STRUTS FOR COOLING FAN MODULE

Description

TECHNICAL FIELD

The present disclosure relates to a cooling fan module for an automotive application, and more specifically, to a cooling fan module having a strut configured to optimize airflow and reduce noise within the cooling fan module. However, the present disclosure can also be used in other applications such as cooling fan modules for a home heating and cooling system or any other similar application.

BACKGROUND

Vehicles often include various components that are cooled by a heat exchanger, such as a radiator. Heated air may be drawn or moved through the radiator by a cooling fan module. Cooling fan modules may include a powered fan that is housed within a frame and operable to move drawn air from an upstream side of the frame to a downstream side of the frame. Air drawn to the downstream side of the frame recirculates to the upstream side through gap between fan blade tip and frame opening, thus leading to inefficiencies. Furthermore, struts which support the fan motor assembly of the cooling fan module may negatively impact the acoustics of the cooling fan module.

SUMMARY

According to one or more embodiments, a cooling fan module is disclosed. The cooling fan module includes a fan assembly including a plurality of fan blades extending from a hub and terminating at a fan ring and a shroud having an upstream side and a downstream side. The fan assembly is arranged to move air from the upstream side to the downstream side, and the shroud includes a first sidewall defining an opening for receiving the fan assembly, a fan shroud positioned concentrically within the opening, and a plurality of struts extending between the fan shroud and the opening defined by the first sidewall. At least one of the plurality of struts further includes a body having at least one non-continuous portion.

In another embodiment, a cooling fan module is disclosed. The cooling fan module includes a fan assembly including a plurality of fan blades extending from a hub and terminating at a fan ring, and a shroud having an upstream side and a downstream side, such that the fan assembly is arranged to move air from the upstream side to the downstream side. The shroud includes a first sidewall defining an opening for receiving the fan assembly, a fan shroud positioned concentrically within the opening, and a plurality of struts extending between the fan shroud and the opening defined by the first sidewall. At least one of the plurality of struts further includes a body having a distal end including a plurality of prongs that extend between the body and the opening of the shroud, and each of the plurality of prongs further includes a non-continuous prong portion.

In yet another embodiment still, a cooling fan module is disclosed. The cooling fan module includes a fan assembly including a plurality of fan blades extending from a hub and terminating at a fan ring and a shroud having an upstream side and a downstream side, wherein the fan assembly is arranged to move air from the upstream side to the downstream side. The shroud includes a first sidewall defining an opening for receiving the fan assembly, a fan shroud positioned concentrically within the opening, and a plurality of struts extending between the fan shroud and the opening defined by the first sidewall. At least one reinforcement member is coupled to at least one of the plurality of struts and extends between the at least one of the plurality of struts and the opening of the shroud. At least one of the plurality of struts includes a non-continuous portion and the reinforcement member includes a non-continuous reinforcement portion.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

FIG. 1 is a downstream side view of an exemplary cooling fan module, according to one or more embodiments shown and described herein;

FIG. 2 is an exploded view of the cooling fan module of FIG. 1, according to one or more embodiments shown and described herein;

FIG. 3 is a partial perspective view of a strut of the cooling fan module of FIG. 1, according to one or more embodiments shown and described herein;

FIG. 4 is a partial perspective view of a strut of the cooling fan module of FIG. 1, according to one or more embodiments shown and described herein;

FIG. 5 is a partial perspective view of another embodiment of a strut of the cooling fan module of FIG. 1, according to one or more embodiments shown and described herein;

FIG. 6 is a partial perspective view of another embodiment of a strut of the cooling fan module of FIG. 5, according to one or more embodiments shown and described herein;

FIG. 7 is a partial perspective view of another embodiment of a strut of the cooling fan module of FIG. 1, according to one or more embodiments shown and described herein; and

FIG. 8 is graphical representation of noise levels associated with embodiments of cooling fan modules, according to one or more embodiments shown and described herein.

Other features and advantages of the present disclosure will be understood from the following embodiments described in detail herein and with reference to the accompanying drawings, in which like reference numerals represent the same or similar components.

DETAILED DESCRIPTION

In the embodiments described herein, a strut for a cooling fan module is disclosed. The cooling fan module may include a fan assembly including a plurality of fan blades extending from a hub and terminating at a fan ring, and a shroud having a first sidewall defining an opening for receiving the fan assembly, a fan shroud positioned concentrically within the opening, and a plurality of struts extending between the fan shroud and the opening defined by the first sidewalls. In these embodiments, at least one of the plurality of struts further includes a body having at least one non-continuous portion. The formation of the non-continuous portion in the body may mitigate the noise generated during operation of the cooling fan module may further enhance the structural integrity of the cooling fan module, as will be described in additional detail herein.

It is to be further understood that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

In the following discussion of the figures, a polar coordinate system is utilized. An axial direction extends along an axis of rotation the fan assembly. A radial direction extends orthogonal to the axial direction from the axis of rotation towards a periphery of the frame of the cooling fan module.

The term orthogonal means one or more surfaces or lines intersect at a right angle or are arranged at a right angle. The term planar means a surface is flat and lies along a plane.

This invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.

As used in the specification and the appended claims, the singular form “a,” “an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

The term “substantially” or “about” may be used herein to describe disclosed or claimed embodiments. The term “substantially” or “about” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” or “about” may signify that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.

Although the terms first, second, third, etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

As described herein, cooling fan modules are commonly used in automotive and other vehicular systems, in which they are used to dissipate heat from engines, turbines, radiators, and other similar heat-generating units by directing airflow across heat exchangers. Traditional cooling fan modules may include a fan assembly including multiple blades rotating about a hub, with the blades and hub enclosed within a shroud that directs airflow generated by the fan assembly.

However, traditional cooling fan modules face limitations in terms of noise generation and airflow efficiency. For example, a primary source of noise in cooling fan modules is the blade passing frequency (“BPF”), which is the noise created as the multiple blades pass struts, or other similar structural elements, within the fan assembly. The BPF noise is not only a nuisance, but can also lead to inefficiencies in airflow management, thereby contributing to performance degradation of the cooling fan module.

The cooling fan module described herein aims to address these shortcomings by providing a structural element (e.g., strut, arm, etc.) that incorporates a non-continuous edge in specific regions of the structural element. In the embodiments described herein, the non-continuous region of the structural element may mitigate the impact of the various structural elements on the BPF noise generated during operation of the cooling fan module. By adjusting the positioning of the non-continuous edge on each of the structural elements, airflow disturbance may be minimized, which may in turn result in drastically reduced noise levels.

It should be further appreciated that, in some embodiments, the formation and/or positioning of the non-continuous edge of each of the structural elements may further enhance the structural integrity of the cooling fan module. For example, the non-continuous edge of each of the structural elements may enhance the aerodynamic profile of the structural elements, which may in turn allow for better airflow management, higher operational efficiency, and reduced acoustic footprint of the cooling fan module.

Embodiments of cooling fan modules will now be described in additional detail herein. The following will now describe these methods in more detail with reference to the drawings and where like numbers refer to like structures.

Referring now to FIGS. 1 and 2, a cooling fan module 100 is provided. The cooling fan module 100 may be configured to move or displace air from a heat exchanger 10 towards a downstream impediment 12. As one example, the heat exchanger 10 may be a radiator or a condenser that may use liquid such as coolant that cools incoming air. The heat source may be an internal combustion engine or an electric motor or other heat generating source. The side of the cooling fan module disposed closest to the radiator may be referred to as the upstream side and the side disposed further away from the radiator may be referred to as the downstream side. In one or more embodiments, the downstream impediment 12 may be an internal combustion engine, an electric machine or motor, one or more batteries, or another vehicle component.

Pressure downstream from the fan may be higher than pressure on the upstream side of the fan. This pressure difference may drive recirculating airflow from the downstream side back to the upstream side through a space between the fan and the opening defined by the frame. This recirculating airflow may be drawn across the fan blades. As a result, tangential airflow velocity may vary, thus decreasing efficiency and leading to unwanted noise.

The cooling fan module 100 may be provided with a fan assembly 102 that may include a number of fan blades 104 that may extend from a fan hub 106 and terminate at a fan ring 108. As one example, the fan assembly 102 may be driven by an electric motor 103 to rotate the fan assembly 102 about a rotational axis RA that may be defined by the fan hub 106, and may be configured to move air from the upstream side to the downstream side.

Referring still to FIGS. 1 and 2, the cooling fan module 100 may further include a shroud 116 that may include a first sidewall 118 that may define an opening 120, such that the fan assembly 102 may be disposed within the opening 120. In these embodiments, the shroud 116 may also be provided with a number of rings. For example, the shroud may include a first ring 122 that may extend axially from the first sidewall 118 towards the downstream side of the shroud. A second sidewall 124 may extend from the first ring 122 to a second ring 126 that may be arranged concentrically with the first ring 122.

As further illustrated in FIGS. 1 and 2, the shroud 116 may further define a shroud hub 130. In these embodiments, the shroud hub 130 may be configured to receive the electric motor 103 of the fan assembly 102, which may in turn couple the fan assembly 102 to the shroud 116. Accordingly, the electric motor 103 and the fan hub 106 may be concentrically positioned within the shroud hub 130 when the cooling fan module 100 is assembled (e.g., as illustrated in FIG. 1).

Referring still to FIGS. 1 and 2, the shroud 116 may further include a plurality of structural support members, such as strut support members 132, and a plurality of struts 134. In these embodiments, each of the plurality of struts may include a proximal end 136 and a distal end 138 positioned opposite the proximal end 136, and a body 140 extending between the proximal end 136 and the distal end 138. As illustrated in FIGS. 1 and 2, the proximal end 136 of each of the plurality of struts 134 may be coupled (e.g., fixedly attached or otherwise) to the shroud hub 130, while the distal end 138 of each of the plurality of struts 134 may be secured to the strut support members 132 positioned about the opening 120 defined by the shroud 116. Accordingly, in these embodiments, the body 140 of each of the plurality of struts 134 may extend between the shroud hub 130 and at least one of the plurality of strut support member 132.

Turning now to FIGS. 3 and 4, the plurality of struts 134 are depicted in additional detail. As illustrated in FIGS. 3 and 4, the body 140 of each of the plurality of struts 134 may be further defined by a first surface 142 and a second surface 144 positioned opposite the first surface 142, with each of the first surface 142 and the second surface 144 extending between the proximal end 136 and the distal end 138 of each of the plurality of struts 134. In these embodiments, at least one of the first surface 142 or the second surface 144 may further include a non-continuous portion 146 extending at least partially along the body 140 of each of the plurality of struts 134.

For example, as illustrated in FIGS. 3 and 4, the second surface 144 of the body 140 of each of the plurality of struts 134 may include the non-continuous portion 146. In these embodiments, the non-continuous portion 146 of the second surface 144 of the body 140 may be positioned adjacent the distal end 138 of the body 140, such that the non-continuous portion 146 of the body 140 terminates at the at least one strut support member 132 to which the at least one of the plurality of struts 134 is coupled.

In these embodiments, the non-continuous portion 146 may be a scalloped portion (e.g., a portion of the body 140 of each of the plurality of struts 134 that has been removed and/or modified). It should be appreciated that, by modifying (e.g. scalloping or otherwise) the body 140 of each of the plurality of struts 134 to include the non-continuous portion 146, the plurality of struts 134 depicted in FIGS. 3 and 4 may mitigate noise levels associated with operation of the fan assembly 102. Furthermore, in some embodiments, the non-continuous portion 146 of each of the plurality of struts 134 may provide enhanced structural integrity to the cooling fan module 100, as the non-continuous portion 146 of each of the plurality of struts 134 may provide an enhanced aerodynamic profile for the plurality of struts 134 while maintaining sufficient support for the fan assembly 102.

Referring still to FIGS. 3 and 4, the non-continuous portion 146 of each of the plurality of struts 134 may have an arced (e.g., curved) profile extending at least partially along a length of the first surface 142 and/or the second surface 144 of the body 140. For example, in these embodiments, the non-continuous portion 146 of the body 140 may have a predetermined curvature, with the predetermined curvature of the non-continuous portion 146 being configured to reduce noise at a particular acoustic frequency. Accordingly, it should be appreciated that the curvature of the non-continuous portion 146 of each of the plurality of struts 134 may be adjusted in order to reduce noise generated by the cooling fan module 100 at various acoustic frequencies and orders.

Furthermore, although the non-continuous portion 146 of each of the plurality of struts 134 is depicted as including a curved profile, it should be appreciated that the non-continuous portion 146 of each of the plurality of struts 134 may include a profile having any shape without departing from the scope of the present disclosure. For example, although not depicted, the non-continuous portion 146 may include a sawtooth profile (e.g., consisting of a series of triangular peaks and valleys along a length of the non-continuous portion), a wavy (e.g. sinusoidal) profile, a notched and/or stepped profile, an indented and/or recessed profile, a perforated and/or slotted profile, a tapered and/or flared profile, or any other similar profile (or combination thereof) without departing from the scope of the present disclosure. Furthermore, it should be understood that, in these embodiments, the profile of the non-continuous portion 146 of each of the plurality of struts 134 may be determined and adjusted according to operational constraints of the cooling fan module 100 described herein.

Referring still to FIGS. 3 and 4, it should be further appreciated that the non-continuous portion 146 may have any encompass any portion of the first surface 142 and/or the second surface 144 of the body 140 without departing from the scope of the present disclosure. For example, although the non-continuous portion 146 is depicted as being adjacent the distal end 138 of each of the plurality of struts 134, it should be understood that, in some embodiments, the non-continuous portion 146 may be adjacent the proximal end 136 of each of the plurality of struts 134 (e.g., adjacent the shroud hub 130). Furthermore, in other embodiments still, the non-continuous portion 146 may extend fully along a length of the first surface 142 and/or the second surface 144 of the body 140, such that the non-continuous portion 146 extends between the proximal end 136 and the distal end 138 of each of the plurality of struts 134 (e.g., between the shroud hub 130 and the plurality of strut support members 132).

Referring still to FIGS. 3 and 4, although the non-continuous portion 146 of the body 140 of each of the plurality of struts 134 is illustrated as being formed on the second surface 144 of the body 140, it should be appreciated that the non-continuous portion 146 may be formed on either surface (e.g., the first surface 142 or second surface 144) of the body 140 without departing from the present disclosure. For example, in some embodiments, the non-continuous portion 146 may be formed on the first surface 142 of each of the plurality of struts 134 rather than on the second surface 144 of the body 140 of each of the plurality of struts 134. In other embodiments, it should be further appreciated that each of the plurality of struts 134 may include a plurality of non-continuous surfaces, such that at least one non-continuous portion 146 is formed on each of the first surface 142 and the second surface 144 of the body 140 of each of the plurality of struts 134.

Furthermore, although FIGS. 3 and 4 depict each of the plurality of struts 134 as including at least one non-continuous portion 146, it should be appreciated that, in some embodiments, only some of the plurality of struts 134 may include the at least one non-continuous portion 146. For example, in some embodiments, only one of the plurality of struts 134 may include the non-continuous portion 146, while in other embodiments, a number less than the total number of the plurality of struts 134 may include the non-continuous portion 146. In these embodiments, the individual struts of the plurality of struts 134 that include the non-continuous portion 146 may be determined based on operational parameters of the cooling fan module 100. For example, in some embodiments, the plurality of struts 134 may be positioned such that each strut including the non-continuous portion 146 is adjacent another strut which does not have the non-continuous portion 146.

Turning now to FIG. 5, another embodiment of the cooling fan module 100 is depicted. In these embodiments, each of the plurality of struts 134 may further include a reinforcement member 150, which may be coupled (e.g., fixedly attached or otherwise) to the body 140 of each of the plurality of struts 134 and extend between the body 140 and the first ring 122 of the shroud 116. As further depicted in FIG. 5, the reinforcement member 150 may further include a reinforcement support member 152, with the reinforcement support member 152 being coupled to the first ring 122 of the shroud 116 to secure the reinforcement member 150 between the first ring 122 of the shroud 116 and the body 140 of each of the plurality of struts 134.

As further depicted in FIG. 5, the reinforcement member 150 may further include a first reinforcement surface 154 and a second reinforcement surface 156, with at least one of the first reinforcement surface 154 and/or the second reinforcement surface 156 including a non-continuous reinforcement portion 158. In these embodiments, the non-continuous reinforcement portion 158 of the reinforcement member 150 may include the same dimensions (e.g., size, shape, length, curvature, etc.) as the non-continuous portion 146 of the at least one of the plurality of struts 134 to which the reinforcement member 150 is coupled. For example, as illustrated in FIG. 5, the non-continuous reinforcement portion 158 of the reinforcement member 150 may have the same curvature as the non-continuous portion 146 of the body 140 to which the reinforcement member 150 is coupled.

In the embodiments described herein, it should be appreciated that the reinforcement member 150 may further enhance the structural integrity of the plurality of struts 134. For example, the additional support offered by the reinforcement member 150 may ensure that the plurality of struts 134 maintain shape and position under various operating conditions of the cooling fan module 100, including high temperatures and/or speeds. Furthermore, by providing the reinforcement member 150 with the non-continuous reinforcement portion 158, the reinforcement member 150 may provide enhanced structural integrity without disrupting noise reduction provided by the plurality of struts 134.

Referring still to FIG. 5, it should be further appreciated that, in the embodiments described herein, each of the plurality of struts 134 may not include the reinforcement member 150. That is, in some embodiments, a number of the plurality of struts 134 that is less than the total number of the plurality of struts 134 may include the reinforcement member 150. Furthermore, in these embodiments, it should be appreciated that each reinforcement member 150 may not include the non-continuous reinforcement portion 158. For example, in some embodiments, a number of the plurality of struts 134 may include a reinforcement member 150 that does not include a non-continuous reinforcement portion 158.

In other embodiments still, it should be understood that each of the plurality of struts 134 that include the reinforcement member 150 may include a non-continuous reinforcement portion 158 having a profile that is different from the profile of the non-continuous portion 146 of the body 140 of each of the plurality of struts 134. For example, in some embodiments, the non-continuous portion 146 of the body 140 may have a curved profile while the non-continuous reinforcement portion 158 of the reinforcement member 150 may have a saw-tooth profile, or any other similar profile as has been described herein. Accordingly, it should be appreciated that the plurality of struts 134 may include a reinforcement member 150 having a non-continuous reinforcement portion 158 with any profile without departing from the scope of the present disclosure.

Turning now to FIG. 6, another embodiment of the cooling fan module 100 is depicted. In these embodiments, the distal end 138 of each of the plurality of struts 134 may be a forked member, such that the distal end 138 includes a plurality of prongs 160 that extend between the body 140 of each of the plurality of struts 134 and the first ring 122 of the shroud 116. As further depicted in FIG. 6, each of the plurality of prongs 160 may further include a prong support member 162, which the prong support member 162 of each of the plurality of prongs 160 coupled to the first ring 122 of the shroud 116 to secure the plurality of prongs 160 between the first ring 122 of the shroud 116 and the body 140 of each of the plurality of struts 134.

As further depicted in FIG. 6, each of the plurality of prongs 160 may further include a first prong surface 164 and a second prong surface 166, with at least one of the first prong surface 164 and/or the second prong surface 166 including a non-continuous prong portion 168. In these embodiments, the non-continuous prong portion 168 of each of the plurality of prongs 160 may include the same dimensions (e.g., size, shape, length, curvature, etc.) For example, as illustrated in FIG. 6, the plurality of prongs 160 may include a first prong 160a having a first non-continuous prong portion 168a and a second prong 160b having a second non-continuous prong portion 168b, such that the first non-continuous prong portion 168a and the second non-continuous prong portion 168b have the same dimensions.

In the embodiments described herein, it should be appreciated that the plurality of prongs 160 may further enhance the structural integrity of the plurality of struts 134. For example, the additional support offered by the plurality of prongs 160 may ensure that the plurality of struts 134 maintain shape and position under various operating conditions of the cooling fan module 100, including high temperatures and/or speeds. Furthermore, by providing each of the plurality of prongs 160 with the non-continuous prong portion 168, the plurality of prongs 160 may provide enhanced structural integrity without disrupting noise reduction provided by the plurality of struts 134.

Furthermore, in these embodiments, the plurality of prongs 160 may further enhance the noise reduction capabilities of the plurality of struts 134. For example, each of the plurality of prongs 160 may act to disrupt and/or diffuse sound waves generated by the passage of the fan blades 104 during operation of the cooling fan module 100. In these embodiments, utilizing the plurality of prongs 160 (or increasing the number of the plurality of prongs 160 positioned on each of the plurality of struts 134) may increase the surface area through which sound dampening occurs, thereby increasing the noise reduction of the cooling fan module 100.

Referring still to FIG. 6, it should be further appreciated that each of the plurality of struts 134 may include a plurality of prongs 160 that have non-continuous prong portions 168 having varying profiles. For example, in some embodiments, the first non-continuous prong portion 168a of the first prong 160a and the second non-continuous prong portion 168b of the second prong 160b may have varying dimensions. Furthermore, in the embodiments described herein, it should be understood that each of the plurality of struts 134 may include a plurality of prongs 160 that include a non-continuous prong portion 168 having a profile that is distinct from each other of the plurality of prongs 160 formed on the plurality of struts 134.

Turning now to FIG. 7, another embodiment of the cooling fan module 100 is depicted. As noted hereinabove with reference to FIGS. 3 and 4, the non-continuous portion 146 of the body 140 of each of the plurality of struts 134 may include a scalloped portion that is removed from at least one of the first surface 142 and/or the second surface 144 of the body 140 to form the non-continuous portion 146. As illustrated in FIG. 7, the scalloped portion 170 that is removed from the body 140 may be adhered to the surface of the body 140 opposite the surface on which the non-continuous portion 146 is formed in order to further aid in noise reduction of the plurality of struts 134. Furthermore, it should be appreciated that the scalloped portion 170 may also aid in providing enhanced structural rigidity to the portion of the body 140 to which the scalloped portion 170 is adhered.

For example, as depicted in FIG. 7, the non-continuous portion 146 may be formed by removing the scalloped portion 170 from the second surface 144 of the body 140 of at least one of the plurality of struts 134. In these embodiments, the scalloped portion 170 may then be adhered and/or fixed to the first surface 142 of the body 140 of the at least one of the plurality of struts 134.

It should be appreciated that, in these embodiments, utilizing the scalloped portion 170 in the manner depicted in FIG. 7 may allow for increased modular noise reduction in each of the plurality of struts 134. For example, because the scalloped portion 170 is adhered and/or fixed to the body 140 of the at least one of the plurality of struts 134, the scalloped portion 170 may be easily replaced if damaged or worn without the need to replace the entire at least one of the plurality of struts 134. Furthermore, it should be understood that the scalloped portion 170 may be utilized to fit struts having various shapes and sizes, such that the scalloped portion 170 may be easily integrated into fan modules.

Referring now to FIG. 8, a graphical representation of the reduction in noise level and fan blade order provided by the various embodiments of the cooling fan module described herein is depicted. As should be appreciated, a noise level of the cooling fan module 100 and a fan blade order of the plurality of fan blades 104 may increase as a rotational speed of the fan 102 is increased. However, by utilizing a plurality of struts 134 that include a non-continuous portion 146, as described herein with reference to FIGS. 1-7, it may be possible to reduce and/or stabilize the noise level generated during operation of the cooling fan module 100 and the fan blade order of the plurality of fan blades 104, as is illustrated in FIG. 8.

In view of the foregoing, it should be appreciated that the embodiments described herein relate to a cooling fan module including a shroud having a plurality of struts having at least one surface that includes a non-continuous portion.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the disclosure and can be desirable for particular applications.

The following is a list of reference numbers shown in the Figures. However, it should be understood that the use of these terms is for illustrative purposes only with respect to one embodiment. And, use of reference numbers correlating a certain term that is both illustrated in the Figures and present in the claims is not intended to limit the claims to only cover the illustrated embodiment.

PARTS LIST

• • Heat exchanger 10
  • Impediment 12
  • Cooling fan module 100
  • Fan 102
  • Electric motor 103
  • Fan blades 104
  • Fan hub 106
  • Fan ring 108
  • Shroud 116
  • First sidewall 118
  • Shroud opening 120
  • First ring 122
  • Second sidewall 124
  • Second ring 126
  • Motor mount 130
  • Strut support member 132
  • Plurality of struts 134
  • Proximal end 136
  • Distal end 138
  • Body 140
  • First surface 142
  • Second surface 144
  • Non-continuous portion 146
  • Reinforcement member 150
  • Reinforcement support member 152
  • First reinforcement surface 154
  • Second reinforcement surface 156
  • Non-continuous reinforcement portion 158
  • Prongs 160
  • Prong support member 162
  • First prong surface 164
  • Second prong surface 166
  • Non-continuous prong portion 168
  • Scalloped portion 170
  • First prong 160a
  • Second prong 160b
  • First non-continuous prong portion 168a
  • Second non-continuous prong portion 168b