Patent Abstract:
A radiator assembly having a support bar, mounting pegs, and a radiator. The support bar has a center portion and respective end portions welded to the center portion. The end portions have respective flared ends that mate with the center portion and a pair of support mounts. The mounting pegs mate have a flexible portion that mates with the support mounts and a comolded fastener that mates with the radiator.

Full Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 62/250,251 which was filed on Nov. 3, 2015. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to vehicles. More particularly, it relates to a support bar for heat exchangers including oil coolers and radiators. 
       BACKGROUND OF THE INVENTION 
       [0003]    In many front part body structures of vehicles, an engine compartment is generally provided in front of a cabin. A front part of the vehicle shown in  FIG. 1  contains the engine compartment and is provided with front side members  2 ,  4  positioned at right and left sides in a lateral direction of the vehicle, a plurality of cross members  6 ,  8  that bridge the side members, suspension support elements  12 ,  14  attached to the front side members, and upper frame members  16 ,  18  fixed at one end at the cabin side, the other ends of the upper frame members are fixed to respective front pillars members  20 ,  22 . Front suspension elements are respectively fixed to the right and left suspension support elements. The upper frame members  16 ,  18  positioned at the right and left sides in the lateral direction of the vehicle are extended in a longitudinal direction of the vehicle and formed a closed sectional structure. The upper frame members  16 ,  18  are joined opposite cabin side by upper cross member  10 . Respective outer body panels are mounted to the various members. The respective members are joined by bolts or welds, typically arc welds. 
         [0004]    A radiator  100  for an automotive engine cooling system is affixed to the front pillar members  20 ,  22 , cross member  6  and the upper member  10 . The radiator  100  typically includes a top tank, bottom tank, and a core. Alternatively, the radiator can be constructed with left and right tanks for cross-flow. Resilient mounts may be used because the radiator may be subject to vibrations, high forces, and shocks during normal use due to jolts, accelerations, or decelerations of the vehicle as it is driven over rugged terrain. Although the frame formed by the various members is advantageous in that rigidity can be obtained, the upper frame bears a load from the front suspension of the vehicle. This load is transferred to the radiator  100 . This load, which may be transferred as torque, can damage the radiator  100 . 
       SUMMARY OF THE INVENTION 
       [0005]    A radiator mounting arrangement on a vehicle includes a frame member having a center assembly, left and right end caps, and radiator mounting brackets. The radiator has respective mounts that mate with the mounting brackets. The radiator mounting arrangement is inexpensive, requires few parts and is fast and easy to assemble and does not transfer damaging forces to the radiator. 
         [0006]    A radiator assembly comprises a radiator and a support bar. The support bar is configured to be attached to a vehicle by respective end caps and brackets. The support bar, end caps, and brackets are produced from die cast steel components, steel plate, and steel tubing. Each of the pieces is about 0.05-2 inches (1.7-5 mm) thick. The entire support bar, end caps and brackets are fully welded to minimize flex and torque transfer from the vehicle to the radiator. The radiator is mounted to the support bar using pegs. The pegs have a threaded bolt portion that is co-molded with a flexible material such as rubber, or the like. The peg threads into the radiator and is secured to the support bar by a retaining clamp. The support pegs further minimize flex and torque transfer from the vehicle to the radiator. 
         [0007]    The radiator assembly comprises a support bar comprising, a center portion and respective end portions welded to the center portion, wherein the end portions having respective flared ends that mate with the center portion; and a pair of support mounts; at least two pegs con figured to mate with the support mounts, the pegs having a rubber portion that mates with the support mounts and a comolded bolt; and a radiator having receiving mounts configured to receive the comolded bolt of the peg. 
         [0008]    According to one embodiment, the center portion is a rectangular tube. 
         [0009]    According to one embodiment, the rectangular tube is substantially 0.07 inches (2 mm) thick. 
         [0010]    According to one embodiment, the respective end portions are cast steel. 
         [0011]    According to one embodiment, the respective end portions mate with the center portion with about 0.03 inches (1 mm) of clearance. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a perspective view of a front part of the vehicle containing; 
           [0013]      FIG. 2  is a perspective view of a radiator support bar; 
           [0014]      FIG. 3  is a front view of the radiator support bar; 
           [0015]      FIG. 4  is a top view of the radiator support bar; 
           [0016]      FIG. 5  is a perspective view of a center assembly of the radiator support bar; 
           [0017]      FIG. 6  is a front view of a center assembly of the radiator support bar; 
           [0018]      FIG. 7  is an end view of a center assembly of the radiator support bar; 
           [0019]      FIG. 8  is a blank for a notch in the center assembly of the radiator support bar; 
           [0020]      FIG. 9  is a perspective view of the formed notch in the center assembly of the radiator support bar; 
           [0021]      FIG. 10  is a tab for the center assembly of the radiator support bar; 
           [0022]      FIG. 11  is a left end cap for the radiator support bar; 
           [0023]      FIG. 12  is a right end cap for the radiator support bar; 
           [0024]      FIG. 13  is a bracket for the radiator; 
           [0025]      FIG. 14  is the radiator mounted to a support bar; 
           [0026]      FIG. 15  is the radiator and mounting peg; 
           [0027]      FIG. 16  is the mounting peg attached to the radiator 
           [0028]      FIG. 17  is the mounting peg; and 
           [0029]      FIG. 18  is a cross section of the mounting peg; and 
           [0030]      FIG. 19  is a cross section of the mounting peg. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0031]      FIG. 2  is a perspective view of a radiator support bar. The radiator support bar comprises a center assembly  200 , a left end cap  300 , and a right end cap  400 . The left end cap  300  and right end cap  400  are attached to the center assembly  200  by welding, bolts, or the like. Also shown in  FIG. 2  brackets  250  and  255  are affixed to the left end cap  300  and the right end cap  400 . Given a specific application for the support bar, notches  500 ,  600  may be present that accommodate hood latches, cables, and the like. 
         [0032]    In one embodiment, the support bar has an anti-corrosive finish, is powder coated, plated, or the like. Alternatively, the support bar is painted. The threads of nuts  202  are preferably protected during any finishing process. By protecting the threads, the threads are able to receive a bolt. 
         [0033]      FIG. 3  is a front view of the radiator support bar and  FIG. 4  is a top view of the radiator support bar. In the front view of the support bar, mounting tabs  270 ,  275  are shown. Mounting tabs  270 ,  275  are welded to center assembly  200 . The left end cap  300  includes mounting ear  302  that extends substantially longitudinally with respect to the center assembly  200 . Another mounting ear  304  extends substantially perpendicular with respect to center assembly  200 . The right end cap  400  includes mounting ear  402  that extends substantially longitudinally with respect to the center assembly  200 . Another mounting ear  404  extends substantially perpendicular with respect to center assembly  200 . 
         [0034]      FIG. 5  is a perspective view of a center assembly of the center assembly  200 . As shown, there is a weld fillet  550  for the weld that attaches the notch  500  to the center assembly  200 . A weld fillet  650  attaches the notch  600  to the center assembly  200 . A weld fillet  273  attaches the mounting tab  270  to the center assembly  200 . A weld fillet  277  attaches the mounting tab  275  to the center assembly  200 . A weld fillet  212  attaches the nut  202  to the center assembly  200 . In one embodiment, the welds are ground smooth as part of the assembly process. 
         [0035]      FIG. 6  is a front view of the center assembly  200  of the radiator support bar.  FIG. 6  shows the center assembly  200  with dimension lines for a specific application. As one skilled in the art would readily appreciate, these dimensions can be adjusted for specific vehicles as required. The placement of the nuts  202  and notches can be adjusted as required for different applications. Further, the mounting tabs  270 ,  275  can be adjusted as required. 
         [0036]      FIG. 7  is an end view of the center assembly  200  of the radiator support bar. As shown, the nuts  202  are welded by weld  212  to the center assembly  200 . The nuts  202  are arranged inside the rectangular tube that forms the center assembly  200 . In one embodiment, the nuts  202  are self-clinching fasteners. The self-clinching fasteners install permanently in metal sheets by pressing them into properly sized holes. This forces displaced sheet material to cold flow into an annular recess in the shank or pilot of the fastener, locking it in place. A serrated clinching ring, knurl, ribs, or hex head prevents the fastener from rotating in the metal when technicians apply tightening torque to the mating hardware. The fasteners can be installed during fabrication or final assembly. 
         [0037]      FIGS. 8 and 9  are an example of the notch  500 .  FIG. 8  is a blank used to form the notch  500 . Edge portions  504 ,  406 , and  508  are folded at substantially 90 degrees on fold lines  502 . As shown in  FIG. 9 , the seam  515  at which edge portions  504  and  506  meet is welded and the seam  515  at which edge portions  506  and  508  meet is welded. This assembly is then welded into the center assembly  200 . In another embodiment, the blank has tabs that can be attached to the center assembly  200  by screws, nuts and bolts, and the like. 
         [0038]      FIG. 10  is an example of mounting tabs  270  and  275 . The tabs are typically made from 0.1 inches (3 mm) thick mild steel plate. The tabs are dimensioned as required for mounting in a given application. The mounting tabs  270  and  275  are dimensioned as required for various mounting configurations. 
         [0039]      FIG. 11  is an example of the left end cap  300  for the radiator support bar. The left end cap  300  is cast mild steel. After casting, the part is finished by sandblasting. The left end cap  300  has a mating portion  306  that mates with the center assembly  200 . The mating portion  306  is configured to mate with the center assembly  200  so that it can be welded. The mounting ears  302 ,  304  are configured to mount with the frame members that form the engine cabin of the vehicle. 
         [0040]      FIG. 12  is an example of the right end cap  400  for the radiator support bar. The right end cap  400  is cast mild steel. After casting, the second part is finished by sandblasting. The right end cap  400  has a mating portion  406  that mates with the center assembly  200 . The mating portion  406  is configured to mate with the center assembly  200  so that it can be welded. The mounting ears  402 ,  404  are configured to mount with the frame members that form the engine cabin of the vehicle. 
         [0041]      FIG. 13  is an example of the brackets  250 ,  255 . Typically, the brackets  250 ,  255  are made from flat mild steel plate. The piece of steel is appropriately punched and folded at fold lines  251 . Nuts  202  are welded into the brackets  250 ,  255 . Alternatively, self-clinching fasteners are used. The brackets  250 ,  255  have a mounting face  252  that is configured to mate with the left end cap  300 , right end cap  400 , or center assembly  200 . 
         [0042]      FIG. 14  is a view of the radiator  100  and support bar from the engine compartment. The radiator  100  is mounted to the support bar via mounting pegs  700 . The mounting peg  700  is held in bracket  250  by strap  290 . The mounting peg  700  is screwed into the radiator and retained in the bracket  250 . The assembly prevents torque from being transmitted through the vehicle to the radiator  100 . 
         [0043]      FIG. 15  is a view of the radiator  100  and the mounting peg  700  prior to the mounting peg  700  being installed on the radiator  100 . The radiator  100  has a threaded mount  110  configured to accept the mounting peg  700 . Alternatively, the mounting peg  700  is welded to the mount  110  or attached in another suitable manner. The mounting peg  700  has a threaded portion  710  that mates with the threaded portion of the threaded mount  110 . 
         [0044]      FIG. 16  is the mounting peg  700  attached to the radiator  100 . The mounting peg  700  is a comolded metal bolt  710  and rubber portion. Typically, the mounting peg  700  is approximately 3 inches (45 mm). The bolt has a head and a threaded portion. The threaded portion is about 0.4 inches (10 mm) long. Alternatively, the threaded portion does not have a bolt head. 
         [0045]      FIG. 17  is the mounting peg  700 . The mounting peg  700  is a comolded metal bolt  710  and rubber portion. The mounting peg  700  is a flexible material, typically a rubber material. In one embodiment, the durometer of the rubber is 80 Shore A. The mounting peg  700  is generally circular and has a diameter of about 1.12 inches (28.5 mm). In one embodiment, the metal bolt  710  is an M8×1.25 bolt. In one embodiment, the metal bolt is grade 10.9 zinc coated steel. It should be noted that other material, finishes, and threads can be used, depending on the application. In one embodiment, in place of the threaded bolt, the mounting peg  700  has a comolded nut and a corresponding bolt is affixed to the radiator. 
         [0046]      FIG. 18  is a cross section of the mounting peg  700 . The head  715  of the comolded metal bolt  710  is shown as being about 0.2 inches (5 mm). It should be noted that the steel insert which comprises the metal bolt  715  and head  715  can have any shape that provides adequate strength. In one embodiment, the head  715  has a diameter of about 0.8 inches (20 mm). 
         [0047]      FIG. 19  is a cross section of the mounting peg  700 . The mounting peg has a nut  725  that mates with a bolt on the radiator. A clearance  730  is formed in the peg to receive the bolt on the radiator. In one embodiment, the clearance  730  is substantially the same diameter as the bolt on the radiator. 
         [0048]    Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.

Technology Classification (CPC): 1