GB2235973A

GB2235973A - Vehicle radiator assemblies

Info

Publication number: GB2235973A
Application number: GB8915485A
Authority: GB
Inventors: Keith Westwood
Original assignee: STERLING ENGINEERED PRODUCTS L
Current assignee: STERLING ENGINEERED PRODUCTS L
Priority date: 1989-07-06
Filing date: 1989-07-06
Publication date: 1991-03-20
Also published as: GB8915485D0

Abstract

A cooling matrix (1) of a radiator for a vehicle is directly connected to an end tank (2, 3), without a separate header plate and rubber seal. The matrix (1) comprises an array of flow tubes (14) through which liquid is conducted to be cooled and an array of open-ended end portions (4) provided at one end of the matrix. The end tank (2, 3) has a wall (8) adjacent said one end of the matrix (1), the wall (8) defining an array of connector regions (11) corresponding to the array of end portions (4). Each connector region (11) has an aperture (13) through which the end portion (4) extends and connector means, e.g. comprising the tight fit of the end portion in the aperture, which seals the associated end portion to the wall (8). The end tank (2,3) provides liquid communication between the flow tubes (14). The end tank (2, 3) is preferably of plastics material and may be moulded directly onto the matrix (1). Alternatively it may be a push fit on the end portions. <IMAGE>

Description

RADIATOR ASSEMBLIES This invention relates to radiator assemblies, primarily but not exclusively for vehicles, having a cooling matrix and an end tank joined to the cooling matrix, to end tanks for such assemblies, and to a method of manufacturing such assemblies.

Radiator assemblies for vehicles are known having a cooling matrix which comprises an array of air-cooled tubes or passages through which water is conducted to be cooled, the matrix having an end at which there is a series of open-ended end portions of the tubes or passages; a header plate sealingly joined to the end portions; a trough-shaped end tank having an out-turned flange at its open end and crimped to the header plate by a crimping strip; and a rubber seal interposed between the header plate and the end tank to seal the crimped joint connecting the end tank to the header plate.

According to a first aspect of the invention a radiator assembly comprises a cooling matrix and an end tank directly connected to the cooling matrix, the cooling matrix comprising an array of flow tubes or passages through which liquid is conducted in use, the matrix having at one end an array of open-ended end portions of the flow tubes or passages and the end tank having a wall which is adjacent said one end of the matrix and which defines an array of connector regions of the wall complementary to the array of end portions of the matrix, each connector region of said wall having an aperture extending through the wall and connector means which sealingly engages an associated one of the end portions to connect the end tank directly to the matrix with the apertures and end portions registering with each other, the end tank providing communication for liquid between the end portions connected to it.

The present invention joins an end tank directly to the end portions of the tubes or passages. This eliminates the need for a header plate, rubber seal, and crimping strip and produces a cheaper and simpler joint. Since the radiator assembly does not have a header plate, nor a crimped connection between the end-tank and a header plate, it avoids leaks from such a joint and is cheaper and simpler to produce.

The matrix may have two opposed ends each having an array of end portions of the flow tubes or passages, and the radiator assembly may then have two similar end tanks, one connected to the end portions of each end of the matrix.

Preferably the or each end tank is of plastics material.

In one preferred embodiment at least one connector region comprises a region defining an aperture in the wall of substantially the same size as the exterior periphery of the end portion to which it is connected, the end portion extending substantially through the wall and being sealingly held in the aperture by the tightness of fit of the end portion in the aperture.

Preferably the end portion extends completely through the wall and projects into the interior of the end tank. An upstanding boss may surround the aperture to increase the thickness of the wall in the region of the aperture.

In another preferred embodiment at least one connector region comprises a sleeve surrounding the aperture of the connector region and extending away from the wall towards the matrix. The sleeve preferably fits over the outside of a corresponding end portion of the matrix so as to form a socket which sealingly engages the end portion. A hollow projection may be provided inside the area defined by the sleeve and defining a bore which registers with the aperture, the projection being of complementary exterior dimensions to the interior dimensions of the end portion of the flow tube or passage to which the connector region is connected, the sleeve fitting outside of the end portion and the projection inside so that the end portion is held between the sleeve and the projection.

According to a second aspect of the invention we provide an end tank for subsequent attachment to a cooling matrix, the end tank defining a substantially enclosed chamber and having an end wall provided with connector regions for sealingly connecting the end tank directly to end portions of the cooling matrix to which it is to be connected, the connector regions comprising an aperture extending through the end wall to the chamber and connector means adapted to sealingly engage an associated one of the end portions of the matrix, the chamber providing communication for liquid between apertures in the end wall.

When an end tank in accordance with the second aspect of the invention is connected to a cooling matrix a radiator assembly in accordance with the first aspect of the invention is formed.

According to a third aspect the invention consists in a method of manufacturing a radiator assembly having a cooling matrix and an end tank comprising the steps of taking a cooling matrix comprising an array of flow tubes or passages through which liquid flows in use, which matrix has at one end an array of open-ended end portions of the flow tubes or passages; providing a lost-core on said one end of the matrix; locating the matrix and associated lost-core relative to a moulding tool and moulding an end-tank around the lost-core and directly onto the end portions of the flow tubes or passages of the matrix; and;removing the lost-core from the end tank, the end portions communicating through a wall of the end tank with a cavity defined by the lost-core.

According to another aspect the invention consists in a method of manufacturing a radiator assembly according to the first aspect of the invention comprising the steps of taking an end tank in accordance with the second aspect of the invention and sealingly securing it to the end portions of the matrix.

Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings of which: Figure 1 shows a radiator assembly in accordance with the invention; Figures 2 and 3 show stages in the manufacture of the radiator assembly of Figure 1 in a first method; Figure 4 shows details of the radiator assembly of Figure 1; Figures 5 to 7 show stages in the manufacture of another radiator assembly in accordance with the invention in a second method; Figure 8 shows detail of an end tank of the radiator assembly of Figures 5 to 7; Figures 9 to 11 show different kinds of radiator assembly which can be made in accordance with the invention; and Figure 12 illustrates a radiator assembly provided with an expansion tank.

A schematic representation of a radiator assembly for a vehicle is shown in Figure 1. The assembly comprises a cooling matrix 1 of conventional form having a series of cooling flow tubes embedded in a block of cooling fins, and a pair of end tanks 2 and 3 sealingly connected to open-ended end portions 4 of the flow tubes. End tank 3 has a water inlet 5 and end tank 2 has a water outlet 6. The end tanks each define a substantially enclosed chamber 7 and have apertured walls 8. The matrix has opposed ends 9 and 10 each having an array of the end portions 4 projecting from them and through the walls 8 of the respective end tank. The end tanks provide fluid communication between the end portions 4 which project into them.

Details of the connection of the end tank 2 to the end portions 4 are shown in Figure 4. Wall 8 has an array of connector regions 11 corresponding the array of end portions 4 protruding from the matrix 1. Each connector region comprises a raised boss 12 on the face of the wall 8 adjacent the matrix, and a through-bore 13 extending through the boss 12 and the wall 8 to the chamber 7. The end portions 4 extend..

through the bore 13 and project into the chamber 7.

The end tank 2 is both mounted on and sealed to the end portions 4 by the engagement of the end portions 4 in the bores 13. Figure 4 also illustrates the flow tubes and cooling fins which are referenced as numbers 14 and 15 respectively.

The radiator assembly of Figures 1 and 4 is made as illustrated in Figures 2 and 3. A lost-core 16 of a low melting point eutectic alloy is mounted, moulded, or otherwise provided on the end portions 4 of the flow tubes of the matrix 1 and the matrix and lost-core combination is brought to a moulding tool 17. The moulding tool 17 and the lost-core 16 together define the shape of the end tank 2 which is to be moulded directly onto the end portions 4: the tool 17 defining the outer surface of the end tank and the lost-core 16 the inner surface. The end tank is then moulded in a plastics material 18, such as nylon, with a melting point which is lower than the melting point of the lost-core. When the plastics end tank has cooled sufficiently the lost-core is removed by any convenient method, such as by immersion in an oil or induction melt-out bath.

Moulding the end tank directly onto the end portions 4 simultaneously seals the end tank to the end portions and mechanically mounts the end tank on the end portions, avoiding the need for separate mounting and sealing means. The boss 12 assists in correctly spacing the end tank 2 from the matrix 1.

An alternative radiator assembly and its method of manufacture is shown in Figures 5 to 8. An end tank 2' is made as a separate moulding of nylon plastics material and is then subsequently secured to end portions 4' of a conventional matrix 1'. The end tank 2' could be secured by friction fit of the end portions 4' and apertures in the end tank, or any suitable sealant adhesive could be employed.

Figure 5 shows the moulding of a lost core 16' which is then used with a moulding tool 17' to mould the end tank 2', shown in Figure 6.

As shown in Figure 6, the end tank 2' has an end wall 8' which in use is disposed adjacent the matrix 1' and part-defines a chamber 7'. A series of connector portions 11' is provided at the wall 8' in complementary positions to the end portions 4' of the matrix 1'.

Each connector portion comprises an annular tubular spigot 20, Figure 8, on the outer face of the wall 8' extending away from the wall. The spigot 20 defines a central bore 21 which extends the full length of the spigot and continues through the end wall 8' to the chamber 7'. An annular sleeve 22 is provided on the wall 8' co-axially surrounding the lower-most portion of the spigot 20 and spaced apart from the spigot.

The internal diameter of the sleeve 22 and the external diameter of the spigot 20 are complementary to the external and internal diameters respectively of the end portions 4' which are to be connected to the end tank by the connector regions. The connector regions 11' are surrounded by a single lip 23 provided on the walls 8'.

As will be appreciated, the sleeve 22 and spigot 20 form a socket in which the open end of an end portion 4' is sealingly received and held by the spigot and sleeve. The annular portion of the wall 8' between the sleeve and the spigot forms an end-stop for the end portions 4' to fully locate the end tank 2' when it is pushed onto the end portions 4'. The lip 23 assists in correctly spacing the end tank 2' from the matrix 1'.

The end tank 2 or 2' may be provided with an expansion chamber 30, Figure 12 illustrating the preferred expansion chamber which comprises a generally conical region of the tank. Cooling water is preferably maintained between maximum and minimum levels 31 and 32 and can be introduced to the radiator assembly through aperture 33.

Since the expansion chamber can be moulded in plastics material it can be moulded in transparent or translucent plastics such that the level of liquid in the radiator assembly can be seen readily.

The end tanks 2 and 2' can be provided on different kinds of radiator assemblies, examples of which are illustrated in Figures 9 to 11.

Figure 9 shows a radiator assembly of the U-flow type which has a single end tank 2" having a central longitudinal baffle 40 integrally moulded with the end tank. The baffle 40 ensures that cooling water must flow from an inlet 41 in one chamber 42 to one side of the baffle, through the matrix to a U-bend 43 in the flow tubes and then back through the matrix before arriving at an outlet 44 in another chamber 45 defined in the end tank.

Figure 10 shows another U-bend type of radiator assembly having two opposed end tanks. A baffle 50 is provided extending transversely in one of the end tanks dividing it into inlet and outlet chambers to ensure that cooling water must flow through the matrix to reach the outlet. The other of the end tanks takes the place of U-bends 43.

Figure 11 shows a standard flow arrangement in which there are no baffles and the inlet and outlet are provided in opposed end tanks.

Claims

1. A radiator assembly comprising a cooling matrix and an end tank directly connected to the cooling matrix, the cooling matrix comprising an array of flow tubes or passages through which liquid is conducted in use, the matrix having at one end an array of open-ended end portions of the flow tubes or passages, and the end tank having a wall which is adjacent said one end of the matrix and -which defines an array of connector regions of the wall complementary to the array of end portions of the matrix, each connector region of said wall having an aperture extending through the wall and connector means which sealingly engages an associated one of the end portions to connect the end tank directly to the matrix with the aperture and end portions registering with each other, the end tank providing communication for liquid between the end portions connected to it.

2. A radiator assembly according to claim 1 in which the end tank is made of plastics material.

3. A radiator assembly according to claim 1 or claim 2 in which the matrix has two opposed ends each having an array of end portions of the flow tubes or passages.

4. A radiator assembly according to claim 3 which has two similar end tanks, one connected to the end portions of each end of the matrix.

5. A radiator assembly according to claim 4 in which one of the end tanks comprises an expansion chamber and is made of transparent or translucent plastics so that the water level in the radiator can be seen.

6. A radiator assembly according to any preceding claim in which a boss surrounds the aperture to increase the thickness of the wall in region of the aperture.

7. A radiator assembly according to any preceding claim in which at least one connector region comprises a region defining an aperture in the wall of substantially the same size as the exterior periphery of the end portion to which it is connected, the end portion extending substantially through the wall and being sealingly held in the aperture by the tightness of fit of the end portion in the aperture.

8. A radiator assembly according to claim 7 in which the end portion extends completely through the wall and projects into the interior of the end tank.

9. A radiator assembly according to any one of claims 1 to 6 in which at least one connector region comprises a sleeve surrounding the aperture of the connector region and extending away from the wall towards the matrix.

10. A radiator assembly according to claim 9 in which the sleeve fits over the outside of a corresponding end portion of the matrix so as to form a socket which sealingly engages the end portion.

11. A radiator assembly according to claim 10 in which a hollow projection is provided inside the area defined by the sleeve and defines a bore which registers with the aperture, the projection being of complementary exterior dimensions to the interior dimensions of the end portion of the flow tube or passage to which the connector region is connected, the sleeve fitting outside of the end portion and the projection inside so that the end portion is held between the sleeve and the projection.

12. A radiator assembly substantially as herein described and illustrated with reference to Figures 1 to 4 of the accompanying drawings.

13. A radiator assembly substantially as herein described and illustrated with reference to Figures 5 to 8 of the accompanying drawings.

14. A radiator assembly substantially as herein described, and as illustrated with reference to any one of Figures 9 to 12 of the accompanying drawings.

15. An end tank for attachment to a cooling matrix, the end tank--defining a substantially enclosed chamber and having an end wall provided with connector regions for sealingly connecting the end tank directly to end portions of the cooling matrix to which it is to be connected, the connector regions comprising an aperture extending through the end wall to the chamber and connector means adapted to sealingly engage an associated one of the end portions of the matrix, the chamber providing communication for liquid between apertures in the end wall.

16. An end tank according to claim 15 which is made of plastics material.

17. An end tank according to claim 16 which comprises an expansion chamber for direct attachment to a radiator and which is made of transparent or translucent material to enable the water level in the expansion chamber to be seen.

18. An end tank substantially as herein described and illustrated in accordance with Figures 1 to 4 of the accompanying drawings.

19. An end tank substantially as herein described and illustrated in accordance with Figures 5 to 8 of the accompanying drawings.

20. A method of manufacturing a radiator assembly having a cooling matrix and an end tank comprising the steps of taking a cooling matrix comprising an array of flow tubes or passages through which liquid flows in use, which matrix has at one end an array of open-ended end portions of the flow tubes or passages; providing a lost-core on said one end of the matrix; locating the matrix and associated lost-core relative to a moulding tool and moulding an end-tank around the lost-core and directly onto the end portions of the flow tubes or passages of the matrix; and removing the lost-core from the end tank, the end portions communicating through a wall of the end tank with a cavity defined by the lost-core.

21. A method of manufacturing a radiator assembly substantially as described herein with reference to Figures 1 to 4.

22. A method of manufacturing a radiator assembly in accordance with claim 1 comprising the steps of taking an end tank in accordance with any one of claims 15 to 19 and sealingly securing it to the end portions of the matrix.