HEAT SHIELD RETAINER ASSEMBLY RELATED APPLICATIONS [0001] This application claims priority to U. S. Provisional Patent Application, Serial No. 60/494,506, filed August 12 ; 2003.

BACKGROUND OF THE INVENTION [0002] Thermal insulating shields are used for various applications including automotive applications to prevent a reduced heat radiating from heat producing sources such as, for example, an internal combustion engine, into areas where the radiated heat is undesirable. One typical automotive application is where a thermal insulating shield is mounted over a manifold to prevent a reduced transport of heat radiating from the manifold as the result of the internal combustion taking place inside the motor of the automobile. Typically, the thermal insulating shield is either mounted to the manifold or to a support bracket associated with the manifold.

[0003] Generally, the thermal insulating shield formed from an aluminum or equivalent non-heat conductive material. For automotive applications, a manifold heat shield is generally formed from a sheet or plate of aluminum of a thickness of between 0.125 and 0.25 inches. A plate includes a top portion and side portions folded downwardly toward the manifold so that the shield wraps around the manifold providing maximum thermal insulation. The shield is retained by four conventional bolts that are received by apertures either on the manifold or support bracket.

[0004] A retainer assembly is used to affix the shield over the manifold and provide sound damping properties along with heat dissipation properties so that the amount of heat the bolt is exposed to is minimized. These assemblies typically include a stainless steel mesh washer along with a stainless steel mesh spacer having a radial flange that sandwiches the shield with the spacer. A tubular insert having an external helical thread is received by the spacer and the washer with the intent to retain the spacer and washer upon the shield until installation of the shield over the manifold. However, the threaded insert has not provided adequate retention to the washer and the spacer during shipment of the shield to a final assembly location. This lack of retention has resulted in labor intensive manual operations at the final assembly location because manual quality checks are required during the installation process. Attempts to modify the stainless steel mesh spacer and washer have not provided a successful solution to the lack of retention of the spacer and washer to the shield. Therefore, it would be desirable to provide an improved retention assembly to the shield to provide an enhanced final assembly operation.

SUMMARY OF THE INVENTION [0005] A retainer assembly for securing a thermal insulating shield defining at least one opening to a heat producing component includes a spacer and a washer. The spacer defines a tubular spacer wall formed from a pliant substrate received by the opening in the thermal insulating shield. The washer is disposed upon an opposite side of the thermal insulating shield from the spacer and defines an opening that is axially aligned with the tubular spacer wall. A retainer has a tubular retainer wall with a radial flange located generally adjacent a proximal end of the tubular retainer wall. A distal end of the tubular retainer wall is received by the tubular spacer wall. The tubular retainer wall includes an outer surface having a plurality of prongs spaced between the proximal end and the distal end. The prongs engage at least the washer retaining the spacer and the washer upon the thermal insulating shield.

[0006] The prongs provide an enhanced retention force between the washer and the spacer that has proven to withstand the vibratory forces associated with transporting the assembly to an installation location, which has resulted in the failure of prior art assemblies. Furthermore, it has been found that the improved retainer assembly has enabled the installation of the thermal insulating shield via robotic apparatus due to both the more accurate retention and reduction in the loss of retention of the assembly.

BRIEF DESCRIPTION OF THE DRAWINGS [0007] Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: [0008] Figure 1 is a perspective view showing an exploded retainer assembly of the present invention ; [0009] Figure 2 is a cross-sectional view showing the exploded retainer assembly; and [0010] Figure 3 shows a cross-sectional view of the retainer assembly affixed to the thermal insulating shield.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0011] Referring to Figure 1, a thermal insulating shield assembly is generally shown at 10. The assembly includes a thermal insulating shield 12 having an upper wall 14 and opposing side walls 16. Preferably, the shield 12 defines a shape that provides adequate coverage of a manifold of a vehicle motor to prevent substantial transmission of heat from the manifold. Preferably, the shield 12 is formed from an aluminum substrate or aluminum composite known to absorb or defuse thermal energy emitted from a manifold. Equivalent substrates for the shield 12 may also be used as desired.

[0012] The shield 12 defines at least one opening 18 the purpose of which will be explained further below. Preferably, the shield 12 defines a plurality of openings 18 disbursed around the shield 12 at spaced locations.

[0013] Each opening 18 receives a retainer assembly 20 (Figure 2) through which a fastener 22 or bolt is received to affix the shield assembly 10 to a manifold (not shown) or bracket (not shown) securing the assembly 10 over the manifold. A spacer 24 defines a tubular spacer wall 26 having a diameter adapted to be received in the opening 18 defined by the shield 12. A spacer flange 28 includes a larger diameter than the tubular spacer wall 26 preventing the spacer 24 from merely sliding through the opening 18 defined by the shield 12. The shield 12 provides a generally planar surface 30 upon which the spacer flange 28 rests where the tubular spacer wall 26 is inserted into the opening 18.

[0014] A washer or generally planar ring 32 is disposed upon an opposite side of the shield 12 from the spacer flange 28. The washer 32 defines a washer opening 34 that is generally coaxially aligned with the tubular spacer wall 26 of the spacer 24. The washer preferably includes an inner diameter that is generally the same as an inner diameter defined by the tubular spacer wall 26. As best shown in Figure 3, the washer 32 abuts the tubular spacer wall 26 and has been inserted through the opening 18 defined by the shield 12. Preferably, the spacer 24 and the washer 32 are formed from a stainless steel mesh that provides both corrosion resistance and heat dissipation of thermal energy produced from the manifold.

Furthermore, the spacer 24 and the washer 32 provide acoustical dampening benefits to prevent vibrations generated in the manifold from resonating through the shield 12 adversely affecting acoustical performance of the vehicle. However, equivalent materials providing resiliency and acoustical and thermal properties to the stainless steel mesh may also be used.

[0015] As best seen in Figure 2, a retainer 36 includes a tubular retainer wall 38 defining a first, or proximal end 40 and a second or distal end 42. A tubular radial flange 44 is located generally adjacent the proximal end 40 of the retainer 36. As shown in Figure 3, when assembled, the spacer flange 28 is sandwiched between the tubular radial flange 44 and the planar surface 30 of the shield 12. At least one prong 46, as best shown in Figure 2, is disposed upon an outer surface 48 of the tubular retainer wall 38. Preferably, a plurality of prongs 46 are spaced along the outer surface 48 between the proximal end 40 and the distal end 42 of the tubular retainer wall 38.

[0016] Each prong 46 defines a frustoconical rib encircling the tubular retainer wall 38 having a minor diameter 50 and a major diameter 52. The minor diameter 50 is located closer to the distal end 42 than the major diameter 52. As set forth above, in a preferred embodiment, a plurality of frustoconical ribs are spaced between the proximal end 40 and the distal end 42 of the tubular retainer wall 38.

[0017] As best shown in Figure 3, the retainer 36 is positioned so that the tubular retainer wall 38 is received by the tubular spacer wall 26 and by the aperture 34 defined by the washer 32. At least one prong 46 engages the washer 32 thereby retaining the washer 32 and the spacer 24 upon the shield 12. More preferably, the plurality of prongs 46 engage both the spacer 24 and the washer to providing additional retention of the retainer assembly 20 to the shield 12.

Preferably, each prong 46 defines an angle with the outer surface of the tubular retainer wall 38 of between 8 and 14 degrees. More preferably, each prong 46 defines an angle with the outer surface of the tubular retainer wall 38 of generally 10 degrees. In one preferred embodiment, the retainer is formed from a steel substrate known to withstand both corrosion and thermal energy. More preferably, the retainer is formed from C1215 steel which is known to withstand both corrosion and thermal energy.

[0018] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.

[0019] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.