COOLING SYSTEM FOR VEHICLES

Abstract: A cooling system for a vehicle. The cooling system (1) has a radiator (3) and a fan (2) that draws cooling air through the radiator (3). The fan (2) is recessed into the radiator (3) such that the motor (6) is substantially cooled by air that has not passed through said radiator (3). The radiator (3) may be an interconnected spaced-apart bi-sectional radiator with the fan (2) interposed therebetween, the radiator being shaped so as to feed air through the fan (2). The cooling system (1) may have a variable speed pump at the outlet to the radiator (3).

Description: TITLE COOLING SYSTEM FOR VEHICLES FIELD OF THE INVENTION The present invention provides a cooling system for a vehicle, especially an automobile The cooling system has a radiator and a fan, with the fan being recessed into the radiator Panels on the radiator are shaped such that air passes through the radiator and is directed towards and through the fan The fan has the motor located towards the leading edge, such that air passing through the radiator is not used in the cooling ofthe fan BACKGROUND TO THE INVENTION Motors on a vehicle require cooling while the motor is operating, to withdraw heat resulting from combustion of fuel This is normally done using a radiator located in the front ofthe vehicle and disposed transverse to the direction of movement ofthe vehicle A fan is located behind the radiator to draw air through the radiator so that cooling may be effected when the vehicle is stationary and to more effectively draw air through the radiator when the vehicle is moving The fan may be separate from the radiator, but in many modern vehicles it is frequently attached to the rear (trailing side) ofthe radiator, to form a cooling system, with a shroud surrounding the blades ofthe fan For vehicles equipped with air conditioning systems, the part ofthe air conditioner that requires cooling is also generally located close to the radiator, and frequently directly in front ofthe radiator, to utilize the beneficial effects ofthe fan Panel heat exchangers formed from thermoplastic polymers, and methods for the manufacture of such heat exchangers, are known For instance, a number of heat exchangers formed from thermoplastic polymers, especially aliphatic polyamides, are disclosed in PCT patent application WO 91/02209 of A J Cesaroni, published February 21, 1991, and in the published patent applications referred to therein Such heat exchangers offer the benefit of reduced weight, compared to traditional metal heat exchangers, while exhibiting efficiencies similar to those of metal heat exchangers While the designs of radiators for vehicles have undergone a number of improvements in recent years, especially to make the radiator and associated fan more compact while retaining the efficiency ofthe heat exchanger, additional improvements in the development of cooling systems for vehicles would be beneficial especially so that the radiator and associated fan would occupy even less space than currently utilized in vehicles. SUMMARY OF THE INVENTION A compact cooling system for a vehicle has now been found, in which the fan is recessed into the radiator and the shroud may be eliminated. An aspect ofthe present invention provides a cooling system for a vehicle, said cooling system having a radiator and a fan, especially a fan with a brushless DC motor, said fan drawing cooling air through said radiator, said fan being recessed into said radiator such that said motor is substantially cooled by air that has not passed through said radiator. In a preferred embodiment ofthe invention, the fan is located between sections ofthe radiator and does not extend outwardly therefrom. In a further embodiment, the fan motor is located in the hub to which the blades ofthe fan are attached, preferably with said blades located over said hub. In another preferred embodiment ofthe invention, the radiator is a double-pass radiator, preferably with the air passing through the radiator such that there is a maximum temperature differential between said air and fluid within the radiator. In another aspect ofthe present invention there is provided a cooling system for a vehicle having a radiator and a fan, said radiator being an interconnected spaced-apart bi-sectional radiator with said fan interposed therebetween, said radiator being shaped so as to feed air through said fan. Another aspect ofthe present invention provides a cooling system for a vehicle having a radiator and a fan, preferably a fan with a brushless DC motor, said fan drawing cooling air through said radiator, said fan being recessed into said radiator such that said motor is substantially cooled by air that is not passed through said radiator, said cooling system having a variable speed pump at the outlet to said radiator In an embodiment ofthe cooling system ofthe invention, the variable speed pump replaces the thermostat for the cooling system In another embodiment ofthe present invention, the fan has an overflow tank located on the shroud ofthe fan, especially located between said fan and said radiator BRIEF DESCRIPTION OF THE DRAWINGS The present invention is illustrated by the embodiments shown in the drawings, in which Figure 1 is a schematic representation of a cooling system ofthe invention viewed from the rear, Figure 2 is a schematic representation of a cross-section ofthe cooling system through B-B of Figure 1, Figure 3 is a schematic representation of a radiator panel, Figure 4 is a schematic representation of a portion ofthe cooling system showing air flow through the system, Figure 5 is a cross- section of a plurality of panels showing airflow restrictions at the trailing edge, and Figure 6 is an alternate embodiment showing substantially complete air-flow blockage at the trailing edge DETAILED DESCRIPTION OF THE ESTVENTION Figure 1 shows a cooling system generally indicated by 1, having a fan generally indicated by 2, and radiator 3 Fan 2 has a housing 5 in which motor 6 is axially located Motor 6 has a plurality of fan blades 7 As shown in Figure 1, motor 6 is centrally located within cooling system 1, but it is to be understood that it could be offset from the center thereof Fan 2 does not have a shroud located thereon, for protective purposes and for directing air passing through the radiator, but utilizes the shape ofthe panels ofthe radiator, as discussed herein, to direct air to the blades ofthe fan Fan 2, with its associated motor, blades and hub, needs to be compact Thus, a preferred fan has its motor located within the hub ofthe fan, with the blades attached to the outside ofthe hub, preferably in a swept-back position such that the blades are located in the same plane as the hub Such a fan is compact A variety of types of motors or methods of driving the fan may be used in the fan, of which a brushless DC motor is preferred because of its compact nature Radiator 3 has inlet 8 located in manifold header 1 1 Manifold header 1 1 also has a centrally located radiator cap 9 Manifold header 11 extends across the top of radiator 3, and then extends downward on each of its opposite sides forming end manifold headers 12. End manifold headers 12 are connected to radiator panels 4, and act as the inlets for radiator panels 4 The outlet for radiator panels 4 is at central manifold headers 13 The embodiment shown has two central manifold headers 13 Such headers extend down to outlet manifold header 14, and terminate in outlet 15 Overflow container 10 is shown as centrally located in the upper portion of cooling system 1, above fan housing 5, and would be connected to radiator 3 by means not shown Thus, Figure 1 shows a bi-sectional radiator as more clearly seen elsewhere Figure 2 shows the cross-section of Figure 1 through B-B Fan housing 5 is centrally located and encloses fan blades 7 Radiator panels 4 are shown in two separate locations on opposite sides of fan housing 5, in each instance extending between end manifold header 12 and central manifold header 13 Figure 3 shows a cross-section of a radiator panel 4 in more detail Radiator panel 4 extends from end manifold header 12 to central manifold header 13 A plurality of channels 17 are shown extending from end manifold header 12 in a pattern that provides fluid-flow passage from end manifold header 12 to a location juxtaposed to central manifold header 13, returning to a location juxtaposed to end manifold header 12 and then returning once again to exit at central manifold header 13 Such a pattern may be referred to as a "dual pass " As discussed herein, a variety of such patterns may be used Figure 3 shows radiator panel 4 with five channels extending from end manifold header 12 to central manifold header 13 It is understood that in practice a radiator would have substantially more than five channels extending between such headers It is also to be understood that radiator panel 4 would have a pattern of channels 17 utilizing the full extent ofthe surface of radiator panel 4 so as to achieve a high degree of transfer of heat Radiator panel 4 has been shown with only five channels in the pattern of Figure 3 for clarity only Figure 4 is a schematic representation of a cross-section of radiator panel 4 with motor 6 and fan blades 7 showing flow of air through the cooling system Fan blades 7 are shown as attached to motor 6 by shaft 19 Air entering the radiator is shown by arrows 20 Air 20 enters radiator panel 4 at front edge 21 and either flows in a curved pattern as indicated by arrows 22 or in a straight-through manner as indicated by arrow 23 The flow pattern of air 20 through radiator panel 4 is achieved by having trailing edge 24 of radiator panel 4 provide complete or partial blockage (restriction) of passage of air passed such edge, as discussed below Thus, trailing edge 24 restπcts air 20 from passing straight through panels 4 and redirects it towards fan blades 7 The rotation of fan blades 7 also serves to draw air in the same direction It will be noted that motor 6 is in contact with air 20 which is cooling air, rather than air following the path of arrows 22 and 23, which is air heated by panel 4 Such air 20 provides all or a substantial portion ofthe air for cooling of motor 6 Methods for achieving complete or partial restriction of air at trailing edge 24 are shown in Figure 5 and Figure 6 Figure 5 shows a cross-section of a plurality of fluid channels 25, corresponding to channels 17, that would extend from end manifold header 12 to central manifold header 13 Fluid flow channels 25 are held in position by panel sheet 26 In the embodiment of Figure 5, panel sheet 26 at trailing edge 24 thereof is curved downwards to form the trailing edge, forming barrier 27 in doing so. Figure 5 as illustrated would be a form of a panel having a trailing edge 24 that exhibits partial blockage ofthe flow of air through radiator panel 4. In the embodiment of Figure 6, a plurality of fluid flow channels 25 held in position by panel sheet 26 are shown. However, in the embodiment of Figure 6, each panel sheet 26 terminates in large channel 28 and moreover, large channels 28 are shown in contact with each other, forming a barrier along trailing edge 24 ofthe panel. However it is to be understood that gaps could be provided between large channels 28 so that air could bleed between the panels, i.e., through trailing edge 24. As disclosed herein, the radiator is in the form of a plurality of panels arranged in a parallel spaced-apart relationship. Such panels are known. The edges ofthe panels are disposed towards the source ofthe cooling air such that the air flows over the panels with minimal restriction. In preferred embodiments, the panels are comprised of a plurality of channels formed in the sheet that forms the panels. Alternatively the channels may be in the form of tubes which are located between sheets in a parallel aligned relationship to form the panel. It is to be understood, however, that a variety of designs of panels may be used in the cooling system ofthe present invention. In preferred embodiments, the cooling system, especially the panels and manifolds may be formed from a variety of polyamide compositions. The composition selected will depend primarily on the end use, especially the temperature of use and the environment of use of such a heat exchanger, including the fluid that will be passed through the heat exchanger and the fluid e.g., air, external to the heat exchanger. Such air may be air that at times contains salt or other corrosive or abrasive matter, or the fluid may be liquid e.g., radiator fluid. A preferred polymer of construction is polyamide. Examples of polyamides are the polyamides formed by the condensation polymerization of an aliphatic dicarboxylic acid having 6-12 carbon atoms with an aliphatic primary diamine having 6-12 carbon atoms. Alternatively, the polyamide may be formed by condensation polymerization of an aliphatic lactam or alpha, omega aminocarboxylic acid having 6-12 carbon atoms. SUBSTITUTE SHEET (RULE 28) In addition, the polyamide may be formed by copolymerization of mixtures of such dicarboxylic acids, diamines, lactams and aminocarboxylic acids Examples of dicarboxylic acids are 1,6-hexanedioic acid (adipic acid), 1,7-heptanedioic acid (pimelic acid), 1,8-octanedioic acid (suberic acid), 1,9-nonanedioic acid (azelaic acid), 1,10-decanedioic acid (sebacic acid) and 1, 12-dodecanedioic acid Examples of diamines are 1,6-hexamethylene diamine, 1,8-octamethylene diamine, 1 , 10-decamethylene diamine and 1 , 2-dodecamethylene diamine An example of a lactam is caprolactam Examples of alpha, omega aminocarboxylic acids are amino octanoic acid, amino decanoic acid, amino undecanoic acid and amino dodecanoic acid Preferred examples ofthe polyamides are polyhexamethylene adipamide and polycaprolactam, which are also known as nylon 66 and nylon 6, respectively While particular reference has been made herein to the use of polyamides as the polymer used in the fabrication of all or part ofthe cooling system, it is to be understood that other polymers may be used Examples of other thermoplastic polymers that may be used are polyethylene, polypropylene, fluorocarbon polymers, polyesters, elastomers e g , polyetherester elastomers, neoprene, chlorosulphonated polyethylene, and ethylene/propylene/diene (EPDM) elastomers, polyvinyl chloride and polyurethane In preferred embodiments ofthe present invention, the channels are formed from tubing that has a thickness of less than 0 7 mm, and especially in the range of 0 07-0 50 mm, particularly 0 12-0 30 mm The thickness ofthe tubing will, however, depend to a significant extent on the proposed end use and especially the properties required for that end use The polymer compositions used in the fabrication ofthe heat exchangers may contain stabilizers, pigments, fillers, including glass fibres, and the like, as will be appreciated by those skilled in the art All seals should be fluid tight seals, to prevent leakage of fluid from the heat exchanger An overflow tank, which may also be referred to as a coolant recovery tank, may be located within the cooling system Such an overflow tank forms part of many vehicles and is attached to the radiator thereof for retention of excess fluid or for replenishment of fluid into the radiator, as is known. In the cooling system ofthe invention, the overflow tank is conveniently located on the exterior ofthe fan, forming part ofthe housing ofthe fan. A suitable connection is then provided from the overflow tank to the manifold to the radiator. The outlet to the manifolds ofthe cooling system may be connected to a pump For instance, central manifold headers 13 shown in Figure 1 could be connected to opposite sides of an impeller of a pump, such pump having a motor attached thereto The pump could be a variable speed pump, operating at a speed appropriate to the requirements imposed on the cooling system. For instance, the pump could remain operational after the engine ofthe vehicle has been turned off, to prevent so-called "after-boil" in the engine or a part ofthe cooling system. It is understood that such a pump could operate independent of a thermostat or replace the thermostat conventionally used in a cooling system. Thus, for example, the pump could eliminate the need for a thermostat within the cooling system, with the pump being operated to maintain a required temperature within the cooling system As disclosed herein, the motor of the fan is primarily cooled using air that has not passed through the heat exchange portion ofthe cooling system. Thus, the motor ofthe fan is maintained at a significantly lower temperature than would be the case if air passing through the radiator was passed over the motor for purpose of cooling the motor. This should result in a longer lifespan for the motor ofthe fan. It is also understood that the shroud normally associated with the fan and motor ofthe cooling system may be eliminated in the cooling system ofthe invention In particular the shroud is replaced by portions ofthe construction ofthe cooling system, especially those parts utilized in maintaining the integrity ofthe cooling system e g braces and the like. The individual panels ofthe radiator have been illustrated herein as being in the shape of a triangle combined with a rectangle. It has been further illustrated herein that the combination ofthe radiator and the fan form the shape of a truncated triangle on a rectangle Such shapes are preferred and result in a compact cooling system However, it is to be understood that some variation in the shape ofthe cooling system is permitted, within the requirements to maintain a compact cooling system and to have the cooling fan located between sections ofthe bi-sectional radiator The cooling system ofthe present invention provides a radiator with associated fan in a compact, substantially cuboid arrangement, with relatively narrow depth The cooling system can reduce the thickness ofthe radiator and associated fan ofthe cooling system of a typical mid-sized automobile by one or more inches, while providing an equivalent cooling capacity for the engine ofthe automobile, thus allowing further design flexibility for automotive engineers The "under the hood" area of an automobile has a large number of components arranged in the area, with little spare space Thus, being able to accommodate the cooling system in a smaller space has significant advantages to the automotive design engineers, to permit further equipment to be placed in the "under the hood" area, to allow flexibility in the shape and area required for the front end ofthe vehicle or the like

Claims: CLAEMS: 1 A cooling system for a vehicle, said cooling system having a radiator and a fan, said fan drawing cooling air through said radiator, said fan being recessed into said radiator such that said motor is substantially cooled by air that has not passed through said radiator 2 The cooling system of Claim 1 in which the fan has a brushless DC motor 3. The cooling system of Claim 1 in which the fan is located between sections ofthe radiator and does not extend outwardly therefrom 4 The cooling system of Claim 1 in which the fan motor is located in the hub to which the blades ofthe fan are attached 5 The cooling system of Claim 4 in which said blades are located over said hub 6 The cooling system of Claim 1 in which the radiator is a double-pass radiator 7 The cooling system of Claim 1 in which air is passed through the radiator such that there is a maximum temperature differential between said air and fluid within the radiator 8 A cooling system for a vehicle having a radiator and a fan, said radiator being an interconnected spaced-apart bi-sectional radiator with said fan inteφosed therebetween, said radiator being shaped so as to feed air through said fan 9 The cooling system of Claim 8 in which the fan has a brushless DC motor 10 A cooling system for a vehicle having a radiator and a fan, said fan drawing cooling air through said radiator, said fan being recessed into said radiator such that said motor is substantially cooled by air that is not passed through said radiator, said cooling system having a variable speed pump at the outlet to said radiator 11 The cooling system of Claim 10 in which the fan has a brushless DC motor 12 The cooling system of Claim 10 in which the variable speed pump replaces the thermostat for the cooling system 13 The cooling system of Claim 1 in which the fan has an overflow tank located on the shroud of the fan 14 The cooling system of Claim 10 in which the overflow tank is located between said fan and said radiator

Inventors: CESARONI ANTHONY JOSEPH, CESARONI, ANTHONY, JOSEPH
Applicants: CESARONI ANTHONY JOSEPH, CESARONI, ANTHONY, JOSEPH
Application year: 1996
Main classification: F04D29
IPC codes: F01P3, F01P5, F01P7, F01P11, F04D29, F28D1, F28F9