Support frame for a vehicle radiator and radiator module

Abstract

A support frame (10) for a vehicle radiator comprises two parallel supports (12, 14) and two interconnected struts (16, 18) forming a rectangular frame. The supports (12, 14) and struts (16, 18) are each one-piece plastic elements that can be assembled and disassembled by connecting and separating the supports (12, 14) and struts (16, 18). A cooler module (30) comprises the above-mentioned support frame (10) and at least one of the following cooler units (32): a low-temperature cooler (34), a high-temperature cooler (36), a condenser (38), an intercooler (44), a fan system (40) and an oil cooler (42).

Description

[0001] The invention relates to a support frame for a vehicle radiator made of plastic and a radiator module with the above support frame and at least one radiator unit.

[0002] Plastic support frames for vehicle radiators are known in the art and feature a U-shaped frame component and a locking head to provide sufficient stability for the support frame. When disassembled, the U-shaped frame elements require a large packaging volume, which leads, for example, to high costs for transporting the disassembled frame elements.

[0003] Furthermore, in cooler modules with such support frames, cooler units can only be inserted into the open end of the U-shaped frame element during assembly. The elements of the support frame itself and the cooler unit are attached using separate fasteners, such as screws. Mounting the support frame and the cooler module is therefore a complicated process.

[0004] US Pat. No. 6,470,961 B1 discloses a condenser, cooler, and fan module suitable for modular installation and simplified individual maintenance of the module components. The module comprises a module frame with a set of channels for accommodating the respective components. The base of the module frame can be removed.

[0005] DE 195 08 112 A1 discloses a water cooler with a radiator for a motor vehicle. The radiator is attached to a plastic mounting frame equipped with vehicle-specific fastening elements. The radiator is connected to the mounting frame via detachable connecting elements.

[0006] The technical problem to be solved is therefore to create a support frame for a vehicle radiator made of plastic, which in its disassembled state has a small packaging requirement and enables an improved assembly of the radiator module.

[0007] This problem is solved by a support frame for a vehicle radiator according to the invention, which has two parallel supports and two interconnected struts forming a rectangular frame. The supports and struts are each integral plastic elements that can be assembled and disassembled by connecting and separating the supports and struts. Additional frame elements are arranged on a front or rear surface of the support frame, the frame elements being connected to at least one of the supports and struts by integral locking elements.

[0008] This design allows the supports and struts to have a relatively simple geometry, resulting in low packaging requirements for the individual frame elements. The simplified geometry also simplifies the manufacturing process, particularly the demolding of the plastic elements. At the same time, the number of different elements required for assembly remains low.

[0009] The need for separate fasteners such as screws can be eliminated if the columns and struts are connected to each other only by locking elements integrally formed on the columns and struts. This simplifies the assembly process of the support frame.

[0010] In addition, the supports and struts may have integrally formed locking elements for fastening at least one radiator unit to the frame.

[0011] A radiator unit can be preferably inserted into the frame when one of the struts is removed. This allows greater flexibility in the assembly process and in the event that radiator units need to be replaced.

[0012] The additional frame elements allow a variety of cooler units to be connected to the support frame.

[0013] A cooler module according to the invention comprises a support frame as described above and at least one of the following cooler units: a low-temperature cooler, a high-temperature cooler, a condenser, an intercooler, a fan system, and an oil cooler. The cooler module can be easily assembled and mounted in the vehicle, preferably in such a way that several cooler units are arranged on the support frame.

[0014] The assembly of the cooler module can be further simplified if a cooler unit and one of the frame elements form a pre-assembled sub-unit during assembly or disassembly of the support frame.

[0015] No separate fastening elements are required if all cooler units are connected to the support frame by locking elements that are integrally formed on the frame elements.

[0016] Further features and advantages of the invention are disclosed in the following description and the drawings to which reference is made. In the drawings: - Fig. 1 a support frame according to the invention; - Fig. 2 the support frame Fig. 1 from a different perspective; - Fig. 3 a section of the corner connection A of the support frame from Fig. 1; - Fig. 4 a section of the corner connection A of the support frame from Fig. 1; - Fig. 5 a section of the corner connection B of the support frame from Fig. 1; - Fig. 6 a section of the corner connection B of the support frame from Fig. 1; - Fig. 7 a section of the corner connection C of the support frame from Fig. 1; - Fig. 8 a section of the corner connection C of the support frame from Fig. 1; - Fig. 9 a section of the corner connection C of the support frame from Fig. 1; - Fig. 10 a section of the corner connection D of the support frame from Fig. 1; - Fig. 11 a section of the corner connection D of the support frame from Fig. 1; - Fig. 12 a section of the corner connection D of the support frame from Fig. 1; - Fig. 13 a section of an additional frame element of the support frame from Fig. 1; - Fig. 14 a section of an additional frame element of the support frame from Fig. 1; - Fig. 15 a section of an additional frame element of the support frame from Fig. 1; - Fig. 16 a section of an additional frame element of the support frame from Fig. 1; - Fig. 17 a cooler module according to the invention; - Fig. 18 the cooler module Fig. 17 from a different perspective; - Fig. 19 a section of the corner connection A of the cooler module Fig. 17 with a low-temperature cooler; - Fig. 20 a section of the corner connection B of the cooler module Fig. 17 with a low-temperature cooler; - Fig. 21 a section of the corner connection C of the cooler module Fig. 17 with a low-temperature cooler; - Fig. 22 a section of the corner connection C of the cooler module Fig. 17 with a low-temperature cooler; - Fig. 23 a section of the corner connection D of the cooler module Fig. 17 with a low-temperature cooler; - Fig. 24 a section of the corner connection D of the cooler module Fig. 17 with a low-temperature cooler; - Fig. 25 a pre-assembled sub-unit with a high-temperature cooler of the cooler module Fig. 1; - Fig. 26 a section of the pre-assembled sub-unit from Fig. 25; - Fig. 27 a section of the corner connection A of the cooler module Fig. 17 with a high-temperature cooler; - Fig. 28 a section of the corner connection A of the cooler module Fig. 17 with a high-temperature cooler; - Fig. 29 a section of the corner connection B of the cooler module Fig. 17 with a high-temperature cooler; - Fig. 30 a section of the corner connection B of the cooler module Fig. 17 with a high-temperature cooler; - Fig. 31 the cooler module Fig. 17 with a capacitor; - Fig. 32 a section of the corner connection B of the cooler module Fig. 17 with a capacitor; - Fig. 33 a section of the cooler module Fig. 17 with a capacitor; - Fig. 34 a section of the cooler module Fig. 17 with a capacitor; - Fig. 35 a section of the cooler module Fig. 17 with a capacitor; - Fig. 36 a pre-assembled sub-unit with an intercooler of the cooler module Fig. 17; - Fig. 37 the cooler module Fig. 17 with the pre-assembled sub-unit with the intercooler from Fig. 36; - Fig. 38 a section of the corner connection A of the cooler module Fig. 17 with a blower system; - Fig. 39 a section of the corner connection B of the cooler module Fig. 17 with a blower system; - Fig. 40 a section of the corner connection D of the cooler module Fig. 17 with a blower system; - Fig. 41 a section of the connection of an oil cooler with the support frame of the cooler module from Fig. 17; - Fig. 42 a section of the connection of an oil cooler with the support frame of the cooler module from Fig. 17; and - Fig. 43 a section of the connection of an oil cooler with the support frame of the cooler module from Fig. 17.

[0017] A support frame 10 for a vehicle radiator is in the Fig. 1 and Fig. 2. The support frame 10 comprises two parallel supports 12 and 14 and two interconnected struts 16 and 18, forming a rectangular frame. The boundaries between these individual elements are indicated by dashed lines.

[0018] The supports 12 and 14 and the struts 16 and 18 are connected at the corners A, B, C and D of the rectangular frame.

[0019] An additional frame element 19 is in the Fig. 1 and Fig. 2, which forms a holder 20 for an additional cooler unit. The holder 20 is attached to the rectangular frame by several arms connected to the supports 12 and 14 and to the upper strut 16, respectively.

[0020] The supports 12 and 14 and struts 16 and 18 are connected to each other only by locking elements 22, which comprise projections 22a, hooks 22b and snap connectors 22c, which are formed integrally on the supports 12 and 14 and struts 16 and 18.

[0021] The supports 12 and 14 and the struts 16 and 18 are each formed as one-piece plastic parts. This is advantageous for the manufacturing process because few individual parts and components are required and the support frame 10 can be manufactured easily and cost-effectively.

[0022] Further additional frame elements 19, in particular the holder 20, are also fastened to the rectangular frame by locking elements 22 which are formed integrally on the parts of the rectangular frame or on the additional frame elements 19.

[0023] Additional locking elements 28 in the form of projections 28a, hooks 28b and snap connectors 28c are formed integrally on the support 12, 14 and on the strut 16 to enable the attachment of the cooler units to the support frame 10.

[0024] The Fig. 3 and Fig. 4 show a section of the upper corner A. A firm connection between the support 12 and the strut 16 is achieved by several locking elements 22, which are formed integrally on the support 12 and the strut 16. In Fig. 3, two hooks 22b formed on the support 12 engage the strut 16. A snap connector 22c is formed on the support 12 and engages a corresponding opening in the strut 16. The snap connector 22c is preloaded against the strut 16 and secures the support 12 and the strut 16 in the position in which the hooks 22b engage the strut 16.

[0025] To disassemble the support 12 and the strut 16, the snap connector 22c must be pressed to disengage from the opening of the strut 16. When the snap connector 22c is disengaged, the support 12 and the strut 16 can be moved relative to each other to disengage the hooks 22b and release the connection between the support 12 and the strut 16.

[0026] Fig. Figure 4 shows a view of the corner joint A from a different perspective. Another locking element 22 can be seen from this perspective in the form of a projection 22a formed on the support 12 and extending through a corresponding hole in the strut 16.

[0027] The Fig. 5 and Fig. 6 show the connection between the upper strut 16 and the support 14 at corner B. The connection between the support 14 and the strut 16 is similar to the connection in corner A, having locking elements 22 in the form of projections 22a, hooks 22b and snap connectors 22c.

[0028] The connection between the lower strut 18 and the support 12 at the corner C of the support frame 10 is shown in the Fig. 7, Fig. 8 and Fig. 9. The connection is formed by locking elements 22 in the form of projections 22a, which are integrally formed on the support 12 and the strut 18, and is secured by a snap connector 22c. Additional locking elements 22 and 28 are provided to attach additional frame elements 19 or one or more radiator units to the support frame 10.

[0029] In Fig. In Figure 9, the boundary between the support 12 and the base 18 is shown with a dashed line. The support 14 and the strut 18 are connected by locking elements 22 in the form of projections 22a and snap connectors 22c.

[0030] Analogous to the Fig. 7, Fig. 8 and Fig. 9 show the Fig. 10, Fig. 11 and Fig. 12 the connection between the lower strut 18 and the support 14 at corner D.

[0031] The connection of the holder 20 to the supports 12 and 14 and to the strut 16 is shown in the Fig. 13, Fig. 14, Fig. 15 and Fig. 16 illustrates. Fig. 13 shows the holder 20, which is attached to the support 12 by a snap connector 22c arranged at the end of one of the side arms of the holder 20. Fig. 14 shows the holder 20 connected to the support 14 by a snap connector 22c and an additional hook 22b on the other side arm of the holder 20, which engages the support 14.

[0032] The Fig. 15 and Fig. 16 show one of the two upper arms of the holder 20, which are inserted into a recess of the strut 16 to form a positive connection. Fig. 16 shows a sectional view of the strut 16 and the holder 20.

[0033] The Fig. 17 and Fig. 18 shows a cooler module 30 with multiple cooler units 32 arranged on the support frame 10. The cooler units include a low-temperature cooler 34, a high-temperature cooler 36, a condenser 38, a fan system 40, an oil cooler 42, and an intercooler 44.

[0034] Fig. 17 shows a first surface of the support frame 10 on which the holder 20 is arranged. The holder 20 of the support frame 10 holds the intercooler 44.

[0035] Fig. 18 shows the opposite, second surface of the support frame 10. An additional frame element 19 is connected to the rectangular frame, forming a support 46 for the fan system 40. Furthermore, the oil cooler 42 is arranged on this surface of the support frame 10 and is connected to the support 14 and the lower strut 18 via integrally formed locking elements 28.

[0036] The following figures show the arrangement of the multiple cooler units in the cooler module and the step-by-step assembly of the support frame 10 and the cooler module 30. In a first step, the two supports 12 and 14 are connected to the upper strut 16.

[0037] The low-temperature cooler 34 is then inserted into the support frame 10 and secured by locking elements 28. Fig. 19 shows the connection between the low-temperature cooler 34 and the support 12, in which a projection of the low-temperature cooler 34 is arranged between two projections 28a of the support 12.

[0038] Fig. Figure 20 shows a similar connection of the low temperature cooler 34 in corner B, where it is connected to the support 14.

[0039] Fig. 21 shows a connection of the low-temperature cooler 34 in the lower corner C to the support 12. The locking elements 28, which fasten the low-temperature cooler 34 to the support 12, are formed on the low-temperature cooler 34 and comprise a straight projection 28a and a snap connector 28c.

[0040] Fig. 22 shows the opposite surface of the cooler module 30. An additional support for the low-temperature cooler 34 is provided by a protruding rib 24, against which the low-temperature cooler 34 rests.

[0041] The Fig. 23 and Fig. 24 show the connection between the low-temperature cooler 34 and the support 14 in the corner D of the support frame 10. A projection of the low-temperature cooler 34 is held between two projections 28a of the support 14 and secured by a snap connector 28c.

[0042] Fig. 25 shows a pre-assembled subunit 26 with the high-temperature cooler 36 and the lower strut 18.

[0043] Fig. 26 shows a sectional view of the strut 18 with the high-temperature cooler 36.

[0044] The preassembled sub-unit 26 of the high-temperature cooler 36 with the strut 18 is then inserted into the support frame 10. The high-temperature cooler 36 is held in position by a plurality of retaining elements 28, which are integrally connected to the upper strut 16 and / or the supports 12 or 14.

[0045] The Fig. 27 and Fig. 28 show a longitudinal sectional view and a side sectional view of the connection at the corner A of the support frame 10. As in Fig. 28, the high-temperature cooler 36 is arranged next to the low-temperature cooler 34 within the support frame 10.

[0046] The Fig. 29 and Fig. 30 show corresponding sectional views of the connection between the high-temperature cooler 36 and the upper strut 16 and support 14 of the support frame 10 at the corner B.

[0047] Fig. 31 shows the connection of the capacitor 38 to the support frame 10 at the corners B and D. A section of the connection at the corner B of the support frame 10 is shown in Fig. 32 in a horizontal section. A round, tubular portion of the capacitor 38 is held by a projection 28a of the support 14. The projection 28a is designed such that the capacitor 38 can rotate about an axis of the tubular portion.

[0048] The condenser 38 is located next to the low-temperature cooler 34 on the surface opposite to the high-temperature cooler 36.

[0049] The capacitor 38 is also connected to the support 12 on the opposite side of the support frame 10. Fig. 33 shows a first connection near corner A of the support frame 10. The condenser 38 has a first connection unit 48 secured to the support 12 by two locking elements 28, which include an L-shaped projection at the bottom of the first connection unit 48 and a snap connector at the upper portion of the first connection unit 48, each integrally formed on the strut 12. The first connection unit 48 enables the connection of a coolant line to the condenser 38. Fig. 34 shows the first connection unit 48 of the capacitor 38 in another view from below.

[0050] Fig. 35 shows a second connection unit 50 that enables the connection of two coolant lines to the condenser 38. The second connection unit 50 is secured between two projections 28a and a snap connector 28c, which are integrally formed on the support 12.

[0051] Fig. 36 shows the holder 20 of the support frame 10, which forms a pre-assembled sub-unit 26 with the intercooler 44.

[0052] Fig. 37 shows the subunit 26 of the holder 20 with the intercooler 44 attached to the support frame 10. The intercooler 44 is located next to the condenser 38.

[0053] The Fig. 38, Fig. 39 and Fig. 40 show the connection of the additional frame member 19, which holds the blower system 40 at the corners A, B, and D, respectively. The blower system bracket 46 has projections that are attached to the support frame 10 via locking elements 22, which position the blower system bracket 46 and secure it with snap connectors 22c.

[0054] Fig. 41 shows the connection of the oil cooler 42 to the support 12 by locking elements 28 comprising a projection 28a and a snap connector 28c which are formed integrally on the support 12 and engage in an opening in the base plate of the oil cooler 42.

[0055] The Fig. 42 and Fig. 43 show a detailed view of the connection of the oil cooler 42 to the lower strut 18 of the support frame 10, in which projections of the base plate of the oil cooler 42 are held in corresponding openings which are formed integrally on the lower strut 18.

[0056] Further features of the invention are readily apparent from the drawings of the support frame 10 and the cooler module 30.

Claims

[1] Support frame (10) for a vehicle radiator, with two parallel supports (12, 14) and two interconnected struts (16, 18) which form a rectangular frame, in which the supports (12, 14) and struts (16, 18) are each one-piece elements made of plastic which can be assembled and disassembled by connecting and separating the supports (12, 14) and struts (16, 18), wherein additional frame elements (19) are provided on the support frame (10), which are attached to a front or a rear surface of the support frame (10) and are connected to at least one of the supports (12, 14) and struts (16, 18) by one-piece locking elements (22). [2] Support frame according to claim 1, wherein the supports (12, 14) and struts (16, 18) are connected to one another only by locking elements (22) which are formed integrally on the supports (12, 14) and struts (16, 18). [3] Support frame according to claim 1 or 2, wherein the supports (12, 14) and struts (16, 18) have integrally formed locking elements (28) for fastening at least one cooler unit to the frame. [4] Support frame according to one of the preceding claims, in which a radiator unit can be inserted into the frame when one of the struts (16, 18) is dismantled. [5] Radiator module (30) with a support frame (10) according to one of the preceding claims and at least one of the following radiator units (32): a low-temperature radiator (34), a high-temperature radiator (36), a condenser (38), an intercooler (44), a fan system (40) and an oil cooler (42). [6] Cooling module according to claim 5, wherein a cooler unit (32) and one of the frame elements form a pre-assembled sub-unit (26) during assembly or disassembly of the support frame (10). [7] Radiator module according to claim 5 or 6, wherein all the radiator units (32) are connected to the support frame (10) by locking elements (28) which are formed integrally on the frame elements.

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