Bracket for a vehicle

Abstract

A bracket 16 made of plastic for mounting between a heat exchanger 54 and a metal cast component 10 of a vehicle, e.g. an electric drive unit, a transmission or an exhaust gas recirculation component. The bracket 16 comprises a plurality of fluid passageways 18 for permitting the flow of one or more fluids into one or both of the heat exchanger 54 and the metal cast component 10, e.g. oil channels 20, 22, 68; bypass channel 62; and / or coolant channels 24, 26. At least one of the fluid passageways comprises a spigot 30 for insertion into a bore 14 of the metal cast component, which may be the fluid inlet.

Description

TECHNICAL FIELD The present disclosure relates to a bracket for a vehicle. Aspects of the invention relate to a bracket for mounting between a heat exchanger and the metal cast component of a vehicle, to a vehicle sub-assembly, to a vehicle, and to a method of manufacture. BACKGROUND It is known to form certain components of vehicle by casting metallic materials. Such components subsequently require machining and / or other post-casting steps or processes to produce the final desired product. Such steps are particularly necessary in arrangements in which the metal cast component is required to connect to or otherwise interface with another component having a particular form, such as a heat exchanger. In such arrangements, the necessary post-casting steps may be lengthy, difficult and / or costly. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a bracket for mounting between a heat exchanger and the metal cast component of a vehicle, a vehicle sub-assembly, a vehicle, and a method of manufacture as claimed in the appended claims. According to an aspect of the present invention there is provided a bracket for mounting between a heat exchanger and a metal cast component of a vehicle, the bracket comprising a plurality of fluid passageways for permitting the flow of one or more fluids into or out of one or both of the heat exchanger and the metal cast component, wherein at least one of the plurality of fluid passageways comprises a spigot for insertion into a bore of the metal cast component. According to an aspect of the present invention there is provided a bracket for mounting between a heat exchanger and a metal cast component of a vehicle, the bracket comprising a plurality of fluid passageways for permitting the flow of one or more fluids into or out of one or both of the heat exchanger and the metal cast component, wherein at least one of the plurality of fluid passageways comprises a spigot for insertion into a bore of the metal cast component, and wherein the bracket comprises plastics material. The bracket may serve to permit mounting of heat exchanger to the metal cast component whilst negating the need for specialist machining or other post-casting processing of the metal cast component that would be necessary for allowing the heat exchanger to be mounted on the metal cast component in the absence of the bracket. The presence of the spigot provides a secure fluid tight fit that permits one or more fluids to flow into or out of one or both of the heat exchanger and the metal cast component when the bracket is assembled and disposed between the heat exchanger and the metal cast component. In certain embodiments, the bracket may comprise an 0-nng on an external surface of the spigot. The O-ring may provide an improved fluid tight connection between the spigot and a bore of the heat exchanger or metal cast component in which the spigot is received. The bracket may comprise a groove on the external surface of the spigot, wherein the O-ring is received in the groove. The groove may reduce the possibility of the O-ring inadvertently moving on the spigot, thereby improving the reliability of the fluid tight connection. In certain embodiments, the groove is defined by a pair of flanges spaced from one another. This arrangement provides a particularly effective way of providing the groove. In certain embodiments, the spigot has a length that is at least two thirds of the diameter of the O-ring. As such, the spigot may extend into a bore of the heat exchanger or metal cast component by a length that may reduce the likelihood of the spigot becoming dislodged out of the bore. In certain embodiments, the bracket may comprise a plurality of mounting holes for receiving fixings for mounting the heat exchanger to the metal cast component. The use of mounting holes provides a simple yet effective means for mounting the heat exchanger to the metal cast component using fixings. In certain embodiments, the bracket may comprise a compression limiter in at least one of the plurality of mounting holes. The use of compression limiters may reduce the possibility of loads imparted by the fixings damaging or otherwise compromising the integrity of the bracket. In certain embodiments, the at least one of the plurality of fluid passageways is a first oil channel configured to permit the flow of oil from an oil outlet of the heat exchanger into the metal cast component through the spigot. In this manner, the bracket 16 may facilitate the passage of oil from the heat exchanger into the metal cast component despite being disposed therebetween. In certain embodiments, the first oil channel comprises a first oil inlet for receiving oil from the oil outlet of the heat exchanger, and a second oil inlet for receiving oil from a further source. In this manner, oil may pass into the metal cast component through the bracket from either the heat exchanger or the further source. In certain embodiments, the bracket may comprise a bypass channel having a bypass inlet for receiving oil from the further source and a bypass outlet in fluid communication with the second oil inlet. In this manner, oil may be channeled by the bracket from the heat exchanger or from the further source through the bypass channel, thereby bypassing the heat exchanger. In certain embodiments, the plurality of fluid passageways comprises a first coolant channel configured to permit the flow of coolant into the heat exchanger and a second coolant channel configured to permit the flow of coolant out of the heat exchanger. In this manner, the bracket may additionally facilitate the flow of coolants in and out of the heat exchanger despite being disposed between the heat exchanger and the metal cast component. In certain embodiments, the bracket may be a moulded component. Moulding may be an inexpensive, simple and / or quick method of manufacturing the bracket. According to another aspect of the present invention there is provided a vehicle sub-assembly comprising a heat exchanger, a metal cast component of a vehicle, and a bracket as described above mounted between the heat exchanger and the metal cast component such that the spigot extends into the bore of the metal cast component. In certain embodiments, the metal cast component comprises an electric drive unit, a transmission or an exhaust gas recirculation component. Such components may benefit from the simple interface provided by the bracket for mounting a heat exchanger thereto. According to another aspect of the present invention there is provided a vehicle comprising the bracket described above, or comprising the vehicle sub-assembly described above. According to another aspect of the present invention there is provided a method of manufacture comprising moulding plastics material to form a bracket for mounting between a heat exchanger and a metal cast component of a vehicle, the bracket comprising a plurality of fluid passageways for permitting the flow of one or more fluids into one or both of the heat exchanger and the metal cast component, wherein at least one of the plurality of fluid passageways comprises a spigot for insertion into a bore of the metal cast component. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 shows a metal cast component of a vehicle in accordance with an embodiment of the present invention; FIG. 2 shows a perspective view of a bracket for mounting between a heat exchanger and the metal cast component of FIG. 1 in accordance with an embodiment of the present invention; FIG. 3 shows a rearview of the bracket of FIG. 2; FIG. 4 shows a cross-sectional view of a vehicle sub-assembly in accordance with an embodiment of the present invention; and FIG. 5 shows a vehicle in accordance with an embodiment of the present invention. DETAILED DESCRIPTION FIG. 1 shows a metal cast component 10 of a vehicle 60 (shown in FIG. 5). In certain embodiments, the metal cast component 10 may comprise an electric drive unit, a transmission or an exhaust gas recirculation component. In the non-limiting embodiment shown in FIG. 1, the metal cast component 10 comprises a plurality ofthreaded bores 12 for receiving fixings, such as threaded bolts, as is described in more detail below. The metal cast component 10 also comprises a fluid inlet 14 configured to permit fluids to be received in the metal cast component 10. FIG. 2 shows a perspective view of a bracket 16 in accordance with an embodiment of the present invention. FIG. 3 shows a rearview of the bracket 16. The bracket 16 is for mounting between a heat exchanger and the metal cast component 10. In particular, in certain embodiments, the bracket 16 provides an intermediate interface between the heat exchanger and the metal cast component 10. To achieve this, one side of the bracket 16 may interface with the heat exchanger, whilst the opposite side of the bracket 16 may interface with the metal cast component 10. In doing so, the requirement for the heat exchanger to interface with the metal cast component 10 directly is negated. Consequently, the metal cast component 10 does not require any complex geometry (which usually requires timely and / or costly machining or other processing) in order to permit the heat exchanger to be mounted thereto. The bracket 16 comprises a plastics material. Consequently, the geometry required to interface with both of the heat exchanger and the metal cast component 10 may be provided by the bracket 16 without the need for timely or costly manufacturing techniques. For example, the bracket 16 may be a moulded plastics component. In certain embodiments, the bracket 16 may be moulded (or otherwise produced) in multiple parts, where the multiple parts may be subsequently joined together, including but not limited to sonic welding. The bracket 16 comprises a plurality of fluid passageways 18 for permitting the flow of one or more fluids into or out of one or both of the heat exchanger and the metal cast component 10. In the non-limiting depicted 4 embodiment, one of the fluid passageways 18 comprises a spigot 30 for insertion into a bore of the metal cast component 10 or the heat exchanger, as is described further below. In the non-limiting embodiment shown in FIG. 1, the bore of the metal cast component 10 that may receive the spigot 30 is the fluid inlet 14. In certain embodiments, the bracket 16 may comprise more than one spigot 30. In the non-limiting embodiment depicted in the Figures, the fluid passageways 18 comprise channels that permit the flow of oils and coolants (albeit separately). In particular, the bracket 16 comprises a first oil channel 20, a second oil channel 22, an intermediate oil channel 68 and a bypass channel 62 for permitting the flow of oil therethrough. The bracket 16 additionally comprises a first coolant channel 24 and a second coolant channel 26 for permitting the flow of coolant therethrough. In the non-limiting depicted embodiment, the first oil channel 20 extends through the spigot 30. Also in the depicted embodiment, the first oil channel 20 comprises a first oil inlet 48 and a second oil inlet 50. The bracket 16 has a bypass channel 62 that has a bypass inlet 64 and a bypass outlet 66 that is in fluid communication with the second oil inlet 50. The second oil channel 22 includes a first volume 28 that is in fluid communication with the bypass inlet 64. The first volume 28 is also couplable to an inlet of the heat exchanger via the intermediate oil channel 68 so that fluid entering the second oil channel 22 may flow into the heat exchanger and / or through the bypass inlet 64 into the bypass channel 62. In certain embodiments, oil may enter the bracket 16 through the second oil channel 22 and pass through the heat exchanger and / or the bypass channel 62. Oil passing through the bypass channel 62 may then pass into the metal cast component 10 via the first oil channel 20. Oil passing through the heat exchanger 54 may enter the bracket 16 (once more) through the first oil inlet 48 and pass into the metal cast component 10 via the first oil channel 20. Thus, the metal cast component 10 may receive oil that has passed through the heat exchanger and / or oil that has bypassed the heat exchanger by flowing along the bypass channel 62. In the non-limiting depicted embodiment, the first coolant channel 24 has a first coolant channel inlet 40 and a first coolant channel outlet 42. Coolant may enter the bracket 16 through the first coolant channel inlet 40 and flow out of the first coolant channel 24 into the heat exchanger through the first coolant channel outlet 42. The coolant may reduce the temperature of oil within the heat exchanger (but may remain fluidly isolated from the oil). Following removal of heat from the oil, the coolant may exit the heat exchanger through a second coolant channel inlet 44, before flowing along the second coolant channel 26 and exiting the bracket 16 via a second coolant channel outlet 46. The interfaces between the bracket 16 and the heat exchanger across which fluids flow may be shaped or otherwise configured to provide a fluid tight engagement between the bracket 16 and the heat exchanger. In certain embodiments, gaskets, O-rings, or other sealing features or sealants may be provided to facilitate the fluid tight engagement. The bracket has a plurality of mounting holes 36 that may receive fixings for mounting the heat exchanger to the metal cast component 10 with the bracket 16 being disposed therebetween. In the non-limiting embodiment shown in the Figures, the mounting holes 36 include compression limiters 38 that may reduce the risk of the bracket 16 being damaged by loads imparted by the fixings when the heat exchanger is mounted to the metal cast component 10. FIG. 4 shows a cross-sectional view of a vehicle sub-assembly 52 in accordance with an embodiment of the present invention. The vehicle sub-assembly 52 comprises a heat exchanger 54 mounted to the metal cast component 10 with the bracket 16 disposed therebetween. As shown in FIG. 4, fixings 58 are provided for mounting the heat exchanger 54 to the metal cast component 10. The fixings 58 may pass through the mounting holes 36 and into the threaded bores 12. In particular, the fixings 58 may each comprise a threaded bolt. In other embodiments, other fixing arrangements may be employed for mounting the heat exchanger 54 to the metal cast component 10 in a manner in which the bracket 16 is disposed therebetween. FIG. 4 shows how an oil outlet 56 of the heat exchanger 54 is in fluid communication with the first oil inlet 48 of the first oil channel 20. It can also be seen from FIG. 4 how the spigot 30 of the bracket 16 extends into the fluid inlet 14 of the metal cast component 10. As is also visible in FIG. 2 and FIG. 3, the spigot 30 comprises a pair of flanges 32 that are spaced from one another such that a groove is defined therebetween. The groove between the flanges 32 may receive an O-ring 34 that may serve to provide a fluid tight seal between the bracket 16 and the metal cast component 10 when the spigot 30 is received through the fluid inlet 14. In other embodiments, the groove for receiving the O-ring 34 may be otherwise defined. In certain embodiments, the O-ring 34 may be provided in the absence of a groove. In certain embodiments, the spigot 30 may have a length that is at least two thirds of the diameter of the O-ring 34. In certain embodiments, in an assembled configuration, the spigot 30 may extend through an opening ofthe fluid inlet 14 by an amount that is at least two thirds of the diameter of the O-ring 34. Such arrangements may provide a secure fluid tight fit. FIG. 5 shows a vehicle 60 in accordance with an embodiment ofthe present invention. The vehicle 60 may comprise the bracket 16 described above. In particular, the vehicle 60 may comprise the vehicle sub-assembly 52 described above. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope ofthe present application.

Claims

1. A bracket for mounting between a heat exchanger and a metal cast component of a vehicle, the bracket comprising a plurality of fluid passageways for permitting the flow of one or more fluids into or out of one or both of the heat exchanger and the metal cast component;wherein at least one of the plurality of fluid passageways comprises a spigot for insertion into a bore of the metal cast component; andwherein the bracket comprises plastics material.

2. A bracket according to claim 1, comprising an O-ring on an external surface of the spigot.

3. A bracket according to claim 2, comprising a groove on the external surface of the spigot, wherein the O-ring is received in the groove.

4. A bracket according to claim 3, wherein the groove is defined by a pair of flanges spaced from one another.

5. A bracket according to any of claims 2 to 4, wherein the spigot has a length that is at least two thirds of the diameter of the O-ring.

6. A bracket according to any preceding claim, comprising a plurality of mounting holes for receiving fixings for mounting the heat exchanger to the metal cast component.

7. A bracket according to any of claim 6, comprising a compression limiter in at least one of the plurality of mounting holes.

8. A bracket according to any preceding claim, wherein the at least one of the plurality of fluid passageways is a first oil channel configured to permit the flow of oil from an oil outlet of the heat exchanger into the metal cast component through the spigot.

9. A bracket according to claim 8, wherein the first oil channel comprises a first oil inlet for receiving oil from the oil outlet of the heat exchanger, and a second oil inlet for receiving oil from a further source.

10. A bracket according to claim 9, comprising a bypass channel having a bypass inlet for receiving oil from the further source and a bypass outlet in fluid communication with the second oil inlet.

11. A bracket according to any preceding claim, wherein the plurality of fluid passageways comprises a first coolant channel configured to permit the flow of coolant into the heat exchanger and a second coolant channel configured to permit the flow of coolant out of the heat exchanger.

12. A vehicle sub-assembly comprising:a heat exchanger;a metal cast component of a vehicle; anda bracket according to any preceding claim mounted between the heat exchanger and the metal cast component such that the spigot extends into the bore of the metal cast component.5 13. A vehicle sub-assembly according to claim 12, wherein the metal cast component comprises an electricdrive unit, a transmission or an exhaust gas recirculation component.

14. A vehicle comprising the bracket of any of claims 1 to 11, or comprising the vehicle sub-assembly of claim 12or13.1015. A method of manufacture comprising moulding plastics material to form a bracket for mounting between a heat exchanger and a metal cast component of a vehicle, the bracket comprising a plurality of fluid passageways for permitting the flow of one or more fluids into one or both of the heat exchanger and the metal cast component, wherein at least one of the plurality of fluid passageways comprises a spigot for insertion into 15 a bore of the metal cast component.

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