The present invention relates to viscous clutch fan drives, and more particularly to viscous clutch fan drives with high-speed fluid reservoirs and bimetal valve activation.
The great majority of vehicles utilize engines run on an organic fuel, such as gasoline. Engine driven cooling fans are used to assist in cooling the engines and engine accessories. There are several types of cooling fan drives in use today, including dry friction clutch drives, wet friction clutch drives, and viscous clutch fan drives.
Due to the need for vehicles to meet restrictive mileage and emission standards, various improvements have been made relative to the components, structures and control of the drives for cooling fans. Viscous fluid clutches, in particular, which provide precise control of the operation and speed of the fans, have been used successfully to assist in meeting these standards.
The principal types of viscous clutch drives used to control the operation and speed of the cooling fans, are those with either electromagnetic-type valves or bimetal-type valves. These valves meter the amount of viscous fluid which can flow into the working chambers and thus can regulate the speed of the cooling fans.
The present invention relates to improved viscous fluid clutch fan drives with bimetal control of the valve mechanisms. The viscous clutch drives have a housing, a cooling fan, a bimetal mechanism, a valve operated by the bimetal mechanism, a fluid reservoir for the viscous fluid, a working chamber and a scavenge system. In some embodiments, the fluid valve mechanism, clutch disk member, and fluid reservoir are rotated at input speed by a pulley member, while the housing, cooling fan, and scavenge system all rotate at fan speed. Input speed also can be referred to as “high speed”. In other embodiments, the fluid valve mechanism can be included as part of the housing.
In one embodiment, the bimetal mechanism includes a bimetal coil member positioned external to the housing and positioned in operable contact with a rotatable valve member which controls the operation of fluid ports in the housing. Movement of the bimetal strip member caused by temperature changes, rotates the valve member and controls the amount of viscous fluid which can flow into the working chamber. A wiper member returns the fluid to the scavenge system where it returns to the fluid reservoir.
In another embodiment, the bimetal mechanism includes a bimetal strip member. The bimetal strip member is positioned external to the housing and is connected to an axial moveable fluid valve member inside the housing. Bending of the bimetal strip member due to temperature changes, moves the fluid valve member axially and controls the amount of viscous fluid which can flow into the working chamber. A wiper member returns the fluid to the scavenge system where it returns to the fluid reservoir.
In a further embodiment, a valve member is provided on the inside of the cover member and is activated by a bimetal coil member. The valve member closes and opens an exit port from a scavenge passageway. Scavenge fluid enters the fluid reservoir which is positioned on the clutch disk member and rotates with it at input speed. Fluid from the fluid reservoir flows directly to the working chamber and a wiper member returns the fluid to the scavenge passageway.
The bimetal mechanisms provide reliable control of the speed of the cooling fans. The high speed fluid reservoir increases the engagement response of the fan drive. This is particularly important at low fan speeds. Also, reducing the fan speed when the fan drive is disengaged results in lower parasitic losses and improves fuel economy.
Other objects, features, benefits and advantages of the invention will become apparent from the following description when viewed in combination with the attached drawings and appended claims.
As shown in the drawings, the fan drive embodiment of the invention shown in
A fan member 80 is attached to the housing 12, as partially shown in
A shaft member 22 is positioned in the axial center A of the fan drive 10 (see
A clutch disk member 30 is positioned inside the housing member 12. The clutch disk member is fixedly connected to the shaft member 22 and rotates with it at input speed. The clutch disk member is connected to the shaft member in any conventional manner, such as by force fit, keying and the like. A fluid chamber cover member 42 is fixedly connected to the clutch disk member 30 and rotates with it. The cover member 42 forms a fluid chamber 40.
The annular outer portion 30A of the clutch disk 30 has at least one, and preferably a pair, of labyrinths 33A and 33B of concentric ridges and grooves, one on each side of the outer portion 30A. Similarly, the cover member 14 and the body member 16 have corresponding labyrinths 14A and 16A which mate and interact with the labyrinths 33A and 33B on the clutch disk member. Mating labyrinths to operate viscous clutch fan drives are in common use today and any conventional type of labyrinths and portions of ridges and grooves can be utilized. Also, although two mating sets of labyrinths are shown in
It is possible, as known in the art, to use other shearing members, such as configurations of ridges and grooves, or two smooth surfaces.
In order to remove viscous fluid from the working chamber, a wiper member 52 and a scavenge channel or passageway 54 are utilized. The wiper member 52 can be any of the conventional wiper members in use today, and preferably is a plastic device that is secured to a surface of the housing adjacent the clutch disk member and is positioned in the annular gap between the housing and the outer surface of the clutch disk member. The scavenge channel 54 is formed in the cover member 14 in any conventional manner, such as by drilling. The end or exit port 56 of the scavenge channel opens up into a central chamber 60 in the housing.
A valve member 70 is also positioned in the fluid reservoir or chamber 40. The valve member is operably connected to the shaft member 22 and rotates with it. The valve member 70 preferably has a central hub member 71 which is connected to the shaft member and a plurality of finger members (or spokes) 72 which extend radially outwardly. Preferably at least two finger members (or spokes) are provided. A valve carrier member 76 is positioned adjacent the valve member 70 and acts to support it. The valve carrier member 76 also rotates with the clutch disk member 30 and valve member 70. The valve support member has a plurality of openings 77 for passage of viscous fluid from one side of the fluid chamber 40 to the other.
Flange members 78 are attached to the outer ends of the finger members (spokes) 72 of the valve member 70. As shown in
Also shown in
In an alternate embodiment, openings (not shown) can be provided in the flange members on the valve member. Rotation of the valve member then can position the openings into and out of alignment with the fluid ports 77 in the clutch disk member, thus opening and closing the fluid ports.
As indicated, the fluid chamber 40 is formed by use of the cup-shaped fluid chamber cover member 42. The chamber cover member is connected to the valve carrier member 76 which in turn is connected to the clutch disk member 30. The cover member 42 and carrier member 76 can be secured together and in place in any conventional manner, such as by folding over an upstanding annular ridge (not shown) on the clutch disk member.
The fluid chamber cover member 42 has a central opening 46. The viscous fluid is immediately directed from the exit port 56 of the scavenge channel 54 into the fluid reservoir 40 through the central opening 46. A drip lip 58 on the fluid cover member assists in directing the viscous fluid into the fluid reservoir.
The introduction of viscous fluid into the working chamber causes the housing 12 and fan member 80 to rotate. As conventional with viscous clutch drives, the amount of viscous fluid in the working chamber regulates the speed of the cooling fan and thus the amount of cooling air stream provided by the viscous fluid clutch fan drive 10.
The clutch disk member 30 is connected to the shaft member and has a central opening 34 that fits around the shaft member 22. The clutch disk member has an outer perimeter flat surface 36 and rotates in the direction as shown by the arrow 38 in
A coil-type bimetal member 90 is positioned at the exterior of the cover member 14. The bimetal coil member contains two metal materials with different coefficients of expansion. When the bimetal coil member is heated, the coil contracts (deforms) and rotates. The higher the temperature, the more the coil contracts and rotates. In general, the amount of rotation of a coil-type bimetal member depends on the types of metal materials, the size of the coils forming the coil member, and the size of the coil itself.
Bimetallic members have been used to convert temperature changes into mechanical displacements. Bimetal members consist of two strips of different metals which expand at different rates as they are heated. The two different materials are typically steel and copper, or steel and brass. The two metal materials are joined together throughout their length, such as by riveting, brazing or welding. The differences in expansion of the two materials force the strip to expand or bend a certain way if heated. If the bimetal member is a strip, then the metal with the higher coefficient of thermal expansion is on the outer side of the curve when the strip is heated.
A bimetallic coil member essentially is a flat bimetallic strip member that is formed into a coil shape. It consists of two layers of metal material with different rates of thermal expansion and contracts radially, rather than bending one way or the other.
The valve member 70 has a cylindrical connection member 92 which is connected to, and rotates with the shaft member 22, valve disk member 30 and valve carrier member 76. Seal member 98 allows the valve connection member 92 to rotate and/or slide freely relative to the cover member 14. The coil member 90 is held in position by support member 96 and secures the end 95 of the bimetal coil 90 in position.
Central shaft member 94 of the bimetal coil member 90 rotates as the coil member heats up and rotates. The shaft member 94 is directly attached to the valve member 70 which causes the valve member to rotate with it. Thus, even as the coil member 90, valve member 70 and clutch disk member 30 rotate at input speed, the valve member 70 can independently also rotate as operated by the bimetal coil member.
When the bimetal coil member is heated, it rotates the valve member 70 and opens the passageway for fluid into the working chamber. When the bimetal coil member is not heated and cooling by the cooling fan is not needed, the openings into the working chamber 50 are closed. In this situation, the viscous fluid has been scavenged from the working chamber and returned to the fluid chamber, and very little viscous fluid remains in the working chamber.
The amount of viscous fluid which is allowed to pass into the working chamber governs the speed of the cooling fan. Thus, with this embodiment, the speed of the rotation of the cooling fan can go from near zero to full speed and anywhere in-between. The speed of the cooling fan is infinitely variable.
With the embodiment shown in
As indicated, the wiper member 52 utilized with the embodiments in
The
The housing 152 includes a cover member 154 and a body member 156. A bimetal strip member 160 is attached to the outer surface 158 of the housing. The bimetal strip member is attached to a mounting member 162 which positions the strip member a short distance from the housing. The mounting member 162 is fixedly secured to the housing.
As shown in
A fan member 80 with a hub member 82 and plurality of fan blades 86 is attached to the housing similar to that described above with reference to
The bimetal strip member includes two layers 160A and 160B of two different metal materials, each with different coefficients of expansion. This is better shown in
A valve member 200 is positioned in the interior of the housing 152. The valve member is attached to a rod member 202 which is slidingly positioned in shaft member 22. The rod member 202 is positioned in a central bore or passageway 208 and slides inside the shaft member 22 as shown by arrow 210.
When the rod member 202 is moved in the directions indicated by arrow 210, the valve member 200 moves in the same directions. The movement of the valve member 200 opens and closes fluid ports 77 in the clutch disk member 130 which regulate the passage of viscous fluid to the working chamber 50. This is similar to the manner in which movement of the valve member 70 in the embodiment of
Like the fan drive discussed above, the shaft member 22 is attached to a pulley member 26 and rotates at input speed. The clutch disk member 130 is attached to the shaft member 22 and rotates at the same speed. Similarly, the fluid reservoir 40 which is connected to the clutch disk member 130, rotates with the clutch disk at input speed. A carrier member from the valve member 200 (such as carrier member 76 discussed above) is not necessary in this embodiment, although one could be utilized if desired.
Similar to the viscous clutch embodiment described above, the working chamber 50 includes labyrinths on the outer portion of the clutch disk member 130 and mating labyrinths in the housing member. A wiper member 52 in the working chamber directs the viscous fluid exiting the working chamber into scavenge channel or passageway 54. The scavenged viscous fluid is directed into the viscous fluid reservoir chamber 40 formed by reservoir cover member 42. This is similar to the wiping and scavenge system discussed above with reference to
The valve member 200 is biased by spring member 190 in an axial direction toward the bimetal strip member 160. The spring member can be any type of conventional spring member, such as a curved washer, or coil spring, but preferably is a coaxial spring. A coaxial spring takes up less space axially when compressed.
The top end or head 232 of the rod member 202 is positioned in contact with the bimetal strip member 160, or a small distance from it. Preferably, the head 232 can rotate independently of the rod member 202. At this initial or “rest” position when fan cooling is not needed, the viscous fluid passageways to the working chamber are closed, and there is little viscous fluid in the working chamber.
Upon bending of the bimetal strip member 160 in a direction toward the outer surface 158 of the housing, the strip member 160 forces the rod member 202 in an axial direction toward the pulley member (in the direction of arrow 212 in
Seal members, such as seal member 225, are provided to prevent leakage of the viscous fluid from the fan clutch drive.
The embodiments of
For example, one alternate valve mechanism for use with the present invention which utilizes a bimetal coil activation system, is shown in
The bimetal coil member 302 is positioned on the external surface 320 of the cover member 322 of the housing, and rotates with the cover member and housing when they rotate. The valve member 310 is positioned adjacent the port 318 which is the outlet port of the scavenge passageway 336. The scavenge passageway transports scavenged viscous fluid from the working chamber 50 through the cover member to the recess 312.
The recess 312 is in direct fluid communication with the viscous fluid reservoir cover 370 which forms the fluid reservoir 360, similar to the systems shown in the other embodiments discussed above. A central opening 364 in the fluid reservoir cover member 370 is directly adjacent to the recess 312. Scavenge fluid entering the recess 312 enters the fluid reservoir 360 where it can be returned to the working chamber 50 to rotate the fan blades and cool the vehicle engine.
Contraction or deformation of the bimetal coil member 302 due to thermal energy, causes the valve member 310 to rotate. The valve member 310 is connected to the bimetal coil member, such as by a screw-type fastener member 316. It can rotate in the two directions shown by arrow 342 in
The valve member thus can control the amount of fluid that can exit from the scavenge port and enter the fluid chamber 360 from 0% to 100%.
The fluid chamber cover member 370 is securely attached to the clutch disk member 380 and rotates with it at input speed. Thus the fluid chamber 360 rotates at input speed together with the clutch disk member 380 and the central shaft member 22.
The housing 12′ includes a cover member 14′ and a body member 16′ which are connected together at 18′ in a manner similar to the embodiments disclosed above. A fan member (not shown) similar to the fan members 80 disclosed above, is secured in the housing. The housing is positioned on the shaft member by bearing member 24 and rotates at fan speed. The operation of the viscous clutch is similar to the operations of the embodiments shown in the preceding Figures.
A wiper member 352 is positioned in the housing and used to wipe off viscous fluid from outer surface of the clutch disk member 380 and transfer it to the scavenge passageway 336. The wiper member 352 can be any type of conventional wiper member.
It is also possible to include a baffle member (not shown) in the fluid chamber 360 to assist in maintaining the viscous fluid in an effective state for passage into the working chamber 50. The baffle can have any shape and have openings and/or spokes as desired to allow passage of viscous fluid.
Appropriate sealing members should also be provided to prevent leakage of the viscous fluid from the cover member around the bimetal member.
Although the invention has been described with respect to preferred embodiments, it is to be also understood that it is not to be so limited since changes and modifications can be made therein which are within the full scope of this invention as detailed by the following claims.
This application is related to U.S. patent application Ser. No. ______ entitled Viscous Clutch With High-Speed Reservoir and Bimetal Coil Member (DKT14067), and U.S. patent application Ser. No. ______ entitled Viscous Clutch With High-Speed Reservoir and Bimetal Strip Member (DKT14160), both filed on the same day as the present application.