Abstract:
A mounting means for an automotive condenser ( 16 ) includes a pair of aligned through holes ( 24 ) at the upper ends of a pair of manifolds ( 20 ), which are pierced outboard of upper end plugs ( 22 ). The lower ends of the manifolds ( 20 ) are unmodified. The tanks ( 14 ) of a radiator ( 10 ) include a pair of mounting features ( 30, 32 ) spaced apart by substantially the end to end length of the manifolds ( 20 ). One pair of mounting features ( 30 ) fits closely within the lower ends of the manifolds ( 20 ), while the other pair ( 32 ) fits closely within the aligned through holes ( 24 ) at the upper ends.

Description:
TECHNICAL FIELD 
     This invention relates to heat exchangers in general, and specifically to an improved means for mounting a vehicle air conditioning system condenser. 
     BACKGROUND OF THE INVENTION 
     Vehicle air conditioning system condensers are mounted in front of the engine cooling radiator and just behind the vehicle body grill. Typically, the radiator is mounted directly to the vehicle body, and the smaller, lighter condenser is mounted to the front of the radiator. The molded plastic radiator tanks are a convenient location in which to integrally mold part of a condenser mounting system, such a hooks or pockets to hold separate fasteners. The other part of the condenser mounting has generally comprised brackets of various sorts, either integrally extruded with the tank, or separate. The mounting brackets may fit down into hooks molded into the tanks, or be attached with threaded fasteners to fasteners held in pockets molded into the tank, or a combination of the two. Typical examples of such mounting schemes may be seen in U.S. Pat. No. 5,219,016 and U.S. Pat. No. 5,139,080. While these provide solid, secure mountings, the brackets represent an additional expense and material, whether integrally extruded or separate. 
     With newer condenser manifold designs, which are basically small diameter cylinders of one or two piece construction, it is more difficult to integrally extrude or separately attach mounting brackets, than with the larger, flat sided manifolds. Mounting mechanisms have been proposed that are better suited to such smaller, cylindrical shapes. An example can be seen in U.S. Pat. No. 5,355,941, where a purpose built lower plug is stamped with an integral depending flange that fits into its own resilient mounting pad. Another example may be seen in U.S. Pat. No. 5,829,133, in which the lower plug is eliminated in favor of an integrally formed lower pin, which, in turn, can fit into its own resilient mounting pad. These two designs are best suited for mounting the condenser independent from the radiator, rather than to the front of the radiator tanks. They also require some deviation from the standard cylindrical manifold design, which is basically a simple tube plugged at each end with a recessed end plug. 
     SUMMARY OF THE INVENTION 
     The subject invention provides a means for mounting a condenser to a radiator which involves essentially no deviation from the standard condenser manifold design, and which incorporates mounting provisions on the radiator tanks that are as easy to provide as current designs. 
     In a preferred embodiment disclosed, a condenser has tubular manifolds closed at each end by recessed end plugs, leaving a short length of manifold wall at each end, outboard of the plug, which is empty and unencumbered with any other structure. At one end of each of the manifolds, a through hole is drilled or punched through the unencumbered length of manifold wall. 
     On the radiator tanks, two opposed mounting features are provided, separated by the basic length of the condenser manifolds. At one end, a short platform stands out from the tank wall, and includes a boss that fits closely within the unencumbered length of manifold wall at one end of the condenser manifold. At the other end, a mounting peg stands out from the radiator tank, long enough to fit through the through hole with a short length protruding. The condenser is mounted by setting one end of each condenser manifold onto the platform protrusions, and then swinging the other ends inward to bring the mounting peg through the through holes. Then, a suitable fastener is placed over the peg. Both ends of the condenser manifolds are thereby held securely to the radiator tanks. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features of the drawings will appear from the following written description, and from the drawings, in which: 
     FIG. 1 is a perspective view of a radiator and condenser according to the subject invention, disassembled; 
     FIG. 2 is a perspective view of one end of a condenser manifold; 
     FIG. 3 is a perspective view of the other end of a condenser manifold; 
     FIG. 4 is a perspective view of one end of a radiator tank, showing a mounting platform and protrusion; 
     FIG. 5 is a perspective view of the other end of a radiator tank, showing a mounting peg and fastener disassembled; 
     FIG. 6 is a side view showing a condenser in the process of being mounted; 
     FIG. 7 is an enlarged, partially broken away view of the lower end of a radiator tank and condenser manifold assembled. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring first to FIG. 1, a radiator, indicated generally at  10 , comprises a central tube and fin core  12  bounded by opposed, molded plastic tanks  14 . Being molded plastic, the tanks  14  are good candidates for the integral molding of additional structural features, especially features related to the physical mounting of the radiator  10  itself, or additional components. Typically, the radiator  10  is securely fixed between upper and lower cross rails of a vehicle body, not illustrated, and can provide a good, solid foundation for the installation of other components. A conventional fan shroud and fan can be fixed to the back of the radiator tanks  14 , pulling outside air through the vehicle grill and through the radiator  10 . Fixed to the front of the radiator tanks  14  is a condenser  16 , which has a basic configuration similar to the radiator  10 . That is, a similar sized central tube and fin core  18  is bounded by a pair of manifolds  20 . Once condenser  16  is mounted to the front of the radiator tanks  14 , air is drawn first through the condenser core  18  before reaching the radiator core  12 , which runs at a higher temperature. Being higher pressure, however, the manifolds  20  are manufactured of metal, typically aluminum tanks, and it is not a simple matter to provide integral mounting provisions, as it is with molded plastic. More detail on both the radiator tanks  14  and condenser manifolds  20  is given below. 
     Referring next to FIGS. 2 and 3, each manifold  20  is basically tubular, consisting of an outer wall closed at each end by a recessed end plug  22 . The end to end or axial length of each manifold ( 20 ) is predetermined the heat exchanger area needed, and each manifold&#39;s end width (or diameter in the cylindrical case) is predetermined by the depth of the core  18 . The tube may actually be comprised of two pieces brazed together, or of a single tube, and the shape, in cross section, need not be perfectly round, even though that comprises the most efficient pressure vessel. In any case, the end plug  22  is typically recessed far enough to leave at least a short length of manifold wall unencumbered, and it may easily be recessed farther to leave an even deeper empty end volume, if desired, with no change in basic tooling or construction. This otherwise unused, empty end volume is put to good use in the scheme of the invention, with minimal change to the basic construction. At one end, preferably the upper end, of each manifold  20 , the outer wall is pierced by an aligned pair of through holes  24 , aligned generally perpendicular to the length axis of the manifold ( 20 ). The through holes  24 , being outboard of the plug  22 , do nothing to disturb the function of the manifold  20 , and have a diameter (or width) sufficiently less than the end width of the manifolds ( 20 ) so as not to overly weaken the wall of the manifold ( 20 ). The empty end of each manifold ( 20 ) is basically a residue of the construction technique, which is otherwise unutilized. 
     Referring next to FIGS. 4 and 5, the mounting features integrally molded to the radiator tanks  14  are described in detail. At one end of each tank  14 , preferably the lower end, a platform  26  stands out from the outer tank surface, at least somewhat farther than the predetermined end width of the manifold ( 20 ). The platform  26  is strengthened by a side wall  28 . Molded to the platform  26  is an upstanding protrusion  30 , preferably in a form which, which, like the truncated triangle or pyramid shown, is narrower at its top than the inside wall diameter or width of the empty end portion of manifold  20 , and slightly wider than that at its base. Above the platform  26 , a cylindrical mounting peg  32  stands out substantially perpendicular to the outer surface of tank  14 , separated from platform  26  by a distance generally equal to the end to end length of manifold  20 . Specifically, mounting peg  32  is spaced from platform  26  by a distance just sufficient to allow peg  32  to pass through the aligned manifold through holes  24  when the opposite end of manifold  20  is resting on platform  26 . In addition, peg  32  is substantially equal in diameter (or width) to the diameter (or width) of the through holes  24 , allowing for a close fit. Peg  32  is also sufficiently longer than the diameter (or width) of the manifold  20  to allow a fastener  34  to be pushed over it after it has passed through the through holes  24 . The integral molding of these mounting features to the plastic tanks  14  would actually be simpler than conventional hooks or fastener pockets, since they have simpler and less convoluted shapes. The relative dimensions and orientations of the radiator tank mounting features just described allow condenser  16  to be mounted as described next. 
     Referring next to FIGS. 6 and 7, condenser  16  is mounted by holding it an orientation where its upper ends are tilted away from the plane of radiator  10  and then setting the empty bottom ends of the manifolds  20  over the protrusions  30 , pushing down firmly enough to wedge the protrusions  30  in place. The relative dimensions noted above create a snug, rattle free insertion, and the plug  22  sits inboard of the lower edge of manifold  20  far enough to provide ample room for the protrusion  30  to fit. Then, the upper ends of the manifolds  20  are swung inwardly toward the radiator tanks  14  until the mounting pegs  32  pass through the through holes  24 . Again, the relative dimensions noted above create a snug fit. Finally, the fasteners  34  are pushed (or threaded, or otherwise fixed) over the pegs  32  and pushed firmly into place to retain the upper ends of the manifolds  20  closely against the outer wall surfaces of the radiator tanks  14 . If desired, a resilient washer could be placed over the pegs  32  before attachment, to cushion the engagement. The end result is a secure, rattle free mounting of the condenser  16 , with a very simple motion, and very few fastening components, beyond the basic tanks  14  and manifolds  20  themselves. No significant modification to the manifolds  20  themselves is needed, such as brackets or extended end plugs. The space outboard of the end plugs  22  is, as noted above, available and empty, as a result of the basic manifold construction used. Only the simple through holes  24  need be added, outboard of one of the end plugs  22 . 
     Variations in the disclosed embodiment could be made. “Radiator” should be broadly construed to include not just plastic tanks, but equivalent structures such as a front end module to which, conceivably, both a radiator and condenser could be mounted. The pegs  32  and platforms  26  could be reversed, or, theoretically, the entire system could be turned ninety degrees, with one tank  14  having both platforms  26 , and the other having both pegs  32 . Other shapes could be given to the protrusion  30 , so long as it fit snugly within the manifold  20 &#39;s empty end, and the through holes  24  and pegs  32  could have a different, but still closely matching, shape. Conceivably, the pegs  32  could be made to snap fit through the holes  24 , and thereby retain the condenser  16  without a separate fastener. The manifolds could have a shape other than cylindrical, but the system disclosed is particularly useful in that context, since it is more difficult to attach separate mounting brackets to a cylindrical shape. Therefore, it will be understood that it is not intended to limit the invention to just the embodiment disclosed.