Fan shroud assembly

A fan shroud assembly according to an example of the present application includes an air intake duct configured to receive ambient air, a fan configured to receive hot air, a motor driving the fan, and an air induction intake box in fluid communication with the fan and the air intake duct to mix the hot air and the ambient air. A vehicle and a method of providing cooling air to a vehicle engine are also disclosed.

BACKGROUND

Engines in vehicles, such as internal combustion engines in automobiles, generate heat as they operate. In general, internal combustion engines facilitate the combustion of fuel with air (which acts as an oxidizer). In automobiles, engines are situated in an engine compartment, which is typically at the front end of the vehicle. Removal of heat generated by the engine from the engine and the engine compartment improves engine and overall vehicle performance. Furthermore, internal combustion engines operate more efficiently when provided with cooler air.

SUMMARY

A fan shroud assembly according to an example of the present application includes an air intake duct configured to receive ambient air, a fan configured to receive hot air, a motor driving the fan, and an air induction intake box in fluid communication with the fan and the air intake duct such that the hot air and the ambient air mix.

A vehicle according to an example of the present application includes an engine arranged in an engine compartment and a fan shroud assembly. The fan shroud assembly includes a fan configured to draw hot air from the engine compartment. The fan is driven by a motor. The fan shroud assembly also includes an air intake duct configured to receive ambient air from outside the vehicle, and an air induction intake box in fluid communication with the fan and the air intake duct such that the hot air and the ambient air mix to form cooling air. The air induction intake box is configured to provide the cooling air to a vehicle component.

A method of providing cooling air to a vehicle engine according to an example of the present application includes drawing hot air from an engine of a vehicle with a fan, mixing the hot air with ambient air from outside the vehicle, and providing the mixed air back to the engine, wherein the mixed air has a temperature that is lower than a temperature of the hot air due to the mixing.

DETAILED DESCRIPTION

FIGS. 1-2show a schematic view of a vehicle front end18. As shown inFIGS. 1-2, the vehicle front end18includes one or more heat exchangers19. In the example ofFIGS. 1-2, the one or more heat exchangers19includes an oil cooler20, a transmission cooler22, a condenser24, and a radiator26. The vehicle front end18also includes a fan shroud assembly28and an engine compartment29with an engine30. The vehicle front end18is in one example a front end of a passenger automobile. However, it should be understood the following description is equally applicable to any gas, diesel, hybrid or electric vehicles, including performance or race cars, trucks, buses, ambulances, tractors, construction equipment, and the like. As shown inFIGS. 1-2, “outside” or ambient air from outside the vehicle passes through the oil cooler20, the transmission cooler22, the condenser24, the radiator26, and the fan shroud assembly28. In some embodiments, hot air from the engine compartment29also flows into the fan shroud assembly28, as shown inFIG. 2.

FIGS. 4-5show a detail view of the fan shroud assembly28. The fan shroud assembly28includes a fan31, which may be a high efficiency fan, arranged in a fan housing32. The fan shroud assembly28also includes a motor34for driving the fan31and a protective screen36for preventing foreign matter from entering the fan housing32and thereby air flow F. Because the fan shroud assembly28includes a motor34, the fan31can be driven even when the vehicle in which it is situated is stationary. Therefore, the fan shroud assembly28can provide cooling and/or turbo charge air to other parts of the vehicle (as will be discussed below) even when the vehicle is stationary.

FIG. 3schematically shows the fan shroud assembly28arranged adjacent the engine compartment29. Outside air from outside the vehicle flows through the one or more heat exchangers19and into the fan housing32, as does hot air from the engine compartment29. Outside air and hot air from the engine compartment29are mixed and cooled by the fan31and then provided to an air induction intake box35. Additionally, ambient air is provided directly to the air induction intake box35via a duct38. Air exiting the fan housing32and ambient air mix in the air induction take box35to create air flow F. Air flow F is colder than hot air from the engine compartment29, by virtue of passing through the fan31and mixing with the cooler ambient air in the air induction intake box35.

Air flow F then exits the air induction box35and is provided to various components of the vehicle. For example, cool air flow F is supplied back to the engine30via duct41, which allows the fan shroud assembly28to act as a turbo charger for the vehicle. Because the fan shroud assembly28is arranged adjacent the engine compartment29, this arrangement eliminates complex ducting that is typically found in vehicle turbo charger systems, which usually are situated in the back end of a vehicle and away from the engine30air intake. Additionally, turbo chargers typically draw air from the vehicle's exhaust, which is relatively hot, and cool the air with a turbo charger cooler. Because the air flow F is already relatively cool due to passing through the fan shroud assembly28, as described above, this arrangement eliminates the need for a separate turbo charger cooler. Finally, because the fan shroud assembly28facilitates the removal of hot engine air from an engine compartment29as well as the supply of cooler air flow F back to the engine30via air induction box35, the air flow arrangement improves engine efficiency and overall vehicle performance, including transmission and HVAC operation, improves fuel efficiency, and reduces emissions from the vehicle.

It should be understood that the ducting for routing air flow F to various vehicle component as shown inFIG. 3is exemplary and any ducting arrangement is contemplated by this disclosure.

Referring again toFIGS. 4-6, the air induction intake box35includes a filter37for preventing dust particles and potentially other foreign matters from entering into the engine30. The air induction intake box35also optionally includes a cooler39, such as an evaporative heat exchanger, which provides additional cooling for air as it exits the air induction intake box35. In one example, where the air induction intake box35does not include a cooler, the air temperature entering the engine could be 5 to 15 degrees F. higher compared to the ambient air temperature. In another example, where the air induction intake box35does include a cooler39, the air flow F is about 30 to 40 degrees F. cooler than ambient air. This provides further benefits to engine performance and fuel economy and reduces emissions.

In some examples, the fan shroud assembly28includes one or more features40,42. For instance, the features can be a reservoir for windshield washer fluid40and a reservoir for coolant42. Because the fan shroud28assembly is adjacent the radiator26(FIGS. 1-2), coolant from the reservoir for coolant42can be provided to the radiator26by a relatively short hose and allow coolant to move back and forth from the radiator26to the reservoir for coolant42. In other examples, the fan shroud assembly28includes other features.

Because the fan shroud assembly28removes heat from the engine30and engine compartment29by taking in hot air from the engine30and provides cool air to various parts of a vehicle, it enables the use of lightweight plastic materials that do not need to withstand high heats. In one example, the fan shroud assembly28is molded from polypropylene. In another example, the fan shroud assembly28is made from a composite material that includes a plastic matrix and fillers such as talc or glass. In a particular example, the material includes up to 20% talc filler in a polypropylene matrix. In another example, the fan housing32, air induction intake box35, and/or features40,42are integral with the fan shroud assembly28. That is, the fan housing32, air induction intake box35, and/or features40,42are integrally molded with the fan shroud assembly28as a single, monolithic component. This eliminates the need for mounting brackets or other parts for mounting the features40,42into the vehicle, and provides flexibility in placing and sizing the features40,42, in turn reducing labor costs and complexity during vehicle assembly. Furthermore, the use of lightweight plastic materials reduces the weight of the vehicle, improving vehicle performance, and reduces the cost of the parts. The fan shroud assembly28can be made by any molding process, such as blow molding or injection molding. Finally, by removing hot air from the engine compartment29and cooling it, the fan shroud assembly28can eliminate the need for heat shields and other parts that typically would be used to protect vehicle components from high heat in the engine compartment29.

FIGS. 7-9illustrate an alternate fan shroud assembly128. The alternate fan housing assembly includes dual fans31. Each fan31is arranged in a fan housing32. In the example ofFIGS. 7-9, each fan31feeds air to an air induction intake box35, which can provide air flow F to various vehicle components, as described above. As above, optional coolers39cool airflow F as it leaves the air induction intake boxes35.

FIGS. 10-11show a detail view of a fan31with blades44arranged on both sides with rounded tips. The fan31generally resembles a cone shape. This shape reduces air turbulence, improves efficiency of the fan, and reduces noise.

Although an embodiment of this disclosure has been explained, a worker of ordinary skill in this art would recognize that certain modifications would come within the spirit and scope of this invention.