WO2003010031A2

WO2003010031A2 - Vehicle fascia support with integral fluid reservoir

Info

Publication number: WO2003010031A2
Application number: PCT/US2002/023930
Authority: WO
Inventors: Stephen J. Eynon; Nicholas S. Herdegen; Jim Swhwaegerle; Matthew T. Murto; Rishi Mehra
Original assignee: Collins & Aikman Automotive Company Inc.
Priority date: 2001-07-26
Filing date: 2002-07-26
Publication date: 2003-02-06
Also published as: EP1409327A2; WO2003010031A3; AU2002330927A1; JP2004535974A

Abstract

A cross-car structure (10) above the radiator of a vehicle (40) contains vehicle fluid chambers (50, 51).

Description

VEHICLE FASCIA SUPPORT WITH INTEGRAL FLUID RESERVOIR

Field of the Invention

The present invention relates to a hollow plastic molded structure, and more particular, to its use as a motor vehicle fascia support and structural support cross member. As a hollow structure, formed via plastics processing, the structure offers additional utility as a storage compartment(s) for various fluids at the front of the vehicle. Background of the Invention

Space is at a premium in today's cars, especially under the hood as engine compartments are packed with electronic modules and, in general, slimmed down with newer cab-forward designs, transverse mounted engines and low profile sloping hoods. Storage for operating fluids is also critical as the containers need to be near the front of the vehicle for easy access and for fluid level inspection. Also, large volume storage is required so that frequent refilling of headlamp washer fluids is not necessitated. Further, hollow low profile molded plastic shapes fit will under the hood and can assume any complex shape required to maximize space utilization.

Combining multiple functions into a single molded structure as in the present invention provides even greater efficiency. In the present invention the hollow plastic molded structure may serve as an upper fascia support providing an attachment surface, a cross-car structural member as the hollow molded structure provides additional cross-car stiffness, and attachment structure for adjunct components such as headlamp housings, fan shrouds and grilles. The upper surface of the structure may be configured to act as an air deflector to assist engine cooling and multiple storage compartments for fluids or any combination previously mentioned.

Various structures have been reported to improve upon vehicle design requirements.

For example, the use of a hollow bumper fascia support is recited in U.S. Patent 5, 580,109 assigned to Chrysler Corporation. Use of a reaction injection molding (RIM) section for supporting fascia is recited in U.S. Patent 5,096,243 assigned to Davidson Textron, Inc., wherein a hollow chamber may be filled with an energy absorbing material.

U.S. Patent 5,649,587 assigned to McCord Winn Textron recites a fan shroud and receptacle arrangement with one or more cooling fan openings, having two or more internal chambers suitable for storing radiator, windshield washer or headlamp washer fluids. Tangue et al U.S. Patent No. 3,692,004 discloses a fan shroud and fluid receptacle arrangement including a cylindrical band or collar extending away from a radiator and a radiator fluid receptacle and a windshield washer fluid receptacle integrally molded on opposite side surfaces of the cylindrical band or collar. U.S. Patent 4,441,463 assigned to Ford Motor Company discloses a container for fluids for various operating functions in a motor vehicle, the container being arranged in the engine compartment and being constructed as an essentially annular or U-shaped hollow body with an interior contour forming an air guide surface or shroud defining an air guide duct for the air cooling fan of the internal combustion engine and having an outer contour shaped to conform to the shape of the radiator associated therewith, the radiator being received within the outer contour within a holding means by way of resilient foam mounting.

Attention is also directed to WO 99/54187, Vehicle Module, to Textron Automotive

UK, which discloses a molded plastic structure to which multiple components can be mounted such as heat exchangers, head lamps, fan shrouds containing reservoirs, headlamp cleaning, apparatus and the like.

WO 01/29949 A2, assigned to McCord Winn Textron, discloses a hollow plastic front end structure for containing vehicle fluids where the exterior contour of the wall section of the hollow structure also comprises head-lamp receptacles, a radiator frame, a fan shroud and a bumper. In addition, U.S. Patent 5,460,420 assigned to McCord Winn Textron discloses a molded plastic front bumper beam for a vehicle which includes upper and lower separate hollow compartments for carrying selected fluids. PCT WO 99 59851 entitled "Fluid Reservoir for Location on a Primary Energy Management System, assigned to Textron Automotive, UK, recites an "L" shaped cross-section reservoir module, that is mounted over and behind the bumper beam.

Summary of the Invention The present invention addresses the deficiencies of the prior art by providing a more compact plastic molded hollow structure for use, preferably, in the front section of a motor vehicle, which can integrate the functions of a fascia support, cross-car structural member, attachment structure for trim, cooling, electrical and body components, and provide air deflection and storage compartments for retention of vehicle fluids, such as coolant or washer fluids, or air.

In one embodiment, the hollow structure preferably extends between the head lamp housings of a vehicle front end and above the radiator and contains segregated compartments for coolant fluid and washer fluid. It has molded-in features to locate fluid pumps and sensors, and openings for access to the radiator cap and hood latch. The vehicle front fascia is preferably attached at the top edge of the hollow structure to retain the fascia in body position relative to the vehicle hood. Accordingly, the top edge provides structural attachment points for fascia attachment.

In another embodiment, the hollow structure can serve as a grille opening upper reinforcement with mounting provisions for trim, cooling, electrical and body components.

Brief Description of the Drawings FIG. 1 is a perspective view of the molded hollow structure in accordance with the present invention.

FIG. 2 is a top view of the structure of FIG. 1. FIG. 3 is a bottom view of the structure of FIG. 1.

FIG. 4 is a perspective view of a motor vehicle showing the hollow molded structure in accordance with the present invention. FIG. 5 is a cross-sectional view taken at the center line of the hollow molded structure of FIG. 2 looking in the direction of arrow A.

Description of the Preferred Embodiments As noted above, FIG. 1 is a perspective view of the hollow structure disclosed herein. The structure 10 comprises an opening 12 for access to the radiator cap. In addition, the structure 10 includes removable caps 14 and 16 to access the stored fluid, e.g. coolant or washer fluid. Also shown is a cut-out 17 to accommodate a hood latch.

Filler n ecks 46, 49 m ay b e formed at spaced apart locations along top wall 26 for communicating with respective chambers 50, 51 formed within the hollow structure 10. Chamber 50, 51 may contain a variety of vehicle operating fluid including washer fluid, engine coolant, brake fluid, air and similar materials.

As can be seen in FIG. 1, structure 10 is of a size so that it may be uniquely positioned above or on the vehicle radiator. In addition, structure 10 does not extend completely downward along the entirety of the vehicle radiator into the front end of the vehicle to reach, e.g. the bumper region, and serves as a cross-car reinforcement structure and air deflector extending across the radiator section of the vehicle.

As can be seen in FIG. 1, the structure 10 may be of a complete unitary or alternatively, two-piece construction, to form the hollow chambers. Such structure is preferably blow molded plastic, and can be formed from various plastics such as polyolefines (HDPE, LDPE, PP), including glass or talc filled grades, engineering thermoplastics (nylons, polyesters, polycarbonates, polysulphones, PPO polystyrene blends), as well as thermoset materials.

Other plastic manufacturing process may be used to manufacture the hollow structure

10 including but not limited to rotational molding, vacuum forming, injection molding, compression molding, transfer molding, liquid casting and reaction injection molding. In instances in other than blow molding or rotational molding it may be necessary to form the hollow structure in two or more parts and join them by plastics welding or adhesive means.

With regards to preferred dimensions, and as shown in FIG. 2, recess regions 18, house a head-lamp housing (not shown). Accordingly, it is preferred that structure 10 span between head lamps from side to side on the vehicle. Also shown in FIG. 2 is a plurality of projecting tabs 20 containing a hole for attachment of fascia.

FIG. 3 illustrates a recess 22 to house a pump 24 that is integrated with structure 10 to convey washer or other fluids. A level sensor for detecting fluid levels is also conveniently integrated and shown at 26. FIG. 4 shows a molded hollow structure 10 of the present invention installed in the front of a motor vehicle 40. The structure spans the distance between headlamps 42 and 44 adding cross-car support due to the double wall construction of the hollow molded structure. The vehicle fascia 30 is attached to and supported by the hollow molded structure 10 along the rear most edge of the fascia 30. FIG. 5 is a cross-sectional view of FIG. 2 taken at the center of the hollow molded structure 10 looking in the direction of the arrow A. The hollow structure comprises external walls 24, 26, 28 and 32. A flange or tap 36 is formed on an edge of the sidewall 32 and extends forward in vehicle. The flange or tab 36 includes spaced mounting holes 38 adapted to accommodate fasteners (not shown) to mount the fascia to the hollow molded structure 10. FIG. 5 also illustrates a fluid 44 such as windshield washer fluid contained within the hollow molded structure 10. In addition, a recess 58 may be formed in the lower wall 24 of the hollow structure 10 to accommodate a pump (not shown). Molded projections 59 allow snap- fit of the pump into recess 58.

Finally, it can be appreciated that the contour of the surfaces shown in FIGS. 1-3 can be selectively adjusted to act as an air inlet deflector to selectively guide air within the engine compartment. Such adjustment can therefore optimize air delivery within and around the vehicle, to improve, among other things, engine cooling.

In accordance with the present invention there has therefore been disclosed a blow molded fascia support member with engine coolant and/or washer fluid reservoirs. The support member serves to reduce total system costs for trim, structures and cooling systems. This results in a reduction in purchased component costs, part count, and assembly requirements.

The blow molded fascia support member can be formed to optimize any free space under the hood for the storage of fluids and in addition provide support means as the structure spans the distance between headlamps and may form an attachment flange for the vehicle fascia. Further, with the structure imparted by the hollow double-walled shape, adjacent components can be mounted to the structure so that it may function as a grille opening reinforcement.

Claims

We claim:

1. A plastic molded hollow structure in the front section of a vehicle engine compartment, said engine compartment containing a vehicle radiator, said structure comprising a hollow molded structure 10 extending cross-car above or resting on vehicle radiator and not extending downward across the entirety of the vehicle radiator, including one or m ore s torage c hambers for fluid, o ne o r a p lurality o f cut-out r egions t o a ccommodate other components within said vehicle engine compartments, and attachment tabs to support a fascia.

2. The plastic molded structure of claim 1, further comprising recess regions to house a head-lamp housing.

3. The plastic molded structure of claim 1, further comprising a recess to house a fluid pump.

4. The plastic molded structure of claim 1 further comprising a level sensor for detecting fluid in said fluid chambers.

5. In an automotive vehicle engine compartment, containing a radiator and other structural features, wherein the improvement comprises a p lastic molded hollow structure, said structure extending cross-car above or resting on said radiator, including one or more chambers for storage of fluid, one or a plurality of cut-out regions and attachment structure to support vehicle fascia.

6. The plastic molded hollow structure of claim 5 further comprising recess regions to house a head-lamp housing.

7. The plastic molded hollow structure of claim 5 further comprising a level sensor for detecting fluid in said fluid chambers.

8. The plastic molded hollow structure of claim 5 further comprising a recess to house a pump.

9. The plastic molded hollow structure of claim 1 wherein said structure contains molded features which act as an air deflector to direct air to the vehicle engine.