Patent Description:
The front end structure of a vehicle typically includes a cooling module with a radiator, positioned behind the front end of the vehicle. The front end usually has a bumper positioned at the very front, with crash-boxes just behind the bumper on each of the sides of the vehicle.

In a frontal impact crash, the front end of the vehicle can be damaged, pushing the bumper and other front parts into the parts behind. This can result in damage to the cooling module and fan, even in very low speed crashes. Such damage to the cooling module can require costly repairs and a tow, since a vehicle with a damaged cooling module and fan can no longer be driven.

A bracket for a cooling module in a front end structure of a vehicle is known from <CIT>.

According to a first aspect of the invention, a bracket for a cooling module in a front end structure of a vehicle comprises forward crash-box connection means; cooling module connection means; a rigid arm extending between the forward crash-box connection means at a forward side and the cooling module connection means at a rearward side; rear crash-box connection means; and a break-away arm extending from the rearward side of the rigid arm to the rear crash-box connection means. Such a bracket can help to minimize or prevent damage to a cooling module in an engine in the event of a front end collision. The bracket allows for the cooling module to move rearward in the event of such a collision with the break-away arm breaking away and moving the cooling module with any movement of the front end of the vehicle. This allows for less-expensive repairs, and often the ability to still drive the vehicle after such a collision.

According to an embodiment, the forward crash-box connection means and/or the rear crash-box connection means comprises a plurality of connectors. Optionally, these can be bores, bolts, screws and/or other types of fasteners to securely connect the parts. Further optionally, these can be two vertically spaced crash-box connection means for each of the forward crash-box connection means and the rear crash-box connection means. Such connection means can provide a strong and stable connection, even when experiences large forces such as in a collision.

According to an embodiment, the cooling module connection means comprises a screw connection to a cooler side bushing. Such a connection means can provide a secure and simple means of connecting the bracket to the cooling module (or an in-between part).

According to an embodiment, the break-away arm extends substantially vertically from the cooling module connection means. This configuration can provide a bracket that is both simple to manufacture and connect while strong enough to withstand normal operational forces but break upon a frontal collision.

According to an embodiment, the angle between the break-away arm and the rigid arm is less than <NUM> degrees. This configuration can help to ensure proper strength levels for the bracket, as well and ensure the bracket remains sufficiently compact to take up less space in the vehicle and be usable with a variety of different vehicles.

According to an embodiment, the rigid arm comprises an arm which expands in height from the rearward side to the forward side. This could also be seen an a taper from the forward side. In some embodiments, there could be more than one taper angle, a first at the forward side, and a second taper angle at the rearward side. This configuration helps the rigid arm have sufficient strength and rigidity to ensure that the cooling module is moved rearward with any movement of the frontal end of the vehicle.

According to an embodiment, the rigid arm comprises cut-out sections and/or sections of reduced material. Such a configuration saves on weight of the bracket and materials costs when manufacturing while still maintaining the necessary strength and rigidity.

According to an embodiment, the bracket further comprises a protrusion on one side of the bracket. The protrusion can be formed and located such that the bracket would only connect on a proper side of the cooling module, reducing the risk that the bracket could be connected on the wrong side and possibly not function as intended.

According to an embodiment, the bracket is formed of metal. Optionally, this can be aluminium (including alloys) or another type of metal or other material with sufficient strength and rigidity. Further optionally, the bracket could be formed by die casting.

According to a further aspect of the invention, a cooling module includes a first bracket as previously described connected to a first cooling module bushing on a first side of the cooling module, and a second bracket as previously described connected to a second cooling module bushing on a second side of the cooling module; wherein for each of the first and second brackets, the cooling module connection means connects to the cooling module bushing with a screw or bolt connection.

According to an aspect of the invention, a frontal vehicle structure includes a cooling module and first and second brackets as previously described, and further comprises a first crash-box on the first side and a second crash-box on the second side. For each of the first and second brackets, the forward crash-box connection means and the rearward crash-box connection means connects to forward and rearward positions of the crash-box, respectively.

Such a cooling module (and frontal vehicle structure) with first and second brackets connected on either side provides a simple, yet strong and durable side connection for the cooling module in normal vehicle operation, and allows for rearward movement of the cooling module in a low-speed frontal impact crash to reduce or eliminate damage to the cooling module in such a collision.

According to an embodiment, each of the first and second brackets are dimensioned such that the break-away arms break in one or more pieces at a frontal impact crash, and the rigid arms maintain their rigidity to move the cooling module rearward upon rearward movement of the crash-box and forward crash-box connection means. This can be provided by the materials and/or configuration of each of the rigid arms and break-away arms. This can ensure that the vehicle performs as intended, such that the break-away arms break upon a frontal impact collision, and the cooling module is able to be moved rearward to reduce or prevent damage to the cooling module, thereby minimizing overall damage and repair costs.

According to a further aspect of the invention, a method of protecting a cooling module in a frontal impact crash using first and second side brackets is provided. Each bracket comprises forward crash-box connection means, cooling module connection means; a rigid arm extending between the cooling module connection means at a rearward side and forward crash-box connection means at a forward side, rear crash-box connection means, and a break-away arm extending from the rearward side of the rigid arm to the rear crash-box connection means. The method comprises a) connecting the cooling module connection means of the first bracket to a first side bushing of the cooling module; b) connecting the forward crash-box connection means of the first bracket to a first side crash-box; c) connecting the rear crash-box connection means of the first bracket to the first side crash-box at a rearward position from the forward crash-box connection means; d) connecting the cooling module connection means of the second bracket to a second side bushing of the cooling module; e) connecting the forward crash-box connection means of the second bracket to a second side crash-box; and f) connecting the rear crash-box connection means of the second bracket to the second side crash-box at a rearward position from the forward crash-box connection means. Optionally, the connections are with one or more bolts and/or screws.

Such a method provides an efficient and secure way of connecting a cooling module to a frontal structure of a vehicle in such a way that the cooling module can move rearward with the frontal end structure in the event of a frontal impact collision. This can reduce and/or prevent damage to the cooling module, and reduce the costs of repair overall.

The bracket is a very versatile bracket, able to be used with a number of different vehicles due to its size and configuration. In some embodiments, the size would vary, but the general configuration is the same as that described and shown in the drawings. This can lead to less costly production (e.g., common tooling), less complex storage, logistics and assembly, as well as an overall less costly product.

<FIG> is a rear perspective view of a cooling module bracket <NUM> connecting a cooling module <NUM> to a side crash-box <NUM>, <FIG> is a side view of the bracket <NUM> and front vehicle structure, with the crash-box transparent for viewing purposes, <FIG> is a side view of the bracket <NUM> and front vehicle structure at the start of a front impact crash, and <FIG> is a side view of the bracket <NUM> and front vehicle structure after the front impact crash.

Cooling module <NUM> includes fan <NUM>, radiator <NUM> and cooling bushings <NUM>. Cooling module <NUM> typically extends along the width of the front end of the vehicle between crash-boxes <NUM> on a first side and a second side (not shown), with a bumper <NUM> or other front structure (see <FIG>) extending in front of the cooling module <NUM>.

Each side of cooling module <NUM> connects to a side crash-box <NUM> via bracket <NUM>. While only one side of the vehicle frontal structure is shown in <FIG>, the other side connection of the cooling module <NUM> to side crash-box <NUM> would be a mirror image of the one shown, also connecting by a bracket <NUM>. Brackets <NUM> would be mirror images of each other on each of the first and second sides, with protrusion <NUM> ensuring that bracket <NUM> is connected on the correct side. Protrusion <NUM> would extend outward, not allowing rear crash-box connection means <NUM> to bolt into crash-box <NUM> if someone attempted to use the bracket shown in <FIG> on the opposite side of the cooling module <NUM>. While protrusion <NUM> is shown as the feature to ensure proper side connection, other embodiments could vary the size, shape, etc. so long as the features function to ensure that the specific bracket <NUM> only connects on the intended side.

Bracket <NUM> includes forward crash-box connection means <NUM>, cooling module connection means <NUM>, rigid arm <NUM> with frontal side <NUM> and rearward side <NUM>, rear crash-box connection means <NUM>, break-away arm <NUM>, and protrusion <NUM>. Forward crash-box connection means <NUM> is shown as two bores in bracket <NUM> for receiving two bolts 17a, 17b spaced vertically from each other along the frontal side of the rigid arm <NUM> and connecting to the crash-box <NUM>. Rear crashbox connection means <NUM> are also shown as two vertically spaced bores in bracket <NUM> for receiving bolts connecting to the crash-box <NUM> at a rearward position from the connection location of forward crash-box connection means <NUM>. While two bores and bolts are shown, there can be more or fewer connectors, different types of connectors and/or could be arranged differently for connecting the bracket to the crash-box at the forward connection means and/or the rearward connection means.

In use, brackets <NUM> connect cooling module <NUM> to the crash-box on a first side and second side of the vehicle (right side and left side when looking at the vehicle from a front). A screw <NUM> extends in a vertical direction through a bore in bracket <NUM> (which could be threaded), connecting a rearward side <NUM> of rigid arm <NUM> with a cooling bushing <NUM> at the side of the cooling module <NUM>. The cooling bushing <NUM> can be integrally formed with parts of the cooling module <NUM>, or can be formed separately and securely connected at a side. The other connection means <NUM>, <NUM> of bracket <NUM> connect to the crash-box <NUM>. Thus, in normal operations, brackets <NUM> (one on each side) secure cooling module <NUM> within the vehicle.

In the case of a low-speed front end collision, the front of the vehicle is typically damaged and the bumper <NUM>, and other front parts of the vehicle are moved rearward from the frontal impact force. In past systems, this typically pushed the front end of the vehicle into the cooling module <NUM>, often damaging the cooling module <NUM>, even in low speed collisions. A damaged cooling module <NUM> is often expensive to repair, and the vehicle is usually not driveable until the repair has been done.

Brackets <NUM>, with rigid forwardly-extending arm <NUM> and break-away arm <NUM>, help to promote distance being maintained between the front end of the vehicle and the cooling module <NUM> in a low-speed frontal impact crash by moving the cooling module <NUM> rearward with any movement of the front end of the vehicle. Brackets <NUM> extend forward of the cooling module <NUM> for their forward crash-box connection means <NUM> to connect to the crash-box <NUM> on either side of the cooling module <NUM>. This can be about <NUM>-<NUM> forward from the connection point, though can vary in different applications, for example, <NUM> - <NUM>. The extension forward makes it possible to sense the forward collision at an early moment.

As shown in <FIG>, upon initiation of a low-speed frontal impact, the front portion of the vehicle, including the portion to which forward crash-box connection means <NUM> connects, moves rearward. Rigid arm <NUM> then translates this to move the entire cooling module <NUM> rearward through cooling module connection means <NUM>. Break-away arm <NUM> breaks upon the impact force, allowing for the rearward movement of the rigid arm <NUM> and cooling module <NUM> in the case of a crash. <FIG> shows the point where break-away arm <NUM> starts to separate, and <FIG> shows the parts of bracket <NUM> and vehicle front end after the crash and resulting movement.

Thus, the use of side brackets <NUM> to connect cooling module to crash-boxes <NUM> is a simple way to reduce or eliminate damage to the cooling module <NUM> from a low speed frontal impact collision. By reducing or preventing damage to the cooling module <NUM>, the overall resulting damage is less and the vehicle is therefore less expensive to repair. Additionally, if the cooling module <NUM> is not damaged in such a collision, the driver can often drive the vehicle to a repair shop themselves, resulting in time and cost savings by avoiding the need for a tow-truck. Moreover, such a bracket <NUM> can result in economic savings in car insurance by reducing the likelihood of costly repairs after low-speed frontal impact collisions.

<FIG> is a perspective view of a first (inner) side of bracket <NUM>, <FIG> is a perspective view of a second (outer) side of the bracket <NUM>, <FIG> is a side view of bracket <NUM>, and <FIG> is a rear view of bracket <NUM>. Bracket <NUM> includes forward crash-box connection means <NUM>, cooling module connection means <NUM>, rigid arm <NUM> with frontal side <NUM> and rearward side <NUM>, rear crash-box connection means <NUM>, break-away arm <NUM>, and protrusion <NUM>. Bracket <NUM> shown in <FIG> is a right side bracket (when viewing the vehicle from a front), and the left side bracket would be a mirror image from the side (<FIG>).

Forward crash-box connection means <NUM> include two vertically spaced bores <NUM>, each for receiving a connector such as a bolt or screw The bores <NUM> could include interior threads. Rear crash-box connection means <NUM> also includes two vertically spaced bores <NUM>, each for receiving a connector such as a bolt or screw, and could be similarly threaded. The vertically spaced bores <NUM> can be in a portion of rigid arm <NUM> which has a tapered shape. The tapered shape can be from the front side <NUM> to the rearward side <NUM>, and in some embodiments, such as the one shown in <FIG>, have two separate tapers, a first larger taper at the front side <NUM>, and a second taper where that ends to the rear side <NUM>. As described and shown, these can have cut-out portions as needed for either accommodating other pass-through parts or for simply saving materials when additional strength is not required.

Break-away arm <NUM> connects rear crash-box connection means <NUM> with rearward side <NUM> of rigid arm <NUM>. Break-away arm <NUM> is much thinner (in a side view, see <FIG>) than rigid arm <NUM>, and is dimensioned such that break-away arm <NUM> will break in one or more places upon a frontal impact collision, disconnecting bracket <NUM> and cooling module <NUM> from rear crash-box connection means <NUM>.

Cooling module connection means is a vertically extending cavity <NUM>, which could include threads for receiving a connector such as a bolt or screw to connect to the cooling module bushing <NUM>. In the bracket <NUM> shown, a collar <NUM> surrounds cavity <NUM> for connecting securely to cooling module and preventing upward movement of the cooling module.

Rigid arm <NUM> extends from a rearward side <NUM> forward and upwards to a frontal end <NUM>. As can be seen in <FIG>, rigid arm expands in height from the rearward side <NUM> to the forward side <NUM> as well, as can be seen clearly in <FIG>. In this embodiment, the lower side of rigid arm <NUM> extends generally straight or planar in a forwards and upwards direction, with the top side having a first section extending upward at an angle, and a second section extending upward at a steeper angle toward the frontal end <NUM>. This angle is typically less than <NUM> degrees. Corners and sides are generally rounded. Additionally, rigid arm <NUM> includes a number of cut-out sections <NUM>, which can reduce the weight and materials needed, as well as could provide throughpaths for cables within the vehicle. There can be other parts <NUM> which are made generally less thick for further reducing material while maintaining strength and stability requirements for rigid arm <NUM> to not break upon a low-speed frontal impact collision, and move cooling module back <NUM> with any movement of the front end of the vehicle.

<FIG> shows sample dimensions for bracket <NUM>, though these could vary in different embodiments. Side length LS between the rear crash-box connection means <NUM> (and cooling module connection means <NUM>) to forward crash-box connection means <NUM> is about <NUM>, the height of bracket <NUM>B from the bottom of bracket <NUM> at crash-box connection means <NUM> to the top of both the rear crash-box connection means <NUM> and the forward crash-box connection means <NUM> is about <NUM>, with the height of break-away arm <NUM>A(from the bottom of bracket <NUM> at crash-box connection means <NUM> to the first connector opening <NUM> of rear crash-box connection means) being about <NUM>.

Bracket <NUM> can be formed by a metal material, for example aluminium (including alloys), and could be formed by die casting and/or other means.

In summary, bracket <NUM> provides a simple, yet strong and durable side connection for the cooling module <NUM> in normal operation, and allows for rearward movement of the cooling module in a low-speed frontal impact crash to reduce or eliminate damage to the cooling module in such a collision. The break-away arm <NUM> is strong enough to handle the durability loads in normal operation (e.g., <NUM> in the Z-direction and <NUM> in the X and Y directions), but thin enough to break very quickly (e.g., within <NUM> miliseconds) upon a frontal impact crash to decouple the cooling module <NUM> from the body structure. This decoupling allows for rearward movement of the rigid arm <NUM> of bracket <NUM> and therefore cooling module <NUM> through the bracket connection means <NUM> to bushing <NUM>. Rigid arm <NUM> is designed to meet high speed crash requirements and minimize materials and weight while ensuring sufficient strength to push the cooling module <NUM> back as much as possible upon impact. The rearward movement of cooling module then helps to protect the expensive cooling module <NUM> as much as possible from damage after a front end impact, only needing the less expensive crash-boxes <NUM> and/or brackets <NUM> needing repairing and/or replacement after such an impact. Additionally, when the cooling module is not damaged, the vehicle can still generally be driven to a repair shop instead of requiring a tow. Bracket <NUM> also meets the requirements for normal operation and for high speed impacts, minimizing or eliminating the possibility of parts unintentionally fully detaching in such a high speed impact crash and damaging other parts of the vehicle.

Bracket <NUM> additionally can be used in many different vehicles, making fewer design variations needed, and thereby simplifying manufacturing and assembly. The ability to use in many different vehicles due to the design also helps to lower overall costs.

While bracket <NUM> with connections means <NUM>, <NUM>, <NUM> are shown with specific design and details in the drawings, such designs could vary. For example, the connection means could differ, the bracket rigid arm <NUM> could have a different configuration and/or the break-away arm <NUM> could be placed slightly differently, as long as the bracket <NUM> design ensures that front connection means are located in front of the cooling module <NUM>, and that in the event of a frontal impact crash, that break-away arm <NUM> will separate to allow rigid arm to move cooling module rearward. The relative dimensions, sizing, and exact configuration of components could vary.

While the bracket is shown and described as connecting directly to the crash-box and the cooling module, some embodiments would not have a direct connection and there could be one or more parts between in the same chain. For example, one or more bushings could be between the bracket and crash-box and/or the bracket could be connected to an external cooling module carrier.

Claim 1:
A bracket (<NUM>) for a cooling module (<NUM>) in a front end structure of a vehicle, the bracket comprising:
forward crash-box connection means (<NUM>);
cooling module connection means (<NUM>); and
a rigid arm (<NUM>) extending between the forward crash-box connection means (<NUM>) at a forward side and the cooling module connection means (<NUM>) at a rearward side;
characterised in that the bracket further comprises:
rear crash-box connection means (<NUM>); and
a break-away arm (<NUM>) extending from the rearward side of the rigid arm (<NUM>) to the rear crash-box connection means (<NUM>).