Abstract:
A fastening system fastens a radiator, an electric fan support and a fan shroud as a single unit. The radiator has lower and upper posts to which slotted plates protruding from the fan support and fan shroud fit over. A structural sandwich is formed with the fan support lying between the radiator and the fan shroud. A flexible lever arm with a locking tab lies adjacent to the upper post of the radiator and connects to the radiator. When the fan support is fitted over the posts, the top plate of the electric fan support locks under the first lever arm tab. The fan shroud also has two slotted plates that also fit over the posts of the radiator. The fan shroud locks into place when a lever arm with a tab on the fan shroud locks under a tab that protrudes from the top plate of the fan support.

Description:
FIELD 
   The present disclosure relates to a component attachment system. More specifically, the present disclosure relates to the fastenerless attachment of multiple components in a vehicle engine cooling module. 
   BACKGROUND 
   The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. Traditionally, engine cooling modules have been assembled using traditional fasteners, such as screws or a bolt and nut arrangement. While these fasteners have proven satisfactory for their purpose, such traditional fastener methods have not been without their share of limitations. 
   There are multiple limitations of traditional fastener systems. One such limitation is that traditional fasteners, whether clips, screws, or a bolt and nut combination, may vibrate loose due to vibrations caused by an engine or road surface as a vehicle travels on a road. Loose fasteners may eventually fall out of their originally secure location. Another limitation is that traditional fasteners are physically separate components from the parts that need to be fastened, and as such, the fasteners must be brought to the parts for which fastening is desired. This represents an added fastener cost and assembly time to install such fasteners. Another limitation is that in a location where installation and removal space of the attached parts is limited, traditional fasteners may be difficult or even prevent certain designs because traditional fasteners require space for installation and removal tools as well as space for the person or machine who installs such parts. Still yet another limitation is that traditional fastening devices do not permit stacking, or a series assembly, of multiple parts of a module, that can be accomplished in a fast, convenient, and reliable manner. 
   What is needed then is an attachment device that permits a fast and secure connection of parts, such as parts assembled in series, without the space and tools necessary to install separate, traditional fasteners. 
   SUMMARY 
   A fastening system applied to a cooling module utilizes three major pieces: a radiator, an electric fan support, and a fan shroud. The radiator has two posts protruding from one side, or one tank, one at a lower location and one at an upper location. The electric fan support has a bottom plate that has a first slot or notch in it such that the bottom plate straddles or fits over the lower post, and a top plate that has a second slot or notch such that the top plate straddles or fits over the second post. The lower and upper posts have two levels of notches that correspond with the notches of the plates to permit the tight fit of the electric fan support against the radiator. 
   To effectively lock the electric fan support against the radiator, a flexible prong with a protruding tab resides on the radiator next to the upper post. The protruding tab fits over the top plate and prevents the electric fan support from moving off of the lower and upper posts. Pressing the flexible prong releases the tab from the top plate and permits the fan support to be lifted from the radiator. 
   The fan shroud also has a bottom plate with a first slot or notch in it such that the bottom plate straddles or fits over the lower post, and a top plate that has a second slot or notch such that the top plate straddles or fits over the second post. The notches in the plates of the fan shroud fit within the second set of notches in the lower and upper posts. That is, the electric fan support fits into the lower notches of the posts while the fan shroud fits within the upper notches of the posts. With the fan shroud held firmly against the fan support and the fan support held firmly against the radiator, the second latching or fastening mechanism engages. 
   The second latching mechanism associated with the top plate of the fan shroud has a flexible prong with a protruding tab connected to the top plate. When the fan shroud plates are placed over the lower and upper posts, the tab and flexible prong are biased when they contact a tab on the top plate of the electric fan support. When the fan support is fully pressed into position, the tab on the flexible prong lodges under the tab on the top plate of the fan support when the flexible prong returns to its unbiased position. With the tab of the flexible prong of the fan shroud under the tab of the top plate of the fan support, the fan shroud is prevented from moving off of the first and second posts. Both of the fan support and the fan shroud are prevented from moving laterally off of the lower and upper posts due to the notches, and from moving vertically off of the posts due to the latching mechanisms at the top plates. 
   Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 

   
     DRAWINGS 
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
       FIG. 1  is a perspective view of an engine cooling module employing a fastening system according to teachings of the present invention; 
       FIG. 2  is an enlarged perspective view of an assembled cooling module utilizing the fastening system; 
       FIG. 3  is an enlarged partial perspective view of an unassembled engine cooling module utilizing the fastening system; 
       FIG. 4  is an enlarged perspective view of a partially assembled engine cooling module utilizing the fastening system; 
       FIG. 5  is an enlarged cross-sectional view depicting a pre-assembly stage of the engine cooling module employing the fastening system; 
       FIG. 6  is an enlarged cross-sectional view depicting a partially assembled stage of the engine cooling module employing the fastening system; 
       FIG. 7  is an enlarged perspective view of an assembled engine cooling module employing the fastening system; 
       FIG. 8  is an enlarged cross-sectional view depicting a pre-assembly stage of the engine cooling module employing the fastening system; and 
       FIG. 9  is an enlarged cross-sectional view depicting an assembled engine cooling module employing the fastening system. 
   

   DETAILED DESCRIPTION 
   The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     FIG. 1  is a perspective view of an engine cooling module  10  that employs a fastening system according to teachings of the present invention. The engine cooling module  10  depicted in  FIG. 1  is an assembly of three major members, a fan shroud  12 , an electric fan support  14 , and a radiator  16 . The radiator  16  is known as the first member, the electric fan support  14  is known as the second member, and the fan shroud  12  is known as the third member. The radiator  16 , or first member, has a left radiator tank  18 , which is also known as a left tank or a top tank, and a right radiator tank  20 , which is also known as a right tank or a bottom tank. The left radiator tank  18  is known as the top tank because it employs a top inlet  22 , also known as a top tank inlet, while the right radiator tank  20  is known as the bottom tank because it employs a bottom outlet  24 , also known as a bottom tank outlet. The bottom tank  20  employs a radiator coolant inlet  26 , which is the location where liquid coolant such as anti-freeze or water is added to the engine cooling system. The top inlet  22  is where liquid coolant continuously enters the radiator  16  while the engine (not shown) is running. The bottom outlet  24  is where the liquid coolant continuously exits the radiator  16  while the engine is running. 
   The liquid coolant generally flows from the top tank  18  to the bottom tank  20  via the radiator core  28 . The radiator core  28  consists of multiple liquid coolant passages surrounded by air gaps, through which air passes to cool or remove heat from the liquid coolant. The radiator core  28  is similar to existing radiator cores, as are known in the art. Continuing, a fan blade  30  spins about a fan central location or fan axis  32 , and when operating, air is pulled through the radiator core  28  by the fan blade  30  which removes heat from the liquid coolant flowing through the radiator core  28 . The fan blade  30  is driven or rotated by an electric motor  34  or fan motor. The fan shroud  12  has a shroud opening  29  for an engine driven fan (not shown), that is separate from the electric motor  34  and fan blade  30 . The engine driven fan also pulls air through the radiator core  28 . 
   The radiator  16  mounts within an engine compartment (not shown) of a vehicle (not shown) with brackets. More specifically, on its bottom side, a bottom radiator bracket  36  has a post  38 , which fits into a hole within the vehicle engine compartment. Once the post  38  is inserted, the top radiator bracket  40  with its slot  42 , is inserted over a corresponding post, such as a bolt (not shown), within the engine compartment. Similar brackets are on the right side of the radiator  16  to facilitate mounting. 
   Now a more detailed description of the operative workings of the teachings of the present invention will be presented.  FIG. 1  depicts a perspective view of a top connection device  44  and a bottom connection device  46 .  FIG. 2  is an enlarged perspective view of a portion of an assembled cooling module assembly  10  utilizing the top connection device  44  and the bottom connection device  46 . More specifically,  FIG. 2  depicts the electric fan support  14 , or second member, installed onto a lower or bottom radiator post  48  at the bottom connection device  46  and the electric fan support  14  snapped or secured into position at the top connection device  44 . 
     FIG. 3  is an enlarged partial perspective view of an unassembled engine cooling module  10  utilizing the fastening system. More specifically,  FIG. 3  depicts three portions of the top connection device  44 . Radiator top latch  50 , top fan support plate  52 , and the fan shroud latch  54 , generally form the top connection device  44 . Continuing, the radiator top latch  50  has a radiator top post  56  or upper post, a top latch surface  58 , a top spring lever arm  60  with a top spring tab  62 , a latch tab  64 , and a stop  66  or over bend stop that prevents overstressing the lever arm  60  when a person presses the spring tab  62 . The portions making up the top connection device  44  may be molded into the radiator top tank  18 . The advantage of such a molded feature is the elimination of separate fasteners and their associated handling costs and installation costs. Additionally, such fasteners may fall out over time due to vibrations in a vehicle.  FIG. 3  also depicts the radiator bottom post  48 , but a bottom surface  68  adjacent to the bottom post  48 . 
     FIG. 3  also depicts fastening portions associated with the top fan support plate  52  of the electric fan support  14 . Continuing, the top fan support plate  52  or first top plate has a top plate slot, groove or notch  70 , a main plate portion  71  having a top fan support plate radiator side  72 , a top fan support plate shroud side  74 , and a top plate extension tab or plate tab  76 . Adjacent to the top fan support plate  52  is structural webbing  78  that provides structural support to the electric fan support  14 . Continuing with the electric fan support  14  of  FIG. 3 , a first bottom plate or bottom fan support plate  80  is depicted. The bottom fan support plate  80  has a bottom fan plate radiator side  82 , a bottom fan plate shroud side  84 , and a bottom fan plate groove, slot or notch  86 . 
     FIG. 3  also depicts fastening elements of the fan shroud  12 , or third member. Continuing with the fan shroud latch  54 , also depicted is a fan shroud spring lever  88  or lever arm, a fan shroud spring lever tab  90 , a fan shroud spring lever lock tab or protrusion  92 , and a fan shroud stop  94  or over bend stop. The fan shroud latch  54  is primarily supported by a fan shroud latch top web  96  and a fan shroud latch bottom web  98 . The webs  96 ,  98  support the fan shroud latch surface  97 , which faces the electric fan support  14 . More specifically, when assembled, the fan shroud latch surface  97  abuts the surface  74  of the plate  52 . Continuing with reference to  FIGS. 3 and 8 , further assembly of the fan shroud  12  to the electric fan support  14  involves aligning the fan shroud bottom plate groove, slot or notch  104  within the bottom post shallow slot, notch or groove  115  between the radiator bottom post groove outer face  114  and the bottom fan support plate  80 . At the same time that alignment of the fan shroud bottom plate  100  (second bottom plate) occurs, so does alignment of the fan shroud latch  54  ( FIG. 9 ). The fan shroud bottom plate (second bottom plate) surface  102  abuts the bottom fan plate (first bottom plate) shroud side  84  ( FIG. 4 ). 
     FIG. 4  is an enlarged perspective view of a partially assembled engine cooling module  10  utilizing the fastening system of the teachings of the present invention. More specifically,  FIG. 4  depicts the top fan support plate  52  in its assembled position against the top latch surface  58  of the radiator top latch  50 . In this assembled position, and with reference to  FIG. 5 , the bottom fan plate groove, slot or notch  86  is inserted in accordance with arrow  87  into a radiator bottom post groove bottom  108  so that the bottom fan plate radiator side  82  is snugly against the radiator bottom post groove inner face  112  and the bottom fan plate shroud side  84  is against the radiator bottom post groove intermediate face  110 . In such a sandwiched position, the electric fan support  14  is secured in the fore and aft directions when installed in a vehicle and during transportation and handling of the sub-assembly (the electric fan support  14  assembled to the radiator  16 ). Stated another way, the electric fan support  14  is secured from lateral movement which means that the fan support  14  can not move toward or away from the radiator  16 . 
   Continuing with  FIGS. 4 and 5 , the top fan support plate  52  is lowered into the radiator top post groove  116  at the same time as the bottom fan support plate  80  is lowered into the radiator bottom post groove bottom  108 . With the top plate  52 , the top fan plate notch end  124  abuts and rests against the bottom of the radiator top post groove  116 . Also, the bottom fan support plate notch end  106  abuts and rests upon a bottom of groove  108 . Positioned as such, the top fan support plate radiator side  72  snugly abuts against the radiator top post groove inner face  120 , and the face of the top spring lever  60 . Additionally, the top fan support plate shroud side  74  snugly abuts against radiator top post groove intermediate face  118 . 
   When the fan support  14  is lowered into its assembled position, as depicted in  FIG. 6 , the spring lever  60  and top spring tab  62  are biased away from the fan support  14  and then spring back when released such that the protuberance or latch tab  64  resides over the top fan support plate top surface  65 . This secures the entire fan shroud  12  so that it can not move off of the posts  48 ,  56 . To assist in securing the latch tab  64  over the top fan support plate top surface  65 , the top spring tab  62  may be pressed by a human finger to bias the top spring lever  60  away from the top fan support plate  52 ; however, pressing by a human finger is not necessary. To prevent over bending of the top spring lever  60 , which may fatigue the top spring lever  60  with repeated use, the top spring lever  60  will contact the stop  66 . When the top spring lever  60  is released, it returns to its equilibrium or neutral stress position with the latch tab  64  over the top surface  65  of the top fan support plate  52 . Again,  FIG. 6  depicts the assembled parts that are depicted unassembled in  FIG. 5 . With the electric fan support  14  assembled against the radiator  16 , the fan shroud  12  can then be assembled to the electric fan support  14  in a similar manner. 
   Before explaining further assembly of the fan shroud  12  to the assembly of the radiator  16  and the electric fan support  14 , an additional advantage of the teachings of the present invention will be explained. With just the electric fan support  14  snapped or secured into position on the radiator  16 , the two-part assembly can then be shipped for further assembly without any additional fasteners of any type. Prior to the teachings of the present invention, screws or a bolt and nut arrangement were necessary to secure the electric fan support  14  to the radiator  16  and then, further similar fasteners were necessary to prevent the two parts from detaching during physical transit to another location for further attachment of the fan shroud  12 . However, the inventive structure of the groove  108 ,  116  and post  48 ,  56  arrangements, and the biasing top spring lever  60 , such previously used fasteners for assembly and transit prior to fan shroud assembly are not necessary. 
   Continuing with the assembly and teachings of the present invention,  FIG. 7  depicts an enlarged partial perspective view of an assembled engine cooling module  10 . More specifically,  FIG. 7  depicts the engine fan shroud  12  mounted to the assembly of the radiator  16  and electric fan support  14 . Continuing with reference to FIGS.  3  and  7 - 9 , further assembly of the fan shroud  12  to the electric fan support  14  involves aligning the fan shroud bottom plate groove, slot or notch  104  within the bottom post shallow slot, notch or groove  115  between the radiator bottom post groove outer face  114  and the bottom fan support plate  80 . When installation is complete, the fan shroud bottom plate notch end  130  will rest within the bottom post shallow groove  115 . At the same time that alignment of the fan shroud bottom plate  100  (second bottom plate) occurs, so does alignment of the fan shroud latch  54 . The fan shroud bottom plate (second bottom plate) surface  102  abuts the bottom fan plate (first bottom plate) shroud side  84 . 
   With reference to FIGS.  3  and  7 - 9 , alignment of the fan shroud latch  54  will be explained. When the fan shroud  12  is lowered in accordance with arrow  132 , the fan shroud spring lever  88  biases as the angled surface of the fan shroud spring level lock tab  92  contacts the top plate extension tab  76  of the top fan support plate  52 . As the biasing is occurring, the fan shroud top plate  55  (second top plate) begins to settle within the notch or groove  123  of the radiator top post  56 . More specifically, the fan shroud top plate notch end  134  will settle within the notch  123  between the radiator top post groove outer face  122  and the top fan support plate shroud side  74 . As that occurs, the fan shroud spring lever lock tab  92  snaps into place under the top plate extension tab  76 . This installation places the fan shroud latch surface  97  (second top plate) securely against the top fan support plate shroud side  74  (first top plate). The assembly of the three pieces  12 ,  14 ,  16  completes the fan shroud assembly  10 . 
   With the fan shroud  12 , electric fan support  14 , and radiator  16  securely assembled, one will recognize that the latch tab  64  over the top fan support plate (first top plate) top surface  65  and the top plate extension tab  76  over the fan shroud spring lever lock tab  92  prevents motion in the vertical, or up and down, direction while the posts  48 ,  56  lateral motion (off the end of the posts  48 ,  56 ). Additionally, for and aft motion with reference to vehicle installation is also prevented. However, one will also recognize that the posts  48 ,  56  also prevent downward motion (in the direction of arrow  132 ) of the electric fan support  14  and the fan shroud  12 . The grooves  108 ,  116  and grooves  115 ,  123  also prevent motion along the length of the posts  48 ,  56 .  FIG. 8  depicts an enlarged cross-sectional view depicting a pre-assembly stage of the engine cooling module  10  while  FIG. 9  depicts an enlarged cross-sectional view of the assembled engine cooling module  10 . 
   While the teachings of the present invention have been described and largely depicted using the top connection device  44  and the bottom connection device  46 , which are located on the left, or driver&#39;s side of a typical vehicle, a corresponding top connection device and bottom connection device are located on the right side of the vehicle, for a total of four connection devices. With a total of four connection devices, one at each corner of the cooling module assembly  10 , the cooling module assembly can securely be held together. 
   The fan shroud  12 , electric fan support  14  and radiator  16  may be constructed from metallic materials or non-metallic materials. Regarding the teachings of the present invention, as an example, the radiator  16 , the electric fan support  14 , and fan shroud  12  may be constructed of various plastics. 
   The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.