by 600 (with Figure 1 to facilitate cross-references between the embodiments. Fig.15 The embodiment shown in is similar to Figure 6 , where the shroud assembly 600 includes openings for four fans 615, two of which are in the first shroud portion 605, and two of which are in the second shroud portion 610. The power supply 680 provides power and controls operation to the fans 615. Similar to Fig.14 In the embodiment shown in Fig.15 The embodiments shown in Figure 6 The embodiment shown in FIG. 1 differs in that Fig.15 In some embodiments, the first shield portion 605 and the second shield portion 610 are each formed as Fig.15 The shape shown is formed from a single piece of metal.

[0058] The first mounting bracket 625, the second mounting bracket 630 and the connecting bracket 685 are used to connect the first shield portion 605 and the second shield portion 610. The connecting bracket 685 is centrally located between the four fans 615 and is a planar bracket connected to the first shield portion 605 and the second shield portion 610 via fasteners 690. The connecting bracket 685 can be formed of plastic or metal. The first mounting bracket 625 and the second mounting bracket 630 are similar to Figure 6 The “T” shaped mounting bracket is shown, but includes six fastener locations 690 for connecting the first mounting bracket 625 and the second mounting bracket 630 to the first shroud portion 605 and the second shroud portion 610 .

[0059] Various additional features and advantages of the invention are illustrated in the accompanying drawings, which show to scale versions of some embodiments of the invention.

Claims

1. A cooling module, comprising: A shield assembly, the shield assembly comprising: Protective cover, including: a first shield portion, the first shield portion having a first hemispherical opening, a second shield portion, the second shield portion having a second hemispherical opening, a first mounting bracket configured to mechanically engage the first shield portion and the second shield portion, and a second mounting bracket configured to mechanically engage the first shield portion and the second shield portion; a heat sink mounted between the first shroud portion and the second shroud portion such that the first mounting bracket and the second mounting bracket, while mechanically engaging the first shroud portion and the second shroud portion, also retain the heat sink between the first shroud portion and the second shroud portion; and a fan mounted within at least one of the first shroud portion and the second shroud portion, the fan being configured to move air through the shroud and past the heat sink, Wherein, the first mounting bracket and the second mounting bracket are configured to attach the shroud assembly, the radiator, and the fan to a vehicle frame.

2. The cooling module according to claim 1, wherein: The first opening in the first shield portion and the second opening in the second shield portion define opposing hemispheres of a single circular opening, and Therein, only one fan is installed in the single circular opening.

3. The cooling module according to claim 1, wherein: The fan is a first fan, wherein the first fan is installed in the first opening, and Wherein, the second fan is installed in the second opening.

4. The cooling module according to claim 3, wherein: The shield assembly includes a connecting bracket that, together with the first mounting bracket and the second mounting bracket, holds the first shield portion against the second shield portion, and Wherein, the connecting bracket is positioned between the first opening and the second opening.

5. The cooling module according to claim 4, wherein: The connecting bracket includes four fingers, each finger extending away from the central portion, wherein two of the four fingers comprise connections to the first shield portion, and Wherein two of the four fingers comprise connections to the second shield portion.

6. The cooling module according to claim 3, wherein: The first shroud portion includes a third opening, and a third fan is mounted in the third opening, and The second shield portion includes a fourth opening, and a fourth fan is installed in the fourth opening.

7. The cooling module according to claim 6, wherein: A fastener is centrally positioned between the first, second, third, and fourth openings, the fastener retaining the first shield portion against the second shield portion.

8. The cooling module according to claim 1, wherein: The first mounting bracket includes a first half and a second half, wherein the first half includes a joint area and a shield mounting member, wherein the second half includes a joint area and a shield mounting member, wherein the joining region of the first half is connected to the joining region of the second half, wherein the shield mount of the first half is connected to the first shield portion, and wherein the shield mount of the second half is connected to the second shield portion.

9. The cooling module according to claim 8, wherein: The second mounting bracket includes a first half and a second half, wherein the first half includes a joint area and a shield mounting member, wherein the second half includes a joint area and a shield mounting member, wherein the joining region of the first half is connected to the joining region of the second half, wherein the shield mounting member of the first half is connected to the first shield portion, wherein the shroud mount of the second half is connected to the second shroud portion, and Wherein, the second mounting bracket is positioned at a side of the first shield portion opposite to the first mounting bracket.

10. The cooling module according to claim 9, wherein: In the first mounting bracket and the second mounting bracket, The joint region of the first half and the shroud mount of the first half are formed from a single sheet of metal that is bent such that the shroud mount of the first half extends obliquely away from the joint region of the first half, and the joining area of ​​the second half and the shroud mount of the second half are formed from a single sheet of metal that is bent such that the shroud mount of the second half extends obliquely away from the joining area of ​​the second half, Such that both the first mounting bracket and the second mounting bracket form a "T" shape.

11. The cooling module according to claim 1, wherein: The first mounting bracket includes a frame flange and a shroud mounting member, wherein the shield mount is a single planar piece of material connected to the first shield portion and the second shield portion, and Wherein the frame flange extends from the shroud mount and includes two isolators configured to be connected to the vehicle frame.

12. The cooling module according to claim 11, wherein: The second mounting bracket includes a frame flange and a shroud mounting member, wherein the shield mount is a single planar piece of material connected to the first shield portion and the second shield portion, wherein the frame flange extends from the shroud mount and includes two isolators configured to be connected to the vehicle frame, and Wherein, the second mounting bracket is positioned at a side of the first shield portion opposite to the first mounting bracket.

13. The cooling module according to claim 12, wherein: The first mounting bracket is formed from a single sheet of metal that is bent such that the shroud mount of the first mounting bracket extends obliquely away from the frame flange of the first mounting bracket, and Wherein, the first mounting bracket forms an "L" shape.

14. The cooling module according to claim 1, wherein: The first mounting bracket includes two isolators configured to be connected to the vehicle frame, and Wherein, the second mounting bracket includes two isolators configured to be connected to the vehicle frame.

15. The cooling module according to claim 14, wherein: The isolator includes rubber.

16. The cooling module according to claim 1, wherein: The first shield portion and the second shield portion are formed of plastic, and The first shield portion and the second shield portion include a grid structure formed by a plurality of walls intersecting each other at an oblique angle.

17. The cooling module according to claim 1, wherein: The first shield portion is formed from a single piece of metal, and Wherein, the second shield portion is formed from another single piece of metal.

18. The cooling module according to claim 17, wherein: The metal is steel.

19. The cooling module according to claim 1, wherein: The heat sink includes heat sink pins for mounting the heat sink, wherein the first shield portion comprises at least two pin holes, wherein the second shield portion comprises at least two pin holes, and The radiator pins extend through the pin holes of the first shield portion or the pin holes of the second shield portion to mount the radiator to the shield.

20. The cooling module according to claim 1, wherein: The heat sink is one of a plurality of heat sinks, and Wherein, the plurality of heat sinks are installed between the first shield portion and the second shield portion.

21. A shield assembly for mounting a radiator to a vehicle frame, the shield assembly comprising: Protective cover, including: a first shroud portion having a first opening configured to receive a fan, the first opening being hemispherical, a second shroud portion having a second opening configured to receive the fan, the second opening being hemispherical, a first mounting bracket configured to mechanically engage the first shield portion and the second shield portion, and A second mounting bracket is configured to mechanically engage the first shield portion and the second shield portion.

22. The shield assembly of claim 21, wherein: The first opening in the first shield portion and the second opening in the second shield portion define opposing hemispheres of a single circular opening, and Therein, only one fan is installed in the single circular opening.

23. The shield assembly of claim 21, wherein: The fan is a first fan, wherein the first fan is installed in the first opening, and Wherein, the second fan is installed in the second opening.

24. The shield assembly of claim 23, wherein: The shield assembly includes a connecting bracket that, together with the first mounting bracket and the second mounting bracket, holds the first shield portion against the second shield portion, and Wherein, the connecting bracket is positioned between the first opening and the second opening.

25. The shield assembly of claim 24, wherein: The connecting bracket includes four fingers, each finger extending away from the central portion, wherein two of the four fingers comprise connections to the first shield portion, and Wherein two of the four fingers comprise connections to the second shield portion.

26. The shield assembly of claim 23, wherein: The first shroud portion includes a third opening, and a third fan is mounted in the third opening, and The second shield portion includes a fourth opening, and a fourth fan is installed in the fourth opening.

27. The shield assembly of claim 26, wherein: A fastener is centrally positioned between the first, second, third, and fourth openings, the fastener retaining the first shield portion against the second shield portion.

28. The shield assembly of claim 21, wherein: The first mounting bracket includes a first half and a second half, wherein the first half includes a joint area and a shield mounting member, wherein the second half includes a joint area and a shield mounting member, wherein the joining region of the first half is connected to the joining region of the second half, wherein the shield mount of the first half is connected to the first shield portion, and wherein the shield mount of the second half is connected to the second shield portion.

29. The shield assembly of claim 28, wherein: The second mounting bracket includes a first half and a second half, wherein the first half includes a joint area and a shield mounting member, wherein the second half includes a joint area and a shield mounting member, wherein the joining region of the first half is connected to the joining region of the second half, wherein the shield mounting member of the first half is connected to the first shield portion, wherein the shroud mount of the second half is connected to the second shroud portion, and Wherein, the second mounting bracket is positioned at a side of the first shield portion opposite to the first mounting bracket.

30. The shield assembly of claim 29, wherein: In the first mounting bracket and the second mounting bracket, The joint region of the first half and the shroud mount of the first half are formed from a single sheet of metal that is bent such that the shroud mount of the first half extends obliquely away from the joint region of the first half, and the joining area of ​​the second half and the shroud mount of the second half are formed from a single sheet of metal that is bent such that the shroud mount of the second half extends obliquely away from the joining area of ​​the second half, Such that both the first mounting bracket and the second mounting bracket form a "T" shape.

31. The shield assembly of claim 21, wherein: The first mounting bracket includes a frame flange and a shroud mounting member, wherein the shield mount is a single planar piece of material connected to the first shield portion and the second shield portion, and Wherein the frame flange extends from the shroud mount and includes two isolators configured to be connected to the vehicle frame.

32. The shield assembly of claim 31, wherein: The second mounting bracket includes a frame flange and a shroud mounting member, wherein the shield mount is a single planar piece of material connected to the first shield portion and the second shield portion, wherein the frame flange extends from the shroud mount and includes two isolators configured to be connected to the vehicle frame, and Wherein, the second mounting bracket is positioned at a side of the first shield portion opposite to the first mounting bracket.

33. The shield assembly of claim 32, wherein: The first mounting bracket is formed from a single sheet of metal that is bent such that the shroud mount of the first mounting bracket extends obliquely away from the frame flange of the first mounting bracket, and Wherein, the first mounting bracket forms an "L" shape.

34. The shield assembly of claim 21, wherein: The first mounting bracket includes two isolators configured to be connected to the vehicle frame, and Wherein, the second mounting bracket includes two isolators configured to be connected to the vehicle frame.

35. The shield assembly of claim 34, wherein: The isolator includes rubber.

36. The shield assembly of claim 21, wherein: The first shield portion and the second shield portion are formed of plastic, and The first shield portion and the second shield portion include a grid structure formed by a plurality of walls intersecting each other at an oblique angle.

37. The shield assembly of claim 21, wherein: The first shield portion is formed from a single piece of metal, and Wherein, the second shield portion is formed from another single piece of metal.

38. The shield assembly of claim 37, wherein: The metal is steel.

39. The shield assembly of claim 21, wherein: in, The first shield portion includes at least two pin holes, wherein the second shield portion comprises at least two pin holes, and The pin hole is configured to receive a radiator pin, and the radiator pin extends through the pin hole of the first shield portion or the pin hole of the second shield portion to mount the radiator to the shield.

40. A vehicle comprising the shroud assembly of claim 21.

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