This application is based on Japanese Patent Application No. 2007-136603 filed on May 23, 2007, the disclosure of which is incorporated herein by reference.
The present invention relates to a cooling module including a fan shroud and an air cleaner unit.
For example, heat exchangers, such as a radiator and a condenser, and a blower for introducing air to the heat exchangers are mounted to a vehicle body through a front end panel. The front end panel is also known as a shroud panel, a carrier, a radiator support and the like. The front end panel is integrally formed with a fan shroud of the blower. The fan shroud is configured to support a fan of the blower and to form an air passage from the heat exchangers to the fan.
Japanese Unexamined Patent Application Publication No. 11-171041 describes a cooling module having a front end panel. In the described cooling module, the front end panel forms a closed space in its upper beam portion, and an air cleaner unit is housed in the closed space.
Japanese Unexamined Patent Application Publication No. 10-238825 describes an exterior unit for a fixed air conditioner. In the described exterior unit, an auxiliary case for supporting a fan is disposed to oppose a radiator and a condenser. The auxiliary case is formed with a fan shroud that has a substantially cylindrical shape for surrounding the fan. Further, a part of the fan shroud is shared with a side wall of an air cleaner. As such, the exterior unit is made compact.
In vehicles, it has been desired to reduce damage to a person, such as a pedestrian, in a case a vehicle collides with the person. To reduce damage or impact to a pedestrian in a collision, it is proposed to increase a clearance between an engine hood and a front end panel, that is, a free space above the front end panel within an engine compartment, thereby easing deformation of the engine hood and the like.
In the cooling module described in Publication No. 11-171041, since the fan shroud and the air cleaner unit are arranged in an up and down direction of a vehicle, the size of the cooling module increases. Further, the weight of the cooling module increases. Also, since the air cleaner is disposed at the upper beam portion of the fan shroud, it will be difficult to sufficiently provide the free space above the front end panel.
In a case where the fan shroud described in Publication No. 10-238825 is employed to a cooling module for a vehicle, a size of the cooling module will be reduced and hence it will be easy to provide the free space above the cooling module. However, in a case where the air cleaner is disposed to oppose the heat exchangers, the air cleaner is heated by air that has passed through the heat exchangers. As a result, the temperature of intake air to be introduced into an engine through the air cleaner will be increased.
The present invention is made in view of the foregoing matter, and it is an object of the present invention to provide a cooling module having a structure capable of reducing the weight and increasing a space on its top in a condition mounted in an engine compartment of a vehicle while effectively cooling air to be introduced to an internal combustion engine.
According to an aspect of the present invention, a cooling module to be mounted to a front part of a vehicle includes a heat exchanger for performing heat exchange between air and a heat medium, a fan shroud, a blower and an air cleaner unit for filtering air to be introduced into an internal combustion engine of the vehicle. The fan shroud is disposed downstream of the heat exchanger with respect to a flow of air passing through the heat exchanger. The blower is held by the fan shroud. The fan shroud includes an air introducing portion defining an air passage from the heat exchanger to the blower. The air cleaner unit is disposed such that a front end of the air cleaner unit is offset from the heat exchanger with respect to a horizontal direction. The air cleaner unit has a side wall that partly forms the air introducing portion of the fan shroud. A clearance is provided between the side wall of the air cleaner unit and the heat exchanger such that air upstream of the heat exchanger is conducted toward a downstream position of the heat exchanger through the clearance.
Accordingly, the air cleaner unit is configured such that a part of the air cleaner unit serves as a part of the air introducing portion of the fan shroud. In other words, the air cleaner unit and the air introducing portion of the fan shroud share a wall between them. Therefore, the weight of the cooling module is reduced. Since the heat exchanger and the air cleaner unit are arranged in the horizontal direction, a space provided above the cooling module in a condition mounted in an engine compartment of the vehicle is increased. For example, the space is effectively used for a pedestrian protection system.
In addition, since the front end wall of the air cleaner unit is offset from the heat exchanger, when viewed along the flow of the air, that is, from the front side, the air cleaner unit is cooled by air that has not passed through the heat exchanger. As such, an increase in temperature of the air to be introduced into the engine is reduced. Further, since the clearance is provided between the side wall of the air cleaner unit and the heat exchanger, air is conducted from an upstream position of the heat exchanger toward a downstream position of the heat exchanger through the clearance. Therefore, the air cleaner unit is effectively cooled by the air passing through the clearance. As such, engine torque is increased while restricting the increase in temperature of the air to be introduced into the engine.
Accordingly, the cooling module having the structure capable of reducing the weight and increasing the space on its top in the condition mounted in the engine compartment while effectively cooling the air to be introduced into the engine is provided.
Other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings, in which like parts are designated by like reference numbers and in which:
A first embodiment of the present invention will now be described with reference to
Referring to
The blower 3 is disposed to introduce the outside air to the radiator 1 and the condenser 2 for cooling the radiator 1 and the condenser 2. The fan shroud 4 is configured to support the blower 3 and form an air passage from the radiator 1 and the condenser 2 to the blower 3. That is, the fan shroud 4 is configured to guide the air to pass through the radiator 1 and the condenser 2 with an operation of the blower 3. The air cleaner unit 5 is provided to filter air to be introduced into the engine. Hereinafter, the radiator 1 and the condenser 2 are also referred to as the heat exchangers. The air to be introduced into the engine through the air cleaner unit 5 is also referred to as intake air. The cooling fluid and the refrigerant correspond to heat mediums.
The condenser 2 is disposed in front of the radiator 1 with respect to a vehicle front and rear direction. In other words, the condenser 2 is disposed upstream of the radiator 1 with respect to a flow direction of the air, which generally flows in a vehicle rearward direction. The blower 3 is disposed on a rear side of the radiator 1 with respect to the vehicle front and rear direction. In other words, the blower 3 is disposed downstream of the radiator 1 with respect to the air flow direction.
The air cleaner unit 5 is offset from the heat exchangers 1, 2 with respect to a horizontal direction, such as in a vehicle width direction that is perpendicular to the vehicle front and rear direction. That is, the condenser 2 and a front end of the air cleaner unit 5 are next to each other with respect to the vehicle width direction when viewed from a front side of the vehicle.
The blower 3 includes a fan 3a for generating the flow of air and an electric motor 3b for driving the fan 3a. The fan shroud 4 is made of a resin, such as polypropylene containing glass fiber. The fan shroud 4 has stays 4a for supporting the fan 3a and an air introducing portion 4b that forms the air passage from the heat exchangers 1, 2 to the fan 3a. The air introducing portion 4b is located upstream of the stays 4a, that is, upstream of a position where the fan 3a is supported, with respect to the air flow.
The air cleaner unit 5 includes an air cleaner element 5a for removing foreign materials from the intake air, an air cleaner case 5b for housing the air cleaner element 5a, and an air cleaner cap 5c. The air cleaner element 5a is disposed between the air cleaner case 5b and the air cleaner cap 5c.
The air cleaner case 5b is made of the same material as the fan shroud 4. That is, the air cleaner case 5b is made of a resin material, such as polypropylene containing glass fiber. The air cleaner case 5b is a container having a generally rectangular parallelepiped shape and defining an opening on one side. The air cleaner element 5a is inserted and fixed to a frame member disposed on a perimeter of the opening of the air cleaner case 5b. The air cleaner case 5b further has an air inlet 51 on another side for introducing the intake air into the air cleaner unit 5. An end of a tubular inlet duct 61 is coupled to the air inlet 51. The other end of the inlet duct 61 forms an air suction port 61a through which the intake air is suctioned into the air cleaner unit 5.
The air cleaner unit 5 is disposed such that a front end wall 5d of the air cleaner case 5b is offset from the heat exchangers 1, 2 with respect to the horizontal direction, when viewed from the front side of the vehicle. Thus, the front end wall 5d of the air cleaner case 5b is exposed to air that is before passing through the heat exchangers 1, 2.
The air cleaner cap 5c is made of the same material as the air cleaner case 5b. That is, the air cleaner cap 5c is made of a resin material, such as polypropylene containing glass fiber. The air cleaner cap 5c is a container having a generally rectangular parallelepiped shape and defining an opening on one side. The air cleaner cap 5c has an engagement structure on the perimeter of the opening. The air cleaner cap 5c is coupled to the air cleaner case 5b such that the openings thereof are opposed to each other through air cleaner element 5a. The engagement structure of the air cleaner cap 5c is engaged with the side of the air cleaner case 5b on which the opening is provided through the air cleaner element 5a.
The air cleaner cap 5c has an air outlet 52 on another side for discharging the intake air, which has been filtered through the air cleaner element 5a, from the air cleaner unit 5. An end of a tubular outlet duct 62 is coupled to the air outlet 52. The other end of the outlet duct 62 is in communication with an intake manifold (not shown), which distributes the intake air into engine cylinders.
The air cleaner element 5a is constructed of a filtering member made of synthetic unwoven fiber, filter paper, or the like. The air cleaner element 5a is disposed substantially parallel to a plane that is perpendicular to the vehicle front and rear direction, that is, the air flow direction. In other words, the air cleaner case 5b and the air cleaner cap 5c are coupled with respect to the vehicle front and rear direction through the air cleaner element 5a. For example, the air cleaner case 5b is located upstream of the air cleaner cap 5c with respect to the air flow direction.
As shown in
Further, a clearance 7 is provided between the part of the outer wall 50, which forms the air introducing portion 4b, and the heat exchangers 1, 2 such that the air in front of the heat exchangers 1, 2 is partly introduced in the clearance 7 in a vehicle rearward direction in accordance with negative pressure generated by the blower 3, as shown by an arrow A1 in
The cooling module further has a reserve tank 8 for absorbing a change of volume of the cooling fluid passing through a cooling fluid circuit. The reserve tank 8 is made of a resin, and is fixed on a wall of the fan shroud 4, the wall facing a downstream position with respect to the air flow direction. Further, the reserve tank 8 is located at a position opposite to the air cleaner unit 5 with respect to the heat exchangers 1, 2.
As shown in
The air inlet 51 is located at a position lower than a middle height (middle portion) of the air cleaner unit 5 (e.g., air cleaner case 5b), shown by a dotted line C in
In the present embodiment, the fan shroud 4 is fixed to the radiator 1. The radiator 1 on which the fan shroud 4 is fixed, is mounted to a vehicle body 10 through elastic members, such as elastically deformable rubber bushings 9. The radiator 1 has pins 1a on its upper and lower ends. For example, the rubber bushings 9 are fixed to the pins 1a beforehand, and the pins 1a are engaged with portions of the vehicle body 10. As such, the radiator 1 on which the fan shroud 4 is fixed, that is, the cooling module is mounted to the vehicle. The condenser 2 can be assembled to the radiator 1 beforehand into the cooling module. Alternatively, the condenser 2 can be independently and directly fixed to the vehicle body 10.
The fan shroud 4 and the air cleaner case 5b are integrally formed by injection molding. After the fan shroud 4 and the air cleaner case 5b are molded in a cavity provided between two moulds, one of the moulds is moved in a direction that is parallel to a direction corresponding to the vehicle front and rear direction. Thus, the integrally molded fan shroud 4 and air cleaner case 5b is removed from the moulds.
As described in the above, the air cleaner case 5b and the fan shroud 4 are integrally formed with each other such that the part of the outer wall 50 forms the part of the air introducing portion 4b of the fan shroud 4. That is, the part of the air cleaner case 5b serves as the air introducing portion 4b. In other words, the air cleaner case 5b and the fan shroud 4 share a wall between them. Therefore, the fan shroud 4 becomes compact, and hence the weight of the cooling module is reduced.
The air cleaner unit 5 and the heat exchangers 1, 2 are arranged next to each other with respect to the vehicle width direction. Therefore, in a condition where the cooling module is mounted in the engine compartment, a space above the cooling module is increased. The space can be effectively used as the free space for a pedestrian protection system. Accordingly, pedestrian protection performance is improved by the structure of the cooling module, and the weight of the cooling module is reduced.
Since the air cleaner case 5b and the fan shroud 4 are integrally formed with each other such that the wall 50 of the air cleaner case 5b serves as the part of the air introducing portion 4b of the fan shroud 4, an area of the integrated air cleaner case 5b and fan shroud 4, when projected in a direction parallel to the vehicle front and rear direction, is reduced. Thus, a size of an injection molding apparatus can be reduced.
In addition, the front end wall 5d of the air cleaner unit 5 is located without overlapping with the heat exchangers 1, 2 when viewed from the front side. Therefore, the air that has not passed through the heat exchangers 1, 2 can be supplied toward the air cleaner unit 5. Because the air cleaner unit 5 is cooled by the air that has not passed through the heat exchangers 1, 2, an increase in temperature of the intake air is suppressed. Accordingly, engine torque is increased.
The fan shroud 4 and the air cleaner case 5b are configured such that the air in front of the heat exchangers 1, 2 is conducted toward a downstream position of the heat exchangers 1, 2 through the clearance 7 provided between the part of the wall 50 and the heat exchangers 1, 2. Thus, the air cleaner unit 5 is effectively cooled by the air passing through the clearance 7. As such, the increase in temperature of the intake air is effectively restricted, and hence the engine torque is further increased.
The air cleaner element 5a is disposed substantially parallel to the plane that is perpendicular to the air flow direction. Therefore, the air cleaner case 5b has the opening in a direction coincide with the direction in which the moulds are opened. Accordingly, the fan shroud 4 and the air cleaner case 5b are easily integrally formed with each other without requiring a specific sliding mould. Further, the moulds for molding the fan shroud 4 and the air cleaner case 5b are reduced in costs, and hence capital-investment spending is reduced. Accordingly, an increase in manufacturing cost of the fan shroud 4 with which the air cleaner case 5b is integrated is suppressed.
In general, nothing is disposed under an air cleaner unit in an engine compartment. That is, a space under the air cleaner in the engine compartment is a dead space. In the present embodiment, on the other hand, since the height H of the air cleaner unit 5 is greater than the width W, the space under the air cleaner unit 5 is reduced. That is, the air cleaner unit 5 is arranged while effectively using the space in the engine compartment.
In a case where the width W is greater than the length H in the air cleaner unit 5, a distance between the fan shroud 4 and the furthest portion of the air cleaner unit 5 is large, the furthest portion being furthest from the fan shroud 4 in the air cleaner unit 5. In the air cleaner unit 5 of the present embodiment, on the other hand, since the height H is greater than the width W, the distance between the fan shroud 4 and the furthest portion of the air cleaner unit 5 is reduced, as compared with the air cleaner unit in which the width W is greater than the height H. As such, strength of the air cleaner unit 5 is improved.
In general, the intake manifold is located above the engine. In the present embodiment, since the air outlet 52 is located higher than the middle position of the air cleaner unit 5 with respect to the vehicle up and down direction, handling and arrangement of the outlet duct 62 are eased. Also, since the air inlet 51 is located lower than the middle position of the air cleaner unit 5 with respect to the vehicle up and down direction, the flow of the intake air inside of the air cleaner unit 5 is facilitated. Accordingly, pressure loss is reduced.
Since the air cleaner unit 5 is in communication with the engine through the outlet duct 62, vibration of the engine is transmitted to the air cleaner unit 5. Therefore, if a fan shroud with which an air cleaner unit is integrated is directly fixed to a vehicle body, the vibration of the engine is transmitted to the fan shroud and the vehicle body through the air cleaner unit. In the present embodiment, on the other hand, the fan shroud 4 is fixed to the vehicle body 10 through the rubber bushings 9, which are elastically deformable. Because the vibration of the engine is absorbed by the rubber bushings 9, it is leas likely that the vibration will be transmitted to the vehicle body 10.
When the intake air is suctioned from the air suction port 61a, suction noise will be generated. If the suction noise is transmitted into a passenger compartment, a passenger will feel unpleasant.
In the case where the air cleaner unit 5 is integrated with the fan shroud 4, the mass of parts connected to the inlet duct 61 is increased, as compared with the case where the air cleaner unit 5 is solely provided. Therefore, as shown in
The fan shroud 4 is provided with the reserve tank 8, and the reserve tank 8 is arranged opposite to the air cleaner unit 5 with respect to the heat exchangers 1, 2. Therefore, balance of the weight of the fan shroud 4 with respect to the vehicle width direction is improved.
A second embodiment of the present invention will now be described with reference to
In the present embodiment, as shown in
In the above embodiments, the air cleaner case 5b is integrated with the fan shroud 4. Alternatively, the air cleaner cap 5c can be integrated with the fan shroud 4.
In the above embodiments, the air cleaner case 5b has the air inlet 51, and the air cleaner cap 5c has the air outlet 52. Alternatively, the air cleaner case 5b can have the air outlet 52 and the air cleaner cap 5c can have the air inlet 51.
Additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader term is therefore not limited to the specific details, representative apparatus, and illustrative examples shown and described.
Number | Date | Country | Kind |
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2007-136603 | May 2007 | JP | national |