Abstract:
A cooling system support structure for removably supporting a cooling system module on a vehicle chassis, comprising: a frame configured to support the cooling system module, said frame having first and second sides; first and second mounting points coaxially mounted along the first side and a third mounting point mounted along the second side, said mounting points positioned to mate with corresponding chassis mounts on the vehicle chassis; and a flexible coupling connecting each mounting point to the respective chassis mount such that the frame is movably supported by the vehicle chassis.

Description:
RELATED APPLICATION  
       [0001]    This application is a continuation of U.S. Provisional Patent Application Serial No. 60/230,275 filed Sep. 6, 2000. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates generally to vehicles, and in particular, to a modular cooling system and a structure for mounting the same in a frame of a vehicle such a bus.  
         BACKGROUND OF THE INVENTION  
         [0003]    As is known, engines are used to propel vehicles such as buses, cars and the like. In order to prevent the engine of a vehicle from overheating, a cooling system is often interconnected thereto. The cooling system includes a radiator operatively connected to the engine such that coolant from the engine flows through the radiator. A heat exchange is effectuated between the coolant in the radiator and the outside, ambient air in order to remove heat from the coolant flowing through the radiator and back to the engine. A fan may be provided to blow air across the fins of the radiator in order to facilitate the heat exchange.  
           [0004]    Radiators are often formed from a plurality of metal parts such as tubes and fins. Since the prior art radiators are often times rigidly connected to the vehicle chassis adjacent the engines of the vehicles, radiators see all of the vibrations associated with the operation of the vehicles. Due to these vibrations, stress may develop at certain points on the radiator resulting in the radiator cracking and/or breaking at such points. In addition, the chassis of a vehicle, such as a bus, is flexible. For example, the chassis will deflect as the bus travels along a road or receives passengers. This deflection of the chassis of the bus may be transmitted to the radiator of the vehicle as additional unwanted stress. Since replacement of a radiator is both labor intensive and expensive, it is highly desirable to provide a mounting structure for a cooling system which eliminates the stress points on a radiator during operation of the vehicle.  
           [0005]    Depending on the type of vehicle, vehicle cooling systems may also contain additional components such as a radiator shroud, a transmission and/or other oil cooler, a heater core, a fan clutch, an expansion tank, and/or other items which may be necessitated by the application.  
           [0006]    The installation and/or replacement of a cooling system for a vehicle is both time consuming and costly due to the fact that prior art cooling systems utilize numerous parts and sub-assemblies. Typically, individual cooling system components are installed essentially one at a time, making installation a very cost and time-inefficient process. Consequently, it is also highly desirable to provide a cooling system which may be quickly and easily installed in a vehicle.  
         OBJECTS OF THE INVENTION  
         [0007]    Therefore, it is a primary object and feature of the present invention to provide a modular cooling system which may be quickly and easily installed in a vehicle.  
           [0008]    It is a further object and feature of the present invention to provide a cooling system for a vehicle which may be mounted to the chassis of the vehicle at a location remote from the engine.  
           [0009]    It is a still further object and feature of the present invention to provide a cooling system for a vehicle which is simpler and less expensive to manufacture than prior art cooling systems.  
           [0010]    It is a further object and feature of the present invention to provide a mounting structure for a cooling system which eliminates the stress points on the cooling system during operation of the vehicle.  
         SUMMARY OF THE INVENTION  
         [0011]    In accordance with the present invention, a cooling system module and a structure for mounting the same in a frame of a vehicle such as a bus is provided. The modular cooling system allows a user to install a single unit into the chassis of a vehicle thereby eliminating the time and labor associated with installation and/replacement of prior art cooling systems. The cooling system may include such items as a radiator, fan, fan drive, charged air cooler, transmission oil cooler, surge tank and/or other items which may be necessitated by the application.  
           [0012]    A preferred embodiment of the present invention includes a cooling system support structure for removably supporting a cooling system module on a vehicle chassis, comprising a frame configured to support the cooling system module. The frame has a first side along which are coaxially mounted first and second mounting points and a second side on which a third mounting point is mounted. Each of these mounting points is positioned to mate with corresponding chassis mounts on the vehicle chassis. A flexible coupling connects each mounting point to the respective chassis mount such that the frame is movably supported by the vehicle chassis.  
           [0013]    In a highly preferred embodiment, the mounting points of the support structure are positioned such that the cooling system module is supported in a balanced state. The term “balanced state” herein refers to the condition such that when the vehicle is generally level and not moving, the weight of the vehicle cooling system is approximately evenly distributed onto the three mounting points. This is accomplished by determining the placement of the cooling system components on the cooling system frame and by choosing the location of the mounting points on the cooling system frame. Mounting the cooling system to be in a balanced state allows each flexible coupling to be utilized to the full extent of available displacement while the vehicle is subjected to vibration, starting and stopping of the vehicle, chassis distortion, or any other loading that might put on the vehicle.  
           [0014]    In an additional embodiment of the invention, the frame of the support structure includes top and bottom frame members each having spaced apart ends and first and second end frame members. The first and second end frame members are secured to a respective spaced apart end of said top and bottom frame members.  
           [0015]    Preferably, the frame of the support structure further includes a first mounting bracket rigidly connected to a first end of the first side, a second mounting bracket rigidly connected to a second end of the first side, and a bracket support element which rigidly connects the first and second mounting brackets. It is highly preferred that the support structure has a first mounting point secured on the first mounting bracket and the second mounting point secured on the second mounting bracket such that the first and second mounting points are aligned coaxially.  
           [0016]    The cooling system support structure preferably includes a first mounting point comprising a first outer bushing secured with respect to the first mounting bracket and a second mounting point comprising a second outer bushing secured with respect to the second mounting bracket, the first and second outer bushings being coaxially aligned. Further, a flexible inner bushing is coaxially secured within each of the first and second outer bushings. These flexible inner bushings are positioned to mate with corresponding chassis mounts on the vehicle chassis.  
           [0017]    In an additional highly preferred embodiment of the present invention, the third mounting point includes a mounting point bracket rigidly connected to the second side of the frame and a flexible coupling comprising a connecting rod flexibly connected to the mounting point bracket and connecting the mounting point bracket to the vehicle chassis. The preferred connecting rod comprises a first rod end secured to a first rod outer bushing and a second rod end secured to a second rod outer bushing, such rod outer bushings positioned at opposite ends of the connecting rod with axes parallel one to the other and perpendicular to the axis of the connecting rod. The connecting rod also includes a flexible inner bushing coaxially secured within each rod outer bushing, the flexible inner bushing secured to the first rod outer bushing being positioned to mate with a mounting point bracket on the second side of the frame, and the flexible inner bushing secured to the second rod outer bushing positioned to mate with a corresponding chassis mount on the vehicle chassis.  
           [0018]    When all or most of the cooling system components are mounted together as a unit, herein called a cooling system module, installation is both less costly and less time-consuming. When the module is flexibly mounted using the three point mounting arrangement of this invention, the components of the cooling system are subjected to much less stress, shock, and vibration, resulting in longer component life.  
           [0019]    The cooling system may be positioned at a remote location with respect to the engine such that vibrations from the engine will not be transmitted directly to the cooling system. Further, by having the cooling system positioned at a location remote from the engine, vibrations from the engine and the chassis may dissipated along the length of the chassis. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    The drawings furnished herewith illustrate a preferred construction of the present invention in which the above advantages and features are clearly disclosed as well as others which will be readily understood from the following description of the illustrated embodiment. In the drawings:  
         [0021]    [0021]FIG. 1 is a perspective view of a vehicle cooling system in accordance with the present invention;  
         [0022]    [0022]FIG. 1 a  is a section view of a first or second mounting point and a flexible coupling in accordance with the present invention, taken along section  1   a - 1   a  shown in FIG. 1;  
         [0023]    [0023]FIG. 1 b  is a perspective view of a chassis mount;  
         [0024]    [0024]FIG. 2 is a rear elevation view of the vehicle cooling system of FIG. 1;  
         [0025]    [0025]FIG. 3 is a front elevation view of the vehicle cooling system of FIG. 1;  
         [0026]    [0026]FIG. 4 is a side elevation view of a first side of the vehicle cooling system of FIG. 1;  
         [0027]    [0027]FIG. 5 is a side elevation view of a second, opposite side of the vehicle cooling system of FIG. 1;  
         [0028]    [0028]FIG. 6 is a top plan view of the vehicle cooling system of FIG. 1;  
         [0029]    [0029]FIG. 7 is a bottom plan view of the vehicle cooling system of FIG. 1;  
         [0030]    [0030]FIG. 8 is a rear elevation view of the vehicle cooling system of FIG. 1 mounted within a vehicle chassis;  
         [0031]    [0031]FIG. 8 a  is a section view of a third mounting point and a flexible coupling in accordance with the present invention, taken along section  8   a - 8   a  shown in FIG. 8;  
         [0032]    [0032]FIG. 9 is a side elevation view of the cooling system module of FIG. 1 mounted within the vehicle frame; and  
         [0033]    [0033]FIG. 10 is a top plan view of the cooling system module of FIG. 1 mounted within the vehicle frame. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0034]    [0034]FIG. 1 shows a perspective view of a preferred embodiment of an exemplary cooling system module  1  in accordance with the present invention. The embodiment shown is intended for use in motor vehicles such as buses and includes a number of cooling system components, including: radiator  3 , fluid conduits  5 , fan  7 , fan shroud  9 , transmission oil cooler  11 , fan drive shaft  13 , gear box  15 , clutch  17 , drive pulley  19 , and expansion tank  21 . In this embodiment, cooling system frame  25  includes top frame member  27 , bottom frame member  29 , first end frame member  31 , and second end frame member  33  (FIG. 2).  
         [0035]    Cooling system frame  25  is supported by first mounting point  35 , second mounting point  37 , and third mounting point  39 . First mounting point  35  is secured to first side  91 of frame  25  by first mounting bracket  41 , and second mounting point  37  is secured to first side  91  of frame  25  by second mounting bracket  43 . First and second mounting brackets  41  and  43  are connected one to the other by bracket support element  45 . First mounting bracket  41  and second mounting bracket  43  are positioned such that first mounting point  35  and second mounting point  37  are coaxially aligned along axis  500  (FIGS. 4 and 6).  
         [0036]    The structure of first mounting point  35  is shown in FIGURE 1 a . Second mounting point  37  is identical to first mounting point  35  and therefore it will be understood that the description with respect to first mounting point  35  also applies to second mounting point  37 . First mounting point  35  includes outer bushing  47  secured by welding to first mounting bracket  41 . Flexible inner bushing  49  is press-fit into outer bushing  47 , and bolt  53  holds first mounting point  35  to vehicle chassis  95  (FIG. 8 and FIG. 10) through chassis mount  51   a . Preferred flexible inner bushing  49  is shown having three concentric members. In the preferred embodiment shown, flexible inner bushing  49  is a center bonded bushing with inner and outer concentric steel members  49   c  and  49   a  respectively, sandwiched around an elastomeric (such as rubber) member  49   b . The structure of flexible inner bushings  149  and  249  is identical to that of flexible inner bushings  49 .  
         [0037]    [0037]FIG. 1 b  is a perspective view of chassis mount  51   a . First, second, and third mounting points  35 ,  37 , and  39  respectively, are all connected to vehicle chassis  95  through chassis mounts  51   a - c . In the embodiment shown in the figures, first and second mounting points  35  and  37  are mounted in similar fashion to chassis mounts  51   a ,  51   b  while third mounting point  39  is connected to vehicle chassis  95  through connecting rod  75 , described below with respect to FIG. 8.  
         [0038]    Third mounting point  39  is shown in FIGS. 2, 3,  5 ,  6 ,  7 ,  8 ,  8   a ,  9 , and  10 . Third mounting point  39  is secured to second side  93  of frame  25  through a mounting point bracket  52  similar to chassis mounts  51   a - c.  Third mounting point  39  is shown additionally in FIG. 3 and FIGS. 5 through 10. FIG. 8 shows connecting rod  75  connecting third mounting point  39  to vehicle chassis  95 .  
         [0039]    [0039]FIG. 8 a  is a sectional detail of third mounting point  39  with flexible coupling  65 , showing first rod end  74  secured to mounting point bracket  52  through outer bushing  139 . Flexible inner bushing  249  is press-fit into rod outer bushing  139 , and bolt  53  secures the outer and inner bushings  139  and  249  to bracket  52 . The second rod end  76  (FIG. 8) is identical to first rod end  74  and is connected to chassis mount  51   c  in an identical manner to that shown in FIG. 8 a  for first rod end  74 .  
         [0040]    As shown in FIG. 8, axis  506  of connecting rod  75  is perpendicular to common axis  504  of third mounting point  39 , rod outer bushing  139  and flexible inner bushing  249 , shown in FIG. 8 a . In identical fashion, at second rod end  76 , the rod outer bushing (not shown) and its corresponding flexible inner bushing have an axis (not shown) parallel to axis  504 . Axis  504  and the corresponding axis at second rod end  76  are perpendicular to the plane of the page on which FIG. 8 is shown and axis  506  is in the plane of this same page.  
         [0041]    In operation, module  1  is positioned as a single unit within vehicle chassis  95 . Preferably, first and second flexible couplings  61 ,  63  are aligned with respective chassis mounts  51   a ,  51   b  and are connected to the chassis mounts  51   a ,  51   b  with bolts  53  inserted through the respective mount and inner bushings  49 ,  149 . Third mounting point  39  is secured to flexible coupling  65  at first rod end  74  by bolt  53  inserted through mounting point bracket  52  and inner bushing  249 . Second rod end  76  is secured to chassis mount  51   c  by a bolt  53  inserted through mount  51   c  and flexible coupling (identical to coupling  65 ) at second rod end  76 . All necessary interconnections between the components comprising the module  1  and the vehicle are then made. For example, the fluid conduits  5  carrying engine coolant between the engine and the radiator  3  are connected.  
         [0042]    In a similar fashion to installation, when maintenance is required, the cooling system module can be easily removed from the vehicle chassis  95 .  
         [0043]    As the vehicle is operated, the vehicle chassis  95  is subject to stress and displacement caused by movement and vibration of the vehicle. The three point mounting system enables module  1  to move because each mounting point has a rotational axis about which the respective flexible coupling  61 ,  63  and  65  is allowed to rotate and because the flexible couplings deform in response to both torsional and translational forces. As a result, the elements of the cooling system are subjected to only minimal stresses and displacements from the chassis, thereby extending the service life of the cooling system components.  
         [0044]    While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention.