Note: Descriptions are shown in the official language in which they were submitted.
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FAN SHROUD AND AIR INTAKE ARRANGEMENT
Field of the Disclosure
5 This invention relates generally to
automotive radiator fan shrouds and, more particularly,
to such shrouds which are blow molded to include hollow
compartments which serve as reservoirs for fluids, such
as coolant fluid, and/or window and headlamp washer
10 fluids and wherein t:he blow molded shroud further
includes an engine air intake conduit for supplying
atmospheric air to t:he air induction system of a
vehicle whose radiator- is cooled by air flow through
the radiator fan shroud.
Background Art
United States Patent No. 5,649,587 assigned
to the assignee of: the present invention and
20 incorporated herein by reference, discloses a blow
molded fan shroud and receptacle arrangement wherein a
hollow body serves to define a primary air flow passage
through the fan shroud for cooling a radiator
associated with the arrangement. The hollow body
25 further includes campartments that define reservoirs
for engine coolant; washer fluid and the like.
The aforesaid fan shroud and receptacle
arrangement is desirable in that it eliminates the need
for separate fasteners for the fan shroud and the
30 compartments formed thereon. More specifically, it is
desirable in that the fluid compartments therein are
readily farmed in one blow molding operation.
An additional requirement for combustion
engines having radiators for removing heat from coolant
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circulated through the engine is that they have an air
induction system for connecting atmosphere through an
air cleaner. In the past, such systems have required
separate mounting arrangements for a front engine
5 compartment mounted air intake element and furthermore
have required a path for flow of the inlet air to the
engine that in certain engine layouts can encroach upon
the location for the cooling air that must be directed
across the engine coolant radiator.
Summary Of The Invention
A general object of the invention, therefore,
is to provide an improved, compact and efficient blow
15 molded radiator fan shroud with an integral engine air
induction intake conduit far directing air from the
atmosphere to the air induction system of an internal
combustion engine having coolant flow there through
conditioned by air flow through a fan shroud for
directing cooling air across a radiator.
Another object of the invention is to provide
a one-piece fan shroud arrangement with a fluid
compartment and an associated engine air flow conduit
for directing coolant into the engine for cooling the
25 engine and for directing air into the engine induction
system for mixing with fuel and combustion within the
engine.
Another object of the invention is to provide
a compact, one-piece fan shroud and engine air intake
30 and fluid receptacle arrangement that reduces the need
for fasteners and handling of components within the
vehicle.
A further object is to provide a combination
fan shroud and engine air intake unit for use adjacent
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a vehicle radiator and an engine air intake manifold
assembly, and around one or more cooling fans
including a body of a predetermined depth and having a
front face adapted to face the front of the vehicle
5 and being adjacent to the radiator, a rear face spaced
apart from said front face, a top wall and a spaced-
apart bottom wall, oppositely disposed side walls, and
at least one inner wall defining a primary air opening
through the body of a size to accommodate air flow
10 through the radiator for cooling anti-freeze or other
fluids directed there through and wherein the body
defines at least one engine air intake ~~onduit
extending rearwardly through the body from the front
face the air intake conduit having an intake end
15 defining an intake opening disposed adjacent the front
face in communication with atmosphere and an outlet
end spaced apart from the intake end and configured
for connection to an air induction system of the
engine.
20 A further object of the invention is to
provide such an arrangement wherein the body has a
single engine air intake conduit.
Yet another object of the invention is to
provide such an arrangement wherein the air intake
25 conduits are spaced apart about the periphery of the
body.
Still another object of the invention is to
provide such an arrangement wherein there are three
air intake conduits.
30 Another object of the invention is to
provide such an arrangement wherein the body is formed
from blow molded plastic.
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Another object of the invention is to
provide such an arrangement wherein the body is formed
from gas-assist injection molded plastic.
A feature of the invention is to provide the
arrangement of_ the preceding objects including an
engine air induction noise reduction device downstream
of the engine air intake end, and wherein the noise
reduction device is integral with the body and is in
communication with the air intake conduit.
A further feature of the invention is to
provide such a noise reduction device as a resonator
that is fully encompassed within the confines of the
aforesaid body.
A sti:Ll further feature is to provide the
resonator as a quarter wave tube configuration.
Yet another object of the invention is to
provide a compartment within the body configured as an
air filter housing formed integrally with said body
and disposed between the intake and outlet ends of the
engine air conduit and whereby the air filter housing
is adapted to receive an air filter for filtering air
passing there through.
These and other objects and advantages of the
invention will become apparent when reference is made
to the following drawings and the accompanying
description.
Brief Description Of The Drawings
Figure 1 illustrates a perspective view of an
engine air induction system and engine radiator coolant
system associated with one embodiment of a fan shroud
and air intake arrangement according to the present
invention;
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Figure 2 is an enlarged perspective view of
the fan shroud
and air intake
arrangement in
the engine
air induction system
and radiator cooling
system shown
in Figure l;
5 Figure 3 is an enlarged fragmentary sectional
view taken along the line 3-3 of Figure 2, looking in
the direction of the arrows;
Figure 4 is a perspective view of another
embodiment of the
invention shown
in a schematic
relationship to the air induction system and radiator
cooling system an internal combustion engine;
of
Figure 5 is an enlarged perspective view of
the fan shroud
and air intake
arrangement in
the system
of Figure 4;
Figure 6 is a perspective view of a fan
shroud and an ai r intake arrangement including an air
duct and an air filter box embodiment of the present
invention;
Figure 7 is an enlarged sectional view taken
along the line 7-7 of Figure 6, looking in the
direction of the arrows:
Figure 8 is an enlarged sectional view taken
along the line 8-8 of Figure 6, looking :in the
direction of the arrows;
Figure 9 is a fragmentary perspective view
of
another embodime nt of an air duct and air filter
according to the invention;
Figure 10 is a sectional view taken along the
line 10-10 of Figure
9, looking in
the direction
of the
arrows;
Figure 11 i~~ a perspective view of an air
duct and resonator embodiment of the present invention;
Figure 12 is a sectional view taken along the
line 12-12 of Figure 17. looking in the direction of the
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arrows;
Figure 13 is a sectional view taken along the
line 13-13 of Figure 1~_ looking in the direction of the
arrows; and
5 Figure 14 is a fragmentary sectional view of
a modified air intake configuration for use in the
embodiment of Figures 11-13.
Best Modes For Carrying The Invention
Referring now to the drawings in greater
detail, Figure 1 illustrates an internal combustion
engine 10; an associated air induction system 12 and an
associated radiator coolant system 14.
15 The air induction system 12 is shown
representatively and sc>mewhat schematically. A conduit
therein is connected at one end to an air cleaner
I6. The opposite end of conduit 15 is connected to an
air intake manifold 18 on the engine 10. An air intake
20 conduit 19 connects to the air filter 16. Conduit 19
may have a noise attenuation device 20.
The radiator coolant system 14 includes a
radiator 22 shown in outline having the usual hoses 24,
26 thereon connected between the engine and a radiator
25 coolant fittings 27, 28 for directing coolant between
the radiator 22 and the cooling passages of the engine
10.
In accordance with the present invention, the
air induction system 12 and the radiator coolant system
30 14 are associated with a combination fan shroud and air
intake unit 30. The fan shroud and air intake unit 30
is downstream and adjacent the vehicle radiator 22 and
upstream of the air induction system 12 including the
air intake manifold 18. In the illustrated embodiment,
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a single cooling fan 32 is mounted on the unit 30 by
suitable brackets 34. If desired the unit 30 can be a
dual cooling fan arrangement as disclosed in United
States Patent No. 5,,649,587 commonly assigned and
incorporated herein by reference.
Figure 2 shows the details of the unit 30
with the fan removed to better show the parts of a
hollow body 36 in the unit that combines fluid
compartments; a fan shroud and an air induction
conduit in a single unitary configuration. More
particularly, the hollow body 36 has a predetermined
depth between a front. face 38 and a rear face 40
thereof. The front face 38 is configured to face the
front of the vehicle and is located closely adjacent
the aft surfaces of the radiator 22 as best seen in
Figure 1.
As will be explained more specifically
herein, the hollow body 36 has a configuration suited
for formation by blow molding including techniques of
the type set-forth in United States Patent No.
5,037,289 wherein hollow double walled configurations
can be obtained by u;~e of molds including male and
female mold parts with pinch off points therein that
will form tack-off regions in the hollow body to
separate various regions therein in a manner to form
separate compartments of the type discussed more
particularly in United States Patent No. 5,649,587.
Alternatively, the hollow portions of the hollow body
36 can be formed by use of gas-assisted injection
molding techniques.
In the illustrated arrangement, the hollow
body 36 is shaped between the front face 38 and the
rear face 40; <~ top wall 42; a spaced-apart bottom
wall 44; oppositely disposed side walls 46, 48 and at
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least one inner fan shroud wall 50 defining a primary
air opening 52 through the body 36 of a size to
accommodate air flow through the radiator for cooling
anti-freeze oz' other coolant fluids directed there
through. Additionally, the body 36 has an engine air
intake conduit. 54 extending rearwardly through the
body 36 from the front face 38 to the rear face 40.
The engine air intake conduit 54 has an intake end 56
defining an intake opening 56a disposed adjacent the
front face 38 in communication with atmosphere. The
engine air intake canduit 54 further includes an
outlet end 58 spaced apart from the intake end 56.
The outlet end 58 includes a bellows 60 thereon
configured for connection to the inlet hose 19 in the
air induction system 12 for the engine 10.
Flanges or tabs 62 are formed on an edge of
each side wall. 46 and 48. The flanges 62 include
spaced mounting holes 64 adapted to accommodate
fasteners 66 to mount the body 36 on the radiator 12 of
the vehicle involved, as shown in Figure 1.
A pair of filler necks 68 and 70 are formed
at spaced-apart locations along the top wall 42 for
communicating with respective fluid chambers 72 and 74
formed within the hollow body 36, adjacent and around
the cylindrical. wall 50, as will be explained. A pair
of removable caps 76, 78 are mounted respectively, on
the filler neck. 68 and the filler neck 70.
As best shown in Figure 3, vertically
oriented recess 80 is formed in the top surface 42 to
provide side walls 82, 84 between the fluid chamber 72
and one side of the air intake duct 54. Vertically
oriented recess 86 formed in the top surface 42
provides side walls 88, 90 between the fluid chamber 74
and one side of the air intake duct 54. A pair of
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recesses 91, 92 are provided between the bottom wall 44
and the cylindrical wall 50 to provide a separation
wall 94 betweerz the fluid chambers 72, 74.
Thus, the chamber 72 is enclosed by the front
and rear faces 38 and 40, the top wall 42, the side
wall 48, the bottom wall 44, the walls 82 of the recess
80 and the wall 94. The chamber 74 is enclosed by rear
faces 38 and 40, the top wall 42, the side wall 46, the
bottom wall 44, the wall 88 of the recess 86 and the
wall 94.
As represented in phantom in Figure 3, a blow
molding apparatus of the type set-forth above will have
"tacks offs" T~ and Tz at the various recess points to
separate the chambers 72 and 74 and the air intake duct
54 in the molding process.
Referring to the embodiment of Figure 4, a
combination fan shroud and air intake unit 100 is
shown. The fan shroud and air intake unit 100 is
downstream and adjacent a vehicle radiator 22' and
upstream of an air induction system 12' including an
air intake manifold 20'. In this embodiment, the
induction system is coupled to the fan shroud and air
intake unit 100 by an adapter fitting 102 having three
intake branches 102a, 102b and 102c joined at a common
manifold 102d that includes an outlet fitting 102e
connecting to an air intake hose 18'. In the
illustrated embodiment, a single cooling fan 32~ is
mounted on the unit 100 by suitable brackets 34'. If
desired, the unit 100 of this embodiment can also be a
dual cooling fan arrangement as disclosed in United
States Patent No. 5,649,587. The unit 100 includes a
hollow body 36' of a predetermined depth and having a
front face 38' adapted to face the front of the vehicle
and being adjacent to the radiator 22'.
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As best shown in Figure 4, where the fan is
omitted for purposes of better showing the component
parts of the hollow body 36' pairs of recessed
surfaces 104, 106 are provided between a side wall 108
5 and a cylindrical wall 110 to form a first air intake
conduit 112. Likewise, pairs of recessed surfaces
114, 116 between a side wall 118 and cylindrical wall
110 form a second air intake conduit 120 on the hollow
body 36~. Pairs of recessed surfaces 122, 124 are
10 provided in a bottom wall 126 to form a third air
conduit 128. The air conduits 112, 120 and 128 are
thus located in spaced relationship to each other and
in surrounding relationship to the primary air passage
52~ formed through the fan shroud surface 110. The
conduits 112, 120, 128 each have an inlet end for
intake of air into the air induction system 12~ and
each have an outlet end that is connected to the
intake branches 102a, 102b and 102c respectively.
While three air intaJ~:e conduits 112, 120, 128 are
shown, the number of intakes and intake branches 102a,
102b, 102c can vary from one to three or more,
depending on the air intake requirements of a
particular engine.
In the embodiment of Figure 5, the fan shroud
and air intake unit 100 further includes a unitary
coolant chamber 130 and a unitary washer fluid chamber
132 separated by a common wall formed by a recessed
surface 134 formed in the top surface 136 of the fan
shroud and air intake unit 100. Filler necks 137, 138
are provided on the top surface 136 for directing
fluid into the coolant tank 130 and the washer fluid
chamber 132, respectively. Caps 137a, 138a are
provided on the filler necks 137, 138 far providing
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access for filling the chambers and for closing the
filler necks following the fill operation.
Referring to the embodiment of the invention
shown in Figure 6, a fan shroud and air intake unit
140 is illustrated having a hollow unitary body 36"'
More particu:Larly, the hollow body 36~ has a
predetermined depth between a front face 38'~ and a rear
face 40~~ thereof . The front face 38" is configured to
face the front of the vehicle and is located closely
adjacent the aft surfaces of the radiator 22" as best
seen in Figure 7.
In the illustrated arrangement the hollow
body 36" is shaped between the front face 38u and the
rear face 40~; a top wall 42'~; a spaced-apart bottom
wall 44"; appositely disposed side walls 46~, 48" and
at least one inner fan shroud wall 50" defining a
primary air opening 52 ~ through the body 36" of a size
to accommodate air flow through the radiator for
cooling anti-freeze or other coolant fluids directed
there through. Additionally, the body 36" has an engine
air intake conduit 142 formed therein at recessed
surfaces 143, 145 in t:op wall 42" formed between the
front face 38~~ and the rear face 40" . The air intake
conduit 142 extends rearwardly and laterally from an
intake end 144 defining an intake opening 144a
disposed adjacent the front face 38~ in communication
with atmosphere. The air intake conduit 142 includes a
hinged blow molded door panel 146 that provides access
into the conduit 142 where a cavity 148 is provided
with support rib 149 for locating an air filter
element 150 within the cavity 148. The hollow housing
36" includes an air outlet 152 that communicates with
the cavity 148 and is adapted to be connected to air
hoses of the types shown in the embodiments of Figures
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1 and 4 for ;:~upplying filtered air flow to the air
induction system of a combustion engine. If desired,
the unit 150 can include two unitized fluid chambers
153, 155 on the side of the unit opposite to the air
filter housing. As in prior embodiments suitable
filler necks 153a, 155a with closures 153b and 155b
can be provided.
Figures 9 and 10 show a fragmentary view of
alternative air intake air conduit unit 140" having a
unitary air filter cavity. In this embodiment an air
intake 154 is located at a lower side segment of the
unit 140~~ . This is a preferred location when space and
connection arrangements do not make it possible to
have a top air intake as in the embodiment of Figures
6-8. In the arrangement of Figure 9, the air intake
154 directs air into a vertically disposed, side
located cavity 156 within the unit 140~~. The cavity 156
is closed at its top by a hinged blow molded door
panel 146' that provides access into the cavity 156.
Supports ribs 158 are provided within the cavity 156
for locating an air filter element 150" within the
cavity 156 at a. point below an air outlet 152~~ that
communicates with the cavity 156 and is adapted to be
connected to air hoses of the types shown in the
embodiments of Figures 1 and 4 for supplying filtered
air flow to the air induction system of a combustion
engine.
In both the embodiment Figure 6 and Figure
9, the door panel 146, 146" is sealed respectively by
an annular perimeter seal 147, 147" held in air tight
engagement when closed by latches 151, 151" formed
respectively on door panels 146, 146". The latches
151, 151" are secured releasably to molded ribs 153,
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153" with undercuts a:~ shown respectively in Figures 6
and 9.
Another embodiment of the invention is
illustrated in Figures 11-13 as including a fan shroud
5 and air conduit unit 160 having a unitized resonator
chamber 162. More particularly, as in the prior
embodiment the fan shroud and air conduit unit 160 is
illustrated as having a hollow unitary body 36~~
More particularly, the hollow body 36~~~has a
10 predetermined depth between a front face 38~~~ and a
rear face 40 ~ ~ ~ . The front face 38 ~ ~ ~ is configured to
face the front of the vehicle and is located closely
adj acent the aft surf aces of the radiator 22 ~ ~ ~ as best
seen in Figure 12.
15 In the illustrated arrangement, as shown in
Figures 11 arrd 12, the hollow body 36~~~ is shaped
between the f rout face 3 8 ~ ~ ~ and the rear f ace 4 0 ~ ~ ~ ; a
top wal l 42 ~ ~ ~ ; a spaced-apart bottom wall 44 ~ ~ ~ ;
oppositely disposed side walls 46 ~ ~ ~ , 48 ~ ~ ~ and at least
20 one inner fan shroud wall 50"~ defining a primary air
opening 52 ~ ~ ~ through the body 36 ~ ~ ~ of a size to
accommodate air flow through the radiator 22~~~ for
cooling anti-freeze or other coolant fluids directed
there through. Additionally, the body 36~~~ has an
25 engine air intake conduit or duct 162 formed therein
at a recessed surface 164 formed between the front
face 38~ ~ ~ the rear face 40~ ~ ~ . The air intake conduit
162 has an air inlet 1.66 defining an opening 166a. The
inlet 166 communicates with a resonator chamber 168
30 formed on one side of the unit 160. The height of the
chamber 168 can be selected to define a quarter wave
length tube by locating a recessed surface 170 in the
unit 160 at the rear face 4 0 ~ ~ ~ thereof to seal of f the
lower end of the resonator chamber 168. In the
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illustrated embodiment, the rear face 40~~~ includes a
pair of spaced cone-shaped tack offs 172, 173 that are
formed at spaced points within the chamber 168 to
prevent collapse of the wall of the resonator. The
5 tack-offs 172, 173 are formed within a depressed
region 175 for stiffening the reservoir wall. An
outlet 174 from conduit 162 is configured to be
connected to the inlet air hose of an air induction
system of the type shown in prior embodiments.
10 In this embodiment, a tack-off or recess 164
is provided to define walls 176, 178 (Figure :13) for
separating the air conduit passage 162a from a fluid
chamber 182 that can serve either as a windshield
wiper fluid container or as a coolant recovery
15 reservoir. In the embodiment of Figures 11-13, the
inlet and outlets of the conduit 162 are formed
following blow molding by removing the ends of blown
hollow portions of the hollow body as shown in outline
at 162b and 1.62c in Figure 12. The portions 162b,
20 162c preferably are removed by guillotine. The hollow
body 3 6 ~ ~ ~ includes integrally mold tabs 62 ~ ~ ~ configured
to be secured to an associated radiator.
Furthermore, as shown in Figures 11 and 13,
an air filter 150~~~ :is provided in the conduit 162
25 between the opening 166a and the resonator chamber
168. It is held between spaced molded ribs 162a, 162b
in the conduit 162, best shown in Figure 13, The
filter 150~~~ i.s accessed for replacement or cleaning
through a door panel 146~~~ connected and sealed like
30 those in the previous embodiments . The door 146 ~ ~ ~ is
shown in outline in the section of Figure 13.
In another embodiment of the invention,
shown in Figure 14, the blow mold for shaping the
hollow body does not include the hollow portions 162b,
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162c. Rather, as shown in the fragmentary view of
Figure 14, a hollow body 180 is formed; an opening 182
is formed in its wall and a molded tube insert 184 has
a flanged end 186 thereon connected to an annular
5 connecting groove 188 (that can be formed during blow
molding of the hollow body 180) for fixing the tube
insert 184 to the hollow body 180. The tube insert
184 directs inlet air into a resonator chamber 168'
corresponding to that in Figure 12. The outlet from
10 the chamber 168' can be formed by a tube insert like
the insert 184 connected in a similar manner. The
connection of the tube insert to the hollow body is
illustrative in nature with it being understood that a
wide range of connections will serve the same purpose
15 including laser or sonic weld connections; bayonet
connections; expandable barb type connections; thread
connections and the like.
Industrial Applicability
It should be apparent that the invention
provides a compact fan shroud receptacle and engine
inlet air structure which eliminates the need for space
and fastening means for a wide range of separate
25 components in the already crowded engine compartment of
today's automobile. It provides substantial cost
savings by virtue of having eliminated the need to
manufacture and assemble various parts associated with
underhood systems, whale utilizing heretofore unused
surface areas of the fa.n shroud.
Additionally, the invention may provide a
standard or uniform structure which is unaffected by
many new vehicular designs. Specifically, the shape of
the fluid chambers; air intake conduits; air filter
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chambers; resonator chambers and the like need not be
redesigned each time the fender wells and other
interior parts are changed on at least some new vehicle
models. Also, the integrally molded windshield washer
5 fluid or headlamp washer fluid compartments may have a
larger capacity than the previously employed separate
containers.
Furthermore, the resultant structure is
extremely rigid, both radially and axially, and damped
10 by fluid in the receptacles, reducing vibration or
excitation of the fan shroud caused by the rotating fan
surrounded thereby, hence diminishing a possible source
of bothersome noise.
While but one embodiment of the inventian has
15 been shown and described, other modifications thereof
are possible within the scope of the following claims.
